WA500-1 10001-Up

SEBM04250107
KOMATSU
WA5004
MACHINE
WA5004
MODEL
SERIAL
10001
No.
and up
This shop manual may contain attachments and optional equipment that are not available in
your area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
WA500-1 mount the S6D140-1 engine;
For details of the engine, see the 6D140-1
Series Engine Shop Manual.
00-l
05-91(02)03261
CONTENTS
10 ENGINE
11
- 12
No. of page
STRUCTURE
TESTING
AND FUNCTION
.........................................
AND ADJUSTING
13
DISASSEMBLY
...........................................
AND ASSEMBLY
......................................
14
MAINTENANCE
STANDARD
20
POWER
21
STRUCTURE
TESTING
23
DISASSEMBLY
24
MAINTENANCE
AND
FUNCTION
.........................................
AND ADJUSTING
...........................................
AND ASSEMBLY
......................................
STANDARD ...........................................
STEERING
SYSTEM
AND FUNCTION
41
STRUCTURE
42
TESTING
43
DISASSEMBLY
44
MAINTENANCE
.........................................
AND ADJUSTING
...........................................
AND ASSEMBLY
......................................
STANDARD ...........................................
50 BRAKE AND
51
STRUCTURE
52
TESTING
53
DISASSEMBLY
54
MAINTENANCE
60 WORK
AND FUNCTION
.........................................
...........................................
AND ASSEMBLY
......................................
STANDARD ...........................................
EQUIPMENT
61
STRUCTURE
TESTING
AND
FUNCTION
.........................................
63
DISASSEMBLY
...........................................
AND ASSEMBLY
......................................
64
MAINTENANCE
STANDARD
81
STRUCTURE
82
TESTING
83
DISASSEMBLY
22-1
23-l
24-1
41-1
42-l
43-1
44-l
AND
...........................................
ELECTRONIC
AND FUNCTION
51-l
52-1
53-l
54-l
SYSTEM
AND ADJUSTING
ELECTRIC
21-1
AIR SYSTEM
AND ADJUSTING
62
80
14-1
13-l
TRAIN
22
40
...........................................
11-l
12-1
61-l
62-l
64-l
63-1
SYSTEM
.........................................
AND ADJUSTING
...........................................
AND ASSEMBLY
......................................
81-1
82-l
83-1
90 OTHERS
91
93
97
OTHERS..
............................................................
DISASSEMBLY AND ASSEMBLY
......................................
GEAR PUMP ........................................................
Ok2
91-1
93-1
97-101
WA500-
01 GENERAL
(THIS SECTION IS NOT USED IN THIS MANUAL)

m
10 ENGINE
20 POWER TRAIN
40 STEERING
SYSTEM
50 BRAKE AND AIR SYSTEM
60 WORK EQUIPMENT
80 ELECTRICAL
90 OTHERS
SYSTEM
AND ELECTRONIC
SYSTEM
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WA5bO- 1
IMPORTANT
Proper service and repair is extremely

The
service
and repair techniques
manual are both effective
important
injury to workers,
cautions
in this manual.
followed
carefully.
If any dangerous
safety, and take the necessary
by Komatsu
of operation.
of your machine.
and described
in this
Some of these operations
re-
by Komatsu for the purpose.
the symbols
The cautions
NOTICE
for the safe operation
recommended
and safe methods
quire the use of tools specially designed

To prevent
SAFETY
iY
and
accompanying
situation
are used to mark safety pre*

these symbols should always be
arises or may possibly arise, first consider
actions to deal with the situation.
A SAFETY
GENERAL
6. Decide
PRECAUTIONS
a place
in the repair
keep tools and removed

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

2.When
carrying
out
any operation,
always
wear safety shoes and helmet.
Do not wear
loose work clothes,

missing.
with buttons
Always
or clothes
wear safety
Always
glasses when
hitting
trained,
work.
wear
safety
glasses
when
experienced
always wear welding

cap
and
welder
carrying
other
out
carry
out the
welding
work,
gloves, apron, glasses,
clothes
suited
for
welding
work.
4.When
carrying
inform
out any operation
work,
always
procedure
your fellow
any step
agree
before
UNDER
workers
REPAIR
controls in the operators

5. Keep all tools
in good
with two
on the op-
starting.
of the operation.
hang
oil or making
any
repairs,
on hard, level ground, and
the wheels
8. Before
starting
or tracks
to prevent
the
before
Before
to the
If this
equipment
to
lock
warning
is not
possible,
insert
the
port
the
In addition,
control
levers
be sure
and
hang
signs on them.
disassembling
the
machine
or assembling,
with
blocks,
sup-
jacks
or
stands before starting work.
starting
starting
machine.
and learn
lower
from falling.
all
other
on the
work,
safety pin or use blocks to prevent the work
10. Remove
compartment.
the correct way to use them.
ripper,
Always
signs
condition
blade,
or any other work equipment
ground.
9. When
or more workers,
erating
block
bucket
repairs are needed, always have a
When
adding
machine from moving.
grinding parts with a grinder, etc.

3. If welding
7. Before
FOR WORK
park the machine
parts with a hammer.

l
PREPARATIONS
or
steps
machine.
If
it
all mud and oil from
places
used
Always
to get
the steps or
on and off
use the handrails,
when
getting
on
or
the
ladders
off
the
Never jump on or off the machine.
is impossible
to
use
the
handrails,
ladders or steps, use a stand to provide safe

footing.
00-3
PRECAUTIONS
1 1. When
or
DURING
removing
the oil filler
hydraulic
loosen
pressure
them
spurting
slowly
19 Be sure to assemble
WORK
cap, drain
measuring
to prevent
plug
places.
Replace
any damaged
plugs,
of the
remove
oil,
the
or removing
water
pressure
compo-
or air circuits,
completely
from
the
20 . When
the
engine
when
oil
in the
circuits
is stopped,
are
hot
so be careful
that
rying
out
any
work
to cool before
on
the
oil
car-
or
water
starting
battery.
14 When
work,
remove
Always
the negative
(-1
remove
terminal
raising
Check
that
heavy
the
parts
lead
from
high
first.
rope,
are free from
damage.
use
lifting
ample
capacity.
Install
the
places.
use
equipment
a hoist
other
covers
ternal
pressure
or
spring,
always
sides. Slowly
loosen
bolts
components,
removing
the floor,
on the
any
in-
from
a
on
the pressure,
the
piping,
be careful
wiring.
not
Damaged
fires.
stop
the fuel
or oil
out. If any fuel or oil drips on to
wipe
floor
with
the bolts to remove.
or damage
spilling
hit-
in position
release
it up immediately.
can cause
you
Fuel or oil
to slip, or can
even start fires.

18. As
a general
wash.parts.
mum
parts.
00-4
of
rule,
do
In particular,
gasoline
when
not
use gasoline
to
use -only the miniwashing
not
which
speed,
hoses,
twisted.
make
Damaged
so be extremely
check
for
that
high
care-
pressure
connecting
or installing
tightening
protective
parts
two
fingers
caught
always
When
violently
be particularly
or hand.
parts,
torques.
parts such as guards,
vibrate
aligning
or
rotate
careful
or
at
to check
correctly.
holes,
never
Be careful
insert
your
not to get your
in a hole.
electrical
measuring
the
24. Take
hydraulic
measuring
bled before
from
are under
pressure
may cause electrical
17 When
from
under
leave two
removing
wiring
operate
which
the ma-
installed.
fingers
that
by the hoist or crane.
removing
break
correct
and
Do not work
when
has
at the
the component
15 When
opposite
which
or crane
part.
part still raised
then slowly
and hooks
equipment
to prevent
any
chains
be
by
pressure
that they are installed
23. When
lifting
Use
slowly
to
Also,
the leads from
components,
wires,
be damaged
parts
tubes
assembling
22. When
the wire
Always
16 When
are
installing
are correctly
installing
hoist or crane.
ting
high
use the specified
13 Before
not
other
they
ful when
21 When
circuits.
the
will
are dangerous,
circuits.
not to get burned.

Wait for the oil and water
with
installing
sure
and
they
new parts.
and
chine is being operated.
tubes
water
hoses
in their
first
circuit.
12 The
that
again
parts with
installing
contact
disconnecting
nents
When
sure
the oil from
out.
Before
all parts
original
care
taking
when
tracks
of track-type
removing
either
pressure,
check
is correctly
assem-
any measurements.
removing
When
rates suddenly,
tool
or installing
the
machines.
the
track,
so never
end of the track.
the
track
let anyone
sepa-
stand
at
FOREWORD
This shop
serviceman
manual
has been prepared
an accurate
understanding
repairs and make judgements.
as an aid to improve
of the product
the quality
and by showing
Make sure you understand
of repairs
by giving the
him the correct way to perform
the contents
of this manual and use it to full
effect at every opportunity.
This shop manual mainly contains
the necessary
technical
information
for operations
performed
in
a service workshop.
For
ease
components;
of
understanding,
these chapters
STRUCTURE
AND
This
section
adjustments
This
section
assembling
MAINTENANCE
into
chapters
for
each
main
group
of
sections.
the structure
of the structure,
and function
of each component.
but also serves as reference
It serves not only to give
material for troubleshooting.
ADJUSTING
explains
checks
to be made
to be made at completion
Troubleshooting
DISASSEMBLY
is divided
FUNCTION
an understanding
AND
manual
are further divided into the following
This section explains
TESTING
the
charts correlating
AND
before
and after
performing
repairs,
as well
as
of the checks and repairs.
Problems
to Causes
are also included in this section.
ASSEMBLY
explains
the order to be followed
each component,
when
as well as precautions
removing,
installing,
disassembling
or
to be taken for these operations.
STANDARD
This section gives the judgement
standards
when inspecting
disassembled
parts.
NOTICE
The
specifications
contained
in this
shop
time
and without
any advance
notice.
Contact
latest
manual
your
are
subject
KOMATSU
to change
at any
distributor
for the
information.
00-5
HOW
TO READ THE SHOP
MANUAL
HOW
TO READ THE SHOP
MANUAL
Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
When a manual is revised, an edition mark is

recorded on the bottom outside corner of the
pages.
volume:
Engine volume:
Issued for every machine

model
Issued for each engine series
Electrical volume
Attachments
volume
:
:
Each issued as
one volume to
cover all models
These various volumes are designed to avoid

duplicating the same information.
Therefore to
deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment volumes are ready.
DISTRIBUTION
MARK
-... )
REVISED
Chassis
EDITION
(a@@
VOLUMES
AND
UPDATING
Any
changes
Get the
you start
amendments
or other
additions,
will be sent to KOMATSU
distributers.
most up-to-date
information
before
any work.
FILING
METHOD
REVISIONS
Revised pages are shown at the LIST OF
REVISED PAGES on the between the title page
and SAFETY page.
SYMBOLS
So that the shop manual can be of ample
practical use, important
places for safety and
quality are marked with the following symbols.
Symbol
1. See the page number on the bottom of the

page. File the pages in correct order.
2. Following examples shows how to read the
page number.
Example 1 (Chassis volume):
1 Item
Remarks
Special safety precautions
are
necessary
when performing
the
work.
A
Safety
Extra special safety precautions

are necessary
when performing
the work because it is under
internal pressure.
YY
9
IO-3
17_
Item number (I 0. Structure

and Function)
Consecutive page number for
each item.
Special technical precautions

other precautions
for
preserving
standards
are
necessary when performing
work.
Caution
Example 2 (Engine volume):
Weight
3. Additional
pages: Additional
pages are indicated by a hyphen (-1 and number after the
page number. File as in the example.
Example:
4
4
1 o-4
12-203
1 o-5
12-204
00-6
Places that require special

attention
for the tightening
torque during assembly.
Places to be coated with
adhesives
and lubricants
Oil, water
Drain
the
Weight of parts or systems.

Caution necessary when
selecting hoisting wire, or when
working
posture is important,
etc.
12-410
Unit number (I. Engine)
Item number (2. Testing and
Adjusting)
Group No. (4. Fuel system)
Consecutive page No. (Page
10 of Group 4)
or
etc.
Places where oil, water or fuel

must be added, and the
capacity.
Places where oil or water must
be drained, and quantity
to be
drained.
HOISTING
INSTRUCTIONS
HOISTING
INSTRUCTIONS
A
Heavy parts (25 kg or more) must be
lifted with a hoist etc. In the Disassembly
and Assembly
section, every part weighing 25 kg or more is indicated clearly with
the symbol &
1. If a part cannot be smoothly removed from

the
machine
by hoisting,
the following
checks should be made:
. Check for removal of all bolts fastening
the part to the relative parts.
. Check
for existence
of another
part
causing interference
with the part to be
removed.
2. Wire ropes
1) Use adequate
ropes depending
on the
weight of parts to be hoisted, referring to
the table below:
Wire ropes
(Standard Z or S twist ropes
without galvanizing)
Rope diameter
(mm)
Allowable
load (tons)
10
1 .o
11.2
1.4
12.5
1.6
14
2.2
16
2.8
18
3.6
20
4.4
22.4
5.6
10.0
30
40
18.0
50
28.0
60
40.0
Slinging near the edge of the hook may

cause the rope to slip off the hook during
hoisting, and a serious accident can result.
Hooks
have maximum
strength
at the
middle portion.
100%
as%
79%
71%
41%
FSO064
3) Do not sling a heavy load with one rope

alone, but sling with two or more ropes
symmetrically wound on to the load.
Slinging with one rope may cause
turning of the load during hoisting,
untwisting of the rope, or slipping of
the rope from its original winding
position on the load, which can result
in a dangerous accident.
4) Do not sling a heavy load with ropes

forming a wide hanging angle from the
hook.
When hoisting a load with two or more
ropes, the force subjected to each rope
will increase with the hanging angles. The
table
below
shows
the variation
of
allowable load (kg) when hoisting is made
with two ropes, each of which is allowed
to sling up to 1000 kg vertically, at various
hanging angles.
When two ropes sling a load vertically, up
to 2000
kg of total weight
can be
suspended. This weight becomes 1000 kg
when two ropes make a 120 hanging
angle. On the other hand, two ropes are
subjected to an excessive force as large as
4000 kg if they sling a 2000 kg load at a
lifting angle of 150.
A
The allowable
load value is estimated
to
be one-sixth
or one-seventh
of the
breaking strength of the rope used.
2) Sling wire ropes
of the hook.
from
the middle
portion
Lifting
angle
: a
FSO065
00-7
STANDARD
TIGHTENING
TORQUE
STANDARD
1. STANDARD
TIGHTENING
TIGHTENING
TORQUE
OF BOLTS
The following charts give the standard tightening

sections of Disassembly
and Assembly.
Thread diameter
of bolt
(mm)
AND
torques
TORQUE
NUTS
of bolts and nuts. Exceptions
are given in
Width
across flat
(mm)
kgm
Nm
10
1.35kO.15
13
3.2kO.3
31.4t2.9
10
17
6.7f0.7
65.7k6.8
12
19
11.5+1.0
112k9.8
14
22
18.0~2.0
177r19
16
24
28.5t3
279+29
18
27
39I+4
20
30
56+6
13.22
383t39
549k58
22
32
76-t8
745r+78
24
36
94.5*10
927*98
27
41
30
46
33
50
36
55
39
60
1.4
This torque table does not apply to the bolts with which nylon packings or other nonferrous metal washers are to be used, or which require tightening
to otherwise
specified
torque.
*
Nm (newton
2. TIGHTENING
meter):
TORQUE
INm
& 0.1 kgm
OF SPLIT
FLANGE
BOLTS
Use these torques for split flange bolts.
Threa$
00-8
gtlyeter
Tightening
torque
(mm)
Width
across flats
(mm)
10
14
12
17
11.5&l
112k9.8
16
22
28.5+3
279229
kgm
6.71~0.7
Nm
65.7k6.8
STANDARD
TIGHTENING
TORQUE
Sealing surface
3.TlGHTENlNG
Use these
TORQUE
torques
FOR
NUTS
OF
FLARED
for nut part of flared.
Tightening
Thread diameter
of nut part
(mm)
Width across flats

of nut part
(mm)
14
19
2.520.5
18
24
5k-2
Nm
kgm
24.5 24.9
49k19.6
22
27
8k2
24
32
14k3
137.3k29.4
30
36
1823
176.5 k29.4
33
41
2OC5
196.1
36
46
25+5
245.2*49
42
55
3OA5
294.2249
COATING
The recommended
coating
Nomenclature
materials
Grease
(Lithium grease)
249
MATERIALS
in Komatsu
Shop
Manuals
are listed
below.
Applications
LT-1A
Used to apply rubber pads, rubber gaskets, and cork plugs.
LT-IB
Used to apply resin, rubber, metallic and

non-metallic parts when a fast, strong seal is needed.
LT-2
Preventing
LT-3
Provides an airtight, electrically

Used for aluminum surfaces.
LT-4
Used to coat plugs (plate shaped, bowl shaped) and holes, and
mating portion of shaft.
LG-1
Used with gaskets and packings to increase sealing effect.
LG-3
Heat-resistant gasket for precombustion

and exhaust piping.
LG-4
Used b itself on mounting surfaces on the%al drive and transmission

cases. YThrckness after tightening:
0.07 - 0.08 mm)
LG-5
Used by itself to seal grease fittings, tapered screw fittings and tapered
screw fittinas in hvdraulic circuits of less than 50 mm in diameter.
Sealant gasket
Antifriction compound
(Lubricant including
molvbdenum disulfide)
prescribed
78.5 f 19.6
Komatsu code
Adhesives
Vaseline
torque
LG-6
bolts, nuts and plugs from loosening and leaking oil.

insulating seal.
1 Srlrcon
.
base type used in combination
chambers
-
with LG-1 and LG-4.
LG-7
Has a shorter curing time than LG-6, and is easier

to peel off.
LM-P
Applied to bearings and taper shafts to facilitate

prevent sticking, burning or rusting.
G2-LI
Applied to bearings, sliding parts and oil seals for lubrication,

prevention and facilitation of assembling work.
Used for protecting
battery electrode
press-fitting
and to
rust
terminals from corrosion.
LT-2 is also called LOCTITE in the shop manuals
00-9
ELECTRIC WIRE
CODE
ELECTRIC
In the wiring
diagrams,
various
colors
and symbols
This wire code table will help you understand

Example:
5WB
indicates
CLASSIFICATION
a cable
having
a nominal
Number
Dia. Tp$nds
to indicate
the thickness
of wires.
DIAGRAMS.
number
5 and white
coating
with
black stripe.
Cross section
Cable O.D.
Current rating
(mm)
(A)
2.4
12
Applicable
circuit
(mm*)
11
0.85
CODE
BY THICKNESS
strands
0.32
0.88
Starting,
lighting, signal etc.
26
0.32
2.09
3.1
20
Lighting,
signal etc.
65
0.32
5.23
4.6
37
Charging
and signal
15
84
0.45
13.36
7.0
59
Starting
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
217
0.80
230
Starting
100
CLASSIFICATION
are employed
WIRING
Copper wire
Nominal
number
Prioritv
WIRE
I\
BY COLOR
109.1
AND
CODE
Charging
Starting
Ground
Lighting
I tPri-
Circuits
Classk
fication
marY
17.6
(Glow plug)
Code
Red
Color
RW
White&
Red
WB
White & Black
Black&White
BY
Black &Yellow
Red & White

RB
Red & Black
RY
YB
GR
Yellow & Black 1 Green & Red

YG
GY
LR
Blue & Red
LY
Red & Yellow

RG
00-l 0
Red & Green
Yellow & Blue
RL
YW
(GL)
Red & Blue
Yellow & White
(Green & Blue)
WEIGHT
TABLE
This weight table is a guide for use when transporting
or handling components.
Unit.
Machine Model
WA500- 1
Machine Model
Serial Number
10001 -
Serial Number
pump
WA500-1
10001 -
Engine assembly
1453
Hydraulic
Radiator
assembly
285
Steering and POC pumps
Torque converter assembly
193
Switch pump
13
Transmission assembly
980
POC valve
Damper
91
Machine control valve
Upper drive shaft
18
Lift cylinder
Center drive shaft
33
Dump cylinder
Front drive shaft
44
Engine hood
Rear drive shaft
42
Front frame
Front axle assembly
2028
Rear axle assembly
1776
Front differential
288
Rear differential
assembly
assembly
282
Planetary carrier assembly (1 piece)
80
Planetary hub assembly (1 piece)
102
Axle pivot (Rear axle)
(1 piece)
Lift arm (with bushing)
20
90
279
283
43
1996
931119
Tire (1 piece)
421
Battery (1 piece)
Steering valve
55
Cab assembly
47
Air conditioner
Brake (1 piece)
170
Hydraulic
156
WA500-1
13
2486
Fuel tank
tank
240
(1 piece)
Wheel (1 piece)
Steering cylinder
kg
328
53
305
unit
115
Operators seat
40
Floor plate
131
02
TABLE OF OIL AND
QUANTITIES
AMBIENT
KIND OF
.FLUID
RESERVOIR
COOLANT
_22
-30
-1014
-240
320
CAPACITY
TEMPERATURE
50
10
68
20
Engine oil pan
Specified
$E
Refill
I !
32
~~~,~~~~~~~,~~
!...
,.,,I,,,..,.....,.:_.,.,.,,,.,
., .(.,,,.,..,....
-l-
IQ)
28.5
Engine oil
Brake
Transmission case
Hydraulic system
Axle
(Front and rear)
See NOTE
each 75
(4)
each 75
Fuel tank
Water
Cooling system
Add antifreeze
ASTM:
American
SAE:
Society of Automative
API:
American
Society of Testing and Material

Petroleum
Specified capacity:
Refill capacity:
80
Engineers
Institute
Total amount of oil including oil for components and oil in piping.
Amount
of oil needed to refill system during normal inspection and maintenance.
NOTE:
(I)
When
change
fuel
sulphur
oil in the
content
nance hours described

Change
oil according
sulphur content
is less
oil pan every
than
periodic
0.5%,
to 10C
(3)
Above 1 .O%
the engine
(4)
l/2 of regular interval
SAElOW-30
and
an atmospheric
Use API classification
SAE15W-40,
temperature
goes up
CD as engine
CC, reduce
the
oil and if API
engine
oil change
to half.
For axle oil, use only recommended

SHELL:
DONAX
CALTEX:
RPM TRACTOR
TRACTOR
TEXACO:
TDH OIL
MOBIL:
MOBILAND
* It is possible
oil as follows.
TT or TD
CHEVRON:
SAE30
HYDRAULIC
HYDRAULIC
to substitute
SUPER
FLUID
FLUID
UNIVERSAL
engine
oil CLASS-CD
for axle oil.
If noise comes
from the brake,
it is no problem
durability.
0i2
tem-
more or less in the day time.
classification
interval
in an atmospheric
of lower than OC, be sure to use engine
even though
if fuel
Change interval of oil

in engine oil pan
starting
oil of SAElOW,
table
is above 0.5%.
Fuel sulphur content
When
perature
in this manual.
to the following
0.5 to 1.0%
(2)
mainte-
WA500-
of
PRECAUTIONS
4. Bearing
FOR
DISASSEMBLY
AND
ASSEMBLY
separator
5. Hook wrench
A hook wrench
has a claw which
turning
of round nuts. The wrench
defined
sockets
by the
turned.
The
wrench
designed
different
outer
diameter
accompanying
of the
figure
for use with
hooks
into the
size is
round
shows
nut
a hook
round nuts of two
sizes.
FSOOl4
FSOO 13
:
FSOO15
Removal
and Installation
of the Sprocket
Wheel
02P-023
FSOO16
00-l 3
PRECAUTIONS
FOR
S.CLEARANCE
Store
DISASSEMBLY
AND
ASSEMBLY
12. CENTERING
ADJUSTMENTS
each set of shims or washers
can be installed
in their
original
so that they
condition
at the
time of reassembly.
Centering
power
is very important
train
for example,
and
the
transmission
bevel
gear
shaft
centering
deviation
parts,
between
and
the stresses
so always
is within the specified
in the
the engine
between
and the final drives.
only increases
the turning
for interfaces
make
the
Incorrect
acting
on
sure that the
limits.
Engine
10. LINK
RODS
1) If it is necessary
to change
the length
of the
link rod in order to remove
it, first record
original
rod can
length
reassembled
2) Remove
so that
the
in its original condition.
the link rod at the pins.
Rod
r-l----
Correct
o]
Transmission
the
be easily
Yoke
Pin
FSOOI
Transmission
11 .SHIMS
1) Shims
adjust
AND
WASHERS
are
used
the action
very carefully
2) Record
the
adjustment
center
of the
the
bevel
engine
gears.
as they get deformed

numbers
and
Handle
Correct
easily.
and positions
to speed
after reinstallation.
3) Do not reuse
deteriorated,
to
any shims
damaged,
or washers
that
are
bent or deformed.
4) Insert thin shims between
thicker ones.
FSOO18
00-14
MEASURING
INSTRUCTIONS
MEASURING
PREPARATIONS
1. Cleaning
Wash
BEFORE
INSTRUCTIONS
CHECKING
BLOCK
To bring two blocks into contact,
of parts
parts to be checked.
Special
paid to thoroughly
remove
surfaces
measurements
on which
care should be
dust and dirt from
the
are to be made
repair
Remove
of part surfaces
scratches,
be checked.
ments
and rust from
If the surface
will
surface,
dents
be careful
parts to
When
smoothing
not to use an oilstone
paper coarser than the finished
benzene
wipe
with
to remove
a clean cotton
the other,
causing
wash each block
rust-preventing
oil and
cloth. Put one block on
a sliding or twisting
movement
the two.
If the
contact
apply
a fine-grade
their edges.
between
two
oilstone
blocks
to the
feels
rough,
blocks
(Do not try to rub thecontact
along
surface
of the blocks.)
are rough, the measure-
be inaccurate.
with
between
so that possible errors can be eliminated.

2. Minor
GAUGES
any
or sand
Do not leave the blocks in contact

Long-time
separate
surface.
contact
for a long time.
will make the blocks difficult
to
or cause black rust to appear on the con-
tact surfaces.
3. Preparation
Clean
the tools
dirt from
the
of measuring
and thoroughly
the surfaces
tools
for
adjustment.
When
tools
which
proper
Remedy
remove
contact
function
dust and
parts. Check
and
storing
Handle
of measuring
all tools
subject
them
which
with
to
can affect
odically
check
necessary,
sufficient
their delicate
the
tools
calibrate
them.
their cases and return

locations
whenever
care
and do not
force
or shocks
construction.
for
accuracy
by force
them.
or strike
gauge,
coat
wipe
with
off
moisture,
a rust-preventing
such as Vaseline, and put the gauge back
Periand,
if
them
to their fixed
VERNIER
CALIPERS
At the start
storage
not in use. It is recommended
of measuring
slide or twist
apart,
Put the tools back into
to assign a person to be responsible

storage
blocks,
in its case.
tools
unreasonable
a block
dirt and fingerprints,
any abnormality.
lubricant
4. Maintenance
two
them with a mallet.

When
zero-point
separating
Do not try to pull them
for the proper
is no clearance
tween
and that
the jaws
graduation
tools.
of measurement,
check that there
is in exact
close the jaws
and
(due to wear)
be-
the zero
alignment
with
point of the
the zero
point of the vernier scale.
MEASURING
Repeat
TOOLS
each
eliminate
measurement
possible
necessary,
Measuring
if
two
or three
errors. Further
there
is a
large
times
an outer
diameter
to
repetition
will be
variation
in the
readings.
When
measuring
a cylindrical
measuring
angles
the inside or outside
object,
device
take
put
two
in two
to each other. Repeat
diameter
readings
with
directions
of
the
at right
this at several
points
along the overall length of the object.

Along
may
eye-measurement
be used for
two approximately
racy
of
such
considered
At
the
for judging
allowable
below
the unit of a scale
a comparison
equal measurements,
eye-measurements
between
the accu-
should
not
be
a
as reliable.
start
measuring
making
of
device
whether
limit.
each
measurement,
select
having
an accuracy
appropriate
the measurement
reaches
Correct
its
FSOO 19
00-l 5
MEASURING
INSTRUCTIONS
Measuring
DIAL
an inner diameter
GAUGES
Carefully
to
be
put the gauge contact-point
measured
to
protect
the
on a surface
delicate
gauge
against shock.
Set the zero-point
@
Correct
the
movement
of the gauge
of
the
with care to keep
contact-point
within
its
stroke during measurement.

Careless
setting
spindle
to
making
The
Correct
Measuring
measurement
minute
by
extend
pointer
of
of
errors)
through
the
the
are
protrusions,
probe
does
thus
gauge
are
errors
because
mechanism
dial
using
can not
unit on the scale.
depressions
so that vertical
not exceed
(and
by the
of eye measurements
Measuring
zero-point
the
limit,
contact-point
below the minimum
the
dial
indicated
be assured
Set the
its
large
an expanding
gears. The reliability
may cause
to
impossible.
relatively
variations
accompanying
a depth
or
measurements
accompanied
FSOOZO
of the zero-point
retract
or steps
movement
its stroke
limits,
of
and
slide the base of the gauge on a fiat surface.
Correct
Wrong
FSOO21
MICROMETERS
Put the anvil onto an object
turn in the spindle
the object.
two
or
Rotate
three
at a right angle
until it comes
the ratchet
idle
into contact
stop until there
rotations,
then
and
with
read
are
the
FSO023
measurement.
When
reading a measurement,
right angle to the graduation

To turn back the spindle,
keep your eyes at a
Measuring
bending
on the sleeve.
rotate
the thimble
with
your fingers.
Wrong
Correct
FSO022
Read
the
moving
When
storing
ance between
a micrometer,
leave
a slight
the anvil and the spindle.
clear-
Indicator
object
Turn
the
the
difference
minimum
00-l 6
Total
the
object
back
Reading
and
forth
one complete
between
indications
the
(T.I.R.)
while
or vertically.
rotation
and read
maximum
of the gauge pointer.
and
MEASURING
Measuring
INSTRUCTIONS
end play,
looseness
or deviation
Measuring
gear backlash
Lever and fulcr
dial gauge
FSO025
Read the T.I.R. while
moving
the object
1) Fully mesh one of two gears and place the dial
back and
gauge
forth or vertically.
Measuring
face runout
or radial
runout
contact-point
on a tooth
of the
other
gear. Swing
the free gear within the limits of its
play in the
rotational
directions,
and read the
T.I.R.
2) Use of the lever and fulcrum
recommended
point
type dial gauge
for this purpose
placed
is
as the contact-
on the gear is moved
tangentially
to the gear pitch circle.

3) The lever and fulcrum
for
use
measurement
Radial runout
type dial gauge is suitable
in a narrow
space
which
contact-point
or for
requires
on an object
a special
placing
at an angle
the
to the
spindle of the gauge.

Since
FSOO26
1) Read runout
complete
at six or more positions
rotation
point at the middle

the spindle
during one
fully checked
movement.
Be careful
range
for contact
of gauge
(usually
should
be care-
with the object during
of
not to con-
fuse positive and negative readings of runout.
CYLINDER
l
GAUGES
Install
a contact-point
mately
equal to the cylinder
on the cylinder
test indicator
cylinder
gauge.
having
a length
Set the zero-point
to the bore diameter
measured
with
approxi-
bore to the measured
a reference
of the
of the standard
ring gauge
or
a micrometer.
When the pointer is

to the left of 0
3) When
range
measurement.
set the zero-
of the assumable
of this type
measuring
mm or less), the contact-point
of the object.
2) At the start of each measurement,
the contact-point
has a very narrow
measuring
contact-point
face
runout,
place
the
on the object along a circle 2 or 3
mm smaller in diameter
ter of the object.
than the outside diameContact-point
Measuring
point
FSO028
00-17
PARTS
CHECKING
INSTRUCTIONS
Insert the gauge into the bore to be measured

read the minimum
while
giving swings
the detachable
l
indication
When
the
and
of the test indicator
to the gauge
about
the tip of
rod used as the fulcrum.
minimum
reading
right side of the zero
is obtained
on the
point of the test indicator,
and the reading to the standard
value to which the
zero point is set.

When
the minimum
reading
side of the zero point,

the standard
is obtained
subtract
Check
from
value.
PARTS
l
on the left
the reading
disassembled
CHECKING
parts to see if they are reusa-
INSTRUCTIONS
3. PITTING
ble or need repair. If the part failed due to an external
source,
before
determine
the
cause
and
correct
1) Pitting
by cavitation
In most
assembly.
cases,
chemical
scale, carefully
1. GENERAL
PRECAUTIONS
When
Visually
inspect
rosion,
scoring,
inspection,
every
parts
for
cracks,
ridging
etc.
part
should
To
be
pitting,
cor-
ensure
proper
clean
before
If the cause of the defect

great
help to analyze
the defect
can be found,
it will be a
whether
the part condition;
will progress
Knowing
the cause of the defect,
can give good advice
the service
to the customer
man
to prevent
him from having the same trouble again.

l
Visual
inspection
damage.
Other
can
not find
methods
of
minute
or hidden
inspection
are
as
follows;
a)
Water-pressure
b)
Color check or magnetic
or air-pressure
damage
test
test
2. CRACKS
l
If
the
part
inspection,
l
is found
to
be
it should be replaced
cracked
If the length or depth of crack exceeds

thickness
by
visual
or repaired.
113 of the
of the part, it should be replaced
instead
of repaired.
l
A part having an internal crack should be replaced.
00-l 8
removing
rust
by
or
within the
limit, replace the part.

is not deep,
removing
the rust and scale.
due to removal
resurface
the part after
of surface
If ball bearing is pitted, replace it.

If more
than
l/3
of the contact
face
is pitted,
the part should be replaced.
or not, and the possibility
of future trouble.
is accompanied
inspect the depth of pitting.
If pitting
2) Pitting
inspection.
l
After
the pitting can not be repaired
allowable
l
cavitation
corrosion.
If pitting is not serious, resurface
the part.
PARTS
HANDLING
PARTS
HANDLING
1. OIL SEALS
3) Use a suitable
in the
proper
direction,
as shown
in the
press to press fit the oil seal into
the housing.
1. Direction
Be careful to install the oil seal with its lips facing
When
installing
the
oil seal flush
with
the
housing surface..
figure
below.
Oil seal nominal outside
Oil
pressure
side
Main lip
&.t
lip
FSO031
FSO029
2. Inspection prior to installation

1) Keep the oil seals free from
dust,
rust
and
scratches.
Take
special
care to prevent
on the lips.
slide
a wire
across
its
surface.
gently
If the
replace the oil seal with a new one.
sure that
the wire
the
oil
seal
inside
the
outside diameter
l.O)mm
outside diameter
l.O)mm
wire
catches,
Make
installing
housing..
Oil seal nominal
Oil seal nominal outside diameter
+ (0.5 I
- (0.5 - l.O)mm
Oil seal nominal
- (0.5 t-L-7
rust or scratches
2) To check the oil seal lip for smoothness,
When
used for this test
does not scratch the lip surface.

3) Do
not
would
use the
come
oil seal
into contact
on a shaft
where
it
FSO032
with rust or scratches
FSO033
on the shaft surface.

4) When
removing
damage
3. Installing
1) Coat
the
oil seal, take
not to
4) After
press-fitting
the oil seal, check that it has
not been installed at an angle to the housing.
the oil seal

the surface
to which
applied with a lubricant

+
care
the housing or shaft surfaces.
If the lip should double

being
proper
fitted
place
over
by
the oil seal is to be
or grease.
the
over as the oil seal is

shaft,
rotating
return
the
it to its
shaft
and
pulling the oil seal slightly backwards.

2) When
with
installing
a
keyway,
an oil seal on a shaft

splines,
suitable jig to protect
or
machined
threads,
use
Max. permissible oil seal slant

(H, -
the lip.
HI)/2 S l/400
FSO034
Lip protectton jig
FSOO30
00-l 9.
PARTS
HANDLING
4. Applying grease to the lips

Before installing an oil seal, coat it with grease
according to the following procedure to prevent
friction from burning the seal surfaces while the
machine is being started.
1) Single-lip oil seal
Place a flat, uniform coating of grease on the
surface away from the sealing surface.
Grease
FSO035
2) Double-lip oil seal

Coat the entire surface between the two lips
with grease in the manner shown in the accompanying figures.
Grease
2. FLOATING
SEALS
1. Handling floating seals

1) Keep each pair of floating seals bundled
together with tape to avoid mix-ups when they
are reinstalled.
2) Discard the old O-rings. Always use new ones
when installing the floating seals.
3) Replace a floating seal if its contact surface is
rusted.
2. Installing floating seals

1) Remove all rust and dust from the mounting
surfaces of the seal. Use sandpaper to remove
any rust that might come into contact with the
O-ring.
2) When installing the floating seal, coat the
mounting surfaces with oil. Then install the
O-ring, taking care not to twist it.
* Do not coat the O-ring with oil.
* The floating seal has been correctly installed
if the seal ring rotates.
3) After installing the O-ring and seal rings in both
housings, mate the two together.
Grease
FSO036
Housing
Seal ring
FSO037
5. Applying adhesives
Take special care when applying adhesives. to the
outer surface of oil seals. Adhesive on the surface
of the lip or shaft leads to oil leakage.
* Since any adhesives on the surface of the press
jig will soon transfer to the oil seal lips, clean
the jig before use.
4) An installer is recommended for inserting the

O-rings.
t Using a screwdriver or other pointed object
risks scarring the O-ring.
5) Attempting to mate the two housings together
without the O-rings and seal rings in place can
damage the O-rings and lead to oil leakage.
O-ring
Housing
Seal ring
FSO038
00-20
PARTS
HANDLING
4. GASKETS
3. O-RINGS
1. Handling
1. Handling
1) Discard
any O-ring
that has been in storage
too
2) Use only the O-rings

for
rings
used
parts, where
materials
prescribed
for the part in
BOOK. This is especially
those
engine
with
important
USE
NEW
2) Make
packings,
gaskets
and copper
with new ones.
sure that there
on the contact
are no scratches
surfaces
or burrs
of the gasket.
high-temperature
heat-resistant
and durable
2. Installing
gaskets
I) Make
such as silicon are required.
3) ALWAYS
replace
packings
long or has hardened.

the PARTS
gaskets
I) Always
sure that
the holes in the gasket
those in the mating
O-RINGS.
2) Apply
gasket
match
part.
sealant
to the joints so specified
in the SHOP MANUAL.

2. O-ring
types
KOMATSU
as shown
O-rings
are marked
in the accompanying
with colored
dots
3. Precautions
gasket
2) Coat
Material
Part Number
Marking
Application
One blue spot
07000-0
..... Nitrile rubber
For
low-pressure
Two blue spots
07000-1
For
high-pressure
One green spot
07000-3
..... Fluorine rubbel
For
low-pressure
07000-2
Fluorine rubbel
07000-4
One red spot
For
high-pressure
For
low-pressure
in cold weather
all scratches,
the specified
07000-5
Two red spots
,..., Nitrile rubber
applying
a new coat.
area evenly
and let dry for
several minutes.
3) Assemble
sealant
the
mating
parts
when
the
gasket
is stickly to the touch.
5. BEARINGS
1) Shield
bearings
the
bearings
from
dust
and dirt;
the tiniest speck rapidly accelerates

+
Leave
the
packaging
bearings
until just
in
their
before
even
wear.
protective
they
are to be
installed.
2) Protect
For
high-pressure
in cold weather
dirt, paint, grease and old
sealant before
1. Handling
Two green spots
for using liquid gasket
1) Remove
chart.
a bearing
from
excessive
force
and
compressed
air
shocks.
*
Never
dry
a bearing
with
after cleaning.
07000-6
Orange spot
..... Silicon rubber
For
low-pressure
in hot weather
2. Installing
bearings
I) Never drive a bearing onto a shaft by pounding

on
the
outer
pounding
produces
3. Inserting
After
O-rings
coating
so as not
the O-ring
to damage
2) When
with
oil, insert
it. Silicon
rubber
carefully
O-rings
race
on the
into
an
race.
Such
opening
by
pounding
dents in the tracks in the races.
a bearing
with some
or
inner
must
interference,
with the jig shown
be fitted
press-fit
onto
a shaft
the inner race
in the accompanying
figure.
require special care since they tear easily.

Jig
Press fit
FSO039
00-2 1
PARTS
HANDLING
6. PRESS
3) If the shaft
ference,
*
of opening
has considerable
heat the bearing before
with
a non-separable
interference
the jig shown
BUSHINGS
Do not drive in a bushing
installing.
Use a press so that
Do not heat above 120C.
4) When
FITTING
inter-
bearing
must
for both races,
be fitted
press-fit
in the accompanying
with
1) If no press is available,
a
distributed
with a hammer.
is uniform
over the
entire circumference.
using
figure.
directly
pressure
driving
tool
hammer
so
that
in the bushing
the
force
is
evenly.
Jig
I
Press fit
FSOO40
5) Thoroughly
coat
the
bearing
with
oil before
installing.
6) Install
the
chamfered
bearing,
surface
spacer
or washer
with
its
facing the step on the shaft.
2) If the bushing
has an oil hole, bring the hole into
exact alignment
with the oil hole in the housing.
Rear face of
To injection
FSO043
3) When
Correct
burrs
FSO041
a bushing
and
has been removed,
foreign
matter
from
the
remove
all
mounting
hole, and then clean.
7. REMOVING
I) Use snap
SNAP
RINGS
ring pliers to remove
rings. Do not overexpand
or install snap
them-especially
the
smaller ones.
2) After
installing,
check
to make
sure that
snap ring is firmly in place within its groove.
00-22
the
PARTS
HANDLING
8. HYDRAULIC
2. Installing
PIPING
the hydraulic
I) Thoroughly
B
Precautions
ment
for
hydraulic
I) Lower
servicing
the
work
equip-
equipment
to the ground
and
the oil filler cap to relieve
the hydraulic
3) Operate
eliminate
pressure
in
to
control
levers
hydraulic
pressure
or
times
remaining
in the
the
work
equipment
prevent
it
removed
and the hydraulic
1. Removing
from
falling
the hydraulic
1) Disconnect
tubes
by
male
side
loosening
hydraulic
holding
remove
all
with compressed
air.
when
the
pressure
and
4) Install
the
piping
so that
piping!
alt the identification
tags match.
a pipe
must
be joined
at
both
ends,
to
tightening
only one end at a time may make
is
too short.
First fit both ends by hand and then
piping
is released.
it
tighten the ends by turns. (See figure.)
piping
nut on the
joint)
one
on a stand
a
oil,
tubes from hoses or other
the
of the
the
and
with
light
dents are too large, replace.
5) When
piping to be disassembled.
4) Support
trichloroethane)
traces of detergent
of piping
example,
3) Do not use gasket sealant for hydraulic
oil tank.
the
piece
(for
2) Repair the sealing faces or, if the scratches
turn off the engine.

2) Loosen
piping
each
detergent
kerosene,
system
the work
suitable
clean
with
on the
spigot
a wrench
socket
(the
(the
while
female
side).
Tighten gradually and alternately

the both ends.
FSO045
6) To ensure tight-fitting
80%
then tighten
FSO044
7) After
engine
2) Seal
the ends
hoses
and
equipment
matter.
oil
ports
For the same
reason,
the
tubes
and
hydraulic
neath to catch
Then
idling
levers
check
90,
and
of
all
speed
the
connections,
and
operate
run
the
hydraulic
all the
attachments.
the oil level in the hydraulic
tank
and add oil as necessary.
tape.
containers
the hydraulic
control
the nuts to
loosen
to the full torque.
completing
at
torque,
seal the ports of
tank with adhesive
appropriately-sized
out when
to
with blind plugs to keep out foreign
the hydraulic
3) Have
of the disconnected
the
seals, tighten
of the specified
under-
fluid that will flow
the piping is disconnected.
Clean
up
all spills immediately.

4) When
working
yourself
5) Tag
under
the
machine,
position
out of the way of the oil shower.
the ends of all piping
removed
as well as
the ports to which they were attached.
00-23
PARTS
HANDLING
3. Handling
high-pressure
hoses
I) Do not try to shorten

the accompanying
Shorting
under
the hose. A hose shorter
than the specified
length is subject
to the defects
shown
in
figures.
pressure
increases
the tension.
Too
sharp
a bend
damages
FSO046
2) Make sure the hose is not twisted

The
FSO047
after it is installed.
letters
printed
on the
hose
soon
reveal
any twists.
FSO048
3)
Similarly,
the hose must not twist as it moves.
FSO049
Improper
the pipe
connection
causes
the
hose
to twist
as
moves.
FSOO50
4) The last figures on this page are examples
of poor connections.
e must
have
it to contract
FSO05
Rubbing
FSO053
00-24
sufficient
under
play
pressure
FSOO52
PARTS
HANDLING
4. Handling
hoses with
self-seal
1) Do
attempt
to connect
not
coupling
without
hydraulic
pressure.
The gushing
first
use
relieving
hydraulic
also damage
or disconnect
the
or
internal
fluid will not only soil
but the high flow rate may
the O-ring
a hammer
halves
tighten
them
tightly
together,
distance
the surroundings,
2) Never
2) Press the two
couplings
they
equivalent
the fastening
pathway
completely
uniformly.
If they
will
to the
together
and
are
held
separate
clearance
bolts and their
not
by
between
holes, forming
for oil leakage.
of the coupling.
to tighten
or loosen
coupling.
*
Such
sharp
leading
to
blows
oil
can deform
leakage
the coupling,
or cracking
of
the
coupling.
3) Protect
the
intrusion
disconnected
of
dust
disconnected
for
necting
to another
and
dirt
some
coupling
piping
from
the
! If it is to remain
time,
seal
by
or by fitting
cona dust
FSO057
cap or a blind plug to each end.

6. Using sealing
1) To
tape
prevent
around
oil
leakage,
the tapered
thread
wind
sealing
before
inserting
tape
the
plug into the plug hole.

2) Wrap
then
all but the first 1.5 threads

force
fingernail.
I.4
During
FSOO54
1) Follow
Wind
tape
into
the
at the tip and
threads
with
the tape in the same direction
as the threads.
storage
FSO055
5. Handling
the
ave 1.5 threads
FSO058
split flanges
the
bolt
bare.
tightening
sequence
given
in
the figure.
FSO056
00-25
PARTS
HANDLING
9. SPRING
Judging
ll.PUMP
WASHERS
I) After
suitability
I) Discard
the spring
washer
if the overlapping
assembly
pump
with
and before
oil
through
installation,
the
intake
fill the
port
to
provide initial lubrication.
portion is worn or damaged.
2) Before
installing
shaft
by
hand
smoothly
the
to
without
pump,
make
turn
sure
the
that
drive
it turns
any catching.
*
Inlet
-
If
FSO059
2) Discard if the distance P is more than 2t/3.
FSO062
3) Test
run the
installed
pump
and
check
for
unusual noises and leakage.
12. SEAL
I) Seal
FSOO60
RINGS
rings
are very
delicate,
so handle
and
store carefully.
2) Do not reuse rubber seal rings.

3) Avoid excessive stretching when fitting a seal
10. SPRING
(ROLL)
ring
PINS
over
a shaft;
it decreases
the
rings
fitting
a seal
performance.
Handling
spring
4) Remove
pins
all sharp
edges
before
ring into a slot on an abutment.

1)
A spring
pin performs
the split is placed
facing
somewhat
better
the load instead
when
of at a
right angle to the load.
Check for sharp edges and scratches
FSOO61
Seal ring
00-26
HOISTING
INSTRUCTIONS
HOISTING
INSTRUCTIONS
Slinging
near the edge of the hook may cause
Heavy parts (25 kg or more) must be lifted
the
with
a hoist etc. In the Disassembly
and As-
and a serious
25 kg or
maximum
strength
100%
88%
sembly
section,
every
more is indicated
1. If a part
cannot
machine
part weighing
clearly with the symbol
be smoothly
by hoisting,
removed
the following
Check
Check
for
removal
from
checks
of all bolts
to slip off the

accident
hook
during
hoisting,
can result. Hooks
the
should
fastening
the
79%
71%
41%
FSOO64
part to the relative parts.

for
interference
existence
of another
part
causing
with the part to be removed.
3) Do not sling a heavy load with one rope alone,

but sling with two or more ropes symmetrically
wound
2. Wire
ropes
I) Use adequate
of
parts
ropes
depending
to be hoisted,
referring
on to the load.
Slinging
with one rope may cause turning
of the load during
hoisting,
the rope, or slipping
on the weight
original
to the table
winding
untwisting
of
of the rope from
its
position
on
which can result in a dangerous
below:
When
galvanizing)
hoisting
the force
Rope diameter
(mm)
load,
Allowable
load (tons)
with
a load with two
subjected
the
hanging
shows the variation

hoisting
1 .o
10
angles.
to sling up to 1000
1.4
various hanging angles.
12.5
1.6
When
2.2
16
2.8
18
3.6
two
becomes
make a 120
ropes
as large
4.4
20
ropes
ropes,
table
below
load (kg) when

kg vertically,
sling a load vertically,
kg of total weight
weight
two
The
of allowable
11.2
2000
or more
to each rope will increase
is made with two ropes, each of which
is allowed
14
wide hanging angle from the hook.
Z or S twist ropes
without
the
accident.
4) Do not sling a heavy load with ropes forming
Wire ropes
(Standard
have
at the middle portion.
&
be made:
l
rope
1000
at
up to
can be suspended.This
kg when
two
ropes
hanging angle. On the other hand,
are subjected
as 4000
to an excessive
kg if they
force
sling a 2000
kg
load at a lifting angle of 150.

5.6
22.4
10.0
30
The
40
18.0
50
28.0
60
40.0
allowable
one-sixth
strength
or
load
value
one-seventh
is estimated
of
the
to be
breaking
of the rope used.

30"
2) Sling wire ropes from the middle

hook.
portion
of the
60"
Lifting angle
SO'
120"
1500
: cy
FSO065
00-27
HOISTING
INSTRUCTIONS
Approximate
reduction
of
allowable
load
for
3. Hanging
bolts
wire ropes at various hanging angles.
Hanging
91
angle
Reduction
120
50%
in %
02P-02
Hanging angles should not exceed
150.
5) When
hoisting
several
parts as a unit, be
careful not to allow any part of the unit to fall.
Use a suitable container when hoisting many
small parts at a time.
6) Select
the most suitable
hoisting a specially-shaped
sling device
object.
when
Part Number
04530-0815
Cylinder
head
7) When using a hoist to turn over a heavy part,

observe the following instructions:
l Clear as much
of the area surrounding
the
part as possible.
.
When
the ropes from slackening
changes.
Gradually
slacken
sure
that
the
the
wire
part
ropes
after
is completely
Slackening
the
ropes
before
complete
of the part may cause the part to fall
back to its original position.
80
018
10
1.5
18
150
04530-l
222
12
1.75
22
220
04530-l
628
16
2.0
28
450
04530-2030
20
2.5
30
630
04530-2438
24
3.0
38
950
04530-3045
30
3.0
45
1500
04530-3655
36
3.0
55
2300
04530-4625
46
3.0
25
3400
04530-487C
48
3.0
70
4500
* The
allowable
load
maximum
static
withstand.
The
in the
table
these
values
should
safety
in the
load
table
which
actual
hoisting
in the
table
factors
reduced,
means
the
bolt
can
load given
taking
the
into consideration,
as
operation.
are applicable
from a hoist.
the
of allowable
be
bolts will be subjected
vertically
00-28
15
04530-l
necessary
turned over.
turning
1.25
Allowable
load (kg)
and the
part from slipping when the center of gravity
making
turning the part over, take special care
to prevent
Pitch
to shocks
The
allowable
to the
bolts
during
loads
slung
STANDARD
TIGHTENING
TORQUE
STANDARD
1. STANDARD
TIGHTENING
The following
Disassembly
TIGHTENING
TORQUE
charts give the standard
OF
BOLTS
tightening
AND
torques
TORQUE
ml4
NUTS
of bolts and nuts. Exceptions
are given in sections
and Assembly.
Thread diameter
of bolt
(mm)
Width
across flat
(mm)
07
z
Nm
kgm
6
10
13
10
17
12
19
1 1.5 f
14
22
18.Ok2.0
16
24
28.523
279*29
18
27
39*4
383239
20
30
56?6
549t58
22
32
76a8
745278
24
36
94.5&10
927+98
27
41
135+15
1320&140
30
46
175220
1720&l
33
50
225&25
22102240
36
55
280*30
2750+290
39
60
335235
3280?340
1.35*0.15
This torque table does not apply to the bolts with which
to be used, or which
*
of
Nm (newton
2.TlGHTENlNG
require tightening
meter):
TORQUE
1 Nm f
OF
to otherwise
13.2+
3.2 a0.3
31.422.9
6.7 20.7
65.7t6.8
1 .o
112k9.8
177*19
nylon packings
specified
1.4
or other non-ferrous
90
metal washers
are
torque.
0.1 kgm
SPLIT
FLANGE
BOLTS
Use these torques for split flange bolts.
Threatf difi;eter
Tightening
torque
(mm)
Width
across flats
(mm)
10
14
12
17
11.5*1
11229.8
16
22
28.523
279+29
kgm
6.7kO.7
Nm
65.7k6.8
00-29
STANDARD
TIGHTENING
3. TIGHTENING
TORQUE
TORQUE
Use these torques
FOR
NUTS
OF
Sealing surface
FLARED
for nut part of flared.
FSOO68
Thread diameter
of nut part
(mm)
Width across flats

of nut part
(mm)
14
19
Tightening
torque
Nm
kgm
2.5 F0.5
24.5 t4.9
18
24
522
22
27
812
24
32
1423
137.3t29.4
30
36
1823
176.5t29.4
49tlS.6
78.5 k 19.6
33
41
2Ok5
196.1
36
46
2525
245.2*49
42
55
3oi5
294.2a49
COATING
The recommended
coating
Nomenclature
materials
prescribed
r+49
MATERIALS
in Komatsu
Shop
Manuals
Komatsu code
are listed
below.
Applications
LT-1A
Used to apply rubber pads, rubber gaskets, and cork plugs.
LT-1B
Used to apply resin, rubber, metallic and

non-metallic parts when a fast, strong seal is needed.
LT-2
Preventing
LT-3
Provides an airtight, electrically

Used for aluminum surfaces.
LG-1
Used with gaskets and packings to increase sealing effect.
LG-3
Hea;t-resistant
Adhesives
bolts, nuts and plugs from loosening

insulating
gasket for precombustion
and leaking oil.
seal.
chambers
and exhaust piping
Liquid gasket
LG-4
Used by itself on mounting surfaces on the final drive and transmission

(Thickness after tightening:
0.07 - 0.08 mm)
cases
LG-5
Used by itself to seal grease fittings, tapered screw fittings and tapered screw
fittings in hydraulic circuits of less than 50 mm in diameter.
Antifriction compound
(Lubricant including
molybdenum disulfide)
LM-P
Applied to bearings and taper shafts to facilitate

prevent sticking, burning or rusting.
Grease
(Lithium grease)
G2-LI
Applied to bearings, sliding parts and oil seals for lubrication,

prevention and facilitation of assembling work.
Vaseline
LT-2
00-30
Used for protecting
is also called
LOCTITE
battery electrode
in the shoo manuals
press-fitting
terminals from corrosion.
and to
rust
ELECTRIC WIRE
CODE
ELECTRIC
In the wiring
diagrams,
various
colors
and symbols
This wire code table will help you understand

Example:
05WB
indicates
CLASSIFICATION
a cable having
WIRE
are employed
WIRING
a nominal
the thickness
of wires.
number
05 and white
coating
with
black stripe.
BY THICKNESS
Number
strands
Dia. of strands
(mm)
Cable O.D.
(mm)
Cross section
(mm?
Current rating
(A)
Applicable circuit
01
11
0.32
0.88
2.4
12
Starting, lighting, signal etc
02
26
0.32
2.09
3.1
20
Lighting, signal etc.
05
65
0.32
5.23
4.6
37
Charging and signal
15
84
0.45
13.36
7.0
59
Starting (Glow plug)
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
j7a
Starting
100
217
0.80
17.6
230
Starting
CLASSIFICATION
to indicate
DIAGRAMS.
Copper wire
Nominal
number
CODE
BY
COLOR
109.1
AND
CODE
Instrument
Other
Code
Color
Black
White
Red
Green
Yellow
Blue
YR
LW
Yellow & Red
Blue & White
GR
YB
LR
Green & Red
Yellow & Black
Blue & Red
GY
YG
LY
Yellow & Green
Blue &Yellow
Primary
BW
2
WR
Black & White
RW
White & Red
Red &White
Green &White
3
Auxiliary
4
Black & Red
1 White
&Blue
1 Red &Yellow
Green &Yellow
Code
WY
RG
GB
YL
LB
Color
White &Yellow
Red & Green
Green & Black
Yellow & Blue
Blue &Black
Code
WG
RL
GL
YW
Color
White &Green
Red & Blue
Green &Blue
Yellow &White
00-3 1
WEIGHT
TABLE
This weight table is a guide for use when transporting or handling components.
(Unit: kg)
Engine assembly
1453
Radiator assembly
Torque converter assembly
I
I
Steering cylinder (I piece)
285
Brake (1 piece)
193
Hydraulic tank
980
Main control valve
47
170
90
Damper
91
Lift cylinder (I piece)
279
Center drive shaft
33
Dump cylinder
283
44
Engine hood
42
Front frame
2486
2012
Front drive shaft
Rear drive shaft
Front axle assembly
2028
Rear frame
Rear axle assembly
1776
Bucket link (with bushing)
Front differential assembly
43
94
288
Tilt lever (with bushing)
1::
Lift arm (with bushing)
1996
Planetary carrrer assembly (I prece)
Bucket with teeth
2351
Planetary hub assembly (I piece)
Counterweight
Rear different:
assembly
I
1
Axle pivot (Rear axle)

Wheel (I piece)
Tire (1 piece)
Steering valve
WA500-
92 (I 19)
Fuel tank
240
Battery (I piece)
421
Operators seat
55
Floor plate
457
880
I
I
328
53
40
131
0if3
TABLE OF OIL AND
RESERVOIR
KIND OF
FLUID
COOLANT
QUANTITIES
CAPACITY (PI
AMBIENT TEMPERATURE
-22
-30
-2
-1014
320
50
10
;:
::
g$E
Specified
Refill
,,,,.,.
,,,, :.:.:.:.:.:.:c:<.:;:.:.:.
,, ,.,,,,,......,,
~~~~~~~~~ii.i~~~~~~~~~
.:<.:.:.y..:.:.:<.:.:<.>,,,&
..,,._
(1.
*, ,n ,.,,,,.
.,.:,,.,............
Engine oil pan
28.5
Engine oil
Brake
2.4
62
Transmission case
150
Hydraulic system
AMa
(Front and rear)
Fuel tank
SW NOTE (4)
Diesel fuel
ASTM:
SAE:
each 75
435
Add antifreeze
Water
Cooling system
each 75
80
American Society of Testing and Material

Society of Automative Engineers
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity:
Amount
of oil needed to refill system during normal inspection and maintenance.
NOTE:
(I) When fuel sulphur content is less than 0.5%,
change oil in the oil pan every periodic maintenance hours described in this manual.
Change oil according to the following table if fuel
sulphur content is above 0.5%.
Change interval of oil
in engine oil pan
Fuel sulphur content
0.5 to 1.O%
Above 1.O%
I
I
(2) When starting the engine in an atmospheric temperature of lower than OC, be sure to use engine
oil of SAEl OW, even though an atmospheric temperature goes up to 10C more or less in the day
time.
(3) Use API classification CD as engine oil and if API
classification CC, reduce-the engine oil change interval to half.
(4) For axle oil, use only recommended oil as follows.
DONAX TT or TD
SHELL:
RPM TRACTOR HYDRAULIC FLUID
CALTEX:
CHEVRON: TRACTOR HYDRAULIC FLUID
TEXACO:
TDH OIL
MOBILAND SUPER UNIVERSAL
MOBIL:
* It is possible to substitute engine oil CLASS-CD
SAE30 for axle oil.
If noise comes from the brake, it is no problem of
durability.
o634
WA500- 1
10 ENGINE
VHEEL n4DER
ENGINE
11 STRUCTURE
AND
FUNCTION
Engine mount .............................

Radiator ..................................
Fuel tank and piping ........................
Engine control .............................
WA500-
11-2
11-3
11-4
11-5
11-l
ENGINE MOUNT
Section A - A
Section B - B
425FOO7
The engine is mounted
separately from the torque
converter and transmission.
Both front and rear have rubber mounts.
1. Rear mount
2.
11-2
Front
mount
WA500-
RADIATOR
Section A - A
1.
Radiator
2.
Coolant level sensor
3.
Fan guard
425FOO8
Specifications
Core type:
Total
Cross-sectional
4.
G7 type
heat dissipating
area:
area of water
89.9
cm2
tubes:
193.8
cm2
Torque converter oil cooler
5.
Hydraulic oil cooler
A.
Coolant inlet port
B. Coolant outlet port

C. Wind
WA500-
11-3
FUEL TANK
AND
PIPING
The fuel level sensor is installed in the fuel tank.
11-4
1.
Fuel level sensor
2.
Drain valve
3.
Injection pump
WA500-
ENGINE
CONTROL
F42101002
WA500-
1.
Accelerator pedal
2.
Accelerator cable
3.
Injection pump
1 l-5
ENGINE
12 TESTING
AND
ADJUSTING
...................
...........
Adjusting valve clearance ................
Measuring compression pressure ...........
.........
Testing and adjusting fuel injection
Measuring blow-by pressure ..............
Testing and adjusting belt tension ..........
Measuring exhaust gas color ..............
Standard value table
Tool list for testing and adjusting
Measuring engine oil pressure and temperature

Adjusting fuel cut solenoid
...............
12- 2
12- 3
12- 4
12- 5
12- 6
12- 8
12- 9
12-10
. . 12-l 1
12-12
Measuring accelerator pedal operating force
..................
and operatin angle
The following
precautions
12-13
are necessary when using the Standard Value Tables to make judgement
during trouble-
shooting or during testing and adjusting.

1.
The values in these tables are based on the values for new machines leaving the plant, so they should be used
as target values when repairing or when estimating wear after a period of use.
2.
The standard
values in these tables for judgement
when troubleshooting
are estimated
values based on the
standard values for the machine when shipped from the plant, and on the results of various tests.
Therefore,
they should be used as reference in combination
with repair and operating
records when making
judgements.
3.
These
standard
these values
WA500-
value
alone
tables
to make
must
simple
not be used for standard values
when
judging
claims.
In addition,
do not use
judgements.
12-1
0
STANDARD
VALUE TABLE
Engine
Cate-
KOMATSU
Condition
Item
S6D140-1
Unit
Standard value
Permissible value
rpm
2250 - 2350
slow
High idling speed
I-----
Engine speed
:
E
b
=
a
. Necessary
660 - 720
starting speed
Intake resistance
z
>
0l
Exhaust temperature
5
2
!z
0
:
Exhaust gas color
Oil pressure
(entine water tempwrature
green range
E
r
t
All speed (intake air temp. 2OC
OC
Oil temperature
1 Oil consumption ratio
Bosch index
Max. 4.0
5.0
At high idling
Bosch index
Max. 1 .O
2.0
Intake valve
mm
0.43
Exhaust valve
mm
0.80
Oil temperature 40 - 60C

(engine speed: 160 - 200 rpm)
kg/cm
Min. 32
22
At high idling
mmH,O
Max. 100
200
kg/cm
3.5 - 5.5
2.0
Min. 1.0
0.7
Min. 1 .O
0.7
At high idling
At low idling
SAE30
Coolant temperature
kg/cm
Whole speed range

(inside oil pan)
OC
At continuous rated horesepower

(proportion
rg
110
120
Max. 0.5
1 .o
80-
to fuel consumption)
Nozzle tester
kg/cm2
Before top dead center
degree
27
27 * 1
70 - 95
100
74.5 - 78.5
74.5 - 78.5
Whole speed range

(at engine outlet)
250*
E
t;
?;
10
250 c 10
90
90
Thermostat function
.-r
5
s
Max. 650
At abrupt acceleration
SAEIOW
.-5
Max. 650
9.5 Fan belt tension

(Tension pulley-
9.5 -
10.5
6
I
kg
8-9
Max. 13.5
I
i
z
&
z
s
Operatinganglea
Stopper height L,
o1 45 os 30
15-25
14-24
136 -
12-2
0
10.5
146
WA500-1
TOOL LIST FOR TESTING

NO
Testing and measuring
item
AND
Tool Name
Battery
specific gravity
Coolant
freezing temperature
Water temperature,
oil temperature, intake temperature
Battery
Exhaust temperature
Lubricating
Fuel pressure
Intake pressure,
exhaust pressure
Blow-by
coolant
Thermistor
temperature
Part No.
Remarks
xx
Digital display 60-19999
Tachometer
Engine speed
ADJUSTING
tester
rpm
gauge
799-l 01-6000
0 -
oil pressure
Engine pressure
measuring kit
799-203-2002
10 kg/cm
2
0 - 1000 mmH,O
pressure
10
11
Compression
12
Blow-by
13
Valve clearance
Feeler gauge
795-l 25-1210
0.43, 0.80 mm
14
Exhaust gas color
Handy smoker checker
799-2 1O-9000
Discoloration
(Discoloration
15
Fuel on water mixed in oil
Engine oil checker
799-201-6000
Water content 0.1%. 0.2%

in standard sample
16
Coolant
Water quality
799-202-7001
PH. nitrous
17
Leakage from cooling
Cap tester
799-202-9001
0 - 2 kg/cm
18
Fuel injection pressure

Nozzle injection condition
Nozzle tester
Commercially
available
0 - 300 kg/cm
19
Electrical
Tester
Commercially
available
Current,
20
Accelerator
Push-pull scale
79A-262-0020
Commercially
Compression
pressure
Blow-by
pressure
quality
circuit
pedal force
system
gauge
checker
tester
0 to 70% standard color

%x l/10 = Bosch index)
acid ion concentration
voltage, resistance
available 0 - 25 kg
n!
When carrying out testing, adjusting or troubleshooting,
Qf
When working in groups, use agreed signals and do not allow unauthorized
n!
When checking the water level in the radiator wait for the water to cool.
Qt
Be careful not to get caught in rotating parts.
stop the machine on level ground, insert the safety pins
and block the tires.
the water is hot.
WA500- 1
persons near the machine.

Do not remove the radiator cap while
Boiling water may spurt out.
12-3
0
ADJUSTING
*
Condition:
Adjust
VALVE CLEARANCE
Engine is cold.
clearance
between
crosshead
and rocker
lever
as follows.
Unit:
mm
Intake valve
Exhaust valve
0.43
0.80
Cold
Special tool
Part No.
A
Part Name
Feeler gauge
795-l 25-1210
Remove cylinder
Rotate
the
align
pointer
(2) with
shaft
pulley.
When
1.6 TOP
head cover (1).
crankshaft
of the valves.
Qty
in the
normal
rotating,
to
on crank-
check the movement
When the pointer
mark,
direction
the 1.6 TOP mark
is in line with
No. 1 cylinder
should
the
be at com-
pression top dead center.

When
No.
1 cylinder
is at compression
center, adjust the valve marked

When
No.
6 cylinder
is at compression
center, adjust the valves marked

Cylinder No.
I,
I-
Intake valve
To
adjust,
insert
and crosshead
until
I,
Exhaust valve
4.
2
l
tool
is a sliding
nut (6) to hold adjustment

m
5.
Lock nut:
Next,
rotate
crankshaft
and adjust
maining
valves marked
After
adjusting
top dead center,

shaft
120
ance
of
Then
rocker
adjustment
fit.
I II
lever
(3)
screw
(5)
tighten
lock
screw in position.
one turn
the
valve
in the normal
clearance
of the
dire-
0.
No.
1 cylinder
at compression
it is also possible to turn crank-
each time and adjust
each
dead
6.0 ? 0.6 kgm
rection
*
top
II
A between
(4) and turn
clearance
deal
0.
3
I,
top
0.
cylinder
the valve clear-
according
to the
firing
order.
- Firing order:
*
After
tightening
l-5-3-6-2-4
the
lock
nut,
check
the clear-
ance again.
615OF201
12-4
0
WA500-
MEASURING
*
Measurement
COMPRESSION
PRESSURE
condition
* Coolant temperature:
Inside operating range.
* Engine valve clearance: Standard value.
* Engine speed: 160 to 200 rpm
Unit:
Item
kg/cm*
Standard value
Permissible value
Min. 32
22
Compression
pressure
Special tools
Part No.
Compression gauge
510
/
1
Adapter
520
Plate
Tachometer
795-502-I
204
795-502-I
A,
1
I
795-502-I
8
*
799-203-8000 1
If performance
the piston,
tests
piston
or troubleshooting
ring or cylinder
When
1.
measuring
the
compression
pressure,
be
the
manifold
or
not
muffler,
or to get caugh t in rotating
Adjust
touch
exhaust
careful
to
shows that
liner may be worn,
pressure.
measure the compression
I Otv
Part Name
parts.
valve clearance.
For
details,
see ADJUSTING
VALVE
CLEAR-
ANCE.
2.
Warm up engine (oil temperature
3.
Remove nozzle holder

*
40 to 6OC).
assembly.
For details, see REMOVAL
OF NOZZLE
HOLD-
ER ASSEMBLY.
4.
Install
tool A, AI
assembly,
and Az in mount
and connect
5.
Set engine tachometer
6.
Disconnect
B in position.
fuel CUT-OFF
Crank engine with
of nozzle holder
pressure gauge.
solenoid
valve connector.
motor
and measure com-
starting
pression pressure.
*
Measure
where
the
the
compression
pressure
pressure
gauge
at the point
indicator
remains
steady.
*
When
measuring
measure
within
*
Installing
the
the specified
the
nozzle
ing the compression

For
the
engine
details,
see
compression
speed to confirm
pressure,
that
it is
range.
holder
assembly
after measur-
pressure.
INSTALLATION
HOLDER
ASSEMBLY.
WA500-
OF
NOZZLE
TESTING
*
AND
ADJUSTING
FUEL INJECTION
TIMING
Measurement condition
- Coolant temperature:

Unit:
Fuel injection
timing
TESTING
B.T.D.C.
FUEL
1.
Disconnect
2.
Remove
delivery
Permissible value
Standard value
Item
degree
27
27 + 1
INJECTION
TIMING
fuel injection pipe (1) of No. 1 cylinder.
delivery
valve
holder
(2),
then
remove
valve (3) and spring (4). and install deliv-
ery valve holder (2) again.

3.
4.
Place accelerator pedal at FULL

Operate
slowly
priming
in normal
pump
position.
and
direction.
rotate
Check
crankshaft
point
where
fuel stops flowing from delivery valve holder (2).

5.
Check that 27 I.J. line on damper (5) and pointer

(6) are aligned at point where fuel stops flowing.
*
BEYOND
injection timing line:
Timing
*
BEFORE
RETARDED
injection timing line:
Timing ADVANCED
*
If the test shows that the fuel injection
timing
is
incorrect, adjust as follows.
12-6
0
WA500- 1
ADJUSTING
FUEL INJECTION
BY DELIVERY
CHECK
6.
Turn
crankshaft
TIMING
back 30 to 40
from
top
dead
center.
7.
Rotate
crankshaft
to align 27
I.J. line on crank-
shaft pulley and pointer correctly.

8.
Loosen nut
(7) on the
injection
flange
and
the
bolt,
rotate
side little
by little
(8)
no fuel
until
pump mounting
flange
on the
pump
by operating the priming pump

flows
out of the
delivery
valve
holder.
9.
Tighten
nut (7) in oblong hole of mounting
flange
of fuel injection pump.

*
After
tightening
the nut, check again that the
fuel stops flowing

at the point
from the delivery valve holder
where
the pointer
the line on the crankshaft

IO.
Remove
delivery
ery valve (3)
is aligned with
pulley.
valve holder
(2), assembly deliv-
and spring (41, then install delivery
valve holder (2) again.

w
11.
Delivery holder:
3.3 f 0.2 kgm
Connect fuel injection pipe (1).

w
Sleeve nut:
WA500- 1
2.4 i 0.1 kgm
12-7
0
MEASURING
*
BLOW-BY
PRESSURE
- Coolant tempe*ure:
* Engine valve clearance: Standard value.
* Engine oil temperature: Min. 60C
Unit:
Permissible value
Standard value
Item
Blow-by
pressure
Max. 100
mmH,O
Max.200
Special tool
Part Name
Part No.
Q
f
799-201-l
Blow-by checker
503
When taking measurements,

the exhaust
Oty
manifold
be careful not to touch
or muffler,
or to get caught
When measuring the blow-by,
warm the engine
in rotating parts.
1.
Measuring blow-by
up thoroughly.
Stop
engine
and
install
adapter
of
blow-by
checker on engine breather hose (1).

Connect
adapter
mmH,O)
to hose.
and
blow-by
(0 to
500
Run the engine at high idling and measure the

blow-by pressure.
2.
Precautions when measuring blow-by

*
The
blow-by
should
be
measured
with
the
engine running at rated output.
- When measuring in the field, a similar value

can be obtained at stall speed.
- If it is impossible to check at rated output

or stall speed, measure at high idling.
In this case, the blow-by value will be about
80% of the value at rated output.
*
Blow-by
may
vary
greatly
according
to
the
condition
of the engine, so if there is any ab-
normality
in the reading,
lem
related
cessive
to
oil
gas color,
defective
consumption,
or
early
check for
blow-by,
defective
deterioration
any prob-
such as exexhaust
or contami-
nation of the oil.
12-8
0
WA500-
TESTING
TESTING
TENSION
AND
AND
ADJUSTING
ADJUSTING
BELT TENSION
FUN
BELT
Approx. 6 mm
Unit:
Standard
value
Item
mm
Permissible
value
I
Deflection of belt
Testing fun belt tension

Check the amount the fan belt deflects when pushed with a force of approx.
6 kg at a point mid-way
between the fun pulley and tension pulley.

Use a scale to measure the amount the V-belt deflection.
Adjusting fun belt tension

1)
Loosen lock nut (I) of tension pulley.
2)
Adjust
the belt tension
of adjusting bolt
(2),
tighten lock nut of tension pulley.
TESTING
AND ADJUSTING
BELT TENSION
ALTERNATOR
Approx.
Unit: mm
Standard
value
Item
Deflection of belt
15 mm
Alternator pulley
Permissible
value
-
15
Approx. 6 kg
Testing alternator
belt tension
Check the amount the alternator

pushed with
mid-way
a force
between
of approx.
the alternator
belt deflects when

6 kg at a point
pulley
and water
pump pulley.
Water pump pulley

425F202
Use a scale to measure the amount the V-belt deflection.

Adjusting alternator
1)
belt tension
Loosen alternator
mount bolt, nut (I) and bolt
(2) of adjusting plate.

2)
Use a bar, rise alternator

tension
adjusting
of
belt
(3),
plate
as
assembly and adjust
and tighten
first,
tighten
bolt
(2)
of
alternator
mount bolt, nut (1).
WA500- 1
12-9
0
MEASURING
*
.
.
Measurement
EXHAUST
GAS COLOR
condition
Coolant temperature:
Valve clearance:
inside operating range.
Standard value.
Unit:
Standard
value
Permissible
value
Acceleration
Max. 4.0
5.0
High idling
Max. 1 .o
2.0
Part Name
Oty
Smoke meter
Item
Exhaust
color
Bosch index
Special tool
Part No.
Commercially
available
Q
f
When measuring the exhaust color,
be careful
not to touch the exhaust pipe.
When measuring the exhaust color, warm the engine

up thoroughly
(oil temperature
6OC).
1.
Insert probe A rn outlet of exhaust pipe (I)

0
secure to exhaust pipe with clip.
2.
Connect
probe hose, connector
switch and air hose

*
and
hose of accelerator
to smoke meter A.
8
The pressure of the air supply should be under
15 kg/cm2.
3.
Connect power cord to socket.

t
Check
that
the power
switch
is OFF
before
connecting the cord.

4.
Loosen cap nut of suction
pump and insert filter
paper.
5.
Turn power switch ON.
6.
Accelerate
engine suddenly.
press accelerator
At the same time, de-
switch of smoke meter, operate re-
lief valve and catch exhaust gas color on filter paper.

7.
Lay filter
top
of
paper used to catch exhaust gas color on
unused
filter
papers (IO
sheets or more)
inside filter paper holder, and read indicated value,
12-10
0
WA500-
MEASEURING
ENGINE
MEASURING
ENGINE
*
.
condition
Measurement
Coolant
OIL
temperature:
OIL PRESSURE
TEMPERATURE
PRESSURE
Inside operating
range.
Unit:
Item
AND
Standard value
kq/cm*
Permissible value
Oil pressure
High idling
Low idling
Min. 1 .O
0.7
Special tool
Part No.
Part Name
Engine pressure
measuring kit
799-203-2002
n
n !
When measuring,
rotating
Oty
be careful
not to get caught in
parts.
Install
and
remove
the
plug
and oil
pressure
gauge with the engine stopped.

*
1.
Measure
the engine
perature
is at the specified
Disconnect
plug
2.
oil pressure when
connector
of
the oil tem-
temperature.
wiring
(I),
then
remove
(2).
Install oil pressure gauge A (20 kg/cm2).

*
Install
the oil pressure gauge so that it is affect-
ed as little as possible by the engine vibration.

3.
Start engine and measure oil pressure.
MEASURING
OIL
TEMPERATURE
Measurement
condition
Coolant
temperature:
Item
Inside operating
Standard value
Oil temperature
range
Permissible value
80-llOC
120c
Special tool
A
Al
1.
2.
I
I
Part No.
Part Name
799-l016000
Thermister temp. gauge
799-l 01-6140
sensor
Qty
Remove dipstick
(1).
Insert sensor A,
of thermistor
temperature
gauge in
sensor to thermistor
temperature
gauge A
dipstick
Connect
guide.
and measure temperature
WA500- 1
of oil in oil pan.
12-11
0
ADJUSTING
1.
FUEL CUT SOLENOID
Adjust rod 15) while pulling rod (5) in the running direction so that there is clearance of 0.4 kO.1 mm between
stop lever (4) and stopper (7).
2.
Turn
on the engine starting
solenoid
key and confirm
that the
has a stroke of 12 mm and clearance of 0.4 *
0.1 mm.
3.
After
turning
reconfirm
on and off the key two or three times,
that solenoid works smoothly and engine runs
v;
or stops completely.
*
If the solenoid does not work

coil
burns
flywheel
in the
horsepower
cause of
smoothly,
solenoid
excessive current
or
downs in the cause of dropp-
ing fuel injection volume.
is
_1
IL
-.
621OFlll
12-12
0
WA500-
MEASURING
ACCELERATOR
AND OPERATING ANGLE
*
PEDAL OPERATING
FORCE
Unit:
Item
Permissible value
Standard value
Operation force of
accelerator pedal
kg
13.5
8-9
Special tool
Part No.
Part Name
aty
423F304
OPERATING
1.
Push-pull scale
79A-262-0020
FORCE
Measuring procedure
1)
Put push-pull
celerator
scale A in contact
pedal at point
150
with the ac-
mm from
pedal
fulcrum a.
*
The
center
contact
of
push-pull
with a point
scale A must be in
150 mm from
the pedal
fulcrum.
2)
Start
tion
the engine, push the pedal in the direcof operation
and measure the maximum
value when pushing from
idling to the end of
the pedal travel (high idling).

Testing and adjusting
1)
2)
Stop the engine.

Disconnect
the cable (1) at the bottom
accelerator
pedal,
of the
and check that the linkage
(2) and ball joint (3) at the bottom of the pedal

move smoothly.
3)
Connect
then
the cable at the bottom
disconnect
injection
pump,
at
the
of the pedal,
connection
for
the
and check that the cable (4)
moves smoothly.
*
When
carrying
out
this
inspection,
or replace parts as necessary.

operating
force
adjust
Measure the
again and check that
it is
within the standard value.
WA500-
12-13
0
OPERATING
ANGLE
OF ACCELERATOR
PEDAL
423F305C
1.
Measuring procedure
1)
2)
Stop the engine.

Measure the operating
pedal
it is operated
a2, put the
angle q,
angle gauge A in contact
with
from
the accelerator
low-idling
and high
idling.
3)
2.
Measure installed
length X of rod (1).
Adjusting procedure
1)
2)
Remove cover under cab.

Loosen
nut
X of the
3)
Loosen
4)
L1
of
Loosen
nut (3) and adjust

L2
Adjust
the
injection
length
pump
high idling
(high
idling)
stopper
value.
pedal
stopper
is
bolt so that installed
accelerator
the standard
length
value.
height
of
installed
the standard
bolt so that installed
accelerator
the standard
within
5)
so that
(1) is within
nut (2) and adjust
height
within
and adjust
rod
pedal
stopper
is
value.
of the
governor
rod
(4) so that
lever
contacts
the
the
when the pedal is depressed
and still
tighten
stopper
bolt
(3)
half turn.
12-14
0
WA500- 1
ENGINE
13
STARTING
DISASSEMBLY
AND
TURBOCHARGER
MOTOR
.. ..
. ...... ..
Installation
. .. .........
Removal
. .
13-2
Removal
. .
13-2
Installation
. .
13- 3
Removal
. .
13- 3
Installation
AIR
ALTERNATOR
...... .
.... ..
Installation
.. .......... ...
Removal
OIL
..............,..
Installation
....., ........
INJECTION
Removal
. .
13-4
Installation
. .
13- 5
...
...
...........
...........
13- 9
_. . . . . . . .
.... ...
...........
...........
13-10
..........
.... ....
...........
13-21
...........
13-23
........._
........
...........
13-25
...........
13-31
..........
_. . . . . . .
...........
13-37
...........
13-38
.....
....
13- 9
13-15
Removal
. . 13- 5
Installation
ENGINE
....
... .
Installation
........
.........
. .
13- 6
Removal
. .
13- 6
Installation
. .
13-7
Removal
. .
13-7
Installation
FUEL
HOLDER
.......
Installation
.
..
Removal
Take
.......
. .....
the
cylinders
1.
2.
following
for
air bleeding
cylinders,
TANK
when
you
start
to operate
hydraulic
pumps and pipings.
Start engine, keep idling.

Operate
hydraulic
cylinder
4 -
5 cycles,
but do not exceed beyond
100 mm or
end.
3.
Continue
4.
After
NOTE:
method
after reassembling
stroke
WA500-
13- 8
... ....
.. ...
RADIATOR
PUMP
Removal
NOZZLE
13- 8
...........
HEAD
. . 13-4
PUMP
...... ..........
Installation
. ............
Removal
WATER
...........
..
COMPRESSOR
CYLINDER
COOLER
Removal
FULE
ASSEMBLY
to operate
finishing
After
cylinder
3 - 4 cycles until
above steps, keep normal
stroke
end.
engine speed.
long storage, same procedure
is required.
13-1
0
REMOVAL
n!
1.
OF STARTING
MOTOR
ASSEMBLY
Disconnect the cable from the negative (-) terminal

of the battery.
Remove catch, open side cover, then
remove two side
covers.
2.
Disconnect connector (1).
3.
Disconnect wire (2).
4.
Remove
ground
connection
(3). then
remove starting
motor assembly (4).
INSTALLATION
OF STARTING
MOTOR ASSEMBLY
1.
Fit gasket and install starting motor assembly (4), then

tighten together with ground connection
(3).
2.
Connect wire (2).
3.
Connect connector
4.
Install cover, close two side covers, then lock with catch.
5.
Connect cable to negative (-)
13-2
0
(1).
terminal
of battery.
WA500-
REMOVAL
Disconnect the cable from the negative (-) terminal

of the battery.
1.
Remove catch, then open side cover.
2.
Disconnect wires (l),
3.
ASSEMBLY
OF ALTERNATOR
Remove
bolt
(4)
(2) and (3).

of
adjustment
plate,
then
loosen
mounting bolt and nut (5).

4.
5.
Remove adjustment
Move alternator
plate (6).
assembly towards lower to loosen belt
tension, then remove belt (7).

6.
Remove mounting
bolt and nut, then remove alternator
assembly (8).
INSTALLATION
OF
ALTERNATOR ASSEMBLY
Install
alternator
assembly
(8), then
partially
tighten
mounting bolt and nut (5).

2.
Fit belt (7) in pulley groove and install,
3.
Install adjustment
4.
Partially tighten bolt (4) of adjustment
5.
plate (6).
Insert a bar between

block,
raise alternator
alternator
plate.
assembly and cylinder
assembly and adjust tension of
belt.
+
The belt should deflect
about
15 mm when pushed
with a finger pressure of 6 kg at a point midway

tween the alternator
Tighten
bolt
be-
and the fan pulley.
of adjustment
plate,
mounting
bolt
and
nut.
Connect wires (3), (2) and (1).
Close cover, then lock with catch.
Connect cable to negative (-)
WA500- 1
terminal
of battery.
13-3
0
REMOVAL
1.
2.
OF OIL COOLER ASSEMBLY
Remove catch, then open engine left side cover.

Loosen drain valves (I),
t
If the coolant
(2) and drain cooling
contains
antifreeze,
water.
dispose of it cor-
rectly.
3.
Remove
connector
(3) between
oil
cooler
and water
pump.
4.
Remove muffler
5.
Disconnect
6.
Remove
sembly
drain tube (4).
turbocharger
mounting
drain tube
bolts
(6), then
(5).
remove
oil cooler
as-
(7).
INSTALLATION
OF OIL
COOLER ASSEMBLY
1.
Fit
gasket and set oil cooler
block
side, then tighten
2.
Fit gasket and connect
3.
Install muffler
4.
assembly
mounting
turbocharger
drain tube
Fit gasket and install
bolts
(7) on cylinder
(6).
drain tube
(5).
(4).
connector
(3) between
oil cooler
and water pump.

5.
Tighten
drain
valve
(I)
and
water filler to the specified

*
Run
the
system.
6.
engine
to
(2) and add water
circulate
the water
through
the
Then check the water level again.
Close engine left side cover and lock with
13-4
0
through
level.
catch.
WA500-
REMOVAL
OF FUEL INJECTION
1.
Remove three side covers of engine right hand.
2.
Disconnect
control
3.
Disconnect
fuel hoses (3). (4) and (5).
4.
Disconnect
fuel feed hose (6).
5.
Remove lubrification
6.
Disconnect
7.
Remove flange lock bolt
8.
rods (1) and (2).
tubes (7) and (8).
6 fuel injection
Remove 4 mounting
tion
*
PUMP
pump assembly
When removing
tubes (9).
(IO) of fuel injection
bolts
(11). then
pump.
pull out fuel injec-
(12).
fuel injection
pump
assembly
do not
lose the key.
INSTALLATION
OF FUEL
INJECTION
PUMP ASSEMBLY
1.
Set fuel
tighten
+
injection
pump
4 mounting
When
assembly
(12) in position,
and
bolts (11).
installing
fuel
injection
pump,
insert
key se-
curely.
2.
Tighten
lock bolts
(IO) of coupling.
3.
Connect
6 fuel injection
Sleeve nut:
tubes (9).
2.4 + 0.1 kgm
4.
Fit gaskets and install lubrication
5.
Fit gaskets and connect
fuel feed hose (6).
6.
Fit gaskets and connect
fuel hoses (5), (4) and (3).
7.
Connect
*
*
control
8.
rods (2) and (I).
To adjust
fuel cut solenoid,
JUSTING
FUEL
To adjust
fuel
ADJUSTING
tubes (8) and (7).
see TESTING
injection
FUEL
timing,
INJECTION
see TESTING
TIMING.
Install cover, close cover, then lock with
WA500-
AND
AD-
CUT SOLENOID.
catch.
AND
ASSEMBLY
REMOVAL
1.
OF WATER
PUMP
ASSEMBLY
Remove catch, then open side cover of engine left side.

Loosen drain valve (1). (2) and drain cooling water.
2.
If the coolant
contains antifreeze,
dispose of it cor-
rectly.
3.
Remove
alternator
ALTERNATOR
assembly
is see
REMOVAL
4.
Remove connector
5.
Disconnect connector
6.
Remove spring (5) and push up tube (6) with bar.
7.
Remove bolt (7) and remove pulley (8).
8.
OF
ASSEMBLY.
(3) between water pump and cooler.
Remove 4 mounting
(4) of water pump outlet tube.
bolts (9) and remove water pump
assembly (10).
INSTALLATION
OF WATER
PUMP ASSEMBLY
1.
Fit O-ring and install water
pump assembly
(lo),
then
tighten 4 bolts (9).

2.
Connect pulley (8) and tighten bolt (7).
3.
Push down tube (6) and install spring (5).
4.
Fit gasket and connect water pump outlet connector
5.
Fit
gasket
on
both
sides and connect
connector
(4).
(3)
between water pump and cooler.

6.
To install alternator
ALTERNATOR
7.
Tighten
assembly, see INSTALLATION
OF
ASSEMBLY.
drain valve (2). and (1) and add water through
water filler to the specified level.

*
Run the
system.
8.
engine to circulate
the water through
the
Close side cover and lock with catch.
13-6
0
WASOO-
REMOVAL
Preparatory
OF NOZZLE
HOLDER
work
Remove side cover, exhaust pipe and hood.

*
Remove
cylinder
sembly,
muffler
head assembly,
assembly intake
cleaner assembly, then disconnect
nozzle
holder
connector
as-
and air
all nozzle holders
No. 1 to No. 6.
1.
Remove mounting
bolt (I) head cover, and remove head
cover.
2.
Disconnect fuel injection tube (3).
3.
Remove lock nut (4) and disconnect connection
4.
Disconnect bolt (6) and remove nozzle holder.
5.
Screw in forcing bolt @

1.5 mm)
to
nozzle
(Thread dia. 10 mm,
holder
and remove
nozzle
(5).
Pitch =
holder
assembly (8).
t
When removing the nozzle holder,
clean around the
nozzle holder and prevent dust or dirt from entering.

*
Checking gasket on the tip of nozzle holder fitting.
INSTALLATION
OF NOZZLE
HOLDER ASSEMBLY
*
Check that dirt and foreign matter are not in the sleeve
of nozzle holder.
Check that there is a gasket on the tip of nozzle holder

fitting.
*
1.
Check that there is no damage to O-ring.

Fit O-ring and install nozzle holder assembly (8). and fit
holder (7), then tighten bolt (6).
w
2.
Bolt:
6.75 +_0.75 kgm
Insert connection
(5) and tighten lock nut (4).
Connection:
Lock nut:
3.8 f 0.3 kgm

6.5 f 0.3 kgm
3.
Connect fuel injection tube (3).
4.
Fit gasket, install head cover (2) and tighten bolt (I).
m
5.
Bolt:
0.4 f 0.1 kgm
Install hood, exhaust muffler and side cover.
WA500-
ASSEMBLY
REMOVAL
Preparatory
OF TURBOCHARGER
work
Remove side cover, exhaust

*
ASSEMBLY
Remove
exhaust
assembly,
muffler
muffler
and hood.
assembly
see REMOVAL
OF
and air cleaner
CYLINDER
HEAD
ASSEMBLY.
1.
Disconnect
clamp
(I)
and disconnect
inlet
connector
(2).
2.
3.
Disconnect
Remove
supply
hose (3) and drain pipe (4).
mounting
turbocharger
bolt
assembly
(5) of turbocharger,
and remove
(6).
INSTALLATION
OF
TURBOCHARGER
ASSEMBLY
1.
Fit
gasket
tighten
*
3.
install
Mount
bolt:
Fit gasket, connect

Fit
turbocharger
mounting
Fit the gasket with
m
2.
and
turbocharger
O-ring
UP
bolt
assembly
(6), then
(5).
mark facing up.
6.75 f 0.75 kgm
drain pipe (4) and supply
and gasket,
install
inlet
hose (3).
connector
(2) and
clamp (I).
*
Install exhaust
For
details,
HEAD
4.
muffler
see
OF
CYLINDER
ASSEMBLY.
Install hood, exhaust
13-8
0
assembly.
INSTALLATION
pipe and side cover,
WA500-
REMOVAL
OF AIR COMPRESSOR
1.
of
Remove
catch
engine right side cover, then
ASSEMBLY
open
cover.
2.
Disconnect air tubes (I),
3.
Disconnect water tube (4).
4.
Remove lubrication
5.
Remove mounting
(2) and (3).
tubes (5) and (6).

bolts (7), then remove air compressor
assembly (8).
INSTALLATION
COMPRESSOR
1.
OF AIR
ASSEMBLY
Fit O-ring and install air compressor assembly (81, then

tighten mounting bolts (7).
2.
Fit gasket and install lubrication
3.
Fit gaskets and install water tubes (4).
4.
Fit gaskets and install air tubes (31, (2) and (I 1.
5.
tubes (6) and (5).
Close cover of engine right side cover, then lock with

catch.
WA500-
13-9
0
REMOVAL
1.
OF CYLINDER
HEAD
ASSEMBLY
Hood, side cover

1) Remove
exhaust
pipe
(I),
sling hood
(2), then
lift
off.
2) Remove left and right hand engine side cover.
2.
Draining
water
Loosen drain valve (3) and drain coolant.

*
If
the
coolant
contains
antifreeze,
dispose
of
it
correctly.
3.
Bracket
Disconnect
4.
cable bracket
(4).
Tube
Disconnect
5.
fuel control
muffler
Piping, corrosion
1) Disconnect
drain tube
(5).
resistor
piping
(6), then
remove
piping
(7) and
(8).
2) Remove corrosion
13-10
0
resistor assembly
(9).
WA500-
6.
Muffler
assembly
1) Disconnect komaclone
pipe at flange (10) end.
2) Remove bracket mounting bolts (11).

3) Remove elbow (12) mounting bolts.
4) Remove
muffler
assembly
(13),
then sling muffler,
bracket and connector as one unit.
el
Muffler assembly:
kg
7.
50 kg
Switch, hose
1) Disconnect
wire
(15).
then
remove
electrical
air
intake heater switch assembly (14).

2) Disconnect komaclone
8.
intermediate
hose (16).
Compressor tube
Remove tube (17) between air cleaner and compressor.
*
9.
Remove two clamps.
Connector assembly
1) Remove clamp (18).
2) Remove
mounting
connector
bolts
(19)
then
remove
(20).
3) Remove electrical air intake heater (21).
WA500-
intake
,,,
10. Air cleaner assembly

1) Remove air cleaner mounting band.
2) Remove
intake
connector
bracket
mounting
bolts
(22).
3) Remove
air cleaner
cleaner and intake

m
11.
assembly
(231, then
sling air
connector as one unit.
Air cleaner assembly:
35 kg
,, ,,,,,
Intake manifold
Remove
mounting
bolts
(24),
then
remove
intake
manifold assembly (25).
12.
Fuel injection tube, fuel spill tube

1) Remove 6 fuel injection tubes (26).
2) Remove spill tubes (27).
13.
Turbocharger
Disconnect
piping
turbocharger
oil
supply
hose
(28)
and
drain pipe (29).
13-12
0
WA500-
14, Turbocharger,
1) Remove
exhaust manifold
mounting
assembly
bolts of exhaust
manifold
(30)
and remove remaining bolts.
Then
with 2 - 3 bolts remaining.

2) Sling turbocharger
remove turbocharger
and exhaust manifold
assembly
(31) as one unit.

Turbocharger,
6 kg
exhaust manifold
assembly:
40 kg
15. Overflow
tube
Remove overflow tube (32).

16. Head cover
Remove
mounting
bolts
(33) then remove head cover
(34).
17.
Rocker arm assembly

Remove
mounting
bolts (35) then remove rocker arm
assembly (36).
*
When install rocker arm, turn the adjustment
screw
back 2 - 3 times to prevent strain on the push rod.
18.
Retainer
Remove mounting bolts (37), then remove retainer (38).
19. Connection
Loosen lock nut (39), then remove connection
pull out.
WA500-
(40) and
20.
Nozzle holder
Using bolt @
(Thread dia. = 10 mm,
Pitch = 1.5 mm),
remove nozzle holder (41).

*
Check that there
is a gasket fitted to the tip of the
nozzle holder.
21.
Push rod
Remove push rod (42).
22.
Rocker arm housing

Remove
mounting
bolts (43) then remove rocker arm
housing (44).
23.
Crosshead
Remove crosshead (45).
24.
Cylinder head assembly

1) Remove
mounting
bolts
(46) then remove cylinder
head assembly (47).

2) Remove gasket (48).
WA500-
INSTALLATION
OF CYLINDER
HEAD
ASSEMBLY
Special tool
I
I
A
1.
Part No.
Part name
795-125-1210
Oty
Feeler gauge
Cylinder head assembly

1) Make sure the mounting
surface of cylinder head and
the inside of cylinders are free from dust and foreign

matter,
and place cylinder
head gasket (48) in posi-
tion.
*
Check that there
is no dirt or foreign
matter on
the surface of cylinder.

*
When installing the gasket, make sure the grommet

is not loose.
Fit the gasket with TOP
2) Install
cylinder
head
mark facing up.
assembly
(47)
and
tighten
mounting bolt (46).

&
Coat the threads and lower side of the bolt

head before
tightening
with lubricant
*
First screw in the

revolutions
by
the mounting
bolts
(LM-P).
mounting
hand,
then
bolts two or three

tighten
the
bolts as
follows.
*
Tighten the bolts in the order shown.
Cylinder head mountint
bolts.
Unit:
Bolt
No.
Order
Target
1st step
15
2nd step
22
Range
14-16
21.5 - 22.5
Mark the bolts and the cylinder
head with a felt-tip

3rd step
1 4th steo
7
2.
kgm
pen, and turn
the bolts with following
90
6.75
degrees.
75O -
105O
6.0-7.5
Crosshead
Install crosshead (45).
*
Adjust crosshead according to following
steps:
i) Loosen lock nut and tighten adjusting screw.

ii)
Hold upper face of crosshead lightly and screw in

adjusting screw.
iii)
After
adjusting
screw comes into contact
valve stem, screw in an additional

iv)
Tighten lock nut at this position.

w
WA500-
Lock nut:
6 ? 0.6 kgm
20.
with
425F253
3.
Rocker arm housing

Fit
gasket
and install
rocker
arm housing
(44).
then
tighten mounting bolts (43).

w
*
Mounting bolt:
IO + 0.5 kgm
Loosen lock nuts of adjustment

each adjustment
screw 2 -
screws, then loosen
3 turns to avoid excessive
pressure being brought to bear on the push rods when

installing the rocker arm.
4.
Push rod
Install push rods (42).
*
Check that the push rod is properly fitted in the cam

follower.
5.
Nozzle holder
*
Check that there is no dirt or foreign matter
inside
nozzle holder sleeve.

*
Check that there
is a gasket fitted to the tip of the
nozzle holder.
Align
mounting
hole of nozzle holder connection
and
insert nozzle holder (41).
6.
Connection
Tighten connection
w
Connection:
Lock nut:
13i6
(40) then lock with lock nut (39).

3.8 + 0.3 kgm
6.5 ?r 0.5 kgm
WA500-
7.
Holder
Fit holder
(38).
then
fit
spherical
washer to mounting
bolts (37) and tighten.

*
Set one side of holder
on head of mounting
bolt
of
rocker arm housing and tighten.
8.
Rocker
lever assembly
Assemble
rocker
lever assembly
(36) and tighten
mount-
ing bolts (35).

*
Check
that
completely
9.
Adjustment
Using tool
round
part
inserted
the
adjusting
screw
is
of valve clearance
A, adjust valve clearance.
For details, see ADJUSTING
10.
of
into the push rod socket.
VALVE
CLEARANCE.
Head cover
Fit O-ring and install
mounting
m
WA500-
head cover
(34) then tighten
bolts (33).
Mounting.
bolt:
0.5 + 0.1 kgm
with
11. Overflow tube

Fit gasket and install overflow tube (32).
m
Joint bolt:
12. Turbocharger,
Fit
gasket
6.75 f 0.75 kgm
exhaust manifold assembly

and
assembly (31)
sling turbocharger,
(30).
* Fit the gasket with the OUT
*
The tightening
tighten
exhaust
as one unit, then tighten
procedure
mounting
manifold
mounting
bolts
mark facing out side.
of exhaust
bolts from
manifold
is to
inner to outer,
alter-
nately and evenly.

m
Mounting bolt:
13. Turbocharger
6.75 f 0.75 kgm
piping
Fit O-ring and connect drain pipe (29) and supply hose
(28).
14.
Fuel spill tube, fuel spill pipe

1) Fit gasket, and install fuel spill tube (27).
w
Joint bolt:
1.15 f 0.15 kgm
2) Install 6 fuel injection tubes (26).

w
15.
Sleeve nut:
2.4*
0.1 kgm
Intake manifold
Fit gaskets.and set intake manifold
assembly (25), then
tighten mounting bolt (24).

*
The tightening
tighten
procedure
mounting
of exhaust manifold
bolts from
inner to outer,
is to
alter-
nately and evenly.

m
Mounting bolt:
13d8
6.75 + 0.75 kgm
WA500-
16. Air cleaner assembly

1) Sling air cleaner
and intake
connector
as one unit,
then install air cleaner assembly (23).

2) Tighten
intake
connector
bracket
(22).
3) Secure air cleaner mounting
17. Connector
mounting
bolts
band.
assembly
1) Fit gaskets and install electrical air intake heater (21).

2) Fit gaskets and O-ring then install intake connector
(20) and tighten mounting bolts (19).
3) Install clamp (18).
18. Compressor tube

Fit
gaskets and install
between
air cleaner
and com-
pressor tube (17).
Install clmaps at 2 points.
19. Hose, switch

1) Connect komaclone
2) Connect
wire
(Is),
intermediate
then
heater switch assembly (14).
WA500-
hose (16).
install electrical
air intake
20.
Muffler
1) Sling
assembly
muffler,
bracket
and connector
as one unit,
then install muffler assembly (13).

2) Tighten elbow mounting bolts (12).
3) Tighten bracket mounting bolts (11).
4) Connect komaclone
21.
pipe at flange (IO) end.
Corrosion resistor, piping

1) Install corrosion resistor assembly (8).
2) Fit gaskets and connect pipes (8), (7) and (6).
22. Tube
Connect muffler drain tube (5).
23.
Bracket
Connect fuel control cable bracket (4).
24.
Refilling with water

Tighten
radiator
drain valve (3) and add water through

+
Run the engine to circulate

system.
25.
the water
through
the
Side cover, hood

1) Install engine left and right side cover.
2) Install hood (2) and exhaust pipe (I ).
3620
WA500-
REMOVAL
Stop
OF RADIATOR
the
machine
on level ground
safety bar on the frame.
ground and stop the engine.

brake
and put blocks
and install the
Lower the bucket
to the
Then apply the parking
under the wheels to prevent
the machine from moving.
Q!
Loosen the oil filler

sure inside the
control
cap slowly to release the pres-
hydraulic
pressure in the hydraulic

*
tank.
Then
operate
the
levers several times to release the remaining

piping.
Loosen plugs (1) and (2) at the top of the hydraulic tank
filter,
and
plugs (3) and (4) of the
pump
piping to
prevent the oil inside the tank from flowing out.

1.
Draining water
*
If
the
coolant
contains
antifreeze,
dispose
of
it
correctly.
- :
2.
Coolant:
80 Q
Cover
Remove engine hood (6), side hood (7) and grille.
& kg
Engine hood:
Side hood:
3.
60 kg
42 kg
Radiator guard
Remove radiator guard (8), then lift it off.
*
Be careful
not to hit the radiator
when
lifting
off
the radiator guard.

*
Disconnect wiring from connector.

Radiator guard
WA500-
: 84 kg
13-21
0
4.
Fan guard, support

1) Remove radiator support (9).
2) Remove fan guard (10) from the radiator.
+
5.
Remove the clamp of hose (11).
Radiator hose
Disconnect
radiator
hoses (12) and (13) at the engine
end.
*
Loosen radiator and clamp at engine end, and remove

tube (14) when removing radiator.
6.
Cooler piping
1) Disconnect
hydraulic
oil cooler hoses (15) and (16)
from the radiator.

2) Disconnect
torque
converter
hoses (17)
and
(18)
from the radiator.
7.
Radiator
Sling radiator
(19), remove mounting
bolts, then lift off
radiator.
*
Disconnect
coolant
level sensor
wiring
from
con-
nector.
*
Sling
radiator
and lift off while moving the radiator
to the rear.
*
Be careful so that fan does not interfere with radiator

core.
Radiator:
285 kgm
WA500-
INSTALLATION
1.
OF RADIATOR
Radiator
Raise radiator
(19), set in mounting
position and install
mounting bolts.
+
Tighten
the
mounting
bolts partially,
then
tighten
them fully after installing the support.

8
Connect coolant level sensor wiring to connector.
Mounting bolts:
56 + 6 kgm
(width across flats:
30 mm)
425P275
2.
Cooler piping
1) Connect
torque
converter
cooler
pipings
(17)
and
(18) to radiator.
m
Cooler hose: 20 + 5 kgm

(Width across flats:
2) Connect hydraulic
41 mm)
oil cooler pipings (15) and (16) to
radiator.
N
Cooler hose: 20 * 5 kgm

3.
41 mm)
Radiator hose
Connect radiator hoses (12) and (13) to engine.
4.
Install the clmap properly.
Set the tube (14) in position, then tighten clamp.
Fan guard, support

1) Install fan guard (IO) to radiator.
*
Install
so that
the
clearances
between
the
fan
and fan guard at the left and right, and top and
bottom are the same.
*
Install clamp of hose (1 1).
2) Install radiator support (9) to radiator.

*
Tighten the radiator mounting bolt.
WA500- 1
&!
I
*i:
g;.
5.
Radiator guard
II
.Qrt radiator guard (8) in mounting
position and tighten
mounting bolts.
*
Connect wiring to connector.
Install the radiator guard without

Install
so that
interference.
the clearances between
the radiator
guard and radiator at the left and right are the same.
4 .25P269
6.
Hood
Install engine hood (6), side hood (7) and grille.
7.
Refilling with oil, water

1) Tighten drain valve and add water through water filler
to the specified level.
-
Coolant:
2) Tighten
80 !J
plug at the top of hydraulic
tank filter and
plug of pump piping, then add hydraulic
oil through
oil filler to the specified level.

m
Plug at the top of hydraulic tank filter:

1.2 kO.1 kg
3) Add transmission oil through oil filler to the specified

level.
Run
the
engine
to
circulate
the oil and water
through the system.

Then, check the oil and water levels again.
13Gf4
WA500-
REMOVAL
OF ENGINE
Stop the
machine
on level ground and install the
Lower the bucket to the
brake and put blocks under the wheels to prevent

*&
Loosen the oil filler cap slowly to release the pres-
sure inside the hydraulic

control

*
tank.
Then operate
the

piping.
Loosen plugs (I) and (2) at the top of the hydraulic tank
filter,
and the plugs (3) and (4) of the pump piping to

*
Disconnect
the cable from the negative (-)
terminal
of the battery.
1.
Draining water
*
If
the
coolant
contains
antifreeze,
dispose
of
it
correctly.
- :
2.
Coolant:
80 !2
Hood
1) Remove side panel (61, (7) and (8) and grille.
*
Remove left and right hand side panel.
2) Raise engine hood (IO) side hood (9), then lift it off.
FYIkg
Engine hood:
Side hood:
WA500-
60 kg
42 kg
13-25
a
3.
I 1
Radiator guard
Raise radiator
guard (1 I), then lift it off.
not to hit the radiator
Be careful
radiator
when lifting
off the
guard.
Disconnect
electric
Radiator
wiring
guard:
from
connector.
85 kg
425P280
4.
Fan guard, support

1) Remove radiator
support
(12).
2) Remove fan guard (13) from the radiator.

*
5.
Remove clamp of hose (14).
Radiator
hose
Disconnect
radiator
hoses (15) and
(16) at the engine
end.
*
Loosen clamps of hose (15) at the radiator
Loosen
clamp
when removing
6.
Cooler
at engine
end, and remove
end.
tube
(17)
radiator.
piping
1) Disconnect
hydraulic
oil cooler
hoses (18) and (19)
from the radiator.

2) Disconnect
torque
converter
hoses
(20)
and
(21)
from the radiator.
13-26
0
WA500-
7.
Radiator
Sling radiator
radiator
+
(22), remove mounting
bolts, then lift off
(22).
Disconnect
coolant
level
sensor wiring
from
the
connector.
*
Sling radiator
and lift off while moving the radiator
to the rear.
*
Be careful so that fan does not interfere
with radia-
tor core.
Radiator:
8.
285 kg
Wiring
I) Disconnect starting motor wiring (23).

2) Disconnect main breaker wiring (24).
3) Disconnect wiring of engine (25).
4) Disconnect ground connector
*
After
removing
the
(26) and (27).
wirings,
mark
with
tags to
distinguish when installing.
9.
Fuel hose
Disconnect fuel hoses (28),
(29) and (30) from the fuel
tank.
10.
Fuel control cable

Disconnect fuel control
cable (31) from the bracket and
lever.
*
After disconnecting,
WA500-
move cable to front.
13-27
0
2) Sling air cleaner (39), remove it.

*
An O-ring is inserted at the connecting

the
air cleaner
and turbocharger
portion of
so be careful
when removing.
Air cleaner:
&I kg
15.
32 kg
Brake chamber
1) Disconnect air piping (41), oil piping (42) and electrical wiring (43) from chamber.
2) Remove brake chamber (44).
16. Engine
1) Disconnect
end.
WA500-
greasing hose (45) for damper at damper
2) Disconnect
*
Make
drive shaft (46) from

match
marks
before
engine.
disconnecting
the cou-
pling.
3) Temporarily
sling engine,
then
ing bolts and rear mounting

+
Remove
the bracket
from
side and loosen mounting
remove
front
mount-
bolts.
the engine on the front
bolts of bracket.
4) Sling engine (47) and remove it.

Engine:
13-30
0
1,450 kg
WA500-
INSTALLATION
1.
OF ENGINE
Engine
1) Sling engine (47), and set in mounting position.
*
When installing rubber, coat with water or rubber

grease, then install.
Do not use other than specifi-
ed coating.
2) Tighten front and rear mounting bolts.
*
Install front bracket of engine then tighten bracket

mounting
bolts.
Rear mounting
bolt:
95 f 10 kgm

Front bracket mounting
Front mounting bolt:
*
Tighten
between
the mounting
the
engine
bolt:
36 mm)
28.5 * 3 kgm
39 + 3.5 kgm
bolts so that clearance

damper
and the
trunnion
support is the standard value.

Clearance a: 3 - 7 mm
,a
ilil425FO1012
3) Align match marks and install drive shaft to engine.

w
*
Mounting
When connecting
bolt:
11.5 + 1 kgm
the drive shaft, clean the contact
surfaces of the spider and coupling.
4) Connect greasing hose for damper (45) to damper.

*
Connect the hose without
WA500-1
twisting.
2.
Brake chamber
I) Set brake chamber (44) and install mounting
2) Connect
wiring
3.
air piping
(41), oil piping
position.
(42) and electrical
(43) to chamber.
Air cleaner
1) Sling air cleaner
then tighten
*
Be careful
2) Connect
(39),
mounting
and set in mounting
not to damage O-ring
air intake
position,
bolt.
port
(38),
then
(40).
install
tube
(36)
and hose (37).
13-32
0
WA500- 1
4.
Muffler
Sling muffler
(35),
and set in mounting
position, then
tighten mounting bolt.
5.
Drain valve
Connect engine oil drain valve (34) to fuel tank.
6.
Air piping
Connect air pipings (32) and (33).
*
7.
Check the air leakage from connection
of piping.
Fuel control cable

Connect fuel control cable (31) to the lever and bracket.
*
For adjustment
ING
WA500-
AND
of length of cable, refer to 12 TEST-
ADJUSTING.
13-33
0
8.
Fuel hoses
Connect fuel hoses (28), (29) and (30) to the fuel tank.
9.
Wiring
1) Connect ground connection
(26) and (27).
2) Connect wiring of engine (25).

3) Connect main breaker wiring (24).
4) Connect starting motor wiring (23).
*
IO.
Install clamps of wiring.
Radiator
Set radiator
(22)
in mounting
position,
then tighten
bolts partially,
then tighten
mounting bolts.
*
Tighten
the mounting
them fully after installing the support.

*
Connect wiring of coolant level sensor to connector.
Mounting bolts:
56 + 6
kgm
30 mm)
11. Cooler piping

1) Connect
torque
converter
hoses (20)
and
(21)
to
radiator.
m
Cooler hose nut:
20 + 5 kgm
2) Connect
hydraulic
41 mm)
oil cooler hoses (18) and (19) to
radiator.
m
Cooler hose nut:
20 * 5 kgm
13-34
0
41 mm)
WA500-
12. Radiator
hose
Connect radiator hoses (15) and (16) to engine.
13.
Tighten clamps securely.
Set the tube (17) in position, then tighten clamp.
Fan guard, support

1) Install fan guard (13) to radiator.
*
Install
so that
the clearances between
and fan at the circumference

*
fan guard
are the same.
Install clamp of hose (14).
2) Install radiator support (12).

*
14.
Tighten radiator mounting bolts.
Radiator guard
Set radiator guard (11) in mounting position, then tighten mounting bolts.
*
*
Connect wiring to connector.

Install so that clearances between radiator
guard and
radiator at the left and right are the same.
425P280
15.
Hood
1) Set engine hood (10) and side hood (9) in mounting
position, then tighten mounting bolts.
WASOO-
2) Install side panel (6). (7) and (8) and grille.
16.
Refilling with oil, water

1) Tighten
the
drain
valve and
add
coolant
through
G
2) Tighten
Coolant:
80 II
plug and add engine oil through the oil filler

N
Plug at the top of filter:
1.2 f 0.1 kgm
3) Add transmission oil through oil filler to the specified

level.
*
Run
the
engine
to
circulate
the
oil and water
through the system.

Then check the oil and water levels again.
4) Bleeding air from brakes.
*
For details of bleeding air, see 52 TESTING
AND
ADJUSTING.
WA500-
REMOVAL
OF FUEL TANK
Stop the
machine



1.
Draining fuel
Loosen drain valve (1) and drain fuel.
b
&
2.
Fuel:
4359
Drain valve
Remove engine oil drain valve (2) from the fuel tank.
3.
Fuel hose, wiring
1) Disconnect fuel hoses (3). (4) and (5) from the fuel
tank.
t
Remove remote grease clamps from the fuel tank.
2) Disconnect wiring (6) of fuel unit from theconnector.

*
4.
Remove hoses (7) and (8) from clamps.
Fuel tank
1) Sling fuel tank (9), remove mounting bolts, then lift

off fuel tank.
*
Lay a pallet below the fuel tank,
keep the tank
balanced and lower slowly.

Fuel tank:
kg
C?z
330 kg
2) Remove breather tube (IO), and pull the fuel tank

out from under machine.
*
There
is a limitation
on height so be careful that
fuel tank does not interfere with frame.
WA500-
INSTALLATION
1.
OF FUEL TANK
Fuel tank
1) Set fuel tank on pallet, then push into lower mounting position and install breather tube (IO).
2) Raise fuel tank
position, then
tighten mounting bolts.

*
When raising the tank,
keep it horizontal
and set
in the mounting position.

*
Tighten the mounting bolts in the following
order:
Left + rear + right.

w
Mounting bolt:
95 + 10 kgm
2.
36 mm)
Fuel tubes, wiring, clamp

1) Connect wiring (6) for fuel unit to connector.
*
Install hoses (7) and (8) to fuel tank.
2) Connect fuel hoses (3), (4) and (5) to fuel tank.

*
3.
Install remote grease clamp to fuel tank.
Drain valve
Install engine oil drain valve (2) to the fuel tank.
4.
Refilling with fuel

Tighten
the drain valve fuel tank and add fuel through
fuel filler.
Ii8
Fuel:
435 R
425P832
---,
13Z8
WA500-
14
ENGINE
MAINTENANCE
STANDARD
Engine mount .
WA500-
.... ....
. . . . . . . . . . . . 14-2
14-1
ENGINE
MOUNT
Section A - A
Section B - B
425F131
Unit:
Remedy
Criteria
Check item
No.
Clearance between engine damper

and trunnion support
Tightening torque of bolt
94.5 * 10.5 kgm
Tighrening torque of bolt
39.25 i 4.25 kgm
3.0 - 7.0
Adjust
Retighten
14-2
WA500-
mm
20
POWER TRAIN
POWER TRAIN
21 STRUCTURE
AND
FUNCTION
General ................................
.
. Hydraulic circuit for power train ........
.
- Hydraulic circuit diagram for power train
Damper ................................
.
Torque converter and transmission piping . .
Torque converter charging pump .........
.
Torque converter oil cooler. ..............
.
Torque converter oil filter ................
Torque converter .......................
Transmission mount .......
.,............
Torque converter relief valve .............
Transmission ...........................
Transmission control valve ..............
.
Upper valve ........................
..
Lower valve ........................
.
Transmission solenoid valve ..........
.
Emergency manual spool ............
.
Priority valve ........................
..
Modulating valve and quick return valve . .
Accumulator valve ..................
..
Pilot reducing valve ..................
.
. Main relief valve .....................
Reducing valve. .....................
.
Lubrication bypass valve .............
.
Pilot oil filter. . . . .
Transfer . . . .
. ..
. .
Drive shaft
.. . .
.. .
.. .. ..
Center support . . . . . .
Axle mount
...
..
.. .. .
Axle and differential
.
.. .. .
.. .
Final drive . . . . . .
..
Tire and wheel.
_
.
.
WA500-
21- 2
21- 4
21- 5
21- 6
21- 8
21- 9
21-10
21-11
21-12
21-14
21-15
21-16
21-24
21-26
21-27
21-28
21-2s
21-32
21-33
21-36
21-38
21-39
21-40
21-41
21-42
21-43
21-44
21-45
21-46
21-48
21-53
21-54
21-1
GENERAL
16
24
421FOO3
OUTLINE
.
The power from engine (1) is transmitted

flywheel
damper
to damper
alleviates the torsional
the variation
vibration
The
caused by
of the engine torque and transmits the
power to torque
(24).
from the
(2) through the ring gear.
converter
The torque
converter
(6) through
drive shaft
converts the delivered
torque according to the variation
in load on the oil
The output
shaft of transmission
power to the output

the gears.
transfer
(7) transmits the
shaft of transfer
(8) through
The power from the output shaft of the
is transmitted
to both the
front axle and
the rear axle.

The power transmitted
to front axle and rear axle is
reduced through pinion and ring gears in differential
used as the medium, and transmits the power to the
(13) and (19), and is transmitted
input shaft of transmission
The power from the axle shafts is reduced through
(7).
Then, the engine
to the axle shafts.
power is transmitted
to POC pump (3) and steering
final
pump
pump
(12) and (21) through the planetary carrier.
(4), hydraulic
and torque
converter
the
driving
pump
(5). switch pump (22),
charging pump
gear in torque
drive
(10)
and (18) and transmitted
to tires
(23) through
converter
(6),
thereby driving the pumps.
In transmission
(7), the six hydraulically-operated
clutches are operated

and the
valves, which
valves.
ed from
by the forward-reverse
spool
speed change spools in the transmission

are themselves activated
by solenoid
Thus, the desired travel speed can be selectamoung the 4 forward
and 4 reverse gear
speeds.
21-2
WA500-
425FOO6
WA500- 1
1.
Engine (S6D140)
2.
Damper
9.
Parking brake
17.
Rear drive shaft
IO.
Front final drive
18.
Rear final drive
1 I.
Front brake
19.
Rear differential
Rear brake
3.
POCpump
4.
Steering pump
12.
Front wheel
20.
5.
Hydraulic pump
13.
Front differential
21.
Rear wheel
6.
Torque converter
14.
Front drive shaft
22.
Switch pump
7.
Transmission
15.
Center support
23.
Torque converter charging Pump
8.
Transfer
16.
Center drive shaft
24.
Upper drive shaft
21-3
HYDRAULIC
Engine
running,
CIRCUIT
gear shift
* Serial No. 10001

* Serial No. 10001
FOR POWER TRAIN
levers at Neutral.
10186
(Except
D spec.)
and up (D spec.)
27
28
29
31
32
30
c
c
c--
r=
425F503
WA500-1
.
*
HYDRAULIC
Serial
No.
CIRCUIT
10081
* Serial No. 10001
10186
DIAGRAM
(Except
FOR POWER TRAIN
D spec.)
and up (D spec.)
;
5!.!_?_
4
__J
!O kg/cm
M
m
F425CO1003A
1. Transmission case
12.
Oil cooler
23.
I St spool
2.
Strainer
13.
Transmission lubrication relief valve
24.
Emergency manual spool
3.
Torque converter charging pump
14.
Transmission lubrication
25.
Solenoid valve
4.
Oil filter
I 5.
Main relief valve
26.
Accumulator
5.
Priority valve
16.
Lubrication bypass valve
27.
Reverse clutch
6.
Modulating valve
17.
Reducing valve
28.
Forward clutch
7.
Quick return valve
18.
Reverse spool
29.
4th clutch
8.
Pilot oil filter
19.
Forward spool
30.
3rd clutch
9.
Pilot reducing valve
20.
4th spool
31.
2nd clutch
I 0.
Torque converter relief valve
21.
3rd spool
32.
I st clutch
II.
Torque converter
22.
2nd spool
WA500- 1
valve
2&5
Engine running
gear shift levers at Neutral
* Serial No. 10187 and up (Except
D spec.)
F42501006
22-1
WA500- 1
- Serial No. 10187 and up (Except
Dspec.)
27kg,cm2i----_________~
022,3kg/cm2
Min.
_----_
_N i
j 1 0.8kg/cm2
L_____l
7
M
A
-2
1
1. Transmission
case
F425M 1004
12.
Torque converter
23.
2nd spool
2.
Strainer
13.
Oil cooler (water cooled type)
24.
1st spool
3.
14.
Oil cooler (air cooled type)
25.
4.
Oil filter
15.
Transmission lubrication relief valve
26.
Solenoid valve
5.
Priority valve
16.
Transmission lubrication
27.
REVERSE
6.
Modulating valve
17.
28.
FORWARD
7.
Quick return valve
18.
Reducing valve
29.
4th clutch
8.
Pilot oil filter
19.
REVERSE
9.
20.
FORWARD
10.
Main relief valve
21.
11.
1 orque converter relief valve
22.
spool
clutch
30.
3rd clutch
31.
2nd clutch
4th spool
32.
1st clutch
3rd spool
33.
Accumulator
spool
clutch
valve
Czoo-1
2z2
DAMPER
-
Serial No. 10001 -
10809
Section A - A
425FOll
21-6
0
FUNCTION
1.
Coupling
2.
Output shaft
3.
Cover
4.
Bearing
to protect
5.
Bearing
twisting and vibration.
6.
Outer body
7.
Rubber cushion
8.
Inner body
The
damper
reduces
the
caused by the variations

the
twisting
and
in engine torque,
engine and other
vibration
and acts
parts from
WA500- 1
such
.A..
Serial
No.
10810
and up
AI
i
Section
A - A
425FO1103
1. Coupling
2. Output
shaft
3.
cover
4.
Bearing
5.
Bearing
Outer body
7.
Rubber cushion
8.
Inner body
WA500-1
2&7
OPERATION
-l
No load applied
Engine torque
Path of power transmission
Engine torque applied

421 FOlO
The
engine power
is transmitted
to the flywheel
and outer body (6) and rubber cushion (7) absorbs

the twisint
and vibration
of the enigne.
The engine
power is then transmitted
through inner body (8) to
output
here, the engine power is
shaft (2).
transmitted
From
through
the
coupling
to
the
torque
converter and drive shaft.
2ic-1
WA500-1
TORQUE
*
Serial
No.
CONVERTER
10001
- Serial No. 10001
10186
(Except
AND
TRANSMISSION
PIPING
D spec.)
and up (D spec.)
425FOlO
21-8
8
1.
Transmission
5.
2.
6.
Radiator
3.
Transmission control valve
7.
Oil cooler
4.
Torque converter
8.
Torque converter oil filter
WA500-
Serial
No.
10187
and up (Except
D spec.)
F42501007
1.
Transmission
2.
3.
4.
Torque converter
5.
6.
Radiator
7.
Torque converter oil cooler (Air-cooled type)
8.
Torque converter oil cooler (Water-cooled
9.
Torque converter oil filter
WA500-1
type)
2iY
TORQUE
CONVERTER
The torque
converter
CHARGING
charging pump is installed to
PUMP
The torque
the
converter
bottom
charging
pump
the torque converter case. It is driven by the motive
from
of the transfer
force from the engine and supplies oil to the torque
strainer and sends oil to the oil filter.
sucks in oil
case through
converter and transmission system.
Section A - A
425FO12
1.
Drive gear (Teeth 12)
2.
Front cover
3.
Gear case
4.
Rear cover
5.
Driven gear (Teeth 12)
WA500-
Specifications:
Model
Theoretical
SAR(3)-080
discharge:
80 cc/rev
Max. pressure:
210 kg/cm2
Max. pump speed:
2,500 rpm
21-9
TORQUE
*
CONVERTER
Serial No. 10001 -
10186
OIL COOLER
(Except D spec.)
- Serial No. 10001 and up (D spec.)

OUTLINE
The oii which comes out from the torque converter
outlet
port is at a high temperature
Energy used in transmitting

torque
converter
D and enters the oil cooler.

port
This
oil passes through oil cooler port
engine cooling water.

oil outlet
because of the
the motive force.
Here it is cooled by the
The oil then flows out from
C, lubricates
the transmission
and
returns to the transmission case.
/p/y- ---I\,
A
1
C
425FO45
1.
Radiator
A.
Hydraulic oil outlet port
2.
Torque converter oil cooler
6.
Hydraulic oil inlet port
3.
Hydraulic oil cooler
C.
Torque converter oil outlet port
D. Torque converter oil inlet port
WA500-1
Serial No. 10187 and up (Except
D spec.)
OUTLINE
.
The
oil leaving
perature.
This
the torque
oil enters
converter
is at high tem-
pot-t D of the water-cooled
oil cooler and is cooled by the engine cooling water.

It is then discharged from port C, and enters port E
of the air-cooled
oil cooler.
cates the transmission
From port F, it lubri-
and returns to the transmis-
sion case.
View Z
F42501008
F42501009
1.
Radiator
2.
Torque converter
3.
Hydraulic
4.
Torque converter
oil cooler (Water-cooled
oil cooler (Water-cooled
WA500-1
type)
type)
oil cooler (Air-cooled
type)
A.
Hydraulic
oil outlet port
B.
Hydraulic
oil inlet port
C.
D. Torque converter oil inlet port

E.
Torque converter oil inlet port
F.
21
-GO-
TORQUE
CONVERTER
OIL FILTER
Relief valve
Element
Center bolt
Drain plug
Filtration
area:
8,900 cm2
Relief pressure: 3.25 kg/cm2
L-...
__
SectionA-A
-J
425FO13
View 2
&&
To transmission
control valve
OPERATION
.
The
oil from the torque
converter
charging pump
(5) enters the filter inlet port A and passes from the
outside of element
(2) to the inside.
It then flows
to the outlet port B.
423FOlO
To transmission
control valve
If the element
temperature
(2) is clogged with
dirt,
or the oil
is low, the pressure at the inlet port A
rises. When this happens, the oil from the inlet port
A opens relief valve (I)
outlet
and flows directly
to the
port B. This prevents damage to the pump or
element (2).
423FOll
WA500- 1
21-11
TORQUE
CONVERTER
.2
1-
425FO14
-A
1. Mount of switch pump
/*
_.--9
2.
Mount of POC and steering pump
3.
Mount of torque converter charging pump
4.
Mount of hydraulic pump
5.
Drive case
6.
Turbine
7.
Housing
6.
Pump
9.
Stator
10.
Transmission input shaft
11.
PTO gear (drive)
A.
Inlet port
B.
Outlet port
Specifications
Model:
TCA40-1 A
Type:
3-element,
Stall torque ratio:
single stage, single phase

3.22
425FO15-1
Section
2122
X-X
WA500-
Flow of motive force
The
torque
damper
converter
is installed
and transmission.
between
the
The motive force from
the damper passes through the drive shaft and enters

drive case (5).
gear (drive)
Drive case (51, pump (8) and PTO
(11)
are fixed
with
bolts.
They
are
rotated directly by the rotation of the engine.

The
motive
turbine
froce
(6).
of pump
(8) uses oil to rotate
This transmits
motive force to trans-
mission input shaft (10).
The motive force of drive case (5) passes through

PTO gear (drive) (11) and is also used as the motive
rransmission
force to drive the gear pump.
425FO16
Flow of oil
The oil pressure is adjusted by the torque converter

relief
valve and then
enters inlet
port
A,
passes
through the oil passage in housing (7) and flows to

pump (8).
In pump (8) centrifugal
The oil enters turbine

is transmitted
Turbine
force is applied.
(6) and the energy of the oil
to the turbine.
(6) is fixed to transmission input shaft (IO),
so the motive force is transmitted
to the transmis-
sion input shaft (10).

The oil from
turbine
again enters the

passes from
(6) is sent to stator
pump.
However,
the stator through
(9) and
part of the oil
outlet
port B and
is sent to the cooler.
425FO17
WA500-
21-13
TRANSMISSION
MOUNT
Section A - A
Section B - B
425FOO9
View 2
1.
Torque converter
2.
Transmission
3.
Transmission mount
OUTLINE
.
The transmission
is mounted
separately
from the
engine.
To
position
the
transmission
on the engine, the
front mount can be adjusted with shims.
Both front
and rear have rubber mounts.
21-14
WA500- 1
TORQUE
CONVERTER
RELIEF VALVE
FUNCTION
.
The torque
converter
relief valve acts to maintain
the pressure of the oil entering the torque converter

at a constant
pressure.
To each
transmissionspool
It drains the oil if it goes
above the specified pressure.
OPERATION
.
The oil from the pump passes through main relief

It then enters port A and flows to the
valve (1).
torque converter.
lubrication
425FO42
If the oil at oort A Qoes above the specified pres.

sure, it passes through
verter
relief
orifice
a of torque
valve (2) and enters port
moves torque
converter
B.
To each
relief valve (2) to the left.
As a result, the oil from port A is drained,

oil flowing
con-
It then
to the torque
converter
and the
is maintained
at the specified pressure.
425 F043
WA500-
21-15
I-D
f
View Z
Section C - C
Section D - D
Section E - E
425FO18-1
1. Oil filler
21-16
0
2.
Transmission input shaft
3.
Transmission
4.
Transfer
5.
Transfer output coupling
6.
7.
8.
Strainer
WA500- 1
9.
No. 1 sun gear (Teeth 30)
10.
No. 1 planetary
11.
No. 1 clutch
gear (Teeth 28)
12.
No. 1 ring gear (Teeth 70)
13.
No. 1 idle gear (Teeth 86)
14.
15.
No. 2 clutch
16.
17.
No. 2 planetan/
gear (Teeth
18.
No. 3 planetary
gear (Teeth 24)
19.
No. 3 clutch
20.
21.
22.
No. 4 clutch
23.
No. 4 hub
24.
No. 5 clutch
25.
26.
No. 5 planetan/
27.
28.
No. 6 clutch
29.
gear (Teeth 21)
30.
No. 6 planetary
31.
32.
Output
33.
No. 1 carrier
24)
gear (Teeth 20)
shaft
34.
No. 2,3
35.
No. 5 carrier
carrier
36.
No. 6 carrier
Section A - A
425FO19-1
WASOO-1
21-17
0
OUTLINE
The transmission
REVERSE
consists of a 4-FORWARD,
4-
Speed range
Clutch combination
Fl
No. 2, No. 6
F2
No. 2, No. 4
speed planetary gear transmission, trans-
fer, and transmission control valve.

In the transmission, the motive force of the input
shaft is changed by the combination
of No. 1 or
No. 2 clutch with No. 3, 4, 5 or 6 clutch to give

FORWARD
1 - 4
or
REVERSE
F3
hlo.2,
No.5
R4
No.1,
No.3
1 - 4 speed, and
is transmitted to the output shaft.
OPERATION
The
OF CLUTCH
oil sent from the transmission
control
valve
passes through the oil passage inside the transmission.
When it reaches the rear of piston (2).
it
moves the piston (2).

When the piston (2) moves, disc (4) and plate (5)
are pressed together.
Ring gear (6) is meshed with
disc (4), so the rotation is topped.
423FO18
cl
Disengages
When the supply of oii from the transmission control valve is shut off, the pressure of the oil acting
on the rear of piston (2) is reduced.
Thepiston
is
then pushed back to the right by return spring (3).

and disc (4) and plate (5) are separated.
(6)
then
rotates
freely,
and no motive
Ring gear
force
is
transmitted.
423FO19
21-18
WA500- 1
FORWARD
1ST
In 1st FORWARD,
clutch
(28)
No.
2 clutch
are engaged.
(15) and No. 6
The motive force trans-
mitted
mitted from the torque converter by input shaft (2)

is transmitted
.
No.
2 clutch
is actuated
pressure applied to the clutch

ring gear (16)
actuated
in position.
by the hydraulic
The rotation
of the
to planetary gear (17)
through sun gear (14).

by
the hydraulic
piston, and it locks

No.
to the input shaft (2).
input shaft (2) is transmitted
to output shaft (32).

(15)
The motive force from the torque converter is trans-
6 clutch
(28)
is
pressure applied to the
clutch piston and holds gear (29) in position.
Ring gear (16) is held in position by No. 2 clutch so

the rotation
of planetary
gear (17)
rotates carries
(34), which is on the inside of ring gear (16).

carrier
is connected
to No. 5 carrier
This
(33) through
No. 4 ring gear (24), so when No. 6 clutch is actuated, the rotation
of carrier
(33)
is transmitted
to
gear (30) and rotate output shaft (32).
WA500- 1
21-19
FORWARD
2ND
425FO21
In 2nd FORWARD,
clutch
(22)
No. 2 clutch
are engaged.
(15) and No. 4
input

is transmitted
.
ton.
pressure applied to the clutch pis-
No. 2 clutch
hold ring gear (21)

shaft
is transmitted
The rotation
to planetary
and No. 4
Ring gear (16) is held in position by No. 2 clutch, so

the rotation
of planetary
gear (17)
rotates carrier
(34), which is on the inside of ring gear (16).
clutch hold hub (23).
21-20
of the
gear (17)
No. 2 clutch (15) and No. 4 clutch (22) are actuated

by the hydraulic
The motive froce from the torque converter is transmitted
WA500- 1
FORWARD
3RD
425FO22
In 3rd
clutch
FORWARD,
(24)
No. 2 clutch
are engaged.
(15) and No. 5

is transmitted
is held in position by No. 2 clutch
so the rotation
of planetary
gear (17) rotates
carrier (34), which is on the inside of ring gear (16).
Ring gear (16)

(15),
Ring gear (21)
is held in position by spline to car-
No. 2 clutch (15) and No. 5 clutch (24) are actuated
rier (35),
by the hydraulic
mitted to output shaft (32) through sun gear (27).
pressure applied to the clutch pis-
so the rotation
of ring gear (21) is trans-
ton, and they hold ring gears (16) and (25) in position.
The motive force from the torque converter is transmitted
input

shaft
is transmitted
The rotation
to planetary
of the
gear (17)
WA500-
21-21
FORWARD
4TH
14
15
16
17
19
18
21
No.4
__
20
2nd
No.5
3rd
I_
1
NO.6
1st
425FO23
In 4th
clutch
FORWARD,
(19)
No. 2 clutch
are engaged.
(15) and No. 3
Ring gear (16)

(15).
so the rotation
of planetary
gear (17) rotates
carrier (34), which is on the inside of ring gear (16).
is transmitted
Ring gear (21)
No. 2 clutch and No. 3 clutch are actuated by the
(19), so the rotation of carrier (35) is transmitted
hydraulic
planetary
pressure applied to the clutch piston, and
gear (26).
The planetary
they hold ring gears (16) and (21) in position.
the inside of ring gear (21).
The motive force from the torque converter is trans-
(27), which forms one unit with output shaft (32).
mitted
input

shaft
is transmitted
to
The rotation
planetary
and rotates sun gear
of the
gear (17)
21-22
to
gear rotates on
WA500- 1
REVERSE
IST
Reverse Forward
4th
2nd
3rd
1st
425FO24
In
1st
REVERSE,
No.
1 clutch
clutch
(28)
are engaged.
mitted
from
the torque
is transmitted
to output
No.
is actuated
1 clutch
applied
to the clutch
in position.
hydraulic
(11)
The motive
converter
shaft
pressure applied
by input
No.
trans-
shaft (2)
input
through
pressure
and it locks carrier

(28)
is actuated
to the clutch
The motive
mitted
(32).
by the hydraulic
piston,
No. 6 clutch
and
force
(33)
by the
piston
and
force from the torque
to the
shaft
input
shaft
(2).
is transmitted
to
converter
is trans-
The rotation
planetary
of the
gear (IO)
sun gear (9).
Carrier
(33) is held in position
so the
rotation
ring gear (12).

site direction
of planetary
by No. 1 clutch
gear (IO)
Ring gear (13) rotates
from the input
rotates
(11).
the
in the oppo-
shaft (2).
holds ring gear (29) in position.
WA500- 1
21-23
TRANSMISSION
CONTROL
VALVE
425FO25
1. Lower valve
21-24
7.
Priority pressure pick-up
2.
Pilot reducing pick-up
8.
Modulating pressure pick-up
3.
Upper valve
9.
Accumulator
4.
Main relief valve
10.
Transmission solenoid valve
5.
Transmission lubricating pressure pick-up
11.
6.
Torque converter relief pressure pick-up
12.
Connector
pressure pick-up
WA500-
Reverse
Forw;3rd
4th
3rd
2nd
Saction A-A
13.
17.
1st solenoid valve
FORWARD
14.
2nd solenoid valve
18.
REVERSE
15.
3rd solenoid valve
19.
Body
16.
4th solenoid valve
solenoid valve
solenoid valve
Actuation
table
423F026A
for solenoid valve
and clutch
STRUCTURE
.
The transmission
transmission
solenoid valve is installed to the
together
When the directional

operated,
with
the transmission
valve.
lever or speed control lever are
the solenoid valve is actuated and moves
the spool inside the transmission valve.
WA500- 1
21-25
0
UPPER VALVE
1
Lower
valve
425FO26
Upper
valve
Section C - C
425FO27
OUTLINE
-
The oil from the torque converter charging pump

enters port A, and passes through the priority valve
(7) via by main relief valve (3). It is then divided
into three lines; there are; to the clutch pistons, to
the pilot reducing valve(l4) and main relief valve.
The priority valve (7) acts to control the three lines
so that the pilot reducing valve (4) is the priority
circuit.
The oil flowing to the pilot reducing valve (4) controls the pilot pressure used to actuate the directional and speed spools. The oil regulated by the
pilot reducing valve (4) presses through the orifice
in each spool and fills the spool.
21-26
The other oil line flows to the modulating valve (6)

and quick return valve (5). The action of the modulating valve (6) and quick return valve (5) raises the
clutch pressure smoothly.
This reduces the shock
when actuating the FORWARD,
REVERSE and Ist,
2nd, 3rd, and 4th speed clutches to change gear.
The accumulator valve (11) controls the oil flow at
the 2nd clutch and reduces the filling time when
shifting from 2nd to 1st or 3rd gear.
The lubrication valve (15) controls the lubrication
oil inside the transmission.
WA500- 1
LOWER
VALVE
425FO28
Section B -
1.
Piston
7.
Priority valve
13.
FORWARD
2.
Torque converter relief valve
8.
Housing
14.
3.
Main relief valve
9.
1 St spool
15.
Lubrication valve
4.
Reducing valve
10.
2nd spool
5.
Quick return valve
11.
Accumulator
6.
Modulating valve
12.
Pilot filter
WA500- 1
(for 2nd)
16.
REVERSE
17.
4th spool
18.
3rd wool
spool
spool
21-27
0
TRANSMISSION
SOLENOID
VALVE
Function
.
There is one solenoid valve installed for each directional and speed spool in the transmission valve.
in the
operators
solenoid
lever and speed control
compartment
valve is actuated,
actuate the directional
levers
are operated,
the
and oil is drained
to
and speed spools.
Operation
1)
Solenoid valve OFF

The oil of spool (1) enters port A.
(2) shuts off the oil, so directional
However,
valve
and speed spool
(1) does not move.
reducing valve
2)
423FO31
Solenoid valve ON
and gear shift lever are operat-
ed, the solenoid valve is pulled up.

The oil from directional
and speed spool (1) enters
port A and flows from port B to the drain circuit.

Therefore,
port A becomes the low pressure circuit,
and directional
and speed spool (I) is actuated.
2
/
From quick return valve
/
From pilot
&
reducing valve
21-28
423FO32
WA500-
EMERGENCY
MANUAL
SPOOL
Function
If there
is any failure
transmission
does not work,

This spool
spool
in the electrical
control
system,
the emergency
is attached
of the
valve
manual spool is used.
to each directional
and is used to operate
mechanically.
circuit
and the solenoid
and speed
the transmission
valve
(It is used to drive the machine
place where it can be repaired.)

*
Particular
attention
must
be paid
for
to a
when
using this spool.
Operation
1.
When solenoid valve is normal:

(Emergency
When the
manual spool is at normal position)

solenoid
spool is maintained
Oil from
valve
is working
normally,
the
in this position.
directional
and speed spool (1) enters port
A, but it is shut off by solenoid
valve (2).
423FO44
2.
When solenoid valve is abnormal:

a.
Clutch in disengaged position

(Emergency
manual spool is pushed to the left)
Emergency
manual
left,
spool
and the oil at port
of the
action
cannot
flow
of
to
(3) is pushed
A is shut off regardless
solenoid
port
From quick
return valve
to the
valve
B, so the
(2).
The oil
clutch
is not
actuated.
b.
423FO45
Clutch in engaged position

(Emergency
manual spool is pulled to the right)
When emergency manual spool (3) is pulled to

the right,
regardless
(2).
the oil at port

of the
A is drained
operation
As a result, the clutch
to port
of solenoid
From quick
return valve
valve
is actuated.
From
reducing valve
423FO46
WA500- 1
21-29
Cc
FORWARD
IST
Forward
1 St
425F501
1.
Solenoid valve
2.
Solenoid valve
3.
Oil filter
4.
Priority valve
5.
1st spool
6.
FORWARD
7.
Spring
8.
Spring
9.
Piston
spool
There are two oil coolers on Serial No. 10187 and up
IO.
Quick return valve
(except D specification).
11.
12.
Piston
13.
Main relief valve
21-30
@
WA500-
Operation
When
the
directional
moved to FORWARD
and speed control
levers are
Ist, solenoid valves (1) and (2)
The
other
oil
line flows from
quick return valve (10).
priority
valve (4) to
It then flows through orifice
are opened.
a, and directional
The oil from the pump is divided into three lines, but
flows to the FORWARD
when the gears are being changed, the oil flows main-
it starts to flow to the clutch, it passes through orifice
ly to each clutch.
In one of the three
relief
then
valve (13)
lubricates
lines, the oil passes from
through
the torque
the transmission
converter.
main
It
and returns to the
and speed spools (5) and (61, and

clutch and 1st clutch.
a andcreates
a difference
C and port D.
Quick return valve (IO)
right,
and the oil at the
in pressure between port
is filled
port C and port D disappears.
the orifice
of FORWARD
of each speed spool to the
However, solenoid valves (1) and (2)

spool (6) and 1st spool (5) are open,
so the oil passing through

drain circuit.
created
the orifice
As a result, a difference
between
the clutch is then connected.
back
with
to the
oil, the difference

left
in pressure between
The valve is pushed
by the difference
in area of the
valves, and drain circuit Eis closed.

At this point, each clutch is filled with oil, but the oil
flows to the
has not reached the specified
pressure.
in pressure is
port
D flows
back
of
port A and port B, and this over-
comes the force of springs (7) and (8).
The port to
valve
piston (9) flows to drain circuit E. When each clutch
One of the two oil lines flows from the pilot reducing
valve through
moves to the
rear of modulating
transfer case.
solenoid valve.
When
through
modulating
orifice
piston
(9).
The oil at
and reaches the

The piston
(12)
moves to the right and the clutch pressure rises slowly. When the modulating
piston reaches the end of its
stroke, the clutch pressure reaches the specified level,

and the clutch is completely
WA500-
engaged.
21-31
PRIORITY
VALVE
Function
The priority
valve (1) controls the minimum
sure of the pilot reducing valve (2).

priority
valve (I)
gives the oil flow
reducing valve (2) priority
pres-
In addition, the
to the
pilot
over the other circuit.
Operation
.
The oil from the pump flows to port A of priority

valve (1) and port B of pilot reducing valve (2).
To modulating valve
!$
To each transmission spool
To main relief valve
425FO35
The oil entering

priority
port A flows from
orifice
valve (I) to port D. The hydraulic
a of
pressure
and force of poppet spring (3) push back spring (4)

and move priority
valve (1) to the right.
When this happens, port A and port C are connected, and the oil flows from
port
C to the clutch
spool.
To modulating valve
To each transmission wool
To main relief valve
425FO36
21-32
WA500- 1
MODULATING
VALVE
AND
QUICK
RETURN
Function
.
VALVE
k/cm*)
The
modulating
together
to
slowly.
valve
raise the
transmission
In this way,
shifting
gear, and
torque
in the
fatigue
is reduced,
comfort
and quick
they
reduce
prevent
power
the
train.
return
clutch
valve
the shock when
generation
of peak
As a result,
operator
operator
of the power
C
Shifting gear
pressure
and at the same time,
and the durability
40
act
train
are
increased.
30!?
$
h
5
20_
10 -
Time
(Set)
425F175
1)
Immediately
after shifting gear (Point A on Fig. 425F175)
valve
425FO37
Operation
The
oil
sent
from
valve (I) through
the
valve
(21, and enters
(3).
The oil
return
which
valve
port
WA500-
orifice
flows
from
B of quick
passes through
(3)
and flows
orifice
to the
priority
modulating
return
a
valve
of quick
clutch
piston,
when
it passes
it creates a difference
in pres-
has been actuated.
through
pump
port A, passes through
However
sure between
port
B and port
valve moves to the right

(5).
In addition,
to the right,
surized
when quick
drain
oil at the
port
C.
The quick
return
and the oil flows to clutch

return
valve (3) moves
D is opened,
rear of piston
and the pres-
(4) flows to the
drain circuit.
21-33
2)
Clutch pressure rising (Point B on Fig. 425F175)
valve
425FO38
Operation
As the pressure at the clutch piston rises, the pres-
At the same time, pressurized oil also passes thorugh
sure at port C also rises. Quick return valve (3) is
the
pushed back to the left and drain port D is closed.
valve (2).
The oil from
the pump flows from
port C to the
and some of the oil at port A flows to port G.
clutch
and at the same time
it flows from
orifice
piston
b
through
quick
return
valve
(3)
orifice
and
enters poppet
It moves modulating
(7) of modulating
valve (2) to the left
and
enters port E.
The oil at port E acts on the modulating
It
pushes back
spring
(6)
piston (4).
and moves piston
(4)
to the right.
21-34
WA500-
3)
Completion
of rise in clutch pressure (Point C on Fig. 425F1751
To solenoid valve
To pilot reducing
425FO39
Operation
The oil entering
port
When the piston
to push piston
(4).
reaches the end of its stroke,
the
rise in pressure stops.

sure
reaches
valve.
the
In addition,
by piston
(4).
WA500-
set
E continues
When this happens, the prespressure

port
of
the
F and port
modulating
G are closed
ACCUMULATOR
VALVE
Function
The accumulator
when
clutch
shifting
valve acts to reduce the filling time
gear by allowing
the oil at the 2nd
piston to escape slowly when shifting from
2nd to 1st.
This allows the clutch to be engaged
smoothly when shifting from 2nd to 1st.
1.
Shifting to 2nd
* When shifting to 2nd gear, the oil from the pump

passes through the reducing valve and enters port
A of the 2nd spool (5).
When the 2nd spool
moves, port A and port B are connected and the

oil flows to port C.
The oil at port C flows from check valve (2) and
orifice a to port D.
From reducing valve

R
---I
From pilot reducing valve

423FO39
21-36
WA500- 1
As the pressure of the oil entering port D rises,

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

enters port D and acts on the rear of the check
valve (2).
orifice
The oil from

and flows
this way the

reduced.
port D passes through
to the drain circuit.
shock when shifting
In
gears can be
From reducing valve
423FO41
WA500-
21-37
PILOT
REDUCING
VALVE
Function
The pilot reducing valve acts to control the
Pressure
needed to actuate the transmission spools.

Operation
The
filter
The
oil from
the pump
passes through
the
pilot
and enters port A of pilot reducing valve (1).

oil passes through
port B and enters through
the orifice of transmission spool (2) to fill the inside

of port C.
&B To main relief valve
425FO33
When the
pressure inside port C rises, pressurized
oil flows from orifice a of pilot reducing valve (I)

and goes to port D.
As a result, pilot
reducing valve (I)
moves to the
right, and port A and B are shut off, so the pressurized
oil
at
port
C is maintained
at the same
pressure.
@&To
main relief valve
425FO34
21-38
WA500-
MAIN
RELIEF
VALVE
Function
Clutch
The main relief valve acts to supply the necessary oil

to the clutch when shifting
are not being shifted,
gear.
When the gears
it sends all of the oil directly
to the torque converter.
425FO30
Operation
.
The oil from the pump passes through the oil filter
and enters port A of main relief valve (I).
Until the specified pressure is reached, the oil flows

to the priority
valve.
425FO31
.
When the pressure goes above the specified level, oil

passes through the orifice in relief valve (I), pushes
poppet
(21, and moves relief valve (1) to the left.
The oil is relieved to the torque
converter,
converter
so the
specified pressure is maintained.

*
Specified pressure: 27 kg/cm2
425FO32
WA500- 1
21-39
REDUCING
VALVE
Function
The
reducing
valve is in the circuit
quick return valve and the 2nd spool.
between
the
It reduces the
pressure applied to the 2nd clutch, and in this way

acts to protect the 2nd clutch.
The maximum
pressure in the main circuit is kept to
the specified level by the main relief pressure.
Operation
.
The oil from the quick
return
valve enters port A
and then flows from port B to 2nd spool (2).
When the circuit to the 2nd clutch is filled with oil

and the hydraulic
which
flows
poppet (3).
pressure rises, the oil from port B
through
orifice
a to port
C pushes
The reaction to this compresses spring
reducing valve
(4) and moves reducing spool (I) to the left.
425FO40
As a result, port A and port B are closed, and the oil

stops flowing.
The hydraulic
pressure at this point is 20 kg/cm2.
From pilot
reducing valve
425FO41
21-40
-FL
WA500- 1
LUBRICATION
BYPASS
VALVE
Function
When
traveling
are rotating
churning
in 4th
at high
resistance
oil increases.
gear, the transmission

speed.
of the transmission
the
lubrication
To reduce this power loss,only
oil to lubricate
gears
Because of this,
enough
the gears at 4th speed is kept.
the rest of the oil is bypassed
All
to the transmission
case.
Operation
4th clutch
not being operated
When the 4th clutch

no hydraulic
is not being operated,
pressure
at port
a of spool
there
(1).
is
As a
result, spool (I) is pushed to the left by the spring.

The
spool
oil
from
(I),
the
torque
so all the oil
converter
is stopped
is used for lubricating
by
the
transmission.
425F176
4th clutch
being operated
When oil flows

from
4th
spool
to the 4th clutch,

(2) to port
pressure oil enters port

and moves spool
torque
converter
(2).
to the
From quick return valve 2
When
a, it pushed back the spring
(2) to the right.

flows
pressure oil flows
a of spool
j,,,,,,
,,,,,
,*Y~~
,n\*\b*:y,*~~
$?e&@
\ I,
J ~~%e&t&~@>*~i
The oil from the

transmission
lubri-
cation system and drain port b.
lission
ltion
From
reduc
425Fl77
WA500- 1
21-41
PILOT OIL FILTER
IN
OUT
Section A - A
1. Oil filter head

2. Element
3. Case
Specification:
Filtration
21-42
area: 370 cm2
WA500-
OUTLINE
.
Transfer
The transfer
is installed at the power output end of
the transmission
and is secured to the transmission
case by bolts.
TRANSMlSSlON
.
Output
PATH
shaft (I)
of the transmission
transfer input gear (2) by a spline.

is transmitted
is coupled to
The motive force
to output gear (4) through
idler gear
1.
Transmission output shaft
2.
Transfer input gear (teeth 48)
the center
3.
Transfer idler gear (teeth 45)
The rest of the
4.
Output gear (teeth 43)
5.
Output shaft
6.
Rear coupling
(3) and output shaft (5).

Part of the power transmitted
transmitted
to the front
to the output shaft is
axle through
drive shaft and front
drive shaft.
power
to the rear axle through
is transmitted
the
rear drive shaft.
7.
Front coupling
8.
Rotating pick-up sensor
\
To
front a
425FO48
WA500- 1
To
rear axle
425FC49
21-43
DRIVE
SHAfT
OUTLINE
.
The
motive
the damper,
force
from the engine passes through
upper drive shaft (5). torque converter,
transmission and transfer.

passes through
Part of this motive force
rear drive shaft (4) and goes to the
rear axle; the rest of the motive force passes through

center drive shaft (3), center support
(2) and front
When the body is articulated,

from
the
road
or when there is shock
surface during
traveling,
there is shock during operations,

and
behind
the
engine
or when
the axle in front
and transmission
change
position.
To allow the motive force to be transmitted
without
drive shaft (1) and is sent to the front axle. In addition to transmitting
the motive force, the drive
damage to parts of the machine when there is shock
shafts have the following
shafts have a universal
purposes.
or when the components

This allows them
move position,
joint
to handle
the drive
and a sliding joint.

changes in angle and
length.
425FO50
21-44
1.
Front drive shaft
4.
Rear drive shaft
2.
Center support
5.
Upper drive shaft
3.
Center drive shaft
WA500- 1
CENTER
SUPPORT
425FO51
1.
Front coupling
2.
Case
Function
The center support

between
3.
Grease nipple
4.
Rear coupling
is installed to the front
frame
the center drive shaft and the front drive
shaft.
.
With the articulating

twisting
from
frame,
this part is constantly
side to side, so there is liable to be
large stress on the drive shaft.

support is used to transmit
Therefore,
the center
the power smoothly,
to
reduce the stress on the drive shafts, and in this way

improve the durability
WA500-
of the drive shafts.
21-45
AXLE MOUNT
Seotion A - A
21-46
\L
/-
SectionB
425FO58
WA500- 1
-._-J
-..1
View Z
425FO59
1.
Front axle
Front axle
2.
Rear axle
3.
The front axle (1) receives the force directly during

operations,
Front frame
so it is fixed directly
to the front frame
(3) by axle mounting bolts (5).

4.
Rear frame
5.
Axle mounting bolt
Rear axle
The rear axle (2) has a structure which allows the

center of the rear axle to float, so that all tires can
be in contact
with the ground when traveling over
soft ground.
WA500-
21-47
AXLE
.
The
AND
motive
the damper,
DIFFERENTIAL
force
from the engine passes through
torque
converter,
transmission,
trans-
Inside the axles, the motive
force passes from the
bevel pinion to the bevel gear and is sent at right
fer, and drive shafts, and is then sent to the front
angles.
and rear axles.
passes through the front differential

shaft.
At the same time, the speed is reduced and

(1) to the axle
The motive force of the axle shaft is further
reduced by a planetary-gear-type
final drive (4) and
is sent to the wheels.
FRONT
1.
Front differential
2.
Front axle
3.
Brake (See page 51-I 8)
4.
Final drive (See page 21-53)
5.
Parking brake
6.
Drain Plug
\li
21-48
View 2
425FO52
WA500- 1
10
Section A - A
11
425 F053
7.
Side gear (Differential)
8.
Bevel gear (Teeth 37)
9.
Shaft
(Teeth 18)
10.
Pinion (Differential)
(Teeth 10)
11. Bevel pinion (Teeth 9)
WA500- 1
21-49
REAR
View
5
425FO54
21-50
1.
Rear
differential
4.
Final
drive
2.
Rear
axle
5.
Drain
plug
3.
Brake
(See page
51-I
(See page
21-53)
8)
WA500- 1
I I Section
A - A
425FO55
6.
Bevel gear (Teeth 37)
7.
Bevel pinion (Teeth 9)
8.
Shaft
9.
10.
WA500-
Pinion (Differential)
(Teeth 10)
Side gear (Differential)
(Teeth 18)
21-51
OUTLINE
The motive force from the drive shaft passesthrough

bevel pinion
(5).
The
(1) and is transmitted
to the bevel gear
bevel gear changes the direction
of the
motive force by 90, and at the same time reduces

the
It then
speed.
transmits
through the differential
the
motive
force
(4) to the sun gear shaft (2).
423FO59
When driving straight forward
When the
rotating
machine
is driven straight forward,
speed of the
the
left and right wheels is the
same, so the pinion gear (4) inside the differential

assembly (6) is sent through the pinion gear (4) and
the side gear (3) and is transmitted
equally to the
left and right sun gear shafts (2).
423FO60
When turning
When turning,
the
rotating
right wheels is different,
speed of the left and
so the pinion gear (4) and
side gear (3) inside the differential

in
accordance
rotating
with
speed of the
the
difference
assembly rotate
between
left and right wheels.
motive force of the carrier
the
The
(6) is then transmitted
to the sun gear shafts (2).
423FO61
21-52
WA500-
FINAL
DRIVE
To gain a large drive force, the final

planetary
drive uses a
gear system to reduce the speed and send
drive force to the tires.
The motive force transmitted

through
from the differential
axle shaft (1) to sun gear (5) is transmitted
to planetary
gear (2).
The planetary
gear rotates
around the inside of a fixed ring gear (3) and in this

way
transmits
planetary
rotation
carrier
(4).
at a reduced speed to the

This motive force is then sent
to the wheels (6) which
are installed to the plane-
tary carriers (4).
425F057A
WA500-
1.
Axle shaft
2.
Planetary
3.
Ring gear (Teeth 78)
gear (Teeth 29)
4.
Planetary
5.
Sun gear (Teeth 18)
carrier
6.
Wheel
21-53
0
TIRE AND
WHEEL
The tire acts to absorb the shock from the ground
SPECIFICATIONS
surface to the machine, and at the same time they
must rotate in contact with the ground to gain the
TRA code:
*
.
Nominal size of wheel:
power which drives the machine.
Various
pose.
types of tires are available to suit the purTherefore
correct
tires
for
it is very important
the
type
of work
to select the
and
Tire type:
26.5 x 25 - 20PR
L3
Normal in flation
22.00 x 25WTB
pressure: 3.5 kg/cm2
bucket
capacity.
33
--
---\
O;\,
0 1
o\
0)
01
Of
0 //
OO,
--____-x
o,,-
425 FO60
1.
21-54
0
Tire
2.
Rim
3.
Air valve
4.
Lock ring
5.
Side ring
WA500-
POWER TRAIN
22
TESTING
AND
ADJUSTING
...................
...........
Measuring engine stall speed ..............
Standard
Tool
value table
list for testing and adjusting
Measuring
converter
.............
...................
and transmission
shift lever
for operation
The following
shooting
1.
2.
precautions
or during testing
are necessary when using the Standard
spool
Value Tables to make judgements
during
leaving the plant, so they should
or when estimating
values in these tables
values for the machine

they
22-
22-
trouble-
and adjusting.
of use.
Therefore,
22-
22-11
as target values when repairing

The standard
22-10
The values in these tables are based on the values for new machines
standard
22.
of emergency
......................
Tire and wheel .......................
Troubleshooting
......................
manual
2
3
oil pressure of torque
Measuring
Method
2222-
should
for
judgement
when shipped
be used as reference
wear after a period

when
troubleshooting
are estimated
values based on the
from the plant,
and on the results of various test.
in combination
with
repair and operating
be used
records when
making
judgements.
3,
These standard value tables must not be used for standard values when judging claims.
these values alone to make simple judgements.
WA500-
In addition,
do not use
STANDARD
VALUE TABLE
Testing and measuring item
Standard value
Permissible value
. Torque converter oil

temperature:
60-80C
Shift lever operating force and stroke
* Directional
Unit
lever operating force
0.3 - 0.9
Max. ? .4
0.3 - 0.9
Wlax. 1.4
0.3 - 0.9
Max. 1.4
2nd - 3rd
0.3 - 0.9
Max. 1 4
3rd - 4th
0.3 - 0.9
Max. 1.4
N-F
* Engin speed:
Low idling
kg
N-R
Speed lever operating force
kg
lst-2nd
* Directional
lever travel
32 - 42
27 - 47
32 - 42
27 - 47
mm
32 - 42
27 - 47
rm
660 - 720
mm
N-F
N-R
* Speed
lever
1st - 2nd - 3rd - 4th
Inside operating range
Engine stall speed
* Low idling
* High idling
- Torque converter
* Hydraulic stall
- Full stall
* Torque
converter temperature:
60 -80C
stall
2250 - 2350
2085 - 2185
+ Hydraulic temperature:
45-WC
Oil pressure of torque converter and

transmission
* Torque converter oil

temperature: 60 - SO C
- Pilot reducing pressure

* Modulating pressure (except
* Engine
speed: High idling
.g/cm'
F,, R,)
* Reducing valve pressure (for F,,
R, )
- Torque
- Torque
converter inlet pressure
(A)
Tire inflation pressure:

Specified pressure
(B)
- Clearance
of wheel lock ring
1665
mm
Tire
9.8 - 11.8
27 - 30
27 - 30
19 -22
19-22
2-4
10.5
O-ring
9.5 - 10.5
3-5
Max. 2.5
Max. 4.0
2-10
(ct
F4.2301008
423F30W
2%2
1865
9.8 - 11.8
3-5
converter outlet pressure
of wheel lock ring
1265-
9.5 -
Tire and wheel
* Fitting
1950 - 2350
1465 -
2-4
. Lubrication oil pressure
1935 - 2335
2100 - 2200
WA500-1

No.
AND
ADJUSTING
Tool Name
Engine speed
Tachometer
Oil temperature
Thermistor
Oil pressure
Hydraulic
Part No.
Remarks
799-203-8000
Digital display 60 -
kit
799-l 01-6000
0 -
tester
799-l 01-5000
Q1
Pedal and lever

operating force
Measuring clearance
Push-pull gauge
Feeler gauge
79A-262-0020
Commercially
When carrying out testing, adjusting or troubleshotting,
rpm
loooc
0 - 25 kg/cm2
0 -
19999
50 kg/cm2
0 - 25 kg
available
0.1 - 3.0 mm
stop the machine on level ground, install the safety bar
on the frame, lower the bucket to the ground, and stop the engine.
Then apply the parking brake and block the tires.
Do not allow unauthorized
When measuring the engine speed, one worker should measure the engine speed while the other sits in the op-
erators seat to operate the controls.
Always check that the operation
is safe, and use agreed signals.
WA500-
22-3
0
MEASURING
*
Measurement
ENGINE
STALL SPEED
condition
* Hydraulic temperature:
45 - 55C
- Torque converter oil temperature:
60 - 80C
Unit:
Standard
Item
rpm
Permissible
value
value
Low idling
660
High idling
2250
- 2350
2085
- 2185
1935
- 2335
2100
- 2200
1950
- 2350
1665
1265
Torque
converter
Hydraulic
stall
stall
Full stall
- 720
1465-
1865
Special tools
Check
that
the low idling
the standard
Before
and high idling
speeds are
value.
measuring
on
the
Set
tachometer
the
outer
A
rpm
at each stall,
circumference
and
adapter
of
@
put
the
on
mark
damper.
top
of the
engine mount.
Check
If
that the engine speeds are the standard
any
item
is outside
the
permitted
value.
range,
check
for any looseness for play in the linkage.
Block the tires
1.
Measuring
torque
converter
stall
1)
Start engine and run at low idling.
2)
Put
the
REVERSE,
directional
and
lever
speed
in
FORWARD
control
lever
in
or
the
highest speed range.

3)
Using the brake, stop the machine
and measure
the engine speed when the engine reaches accelerator
pedal depress fullv.

the
transmission
* Turn
switch
(Check that the pilot
Do not
cut-off
lamp is OFF).
run at stall speed for more than 20
seconds, and do not let the torque

oil temperature
22-4
0
selector
(1) to OFF, and use the left brake.
converter
rise above 120C.
WA500-
2.
Measuring hydraulic stall

1)
Start engine and run at high idling.
2)
Operate
the dump
the cylinder
or lift control
the relief valve of the main control

3)
move
and actuate
valve.
Measure the engine speed at this point.

*
Do
not
more
control
3.
lever to
to the end of its stroke
run
than
the
20
engine
seconds,
at stall
and
speed
operate
for
the
lever quickly.
Measuring full stall

Measure
stall
the
engine
and hydraulic
time.
WA500-
speed
stall
when
torque
are reached
converter
at the
same
MEASURING
OIL PRESSURE
TRANSMISSION
* Measurement conditions
OF TORQUE
CONVERTER
AND
- Torque converter oil temperature:
60 to 80C
* Engine speed: High idling
Unit:
kg/cm
Standard value
Permissible value
Pilot reducing
pressure
10.8 + 1.0
10.8 i: 1 .O
Modulating
pressure
(Except F,,
28.5 + 1.5
28.5 f 1.5
item
R, )
Torque converter relief

pressure
8*1
8 +l
Special tool
I
A
Part No.
the parking
Oty
1
Hydraulic tester
799-l 01-5000
Apply
Part Name
brake and block the tires.
Measuring procedure
*
The following
measuring
preparatory
work
is necessary
before
any oil pressure.
* Remove covers (2) on left side under the cab.

- Turn the transmission cut-off selector switch
to
OFF
pilot
and use the left
brake.
(Check
that
pull
the
lamp is OFF.)
* Remove the plug from the measuring port of the

transmission
Install
(1)
hydraulic
the
tester
gauge
to
the
A to the measuring
operators
port,
compartment,
then start the engine and measure the pressure.

*
Check that there
is no leakage of oil from
any joints.
valve.
I
/
P!
22-6
0
Pl
P3
425F203
WA500-
1.
Measuring pilot reducing pressure

1)
Measuring
2)
Put the directional

the
port
pressure
(P5).
lever in neutral,
when
the
speed
and measure
control
lever
is
operated.
2.
Measuring modulating
1)
2)
Measuring
port
pressure
(PI).
Put the directional

the
pressure
lever in neutral,
when
the
speed
and measure
control
lever
is
operated.
3.
C38
Torque converter inlet port oil pressure
I)
Measuring port (P8).
2)
Start
the engine and measure the pressure at
high idling.
4.
Measuring lubrication
valve pressure
1)
2)
Start
high idling.
5.
Measuring reducing valve pressure
1)
2)
Start
high idling and low idling.
6.
Measuring torque converter outlet port pressure

1) Measurement
port (3) (PT1/8)
2) Measure
pressure with
the
the engine
at high
idling.
425FOlOlO
WA500-
22-7
@
MEASURING
SHIFT
LEVER
Measuring conditions
- Torque converter
- Engine stopped.
60 - 80C
oil temperature:
Unit:
kg
Standard
value
Permissible
value
0.3 - 0.9
Max. 1.4
Neutral + Reverse
0.3 - 0.9
Max. 1.4
1st - 2nd
0.3 - 0.9
Max. 1.4
2nd - 3rd
0.3 - 0.9
Max. I .4
3rd - 4th
0.3 - 0.9
Max. 1.4
Neutral -+ Forward
32 - 42 mm
27 -47
Neutral + Reverse
32 - 42 mm
27 - 47 mm
In each range
from 1st three
4th speeds
32 - 42 mm
27 - 47 mm
\leutral
+ Forward
1Directional
mm
Directional
lever
3
!z
+
Speed
lever
Special tool
425PO29
-Part
No.
A /
79A-262-0020
A Be
1.
Part Name
Qty
Push-pull scale
sure to set chocks
firmly
against
the tires.
Measuring the lever operating effort

1)
Stop
2)
Attach
the engine.
push-pull
to the
the
lever
The
scale
knob
operating
operating
(I)
A or a spring
at the center
effort
required
to
balancer
and measure
pull
it in the
direction.
measurement
speed
2.
should
be made
in each
range.
425PO30
Measuring the lever travel

1)
Stop the engine.
2)
Put
mark
knob
moved
22-8
@
and
on
the
measure
center
the
in the operating
on the
travel
when
control
the
lever
lever
is
direction.
WA500-
METHOD
SPOOL
OF EMERGENCY
FOR OPERATION
MANUAL
OUTLINE
.
The
transmission
Therefore,
valve
is controlled
electrically.
the emergency manual spool is installed
to enable the machine to be moved if there is any

failure
in the electrical
system, or in the solenoid
valve and spool.
The
emergency
manual spool is for use when
failure in the transmission control

machine
from
being
prevents the
It
moved.
allows
the
machine to be moved from a dangerous place to

a place where repairs can be carried out safety.
The
emergency
manual
spool must never be
used except when the transmission control
has
broken down.
When
operating
follow
the emergency
the correct
manual spool,
order of operation
and pay full attention
exactly,
to safety when moving
the machine.
To prevent the machine from moving, lower the

bucket to the ground, apply the parking brake,
and block the wheels.
inside the air tank
Check that the pressure
is above the specified pres-
sure.
1.
Remove R.H. machine panel.

*
If an air conditioner
is installed, push condenser
(1) over to the front.

Always
stop the engine before
operating
the
spool.
2.
Remove
lock plate
(2)
of the emergency
manual
Y!
spool of the transmission valve.

*
Simply
loosen the mounting
bolts to remove
the lock plate.
Rev&
Forward
spool
spool
spool
3rd
2nd
1st
spool
spool
SPOOl
425F204
3.
Decide the direction
to move the machine (forward
or in reverse),
move the emergency
then
manual
spool to the operating position.

FORWARD:
Rotate
FORWARD
clutch spool and
1st spool counterclockwise,

out approx.
and pull
position.
REVERSE:
Rotate
REVERSE
clutch spool and
1st spool counterclockwise,

out approx.
and pull
10 mm to the operating
Approx.
position.
~pprox.
WA500- 1
I===
I=
00
10 mm to the operating
10 mm
00
421 F203
22-9
0
4.
Check
that
the area around
the machine
is safe,
remove the blocks from under the wheels.

5.
Sit in the operators
seat, and depress the left brake
pedal fully.
6.
Start the engine, release the parking brake, then release the brake pedal gradually to start the machine.
When the engine is started, the transmission
is
engaged and the machine will start. Therefore,

before
starting
the direction
the engine, always check that
of travel is safe, and always keep
the brake pedal depressed.

If the
machine
does not start,
turn
the 2nd
spool, 3rd spool, and 4th spool clockwise,

screw in approx.
7.
After
and
10 mm to the OFF position.
moving the machine,
stop the engine, apply
the parking brake, and block the wheels.

8.
Return
the emergency manual spool to the neutral
position, and install the lock plate.
TIRE AND
WHEEL
Tire
Unit:
Item
No.
Standard value
Max. 2.5
Max. 4.0
kg/cm2
Permissible
value
Fitting of wheel
lock ring
Clearance of
wheel lock ring
2-10
F42301008
Measuring procedure
1.
Fitting of wheel lock ring

Measure distances A and B at four places around
the circumference.
2.
Clearance of wheel lock ring

Measure dimension C.
423F309
22&l
O
WA500-
TROUBLESHOOTING
Precautions
Method
Preventing
Method
recurrence
of locating
troubleshooting
2.
3.
Machine
Torque
too high
WA500-
transmission
table
. .
points when
system
. .
does not move
Excessive timing
machine
4.
of trouble
main problem
. 22-12
....
..
. 22-14
. . . . . . . . . 22-16
table
..
. 22-17
. 22-18
. . . . . . . . . 22-18
Machine lacks power or speed . . . . .
. 22-20
Troubleshooting
1.
..
of reading troubleshooting
. .
..
lag when starting
or shifting
converter
. . . . . .
gear
. . . . . . . . . . . 22-21
oil temperature
..........
. . . . . . . . . . . 22-22
22-11
0
PRECAUTIONS
1.
WHEN
TROUBLESHOOTING
SAFETY
* Stop the machine on level ground, and check that the safety pins and parking brake are correctly applied,
p\.
and that the tires are blocked.
- When working in groups, use agreed signals and do not allow unauthorized persons near the machine.
-
Be careful not to get burned by hot parts or to get caught in rotating parts.
* Always disconnect the cable from the negative (-1 terminals of the battery before disconnecting any wiring.
- Always release the pressure before removing the plugs or caps of any place under hydraulic or air pressure,
and connect all measuring tools correctly.
2.
METHODS
FOR TROUBLESHOOTING
* Just because a failure occurs, do not immediately
start to disassemble the machine.
If the machine is disassembled before making the proper checks.
* The machine may be disassembled in such a way that the problem cannot be located, so the cause of the
problem will be unknown.
As a result,
* The customer and operator will lose confidence in you.

- Time will be wasted, and unnecessary costs will be incurred for excess parts and greasing.
To avoid these problems,use the following
1.
2.
questions about
the breakdown.
a.
Have there been any other problems apart from the one reported?
b.
Was there anything usual before the machine broke down?
c.
Did the breakdown
d.
What was the machine doing when the breakdown
e.
Had the machine been repaired before the breakdown?
f.
Had the same kind of failure occurred before?
Check the following

a.
3.
procedure when troubleshooting.
Ask the customer and operator the following
occur suddenly, or had there been signs of trouble before?

occurred?
If so, who carried out the repair, and when?
items which can be checked simply by visual checks, etc.
Check oil level.
b.
Check for leakage of oil from piping or hydraulic equipment.
c.
Check travel of control levers.
d.
Check stroke of spool in control valves.
Reenact the failure

a.
and check the condition
Ask the user or operator
if
the machine
(particular
conditions
at the time of failure).
if the decision about the failure was made based on measured values, or by com-
parison, or by feeling.
b.
Compare extent of failure with standard values.
- Check safety before carrying out any check.

- Did not make any check or measurement that will make the conditon worse.
4.
Try to locate the possible causes for the failure.

The transmission
system consists of the transmission
itself, the transmission control
valve, and the transmis-
sion electric control.

In particular,
when trouble
occurs in the transmission
system, the probable
location
of the failure can be
divided as follows.
- Transmission itself, or transmission control valve.

- Transmission electric control.
To decide which of the two is the location of the failure, go to page 22-17.
22-12
0
WA500-
5.
Carry out troubleshooting

There are the following
1.
2.
using the troubleshooting
two types of troubleshooting
TROUBLESHOOTING
The troubleshooting
FLOW
charts.
. . . . . . . . . . . . 22
TABLE
TROUBLESHOOTING
charts.
CHART.
_.
POWER TRAIN,
42
STEERING
52
BRAKE
62
WORK
. . . . 82
SYSTEM,
AND Al R SYSTEM,
EQUIPMENT
ELECTRIC
AND
SYSTEM
ELECTRONIC
SYSTEM
charts consist of:
1)
Items which can be checked easily.
2)
Items which are likely to be the cause of such failures.
Follow these charts to carry out troubleshooting.

At the same time, do not forget the following
points.
- Check related items.

- Check that there are no other failures or breakdowns.
*
For details of troubleshooting
6.
Investigate causes of breakdown
Even if the breakdown
tables, see page 22-14.
is repaired, if the original cause of the problem is not removed, the same breakdown
will occur again. To investigate and remove the original cause, see Actions to take to prevent failures from
occurring again.
3.
PRECAUTIONS
WHEN REMOVING,
INSTALLING,
DISASSEMBLING
OR ASSEMBLING
PARTS DURING TROUBLESHOOTING
- If it is necessary to remove, install, disassemble or assemble parts for troubleshooting, remember the following
points.
- Carry out the various testing and adjusting while observing the items on quality control given in Testing and
Adjusting.
+ When removing parts, check their condition of mounting, and distinguish between front and rear, left and right,
and top and bottom.
* Check the match marks, or make match marks to prevent mistakes when installing.
- If part cannot be removed even when the nuts and bolts have been removed, do not use excessive force to remove it.
Check the part to see if there is any problem
with it, and remove the problem
before trying to dis-
assemble the part.
- When installing or assembling, clean off all dust and dirt and repair any scratches or dents.
Remove all grease or oil before coating with gasket sealant.
WA500- 1
22-13
0
METHOD
OF READING
DESCRIPTION
OF SYMBOLS
The
following
column
USED
are used
symbols
to indicate
the method
TROUBLESHOOTING
IN TROUBLESHOOTING
TABLE
TABLE
in the Remedy
of eliminating
the
cause of a fault.
X:
Replace;
A:
Repair;
A:
Adjusting;
C:
Clean
METHOD OF READING
ING TABLE
TROUBLESHOOT-
The symbol 0 in the table is inserted only for causes

which can be diagnosed.
nosed, the corresponding
If a cause cannot be diagbox is left blank.

:
If the result of problems 1 using the troubleshooting

table shown at right
trouble
is abnormal,
the cause of the
can be assumed to lie between a and d.
Because it is not possible to make a problems regardinge,
it is necessary to perform
the next problems
(owing to the possibility of a multiple fault).

If the result of problems 1 is normal, the cause of the
fault
does not lie between
case, before
a and d.
In such a
diagnosing the cause as e, however,
carry out a check by means of problems 2 or 5.

If now the result of problems
1 is abnormal
and the
result or problems 2 normal, the cause is one of a,

b or d.
abnormal,
In addition,
if the result of problems 3 is
the cause will be narrowed down to one of
b or d.
To determine
actual cause, perform
which of b or d is the
problems 4.
If the result of problems is abnormal,

corresponding
blacken out the
in the table and then perform
the
Not necessen/
problems
next problems on these causes in order to narrow the

likely causes.
Example 1 :
Problem 1 + Abnormal
From the table of ex-
Problem 2 + Normal
ample 1, the cause of
Problem 4 + Normal
ti
the fault is b.
Example 2:
Not
From the table of exProblem 1 + Normal

Problem 2 -+ Abnormal
*
ample 2, the cause of

the fault is ,,e,,.
In example 2, it is evident that the cause is e

without
blem
carrying out problems 2, however pro2 is performed
by way of an additional
check.
22-14
0
WA500- 1
Example 3:
Problem 2 -+ Normal
ample 3, the cause is
Problem 3 + Normal
one of a, c and
e.
Continue problems
-i
Problem 4 + Normal
ample 3-1, the cause is
Problem 5 + Normal
C.
x c
1
Example 4:
\
lrlrlrlrl
ample 4, the cause is
Problem 2 + Noraml
one of a, b or d.
Continue problems
Problem 4 -+ Abnormal
ample 4-1, the cause is
Problem 5 + Normal
a or Id.
As can be seen from the above examples, it is not necessary to perform all of the problems.
Also, looking at a particular cause, no matter how many
0 marks there are in the column corresponding
to that
cause, it will cease to be an actual cause if there is even

one 0 mark is the same column.
WA500-
22-15
0
PREVENTING
*
RECURRENCE
The troubleshooting
ment.
OF TROUBLE
table is used to establish the direct cause of damage or breakdown
of a part or piece of equip
It is not able to establish the root cause of the damage or failure, however.
- Also, this table only describes the action to be taken with the particular part or piece of equipment.
It does not
mention what action should be taken to prevent a recurrence of the root cause.
In order to remove the root cause of a fault so as to prevent a recurrence, carefully

referring to the following
investigate the real cause while
items.
Regarding the method of checking and adjusting each part or piece of equipment,
refer to Testing and adjusting in
the Shop Manual.
HYDRAULIC
1.
.
EQUIPMENT
Oil checks
3)
The fundamental
ing in hydraulic
equipment
wash the oil using an oil refresher or replace it.
Accordingly,
the
action.
for
water
2.
Check for ingress of other foreign matter

the drain plug and filter,
by water,
matter
then check
has collected
Check the degree of contamination
to
there.
by means
checker.
Cleaning fragments of damaged parts

If
a part
becomes damaged,
In addition,
valves and
metal
helping
disassemble
fragments
fragments
may
and
to prevent
and wash such parts as
which
other
are liable
foreign
a recurrence
becoming
to
of faults
or not the
oil is satisfactory.
2)
Check of ingress point

If, as a result of the above checks, it is discovered that the oil is contaminated
or other foreign
matter,
by water
it is necessary to find
out where the contamination
is occurring and
also the take steps to prevent it.

Water:
Oil storage tank, breather, etc.
Stand:
Oil replenishing
or replacing meth-
od, etc.
Rubber: Cylinder packing, etc.
Metal:
Wear
or
equipment
motor,
as
damage
to
such
as
well
as
hydraulic
pump
and
transmission
and torque converter, etc.
22k6
thus
due to
lodged in various parts
of the oil using a viscowhether
collect
matter,
of the engine or hydraulic equipment.
meter in order to confirm
pass
It is thus necessary to wash the oil.
cylinders
such fragments
Viscosity check
Check the viscosity
it is
When washing the oil, also wash or replace
into the oil line.
of the tank and also the filter
of a contamination
If the oil is contaminated
ingress by
plate.
see if any foreign
in the oil, either
the strainer and replace the filter.
possible
means of a diesel engine oil checker or a hot
Remove
is discovered
of an oil refresher.
*
oil
matter
not possible to remove the water by means
Check for water ingress
the bottom
or
Oil checks
Check
of metal particles or other
in the oil.
any of the above substances, and
then take appropriate
If a large amount
foreign
it is necessary to check the oil to see whether
1)
Oil cleaning and replacement
is the inclusion of water,
air or other foreign matter

not it contains
cause of almost all faults occurr-
WA500-1
METHOD OF LOCATING MAIN PROBLEM POINTS

TROUBLESHOOTING
TRANSMISSION
SYSTEM
The problem
points
in the transmission
system can be broadly
1.
Transmission
itself and transmission
2.
Transmission
electric
control.
Use the following
method
to decide which
Problem:
control
divided
into the following
WHEN
two areas.
valve.
of the two areas has the problems.
Machine
will not start.
Machine
will only travel in one direction.
(FORWARD
or REVERSE)
Cause
2
Does machine move
if screw of
emergency
spool
forForRandlstis
pushed in?
l-l
Is voltage and
resistance of F or R
solenoid correct?
YES
c
Replace transmission
valve
Go to Troubleshooting
transmission
LSee page 22-18
-
Remedy
control
I I
NO
for
22-22)
1 I Voltage 20 - 3ov.
2) G&yance
approx.
L
NC
Machine will not move in certain
Problem:
electrical system of
transmission
(See page 82-38 -
for
82-43)
speed ranges
Replace transmission
control valve
solenoid for problem

speed range correct?
1) Voltage
20 -
transmission
(See page 22-l 8 -
for
22-22)
30V.
electrical system of
transmission
(See page 82-38
-
WA500- 1
for
82-43)
TROUBLESHOOTING
1.
TABLE
Machine does not move.

Ask the operator the following
points.
- Did the machine suddenly stop moving?

Yes = Component
Was
there
any
chine stopped
seized or damaged.
abnormal
noise
when
the
ma-
moving?
Yes = Comoonentbroken.
Checks before troubleshooting
*
Is oil level in transmission
case correct?
* Is monitor display normal?

* Is drive shaft broken?
Problems
1
Abnormal noise between pump and filter.
Machine does not move in any speed range.

(Item 1 normal)
Machine moves normally in certain speed ranges.
Machine will not move when T/C oil temperature
0
0000
rises.
I
Low at every speed range.
Transmission
modulating
pressure
too low.
0
0
Pilot pressure defective
Note 1:
If
the
Low at certain speed ranges.
Indicator fluctuates violently.
solenoid
are normal,
valve
the I
and
hydraulic
pressure
in the Causes column
in-
dicates that the valve spool does not work.

Note 2:
If
the
but
table,
transmission
the
cause cannot
a possible
clutch
pressure
be found
cause is cracks
is
low,
in the above
in the
valve
or transmission.
2268
WA500- 1
The following symbols are used to indicate the action

to be taken when a cause of failure is located.
WA500-
22-19
0
2.
Machine lacks power or speed

* Is oil level in transmission case correct?

- Is there any leakage of oil from joints of piping
or valves?
- Is parking brake or brake locked?

- Is operation of electric circuit correct?
Checking for abnormalities
- Engine high idling speed

* Torque converter stall speed
-
Machine
Transmission
Pressure at outlet
Pilot reducing
Tire
NO.
travel
inflation
speed
clutch
pressure
port of pump
pressure
pressure
Problems
I Abnormal
noise from between pump and filter.
Torque converter stall speed too high.
Torque converter stall speed too low
45
modulating
Transmission
too
low
pressure
--I
IOIO
(Item 2 abnormal)
Indicator
Low at every
fluctuates
speed range
violently.
I
I
I
I
Pilot reducing pressure too low (Items 4 and 5 normal)

Relief pressure at torque converter inlet port too low
Iron or aluminium particles stuck to strainer of
Modulating pressure drops when oil temperature
rises.
loI

22ifo
WA500-1
3.
Excessive time
lag when starting machine
or shift-
ing gear
- Is oil level in transmission case correct?

- Is there any leakage of oil from joints of piping
or valves?
Is operation
of control
valve normal?
Check
STANDARD
VALUE
that time lag is actually

*
Standard
TABLE
to confirm
excessive.
time lag.
Engine high idling:
Max. 0.8 sec.
No.
Problems
1
Abnormal noise between pump and filter
Excessive time lag in every speed range
Machine moves normally in certain speed ranges.
Transmission modulating pressure too low

in every speed range
As in Item 4; indicator fluctuates violently
Torque converter oil temperature

range.
I Ol
ollolol
I
0
I4
I
0
I
0
is above operating

X : Repalce
A: Repair
A : Adjust
C : Clean
WA500-
22-21
0
4.

- Does not torque

torque
the torque
converter
Yes = Normal
points.
converter
up during
too high
oil
converter
temperature
go
stall, and down when
is not stalled?
(Incorrect
selection
of gear speed)
Checking before troubleshooting
Is oil
level
in
transmission
and
steering
case
correct?
* Is filter clogged?
- Check STANDARD
that torque
VALUE
converter
TABLE
oil temperature
to confirm
is actually
high.
*
If the
oil temperature
temperature
gauge
is normal
is outside
range, the oil temperature
the
but the oil

operating
gauge is defective.
Problems
1
Pump makes abnormal noise when oil temperature
is low.
High idling and low idling speeds are too low.
Hydraulic pressure at inlet port of torque converter too low
Transmission modulating pressure too low
0
0
0
0

22622
WA500-
POWER TRAIN
23 DISASSEMBLY
AND
REAR
DAMPER
Removal .........................
Installation
.......................
Disassembly .......................
Assembly
........................
23- 2
23- 6
23-10
23-12
TORQUE
CONVERTER
CHARGING
Removal .........................
Installation
.......................
23-14
23-14
FRONT
23-l 5
23-22
REAR
Disassembly. ......................
Assembly
........................
23-39
23-49
23-68
23-70
23-72
FINAL
Removal .........................
Installation
.......................
Take
the following
method
.
.
.
......
23-98
23-100
..
_.
..
..
.
.
.
.
..
..
_.
..
..
._
_.
..
.........
.........
.........
23-l 10
23-111
23-112
23-114
. .
..
.........
.........
23-116
23-118
. _.
. .
........
........
.........
SHAFT
..... .
. .. ..
23-119-1
23-119-3
DRIVE
Disassembly
Assembly
.
23-76
23-79
23-88
23-92
. . . . . _ . . . . . . . . . . . . . . . . 23-102
. . . _ . _ . . . _ . _ . . . . . _ . . . 23-106
Disassembly
Assembly
DIFFERENTIAL
..........
. . . _ . . . _ . . _ _ _ ..........
. . . . . . . . . . . . .........
(Serial No. 10001-l

0222)
Disassembly .
..
Assembly
. ... ..
(Serial No. 10223 and up)
VALVE
Removal .........................
Installation
.......................
Disassembly and assembly .............
..........
AXLE
Assembly
23-61
23-64
............
. . . . . . . . __ . .
CENTER SUPPORT
Removal . . . . _ .
Installation
....
Disassembly . . _ .
DRIVE
TRANSFER
Disassembly .......................
Assembly
........................
23-82
23-85
AXLE
Removal .
Installation
23-29
23-33
..........
..........
GEAR
Removal .
Installation
TRANSMISSION
FRONT
. __ . _ . __ . _ . .
............
DIFFERENTIAL
PUMP
TORQUECONVERTER
Disassembly. ......................
Assembly
........................
CONTROL
DIFFERENTIAL
Removal .
Installation
Disassembly
Assembly
.
TORQUE
CONVERTER
AND TRANSMISSION
Removal .........................
Installation
.......................
TRANSMISSION
ASSEMBLY
....
. ..
......
. . . .
for air bleeding when you start to operate
.........
.........
23-120
23-123
hydraulic
cylinders after reassembling cylinders, pump and pipings.

1.
2.

Operate hydraulic
cylinder
4 -
5 cycles, but do not exceed beyond 100 mm of
stroke end.
3.
Continue to operate cylinder 3 - 4 cycles until stroke end,
4.
After finishing above steps, keep normal

NOTE:
WASOO-
engine speed.
After long storage, same procedure
is required.
23-1
a
REMOVAL
OF DAMPER
Stop the
Q1
machine

Q
!

control
Loosen plugs (1) and

tank filter,
tank.
Then operate the

piping.
(2) at the top of the hydraulic
and plugs (3) and (4) of the pump piping to

1.
Cover
1) Remove hydraulic
tank cover (5), side panel (6) and
(7).
2) Sling engine hood (8) and side hood (9), then remove.
& kg
Engine hood:
Side hood:
60 kg
42 kg
425P306
2.
Brake, air piping

1) Remove air pipes (10) and (11) from chamber.
2) Remove brake pipes (12) and (13) from chamber.
+
Disconnect air pipe (11) under the hydraulic tank.
Remove each piping clamp to bulkhead.
2%2
WA500-
2.
POC piping
* Disconnect hose (14) between POC pump and strainer at tube of strainer side.
* Disconnect hose (15) between main control valve and

manifold at manifold
*
end.
Remove clamp.
* Disconnect hose (16) between POC valve and manifold at manifold end.
*
Remove clamp.
Disconnect
hose (17)
between
POC relief valve and
POC valve at POC relief valve end.

*
3.
Hydraulic
-
pull out of bulkhead.
piping
Loosen clamp of hose (18)
between
hydraulic
tank
and switch and hydraulic pump.
* Loosen clamp of hose (19) between hydraulic tank

and steering pump.
- Disconnect hose (20) between hydraulic tank and oil

cooler at tube end.
Disconnect
hydraulic
mission.
WA500-
hose (21) between main control valve and

tank
at connection
at left side of trans-
4.
Bulkhead
1) Disconnect bulkhead wiring (22) at connector end.
2) Disconnect
hose (231, then disconnect air intake port
(24).
3) Sling bulkhead
(251, remvoe mounting bolts, then lift
off.
*
Be careful not to hit the glass of cab when lifting

off the bulkhead.
Bulkhead:
5.
Hydraulic
1) Remove
500 kg
pump
tubes
(26)
and
(27)
then
remove
switch
pump (28).
2) Remove hose (29) then steering and POC pump (30).
3) Remove tubes (31) and (32),then

pump (33).
* Remove manifold
remove hydraulic
(34).
4) Remove hose (35) and tube (361, then remove torque

converter charging pump (37).
*
Remove contact faces of O-ring of each pump.
2&4
WA500-
6.
Drive shaft
Make match marks then remove drive shaft (38).
7.
Damper
1) Disconnect
greasing hose (39) for damper at damper
end.
*
Remove coupling (40).
2) Temporarily
sling cover (41) and remove mounting
bolts, then using forcing screws lift off.
Cover:
kg
3) Temporarily
32 kg
sling damper
(42),
with
eye bolts then
remove mounting bolts and lift off damper.
4kg
WA500-
Damper:
60 kg
INSTALLATION
1.
OF DAMPER
Damper
1) Sling damper
(421, set in mounting
position,
then

Mounting bolt: 11.25 + 1.25 kgm
2) Sling
cover
(41),
set in mounting
position,
then

6
Cover contact surface:
Metal sealant (LG-4)
3) Connect damper greasing hose (39) to damper.

*
2.
Installed coupling (40).
Drive shaft
Align match marks and install drive shaft (38).
m
23-6
a
Mounting bolt:
11.5 f 1 kgm
WA500-
3.
Hydraulic
pump
1) Set torque converter charging pump (37) in mounting

position then connect hose (35) and tube (36).
2) Set hydraulic
pump in mounting
position
and con-
nect tubes (31) and (32).

*
Before
installing
hydraulic
pump
(33),
set mani-
fold (34).
3) Set steering and POC pump (30) in mounting position

then connect hose (29).
4) Set switch pump (28) in mounting position then connect tubes (26) and (27).
4.
Bulkhead
1) Sling
bulkhead
(25)
and set in mounting
position
then tighten mounting bolts.

*
Be careful of glass of cab and install.
Insert suction hose in tube at pump end.
2) Set air intake
port
(24) to air cleaner and connect
hose (23).
3) Connect bulkhead wiring (22) to connector.
WA500- 1
23-7
0
5.
Hydraulic
*
piping
Connect
hydraulic
hose (21)
tank
between
main control
at transmission
valve and
left side connection
end.
Connect
hose (20)
between
hydraulic
tank and oil
cooler at tube end.
* Tighten clamp of hose (19) between hydraulic tank

and steering pump.
*
Tighten
clamp of hose (18)
and switch and hydraulic
6.
between hydraulic
tank
pump.
POC piping
l
Connect hose (17) between POC relief valve and POC

valve at POC relief valve end.
Connect
hose (16) between
POC valve and manifold
at manifold end.
*
Connect clamp.
- Connect hose (15) between main control valve and

manifold at manifold end.
*
Connect clamp.
* Connect hose (14) between POC pump and strainer

at tube of strainer side.
232
WA500-
7.
Brake, air piping

1) Connect brake piping (12) and (13) to chamber.
*
Connect air pipe (11) under the hydraulic tank.
Install each piping clamp to bulkhead.
2) Connect air pipes (IO) and (11) to chamber.
8.
Cover
1) Sling engine hood (8) and side hood (9), then install.
2) Install
hydraulic
tank
cover (5), side panel (6) and
(7).
9.
Refilling with oil

Tighten
pump
plug at top of hydraulic

piping,
then add hydraulic
tank filter, and plug of

oil through
oil filler

m
10.
plug at top of filter:
1.2 f 0.1 kgm
Bleeding air
Bleed air from brakes.
*
For details
of bleeding
air, see 52 TESTING
AND
ADJUSTING.
WA500-1
23-9
0
DISASSEMBLY
1.
OF DAMPER
Cover
1) Remove mounting
bolt, then remove cover (1).
2) Remove oil seal (2) and O-ring (3) of cover (1).
3) Pull out shaft
(5).
4) Remove snap ring (4) and bearing
(8) from shaft
(5).
425F256
5) Remove
snap
rings
(6).
(6A)
and oil seal (9) from
cover (7).
23do
WA500- 1
2.
Damper
1) Using forcing screws, remove flange (10).
*
Tighten the two forcing screw evenly.
It
Do not remove spacer (18) unless necessary.
18
425F258
2) Remove inner body (11) and rubber (12).
3) Remove
snap ring (13)
and oil seal (14) from the
inner body.
4) Remove flange (16) from outer body (15).

t
Screw
in the
mounting
bolts,
then tap with
hammer to remove.
WA500- 1
236
ASSEMBLY
1.
OF DAMPER
Damper
1) Install flange (16) at bottom of outer body (15).
a
Contact surface of flange and outer body:

Gasket sealant:
LG-4
2) Press fit oil seal (14) in inner body (1 l), then assemble snap ring (13).
*
Fit the snap ring securely in the groove.
Set the oil seal with the sleeve on the snap ring
side and fit it close in contact with the snap ring.
3) Assemble
inner body
(11)
in outer
body (15), then
assemble rubber (12).

Whole surface of rubber:
Grease (G2-LI)
Outer surface of inner body:
Grease (G2-LI)
Inner surface of outer body:
Grease (G2-LI)
Between inner body and rubber:

Grease (G2-LI)
423P31OJ
Fill clearance a at four places evenly with 150 g

of grease.
421F3006
23-l 2
0
WASOO-
4) Install flange (IO), and tighten mounting bolts.

&
Contact surface of flange and outer body:

Gasket sealant (LG-4)
2.
Cover
1) Fit the snap ring (6A),
then
fit the snap ring (6)
after press fit oil seal (9) in cover (7).

*
Press fit
the
oil
seal with
the
lip face on the
bearing side.
2) Assemble snap ring (6), bearing (8) and snap ring (4)
in shaft (5). then assemble shaft in cover (7).
6
Shaft splines in contact with inner body:

Molybdenum
disulphide
dry
lubricant
(coat, then leave for 2 - 3 minutes).

&
Contact
surface
of
shaft
and
inner
body
oil seal:
Lithium
type,
molybdenum
disulphide
high pressure grease.

&
Bearing:
Lithium
type,
molybdenum
disulphide
high pressure grease.

3) Press fit oil seal (2) in cover (I), and assemble O-ring.
*
Press fit
the
oil
seal with
the lip face on the
coupling side.
4) Install cover (l), and tighten mounting bolts.
423P3106
WA500-
421
F3008
23-13
REMOVAL
OF TORQUE
Stop the
A!
safety
ment
machine
CHARGING
PUMP
bar on the frame.

to the ground
apply the parking
CONVERTER
Lower the work
and stop the
engine.
equipThen
brake and put blocks under the
wheels to prevent the machine from moving.

*
Remove steering and POC pump.

For details,
see 43
REMOVAL
OF
STEERING
AND
POC PUMP.
1.

1) Disconnect tube (1) between transmission
and pump
at pump end.
2) Disconnect
hose
(2)
between
pump
and filter
at
pump end.
3) Remove torque converter charging pump (3).
Torque converter charging pump:
15 kg
INSTAL .LATION OF TORQUE

CONVE RTER CHARGING
PUMP
1.

1) Set torque converter
charging pump (3) in mounting
position, then tighten mounting bolts.

2) Connect hose (2) between pump and filter to pump.
3) Connect tube (I)
between transmission and pump to
pump.
Install steering and POC pump.

For
AND
details,
see 43
INSTALLATION
OF
STEERING
POC PUMP.
WA500-1
REMOVAL
Af
Stop
OF TORQUE
the
machine
CONVERTER

*
Disconnect
terminal
the
cable
from
the
negative
(-)
of the battery.
Loosen the oil filler cap slowly to release the pres!
control

tank
filter,
tank.
Then operate the

piping.
and plug (3),
(4)
of the
pump
piping to
Loosen drain valve and drain air from the air tank.
1.
Hood
1) Remove covers (1) and (2) of under the cab, remove
hydraulic
tank
cover (3) and remove side panel (4)
and (5).
2) Remove engine hood (6), engine side hood (7).

Engine hood:
& kg
Side hood:
2.
60 kg
42 kg
Cab
1) Remove
arm rest (8) and cover
cab wiring
WA500-
(10) from
connector.
(9), then disconnect
AND
TRANSMISSION
2) Sling cab (1 l), remove mounting bolts and lift out.

t
Take
care so that
monitor
cab does not interfere
with
panel.
Cab: 305 kg
3.
Brake, air piping

1) Disconnect air piping (12) and (13) from chamber.
2) Disconnect brake piping (14) and (15) from chamber.
*
Disconnect
air piping (13)
at bottom
part of hy-
draulic tank.
t
4.
Remove each wiring clamp from bulkhead.
POC hydraulic
piping
Disconnect hydraulic
piping as follows:
* Disconnect hose (16) between POC pump and strainer, from tube on strainer.
- Disconnect hose (17) between work equipment valve

and manifold from manifold.
*
Remove clamp.
* Disconnect hose (18) between POC valve and manifold from manifold.
*
Remove clamp.
Disconnect
hose (19) between
relief valve and POC
valve from relief valve.

*
23d6
take out from bulkhead.
WA500-
5.
Hydraulic
piping
piping as follows:

and switch, hydraulic
pump.

and steering pump.
* Disconnect hose (22) between hydraulic tank and oil

cooler from tube and its connecting part.
Disconnect
hydraulic

tank from
connector
on left side of trans-
mission.
6.
Bulkhead
Disconnect
electrical
wiring
(24)
of bulkhead
from
connector.
Disconnect hose (25) and remove air intake port (26).
Remove mounting bolts and sling bulkhead

*
(27).
Bulkhead balance is bad so be careful and lift off.
WA500-
Bulkhead:
500 kg
23-17
0
7.
Operators seat
Sling operators seat (28) and remove.
*
After
removing seat, remove seat support and blower
box cover.
Operator seat: 40 kg
8.
Blower box
1) Disconnect wiring from connector as follows:
*
*
Cab wiring (29).

Front and rear wiring (30), (31), (32) and (33).
*
Remove the plate inside of the small box, and

after lowering it forward,
disconnect wiring.
2) Remove circuit breaker (34).
3) Remove blower box (35).

*
Remove
cab
wiring
clamp
and
put
inside
left
console.
*
9.
After removing blower box, remove plate (36).
Steering, switch pump

I)
Disconnect
hose
(37),
then
remove
(38).
2) Disconnect tube (39) and manifold
steering
pump
(401, and remove
switch pump (41).
23-18
0
WA500-
10. Upper drive shaft

Remove drive shaft (42),
1:hen
coupling (43) on
damper side.
11. Hydraulic
and torque converter charging pump
1) Remove
manifold
remove hydraulic
2) Disconnect
tube
(441, disconnect
tube
(451, then
pump (46).
(47)
and
hose (48).
and remove
torque converter charging pump (49).
12. Steering piping

Remove wiring as follows:
* Hose (50) between steering pump and steering valve.

* Hose (51) between oil cooler and steering valve.
*
Hose (52) between switch pump and steering valve.
13. Torque converter piping

1) Remove tube
(53)
between
transmission and torque
converter pump.
2) Remove hose (54) between transmission and filter.
WA500-
3) Disconnect hoses (55), (56) between transmission and

cooler.
*
move to rear of machine.
14. Center and rear drive shaft

1) Disconnect center drive shaft (57) from transmission.
4kg
Center drive shaft:
33 kg
2) Disconnect rear drive shaft (58) from transmission.

& kg
15.
Rear drive shaft:
42 kg
Electrical wiring
Disconnect electrical wiring from connector as follows:
*
Wiring (59) of transmission valve.
* Wiring (60) of pickup sensor.

* Wiring (61) of torque converter hydraulic temperature.
16. Torque converter and transmission

1) Remove
mounting
and transmission.
trunnion
*
*
bolts and sling torque
converter
When raised about 10 mm, remove
(62).
Disconnect grease hose.

Be careful
trunnion
not
to
lose shims
inserted
between
and frame.
23620
WA500-
2) Remove bracket
*
Remove
by tapping
lightly
3) Lift out torque

*
Sling torque
fully
Since there
on
WA500-
with
and transmission
plastic hammer.
converter
and transmission
(64).
converter
and transmission,
then care-
is only
the
interference
kg
side.
in bracket
move to rear of machine.
wiring
el
(63) on front
pin inserted
Torque
left
a narrow
side
of
space for the steering

the
machine,
check
and lift out.

converter
and transmission:
1 ,I 73 kg
INSTALLATION
TRANSMISSION
1.
OF TORQUE
CONVERTER
AND
Torque converter, transmission

1) Set torque converter and transmission
(64),
100 mm
in front of mounting position.
2) Install front mounting bracket (63).

t
Align the pin holes correctly.
Mounting bolt:
28.5 f 3 kgm
3) Lower transmission further,

mm from
trunnion,
and when it is about 10
set trunnion
(62)
in mounting
position.
*
*
Connect grease hose.

Insert desired thickness of shims between trunnion
and frame.
2.
Adjusting shim
1) Assemble
desired thickness
nion (62) and frame,
of shims between
and tighten mounting
trun-
bolts to
specified tightening torque.

*
Average shim thickness:
2 mm
Shim
F42501003
2322
WA500-
2) Install
dial
converter,
output
gauge @
and
shaft.
put
to
input
probe
Rotate
coupling
in contact
of torque
with
damper
input coupling of torque con-
verter and adjust position.

*
Runout:
Measure both radial and face runout.
3) After
Within 2 mm
adjusting
position,
tighten
front
and
rear
mounting bolts fully.
3.
Mounting bolt:
28.5 ? 3 kgm
Mounting bolt:
18?
2 kgm
Electrical wiring
Connect electrical wiring to connector as follows:
* Wiring
(61)
of
torque
converter
hydraulic
level
sensor.
* Wiring (60) of pickup sensor.

l
4.
Wiring (59) of transmission valve.
Center and rear drive shafts

1) Connect center drive shaft (57) to transmission.
w
Mounting bolt:
11.5 f 1 kgm
2) Connect rear drive shaft (58) to transmission.

w
5.
Mounting bolt:
11.5 f 1 kgm
Torque converter piping

1) Connect
hoses (55)
and
and cooler to transmission.
WA500-
(56) between
transmission
8.
Upper drive shaft

Fit couplilig
(43) to damper and install upper drive shaft
(42).
m
Mounting bolt:
23if4
11.5 + 1 kgm
WA500-
9.
Steering and switch pump

1) Install switch pump (41), and connect tube (39) and
manifold
(40).
2) Install steering pump (38) and connect hose (37).
10. Blower box

1) Install plate (36), then install blower box (36).
*
Install wiring clamp of cab.
2) Install circuit breaker (34).

3) Connect wiring to connector as follows:
* Wiring for cab (29).

* Wiring of front and rear (30), (31), (32) and (33).
+
WA500-
Install palte inside small box.
12. Bulkhead
1) Sling bulkhead
(27),
set in mounting
position
and

*
Insert hoses of each pump into tubes.
2) Install air intake (26) and connect hose (25).

3) Connect
electrical
wiring
(24)
of bulkhead
to con-
nector.
13.
Hydraulic
piping
Connect hydraulic piping as follows:
* Connect hose (23) between main control valve and

hydraulic
tank
to connection
on left side of trans-
mission.
* Connect hose (22) between hydraulic tank and oil

cooler to tube.
B
Hose connector:
20 t 5 kgm
41 mm)
* Tighten hose (21) clamp between hydraulic tank and

steering pump.
l
Tighten
hose (20) clamp between hydraulic tank, and
switch and hydraulic
2326
pump.
WA500-
14. POC hydraulic
piping
Connect hydraulic
piping as follows:
* Connect hose (19) between relief valve and POC valve

to relief valve.
m
Hose connector:
14 + 3 kgm
Connect
hose (18)
32 mm)
between
POC valve manifold
between
main control
to
manifold.
*
-
Install clamp.
Connect
hose (17)
valve and
manifold to manifold.
*
Install clamp.
* Connect hose (16) between POC pump and strainer at

strainer end.
15.
Brake and air piping

1) Connect brake piping (14) and (15) to chamber.
*
Install clamps on each piping to bulkhead.
2) Connect air piping (12) and (13) to chamber.

+
Connect
air piping
(13)
to bottom
of hydraulic
tank.
16. Cab
1) Sling cab
(11)
and set in mounting
positon,
then

*
Be careful not to cause interference
with monitor
panel.
WA500-
23-27
0
2) Connect
cab
wiring
cover (9) and armrests
(10)
to
connector
and
install
(8).
17. Cover
1) Sling engine hood
(6) and side hood
2) Install
covers
cab lower
(1) and
(7), and install.
(2), hydraulic
tank
cover (3), and side panels (4) and (5).
18. Refilling with oil

1) Install
piping
upper filter
plugs of hydraulic
plugs, then add hydraulic
to the specified
m
oil filler
level.
plug at top of filter:
2) Add transmission
tank and pump
oil through
oil through
1.2 f 0.1 kgm

oil filler.
19. Bleeding air

Bleed air from
brakes.
of bleeding
For details
air, see TESTING
AND
AD-
JUSTING.
23
WA500-
DISASSEMBLY
OF TORQUE
CONVERTER
Special tools
Preparatory
Remove
work
torque
For details,
converter
assembly from
see DISASSEMBLY
transmission.
OF TRANSMISSION
ASSEMBLY.
1.
PTO assembly
1)
Set torque converter assembly (1) in tool A.
2) Remove holder (2) and coupling (3).
3) Using eye-botls
(Thread
dia. = 14 mm,
Pitch =
2.0 mm), sling PTO assembly.

4) Screw in forcing screws @
and remove PTO assem.
bly (4).
2.
Turbine,
case asembly
1) Remove mounting
bolts (5) of pump, leaving 2 bolts
on opposite sides.
2) Set with case at top and remove 2 remaining mounting bolts.
3) Lift off turbine and case assembly (6).
WA500-
ASSEMBLY
4) Disassemble turbine and case assembly as follows.

i)
ii)
iii)
Remove pilot (7) and gear (8).

Remove snap ring (9), then remove spacer (IO).
Using forcing screws @
Pitch = 1.25 mm), remove turbine

*
3.
(11).
Pull out from bearing inner race side.
Stator
1) Remove snap ring (12).
2) Remove stator (13).
4.
Stator shaft, pump assembly

1) Remove 8 mounting bolts (14).
2) Remove stator shaft, pump assembly (15).
2320
WA500-
3) Disassemble
stator
shaft
and
pump
assembly
as
follows.
i)
ii)
Remove 2 plugs (16) at stator shaft end.
Knock out inner race of bearing through holes of

removed plugs, then remove pump (17).
iii)
Remove
bolts,
then
remove
collar
(18),
pump
(17) and cage (19).
425F262
DISASSEMBLY
5.
OF PTO ASSEMBLY
Cover
Remove cover (20).
6.
Bearing
Remove bearing (21).
WA500- 1
7.
Nut
Remove nut (22).
*
8.
Tool kit number:
790-101-2300
(Push-puller)
Gear, bearing
1) Using puller @
*
pull out gear (23).
The gear is in contact
with the outer
race, so it
cannot be removed.
2) Remove bearing (24).
9.
Outer race
1) Remove snap ring (25) and spacer (26).
425F263
2) Using gear puller @
pull out outer race (27) about
10 mm.
3) Remove gear (23), outer race (27) and spacer (28).
425 F264
WA500-
ASSEMBLY
OF TORQUE
CONVERTER
Special tools
Part No.
ASSEMBLY
1.
Part name
OF PTO ASSEMBLY
Gear
1) Install bearing (24) (inside diameter:
50 mm) on gear
(23).
2) Set gear (23) in PTO case (29).
2.
Outer race, spacer

1) Install outer race (27) (outside diameter:
t
90 mm).
Be careful to install facing in the correct direction.
2) Install spacer (28).

3) Install outer race (27) (outside diameter:
90 mm).
* Be careful to install facing in the correct direction.
WA500- 1
ASSEMBLY
3.
,,,
Bearing
Using puller @
install
bearing
(24)
,,,,\
(inside diameter:
50 mm).
,,,,,,,,,
,,,,,,
,,,,
,, ,,
,, ,, ,,
425F266
4.
Snap ring
1) Install spacer (25).
2) Install snap ring (26).
5.
Nut
Tighten nut(22).
m
t
Nut:
42 + 2 kgm
Check that the gear rotates smoothly.
2324
WA500-
,,
6.
Bearing
Install bearing (21) (outside diameter:
7.
130 mm).
Cover
1) Install oil seal (30) to cover (20).
*
Be careful not to deform the oil seal.
Oil seal lip:
Grease (G2-LI)
2) Install cover (20).
1) Assemble stator shaft and pump assembly as follows.

i)
Install bearing (31) (outside diameter:
130 mm)
to cage (19).
ii)
Fit cage (19) to pump (17), then tighten bolts.
WASOO- 1
Bolt:
6.7 + 0.7 kgm
iii)
Install seal ring (33) to stator shaft (32).

*
Coat the seal ring with

protrusion
iv)
v)
Install
pump
grease, and make the
(17) to shaft
(32).
Install 2 plugs (16).

w
Plug:
2) Set torque
0.45 + 0.15 kgm
converter
case (34)
in tool
As.
3) Install stator shaft and pump assembly
m
&
39
from the shaft uniform.
Bolt:
6.7 f 0.7 kgm
Bolt:
Thread tightener
23i?6
A, A,,
and
(15).
(LT-2)
WA500-
9.
10.
Stator
1) Install
stator
2)
snap ring (12).
Install
Turbine,
(13).
case assembly
1) Assemble
i)
ii)
turbine
and case assembly
as follows.
Install
bearing
(37)
to case (36).
Install
turbine
(11)
to case (36).
Support
the
inner
race
of the
bearing
case, and push in the turbine.
iii)
Install
spacer
iv)
Install
inner
v)
Install
gear (8) and pilot
w
&
WA500-
(IO)
and install
race (38)
snap ring (9).
to pilot
(7).
(7).
Bolt:
6.7 f 0.7
Bolt:
Thread
kgm
tightener
(LT-2)
in the
2) Fit guide bolt

mm),
mm,
(Thread
using two
dia. = 10 mm,
eye-bolts
Pitch = 1.5
(Thread
Pitch = 1.75 mm), sling turbine,
dia.
12
case assembly
(6) and then install it.

m
&
Bolt:
6.5 f 0.5 kgm
Bolt:
Thread tightener
(LT-2)
11. PTO assembly

1) Fit O-ring, using eye-bolts
Pitch = 2.0 mm),
sling PTO assembly
(4) and then
install it.
2) Assemble
O-ring, and install coupling
(3) and holder
(2).
m
Bolt:
11.5 f 1 kgm
WA500-
DISASSEMBLY
OF TRANSMISSION
Special tools
Part name
Part No.
799-301-I
Preparatory
500
Leak tester
oty
1
work
Sling torque converter assembly (1) and remove bolts (2)

from transmission assembly.
Pilot filter assembly

Remove pilot filter assembly (3) with tube.
Control valve assembly

Remove control valve assembly (5).
Plate
Remove plate (6).
Sleeve
Using eye-bolts
(Thread
mm), remove sleeves (7).
WASOO- 1
dia. = 16 mm,
Pitch = 2
ASSEMBLY
5.
Transfer assembly
1) Set with transfer at bottom.
2) Using 3 eye-botls @
Pitch =
1.75 mm), sling transmission assembly.

3) Screw in forcing screws @
(Thread
dia. = 12 mm,
Pitch = 1.75 mm), and lift off transmission assembly

(6).
6.
Tie bolts
Remove tie bolt (9).
*
Using tool
A, check operating
condition
of piston
before disassembling.
*
Leaved two tie bolts with mark % ,
so that transmis-
sion assembly can be remove from transfer case.
7.
Input shaft, carrier assembly

Using eye-bolts
Pitch = 2.0
mm), lift out input shaft and carrier assembly (10).

*
Disassemble input shaft and carrier assembly according to following
steps:
1) Remove snap ring (11).

2) Support
housing and push out shaft with press and
remove.
23Go
WA500-
3)
Remove
4) Support
with
snap ring (12).

housing
and
push out
carrier
assembly
(13)
press and remove.
,,.
5) Remove
ings (15)
8.
Remove
washers
springs
Springs
Disc,
planetary
(16)
from
gears (14).
carrier
bear-
case.
(18)
(17)
and (18).
are inserted
between
each plate.
plate
Remove
10.
remove
and thrust
Spring
*
9.
pins, then
discs (19)
and plates
(20).
Ring gear
Remove
ring gear (21).
,,,,
WA500-
,,,,
1
2364
11. No. 1 piston, housing

Using eye-bolts
(Thread
dia. = 16 mm,
mm), lift out piston and housing
Remove piston
(24) from
Pitch = 2.0
(22).
housing
(23).
12. Spring
Remove springs (25) and (26).
*
13.
Springs (26) are inserted
between
each plate.
Disc, plate
Remove discs (27) from
plates (28).
14. Guide pin

Remove guide pin (29).
WA500- 1

Lift out piston and housing (30).
16.
Drum carrier assembly

Using eye-bolts @
mm),
carrier assembly (31
Pitch = 2.0
lift out No. 2 piston and housing (30) and drum
) as one unit.
Disassemble drum and carrier assembly according to

following
steps:
1) Remove snap ring (32), then remove drum (33).

2) Remove bearing (35) from carrier case (34).
3) Remove
pins, then
bearing (37)
remove planetary
and thrust
washer (38)
gears (36).
from carrier
case.
17. Sun gear

Remove sun gear (39).
18. Spring
Remove springs (40) and (41).
*
Springs (41) are inserted between each plate.
WA500-
19.
Disc, plate
Remove discs (42) and plates (43).
20.
No. 3 piston, housing

Using eye-bolts @
Pitch = 2.0
mm), lift out piston and housing assembly (44).
21. Sun gear

Remove sun gear (45)
22.
Sleeve
Remove sleeve (46).
23.
Rotating clutch assembly

Using eye-bolts
Pitch = 2.0
mm), lift off rotating clutch assembly (47) and housing

(48) as one unit.
*
Disassemble clutch assembly according to following

steps:
1) Using puller @
, remove gear assembly (49).
42SP440
WASOO-
2) Remove pin, then remove planetary

(51) and thrust
3) Remove
rotating
washer (52) from
snap ring
clutch
(531, then
assembly
gear (50). bearing
carrier case.
using bar @
(47) from
housing
, remove
(48).
5) Remove discs (561, springs (57) and plates (58).
6) Remove inner gear (59).
7) Remove bearing
WA500-
(60) from
inner gear.
8) Using press fit kit @
(160 mm inner diamter)
com-
press belleville spring and remove snap ring (61).

*
Bellville spring mounting load:
218 kg
9) Remove 3 belleville springs (62).
IO) Using puller
@I
, remove housing (64) from shaft
(63).
11) Remove thrust plate (65) and sun gear (66).

12) Remove snap ring (67) and take out shaft from ring
gear (68).
13) Remove snap ring (691, then remove gear (70).

14) Remove snap ring, then remove bearing (71).
15) Remove
snap ring
(72),
then
remove
bearing
(73)
from housing.
425P454
WA500-
24. Spring
Remove spring (74) and (75).
*
25.
Disc, plate
26.

Using eye-bolts @
Pitch = 2.0
mm), lift off piston and housing (78).
27.
Spring
Remove spring (79) and (80).
*
28.
Guide pin
Remove guide pin (81).
WA500-
30.
Disc, plate
31.
No. 5 ring gear

Remove ring gear (84).
32.

Using eye-bolts @
Pitch = 2.0
mm), lift off piston and housing.
23648
WA500-
ASSEMBLY
OF TRANSMISSION
ASSEMBLY
Special tool
Part name
Part No.
A
1.
799-301-I
500
Oty
Leak tester

1) Install seal ring to piston, then install housing.
2) Using eye-bolts
(Thread
dia. = 16 mm, Pitch =
2.0 mm), sling and install piston and housing (85).
2.
Ring gear
install ring gear (84)
3.
Guide pin
Install guide pin (81).
4.
Disc, plate
Install plates (83) and discs (82).
WA500-
5.
Spring
Install
Ir
6.
springs
Springs
No. 4 piston,
and (79).
are inserted
between
each plate.
housing
1) Install
seal ring to piston,
2) Using
eye-bolts
2.0 mm),
7.
(80)
(80)
then
(Thread
sling and install
install
dia.
piston
housing.
= 16 mm,
and housing
Pitch
(78).
Ring gear, shaft

1) Install
bearing
2)
gear
Install
(71)
(70)
on gear.
to
ring
gear
(68)
and
secure
with
with
snap
snap ring (69).
3) Press fit shaft
(86)
to ring gear and secure
ring (67).
23650
WA500-
4) Align teeth of carrier and ring gear then install ring

gear and shaft assembly (87).
8.
Disc, plate
Install paltes (77) and discs (76).
9.
Spring
Install springs (75) and (74).
*
Insert springs (75) between each plate.
10. Sun gear

Install sun gear (66) and thrust plate (65).
11.
Housing
1) Install bearing (73) to housing and secure with snap
ring (72).
WA500-
2) Install thrust washer (52), bearing (51) and planetary

gear (50) to gear case, insert shaft and tap in pin.
3) Using press, press fit gear assembly (49) to housing.
4) Using eye-bolts
(Thread
dia. = 16 mm,
Pitch =
2.0 mm), install housing (48).
12.
Rotating clutch
*
Assemble clutch according to following steps.

1) Install 3 belleville springs (62).
compress
belleville
(160
mm inner diameter),
springs and install
(61).
* Belleville spring mounting load:
*
snap ring
218 kg
Check that snap ring is completely
inserted into
ring groove.
2322
WA500-
3)
Install
bearing
(60)
to inner
gear and secure
with
snap ring.
4)
Install
inner
gear (59)
5) Install
plates
6)
case (55)
Install
(58),
springs
and tighten
7) Fit seal rings and install

8) Install
to drum.
(57)
and discs (56).
bolts
clutch
(54).
assembly
(47).
snap ring (53).

,,
WA500-
13. Sleeve
Fit seal ring and install sleeve (46).
14. Sun gear
Install sun gear (45).

Using eye-bolts @
Pitch = 2.0
mm), sling and install piston and housing assembly (44).
16. Guide pin

Install guide pin (29).
17.
Disc, plate
18. Spring
+
Insert springs (41) between each plate.
WA500-

Sling No. 2 piston and housing (30) and install.
20.
Ring gear
Install ring gear (29).
21.
Disc, plate
install plates (28) and discs (27).
22.
Spring
+
23.
Insert springs (26) betwen each plate.
Drum, carrier assembly

*
Assemble
drum
and carrier
according
to following
steps:
1) Install thrust washer (38). bearing (37) and planetary gear (36) to gear case, insert shaft and tap in
pin.
425P433
WA500-
425P432
23-55
0
2) Install bearing (35) to carrier case (34).

3) Fit sanp ring (33A)
to drum
32A
(331, then install
drum.
4) Align with
32
\
33A
I
roll pin, and assemble plate (32), then
secure with snap ring (32A).

*
Check that the snap ring installed to the drum

is securely set between the plate and carrier.
. ,,
425P43:
11
425FO1013
4) Install sun gear (30).

5) Using eye-bolts
Pitch
1.5
mm),
(Theread
dia. =
10 mm,
sling and install drum
and
carrier assembly (31).

*
Align
teeth
face of planetary
gear and ring
gear and install.
24.
No. 1 piston, housing.

*
Install piston (24) to housing (23).
Using eye-bolts
2.0 mm),
25.
(Thread dia. = 16 mm, Pitch =
sling and install piston and housing (22).
Ring gear
Install ring gear (21).
425P425
WASOO-
26.
Disc, plate
27. Spring
*
28.
Insert snap rings (18) between each plate.
Input shaft, carrier assembly

*
Assemble
input shaft and carrier shaft according to
following steps:
1) install thrust washer (16). bearing (15) and planetary
gear (14) to gear case, insert shaft and secure with
pin.
2) Install bearing to housing.

3) Support carrier assembly (13) and press fit housing.
4) Install snapring (12).
*
Check that snap ring is completely
inserted in ring
groove.
WA500-
23-57
Gil
5) Support housing and press fit shaft (89).
6) Install snapring (11).
7) Using eye-bolts
2.0 mm),
(Thread
dia. = 14 mm,
Pitch =
sling and install input shaft and carrier as-
sembly (10).
t
Align
teeth
face of planetary
gear and ring gear
and install.
29.
Tie bolt
Tighten tie bolt (9).
w
23F
Tie bolt:
17 k 1 kgm
WA500-
30.
Checking operation
of piston
Using tool A, check operation and stroke of pistons.

*
Air pressure: 3 - 5 kg/cm2
Piston stroke:
mm
31.
Piston
Stroke
No. 1
4.0
No. 2
4.0
No. 3
4.0
No. 5
4.2
Transmission case
1) Using eye-bolts @
(Thread
dia. = 12 mm,
1.75 mm), sling transmission case (8).

2) Fit O-ring and install transmission case.
32. Sleeve
Fit O-ring and install sleeve (7).
33.
Plate
Fit O-ring and install plate (6).
WA500- 1
Pitch =
34.
Transmission
control valve assembly
Fit O-ring and install transmission control valve assembly

(5).
35.
Filter assembly
Fit O-ring and install filter assembly (3).
36.
Fit O-ring, sling torque converter assembly (2), connect

to transmission
assembly,
and tighten
mounting
bolts
(1).
23-60
0
WA500-
DISASSEMBLY
1.
OF TRANSFER
Remove transmission assembly from transfer case.
For details,
see DISASSEMBLY
OF TRANSMISSION
ASSEMBLY.
2.
Input shaft cage

Using forcing screw @
3.
, remove input shaft cage (1).
Input gear assembly

1) Remove input gear assembly (2).
2) Remove worm gear (3), then remove 2 bearings (4).
4.
Coupling
Remove holder (5), then remove coupling (6).
5.
Cage
1) Remove cage (7).
2) Remove oil seal (8) from cage.
WA500-
ASSEMBLY
6.
Speedometer
drive gear
Using forcing screw @

(9).
Sr Check the
number
, remove speedometer drive gear

and thickness
of the shims and
and thickness
of the shims and
keep in a safe place.
7.
Cover
Remove cover (IO).
*
Check the
number
8.
,,
Idler gear assembly
1) Remove idler gear assembly (11).

2) Remove
9.
,,,
::::,:,*I:L,:
,,,
,,: ,,\,>
88:<>i.,
, 8:,:(
2 bearings (12) from idler gear assembly.
Output shaft cage assembly

1) Remove holder
(13),
then remove output shaft cage
assembly (14).
, push out coupling (14) and
remove bearing (15).
2322
WA500-
10. Cage
Using forcing
*
Check
the
screw @
number
, remove cage (16).

and thickness
of the shims and
11. Shaft
1) Remove shaft (17).
2) Remove bearing
(18) from
shaft.
12. Gear
Remove gear (19) and collar
(20).
13. Strainer
1) Remove cover (21), then remove spring
2) Take out strainer
WA500-
(22).
(23) and remove case (24).
23-63
0
ASSEMBLY
1.
OF TRANSFER
ASSEMBLY
Strainer
1) Fit O-ring and install case (24).

2) Install strainer (23).
3) Install spring (22). fit O-ring, then install cover (21 ).
2.
Gear
Set collar (20) and gear (19).
3.
Shaft
, press fit bearing (18) to shaft
(17).
2) Align shaft (17) with collar and shaft and install.
2324
WA500-
4.
Cage
1) Install outer race (25).
2) Fit O-ring and install cage (16).
5.
Output shaft cage assembly

1) Install coupling
@
(14) to cage, and using press fit kit
, press fit bearing (15).
2) Assemble
shims (26),
fit
O-ring, and install output
shaft cage assembly (14).

3) Fit O-ring and install holder (13).
4
Holder mounting bolt:

Thread tightener
6.
Bolt:
(LT-2)
90 + 5 kgm
Idler gear assembly

1) Install outer race (27)
2) Install 2 bearings (12) to idler gear.

3) Install idler gear (I 1).
WA500-
23-65
0
7.
Cover
1) Install outer race to cover (10).
2) Assemble shims (28), fit O-ring and install cover.
8.
Speedometer
drive gear

2) Assemble
shims (30),
fit
O-ring and install speedo-
meter drive gear (9).
9.
Cage
1) Install oil seal (8) to cage.
2) Fit O-ring and install cage (7).
&
Lip of oil seal: Grease (G2-LI)
&
Seal mount surface:
Liquid gasket (LG-4)
10. Coupling
1) Install coupling (6).
2) Fit O-ring and install holder (5).
6
w
23-66
0
Bolt:
Thread tightener
Bolt:
90?
(LT-2)
5 kgm
WA500-
11.
Input shaft gear assembly

1) Install 2 bearings (4) and install worm gear (3).
2) Install input gear (2).
12.
Input shaft cage

2) Install input shaft cage (1).
13. Transmission assembly

Install transmission assembly to transfer case.
For details, see ASSEMBLY
SEMBLY.
WA500-
OF TRANSMISSION
AS-
REMOVAL
OF TRANSMISSION
Stop the
machine
CONTROL
VALVE

*
Disconnect
terminal
1.
the
cable
from
the
negative
(-)
of the battery.
Operators seat
Remove operators seat (1).
*
Pull the operators
seat out to the ladder, then lift
off.
*
Be careful of the glass in the cab door when removing.

Operators seat: 40 kg
2.
Seat support
Remove seat support (2).
3.
Move the floor mat to the front of the cab.
Remove
blower box cover (3).
Electric wiring
1) Disconnect wiring of cab (4).
2) Disconnect wirings of front and rear (5), (6), (7) and
(8).
* Remove the plate inside the tool box, and push to
the front before disconnecting the wiring.
4.
Circuit breaker
Remove circuit breaker (9).
*
Be careful
not to
let the wiring
connector
hit any
other parts when removing.
23h68
WA500-
5.
Blower
box
Remove blower
*
box (IO).
Remove the clamp of the wiring
for the cab, and push
into the L.H. console.

*
The seat is installed

the
box
and the
at the contact
R.H.
console
surface
so remove
between
seat care-
fully.
6.
Transmission
valve
1) Disconnect
hydraulic
2) Using eye-bolts,
(12).
* This
operation
workers,
hose (11) from transmission.
sling and remove

should
transmission
be carried
and the transmission
out
by
valve
three
valve shold be lifted
horizontally.
*
Remove clamp of hydraulic

Transmission
WA500- 1
valve:
tube
(13).
65 kg
23-69
0
INSTALLATION
1.
OF TRANSMISSION
CONTROL
VALVE
Transmission valve
1) Set transmission valve (12) in mounting position, and
*
Position the gasket holes at the matching surface

correctly.
Tighten
the mounting
bolts on opposite
sides in
turn to prevent the valve from being deformed.

*
Remove clamp of hydraulic tube (13).
Mounting bolts:
5 f 0.5 kgm
2) Connect wiring (11) to transmission valve connector.

*
When
installing the connector,
be careful
not to
deform the thread case.
2.
Blower box
Install blower box (IO).
*
Be careful to install the seat at the contact

between
surface
the box and the R.H. console facing in the
correct direction.
*
3.
Install the clamp of the wiring for the cab.
Circuit breaker
Set circuit breaker (9) in mounting position and install.
23ico
WA500-
4.
Wiring
Connect the following wiring to connector.
* Wirings (5), (6), (7), (8) for front and rear.
5.
Wiring (4) for cab.
Install the plate inside the tool box.
Seat support
Install seat support (2).
6.
Set the floor mat in the mounting position.
Install blower box cover (3).
Operators seat
Install operators seat (1).
WA500-
23-71
0
DISASSEMBLY
AND
CONTROL VALVE
DISASSEMBLY
AND
ASSEMBLY
ASSEMBLY
OF TRANSMISSION
OF SPEED VALVE
ASSEMBLY
20
423F421
WA500- 1
23-72
0
DISASSEMBLY
OF SPEED VALVE
1.
Remove
solenoid
2.
Remove
stopper
3.
Remove
valves
4.
Remove
spring
(12)
valve
(2), spring
(I).
(3) and valve
(5) and (6), and shim
and (13),
(8).
then
and spring
5.
Remove
covers
(15)
6.
Remove
spacer
(17).
7.
Remove
spring
(18)
Remove
plug
8.
assembly
(20).
ASSEMBLY
remove
(14)
(4).
(7).
shim
(9),
valves
(1
I),
as a set.
and (16).
and valve
then
(19).
remove
collar
(21)
and spring
(22).
ASSEMBLY
1.
Assemble
then
OF SPEED VALVE
spring
fit O-ring
(22)
in collar
and install
install
in body
Assemble
3.
Install
4.
Fit gasket
and install
Assemble
valve
and spring
(8) in valve (11) and install

in body.
spacer
(18)
(21),
(23),
plug (20).
2.
5.
spring
ASSEMBLY
in valve
(19)
and install.
(17).
shim
(12),
6.
Assemble
7.
Install
valve
(5).
8.
Install
valve
(4), spring
9.
Fit gasket
(16)
spring
(7) in valve
and install
WA500- 1
covers
and (15).
(14).
valve
(6), and install
(3) and stopper

solenoid
(13),
shim
in body.
(2).
valve assembly
(1).
(9)
D\SASSEMBLY
AND
ASSEMBLY
OF MODULATING
VALVE
ASSEMBLY
WASOO-1
DISASSEMBLY
ASSEMBLY
1.
2.
OF MODULATING
VALVE
DISASSEMBLY
ASSEMBLY
Remove cover (1) and (2).
1.
Remove guide (3), then remove spring (4), shim (5),
2.
valves (6), (7) and (9) and spring (8) as a set.

3.
Remove valves (IO),
OF MAIN
RELIEF
VALVE
Remove plug (I), then remove springs (2) and (3).

Assemble
and install shim (4), valves (5) and (6),
spring (7) and valve (8).
(12) and (13) and spring (11)
as a set.
4.
Remove
stopper
(14),
then
remove
quick
return
valve (15).
5.
Remove spacer (16).
6.
Remove cover (17).
7.
Remove
guide (18),
ASSEMBLY
ASSEMBLY
spring (19),
shim (20),
OF MAIN
RELIEF
VALVE
valves
1.
(21), (22) and (24) and spring (23) as a set.
Install together with valve (8), spring (7), valves (6)

and (5) in valve body (9).
8.
Remove valve (25), shim (26) and springs (27) and
Standard shim width:
1.5 mm
(28).
9.
2.
Assemble springs (3) and (2) in valve body.
3.
Fit O-ring and tighten plug (1).
Remove plug (29), washer (30), then remove spring

(31),
valves (32).
(33) and (35) and spring (34) as a
set.
ASSEMBLY
ASSEMBLY
1.
Assemble
OF MODULATING
VALVE
0
spring
(34).
and spring (31),
fit
valves (35),
washer (30)
(33)
and (32),
and O-ring, then
tighten plug (29).

m
2.
Plug:
Assemble
shim
11 + 1.5 kgm
(26)
and springs (27)
and (28)
in
valve (25) and install in valve body.

*
3.
Standard shim width:
Assemble
valve (22)
to
3 mm
valve (21),
then assemble
spring (23), valve (24), shim (20), and spring (19) in

valve body and install guide (18).
4.
Fit O-ring and install cover (17).
5.
Install spacer (16).
6.
Assemble
quick
return
valve (15),
fit O-ring, and
install stopper (14).

7.
Assemble valve (12),
spring (II),
and valve (IO)
in
425F272
valve (13) and install in valve body.

8.
Assemble
valves (9) and (7), spring (8), shim (5),
and spring (4), and install guide (3).

9.
Fit O-ring and gasket and install covers (2) and (1).
WA500- 1
23-75
0
REMOVAL
OF FRONT
DIFFERENTIAL
Special tools
I
I
Part No.
793-520-2610
Bracket
793-520-2510
Bracket
Stop
the
safety
brake
machine
the machine
from
under
Lower
and stop the engine.

and put blocks
Oty
on level ground
bar on the frame.
ground
1.
Part name
and install
the bucket
the
to the

the wheels to prevent
moving.
Draining oil
Remove
drain
plugs (I) and (2), then drain oil from
axle
assembly.
&
2.
Axle assembly:
Approx.
75 (I
Tire, wheel
1) Using lift
arm,
raise front
left housing and put block

2) Sliging
left
tire
and
axle, the put stand under

under front
wheel
(3),
frame.
remove
mounting
bolts, then lift off.

Tire, wheel:
3.
660 kg
Covers
Remove left and right covers (4).
23-76
0
WA500-
4.
Axle shaft
Using forcing
screw, pull out axle shaft (5) and sun gear
(6) about 200 mm.

*
Forcing
screw:
(Thread
dia. = 12 mm,
1.75 mm).
5.
Drive shaft
Disconnect
6.
front
drive shaft
(7).
Sling drive shaft and lower carefully.
Remove disc cover (8).
Spring cylinder
1) Remove linkage
pin (9) and air hose (IO).
2) Remove spring cylinder
WA500-
(11).
Pitch
8.
Differential
1) Remove
2 mounting
bolts of differential
(14),then
remove guide bolt (M20 x 55 mm).

*
*
Screw the thread of the guide bolts in fully.

After
screwing
in the
guide
bolts,
remove
the
remaining mounting bolts.

2) Fit lever block @
*
to differential
case (15).
Fit both edges of lever block to inspection
win-
dow.
4) Install tools A and 6 to garage jack, then insert between
differential
and axle housing, and install tool
A to differential.
5) Adjust
height
of lifting
remove differential
Differential:
6) Operate
tool
and garage jack,
and
(14) carefully.
282 kg
garage jack and pull differential
(14)
out
from under the machine body.

7) Remove O-ring (17).
23;8
WA500- 1
INSTALLATION
1.
OF FRONT
DIFFERENTIAL
Differential
11 Install tools A and f3 to garage jack, then
differential (14) in tool A.
install
2) Fit O-ring (17) to differential.

3) Operate garage jack and pull differential
machine body.
in under
4) When
and axle
clearance
between
differential
housing is about 40 mm.
(14)
Install guide bolts (M20 x
55 mm) in axle housing.

5) Fit lever block @
*
Fit
both
to differential
edges of lifting
case (15).
tool to inspection
win-
dow.
6) Adjust
height
of lifting
assemble differential
*
Fit O-ring
tool
and garage jack,
and
along guide bolts.
(17) securely
in the groove and make
sure that it is not caught when installing.
7) When
clearance
differential
between
axle
housing
(16)
and
(14) is about 20 mm, remove tool A and
tighten mounting bolts uniformly.

8) Remove guide bolts and install mounting bolts.
&
w
Mounting bolt:
Thread tightener
Mounting bolt:
56 + 6 kgm
(LT-2)
WA500-
30 mm)
23-79
0
IA.
Adjusting shaft shim

*
Adjust the shaft shim when the differential
assembly
or axle housing have been replaced.

1) Tighten
the mounting
bolts of shaft (18) uniformly,
and measure clearance a between
the axle housing
and shaft.
*
Do not assembly any shim.

m
Mounting
bolt:
0.4 f 0.1 kgm

(When measuring clearance)
2) Select a shim of 0.1 f 0.05 mm larger than the meas-
425F535
ured value of clearance a, then assemble the shim.

*
Shim thickness = clearance a + (0.1 + 0.05 mm)

w
Mounting bolt:
18
11.5 * 1 .O kgm
426FO1205A
2.
Parkin g brake caliper

Set
pi
srking
brake caliper
(13)
in mounting
position,
insert plate (12) in groove of caliper and tighten mounting bolts.

*
Insert plate in caliper groove completely.
Check assembly of pad.

&I kg
Mounting
bolt:
Thread tightener
Mounting
bolt:
95 f 10 kgm
(LT-2)
3.
36 mm)
Spring cylinder
1) Set spring cylinder
(11)
in mounting
position
and
install.
w
Mounting
bolt:
28.5 + 3 kgm
2) Install air hose (IO) and linkage pin (9).
23zo
WA500-1
4.
Drive shaft
1) Install
front
2) Install
disc cover (8).
drive shaft (7).
When connecting
the drive shaft, clean the contact
&N
surface of th spider and coupling.

w
5.
Mounting
bolt:
11.5 f 1 kgm
Axle shaft
Push in axle shaft (5) together
6.
with
sun gear (6).
Cover
Fit
O-rings
in grooves
of covers
(4) and install
on left
and right sides.

*
Fit
the O-ring
securely
in the groove
and make sure
that it is not caught when installing.

7.
Tire, wheel
1) Raise tire
and wheel
then install mounting

w
Mounting
position,
nuts.
nut:
48 + 5 kgm
(Width
across flats:
30 mm)
2) Remove the stand.

8.
Refilling with oil

Remove
level plug and add oil through oil filler to the
specified level.
*
Set the machine
so that the drain plug of the final
drive is at the bottom when refilling with oil.
Q
9.
Axle oil:
75 Q
Bleeding air from brakes

Bleed air from
*
For details
brakes, then check operation.

of bleeding
air, see 52 TESTING
AND
ADJUSTING.
425P532
WA500-1
23z
REMOVAL
Stop
OF REAR DIFFERENTIAL
the
safety
ground
brake
machine
on level ground
bar on the frame.
Lower

and put
the machine
blocks
from
and install
the bucket
the
to the
under
moving.
- Put blocks under the front wheels and apply the

parking
- Lift
brake securely.
up the
block
machine
with
garage jack
and put
under the rear frame, then support
lower part of counterweight
with
blocks
the
b.
I
1.
425p548 fj
,f
\
---?I
i :\
,_s---
-___~_
425P549
Tire, wheel
Sling right
and left tires and wheels
(l),
remove mount-
ing nuts, then lift off.

Tire, wheel:
2.
660 kg
Drive shaft
Disconnect
rear drive shaft
Rear drive shaft:
3.
(2) from
rear axle.
42 kg
Brake piping
1) Disconnect
hose
slack adjuster
2) Disconnect
(3)
between
brake
chamber
and
from the slack adjuster.
tubes
(4) and (5) between
slack adjuster
and right and left wheel cylinders.

*
When
lifting
off the axle, there
brake tube may be damaged,
23-82
0
is danger that
the
so always remove it.
WA500-
4.
Grease tube
1) Disconnect
grease tubes (6) and (7) from
rear axle
support.
2) Disconnect grease tube (8) from front axle support.

*
Remove clamp of electric wiring from support.
Ir
Disconnect
hose
(9)
between
torque
converter
pump and filter from filter end.
5.
Rear axle, support

1) Fix axle support and rear axle with a chain.
2) Remove mounting
bolts, then using hoist and jack to
maintain balance, lower rear axle and support.

Rear axle, support:
2,050 kg
3) Pull out rear axle and support from under machine.

*
Support both ends of the axle with jacks.
WASOO-1
6.
Front support
Lift off front support (11) from rear axle.
t
Be careful not to damage the seal.

Front support:
7.
93 kg
Draining oil
Remove drain plug (12) and drain oil from axle assembly.
A
8.
Axle oil:
22 !?
Axle shaft
1) Remove cover
(13).
2) Pull out axle shaft (14).

t
9.
Pull out axle shaft about 200 mm.
Differential
Using forcing screw, lift off rear differential
& kg
*
Rear differential:
(16).
282 kg
Remove O-ring from contact surface.
425PM6
23:4
WA500- 1
INSTALLATION
1.
OF REAR DIFFERENTIAL
Rear differential
Raise differential
(15),
tighten mounting
bolts.
set in mounting
install the differential
Check that there is an O-ring fitted
position,
then
raising it horizontally.
to the mounting
face of the differential.

a
w
Mounting
bolt:
Thread tightener
Mounting
bolt:
56 ?r 5 kgm
(LT-2)

IA.
30 mm)
Adjusting shaft shim

Adjust
the shaft shim when the differential
assembly
or axle housing have been replaced.

Tighten
the mounting
bolts of shaft (16) uniformly,
and measure clearance a between
the axle housing
and shaft.
*
Do not assembly any shim.

w
Mounting
bolt:
0.4 f 0.1 kgm

(When measuring clearance)
Select a shim of 0.1 f 0.05 mm larger than the measured value of clearance a, then assemble the shim.
*
Shim thickness = clearance a + (0.1 * 0.05 mm)

m
Mounting
bolt:
11.5 + 1 .O kgm
425F537
2.
Axle shaft
1) Push in axle shaft (14).
*
If the axle shaft

differential
cannot
coupling
be inserted,
lightly.
rotate the
Never try to force
the shaft in.

2) Fit O-ring on cover (13) and install cover.
*
Make
sure that
the
O-ring
is not caught
when
installing.
426FO12056
425P546
WA500-1
23z5
3.
Front support
Lift
up front
support
(11)
and insert on the rear axle
mount.
*
Be careful not to damage seal with the coupling.
&
4.
Rear axle mount:
Grease (G2-LI)
Rear axle, support

1) Pull rear axle and support (10) under machine.
*
Secure the rear axle and axle support with a chain.
2) Using
hoist
mounting
and jack
position,
to
then
maintain
tighten
balance,
mounting
set in
bolts of
axle support.
*
Always
tighten
the mounting
bolts for the front
support on opposite sides in turn.

w
Mounting
bolt:
160?
20 kgm
5.
46 mm)
Grease tube
1) Connect
grease tube (8) to front
axle support posi-
tion.
* Install clamp of electric wiring to axle support.

* Connect hose (9) between torque converter pump
and filter.
2) Connect grease tubes (6) and (7) to rear axle support.
WA500-1
6.
Brake piping
1) Install
tubes
(4) and
(5) between
slack adjuster
and
right and left wheel cylinder.

2) Connect
tube
adjuster
7.
(3) between
brake
chamber
and slack
to slack adjuster.
Drive shaft
Connect
*
rear drive shaft
When
connecting
(2) to rear axle.
the drive
shaft,
clean the contact
surfaces before installing.

w
8.
Mounting
bolt:
11.5 + 1 kgm
Tire, wheel
Set right
tion,
and left tires and wheels
then tighten
mounting
Mounting
nut:
(I)
in mounting
48 * 5 kgm
Remove
the
support
9.
block
posi-
nut.
under
the
rear
frame
30 mm)
and
the
under the counterweight.
Refilling with oil

Tighten drain plug and add axle oil through
the specified
*
oil filler
to
level.
Set the machine
so that
drive is at the bottom

Axle oil
the drain
when refilling
plug of the final

with
oil.
: 22 L?
10. Bleeding air from brakes

Bleed air from
*
For
details
ADJUSTING.
WA500-
brakes, then check operation

of
bleeding
of brakes.
air, see 52 TESTING
AND
DISASSEMBLY
OF DIFFERENTIAL
GEAR ASSEMBLY
Special tools
Part name
Part No.
Qty
790-501-5000
Unit repair stand
Al
790-901-4
Bracket
A2
793-310-2160
Plate
Preparatory
110
work
Set differential
assembly (I)
on special tools A, AI,
and
A2.
Differential
1.
assembly:
230 kg
Pinion assembly
1) Remove case (2).
2) Remove oil seal (3) from case.
3) Screw
in forcing
screw @
(Thread
dia. = 18 mm,
Pitch = 1.75 mm), and lift out pinion assembly (4).

*
Check number of shims (5).
23z8
WA500- 1
2.
Differential
,,,,,,:,
,,~;\;,,,,;,
,, jj, ,I L ,,G
j_ j ,,
gear case assembly
1) Remove left and right locks (6), and with a bar, turn
nut (7) until it becomes loose.
V<\z::
2,
2) Remove mounting bolts (9) of cap (8).
3) Remove nut and lift out differential

bly (10).
WA500-
gear case assem-
:, ,,
j, ,\Q
,\>;
yy*,,,\,t,**,,*%,,
_\\
&*q?ya,,*\\*
,\*b_,
,\:&
FINE
3.
DISASSEMBLY
OF PINION
ASSEMBLY
Bearing, collar, cage

1) Support
cage (1 1 ), push shaft with
press and take out
pinion.
2) Remove bearing
3) Remove outer
4.
(12) and collar from cage.
races (13) and (14) from
cage.
Pinion, bearing
1) Remove snap ring (15), then remove bearing
2) Remove bearing
23-90
0
(16).
(17).
WASOO- 1
FINE DISASSEMBLY
CASE ASSEMBLY
5.
Remove
mounting
bolts,
using
eye-bolts
Pinion
plate (19) and bevel gear (20).
pinion
gear (211, cross shaft
(23) as one unit.
Bevel gear (small)

Remove bevel gear (24) and thrust
9.
(Thread
gear, cross shaft
Remove
8.
Pitch = 2.0 mm), lift off bevel gear (18).
Bevel gear (small)

Remove thrust
7.
GEAR
Bevel gear (large)

dia. = 16 mm,
6.
OF DIFFERENTIAL
plate.
Bearing
Remove bearing
WA500- 1
(26) from case (25).
(22), and washer
ASSEMBLY
OF DIFFERENTIAL
GEAR ASSEMBLY
Special tools
Part No.
I Qw
Part name
792-525-l
100
Differential
micrometer
BI
792-525-l
230
Adapter
FINE ASSEMBLY
CASE ASSEMBLY
1.
OF
DIFFERENTIAL
GEAR
Bearing
Using press fit kit @
(120
mm inner diameter),
press
fit bearing (26) to case (25).
2.
Bevel gear (small)

Install thrust and small bevel gear (24) in case.
*
3.
Align thrust with dowel pin and install.
Pinion gear, cross shaft

Assemble
pinion gear (21) and washer
(23) with
cross
shaft (22).
*
Align
washer
groove
with
dowel
pin of case and
install.
424P583
4.
Bevel gear (small)

Install bevel gear (20) and thrust (19)
2322
WA500- 1
5.
Bevel gear (large)

Using eye-bolts
Pitch = 2.0
mm), lift and install bevel gear (18).

*
Align
pin hole of thrust
and dowel pin on case side
and install.
FINE
6.
ASSEMBLY
OF PINION
ASSEMBLY
Bearing
(26 mm inner diameter),
install
install
pinion bearing (17).

bearing (16).
&
Rotating surface of bearing:

Engine oil (E030CD)
7.
Cage
1) Install outer races (14) and (13).
2) Install cage (11) to pinion assembly.
8.
Collar
lnstal collar (27).
9.
Bearing
Using press fit kit @
install
bearing (12).
WASOO- 1
23if3
ASSEMBLY
*
OF DIFFERENTIAL
Set differential
ASSEMBLY
case on special tools A, A,,
and AZ.
10. Pinion assembly

1) Assemble shims (5) removed
*
Standard
when disassembled.
shim thickness:
2) Using eye-bolts
2.1 mm
(Thread
1.75 mm), install pinion
dia. = 12 mm,
assembly
Pitch =
(4).
3) Install oil seal (3) to case.

&
Lip of oil seal:
Grease (G2-LI)
4) Fit O-ring to case, and install case (2).

&
m
Mounting
bolt:
Thread tightener
Mounting
bolt:
2.8 f 3 kgm
5) Install coupling
&
w
*
Fit
(28), fit O-ring and tighten
Mounting
bolt:
Thread tightener
Mounting
bolt:
94 2 10 kgm
the
balancer
to
and measure the rotating

*
11.
Rotating
Differential
hole
of
holder.
(LT-2)
coupling,
torque.
Max. 5.1 kg
gear assembly
Sling differential
23z4
torque:
bolt
(LT-2)
gear assembly
(10) and install case.
WA500- 1
12. Nut, cap

1) Align
nut (7) with
differential
2) Install cap (8) and tighten

&
w
*
case groove and install.
bolt
(9).
Mounting
bolt:
Thread tightener
Mounting
bolt:
95 + 10 kgm
Check
match
marks
on bearing
(LT-2)
cup before
instal-
ling.
*
Rotate
bevel gear 20 -
tighten
bolt.
Bearing pre-load
1) Install tool
2) Measure
adjustment
30 times to settle in, then
steps are as follows:
B1 to cap on both sides,
clearance
between
tool
B1 with
tool
B.
\
3) Add
0.26
0.07
mm to measurement
and set scale on tool

*
The added
bending
425F290
dimension
B.
dimension
becomes
the amoutn
of the case, given before
pre-load
of
and
given after pre-load.

4) Tighten
amount
WA500-
adjusting
nut
with
bar
becomes 0.26 f 0.07 mm.
until
increased
Caution for pre-load adjustment

When adjusting nut is overtightened,
in case the amount
of
satndard
increased
bending
surpasses the
measure-
ment,
return adjusting nut to position before adjusting.
Then,
while
rotating
bevel gear, lightly tap bearing cap
and bevel gear with plastic hammer, and check that there
is no clearance in portion
b.
.No
clearance
425F291
13. Adjusting tooth contact, backlash

Adjust
the backlash, and at the same time adjust tooth
contact.
1) Adjust backlash as follows:
i) Movement
nut (7).
of bevel gear is done with

At this time,
load pressurization
adjusting
so as not to change pre-
of bearing, turn nuts on both
sides, the same amount each, in same direction.

ii)
Put dial gauge @
in vertical
contact
with for-
ward and reverse sides of outer edge of bevel gear

tooth
face,
and
adjust
until
gauge meter
while
turning
adjusting
fluctuation
nut,
becomes
0.3 - 0.4 mm.

*
425F292
Measure at 3 or 4 places, and keep the pinion

gear fixed when measuring.
2) Adjust tooth contact as follows:

i)
Adjust
bevel pinion
differential
ii)
by adjusting shims between
case and bearing cage.
Adjusting tooth contact

For
details,
see ADJUSTING
TOOTH
CON-
TACT.
23-96
0
WA500-
3) Adjusting tooth contact

Coat face of 7 or 8 teeth of bevel pinion lightly with red lead (minimum).
Hold the bevel gear by hand to act
as a brake, rotate the pinion gear forward and backward and inspect the pattern left on the teeth.
2OBF514
Procedure for adjustment
Cause
Tooth contact
The tooth contact pattern should

start from about 5 mm from the
toe of the bevel gear and cover
about 50% of the length of the
tooth.
It should be in the center of the
tooth height.
Adjust the pinion gear by adjusting the shims at the

:age. Adjust the bevel gear in the same way as when
adjusting backlash.
1. Reduce shims at pinion gear to bring closer to bevel
Pinion gear is too far from
gear.
bevel gear.
2. Move bevel gear further away

from pinion gear and adjust
:,
backlash correctly.
?A
2OBF515
Pinion gear is too close
2OBF519
1. Increase shims at pinion gear to move away from
to
bevel gear.
bevel gear.
2. Move bevel gear closer to pinion

gear and adjust backlash
2
c
correctly.
208 F520
Bevel gear is too close to pinion

gear.
1. Reduce shims at pinion gear to bring closer to bevel

gear.
2. Move bevel gear further away
from pinion gear and adjust
backlash correctly.
2OBF519
Bevel gear is too far from

pinion gear.
1. Increase shims at pinion gear to move away from

bevel gear.
2. Move bevel gear closer to pinion
gear and adjust backlash
When adjusting the driven gear, do not change the pre-load of the bearing.
the same amount each (check by the numberof
WA500-
?d
correctly.
2
c
2OBF520
Turn the left and right adjusting nut,
notches), in the same direction.
REMOVAL
n!
OF FRONT AXLE
Stop the
safety
machine
bar on the frame.

Put blocks under the rear wheels to prevent the machine

from moving, and apply the parking brake sec,urely.
Insert block 0
between frame (2) and the top surface
of rear axle housing (1).
Jack
up the
machine,
and
put blocks @
under the
front frame on the left and right sides.
1.
Tire, wheel
Sling left and right wheels (3), remove mounting
nuts,
then lift off.

Tire, wheel:
2.
660 kg
Drive shaft
Disconnect drive shaft (4) at differential
*
Align
match
marks on the coupling
end.
of drive shaft
before assembling of drive shaft.
23698
WA500-
3.
Brake tube
1) Disconnect brake tube (5) from slack adjuster.
2) Disconnect brake tubes (6) and (7).
*
After
disconnecting
the piping, cover to prevent
dust or dirt from entering.
4.
Air piping
Disconnect air hose (8) from spring cylinder.
*
5.
Loosen drain valve and drain air.
Front axle
1) Sling
front
axle
housing
(9) on one side, and fit
garage jack under other side.

2) Fit garage jack under bottom of differential
t
case.
Be careful not to damage the side face of the parking brake cover.
3) Remove mounting
bolts, then using hoist and jack to
maintain balance, lower front axle.

Sr Be careful
not to parking
brake
caliper bracket
interfere with frame.

*
Be careful not to let the slack adjuster on the top

surface of the axle housing hit against the frame.
& kg
Front axle:
2,100
kg
4) Pull out front axle from under machine.
WA500-
INSTALLATION
1.
OF FRONT AXLE
Front axle
1) Pull front axle under machine body.
2) Fit lifting tool to front axle (9), set garage jack under
differential
case and maintain
balance while
setting
in mounting position.
3) Tighten mounting bolts of front axle.
Mounting bolt:
280 + 40 kgm
55 mm)
425Pem
2.
Air piping
Connect air hose (8) to spring cylinder.
3.
Brake tube
1) Install brake tubes (6) and (7).
2) Connect brake tube (5) to slack adjuster.
*
4.
Wipe the connection with a clean cloth.
Drive shaft
Connect front drive shaft (4) at differential
w
23- 100
0
Mounting bolt:
11.5 f
end.
1 kgm
WA500-
5.
Tire, wheel
1) Set left and right wheels (3) in mounting
position,
then install mounting nuts.

m
Mounting
nut:
48 i. 5 kgm
2) Jack up machine, then remove block @
30 mm)
from under
front frame.
3) Remove block @
from
between
frame
(2) and top
surface of rear axle housing (1).
6.

Bleed air from brakes, then check operation.
*
For details
of bleeding
air, see 52 TESTING
AND
ADJUSTING.
WA500-
23iio1
REMOVAL
Stop
OF REAR AXLE
the
safety
machine
ground
and put
the machine
Put
blocks
Jack
blocks
from
under
chine from
.
Lower
brake
on level ground
bar on the frame.
up the
the
to the
under
moving.
the front
moving,
and install
the bucket
wheels
to prevent
the ma-
and apply the parking brake securely.
machine,
frame, and put a stand
put
@
block
under
the
rear
under the counterweight.
b
I
1.
425P548
Tire, wheel
Sling
left
and right
wheels
(l),
remove
mounting
nuts,
then lift off.

Tire, wheel
2.
: 660 kg
Drive shaft
Disconnect
rear drive shaft
Rear drive shaft:
3.
(2) from
rear axle.
42 kg
Brake piping
1) Disconnect
tube
slack adjuster
2) Remove
tubes
(3)
between
brake
chamber
and
from slack adjuster.

(4) and (5) between
slack adjuster
and
is danger that
the
right and left wheel cylinders.

*
When
lifting
off the axle, there
brake tube may be damaged,
23-102
0
so always remove it.
WA500-
4.
Grease tubes
1) Disconnect
grease tubes (6) and (7) from
rear axle
support.
2) Disconnect grease tube (8) from front axle support.

*
Remove clamp of electric wiring from support.
Disconnect
hose
(9)
between
torque
converter
pump and filter from filter end.
5.
Rear axle, support assembly

1) Secure alxe support and rear axle with chains.
Remove mounting
bolt, then using thoist and garage
jack to maintain balance, lower rear axle and support.

Rear axle, support:
2,050
Pull out rear axle and support
kg
(10) from under the
machine.
* Support both ends of the axle with jacks.
WA500-
6.
Front support
1) Remove front support (1 I) from rear axle.
*
Be careful not to damage the seal.

Front support:
93 kg
2) Remove bushing (12) from front support.
12
425P606
3) Remove seals (13) and (14) from front support.
425F282
7.
Rear support
1) Sling rear support, remove thrust cap (15)
23-iho4
WA500-
2) Remove
thrust
washer
(16),
thrust
plate
(17)
and
thrust washer (18) from rear axle.
16
425F283
3) Lift off rear support (19).

Rear support:
120 kg
4) Remove bushing (20) from rear support.
5) Remove seal (21) from rear support.
*\
27
425F284
WA500-
425P6:. ?
INSTALLATION
1.
OF REAR AXLE
Rear support
1) Install seal (21) on rear support.
&
Seal lip:
Grease (G2-LI)
2) Install bushing (20) on rear support.

*
Assemble the bushing with the chamfered edge on

the axle housing side.
*
&
Check that the slit of bushing faces sideways.

Bushing:
Grease (G2-LI)
425F285
3) Raise rear support
(19) and set in position
on rear
axle mount.
&
Rear axle mount:
Grease (G2-LI)
4) Install thrust washer (181, thrust plate (17).

a
B
Thrust washer:
Grease (G2-LI)
Mounting bolt:
28.5 f 3 kgm
23-Ao6
WA500-
5) Install thrust washer (16) and thrust cap (15).

&
m
2.
Thrust washer:
Grease (G2-LI)
Mounting bolt:
28.5 + 3 kgm
Front support
1) Install seal (13) and (14) on front support.
&
Seal: Grease (G2-LI)
24
13
14
425F282
2) Install bushing (12) on front support.

*
Assemble the bushing with the chamfered edge on

the axle housing side.
Check that the slit of bushing faces sideways.
Bushing:
Grease (G2-LI)
425F287
3) Raise front support
(1 I), and set in position on rear
axle mount.
*
Be careful not to damage seals with coupling.
WA500-
Rear axle mount:
Grease (G2-LI)
429606
3.
Rear axle, support

I) Pull rear axle and support assembly (10) to underside
of the machine.
*
Secure rear axle and axle support with chains.
2) Using hoist and garage jack to maintain balance, set

in mounting
position, and tighten mounting
bolts of
axle support.
*
Tighten
the mounting
bolts of the front support
on opposite sides in turn.

w
Mounting bolt:
160 + 20 kgm
4.
46 mm)
Grease tubes
1) Connect grease tube (8) to front axle support.
*
Install clamp of electric wiring to axle support.
Connect
hose (9) between
torque
converter
and
filter to filter end.
2) Connect grease tubes (6) and (7) to rear axle support.
23-108
0
WA500-
5.
Brake piping
1) Install
tubes
(5) and
(4) between
slack adjuster
and
right and left wheel cylinders.

2) Connect
adjuster
6.
hose (3) between
brake
chamber
and slack
to slack adjuster.
Drive shaft
Connect
*
rear drive shaft
When
connecting
(2) at rear axle end.
the
drive
shaft,
wipe
the contact
surface when installing.

m
7.
Mounting
bolt:
11.5 + 1 kgm
Tire, wheel
I) Set left
and right
then tighten
Mounting
wheels
mounting
nut:
(1) in mounting
48 f 5 kgm
(Width
8.
Bleeding
air from
across flats:
brakes, then check operation.
of
details
30 mm)
brakes
Bleed air from

For
position,
nuts.
bleeding
air, see 52 TESTING
AND
ADJUSTING.
WA500-
23-109
8
REMOVAL
Stop
the
OF CENTER
machine
completely
the
Lower
stop the engine.

put blocks
1.
on level ground,
to the left and install
frame.
from
SUPPORT
the bucket
Then apply
turn
the wheel
the safety
bar on
to the ground
the parking
under the wheels to prevent
and
brake and
the machine
moving.
Drive shaft
1) Disconnect
the
center
drive
shaft
(I)
from
center
support.
*
Set block
under drive shaft and remove.
Center drive shaft:
33 kg
2) Sling front drive shaft (2) and disconnect
from
center
support.
Front
23-110
0
drive shaft:
44 kg
WA500-
INSTALLATION
1.
OF CENTER
SUPPORT
Center support
1) Set center
support
(4)
in mounting
position
and

*
Adjust
shims so matching
surface of center
of
center pin and coupling are parallel.

w
Mounting bolt:
56+
6 kgm
30 mm)
2) Connect grease tube (3) to center support.
2.
Drive shaft
1) Connect front drive shaft (2) to center support.
B
Mounting bolt:
11.5 2 1 kgm
2) Connect center drive shaft (I) to center support.

*
Clean.mounting
surface of coupling with
cloth.
m
WA500-
Mounting bolt:
11.5 f
1 kgm
a clean
DISASSEMBLY
I.
OF CENTER
SUPPORT
Coupling
Remove center bolt (I), then remove retainer (2), O-ring
(3), and coupling (4).
2.
Retainer
Remove mounting bolts (5) of retainer.
*
3.
Remove all mounting bolts while rotating coupling.
Shaft
1) Set shaft case assembly (6) on press stand.
2) Push out shaft (7) with press.
*
Be careful because the shaft will fall out suddenly.
425F273A
3) Remove spacer (8), bearing cone (9) and retainer (5)

from shaft.
23-l 12
0
WA500-
4.
Oil seal
1) Remove oil seal (IO) and O-ring
(11) from
retainer.
425F274
2) Remove oil seal (12) from

5.
case.
Case
Remove
bearing
cone
(13)
and bearing
outer
race (14)
and (15).
425F275
WA500-
23-&1
3
ASSEMBLY
I.
Bearing
outer
Assemble
OF CENTER
SUPPORT
race
bearing
(14)
and
(15),
in case (16).
425F276
2.
Oil seal
Assemble
&
oil seal (IO)

Outer
in retainer
circumference
(5).
of oil seal:
Grease
(G2-LI)
425F277
3.
Bearing
cone
Assemble
retainer
(5)
shaft
and
press fit
bearing
cone
there
is no
(9).
*
*
4.
After
assembling
bearing,
clearance
at tip of shaft.
Assemble
spacers.
Lip of seal:
&
Inner
Grease
circumference
check
that
(G2-LI)
of bearing:
Grease
(G2-LI)
Case
1) Assemble
*
Insert
O-ring
O-ring
23G14
(11)
in retainer.
completely
in groove.
WA500-
2) Stand shaft and insert case (16).

*
Fill
and b
of case and inner circumference
of oil seal completely
with
grease.
-16
5.
Retainer
Secure retainer
*
(5) in case.
Be careful
that
O-ring
does
not
get caught
when
installing.
Mounting
bolt:
6.7 + 0.7 kgm
425F278
6.
Bearing cone, seal

1) Press fit bearing cone (14) to shaft.
2) Assemble oil seal (12) in case.
*
Dimension
of seal press fit and outer edge of case:

0.5 mm
&
7.
Seal:
Grease (G2-LI)
coupling
(4), install
Coupling
Assemble
(2), and secure center bolt

Center bolt:
O-ring
(3) and retainer
(1).
95 i: 10 kgm
8.
36 mm)
425P633
Inspection of end play

Check that end play is within
*
*
End play:
If end play
with
specified
range.
Less than 0.22 mm

is 0,
with
the seal and bearing
grease, check that the free rotating
coated
torque
is less
than 0.4 kgm.
425F279
425Q637
WA500-
425P632
23i5
DISASSEMBLY
Serial
1.
No.
10001
OF DRIVE SHAFT
10222
Splined yoke
Loosen retainer (I) and remove splined yoke (2).
425P616
2.
Bearing assembly
Remove
mounting
bolts
(3), then
remove bearing
assembly (4).
*
Make match marks on yoke and bearing.
425P617
3.
Bearing cap
1) Remove bearing cap (5) from bearing assembly.
*
Remove strap (6) of cap.
425P618
2) When replacing bearing (7), seal (8), and Derling

washer (9) from
bearing cap, replace whole cap
assembly.
*
Carry
out the same procedure
at the sleeve
7
yoke end.
8
425F280
23-&1
6
425P639
WA500-
4.
Sleeve yoke
1) Remove mounting
bolts (11) from sleeve yoke (IO),
then remove bearing assembly (4).

*
Stamp of mutch marks on yoke and bearing.
425P620
2) Remove bearing cab (5) from bearing assembly.
WA500- 1
23iA17
ASSEMBLY
Serial
1.
No.
10001
OF DRIVE
-
SHAFT
10222
Bearing cap
1) Install bearing (7), and seal (8) to bearing cap (5).
a
Bearing, seal: Grease (G2-LI)
425F281
2) Assemble
Delrin
washer (9), and bearing cap (5) to
bearing assembly (4).

a
Bearing cap: Grease (G2-LI)
425P623
2.
Bearing assembly
Assemble bearing assembly (4) to sleeve yoke (10).
+
*
Carefully align match marks.

Clean the mounting face of the bearing cap by wiping
with a clean cloth.
Mounting bolt:
14.5 + 1 kgm
425P624
3.
Splined yoke
1) Assemble bearing (7) and seal (8) in bearing cap (5).
&
Bearing seal: Grease (G2-LI)
7
8
7
425P67
425F280
23-k
*
WA500-
2) Assemble
Delrin
bearing assembly
*
Be careful
welding
washer
(9) and bearing
cap (5) to
(4).
not to damage bearing
with
heat when
strap.
425P625
3) Assemble
bearing assembly
Carefully
Clean
the
wiping
with
(4) to splined yoke
(2).
align match marks.

mounting
face
of the
bearing
cap by
!+
\
a clean cloth.
Mounting
bolt:
14.5 * 1 kgm
425P626
4) Align
match
marks, insert splined yoke
(IO), and secure with

*
Check that
retained
the yokes
in sleeve yoke
(1).
are facing
in the same direc-
tion.
*
If the spline is worn,
replace the whole
drive shaft
assembly.
425P627
WA500-
23i9
DISASSEMBLY
Serial
1.
No. 10223
OF DRIVE SHAFT
and up
Shaft
1) Remove
*
shaft
Make
ensure
marks
that
assembly
*
(2).
match
Cover
a before
direction
removing
of
the
to
spider
does not change.
(1)
places,
the
is caulked
so
it
must
with
not
be
a punch
at four
removed
unless
necessary.
+
When
removing
not to damage
*
When
cover (I), be extremely

cover
removing
caulking
with
careful
a
(1) and yoke (3).

the
caulking,
raise
425FO1628
the
a screwdriver.
Seal
426FO1203A-K
2) Remove
mounting
assembly
+
Make
bolts
(4), then
remove
spider
(5).
match
marks
on yoke and spider.
425FO1629
3) Remove
*
bearing
Remove
strap
caps (6) from

(7) of cap.
spider
assembly.
425FO1630
23-:
9-1
WA500-1
4) When
replacing
washer
bearing
(10) from
(8), seal (9), and Derling
bearing
cap (6), replace
whole
cap assembly.
425F281
2.
Yoke
1) Remove
remove
*
Stamp
mounting
spider
bolts
(11) from
assembly
match
marks
yoke
12
(3), then
425FO1631
A-K
(12).
on the
yoke
and
spider.
11
2) Remove
3) When
Derling
replace
bearing
replacing
washer
whole
caps (13) from
bearing
(16)
from
(14),
spider
seal
bearing
425FO163:
425FO1633
assembly.
(15)
cap
and
(13),
cap assembly.
425F281
WA500-1
B-K
425FO1634
23-A9-2
ASSEMBLY
OF DRIVE SHAFT
Serial No. 10223
and UP
1.
Yoke
1) Install
bearing
(14), and seal (15) to bearing
cap
15
(13).
&
Bearing,
seal: Grease
13
(G2-LI)
14
I
425F281
2) Assemble
Derling
(13) to spider
9r Be careful
when
&
washer
assembly
(16),
Bearing
cap
(12).
not to damage
welding
and bearing
B-K
bearing
with
heat
strap.
cap: Grease
(G2-LI)
Q
16
425FO1635
3) Assemble
spider
Carefully
Clean
the
by wiping
w
assembly
align
mounting
with
Mounting
match
(12) to yoke (3).

marks.
face
a clean
bolt:
of the
bearing
12
cap
cloth.
14.5 *
1 .O kgm
2.
425FO1636
Shaft
1) Assemble
bearing
(8) and seal (9) in bearing
cap
(6).
#??TY=
Bearing
seal:
Grease
(G2-LI)
9
8
8
425F281A-K
23-A9-3
425FO163
WA500- 1
2) Assemble
Derling
washer
(6) to spider assembly

+
Be careful
when
&
(10) and bearing
not to damage
welding
Bearing
cap
(5).
bearing
with
heat
strap.
cap: Grease
(G2-LI)
1'0
3) Assemble
+
+
spider assembly
Carefully
Clean
the
by wiping
m
align match
mounting
425FO163
(5) to shaft (2).
marks.
face
of the
bearing
cap
with a clean cloth.
Mounting
bolt: 14.5 zb 1 kgm
4) Align
match
marks
a, then
install
shaft
(2) to
yoke (3).
*
Checkthat
the direction
of the spider assembly
is the same.
*
If the spline
is worn,
replace
the whole
drive
shaft assembly.
a
Spline:
Grease
(G2-LI)
a
425FO1626
5) If cover (1) has been removed,

i) Insert
(2).
seal and retainer
assemble
cover
punch on diagonally
(l),
do as follows.
to cover (1) and shaft

then
opposite
caulk
with
sides.
426F01203A.K
WA500-1
23-;9-4
DISASSEMBLY
Q7
Stop the
safety
OF FINAL
machine
DRIVE
bar on the frame.

Special tool
Part No.
I Q'tv
I
910
795-520-l
Part name
Fixture
425E355
Tire assembly
Loosen wheel nuts, raise machine with equipment
insert
stand
under
axle,
sling tire
assembly,
tools,
remove
wheel nuts, then remove tire assembly (1).

Tire assembly:
E?lkg
600 kg
Draining oil
Remove drain plug (2) and drain oil.
*
u
Set the drain plug at the bottom.

:
Axle oil
: Approx. 20 J?
Cover
Remove mounting bolts (3), then remove final drive case
425P856
cover (4).
Axle shaft
Screw in bolt @
Pitch = 1.75
mm) to axle shaft and lift out axle shaft assembly (5).
5.
Planetary carrier
Remove
mounting
(Thread
dia.
bolts
= 12 mm,
(6),
and
Pitch
using eye-bolts @
= 1.75
mm),
lift
out
planetary carrier assembly (7).

*
Because balance is bad, adjust the center of gravity

with a bar and remove.
Planetary assembly:
23-A20
90 kg
WA500-
6.
Ring gear
1) Using
tool
A, hold
wheel
hub
(9) and brake
housing
(8) in position.
*
Install
tool
washers
2) Remove
(11)
*
on opposite
mounting
There
bolts
are shims
and
reference
,-.
inside
thickness
when
sides, and use
clearance.
(lo),
and ring gear assembly

number
7.
A to points
to adjust
then
remove
retainer
(12).
the
retainer,
of the
so check
shims,
and
the
use for
installing.
Ring gear:
50 kg
Disassembly of planetary carrier

1) Using a press,
pull
out
shaft
(13)
and
remove
pinion
gear (14).
*
There
is a lock ball (15)
on the shaft,
so be careful
not to lose the ball.

*
Write
a number
moved
2)
Remove
bearing
ring (20),
*
The
on the
parts separately
from
bearing
gether,
case and
(17),
cup
(18),
pinion
gear
(14).
and
so mark
other
keep
all the
re-
in sets.
parts
spacer
have
(19)
and snap
settled
the parts and keep them
in to-
in sets.
423F435A
18
14
19
20
18
423F436A
WA500-
423P938A
23-A2
8.
Disassembly of ring gear

1) Remove
lock
plates (22)
from
ring gear hub (211,
then remove ring gear (23).

2) Pull out bearing (24) from ring gear hub (21).
23-122
0
WA500-
ASSEMBLY
OF FINAL
DRIVE
Special tool
Part name
Part No.
A
1.
795-520-I
oyy
Fixture
910
Assembly of ring gear
1) Press fit bearing (24) on ring gear hub (21).

*
After
press fitting the bearing, check that there is
no clearance between the rib and bearing.

2) Set ring gear hub (21) on ring gear (231, then install
lock plates (22).

*
Install the lock plates with the wider ones on the

inside.
Rmove all grease and oil from the bolt.
Mounting bolt:
Thread tightener
Mounting bolt:
3.2 ir 0.3 kgm
(LT-2)
423F436A
2.
Assembly of planetary carrier
1) Install snap ring (20) and spacer (19) on pinion gear

(14).
2) Press fit cup (18)
on pinion
gear, and set bearing
(17).
3) Set pinion gear in carrier case, insert ball (15) in shaft

(13),
*
then
press fit.
Press fit so that

outside
the front
After
the hole for the lock
circumference,
stop
ball is on the
with
the
hole
at
and align the holes.
press fitting
rotates
then
the shaft, check
that
the
gear
smoothly.
423F435A
WASOO-1
23-;23
3.
Adjusting
method
1) Insert
ring
retainer
(IO),
*
of wheel bearing
gear assembly
(11) tighten
in axle
with
housing
fit
bolts
secure wheel
hub
(9) and brake
(8).
Measure thickness
12
of retainer
before installing.
I
*
housing,
mounting
and remove tool A.
When removing,
(12)
temporarily
425F293
Do not insert shims in the retainer
when tightening
temporarily.
t
Rotate
the wheel
hub 20 -
the bolts to a uniform

w
Mounting
2) Using a depth
measuring
a
bolt:
8 + 0.5 kgm
micrometer
or dial gauge, insert through
hole of retainer
from
retainer
30 times and tighten
torque.
(25) and measure clearance
to face of housing.
Measure at 2 places and take the average.
0.3
mm
C =
a - b, becomes shim thickness.
added
to
Use the smallest

required
3) After
hub,
installing
remove
When
always
tool
difference
of shims which
A to brake
retainer,
tighten
insert
gives the
shims,
the
mounting
after
mounting
tightening
housing
the required
then tighten
assembling
the specified
&
number
value
thickness.
shims and retainer,

t
measured
and wheel
number
installing
bolts
of
10
bolts.
tool
uniformly
A,
to
torque.
Mounting
bolt:
Thread tightener
Mounting
bolt:
28.5 f 3 kgm
(LT-2)
423F439
23-124
0
WA500- 1
Planetary carrier
4.
Fit
O-ring,
using eye-bolts @
Pitch = 1.75
(Thread
mm) sling planetary
dia. = 12 mm,
carrier assembly (7),
set in mounting position and tighten mounting bolts (6).

*
Because balance is bad, adjust the center of gravity

with a bar and install.
5.
Axle shaft
Screw in bolt @
Pitch = 1.75
mm) in axle shaft and insert axle shaft assembly (5).

+
If the position of the sun gear does not match, rotate

the wheel hub to align.
6.
Cover
Fit
O-ring,
install
final
drive cover
(4),
then
tighten
mounting bolts (3).

m
7.
Mounting bolt:
7 * 1 kgm
Refilling with oil

Tighten
drain
plug (2) and add oil through
level plug
(26) to the specified level.

*
Set the
machine
so that the level plug of the final

Axle oil
8.
: Approx. 20 Q
425?865
Tire assembly
Sling tire assembly
(I),
set wheel hub, and after tem-
porarily tightening wheel nuts, raise machine with garage

jack and remove support from under axle.
the machine to the ground, and tighten
Then lower
wheel nuts to
the specified torque.

m
Wheel nut:
48 + 5 kgm
(Width across flats: 30 mm)
WA500-
23k25
POWER TRAIN
24 MAINTENANCE
STANDARD
Transmission mount ...........

Damper .......................
Torque converter ..............
Transmission ..................
Transfer.. ....................
Drive shaft ....................
Center support ................
Differential ....................
Axle mount ...................
Final drive .....................
WA500-
.. ...
.. ...
.. ...
...
...
.
...
. ...
. ...
. .
.
.
..
.
.
..
.
..
24- 2
24- 3
24- 4
24- 5
24- 6
24-14
24-l 6
24-l 7
24-l 8
24-22
24-24
24-l
-_
TRANSMISSION
MOUNT
Section A - A
!!!i/l
.,
425F132
Unit:
Check item
No.
Criteria
Thickness of shim for mounting
Tightening torque of mounting

bolt
28.2 * 3.2 kgm
Tightening torque of bracket

mounting bolt
28.2 f 3.2 kgm
Tightening torque of bracket

mounting bolt

bolt
2mm
Remedy
Adjust
Ff.+ih+P
24-2
18?2kgm
28.2 f 3.2 kgm
WA500- 1
mm
TORQUE
CONVERTER
CHARGING
PUMP
Model SAR (3)-080
Section A - A
\
5
425F134
Unit:
No.
Criteria
Check item
Remedy
Clearance limit
Standard clearance
1
Clearance between gear case

and side plate, gear
0.19
0.10-0.15
Replace
Clearance between inside diameter

of plain bearing and outside diameter of gear shaft
Insertion depth of pin
Rotating torque of spline shaft
0.7 - 1.2 kgm
25.2 f 1.7 kgm
Discharge
Oil:
0.20
0.06 - 0.149
WA500- 1
45 - 55C
L
x:9
14:.5
Retighten
Revolution
(rpm)
Pressure
(kg/cm )
Standard
discharge
(Qimin.)
Repair limit
discharge
(Q/min.)
2,500
210
IS4
170
EOlO-CD
Temperature:
mm
24-3
DAMPER
Serial
No.
10001
10809
1
2
/f-T--\
Serial
No.
10810
425F133
and up
m
6.75CO.75kp
-11.25f
1.25kgm
/A-i
/\I\
~sxO+Hqm i 2 1
24-4
0
Section A - A
425FO1213
WA500-1
Backlash of spline
6.75 c 0.75 kgm
WA500-1
24-4- 1
0
TORQUE
CONVERTER
425F135
Criteria
Check item
Inside diameter of seal ring

surface of retainer
Inside diameter of seal ring

surface of sleeve
Width and
thickness of
seal ring
Width
Tolerance
Repair limit
120
+0.035
0
120.5
65
+0.025
0
65.1
3.95
Thickness
4.6
2.1
+0.1
Backlash of PTO gear

(Drive gear)
6.7 f 0.7 kgm
11.2 t 1.2 kgm
Tightening torque of nut
5.5 i: 0.5 kgm
6.7 t 0.7 kgm
6.7 r 0.7 kgm
0.18 - 0.49
mm
Remedy
Standard size
WASOO- 1
unit:
Repair
chrome
plating or
replace
3.55
Replace
4.14
42.5i2.5kgml
24-5
TRANSMISSION
(l/2)
13 18
14 19 15
\\
17 11 12 5
9'
425F136
24-6
WA500- 1
unit:
mm
No
No.1 clutchsprings
(12 pieces)
No.2 clutchsprings(12 pieces)
3
4
9
10
11
Thicknessof 1 disc
12
Thicknessof 1 plate
14
15
16
17
la
WA500-
24-7
TRANSMISSION
(2/2)
425F137
Unit:
No.
Check item
Criteria
Backlash between No.1 sun gear and

planetary gear
0.13 - 0.31
Backlash between No.1

and ring gear
0.15 - 0.38

planetary gear
0.14 - 0.35
Backlash between No.2 planetary gear

and ring gear
0.15 - 0.39

planetary gear
0.14 - 0.35
Backlash between No.3

and ring gear
0.15-0.39

planetary gear
0.14 - 0.35

and ring gear
0.15 - 0.39

planetary gear
0.14 - 0.35

and ring gear
0.15 - 0.39
10
24-8
planetary gear
planetary gears
mm
Remedy
Replace
WA500- 1
SOLENOID
VALVE
Section A - A
425F142
Unit:
No.
Check item
Criteria
Tightening torque of solenoid valve

mounting screw
0.17 * 0.01
Tightening torque df solenoid valve

terminal screw
0.17 + 0.01

terminal screw
0.075 f 0.005

connector mountina screw
0.07 t 0.01
Tightening torque of temrinal

mounting screw
0.07 t 0.01

mounting bolt
Remedy
WA500- 1
kgm
Retighten
6.7 t 0.7
24-9
TRANSMISSION
.
UPPER
CONTROL
VALVE
VALVE
13
\
425F139
425F140
24-10
WA500- 1
.- _-.
Unit:
I
No.
Check item
Criteria
Clearance between reducing valve

and body
relief valve spool and body

Clearance between torque converter
Clearance between priority valve

soool and body
25
Remedy
-0.045
-0.035
0
+0.013
0.058
0.035 -
25
-0.035
-0.045
+0.013
0
0.035 0.058
0.08
Clearance between quick return

valve spool and body
12
-0.035
-0.045
+0.013
0
0.035 0.058
0.08
Clearance between modulating

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

spool and body
28
-0.035
-0.045
+0.013
0
0.035 0.058
0.08
I
I
mm
0.08
Standard size
7
Priority valve spring
Replace
Repair limit
Free
length
Installation
length
Installation
load
Free
length
Installation
load
62
37.7
22.1 kg
59.6
19.9 kg
62
48
12.8 kg
60.6
11.5 kg
Torque converter relief valve spring
Modulating valve spring (Inner)
118
110
5.55 kg
117
5.3 kg
10
Modulating valve spring (Outer)
145.7
144
1.69 kg
141
1.60 kg
11
Main relief valve spring (Inner)
12
Main relief valve spring (Cuter)
13
Thickness of shim for reducing
14
Thickness of shim for modulation valve
3 mm (pressure per 1 piece: 0.20 kg/cm
15
Thickness of shim for priority valve
2 mm (pressure per 2 piece: 0.26 kg/cm
16
Thickness of shim for torque converter

relief valve
4 mm (pressure per 1 piece: 0.26 kg/cm*)
17
Thickness of shim main relief valve
1.5 mm (pressure per 1 piece: 0.39 kg/cm
18
Tightening torque of modulation
I
I
VdVe
108
122
83.5
83.5
30.8 kg
37.9 kg
105
29.3 kg
36.0 kg
118
)
I
3 mm (pressure per 1 piece: 0.65 kg/cm)
Adjust
WA500-
lock nut
4.25 i 0.75 kgnt
)
Retighten
24-11
0
-_
LOWER
VALVE
12
\
425F141
24-12
WA500- 1
Unit:
NO.
Check item
Criteria
Clearance between FORWARDREVERSE spool and body
Remedy
Tolerance
Standard
size
22
Standard
clearance
Clearance
limit
+0.013
0
0.035 0.058
0.08
Shaft
Hole
-0.035
-0.045
mm
Clearance between 1 st speed

spool and body
22
-0.035
-0.045
+0.013
0
0.035 0.058
0.08
Clearance between 2nd speed

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

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

spool and body
22
-0.035
-0.045
+0.013
0
0.035 0.058
0.08
Clearance between pilot reducing

valve and body
25
-0.035
-0.045
+0.013
0
0.035 0.058
0.08
Clearance
between
lubrication
valve
plunger
and body
22
-0.035
-0.045
+0.013
0
0.035 0.058
0.08
Replace
Standard size
FORWARD-REVERSE,
No. 1, No. 2, No. 3 and
No. 4 speed spring
Free
length
Installation
length
Installation
load
Free
length
Installation
load
78
47
10.9 kg
75
10.4 kg
162
125.6
Pilot reducing valve spring
62
11
Lubrication valve spring
39.4
12
Thickness of shim for accumulator
13
Thickness of shim for pilot

reducing valve
Accumulator
10
WA500-
spring
Repair limit
Transmission
No.lOOl-1599
140kg
1158
/36kg
IReplace
43.7
16.7 kg
60.1
15kg
37
6.2 kg
39.2
5.6 kg
1 mm (pressure per 1 piece: 0.19 kg/cm)

Adjust
3 mm (pressure per 1 piece: 0.26 kg/cma
24-13
0
TRANSFER
Tl
13
9
17
425F138
24-14
WA500- 1
Unit:
mm
Out-side diameter of idler shaft (Rear)
Out-side diameter of output shaft bearing
Out-side diameter of output shaft
WA500- 1
24-15
DRIVE SHAFT
425F144
NO.
torque of front
shaft mounting bolt
drive
Tightening torque of front

shaft mounting bolt
drive
3 ~_ Tightening torque of front

shaft mounting bolt
drive
11.5 * 1 .O kgm
Tightening torque of front

shaft mounting bolt
drive
14.5 + 1 .O kgm
11.5 t 1 .O kgm
I
14.5 i 1 .O kgm
Tightening torque of center support

mounting bolt
56.0 ?:6.0 kgm
Tightening torque of center Idrive

shaft mounting bolt
14.5 r 1 .O kgm
Tightening torque of center

shaft mounting bolt
drive
11.5 ?:1 .O kgm
Tightening torque of center drive

shaft mounting bolt
11.5 * 1.0 kgm
Tightening torque of center drive

shaft mounting bolt
14.5 2 1 .O kgm
10
Tightening torque of rear drive

shaft mounting bolt
14.5 f 1 .O kgm
11

shaft mounting bolt
11.5 * 1 .O kgm

shaft mounting bolt
13

shaft mounting bolt
14
Tightening torque of upper drive

shaft mounting bolt
15
Tightening torque of upper drive

shaft mounting bolt
24-16
Remedy
Criteria
Check item
Retighten
11.5 * 1 .O kgm
14.5 * 1 .O kgm
14.5 i 1.0 kgm
I
I
11.5 + 1 .O kgm
WA500-
CENTER
SUPPORT
425F143
Unit:
:
Check item
No.
Criteria
Shaft
1
Standard
clearance
Clearance
limit
Hole
Clearance between case and bearing

140
-:.018
-0.036
-0.061
-0.018
-0.061
-0.015
130
-:.OlS
-0.036
-0.061
-0.018
-0.061
Clearance between coupling shaft

and bearing
80
+0.051
+0.032
0
-0.015
0.032
0.066
0.029
Clearance between coupling shaft

and bearing
75
+0.051
+0.032
-:.015
0.032
0.066
0.029
Clearance between case and bearing
Standard size
i:
3
Remedy
Tolerance
Standard
size
mm
Tolerance
-0.015
Replace
Repair limit
Wear of oil seal surface
95
0
-0.087
-0.18
Wear of oil seal surface
105
-:.087
-0.18
End play of coupling shaft
Tightening torque of coupling

mounting bolt
Tightening torque of mounting bolt
Repair
chrome
plating or
replace
Preload max. 0.4 kgm
Replace
95 i: 10 kgm
-
WA500-
Retighten
6.7 ? 0.7 kgm
24-17
DIFFERENTIAL
(l/2)
il
Section A -
r--r
ill
A
12
425F145-1
WA500-1
Unit:
No.
Check item
Criteria
I
Standard
size
Clearance of bearing outer lace

in differential gear assembly
Tolerance
Shaft
Hole
Remedy
Standard
clearance
Clearance
limit
180
0
-0.025
+0.054
+0.014
0.014 0.079
Clearance of side bearing inner

lace in differential gear
assemblv
Clearance of outer lace of

pinion shaft bearing
171.45
+0.025
0
+0.026
-0.014
0.026 -0.039
Clearance of inner lace of

76.2
+0.064
+0.038
+0.013
0
-0.025
-0.064
Clearance of inner lace of

76.2
+0.030
+0.011
+0.013
0
0.002 -0.030
Clearance of outer lace of

pilot bearing
120
-:.015
+0.034
+0.012
0.012 0.049
pilot
Clearance
bearing
of inner lace of
55
+0.039
+0.020
-0.010
-0.025
cage
Clearance
carrier andbetween
differential
210
-0.060
-0.020
+0.010
+0.046
0.0300.106
-
differential
Clearance between
pinion bushing
spider and
40
-0.050
-0.025
+0.085
0
0.0250.135
-
10
Backlash of bevel gear
11
Backlash of differential
12
End play of pinion gear
131
F ree rotating torque of bevel gear
14
Preload of bevel gear
15
Rear face runout of bevel gear
16
Standard thickness of shims

for stop shaft
-0.030
-0.064
-
Replace
0.30 - 0.41
gear
0.30 - 0.41
Max. 0.11
Max. 0.85 kgm
Max. 800 kg
0.1
Clearance a + (0.1 * 0.05)
WA500-1
24Li9
mm
DIFFERENTIAL
(Z/2)
12
\
11
10
/
425F146-1
WA500-
Unit:
mm
Thickness of side gear washer
ightening torque of mounting
56.0 + 6.0 kgm

bolt
94.5 f 10.5 kgm

Retighten

bolt (for Fl
28.5 f 3.0 kgm

bolt (for F)
28.5 + 3.0 kgm
11

bolt
28.5 f 3.0 kgm
12

bolt
94.5 t 10.5 kgm
13

bolt
,o
WA500-1
1st step:
2nd step:
0.4 * 0.1 kgm (when measuring clearance (no shim))

11.5 c 1 .O kgm (shim installed)
2&21
AXLE MOUNT
425F148
\
L..
T
Section
A - A
)_
425F149
24-282
WA500- 1
Unit:
mm
Clearance of shaft and hole

Front support side
Clearance of shaft and hole
Thickness of wear plate
Thickness of wear plate
81 1.5
WA500-
24-23
0
FINAL
DRIVE
Clearance between planetary

shaft and bearing
tween p anet gear
9 + 3.5 kgm
24-24
0
WA500-1
40 STEERING
SYSTEM
STEERING SYSTEM
41 STRUCTURE
AND
FUNCTION
General ...............................
Hydraulic circuit for steering ............
- Hydraulic circuit diagram for steering . .
- Operations of steering valve ..........
Steering control system ................
- Steering valve ......................
- Steering relief valve .................
. Safety valve (with suction valve) ......
- Operation of demand spool ..........
- Two-way restrictor valve ............
. Rotorseal ..........................
Steering cylinder .......................
Steering column and gear box ...........
Steering linkage .......................
Steering pump ........................
Center hinge pin .......................
WASOO- 1
.
.
.
.
.
41- 2
41- 4
41- 5
41- 6
41- 8
41- 8
41-10
41-11
41-12
41-15
41-16
41-17
41-18
41-19
41-20
41-21
41-1
GENERAL
OUTLINE
.
The oil from

valve
hydraulic
tank
(2) by hydraulic
gear box,
pump
(5) and
When
steering
steering
valve
cylinder
(2)
(2)
is actuated,
and
oil
(8) and the
flows
steering
wheel
by
is operated,
steering
drag link,
column,
and link,
the
movement
universal
and actuates
is
joint,
steering
When steering
oil
which
control
wheel
enters
is not
steering
being
valve
operated,
(2) flows
is
all the
to main
valve.
valve (2).
425FlOO
41-2
to
actuated.
(6).
When steering
transmitted
(3) is sent to steering
and steering
WA500- 1
: Rightturn
c=7:
Left turn
FO425001
A*
1.
Steering cylinder
5.
Hydraulic pump
2.
Steering valve
6.
Steering pump and POC pump
3.
Hydraulic tank
7.
Two-way restrictor valve
4.
Switch pump
8.
Steering cylinder
WA500- 1
41-3
HYDRAULIC
CIRCUIT
FOR STEERING
425FO76
In
neutral,
Therefore,
the
steering
wheel
is not
operated.
steering spool (3) does not move.
motion
of demand
engine is running
spool
The oil from the steering pump flows port A and
further
the oil from
from the steering pump.
the switch pump flows into port B.
Some of the oil from the hydraulic

the work
equipment
circuit
pump flows into
and the rest of the oil
(2)
The merged oil flows to steering spool (3).

ever, since the steering valve is in neutral,
pushes check valve (I) open to flow into port B and
does not flow into the cylinder,

through port t.
41-4
that
the
The merged oil
flows into port A and merges with the oil
merges with the oil from the switch pump.
(The
indicates
at low speed.)
Howthe oil
but into the drain
WA500-
HYDRAULIC
CIRCUIT
DIAGRAM
FOR STEERING
Neutral
Bf
1
A
\(
f1
/
M-
To main control valve
_J
F42101006
1.
Check valve
7.
Steering valve
13.
Safety valve (with suction)
2.
Demand spool
8.
Hydraulic tank
14.
Steering cylinder
3.
Steering spool
9.
Oil filter
15.
Hydraulic pump
4.
Steering pump
10.
Breather
16.
Switch pump
5.
11.
Oil cooler
17.
Relief valve
6.
12.
18.
Orifice
WA500- 1
41-5
OPERATIONS
OF STEERING
VALVE
Turning right
01 valve
425 iF077
When
the
steering
steering
spool
wheel
is turned
to the
right,
(3) moves to the right through
the
activated control linkage.

flows
into
port
valve and merges with
steering
pump.
41-6
equipment
switch
B and port A through
demand
The
Then,
rod through
Some of the oil from the work

pump
spool (3).
the L.H. cylinder
the oil from
port
the oil flows into the bottom
of
and the sides of the R.H. cylinder

C in the spool,
making a R.H.
turn.
the
The oil from the L.H. and R.H. cylinders is drained
the
from
merged oil flows to steering
two-way
restrictor
valve (5) through
port D
in the steering spool.
WA500- 1
Turning left
425FO78
When
the
steering
steering
spool
(3)
wheel
is turned
moves to the
activated
control
the work
equipment
linkage.
Some
to
the
left through
B and port A through
the
of the oil from
the demand
spool (2) and
merged oil flows to steering spool (3).
oil
the
switch pump flows into port
merges with the oil from the steering pump.
WA500-
left,
The
Then, the
flows
from
two-way
side of the
bottom
L.H.
restrictor
cylinder
valve (5)
into
rod
and into the
of the R.H. cylinder through
port D in the
spool, making a L.H. turn.

The oil from the L.H. and R.H. cylinders is drained
from
two-way
restrictor
valve (6) through
port C
in steering spool (3).
41-7
STEERING
STEERING
CONTROL
SYSTEM
VALVE
425FO64
A. To steering cylinder
E.
From steering pump
B. To hydraulic circuit
F.
From switch pump
C. To steering cylinder
G. To hydraulic tank
D.
41-8
From hydraulic pump
WA500- 1
Section A - A
Section B - B
Section C - C
425FO65
WA500-
I.
Demand spool
5.
Lever
2.
Check valve
6.
Relief valve
3.
Orifice
7.
Valve body
4.
Steering spool
8.
41-9
STEERING
RELIEF
VALVE
1.
Main valve
2.
Valve seat
3.
Pilot poppet
4.
Spring
5.
Adjustment screw
Function
.
The steering
relief
valve is inside the steering
When
the
steering
stroke
and abnormal
sent from
the
This prevents
(The relief
cylinder
pressure
pump
valve.
reaches the end of its

is generated,
is relieved
through
the oil
this valve.
damage to. the pump or circuit.

valve sets the maximum
pressure of the
circuit.)
Operation
Port A is connected
C is connected
through
to the pump
to the drain
the orifice
B. Pilot poppet
circuit,
circuit.
in main valve
(3) is in contact
and port
The oil passes
~~~
b
(I) and fills port
with
valve seat (2).
56OBFO7
When the pressure inside port

pressure
set
by
the
pilot
poppet
port
B escapes from
poppet
A and B reaches the

spring
(set pressure),
(3) opens and the hydraulic

port
D to port
C.
pressure at
This lowers
the pressure at port B.
When
the pressure
main
valve
between
opened
at port
(1) generates
port
and
port
B drops,
a difference
B.
Main
the orifice
of
in pressure
valve
(1)
is
56OBFO72
by the pressure at port A and the oil at port
A is relieved.
41-10
WA500- 1
SAFETY
VALVE
(with suction valve)
1. Suction valve
2.
Main valve
3.
Main valve spring
4.
Pilot piston
5. Suction valve spring

6.
Valve body
421 F045
Function
- The safety valve (with suction

If shock
der
when
(with
valve)
causes any abnormally

the
suction
protects
is in the main valve.
high pressure in the cylin-
main
valve
valve)
releases the abnormal
the cylinder
is at neutral
from
the safety
valve
pressure
and
B is the drain
cir-
damage.
Operation
As a safety valve
* Port A is the cylinder
circuit
and port
cuit.
The pressure oil in port
in the pilot
piston.
fice consisting
(4).
The
pilot
nut.
a hole
an ori-
is secured
diameter
If abnormally
tion
valve
(cross-sectional
of dz>d,>ds>d4.
A, the suc-
421 F046
because of the relationship
d3>d4
in port A and
pressure on the main valve (2) is equiva-
to the area difference
between
pressure goes up to the poppet

the poppet
piston
valve by a lock
high oil pressure occurs in port
C, the hydraulic
lent
to the safety
(1) is not actuated
dzX.
However,
(2) and the pilot
of the cross section
area) gives a relationship
A flows
of the mainvalve
piston
The
to port D through
It also flows to port C through
is actuated,
ds and d4.
spring force
If this
(set pressure),
and the oil in port
A flows
into
port B.
As a suction
valve
If negative
negative
pressure is generated
pressure,
with
each other.
port
E.
Hydraulic
between
because
pressure
equivalent
is applied
of the tank pressure in port

hydraulic
and hydraulic
(1).
If the
in port
hydraulic
to
42 1 F047
to the safety
valve because
E.
pressure
pressure a
pressure
pressure)
D also has
D and A are connected
The tank pressure in port B is applied
d2 and dl
Therefore,
in port A, port
port
acts to open the valve
acts to close the suction

drops,
pressure a
(approaching
valve
negative
becomes smaller than oil
pressure e.
When
a
oil
pressure
+ valve spring
becomes
(5) force,
larger than
the suction
oil pressure
valve (1) opens,
causing the oil to flow from
port B into port A. This pre-
vents negative
building
WA500-
pressure from
421 F048
up in port A.
41-11
OPERATION
OF DEMAND
SPOOL
Engine running at idling when turning to the left
The oil from the steering pump (4) flows into port
As its flow increases, the oil pressure at port C rises
A and the oil from the switch pump (16) flows into
because of orifice b in port A, and exceeds the force
port B.
of spring (2A).
The oil from
the work equipment
pushes
Then,
the direction
Then, the oil flows into port B and merges with the
the oil from the hydraulic
oil
work equipment
delivered
from
the
switch
pump
(16).
The
marked +
demand spool (2) moves in
check valve (1) open because the circuit is closed.
. For this reason, some of

pump (15) flows into the
circuit through port D.
merged oil then flows into port A and merges with
Thus, all the oil delivered from
the oil delivered from the steering pump (4).
(4) and the switch pump (16) plus some of the oil
Then,
the merged oil flows into port C through orifice a in
delivered
demand spool (2).
the steering cylinder.

From steering
cylinder
from
the hydraulic
the steering pump
pump
(15)
flow into
To steering
cylinder
425FO73
41-12
WA500- 1
Engine
running at medium
speed when turning
to the
left
.
more than that when the engine is running at low
speed, the oil pressure at port C rises because of
port B.
pump
The pressure of the oil from the hydraulic

(15)
increases because the circuit
is closed
and pushes check valve (1) open, overcoming

spring force in the valve.
the
Thus, the oil flows into
orifice b in port A, and exceeds the force of spring

(2A).Then
marked
demand spool (2) moves in the direction
. For this reason, all the oil from the
hydraulic
pump (15) plus some of the oil from the
port B and merges with the oil delivered from the
switch
switch
circuit through port D.
pump
(16).
Then,
the merged oil further
pump
(16)
flow
into the work
equipment
flows into port A and merges with the oil delivered
Ail the oil delivered from the steering pump (4) and
from the steering pump (4).
some of the oil delivered from the switch pump (16)
The merged oil flows through

spool (2) into port C.
orifice
a in demand
flow into the steering cylinder.
As the oil flow has increased

From steering
cylinder
To steering
cylinder
425FO74
WA500-
41-13
Engine running at high speed when turning to the left

.
more
medium
that
when
the
engine
is running
at
speed, the oil pressure at port C further
rises because of orifice
port B.
b in port A, exceeding the
force of spring (2A). Therefore,
the demand spool is
its pressure because the circuit is closed and pushes
further
marked
check valve (I),
this reason, the circuit
The
valve.
with
oil
from
the hydraulic
pump
(15)
increases
overcoming the spring force in the
Thus, the oil flows into port B and merges

the oil from
the switch pump
(16).
Further,
the merged oil flows into port A and merges with

The
merged oil flows into port C through
a in demand
spool (2).
As the oil flow
from
moved in the direction
the switch
draulic
pump
pump (16)
(15)
work equipment
is closed.
flow
. For
Thus, all the oil
and that from the hy-
through
port
D into the
circuit.
All the oil from the steering pump (4) flows into the
the oil from the steering pump (4).
than
orifice
steering
cylinder.
increases
From steering
cylinder
To steering
cylinder
~~~$gg;
p------Q
: .. . : ,.
To main control
valve
425FO75
41-14
WA500-
TWO-WAY
RESTRICTOR
VALVE
1.
Body
2.
Spring
3.
Poppet
425FO70
Function
To reduce the shock

machine
when
caused
by the inertia of the
the steering is operated,
an orifice
is installed in the oil line of the return circuit from

the cylinder.
oil,
and
This applies pressure to the returning
regulates
the
movement
of the cylinder
piston.
Operation
When the oil is flowing

spring (2) and flows
to arrow
through
, it pushes
the orifice,
and be-
tween poppet (3) and the poppet seat.

To cylinde
Q
425FO71
When the oil is flowing to arrow

only
from
orifice
, the oil flows
a inside the poppet
(3), so the
flow is controlled.
ForIll
cylinder
*
425FO72
WA500-
41-15
ROTOR
SEAL
Section A - A
Section B - B
421FO44
41-16
1.
Shaft
2.
Lever
3.
Body
4.
Steering spool
WA500-
STEERING CYLINDER
I /
425FO79
1.
Head
2.
Rod
Specifications
Cylinder bore:
110 mm
Rod diameter:
55 mm
3.
Cylinder
4.
Piston
Cylinder max. length:
5.
Piston nut
Cylinder
Stroke:
486 mm
min. length:
1329
mm
843
mm
Width across flats of piston nut: 55 mm
WA500-
41-17
STEERING
COLUMN
AND
GEAR BOX
Outline
The steering gear is a recirculating

In this
thread
type
of
gear there
ball type
gear.
is a round-bottomed
cut in the steering shaft.
There are several
Balls (6) move in the nut groove of the shaft together with the rotating of the steering wheel.
pass from the end of the nut through
balls (6) between the nuts which slide in this thread.
on the
Ball nut (5) moves up and down in accordance with
circulated.
the rotation
outside,
and return
to the
nut to be re-
of the steering shaft, and turns center
shaft.
Y
Section A - A
Section D - D
423FO72
Section B - B
41-18
Section C - C
1.
Steering wheel
6.
Ball
2.
Center shaft
7.
Worm
3.
Steering column
8.
Tilt lever
4.
Gear box
9.
Pitman arm
5.
Ball nut
They
the passage
WA500- 1
STEERING
LINKAGE
Section A - A
\,
\ _.
._
Section B - B
425FO62
WA500-
1. Gear box
5.
2.
Link
6.
Link
3.
Steering valve
7.
Pitman arn-
4.
Steering column
Drag link
41-19
STEERING
PUMP
Steering pump
POCpump
SAR(3)-080
SARI1 j-014
425FO63
Specification
Model:
delivery:
(Front pump)
80.0 cc/rev
Max. delivery pressure: 210 kg/cm2
SAR(l)-14
Theoretical
2.
Front cover
3.
Gear case
4.
Rear cover
5.
Driven gear
delivery:
The steering
pump is installed to the torque
verter case.
It is driven by engine power and sup-
(Rear pump)
The steering pump sucks in oil from the hydraulic

tank, and sends the oil to the steering valve.
14.5 cc/rev
Max. delivery pressure:
210 kg/cm2
Max. speed: 3500 rpm
41-20
con-
plies oil to the steering system.
Max. speed: 2500 rpm

Model:
Drive gear
Outline
SAR(3)-80
Theoretical
1.
WABOO- 1
CENTER HINGE PIN

Outline
.
The front
frame
nected through
(5).
the
(6).
(3) and rear frame
The steering cylinders
left and right front
the cylinders
(4) are con-
a bearing by the center hinge pin

are connected
to
and rear frames, so when
are operated,
the frame bends at the
middle to give the desired angle, that is the desired

turning radius.
425F116
1. Front axle
2.
Rear axle
3.
Front frame
4.
Rear frame
5.
Upper hinge pin
6.
Lower hinge pin
WA500- 1
Section A -
Section B - B
425F117
47-21
STEERING SYSTEM
42
TESTING
AND
ADJUSTING
.. .......
.
Measuring steering wheel play . . .
Standard
Measuring
operating
Operating
The following
shooting
1.
2.
precautions
or during
are necessary when using the Standard
wheel
.....
time of steering
wheel
leaving the plant,

of use.
standard
they
or when estimating
values in these tables
values for the machine
Therefore,
..
.
..
..
..
..
..
..
.
.
.
.
.
.
.
.
.
.
42-4
42-5
42-6
42-7
42-8
. . . . 42-9
Value tables to make judgements
as target values when repairing

The
during
trouble-
should
be used
testing and adjusting.
The values in these tables are based on the values for new machines
standard
force of
.....
.
Testing steering linkage . . . . . .
Adjusting steering linkage.
.....
Steering oil pressure . . . . . . . . .
Troubleshooting
..... ......
steering
. . . 42-2
. . . 42-2
. . . . 42-3
value table
should
for
judgement
when shipped
be used as reference
wear after a period

when
troubleshooting
from the plant,

in combination
so they
are estimated
values
based on the
and on the results of various tests.

with
repair and operating
records
when making
judgements.
3.
These standard
value tables must not be used for standard
values when judging
claims.
In addition,
do not use
_I
WA500-1
4%1
STANDARD
VALUE TABLE
Unit
Steering wheel
Road surface:
* Steering wheel play

. Steering wheel operating force
* Operating time of steering wheel
horizontal, dry, paved surface
Max. 3.0
sec.
3.8 - 4.3
Max. 6.5
2.8 - 3.1
Max. 4.7
mm
S-12
kg/cm2
210:;
210+10
-8
Machine posture:
Specified pressure
Hydraulic temperature:
45-555OC
Main relief oil pressure
Engine speed:

No.
20 - 100
1.5 - 2.0
Tire inflation pressure:
Clearance between front and rear frame
Steering oil pressure
20-70
kg
Facing straight
Steering linkage
mm
(High idling)
Permissible value
Flat
45 - 55C
(Low idling)
Standard value
High idling
AND
ADJUSTING
Tool Name
Remarks
Part No.
Steering wheel operating force
Push-pull scale
Steering wheel operating play
Convex scale
Commercially available
Steering wheel operating time
Stop watch
1 /lO second
Clearance between front frame

and rear frame
Convex scale
Steering oil pressure
Hydraulic tester
799-l 01-5000
0 - 250 kg/cm
When carrying
Then apply
42-2
0
adjusting
lower the bucket
the parking
When installing
tank.
A
A
out testing,
bar on the frame,
or removing
measurements,
The oil in the circuit
or troubleshooting,
to the ground,
stop the machine
0-25kg
on level ground,
install
the safety
brake and block the tires.

gauges, loosen the oil filler
Then operate the control
When taking
79A-262-0020
cap slowly
to release the pressure inside the hydraulic
do not allow unauthorized
is hot, so be careful
piping.
not to get burnt.
WA500-
MEASURING
*
Measurement
STEERING
WHEEL
PLAY
condition
- Engine speed: Stop

+ Machine posture: Facing straight
Unit:
Standard
Item
Steering
HOW
wheel
TO
Permissible
value
20-70
play
20 -
mm
value
100
MEASURE
1.
Turn
the
steering
counterclockwise
the
neutral
Put
mark
wheel
two
position
(1)
lightly
or three
of
on the
the
outer
clockwise
and
times
and confirm
steering
mechanism.
frame
of the
l-J---Play
vehicle
monitor.
2.
Turn
the
steering
steering
wheel
steering
valve
wheel
starts
to
clockwise,
become
lever starts to move),
on the steering wheel in line with
and when
heavy
the
(when
the
make mark
mark
(2)
(1).
419F302A
3.
Turn the steering wheel counterclockwise,
and when
the steering wheel starts to become heavy
[when the
steering
valve
lever starts to move),
on the steering
wheel
measure the distance

(2) and mark
TESTING
Inspect
AND
in a straight
mark
(I).
line between
mark
ADJUSTING
linakge
(4) and (5) for looseness
If any, adjust the linkage.
1.
Loosen lock nuts (6) on the steering gear box.
2.
Then,
adjust
(3)
Then
(3).
the steering
and free play.
in line with
make mark
by turning
adjustment
sdrew
(7)
in
or out.
*
To decrease the free play, turn the adjustment
screw
(7) in. to increase the free play, turn the screw out.
__
J_
_423F311
WA500-1
4&3
MEASURING
*
OPERATING
FORCE OF STEERING
WHEEL
*
-
Road surface:
Flat,
Hydraulic
horizontal,
oil temperature:
Tire inflation
Engine speed:
dry, paved surface.

45 to 55C
pressure: Specified pressure.

Low idling (bucket unload).
Unit:
Item
Standard
Force of steering wheel
value
Permissible
1.5 - 2.0
mm
value
Max. 3.0
Special tool
Part No.
79A-262-0020
Part Name
Oty
Push-pull scale
Measuring procedure
1.
Hook push-pull scale A to the knob of the steering

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

*
After
starting the engine, raise the bucket about
400 mm and remove the safety bar.

3.
Set push-pull scale A at a tangent, and read the value

when the steering wheel is moving smoothly.
*
Do not read the value at the time the steering

425PO44
wheel starts to move.
42-4
0
WA500-
OPERATING
*
*
*
*
*
TIME
OF STEERING
WHEEL
Road surface:
Flat, horizontal,
Hydraulic
oil temperature:
Tire inflation
dry, paved surface.

45 to 55C
Engine speed:
Low idling and high idling.
Unit:
sec.
425PO45
~
Special tool
Part No.
A
Part Name
/ Qty
Stop watch
Measuring procedure
1.
Start the engine.

*
After
starting the engine, raise the bucket about
400 mm and remove the safety bar.

2.
Turn
the
steering
wheel
so that
the
machine
is
turned fully to the left or fully to the right.

3.
Measure the time taken for the steering wheel to be

turned to the right (left) to the full lock position.
*
Turn the steering wheel as fast as possible without forcing it.
Measure at low idling and high idling, and when

turning to the right and to the left.
WA500-
42-5
8
TESTING
*
Measurement
Hydraulic
STEERING
LINKAGE
condition
temperature:
Road surface:
45 to 55C
Flat, horizontal,
Tire inflation
pressure:
dry, paved surface.
Specified
Engine speed:
1200 rpm
Center
lever:
Square
Pitman
arm:
with
pressure.
the machine
Prependicular
to
the
center
line.
machine
rear
frame.
Unit:
Measuring
procedure
1.
the
Start
engine
to set the front

2.
Loosen
and
mounting
and check
operate
the
steering
and rear frames in a straight

bolt
(1) and nut
play of ball joint
sec.
wheel
line.
(2) of linkage
(3). rod (41, and center

425F205
lever bearing (5).

3.
Check
that
the
to the center
*
center
The steering spool should
4.
Check that the pitman
5.
Start
left
lever
stoppers
to the full
a between
pitman
the steering
wheel to the
lock position.
frame
Check that
and rear frame
value.
14 * 2 mm
measuring
justment
When
angles
be at neutral.
the front
is the standard
Clearance a:
When
is at right
arm (7) is perpendicular.
the engine and turn

and right
clearance
(6)
line of the machine.
the clearance
screw (8) should
to the right,
be in contact
with
adthe
arm.
measuring
justment
screw
the pitman
clearance
to the
left,
be in contact
ad-
423F313
with
arm.
When measuring
(9) and
the
(10) should
the clearance,
(11) do not
in contact
adjustment
with
screws
valve lever
respectively.
42-6
8
WA500-
ADJUSTING
*
Measurement
STEERING
LINKAGE
condition
45 to 50C
* Road surface: Flat, horizontal, dry, paved surface.
- Tire inflation pressure: Specified pressure.
Set
the
safety
machine
facing
Adjustment
Disconnect
2.
Adjust
steering
linkage
linkage
(2)
the
front,
(8) is at the neutral
(I) from the pitman
so that
angles to the center
fit
the
center
lever
(9) is at right
line of the chassis when valve lever

position.
in Step 2, move the steering
In the condition
arm.
valve
lever
to the end of its stroke,
and when the valve lever con-
tacts
(4),
stop
bolts
(3)
secure in position
*
4.
to
procedure
1.
3.
straight
bar, and stop the engine.
Always
Adjust
and
turn
back
l/2
turns
nd
with the nut.
adjust the valve lever first.
the length
is perpendicular
of linkage
to the front
(1) to the pitman
(1) so that
frame,
pitman
then connect
arm (7)
linkage
arm.
425P053A
5.
Remove the safety
6.
Start
the engine,
and right,
stopper
frame
bar.
turn
and adjust
the steering wheel fully

so that
the pitman
bolts (5) and (6) when the clearance

and
rear
frame
stoppers
(clearance
to the left
arm contacts
of the front
a on the
previous
page) is 14 ? 2 mm, then secure with the nut.
making
After
the above adjustment,
check again that
the value is standard.
425PO55
WA500-1
42-7
8
STEERING
*
Measurement
OIL PRESSURE
condition
- Hydraulic temperature:
45 to 55C
- Engine speed: High idling
Unit:
Standard
value
Item
Main
relief
oil
pressure
kg/cm2
Permissible
value
210;;
425PO56
Special tool
Part
799-l
Procedure
No.
01-5000
Loosen
the
inside
the
Hydraulic
for measuring
pressure
oil
steering
maining
Part
wheel
tester
cap
slowly
hydraulic
several
times
1.
Fit safety
bar (1) on the frame.
2.
Remove
plug
for
to
tank.
release
Then
the
operate
to release the
(2)
Oty
main relief pressure
filler
the
Name
re-
piping.
measuring
the
right
turn
steering circuit.
3.
Install hydraulic
4.
Start
tester A to the measuring
the engine
steering
wheel
and run at high

to
the right
idling.
and measure
port.
Turn
the
the pres-
sure when the relief valve is actuated.

+
When
removing
steering
the
circuit,
plug
turn
(3)
the
for
the
steering
left
turn
wheel
to
the
hy-
the left and measure.
Always
draulic
stop
the
engine
before
adjusting
pressure.
1.
Stop the engine.
2.
Remove cap nut (4) of the relief valve.
3.
Loosen
lock
nut
(5).
then
turn
adjustment
screw
(6) to adjust.
Amount
of
adjustment
for
1 turn
of
adjust-
ment screw.
1 turn:
Approx.
Adjust
the set pressure as follows.
To INCREASE
To DECREASE
If
the
curately,
relief
24.8 kg/cm
pressure, TIGHTEN
pressure,
pressure
LOOSEN
cannot
screw.
screw.
be measured
ac-
do not try to adjust the pressure.
5
423F315
4&8
WA500-
TROUBLESHOOTING
Steering
wheel does not turn
2.
. _ _ . . _ . . . . . . . . . . . . 42-10
. _ . . . . . . . . . 42-10
Steering wheel is sluggish . . . . . . _ . . . _ _ . 42-11
3.
Steering
wheel moves unsteadily
Troubleshooting
1.
table
is subjected
4.
Before
carrying
page 22-12,
RENCE
out
METHOD
OF TROUBLE
WA500-
the
troubleshooting
OF READING
in this section,
TROUBLESHOOTING
direction
TABLE
in one
when traveling
Left and right turning
read PRECAUTIONS
or
. . . _ . . . . . . . 42-l 2
Machine tends to turn naturally

particular
5.
to large shock
. . . . . . 42-12
. . . 42-12
radii are different
WHEN
TROUBLESHOOTING
page 22-14 and PREVENTING
RECUR-
page 22-16.
4%9
TROUBLESHOOTING
1.
TABLE
Steering wheel does not turn.

Did
the
steering
+ Damage
wheel
questions.
suddenly
to equipment
cease
to turn?
in steering circuit.
* Did steering wheel show signs of being sluggish for

circuit
some time?+
or faulty
Worn
parts in steering
seal.
Checks before troubleshooting.
Is
oil
level
in hydraulic
tank
and type
of oil
satisfactory?
Is there any damage to the steering gear box or

the steering linkage?
- Has the safety bar been removed from the frame?

- Is the steering lihkage properly adjusted?
Steering wheel cannot turn left or right.
Fault of item 1 and also work equipment does not

operate normally.
I Ol I I 11~1
Steering wheel Mn only turn to either left or right.
Steering wheel is sluggish and does not turn properly.
Oil pressure in steering circuit does not rise at all
Because the
steering
ment
are intimately
circuit
check the operation
circuit
and the
related
work
equip-
to each other,
of the work equipment
if the
steering behaves abnormally.

X
A
426
O
:
:
Rapalce
Adjust
A:
C
Repair
Clean
WA500-
2.
Steering wheel is sluggish.

- Did the steering
wheel
questions.
suddenly
become
slug-
guish?
Damage to equipment
in steering circuit.
- Did the steering wheel show signs of being sluggish
for
circuit
some
or faulty
time? + Worn
parts
in
steering
seal.
* Is oil level in hydraulic
tank
and type
oil satis-
factory?
* Is there any abnormality

mounting
part,
in the steering gear box
steering
column
or
linkage?
+ Is the adjust of the steering valve control
lever
correct?
- Is there any oil leakage from

hose, valves, cylinders,
Is there any seizure

and bushing
cylinder
the
oil
pressure
etc.?
between
of the center
the pin, pin bearing
hinge and the steering
pin and bushing?
* Check tire inflation
pressure.
Fault check
- Measure the operating

wheel
machine
check
criterion
force
and also the time

when
the
the steering
results
table
of the steering
required
to turn
is operated,
against
to see whether
the
the
then
judgement
or not there
is
any abnormality.
Steering wheel is sluggish in both left and right directions.
Steering wheel is sluggish in one of left and right directions.
Steering wheel is particularly sluggish at low engine speed.
Boom lifting speed is insufficient when engine is at full

throttle.
Steering wheel is sluggish and jerky.
Hydraulic oil overheats.
Steering circuit pressure is low.
Oil pressure in return side piping of steering cylinder rises.
0
0
0
0
00

WA500-
42d
3.
Steering wheel moves unsteadily
or is subjected to
large shock.
* Is oil level in hydraulic
tank
and also oil type
satisfactory?
Is there any damage to the steering

mounting
part, steering column
Is there
any
play
in the center
ring or steering cylinder
* Does tire inflation
gear box
or linkage?
pin hinge
bear-
pin bushing?
pressure fluctuate?
Fault check
Operate
check
the
the
wheel
loader
conditions
in a safe place
under
which
and
the steering
wheel becomes unsteady.

*
If,
in
addition
to the
there
unsteady,
sluggishness,
are
steering
other
refer
etc.,
to
wheel
faults
item
being
such
as
2 Steering
wheel is sluggish.
I I
1
Problems
-----.-
Remedy
NO.
Machine body is unsteady when traveljng on bumpy

road surface.
aA
x
X
0
if suddenly turned
4.
Machine body becomes unsteady when traveling at high speed.
Machine body becomes unsteady during engine starting.
Machine
tends to turn
naturally
0
0
in one particular
direction when traveling.

Cause:
Faulty
*
*
5.
steering valve
Incorrect
Faulty
positioning
of spool
safety valve
Oil leakage in steering

Does tire inflation
cylinder.
A:
Repair
X : Rep&e
C : Clean
A : Adjust
pressure fluctuate?
Left and right turning radii are different.

Cause:
Incorrectly
Left
adjusted
and right
steering
steering
linkage.
balance,
lock
posi-
tion of stopper.
(Valve
relief
completion
426
2
noise
can
be
heard
upon
of turning.)
WA500-
STEERING
GEAR
BOX
.........
: ...............
Installation
.......................
Disassembly. ......................
Assembly
........................
Removal
STEERING
43-
43-
43-
43-
43-
43-
VALVE
.........................
.......................
Removal
installation
Disassembly and assembly

STEERING
PUMP AND
.............
43-11
POC PUMP
. . . . . . . . . . . . . . . . . . . . . . . . . 43-13
Installation
. . . . . . . . . . . . . . . . . . . . . . . 43-14
Removal
STEERING
CYLINDER
Removal
.........................
.......................
Disassembly. ......................
43-15
Installation
43-l 6
Assembly
43-19
CENTER
43-17
........................
HINGE
PIN
. . . . . . . . . . . . . . . . . . . . . . . . . 43-22
Installation
. . . . . . . . . . . . . . . . . . . . . 43-28
Removal
Take
the following
method
cylinders after reassembling cylinder,

1.
2.
hydraulic
pumps and pipings.

Operate hydraulic
cylinder 4 -
stroke end.
3.
Continue to operate cylinder 3 - 4 cycles until stroke end.
4.
After finishing above steps, keep normal engine speed.

NOTE:
WA500-
After long storage, same procedure is required.
43-l
0
REMOVAL
OF STEERING
Stop the
A!
machine
GEAR BOX



After stopping the engine, turn the steering wheel several

times to the left and right to set the steering valve in
NEUTRAL.
1.
Cover
Remove covers (1) and (2) from under the cab.
2.
Pitman arm
Using puller @
t
Before
, remove pitman arm (3).
removing,
make
match
marks on the sector
shaft of the steering gear and pitman arm.
3.
Steering gear box

1) Loosen lock bolt (4), then pull out column joint
(5)
from steering gear shaft.

+
Make
match
marks
on
the
column
joint
and
steering gear shaft.
2) Remove
mounting
bolts, then remove steering gear
(6).
43-2
0
WA500-
INSTALLATION
1.
OF STEERING
GEAR BOX
Steering gear box

1) Set steering gear box (6) in mounting
position, then
install mounting bolts.

w
Mounting bolt:
2) Align
match
gear shaft,
11.5 f 1 kgm
marks of column joint

and insert joint,
(5) and steering
then tighten
lock bolts
(4).
B
3.
Mounting bolt:
5.7 + 0.7 kgm
Pitman arm
Align
match marks of pitman
arm (3) and sector shaft
(7). install pitman arm.

m
Mounting nut:
19 f 3 kgm
4.
32 mm)
Cover
Install covers (1) and (2) under the cab.
5.
Checking steering linkage

After
completion
of assembly,
check the
linkage and
adjust if necessary.
*
For details, see 42 TESTING
WA500-
AND
ADJUSTING.
DISASSEMBLY
I,
OF STEERING
GEAR BOX
Side cover
1) Loosen lock nut (3) of adjustment
screw (2), then
remove mounting bolts (4) of cover.
2.
:,w *,
Sector shaft
Turn
steering gear shaft
(5) so that sector shaft is in
Be careful
not to damage the thread and bushing of
sector gear when removing.
3.
,, ,~
::,,,:::
~~~~
,,,,,,
:,LjjI,,,,,,,,,,
,,/,,,,,:
:>i:,
,,,,
,-::ro+s
:, ,,\
vertical position, and remove sector shaft (6).

*
,, ,,,
uu,
_,
,,
Rear cover, shaft, ball nut assembly

Remove rear cover (7). then remove shaft and ball nut
assembly (8).
43-4
0
WA500-
ASSEMBLY
1.
OF STEERING
GEAR BOX
Bearing outer race
1) Press fit bearing outer race (10) on gear box (9) and
rear cover (7).
2) Press fit
oil
seals (ll),
(12)
on gear box
and rear
cover.
*
If bushing
(13)
of the
gear box
is badly
worn,
replace the gear box.

&
2.
Shaft,
Lip of oil seal:

ball nut assembly,
Assemble
shaft
then install
&
Grease (G2-LI)
rear cover
and ball nut assembly
(8) in gear box,
rear cover (7).
Shaft, ball nut assembly,
bearing
(14):
Grease (G2-LI)
If there
is any problem
with
shaft (15) or ball nut (8)
of the shaft and ball nut assembly,
replace the whole
shaft and ball nut assembly.

3.
Adjusting
shim
Select
shim thickness
within
standard
so that
starting
First assemble a larger thickness

reduce the thickness
to adjust.
Measure the starting
torque
Standard
WA500-
range for starting
Mounting
torque
of shaft
is
range.
bolt
with
torque:
than necessary, then

torque
wrench
A.
3.5 - 6.5 kgm
(16) of rear cover:
4.5 + 1 kgm
4.
Sector shaft, side cover

Assemble
so that
sector gear is meshed at center
of ball
nut.
*
If bushing
of the side cover (3) is badly worn,
replace
the assembly.
w
5.
Mounting
Adjusting
bolt:
adjustment
1) Temporarily
screw
install
ly and tighten
4.5 + 1 kgm
pitman
adjustment
arm (17). move arm lightscrew (2) so that
backlash
is 0.
2) Turn
adjustment
shaft is within
*
m
6.
Standard
screw
standard
so that
range for starting
Lock nut:
starting
torque
range, then tighten

torque:
of
lock nut.
3.5 - 7 kgm
2.5 + 0.5 kgm
8;;
Plug, dust cover

Pump
in grease through
plug mount,
install
plugs (18)
. .
.+?g
and (19), then install dust cover (20).

6
43-6
0
Amount
of grease:
Grease (G2-LI)
490 g
WA500-
REMOVAL
n!
Stop
OF STEERING
the
safety
machine
and put
the machine
Loosen
sure
from
wheel
Loosen
tank
prevent
1.
plugs
filter,
cap slowly
to release the pres-
tank.
Then
operate
the
lever several times to the
to release the remaining
pressure
in
piping.
(I)
and
(2) at the top
of the hydraulic
the oil inside the tank from
flowing
out.
Cover
Remove bottom
2.
the
to the
moving.
and steering
and right
and install
the bucket
under
the hydraulic
the hydraulic
blocks
the oil filler
inside
steering
left
Lower
brake
!
f-3
on level ground
bar on the frame.
ground
VALVE
Hydraulic
Disconnect
hoses as follows:
hose
(5) between
steering
valve
and main
valve from steering valve.
* Disconnect
cover of cap.
piping
Remove
control
inspection
tube
(6) between
ing cylinder
from
steering valve.
steering valve and steer-
Disconnect
tube
(7) between
hydraulic
pump
and
steering valve from steering valve.
* Disconnect
hose (8) between
switch
pump
ing valve from steering valve.

*
Remove tubes from
WASOO- 1
connectors
of hoses.
and steer-
Disconnect
from
tube
(9) between
steering valve and cooler
steering valve.
- Disconnect
tube
steering cylinder
* Disconnect
(IO)
from
tube
between
steering
valve
and
pump
and
steering valve.
(11)
between
steering
steering valve from steering valve.
3.
Linkage
Remove steering valve linkage
4.
(12) from
steering valve.
Steering valve
Remove
mounting
bolts,
place
valve (13), and pull out from

*
Remove
floor
*
*
Install
the demand
board
below
steering
machine.
spool cover which
is inside the
frame.
eye-bolts
in floor
valve slightly
and pull out.
The steering
valve
and steering
is wet with
valve, raise the
oil, so be careful
not
to let it slip.
Steering valve:
45 kg
WA500-
INSTALLATION
1.
OF STEERING
VALVE
Steering valve
Set steering valve (13) in mounting position, and tighten
mounting bolts.
*
Install eye-bolts
in steering valve and floor,
raise the
valve slightly, and set in mounting position.

*
Install demand spool cover.
After
connecting
hydraulic
piping, tighten mounting
bolts.
2.
Linkage
Install steering valve linkage (12) to steering valve.
*
Check that the steering valve is a tneutral.
Align the key groove correctly.
@EI
Mounting bolt:
Connect
3.2 * 0.3 kgm
hose (8) between switch pump and steering
valve to steering valve.

*
Connect tubes to hoses.
- Connect tube (7) between hydraulic pump and steering valve to steering valve.
WA500-
43-9
0
Connect tube (6). between steering valve and steering

cylinder to steering valve.
Install hose (5) between steering valve and main control valve to steering valve.
4.
Cover
Install bottom
5.
inspection cover of cap.
Refilling with oil

Tighten
plugs at top of hydraulic
tank filter,
and plugs
and pump piping, and add hydraulic oil through oil filler
w
Plug at top of filter:
1.2 + 0.1 kgm
WA500-
DISASSEMBLY
AND
ASSEMBLY
OF STEERING
VALVE
27
425F294
DISASSEMBLY
1.
2.
OF STEERING
VALVE
5.
Remove tube (1).

Remove main relief valve assembly
Remove
case
(2).
1) Remove
3.
Remove
safety
valve
(with
suction
(14),
(15).
* Disassembly
then
and assembly
bolt
(16),
then
spring (18) and retainer
valve) assembly
(3).
remove
Loosen bolt
spool
of spool assembly.
remove
(19) from
(16) with
assembly
retainer
(17),
spool (20).
the spool assembled in
the body.
4.
Remove case assembly

*
Disassembly
(4).
and assembly
6.
of case assembly.
1) Remove covers (5) and (6).
Remove
plate
(21),
then
remove
orifices
(22) and
(23).
2) Remove dust seal (7).

3) Loosen
bolt
(9) of lever
(8), then
(IO).
4) Remove oil seal (11) and bearing
remove
shaft
7.
Remove cover (24), then remove spring (25), washer

(26) and spool (27).
(12) and (13).

8.
Remove
plate
(30) and poppet
(28),
then
Steering demand
WA500- 1
remove
seat (29),
spring
(31).
valve assembly:
55 kg
43-11
0
ASSEMBLY
1.
OF STEERING
Assemble poppet
VALVE
(31) and spring (30) in valve body
(32).
2.
Fit
O-ring
and backup
ring to seat (29)
in valve
body, then fit O-ring and install plate (28).

3.
Assemble spool (271, washer (26) and spring (25) in

valve body, then fit O-ring and install cover (24).
4.
Assemble orifice
(23) and (22) in valve body, then
fit O-ring and install plate (21).

*
Disassembly and assembly of spool assembly.
1) Assemble
retainer
(191, spring (18) and retainer
(17) in spool (20) and tighten bolt (16).

*
Tighten
bolt (16) with the spool assembled in
the body.
5.
Assemble
spool assembly
(15)
in body, fit O-ring
and install case (14).

*
Disassembly and assembly of case assembly
1) Install bearing (13) and (12) and oil seal (11) in

case.
&
Oil seal: Grease (G2-LI)
2) Assemble
lever (8) in case, then fit
key, install
shaft (IO), and tighten bolt (9).

3) Install dust seal (7).
4) Fit O-ring and install covers (6) and (5).
6.
7.
Fit O-ring and install case assembly (4).

Fit O-ring and install safety valve assembly (3) with
suction valve.
w
8.
Fit O-ring and install main relief valve assembly (2).

m
9.
Safety valve: 4.5 f 0.5 kgm
Main relief valve: 8.5 + 1.5 kgm
Fit O-ring and install tube (I).
43i2
WA500-
REMOVAL
n!
OF STEERING
Stop the
safety
machine
PUMP
bar on the frame.

9!
Loosen the oil filler cap slowly to release the pressure inside the hydraulic
left
Then operate the
and right to release the remaining
the hydraulic
tank.
steering wheel and steering lever several times to the

pressure in
piping.
filter,
and
plugs (3) and
(4) of the
pump
piping to

1.
Cover
Remove cover (5).
2.
Hydraulic
piping
1) Disconnect
tube
(6)
between
steering
pump
and
pump
and
hydraulic tank at steering pump end.

2) Disconnect
hose
(7)
between
steering
steering valve at steering pump end.

3) Disconnect
hose (8) between
POC pump and POC
strainer at POC pump end.
3.

Remove steering pump and POC pump (9).
Steering pump and POC pump:
WA500-
15 kg
AND
POC PUMP
INSTALLATION
1.
OF STEERING
PUMP
AND
POC PUMP

Set steering
pump
and
POC
pump
(9)
in mounting
position, then tighten mounting bolt.

t
Fit the O-ring securely
in the groove and make sure
2.
Hydraulic
piping
1) Connect
hose
(8)
between
POC
pump
and
POC
strainer at POC pump end.

2) Connect hose (7) between steering pump and steering
valve at steering pump end.
3) Connect tube (6) between steering pump and hydraulic tank at steering pump end.
3.
Cover
Install cover (5).
4.
Refilling with oil

Tighten
plugs (1) and (2) at top of hydraulic tank filter
and plugs (3) and (4) for pump piping, then add hydraulic oil through oil filler to the specified level.
m
43-l 4
0
1.2 f 0.1 kgm
WA500-
REMOVAL
OF STEERING
Stop the
A
.
machine
CYLINDER

Loosen the oil filler cap slowly to release the pres!
;r
tank.
Then operate the
steering wheel several times to the left and right to

release
the
remaining
pressure
in the
hydraulic
piping.
1.
Hydraulic
piping
Disconnect hoses (I) and (2) from cylinder.

2.
Steering cylinder
1) Remove bolt at rod end, then remove pin (3).
2) Remove bolt at bottom end, then pull out pin (4).

+
Check and record the number and thickness of the

shims, and use as a guide when assembling.
3) Sling steering cylinder
(5) with
lever block and re-
move steering cylinder.

*
Be careful not to scratch the cylinder rod.
WA500-
Steering cylinder:
47 kg
INSTALLATION
1.
OF STEERING
CYLINDER
Steering cylinder
1) Raise steering
cylinder
(5)
and
set
in mounting
position.
2) Install pin (4) at bottom end, then install bolt.

3) Install pin (3) at rod end, then install lock bolt.
Use a bar to align the pin holes.

p\ .
*
Never use
your fingers.
Adjust shim so that clearance a becomes standard

value.
Clearance a
: Max. 1 .O mm
425F295
2.
Hydraulic
piping
Connect hoses (2) and (1) to cylinder.

m
Hose nut:
14 Itr 3 kgm
(Width across flats 32 mm)
3.
Greasing
Grease cylinder pins well.
*
Wipe off any grease which comes out.
43-l 6
0
WA500-
DISASSEMBLY
OF STEERING
CYLINDER
ASSEMBLY
Special tools
Set cylinder assembly (I) in tool A.

Raise lock
of
cylinder
head
(2),
then
using tool
B,
remove cylinder head (2) from cylinder.
Pull cylinder
cylinder
*
head and piston rod assembly (3) out from
(4), then lift off.
Oil will come out when the piston rod assembly is

removed from the cylinder, so catch it in a container.
Remove cylinder
5.
(4) from tool A.
Set cylinder head and piston rod assembly in tool A, and

using power wrench
6.
Power wrench:
Socket @
and socket @
, loosen nut (5).
x 16
: Width across flats: 55 mm
Remove nut (5), then remove piston assembly (6), and

cylinder head assembly (7) from rod (8).
WA500-
43-l 7
0
7.
Disassembly of piston assembly

1) Remove wear ring (9).
2) Remove piston ring (IO) from piston (11).
8.
Disassembly of cylinder head assembly

1) Remove snap ring (16), then remove dust seal (17).
125P387A
2) Remove rod packing (1 El), retainer
(14) and snap ring
(15).
3) Remove bushing (19) from cylinder
head
125P388A
(20).
4) Remove O-ring (21) and backup ring (22).
125P390A
43-18
0
WA500-
ASSEMBLY
OF STEERING
CYLINDER
ASSEMBLV
Special tools
Part No.
790-502-I
Part name
001
Oty
Stand
790-l 02-2301
Wrench
790-720-I 000
Expander
796-720-I
Ring
660
Clean all parts, and check for dirt or damage.
Coat the
sliding surfaces of all parts with engine oil before installing.
Be careful
not to damage the rod packings, dust
seals or O-rings when assembling.

1.
Assembly of cylinder head assembly

1) Using push tool,
press fit bushing (19)
on cylinder
head (20).
*
Be careful
not to deform the bushing when pres-
sing it in.
2) Install rod packing
(18),
retainer
(14) and snap ring
(15).
* Be careful to install the rod packing (18) facing in
the correct direction.
,,,
,, ,, ,,,,,
,,~,, ,, ,,,,,,,
423PE5iOA
~
18
125P388A
3) Using
push tool,
install
dust seal (17)
to cylinder
head (20).
5) Install buckup ring (22) and O-ring (21).
*
Do not try to force the backup ring into position.

Warm it in warm water
(50 - 60C)
before fitting
it.
125P390A
WA500-
43-19
0
2.
Assembly of piston assembly
1) Using tool C, expand piston ring (10).

*
Use the piston ring on the expander

handle 8 -
and turn the
10 times to expand the ring.
2) Remove piston ring (IO) from tool C, and assemble

on piston (11).
3) Fit tool D on piston ring, then using clamp @
, con-
tact piston ring.

*
Part No. of clamp @
: 07281-01279
4) Assemble wear ring (9).
3.
Set piston rod (8) in tool A.
4.
Assemble cylinder
head assembly (7) and piston assem-
bly (6) no rod, then fit nut (5).
5.
Using power wrench

m
and socket @
tighten nut (5).
Piston nut:
Power of power wrench 0
Width across flats of nut (5)
Tightenins torque of nut
43620
x 16
55 mm
145 t 14.5 kam
WA500-
8.
Remove piston rod and head assembly from tool A.
7.
Set cylinder
8.
Raise piston rod and head assembly

in cylinder
9.
(4) in tool A.
(31, and assemble
(4).
Using tool B, tighten cylinder head nut (2)

w
Cylinder head nut:
95 +_9.5 kgm
10. Bend lock into notch on cylinder side.

11.
Remove cylinder assembly from tool A.
WA500-
43-2 1
0
REMOVAL
OF CENTER
HINGE
PIN
Special tool
-Parto.
790-101-2102
Before starting work,

see 63 REMOVAL
Part name
Qty
Puller
remove the bucket.
OF WORK
Stop the machine
For details,
EQUIPMENT.
Lower the bucket to the.

steering wheel
release
the
tank.
and control
remaining
Then operate the
levers several times to
pressure
in
the
hydraulic
piping.
tank filter,

Loosen drain valve and drain air from air tank.
Cover
Remove cab bottom
covers (5),
(6) and (7) and trans-
mission inspection cover (8).
Steering cylinder pin

Remove left and right steering cylinder pins (9).
*
Check
the
number
of shims inserted
between
the
frame, and the steering cylinder.
3.
Center drive shaft

Remove guard (lo), then remove center drive shaft (11).
Center drive shaft:
43-22
0
44 kg
WA500-
4.
Air, brake hose

1) Disconnect
air hoses (121, (13), and (14) from tube
connectors.
*
Attach
tags on hoses to be able to identify
them
when intalling.
2) Disconnect brake hose (15) from tube connectors.
*
After
disconnecting
each
hose,
move to
front
frame.
5.
POC hose
1) Disconnect
accumulator
hose (16)
from
tube
con-
nector.
2) Disconnect
POC hoses (17). (181, (19). and (20) from
tube connectors.
*
After
disconnecting
each
hose, move
to
front
tags on hoses to be able to indentify
them
frame.
*
Attach
when installing.
6.
Hydraulic
hose
1) Disconnect hose (21) between steering valve and main

control valve from tube connectors.
*
Remove clamp of hose (22).
2) Disconnect
hydraulic tank from tube connectors.
7,
Electrical wiring
Disconnect
electrical
wiring
(24) from
connector,
and
move to front frame.

*
Remove wiring clamp.
WA500-
43-23
0
8.
Steering linkage
Disconnect
steering linkage
(25) and (26) from
center
lever, and remove linkage (27).
9.
Frame support
1) Using hydraulic
jack on rear frame, insert block @
while adjusting height.

*
Insert the hydraulic jacks and blocks under the left

and right frames.
2) Insert support stand @
under counterweight.
3) Using garage jack under front frame, insert block@
10.
Lower hinge pin

1) Remove mounting bolts, then remove retainer (28).
*
There
are shims between the retainer
so check the number
and frame,
and thickness of the shims,
and keep in a safe place.
43-24
0
WA500-
2) Pull out lower hinge pin (29) while adjusting height.

*
Adjust
the height carefully
until
it is possible to
easily remove the pin by hand.
3) Remove spacer (30).
11. Upper hinge pin

1) Remove mounting bolt, then remove retainer (31).
2) Using
puller
A,
remove
upper
hinge pin
(32)
and
spacer (33).
Front
frame
425F304
12. Disconnecting frame

Remove
safety bar, pull out front
frame to front
and
disconnect frame.
Be careful
not to
let the spacer at the top of the
lower hinge bite into the rear frame.

Be careful to maintain
the balance when carrying out
the operation.
Move the frame about 100 mm at a time.
WA500-
43-25
0
2) Remove dust seal (35) from retainer.
3) Remove
spacer (36)
and dust seal (37) from
front
frame.
43-26
0
WA500-
14.
Upper hinge
1) Remove retainer (39).
+I There are shims between the retainer and frame, so
check the number and thickness of the shims, and
2) Remove dust seal (40) from retainer.

*
Remove dust seal (41) from frame.
WA500-
43-27
0
INSTALLATION
OF CENTER
HINGE
PIN
Special tools
Part No.
Part name
/ Oty
1
790-I 01-l 002
Pump
790-101-2102
Puller
790-I 01-2300
Push-puller
793-520-2640
Push tool
Dl
793-520-2550
Guide (lower)
D2
793-520-2530
Guide (upper)
D3
793-520-2630
Bar
D4
01010-31480
Bolt
01643-31445
Washer
D,
1.
Upper hinge
1) Assemble tools A, B, C, D1, and D3 at top of front
frame
upper
hinge, and set bearing (42)
in tool
D.
Set the upper hinge on from top and press fit.

*
When press fitting, use tool D2 as a guide.
Be careful not to fit the bearing at an angle.
Fill the inside of the bearing with grease.
When
assembling
the
bearing,
do not forget
to
assemble spacer (43).

*
The clearance
adjusted,
of the bearing and spacer (43) is
so do not change the combination.
When replacing the bearing and spacer, replace as

a set.
D3
D2
425F307
425 F306
2) Press fit dust seal (40) on retainer.

*
When
press fitting
the dust seal, fit with
the lip
on the outside.
6
Seal lip:
Grease (G2-LI)
425F308
43-28
0
WA500-
3) Tighten retainer (39) with 3 mounting bolts, measure

clearance a of retainer and hinge at 4 locations on
circumference,
and
select
shims so the
measured
value is less than 0.08 - 0.18 mm.

*
After
selecting
the
shims,
assemble
retainer
to
specified torque.
B
Mounting bolt (when adjusting shims):

6 + 0.6 kgm
Mounting bolt:
18 f 2 kgm
425F309
4) install seal (40) to bottom of front frame.

*
When
press fitting
the dust seal, fit with the lip
on the outside.
a
2.
Seal lip:
Grease (G2-LI)
Lower hinge
1) Using tools A, 6, D, D4 and Ds , press fit bearing (38)
and spacer (37) on front frame.
*
When press fitting, use tool D2 as a guide.
Be careful not to fit the bearing at an angle.
Fill the inside of the bearing with grease.
When
assembling
the
bearing,
do not forget
to
assembling the bearing, do not forget to assemble

the spacer (37).
*
The clearance of the bearing and spacer (37) is adjusted, so do not change the combination
When
replacing the bearing and spacer, replace as a set.
425F310
WA500-
425F311
43-29
0
2) Press fit dust seal (35) on retainer (34).

*
When press fitting the dust seal, fit with the lip on
the outside.
&
Seal lip:
Grease (G2-LI)
3) Tighten retainer (39) with 5 mounting bolts, measure

clearance a of retainer and hinge at 4 locations on
circumference,
and
select
shims so the
measured
values is less than 0.08 - 0.18 mm.

*
After
selecting
the
shims,
assemble
retainer
to
specified torque.
B
Mounting bolt (when adjusting shim):

lot
Mounting bolt:
1 kgm
18 + 2 kgm
425F312
4) Press fit
dust seal (37)
and install
spacer (36)
on
frame.
*
When press fitting the dust seal, fit with the lip on
the outside.
Assemble
spacer (36)
so that
the side with the
large chamfer is on the bearing side.

&
Seal lip:
Grease (G2-LI)
&
Inside circumference
of spacer:
Grease (G2-LI)
425P803
43zo
WA500-
3.
Connecting frame
Move
front
frame
towards
rear frame
and align pin
u se a bar to align the pin holes.
Never use your
holes.
Q7
fingers.
*
4.
Align the pin holes correctly.
Upper hinge pin

Assemble spacer (33), insert upper hinge pin (32), tap
lightly
3 times with a copper hammer
45
until it settles
in.
*
Tap lightly with copper hammer, do not tap hard.
It
Absolutely,
do not coat spacer (33) with grease.
Outer circumference
of hinge pin:
Grease (G2-LI)
Assemble retainer (31).

&
Mounting bolt (45): Thread tightener
Mounting bolt (45):
1822kgm
QEl
Mounting bolt (46):
18*
lf the torque of the mounting
(LT-2)
425F313
2 kgm
bolts (45) and (46)
do not reach the specified there may be grease on

spacer (33), so remove it and tighten the mounting
bolts again.
5.
Lower hinge pin

1) Insert lower hinge pin (29) and assemble spacer (30).
&
Outer circumference
of hinge pin:
Grease (G2-LI)
2) Install retainer
settles
retainer
in
(28) to lower hinge pin, and after it
fully,
and frame
measure
clearance
between
at 4 locations on circumference,
and select shims so the measured value is less than

0.08 - 0.18 mm.
WA500-
425F314
When adjusting the shims, tighten the retainer mounting bolts temporarily
Tighten
to prevent them from turning.
the retainer
tightening
torque,
mounting
then
bolts to the specified
tighten
the
pin
mounting
bolts.
After
selecting the shims, install the retainer with the
specified torque.
Completely
remove grease on the mounting bolts and
mounting holes.
&
Mounting bolts (47) and (48):

Thread tightener
(LT-2)
Mounting bolt (47):

28.5 + 3.0 kgm (When adjusting shim)
Mounting bolt (47):
28.5 f 3 kgm
Mounting bolt (48):
39 + 3.5 kgm
425F315
3) Lock safety bar.

6.
Frame support
1) Remove block @
from front frame.
2) Remove support beam @
from couterweight.
3) Jack up rear frame and remove block 0
7.
Steering linkage
Install linkage (27) and connect steering linkage (25) and
(26) to center lever.
a
Mounting bolt of linkage (27):

Thread tightener
Mounting bolt of linkage (27):
Mounting bolts of linkage (25) and (26):
(LT-2)
18 + 2 kgm
12.5+- 1 kgm
4322
WA500-
8.
Electrical wiring
Connect electrical wiring (24) to connector.
*
9.
Install wiring bracket.
Hydraulic
hose
1) Connect
hose (23)
between
main control
valve and
hydraulic tank to tube.

2) Connect
hose (21)
between
steering valve and main
control valve to tube.

*
Clamp hose (22).
10. POC hose

1) Connect POC hoses (17), (IS),
2) Connect accumulator
(19) and (20) to tube.
hose (16) to tube.
11. Air, brake hose

1) Connect brake hose (15) to tube.
2) Connect air hoses (121, (I 3) and (14) to tube
WA500-
12. Center drive shaft

Fit center drive shaft (11) and install guard (10).
m
Mounting bolt:
11.5 f 1 kgm
13. Steering cylinder pin

Install left and right steering cylinder pins (9).
Q7
u se a bar to align the pin hoels.
Never use your
fingers.
*
Adjust
shims
so clearance
become
specified
value.
Clearance a = less than 1 mm
a
425F295
14. Cover
Install covers (5),
(6) and (7) at bottom
of cab and of
transmission inspection cover (8).
15.
Refilling with oil

Tighten plugs at top of hydraulic
filter cover, and plugs
of pump piping, then add hydraulic oil through oil filler

m
16.
Plug at the top of filter:
1.2 + 0.1 kgm
Bleeding air
Bleed air from brake system.
t
For details
of bleeding
air, see 52 TESTING
AND
ADJUSTING.
4324
WA500-
STEERING SYSTEM
44 MAINTENANCE
STANDARD
Steering linkage ..............

Steering column and gear box .
Steering pump ..............
Steering valve ...............
Steering cylinder mount ......
Steering cylinder .............
Center hinge pin .............
WA500-
..
..
..
..
.
44-2
...
. . . . . . 44-3
. . . . . 44-4
. . . . 44-5
. . . . . . 44-6
. . . . . . 44-7
. .
44-8
44-1
STEERING
LINKAGE
Section A - A
10
Section B - B
425F151
Unit:
No.
v:er
,everbearing
Interference of press-fitting
Remedy
Criteria
Check item
CStamford
-1
fEZZ2
62.0
+0.020
-0.027
2.013
Clearance of articulation stopper

(at engine speed 1,200 rpm)
Tightening torque of mounting nut
Tightening torque of mounting nut
Tightening torque of lock nut
28.5 f 3.0 kgm
7.75 + 1.25 kgm
3.15 r 0.35 kgm
9.0 r 3.5 kgm
18.0 f 2.0 kgm
IO
7.75 r 1.25 kgm
44-2
10 i 2
0.027 0.033
19It3kgm
12.25 f 1.25 kgm
Retighten
WA500- 1
mm
STEERING
COLUMN
AND
_,
GEAR BOX
Section A - A
77%
Section D - D
Section B - B
Section C - C
423F217A
Unit:
mm
Clearance between sector shaft
5.7 i 0.7 kgm
WA500-
44-3
STEERING
PUMP
SAR(3)-080
425F150
Unit:
No.
Check item
Criteria
Remedy
Standard clearance
1
Clearance limit
Clearance between gear case

and side plate, gear
0.10 -0.15
0.19
Replace
Clearance between inside diameter of

plain bearing and outside diameter of
gear shaft
0.7 - 1.2 kgm
25.2 + 1.7 kgm
Discharge
EOI O-CD
45 - 55Oc
44-4
0.06 - 0.149
0.20
144.5
-
Retighten
Revolution
(rpm)
Discharge
pressure
(kg/cm )
Standard
discharge
(Q/min.)
Repair limit
discharge
(Qimin.)
2500
210
164
170
WA500-
mm
STEERING
VALVE
4I
5
2.\
/
,,,
425F152
Unit:
mm
Check item
Criteria
Clearance between steering spool

and valve body
Steering spool return spring
Check valve return spring

Tightening torque of steering
relief valve
6
I
42.4
33.5
0.345
kg
0.3 kg
8.5 ? 1.5 kgm
Tightening torque of safety

valve with suction
Tightening torque of plug
WA500-
4.5 f 0.5 kgm
Retighten
3.8 t 0.2 kgm
44-5
STEERING
CYLINDER
MOUNT
425F153
-3.4
425F154
Section A - A
Unit:
No
Criteria
Check item
Clearance between mounting pin

and bushing connection of steering
cylinder rod and frame
Standard
size
60
2
-
Clearance between mounting pin

and bushing at connection of
steering cylinder bottom and frame
60
Width of boss
3
Connection of steering cylinder

and front frame
Connection of steering cylinder

and rear frame
466
mm
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
Jo74
+0.174
+0.100
0.100 0.248
0
-0.074
+0.174
+0.100
0.100 0.248
Width of hinge
Replace
Standard clearance
(Clearance a + b)
70+0.8
0
742
1.2 - 6.0
70+0.8
0
74r
1.2 - 6.0
After adjusting
with shim
Max. 1 .O
WA500-
STEERING
CYLINDER
425F155
Unit:
mm
Clearance between rod and bushing
Tightening torque of cylinder head
95 + 9.5 kgm
Retighten
Tightening torque of piston nut
WA500-
145.0 I 14.5 kgm (Width across the flats 55 mm)
44-7
CENTER
HINGE
PIN
425F166
12
23
10
8
21
*17
8
11
7
44-8
Section
A - A
Section B - B
425F167
WA500- 1
Unit:
Check item
No.
Criteria
Clearance between lower hinge

pin and rear frame
I
2
Tolerance
Standard
size
Hole
Shaft
100
Remedy
Standard
clearance
Clearance
limit
-0.036
-0.058
+0.054
+o
0.036 0.112

pin and spacer (small)
100
-0.036
-0.058
+0.054
+o
0.036 0.112
pin and bearing

Clearance
between
lower hinge
100
-0.058
-0.036
-:.020
0.058
0.016

pin and spacer (large)
100
-0.036
-0.058
+0.054
0
0.036 0.112
Clearance between rear frame and

spacer (large)
120
-0.036
-0.090
+0.090
+0.036
0.072 0.180
upper hinge
bearingfront frame and
Clearance
between
155
-0.025
0
-0.088
-0.048
Clearance between upper hinge

pin and rear frame
100
-0.096
-0.118
+0.071
+0.036
0.132 0.189
Clearance between upper hinge

pin and bearing
100
-0.096
-0.118
2.020
0.076 0.118
Clearance between front frame and

lower hinge bearing
160
0
-0.025
-0.050
-0.090
1o
Clearance between rear frame

and bushing
125
-0.043
-0.083
+0.063
0
0.043 0.146
11
Clearance at press-fitted part of

seal of upper hinge pin
115
+0.280
+0.180
+0.054
0
-0.126
-0.28
12
seal
of lower
hinge pin part of
Clearance
at press-fitted
135
+0.210
+0.310
0
+0.063
-0.147
-0.31
13
Height of lower hinge spacer

(small)
Standard size
I4
Height of lower hinge spacer

(large)
I
Replace
Repair limit
-
kO.1
I
to.1
,5
Shim thickness for lower hinge

and retainer
2.3
16
Shim thickness for lower hinge

and retainer
1.6
Shim thickness for upper hinge

and retainer
1.6
17
-0.025 -0.090
82.5
-0.088
-0.023
Tolerance
35
I
mm
When adjusting with shim: IO f 1 kgm

18
Tightening torque of lower hinge

retainer mounting bolt
Final value:
18 + 2 kgm
Adjust
1g

retainer mounting bolt
When adjusting with shim: 28.2 2 3.2 kgm

Final value: 28.2 + 3.2 kgm
2.
21

pin mounting bolt
Tightening torque of upper hinge

pin mounting bolt
39.2 + 4.2 kgm

When adjusting with shim: 6.0 f 0.6 kgm
Final value:
22
23
18 t 2 kgm

pin mounting bolt
18+2kgm

oin mountina bolt
18*2kgm
WA500-
IlrrlylIrc,,
44-9
50 BRAKE AND AIR SYSTEM
BRAKE AND AIR SYSTEM

51 STRUCTURE
AND
FUNCTION
General ...................
Air tank ...................
Safety valve ...............
Brake valve ................
. Brake actuated ..........
. Operating in balance .....
. Brake released ..........
Air governor ...............
Two-way valve ............
Brake chamber ............
Slack adjuster .............
Brake .....................
Parking brake .............
Parking brake solenoid valve
Spring cylinder ............
Brake caliper ..............
WA500-1
.
.
.
.
.
..
.
..
..
.
.
.
.
..
.
.
..
..
.
..
..
...
..
..
.
.
.
..
..
..
.
.
.
..
..
.
.
.
..
.
..
..
..
51- 2
51- 5
51- 5
51- 6
51- 7
51- 8
51- 9
51-10
51-12
51-13
51-15
51-18
51-20
51-22
51-23
51-24
51-l
GENERAL
Outline
- The air compressed by the air compressor (1) enters
When the brake valves (1 I), (12) are actuated, the air
The
in the dry tanks (6), (7) flows to the brake chamber
air then enters two dry tanks (6), (7) and also flows
and applies pressure to the brake oil in the master
to the parking
cylinder.
The pressurized oil passes through the slack
adjusters
(17),
the wet tank
(5) and the moisture

brake valve (21).
is removed.
The air in the dry
tanks (6), (7) flows to the brake valves (1 I), (12).
- When the air compressed by the air compressor (1)

fills the circuit
and the air pressure in the wet tank
(5) reaches the maximum
set pressure of the air govIt opens
ernor (2), the air governor (2) is actuated.
(18)
and pushes the wheel piston to
apply the brakes (19), (20).

The parking brake (24) is applied mechanically
spring in the spring cylinder (23).
released by air pressure. Therefore,
by the
It is designed to be
if the air pressure
the unloader valve of the compressor, so the compres-
is less than the force of the spring in the spring cylin-
sor (1) is put in a noload condition
der (23), the brake is kept applied.
pressed.
and no air is com-
When the air is used and the air pressure in-
side the tank drops below the minimum

of the air governor
ated.
set pressure
(2), the air governor (2) is actu-
When the air pres-
sure rises and the parking brake release is reached, a

solenoid
valve is actuated to supply air to the spring
cylinder
(23).
This releases the parking brake (24).
It closes the unloader valve of the compressor
and the compressor (1) is actuated.

nor (2)
does not work
inside the tank
properly,
If the air goverand the
pressure
reaches the set pressure, the safety
valve (28) opens and the air pressure is released to the

atmosphere.
51-2
This protects the air circuit.
WA500-
Air compressor
Air governor
3.
WA500-1
Tire inflation
4.
Drain valve (Serial No. 10001
4A.
and up)
10427)
5.
Air tank
:
6.
Air tank (dry)
(wet)
7.
Air tank
Check valve
[dry)
9.
Check valve
10.
IOA.
and up)
11.
R.H..brake
12.
L.H. brake valve
13.
Two-way
valve
14.
Two-way
valve
15.
Front brake chamber
valve
16.
Rear brake chamber
17.
Front slack adjuster
18.
Rear slack adjuster
19.
Front brake
20.
Rear brake
21.
Parking brake solenoid vaive
22.
Parking brake sense:
23.
Spring cylinder
24.
Horn valve
25.
Horn
26.
Brake oil tank
27.
Safety
28.
Air pressure sensor
29.
Emergency
valve
brake switch
30.
Stop lamp switch
31.
Transmission
cut-off
switch
10427)
AIR TANK
WET
DRY
TANK
TANK
IA
BCD
425FO84
A. To air governor (PT l/2)

B. Air pressure sensor pick-up
(PT l/8)
G.
Drain valve (PT 118)
H.
From air tank (wet) (PT l/2)
C. To air tank (dry) (PT 112)
I.
Plug hole (PT l/8)
D. Plug mount (PT l/4)
J.
To brake valve (PT 3/8)
E. From air compressor (PT l/2)

F. To drain valve (PT 114)
Name
Maximum
(!?I
pressure
9.4
9.5 kg/cm2
Dry tank (L)
26.6
9.5 kg/cm2
Dry tank (R)
26.6
9.5 kg/cm2
Wet tank
421
Capacity
F059
The air tank consists of one wet tank and two dry
tanks.
wet
The air from the compressor first enters the
tank
and the
moisture
is removed.
It is then
divided and sent to the left and right dry tanks.
* A safety valve and air pressure sensor are installed in

the wet tank.
SAFETY
VALVE
Function
1. Adjustment
- The safety valve is installed in the wet tank, and acts

as a safety device for the air circuit.
Operation
If the air governor does not work

pressure inside the air tank
properly
and the
rises above the set pres-
sure, ball (4) is pushed up and the air escapes to the

atmosphere.
2.
Spring cage
3.
Spring
4.
Ball
5.
Lock nut
6.
Relief valve
7.
Body
nut
423FO96
WA500-
51-5
BRAKE VALVE
Outline
* There are two brake valves installed in parallel at the

bottom
of the
operators
compartment.
These are
operated by depressing the pedal.
* When the right pedal is depressed, air is sent to the

brake chamber and the brake is actuated.
When the
left pedal is depressed, the brake is actuated

same way
as with
time,
transmission
the
electrically,
the right pedal,

solenoid
in the
but at the same

valve is actuated
and the transmission is put in neutral.
.I
I rIIL
7
Brake pedal
A.
From air tank
2.
Plunger
B.
From air tank
3.
Piston
C.
To front brake chamber
4.
Inlet valve
D.
To rear brake chamber
5.
Piston
6.
Inlet valve
7.
Rubber spring
1.
51-6
423Fo97
WA500-
BRAKE
ACTUATED
Upper part
- When pedal (1) is depressed, the operating

passes through
is transmitted
force
plunger (2) and rubber spring (71, and

to piston (3).
When piston (3) moves
down, exhaust port (9) is closed, and at the time inlet

valve (4) is moved down and air from the air tank
(11) flows from port A to port C.
This actuates the
front brake chamber (12).
Lower part
* When pedal (1) is depressed, the operating

passes through
is transmitted
down,
force
plunger (2) and rubber spring (7), and

to piston (3).
When piston (3) moves
inlet valve (4) is moved down,
and air from
the air tank flows from port B to port D. This actuates the rear brake chamber.
To front
slack
*To, rear slack

adjuster
423FO98
Operation
of brake when lower valve fails
* Even if there is leakage of air in the lower piping, the

upper part will operate normally.
The brake for the lower circuit will not operate.
423FO99
WA500- 1
51-7
Operation
of brake when upper valve fails
* Even if there is leakage of air in the upper piping, if

pedal (1) is depressed, piston (5) will be pushed down
mechanically
and the upper part will operate normal-
ly.
The brake for the upper circuit will not operate.
OPERATING
IN BALANCE
To rearslack
adjuster
Upper part
* When the pressure in the space below piston (3) and
423FlOO
the air pressure from the brake chamber become high,

the pressure pushes rubber spring (71, and piston (3)
moves up to close inlet valve (4).
exhaust port (9) stays closed.
ing the brake chamber
When this happens,
The air pressure enter-
is retained
and the brake is
kept applied.
Lower part
Upper piston (3) moves up, and inlet valve (4) closes.
Piston
(3)
is pulled
up by an amount
equal to the
amount
of movement
and inlet valve (6) closes. The
exhaust
valve is closed, so the air pressure is main-
tained and the brake is kept applied.

The air pressure in the space at the upper part balances the operating force of the pedal.
The pressure
in the space at the lower part balances the pressure in

the space at the upper part.
When pistons (3) and (5) move to the end of their
stroke, inlet valves (4) and (6) are fully opened.
The
spaces in the upper and lower parts, and the air pressure in the
left and right brake chambers
equal to the air pressure in the tank.

braking
brake
effect
pedal
can be adjusted
is depressed.
Therefore,
the
by the amount
the
When the
om frontslack
become
pistons move
down to the end of their stroke, the brake is applied
ont rearslack
fully.
423FlOl
51-8
WA500- 1
BRAKE
RELEASED
Upper part
-
When the pedal (1) is released and the operating pressure is removed from the top of the piston, the air at
the bottom of the piston, and the piston return spring
move the piston up.
Exhaust port (9) is opened and
the air pressure in the brake chamber
is released to
the atmosphere.
Lower part
- When the pedal is released and the air at the top of

piston (5) is let out, the air at the bottom
(5) and spring (13) pull the piston up.
(10)
opens at the
of piston
Exhaust port
air pressure in brake chamber
is
released to the atmosphere.
Om
rear slack
423F102
WA500- 1
51-9
AIR GOVERNOR
1.
Spring
2.
Exhaust port
3.
Piston
4.
Unloader port
5.
Exhaust stem
6.
Inlet valve
7.
Tank port
8.
Filter
Specifications
* Cut-out pressure:
* Cut-in pressure:
8.3 + 0.3 kg/cm*

7.0 t 0.3 kg/cm*
423F091A
Function
* The air governor maintains the pressure in the air

circuit to the specified range.
OPERATION
Compressor working
* The air pressure in the wet tank (9) passes from the
tank
port
(7) through
the filter
(8) and acts on the

Compressor
bottom of the piston (3).

When
the air pressure in the tank
specified
pressure (cut-out
(9) is below the
pressure) the piston (3)
pushed down by the spring (1).
* When this happens, the air at the unloader port (4)

passes through
the exhaust
stem (5) to the atmos-
To dry
+
Check valve
phere and the compressor is actuated.
Compressor loaded
421
51-10
WA500-
F057A
Compressor stopped
* When the pressure in the wet tank (9) rises, and

reaches the set pressure (cut-out pressure), the piston
(3) is pushed up against the spring (1).
- When the piston (3) is pushed up, the exhaust stem

(5) is closed and the inlet valve (6) opens.
- The pressure from the tank passes through the inlet

valve (6) and unloader port (4), and acts on the unloader valve of the compressor.
This
puts the compressor in a no-load condition.
* When the air pressure inside the tank drops, the pisCompressor
ton (3) is pushed down by the spring (I ).
- When the pressure drops below the specified pressure

(cut-in pressure),
the inlet valve (6) closes and the ex-
haust stem (5) opens.

port (4) passes through
The pressure at the unloader

the exhaust stem (5) and is
released in the atmosphere, so the compressor starts
To wet
+=
Check valve
to work again.
Compressor no-load
421 F058A
WA500- 1
51-11
TWO-WAY
VALVE
Function
* The two-way
valves.
valve is installed
It acts to prevent
ing from
between the two brake
the air pressure from
one brake valve when the other
escap-
brake valve
is depressed.
Operation
- The air circuit

connected
actuated
of the
so that
the
left
and right
brakes
brake
on all four
valves is
wheels are
when either of the pedals is depressed.
The air pressure entering
from
port A of the two-way
valve moves seat (2) and shuts off the circuit

B.
Therefore,
the air pressure flows
and actuates the brake chamber
only
to port
to port
(5).
423F103
1.
Body
4.
Cap
2.
Seat
5.
Brake chamber
3.
Plug
423F104
51-12
WA500-
BRAKE CHAMBER
lo -
01
425FO85
View Z
1.
Air cylinder
6.
Piston
2.
Air piston
7.
Master cylinder
3.
Spring
8.
Piston valve
4.
Rod
9.
Body
Specifications
1.
Air cylinder
Cylinder bore:
5.
Breather
10.
Sensor
2.
133.5 mm
Cylinder capacity:
3,600
cc
Master cylinder
Cylinder bore:
WA500-
180 mm
Stroke:
68 mm
Stroke:
132.5 mm
Delivery:
472 cc
51-13
OPERATION
Brake operated
When the
brake
pedal
is depressed, compressed air is
supplied from the brake valve to the brake chamber.
Air
piston (2) moves rod (4) and pushes piston (6) of master
cylinder
(7) to the right.
Brake oil is sent by piston (6)
to the brake piston to actuate the brake.
From brake
valve
@
425FO86
Brake held in position

When the
brake pedal is kept depressed at a constant
force,
hydraulic
the
pressure is kept
constant,
so the
brake is kept applied.
From brake
valve
@
425FO87
Brake released
When
the operating
force on the brake pedal is partly
released, the compressed air supplied to the back of piston (2) of the brake chamber
valve, and the hydraulic
(7)
drops.
is released from the brake
pressure inside master cylinder
If the brake pedal is released further,
the
brake oil sent to the piston of the brake is sent back to

the
inside of master cylinder
(7) by the force of the
brake return spring.

From slack
adjuster
To brake
valve
0
425Foaa
51-14
WA500-
SLACK
ADJUSTER
Function
- The slack adjuster is installed in the brake oil line

from the brake chamber to the brake piston.
to keep the clearance
discs constant
It acts
between the brake piston and
even when the brake discs are worn.
In
this way it acts to keep a constant time lag when the

brake is operated.
5
423F109
1.
Bleeder
2. Cylinder
3.
WASOO- 1
A.
Inlet port
B.
Outlet port
Check valve
4.
Piston
5.
Spring
51-15
OPERATION
1.
Brake pedal depressed
Serial
Brake
No. 10566
and up
oil tunk
425F504
When
the brake pedal is depressed, the oil dis-
charged from brake chamber

the slack adjuster.
(6) enters port P of
It is then divided and enters
left and right cylinders
(2),
and moves left and
right pistons (4) to the left and right by a distance equal to the total travel S.
Brake
Because of this, an amount
oil tunk
of oil equal to travel
S flows from port C to brake cylinder
(7).
When this happens, the clearance between brake

piston (8) and the plate becomes 0, but no braking force is generated.
WA500-1
If the brake
oil pressure
is depressed
further,
inside brake chamber
(6) goes above
pressure,
the oil flows
to ports P and C and brake cylinder
(7).
The
check valve
discs and plates
tightly
as the braking
(3) opens and
are then
by brake piston
425F506
and the
the specified
gether
2.
pedal
pushed
to-
(8), and this acts
force.
Brake pedal released
425F507
-
When
the
brake
pedal
is released,
the force
brake return
spring (9) causes brake piston
return,
the
piston
brake.
and
oil
equal
(4) to its original
to
travel
position
of
(8) to
S returns
to release the
In addition,
the
brake cylinder
travel
amount
S of piston
oil returning
from
of
(4), so travel T of brake piston
(8) does not change.

diaphragm
of
(7) is only equal to the amount
is always
In other
constant
words,
the brake
regardless
of the
wear of the brake discs.
WA500-1
51-17
8
BRAKE
Function
* The brakes are wet-type mutiple disc brakes,and are

fitted to all four wheels.
Detail P
c
L
425FO89
51-18
1.
Guide pin
5.
Inner gear (teeth 112)
2.
Return spring
6.
Plate
3.
Brake piston
7.
Disc
4.
Outer gear (teeth 164)
WA500-
Operation
- When the brake pedal is depressed, pressure is applied

to the brake oil by the master bylinder
chamber.
Brake piston
disc (7) is kept

(7) rotates
the rotation
in close contact
together
with
is stopped
of the brake
(3) is moved to the right, and

with
wheel,
plate
so when
(6).
Disc
it is held,
and the brakes are applied
to
From slack
adjuster
I@
stop the machine.
425FO90
When the brake pedal is released, the pressure on the

rear of brake piston
moved
to the
left
(3) is released.
by the force
and the brake is released.
The piston
of return
is then
spring
(2)
TO
adj
425FO91
WA500-
51-19
PARKING
BRAKE
Outline
* The parking
the front
brake
is a disc type
and is installed
on
axle.
ferential
* The force of the spring inside the spring cylinder

is used to apply
* The parking
the brake mechanically;
(2)
it is released
brake
caliper
is fixed
to the front
dif-
case.
The disc is installed

tates together
to the differential
yoke
and ro-
with the coupling.
by air pressure.
425FO94
51-20
1.
Parking brake disc
2.
Spring cylinder
WA500-
Brake operated
- When the parking brake switch lever is moved to ON,

solenoid
tank
valve is actuated
and the air from the air
is shut off by valve.
At the same time, the air
from the spring cylinder is released to the atmosphere

from between valve and body.
of spring cylinder
Therefore,
the piston
(1) is pushed by the tension of the
spring, so when lever (2) is pushed, the parking brake

is applied.
* Lever (2) rotates piston shaft (3) and moves piston

(4) to the axial direction.
Therefore,
the pads are
pushed against the disc, and the parking brake is applied.
425FO97
Brake released
When the parking brake switch is turned to OFF, the
/OFF
solenoid valve is actuated and valve closes the exhaust
I,-.
,-\:
I__,/
port.
At the same time,
Neutral
the air in the air tank enters the
top part of the piston of spring cylinder
(1).
solenoid
It over-
comes the force of the spring and pushes the piston.

This pulls rod (51, moves piston (4) and releases the
brake.
Therefore,
air pressure is applied to the spring cylin-
der and the parking brake is kept released.

However,
if the air pressure inside the tank drops to a
level where
it cannot maintain
the normal operation
of the brake, the pressure sensor installed to the tank

sends an electric signal to the solenoid valve. This releases the
spring
cylinder
brake is automatically
circuit,
and the
parking
applied.
Ii
425FO98
WA500- 1
51-21
PARKING
BRAKE SOLENOID
VALVE
425FO1155
1. Core
Function
The
parking
brake
air to the parking

and
actuated
ment.
5i22
solenoid
valve
is a valve to switch
brake spring cylinder.
by a switch
2.
Spring
3.
Body
4.
Seat
5.
Filter
6.
Filter
7.
Valve
8.
Plunger
9.
Coil
It iscontrolled
in the operators
compart-
10.
Connector
A.
Outlet port
B.
Exhaust port
c.
Inlet port
WA500-1
OPERATION
- Parking brake actuated

When the parking brake switch in the operators compartment
is turned ON (actuated),
is turned
OFF
(no current
the solenoid valve
flows),
so plunger
(8) is
moved down by spring (2).

The air from the tank enters port C, but valve (7) is
seated, so no air flows.
In addition,
the air from the
spring cylinder enters port A, then enters port B from

seat (4), and is released.
Therefore,
the parking brake is actuated by the force
of the spring in the spring cylinder.
To dry tank
425FO1156
Parking brake released

When the parking brake switch in the operators compartment
is turned
OFF (released), the solenoid valve
is turned ON (current flows), and plunger (8) moves

up. Valve (7) that are connected
by a rod also move
up at the same time, and exhaust port B is shut off

by seat (4) and valve (7).
The
air from
the tank
passes from
port C around
valve (7), enters port A, sends air to the spring cylinder, and releases the parking brake.
Todry
tank
425FO1157
WA500-1
5-i2-
.-
BRAKE CALIPER
425FO95
Section A - A
1.
Caliper
2.
Pad
3.
Piston
4.
Piston shaft
5.
Lever
6.
Adjustment bolt
Outline
There
is a piston
guide
provided
on the
Piston (3) and piston shaft (4) are fitted

the
rotation
of the
piston shaft
caliper.
in this, and
makes the piston
The caliper body moves according to the wear of the

pad and slides in the axial direction.
* Adjustment
bolt (6) of lever (5) is used to adjust the
move in an axial direction to press against pad (2).
clearance
Lever (5) is connected
kept stationary,
by a spline to the splined end
of the piston shaft.
between
the pad and disc.
the adjustment
With the lever
bolt is turned to ad-
just the clearance.
Pad (2) is held in the caliper mount support with caliper.
To INCREASE
To DECREASE
51-24
clearance, turn COUNTERCLOCKWISE.

clearance, turn CLOCKWISE.
WA500- 1

52 TESTING
AND
ADJUSTING
...................
...........
Measuring brake pedal ..................
Measuring air ........................
Brake performance ....................
Checking brake oil pressure ..............
Measuring wear of brake disc .............
Air bleeding from brake line ..............
Parking brake performance ...............
Checking and adjusting parking brake ........
......................
Troubleshooting
The following
52- 2
52- 3
52- 4
52-
52- 8
52- 9
52-10
52-11
52-12
52-13
52-15
precautions are necessary when using the Standard Value Tables to make judgements during trouble-

1.
The values in these tables are based on the values for new machines leaving the plant, so they should be used as
target values when repairing or when estimating wear after a period of use.
2.
The standard values in these tables for judgement
are estimated
values based on the
standard values for the machine when shipped from the plant, and on the results of various tests. Therefore,
3.
with repair and operating records when making judgements.
These standard values tables must not be used for standard values when judging claims.
In addition,
do not use
WASOO-
52-l
0
STANDARD
VALUE TABLE
Standard
value
Unit
Permissible
value
T
Brake pedal
- Operating
- Operating
force
. Engine speed: Low idling
angle
- Air pressure: 7 kg/cma

- Brake pedal operating force:
- Play
kg
degree
39-47
Max. 61
Max. 27
16.5 - 20.5
43 kg
Max. 10
4-8
Air system
* Air governor cut-in pressure
* Air governor cut-off pressure
- Safety
inside operating range
kg/cm2
valve actuating pressure
6.7 - 7.3
6.7 - 7.3
8.0 - 8.6
8.0 - 8.6
9.1 - 9.9
9.1 -9.9
Warning buzzer
- Actuating
starting pressure
- Actuating stopping pressure
. Coolant temperature:
* Road surface:
paved surface
5.9 - 6.1
5.9 - 6.1
6.0 - 6.4
6.0 - 6.4
Max. 5
Max. 5
kg/cm2
Max. 5
Max. 5
3.34 - 4.26
Max. 6.3
kg/cm
Flat, horizontal, dry,
- Speed
when applying brakes:

20 km/h
Brake performance
* Time lag when pressing the pedal:

0.1 sec.
* Air
pressure: 6 kg/cm2
. Brake pedal operating force:

38 kg
* Tire inflation pressure:
Specified pressure
Drop in brake oil pressure
- Test
Wear of brake disc
pressure: 53 kg/cm/5
min.
* Piston stroke
mm
* Tire inflation pressure:

Specified pressure
Parking brake performance
* Road
surface:
Flat, dry, paved surface with
115 (1 l20) gradient
- Machine:
In operating condition
. Thickness of pad
* With back plate
* Clearance between disc and pad
* Total of both side
52-2
0
Machine
stopped
mm
31.7
/
0.88
12.7
- 1.24
WA500-
2.3
AND
ADJUSTING
7-

1
Tool name
Part number
Remarks
Brake pedal operating force
Push gauge
799-l01-I001
O-110
Brake oil pressure
Brake test kit
793-520-I
0 - 100 kg/cm2
Wear of brake disc
Vernier calipers
150mm-2OOmm
Brake distance
Tape measure
30 m
Clearance of pad
Feeler gauge
0.1 - 3.0 mm
Hydraulic tester
799-l 01-5000
0 - 25 kg/cm
0 - 50 kg/cm>
Nipple
790-301-I190
6-1
Measuring air
6-2
801
kg
6-3
Connector
When carrying out testing, adjusting or troubleshooting,
20PF
(Commercially available1
stop the machine on level ground, install the safety
bar on the frame, lower the bucket to the ground, and stop the engine.
When taking measurements, do not allow unauthorized
WA500-
52-3
0
MEASURING
BRAKE
*
.
Engine speed:
Air pressure: 7 kg/cm
PEDAL
Low idling
Item
Standard
value
Permissible
value
4 - 8
Max. IO
<
Brake pedal
Play
Special tool
Part No.
Part Name
799-l 01-l 001
Push gauge
1.
Measuring operating force of pedal
1)
Oty
Fit push gauge A to the operators foot.

*
Align the center of the push gauge with the

center of the pedal.
2)
Start
the engine and run at low idling, then
depress the
pedal and measure the operating
force.
2.
Measuring travel of pedal

1)
Fit push gauge A to the operators foot.

*
Align the center of the push gauge with the

center of the pedal.
2)
Start
the engine and run at low idling, then
depress the
pedal with
an operating
force of
43 kg and measure the travel of the pedal with

an angle meter B.
3.
Measuring play of pedal

1)
2)
Start the engine.

Push the brake pedal in lightly by hand, and use
an angle meter
B to measure the travel of the
pedal to the point where
it starts to become
heavy,
WA500-
MEASURING
AIR
inside operating range.
Air governor
Unit:
Standard
kg/cm
value
Permissible
value
Cut-in pressure
6.7 - 7.3
6.7 - 7.3
Cut-off pressure
8.0 - 8.6
8.0 - 8.6
Item
Warning buzzer
Unit:
kq/cm2
Item
Standard
value
Permissible
value
Actuating starting pressure
5.9 - 6.1
5.9 - 6.1
Actuating stopping pressure
6.0 - 6.4
6.0 - 6.4
Safety valve
Unit:
Standard
value
Item
Actuating pressure
kg/cm*
Permissible
value
9.1 -9.9
9.1 -9.9
Special tools
Part Name
Part No.
790-301-I190
Qty
Hydraulic tester
Nipple
1 1
20PF
C
( co~$ear;;~llY
Connector
When measuring, connect nipple B, connector

gauge A, then insert in the tire inflation
C to
coupler on
the machine.
1.
Measuring set pressure of air governor

Open the drain
valve and drain
air from the
tank.
Start
the engine and raise the pressure inside
the tank.
Measure the pressure at which the air governor
is actuated
and the air compressor
is cut-off
(no-load rotation).
With
the engine at low idling,
pedal to
lower the air pressure.
pressure at which
(Start of operation).
WA500-
use the brake

Measure the
the air compressor
cuts in
Adjusting
1)
2)
Stop the engine.

Loosen
lock nut
(I),
and turn adjustment
screw (2)
to adjust.
*
Turn the adjustment

To DECREASE
To INCREASE
Amount
After
screw as follows.
set pressure, TIGHTEN

set pressure, LOOSEN
of adjustment
screw.
screw.
for 1 turn of screw.
Approx.
1.4 kg/cm*
adjusting
as above,
measure
again
and
check that all values are standard.
425F206
2.
Measuring
cut-off
pressure of
air
pressure alarm
buzzer
1)
Start the engine and run at low idling.

brake
pedal
to
lower
the
air
Usethe
pressure,
and
measure the pressure at which the buzzer starts

to sound.
2)
If the pressure is not standard

switch.
*
If the
pressure
the switch.
*
After
value, check the
If necessary, replace the switch.

is not standard
value, check
If necessary, replace the switch.
replacing
the
switch,
measure
the
pressure again.
52-6
0
WA500-1
3.
Measuring safety valve

1)
Loosen
nor
the adjustment
and set the
governor
above
screw of the air gover-
actuating
the
pressure
actuating
of the air
pressure
of the
safety valve.
2)
Start the engine and measure the pressure when

air comes out of the safety valve.
After
measuring,
governor
*
If the
do
not
to the specified
safety
valve
forget
to
return
the
air
pressure.
is defective,
replace
the
valve
assembly.
Do not try to adjust it.
*
Hook
the
tool
removeing.
*
on
part
Never use part b
Install so that the exhaust
port
when
tightening
or
when tightening.
(c) face down.
a
423F318
WA500-
BRAKE
*
.
.
.
PERFORMANCE
Time lag when pressing the pedal : 0.1 sec.
Air pressure: 6.0 kg/cm2
Road surface:
Fiat, horizontal,
Machine speed:
Tire inflation
straight, dry, paved surface.
Speed when applying brakes:
20 km/h
Unit: m
Standard
Item
Permissible
value
value
Brake
performance
Max. 5
Max. 5
Special tool
Part No.
Part Name
Oty
Commercially
available
Tape measure
Conditions for measurement

1)
Start the engine and then start the machine.
2)
Place the speed control
lever in the highest speed
range and drive the machine.

3)
When the machine
is traveling at 20 km/h,
depress
the left brake pedal with 38 kg.

*
Decide the run-up road and point to apply the
brakes, then apply the brakes when the braking
point is reached.
Turn
the transmission
cut-off
selector switch
ON.
4)
Measure the distance from the braking point to the

point where the machine stops.
Carry out the test three times and take the average
value.
Braking point
Stopping point
I
Braking distance
Brake pedal operating

position
Runup
road
423F319
5G8
WA500-
CHECKING
BRAKE PISTON
*
.
Test pressure:
Air pressure:
Measurement
LEAKAGE
condition
53 kg/cm*
Unit:
Item
Standard
value
Drop in pressure
Max. 5.0
kg/cm
Permissible
value
Max. 5.0
Special tool
Part No.
793-520-I
Q1
Part Name
Brake test kit
801
Qty
Block the tires securely.
Measuring procedure
1.
Remove
bleeder
screw (I),
then
install tool A in
bleeder screw mount.

2.
3.
Start the engine and bleed the air.

*
Bleed air from plug (2).
Turn the transmission cut off switch ON.
Depress the left brake.

53
kg/cm*,
leave for
When the gauge reading is

5 minutes
and check how
much the pressure drops.

4.
After
measuring,
stop the engine,
and loosen the
bleeder screw.
Lower the pressure, then remove tool A.
*
After
completing
operation,
the brake circuit again.
WA500-1
bleed the air from
MEASURING
*
.
.
WEAR
OF BRAKE
DISC
Air pressure:

Unit:
mm
Item
Standard
value
Permissible
value
Piston stroke
3.34 - 4.26
Max. 6.3
Special tool
Part No.
Commercially
available
Part Name
Qw
Vernier calipers
Stop the machine on level ground and block the

tires.
Method of testing
1.
Remove plug (1).
2.
Depress the brake pedal to the end of its travel.
3.
Measure depth b from the end face of the housing

to the spring guide.
*
Keep the brake pedal depressed when measuring.
4.
Install a vinyl hose to bleeder (2). loosen the bleeder

and bleed the brake oil.
*
After bleeding the brake
brake
piston
has returned
oil, check that
the
to the end of its
stroke.
5.
Measure depth a from the end face of the housing

to the spring guide.
Calculating piston stroke

S=b-a
S = Max. 6.3 mm
425F204
526
O
WA500-
AIR BLEEDING
FROM
BRAKE
LINE
Block the tires securely.
Order of operation
Remove cap (I)
of the bleeder screw, insert vinyl
hose (2) into the screw and put the other end in a
container.
Start the engine.
Depress the brake pedal, loosen the bleeder screw
and bleed the air.
Then tighten the bleeder screw
and slowly release the brake pedal.

*
Two
workers
are needed for this operation:
one depresses the pedal and the other bleeds

the air from bleeder screw.
*
*
Depress the left brake pedal.

Keep adding brake oil so that the oil circuit is
always full.
Repeat this operation
until no more bubbles come
out from the hose. Then depress the pedal fully and
tighten the bleeder screw while oil is flowing out.
*
Follow
the
same procedure
to bleed the air
from each cylinder.

After
bleeding all the cylinders,
check the level
of the oil tank and add oil.

*
To bleed the air completely,
bleed the air first
from
from
the
cylinder
furthest
the
master
cylinder.
+
When the air has been bled from

inders, confirm
all the cyl-
that rod (4) for the over-stroke
sensor of brake chamber
(3) is in place.
If it is
out of place, push it in as far as the sensor

installation
WA500-
end face of chamber.
52-11
0
PARKING
*
.
.
Tire inflation
pressure: Specified pressure
Road surface:
(1 I207
PERFORMANCE
BRAKE
Flat,
dry,
paved surface with
l/5
gradient.
Machine:
In operating condition
Standard
value
Item
Permissible
value
Keeps machine on l/5

gradient
Parking brake performance
423F321
(1120)
Measuring procedure
1.
Start the engine and drive the machine straight up a

l/5 gradient with the bucket unloaded.
2.
Depress the brake, place the F-R lever in neutral,

then stop the engine.
3.
Turn
the
parking
brake
switch
ON,
then
slowly
release the brake pedal and keep the machine must

be kept stopped.
.
The measurement
must
be
made
with
the
machine facing either up or down the slope.

423F322
WA500-
CHECKING
*
.
AND
Measurement
condition
Air pressure:
Maximum
ADJUSTING
PARKING
set pressure
Unit:
Thickness of pad
(with back plate)
mm
Permissible
value
Standard
value
kern
31 .J
12.7
Block the tire securely.
Remove front
Method
1.
BRAKE
frame
inspection
cover (1).
for measuring
Turn
the
main
switch
ON,
and turn
brake switch
OFF to release the brake.
the
Operate
parking
it is not operated
brake
slowly,
the
switch
parking
slowly.
If
it may be impossible
to release the brake.

2.
Measure the thickness
of pad (3).
When the main switch

ing brake
is applied,
is turned
OFF, the park-
so be careful
not to turn
it
OFF.
For
details
of removing
ASSEMBLY
AND
the pad, see 53 DIS-
ASSEMBLY.
Measure 2 pads.
If
the
thickness
is not
within
the
standard
value, replace the 2 pads as one set.

For details
BLY
Measuring
AND
of replacement,
see 53 DISASSEM-
ASSEMBLY.
clearance
Unit:
mm
Item
Standard
value
Permissible
value
Clearance between disc and

pad (a + b)
0.88 - 1.24
2.3
Measurement
procedure
1.
Turn the parking
brake switch
2.
Insert thickness
gauge between
OFF to release brake.

disc (4) and pad (3),
then measure the clearances.

*
The clearance
the total
value mentioned
value of both
above indicates
sides. (a + b)
425F208
WA500- 1
52153
Adjustment
*
If the value is not within
the standard range, adjust
as follows.
.
Remove inspection cover (1) of front frame.
1.
Turn the starting switch ON, then turn the parking

brake switch OFF to release the brake.
*
If the starting switch is turned OFF, the parking brake will be actuated,
so be careful not to
switch it off.
2.
Turn adjustment
bolt (2) at the caliper lever clock-
wise until pad (3) is lightly in contact with disc (4).

*
If the adjustment
bolt is tightened
too much
and pad (3) and disc (4) are brought strongly

into contact,
it may cause the brake to squeak
or the discs to overheat.

3.
Turn
adjustment
bolt
notch) counterclockwise.
180
+ 30 (three
or four
This will adjust the total
clearance (a + b) on the left and right between pad

(3) and disc (4) to 0.88 *
1.24 mm.
When replacing the pad, always replace in sets

of two pads.
After
adjusting,
measure the
brake
performance
again and check that it is within the standard value.
425F208
52-l 4
0
WA500-
TROUBLESHOOTING
does not rises at all
2.
does not rise to the
Air pressure
specified
5.
.....
range
Brake is ineffective
effective
4.
Parking
Before
carrying
RENCE
WA500-
out the troubleshooting
METHOD
OF TROUBLE
OF READING
in this
section,
TROUBLESHOOTING
..
52-16
52-l
52-l
52-l
or not very
...... ... . .
Brake does not release,
or drags
51-19
brake does not release,
ordrags......................
page 22-12,
..
table
1. Air pressure
3.
. ...
Troubleshooting
52-20
read PRECAUTIONS
WHEN TROUBLESHOOTING
TABLE
RECUR-
page 22-16.
52i5
TROUBLESHOOTING
1.
TABLE
Air pressure does not rise at all.

questions.
Did the air pressure suddenly

Damage in air circuit
Was the air pressure difficult

time?
+ Air
leakage,
cease to rise? -+
or equipment.
to raise for some
performance
drop
in air
equipment.
Check before troubleshooting
.
.
Damaged
air hose or tube,
external
equipment
associated with
air system.
Is the drain cock completely
damage to
closed?
Fault check
.
.
Check the air pressure by air gauge.

If the
ment
air
pointer
of the air gauge on the
panel remains at 0
drain
pressurized,
valve
and
despite
confirming
instru-
opening
that
the
the air is
the gauge is faulty.
om discharge pipe of compressor
engine is running but pressure does not build up.
The following symbols are used to

to be taken when a cause of failure
A:
X: Replace
C:
A: Adjust
52-16
0
indicate the action

is located.
Repair
Clean
WA500-
2.
Air pressure does not rise to the specified

range.
Check
for
possible
air
leakage from
air hose,
tube and air equipment.

.
Is the drain cock completely
Check
for
intake
hose.
deformation
closed?
of compressor
or air
Fault check
Install
a pressure
measure
measured
the
air
value
gauge in the air circuit

pressure,
with
table to see whether

specified
the
then
and
compare
judgement
the
criterion
or not it deviates from the
value.
Air discharge from compressor discharge pipe is weak

when engine is running.
Compressor starts to build up pressure when circuit

between air governor and unloader is disconnected.
Air comes out of discharge pipe of compressor when

engine is running but pressure does not build up.
II
The following symbols are used to

to be taken when a cause of failure
A:
X: Replace
A: Adjust
C:
WA500-
indicate the action

is located.
Repair
Clean
52-17
0
3.
Brake is ineffective
or not very effective.
Ask the operator the following questions.

.
Did the brake suddenly ceases to be effective?
+ Damge in air or brake equipment.
.
Did brake gradually deteriorate? + Deterioration of seal or packing, wear of lining.
.
.
f
.
.
.
.
Is kind of brake oil correct? (SAEIOW-CD)

Is air pressure and brake oil quantity satisfactory?
Is there any leakage of air or brake fluid when
the brake is operated?
Is there any external damage to air or brake
piping or equipment?
Check residual thickness of brake lining.
Check tire inflation pressure and tire tread.
Measure the pressure in the air circuit. If there
is an abnormality,
refer to item 1 Air pressure
is completely ineffective and item 2 Air presIf
sure does not rise to the specified value.
the measured value is normal,
following problems.
move on to the
Fault check
Check it against the valve in the judgement
criterion table to see whether or not braking
performance is bad.
The left and right wheels at both front and rear.
Air leaks from brake valve when a certain brake pedal is

depressed. Braking action is action when other brake
, abnorma
noise IS
at the air inlet of the brake chamber is disconnected and
The following symbols are usad to indicate the action

526
8
WA500-
4.
Brake does not release, or drags.

Does brake pedal return completely?
Does parking brake completely
disengage?
Fault check
.
.
NO.
Abnormal
heat generation in brake.
Inertial travel on flat ground.
Problems
Atr comes out and brake disengaged if brake chamber air
input is disconnected when brake pedal is released.
Clrcult pressure fails off and brake

21I from
air bleeder when brake pedal
,
3
disengages if oil is bled

is released.
A particular wheel rotates sluggishly when the machIne

is raised with a 4.wheel jack, the wheel axles placed on a
stand, the engine shut down and the tires rotated by hand
with the parking brake released.
The following
symbols are used to indicate the action
WASOO- 1
5229
5.
Parking brake does not release, or drags.

(Applies to machine equipped with air parking brake.)
.
Is the pressure in the
specified
range?
4.0 kg/cm2
valve will
parking
No.
air circuit
(if the air circuit
or less, the parking

automatically
operate
within
the
pressure
is
brake solenoid
to engage the
brake.)
Problems
Parking brake not released even when parking brake switch

is turned OFF.
When parking brake switch turned to OFF, air leaks from

spring cylinder, and cylinder rod does not return fully.
The spring cylinder operates normally and the rod and lever
return. however the brake draas.

A: Repair
X : Repalce
C : Clean
A : Adjust
52-20
0
WA500- 1
AIR SYSTEM
53
AIR
DISASSEMBLY
AND
GOVERNOR
Disassembly.
Assembly
BRAKE
BRAKE
......................
........................
Removal
53- 3
Installation
VALVE
..........................
.......................
Disassembly .......................
Assembly
........................
Removal
53- 4
53-
SPRING
Removal
53- 8
Installation
CHAMBER
.........................
Installation
.......................
Disassembly.
......................
Assembly
........................
53-12
PARKING
the
1.
2.
.............
53-23
.............
53-25
.............
............
53-28
53-30-2
.
.
.
.
.
.
.
.
.
.
.
.
.
.
_
.
.............
53-34
.............
53-35
.............
53-36
.............
53-36
53-17
Installation
BRAKE
53-20
Removal
53-20
Installation
..
..... .
.......
.............
53-37
.............
53-40
.............
.............
53-43
PAD
..... ..
. .. .....
53-43
53-22
following
method
for
air bleeding
cylinders,
when
you
start
to operate
hydraulic
pumps and pipings.

Operate
hydraulic
cylinder
4 -
5 cycles,
but do not exceed beyond
100 mm of
end.
3.
Continue
4.
After
NOTE:
. _.
.. .
_. _
.. .
53-21
after reassembling
stroke
WA500-
.
....
. . _.
....
Removal
PARKING
.........................
Installation
.......................
Disassembly.
......................
Assembly
........................
cylinders
..
..
_.
..
BRAKE
53-14
ADJUSTER
Take
..
..
..
_.
53-10
Removal
.
.
.
.
CYLINDER
...
.
Disassembly .
Assembly
..
53- 6
Removal
SLACK
_. .
.
Disassembly .
Assembly
..
53- 2
Installation
BRAKE
ASSEMBLY
to operate
finishing
After
cylinder
3 - 4 cycles until stroke
above steps, keep normal
end.
engine speed.
long storage, same procedure
is required.
53-1
0
DISASSEMBLY
1.
OF AIR GOVERNOR
cover
Remove cover (15), then remove retaining
2.
ring (14).
Spring seat
1) Remove
spring
seat assemblies
(IO),
(II),
(12).
(13), (16) and (17).

t
Remove
lock
assembly
before removing
2) Remove
exhaust
top of piston
3.
nut
(16)
stem
inside
the spring
seat
the assembly.
(9) and spring
(8) from
(3).
Piston
I) Turn
piston
body
(I)
upside
(3) from
bottom.
2) Remove spring
*
If the piston
lightly
from
down
and tap to remove
(4) and valve (5) from

does not come out,
piston
(3).
blow
in air
port a.
/
3
'1
425F296
WA500-
ASSEMBLY
&
Inside
OF AIR GOVERNOR
surface
of
body,
outside
surface
of
piston, O-ring groove, spring guide, adjustment

screw:
1.
Grease (G2-LI)
Piston assembly
I) Insert O-ring (6) in stem hole of piston (3). then
install washer and insert spring (8) and exhaust
stem (9).
2) Insert valve (5) in bottom

spring
(4),
of piston
(31, insert
fit in groove, then install on O-ring
(18) and assemble piston assembly in body (1).

2.
Spring seat assembly

Assemble lower spring seat (11A) spring guide (lo),
lower spring seat (11). spring (12) and upper spring
seat (13) in order on adjustment screw (17).
Tight-
en lock nut (16) so that distance from bottom face

of adjustment
screw to top face of upper spring seat
(13) is b = 47.6 mm.

*
Check that
correctly
exhaust stem (9) and spring (8) are
fitted on piston (31, then insert the ad-
justment screw assembly in the body.

3.
Cover
Stop cover (15) with retaining ring (14). then install.
4.
Filter
Install filter
*
423F443
(2).
Install the governor on the machine and connect

the air piping.
Check the air pressure when the
air compressor
is increasing
sure.
If the
and decreasing
pressure is outside
pres-
the specified
value, adjust it.
423F444A
WA500-
53-3
0
REMOVAL
OF BRAKE VALVE
Stop the
machine

1.
Cover
Remove cover under the cab.
2.
Draining air
Loosen drain valve and drain air from air tank.
.
3.
Air piping, wiring

Disconnect
air pipings (I),
(2), (3), (4) and (5). connec-
tor (6) and wiring (7).
4.
Pedal
Pull out cotter
pin
(9) of pin
(8),
remove
pin, then
remove pedal (10).

*
5.
Remove floor mat.
Brake valve
1) Remove mounting bolt (11).
*
Loosen bolt (12).
2) Remove bolt (12) and disconnect valve body (13) and

mount flange (14).
*
When
bolt
(12)
fall, therefore,
*
is removed valve body
(13) will
remove carefully.
Pull otu plunger (15) from mount flange.
WA500-
INSTALLATION
1.
OF BRAKE VALVE
Brake valve
1) Set
valve
body
(13)
in
mounting
position,
then
tighten mount flange (14) and bolt (12).

*
Assemble of plunger in mount flange.
Plunger:
Brake oil
2) Tighten mounting bolts (11) and secure valve.
2.
Pedal
Set pedal
(10)
in mounting
position,
insert pin
(8),
align stopper hole on left side of pin and assemble on

right with cotter pin (9).
3.
Bend the cotter pin securely.
Check assembled spacers.
Air piping, wiring

Connect air pipings (5), (4), (3), (2) and (I),
and connector
4.
wiring
(6)
(7).
Air leakage check

Tighten drain valve, start engine, then check for leakage
of air, and check operation
5.
of brakes.
Cover
Install cover from under the cab.
WA500-
DISASSEMBLY
1.
OF BRAKE VALVE
Body assembly
1) Make
match
mark
on upper
body
and lower
body.
2) Loosen mounting
bolts (I),
remove upper body (2)
and lower body (3). then disconnect them.
2.
Upper valve assembly

1) Hold slot-head screwdriver
in vice @
and fit in
slot in stem inside exhaust passage of relay piston.
2) Loosen nut (4). then remove washer (5), plain washer

(6), spring seat (7). rubber spring (8), upper piston
(9), return spring (IO),
relay piston spring (II),
relay
piston (12), and stem assembly (13).

When loosening the nut, the piston may fly
out under the force of the return spring, so
hold the piston by hand when loosening the
nut.
53-6
0
WA500-
31 Remove
snap
(15) from
ring
(14),
then
remove
primary
valve
upper body.
56OBP376
4) Remove
valve
snap
into
ring
washer
(19) and (20).
(16),
(17),
then
O-ring
disassemble
retainer
upper valve spring
primary
(18).
O-rings
(21), valve retainer
(22), and upper valve (23).
,,56OBPJY-J .,,,,
3.
Lower
valve assembly
1) Remove
exhaust
valve assembly
cover
(24),
2) Remove O-ring (26) from
3) Remove
snap ring
valve assembly
then
(27),
then
into washer
(31).
disassemble
secondary
(28), O-ring retainer
(30) and
retainer
(33). and lower valve (34).
secondary
lower body.
O-rings
WA500-
remove
(25).
lower valve spring
(29),
(32), valve
ASSEMBLY
I_
OF BRAKE VALVE
Lower valve assembly

1) Set lower
sembly
valve (34) with
valve
retainer
O-ring retainer
valve seat at bottom,
(33).
lower
valve spring
as(321,
(29) and washer (28), then secure with
snap ring (27).

*
Assemble
retainer
O-rings
(30)
and
(31)
on
the
O-ring
first.
,,,,,,,,,
,,,,,,
,,,,
56OBP379-
2) Assemble
body,
secondary
then
valve
install exhaust
assembly
(25)
in lower
cover (24).
56OBP378
2.
Upper valve assembly

1) Set upper valve (23) with
semble
valve
O-ring
retainer
with
t
retainer
(18)
(22).
valve seat at bottom,

upper
and washer
valve spring
(171, then
as(211,
secure
snap ring (16).
Assemble
retainer
O-rings
(19)
and
(20)
on
the
O-ring
first.
56OBP377
2) Assemble
primary
then secure with
valve assembly
(15) in upper body,
snap ring (14).
S6OBP376
53-8
0
WA500-
._,
3) Hold slot-head screwdriver

relay piston spring (11).
in vice @
, assemble
relay piston (12) and stem
assembly (13) in bottom of upper body, then set with

screwdriver.
Do not forget to fit an O-ring on the relay piston.
4) Assemble return spring (IO), upper piston (9), rubber

spring
(8), spring seat (7). and washers (5) and (6)
from top of upper body, then tighten with nut (4).

Do not forget to fit an O-ring on the upper piston.
The piston may fly out under the force of

!
G
the return spring, so hold the piston by hand

when assembling.
3.
Nut:
0.55 f 0.15 kgm
Body assembly
1) Install O-ring (35) on lower body (3).
2) Align match marks a on upper body (2) and lower

body (3), assemble and tighten mounting bolts (1).
WA500-
REMOVAL
Af
OF BRAKE CHAMBER
Stop the
machine

1.
Draining air
Loosen drain valve (1) and (2) drain air from air tank.
2.
Hood
Remove engine hood (3).
el
kg
3.
Engine hood:
60 kg
Brake air piping

1) Disconnect
hose
(4)
between
brake
chamber
and
brake oil tank at brake chamber end.

*
The oil will come out of the tank, so catch the oil
Disconnect electric wiring (5) from connector.
in a container.
2) Disconnect
hose (6) between slack adjuster and brake
chamber at brake chamber end.

3) Disconnect
tube
(7) between
brake valve and slack
adjuster at brake chamber end.
53i20
WA500-
4.
Brake chamber
1) Temporarily
sling brake
chamber
(8)
and
remove
mounting bolts (9).

2) Remove brake chamber bracket (IO).
*
Remove upper and lower brackets.
3) Sling brake chamber (8).
Remove
carefully
because working
space is nar-
row.
wkg
*
Brake chamber:
20 kg
The front brake chamber is removed after the rear

brake
chamber,
the front
brake
however,
the steps for removing
chamber
is the
same
as for
the
rear.
WA500-
53-11
0
INSTALLATION
1.
OF BRAKE CHAMBER
Brake chamber
1) Sling and set brake chamber
2) Install bracket
*
(10) of chamber.
Install both upper and lower brackets.
3) Tighten
2.
(8).
mounting
bolts (9) of chamber
(8).
Brake and air piping

1) Connect
chamber
2) Connect
adjuster
3) Connect
chamber
*
tube
between
hose (6) between

at brake chamber
hose (4) between

at brake chamber
Connect
53i2
(7)
at brake chamber
connector
brake
valve
and
brake
end.
brake
chamber
and slack
oil tank
and brake
end.
brake
end.
(5) of electric
wiring.
WA500-
3.
Hood
Remove engine hood (3).
4.
Air bleeder of brake system

Fill
brake
oil tank
with
oil, then
bleed air of brake
system.
*
*
Always keep the brake oil tank full.

For
details
of
air
bleeding,
see TESTING
AND
ADJUSTING.
*
*
Push in caution sensor rod of brake line.

Install the front frame chamber the same as tl ne rear
frame chamber.
WA500-
DISASSEMBLY
1.
OF BRAKE CHAMBER
Accessories
Remove breather (I), bleeder (2) and sensor (3).
2.
Cylinder
Loosen lock nut (4), then remove cylinder
*
(5).
There is O-ring fitted on the thread of the cylinder, so

remove it.
3.
Piston assembly
1) Move
retainer
(6)
to
right,
remove
pin
(7),
then
remove piston assembly (8).

+
Use a guide pin (Outer dia. = 2.5 mm,
length = 50
mm) to remove the pin.
423F446
2) Remove rod (9), then remove O-ring.
4.

1) Remove snap ring (IO), then remove seat (11). spring
(12) and valve (13).
t
Spring (12) is small, so be careful not to lose it.
2) Remove packing (15) from piston (14).
423 F447
53d4
423P%%
WASOO- 1
5.
Body
Hold body (16) with hand, remove mounting bolt, then
remove body.
The tension
!
Q
t
of the spring on the body is 25
kg, so be careful when removing it.
Remove the O-ring from the contact surfaces of the

body and air cylinder.
6.
Disassembly of body
1) Remove
snap
ring
(17),
then
remove
ring
(18),
packing (19), seat (20) and packing (21).
2) Remove
snap ring (22).
then remove ring (23)
and
seal (24).
7.
Air piston
1) Remove spring (27) and piston assembly
air cylinder
WA500-
(25).
(26) from
2) Remove nut, then remove piston (28) and rod (29).

3) Remove packing (30) and ring (31) from piston (28).
4) Remove O-ring (32) and washer (33) from rod.
53-16
0
WA500-
ASSEMBLY
1.
OF BRAKE CHAMBER

1) Install washer (33) and O-ring (32) on rod (29).
*
When
fitting
threads
of
the
the
O-ring,
rod to
wind
tape around
prevent
damage
the
to
the
O-ring.
4
O-ring:
Brake oil
2) Assemble packing (30) and ring (31) on piston (28).

6
Packing:
Grease (G2-LI)
3) Insert rod (29) in mount of piston (28), then secure

with nut.
+
After
tightening
the
nut, check that there
is no
clearance between the stepped part of the rod and

the piston.
&
Piston mounting hole:
m
2.
Nut:
Grease (G2-L .I)
14 + 2 kgm
Assembly of body
1) Install seal (24)
and ring
(23)
in body
(1 6), then
secure with snap ring (22).

*
Install the seal with the lip facing the outside.
Check that the snap ring is fitted
securely in the
groove.
6
Seal:
Brake oil
23
24
16
423F449
WA500-1
2) Turn over body, assemble packing (21), seat (20) and

packing
(19),
insert ring (18). then secure with snap
ring (17).
t
Install the seal with the lip facing the outside.
Check that the snap ring is fitted
securely in the
groove.
a
Packing:
Brake oil
423F450
3.
Piston assembly
Insert piston assembly (27) in air cylinder
(25).
Coat inside of air cylinder with grease.

When inserting the piston assembly, tilt at an angle
of about 30,
insert about l/3,
then lay the air cyl-
inder on its side and insert the piston fully.

Check that the piston assembly moves smoothly.
4.
Body assembly
Insert spring
(26)
in mount
of air cylinder,
fit O-ring
(34) in body assembly (16), then install in air cylinder.

*
Push in the
in
body by hand, install 2 mouting
diametrically
opposite
positions,
then
bolts
tighten
together with bracket (35).

w
5.
Mounting bolt:
4.4 f 0.6 kgm
Assembly of piston
1) Insert valve (13), spring (12) and seat (11) in piston
(14), then secure with snap ring (10).
*
Be careful to insert the spring facing in the correct

direction.
Check that
the snap ring fitted
securely
in the
groove.
53d8
WA500-
2) Assemble packing (15) on piston.

*
Install the packing with the lip facing the outside.
6.
Packing:
Grease (G2-LI)
Piston assembly
Blow air into air cylinder
assembly
(8) in mounting
and blow out rod.

position,
Set piston
then connect with
pin (7).
*
The pin hole is hidden by the retainer,
so move the
retainer to the right and insert the pin.

*
After
inserting
the pin, check that the retainer
has
moved back to its original place and the pin is hidden.
7.
Cylinder
Install
nut
(4) and O-ring
(36)
on cylinder
(5), screw
into mount, then secure with nut.

*
Screw the cylinder
in fully,
then turn back until the
breather and bleeder are in a straight line.
8.
Inside surface of cylinder:
Nut:
142
Brake oil
3 kgm
Sensor
Fit O-rings on rod
(9) and sensor (3). then install in
mounting position.
*
Insert the rod until it is level with the body.

m
9.
Sensor:
5.6 f 0.6 kgm
Accessories
Install breather (1) and bleeder (2).
w
WA500-
Bleeder:
0.95 + 0.25 kgm
53-19
m
REMOVAL
n!
OF SLACK
Stop the
machine
ADJUSTER

1.
Brake piping
1) Remove cover (1).
2) Disconnect tube (2) between slack adjuster and brake
chamber at slack adjuster end.
*
Tube (3) at rear.
3) Disconnect
tube
(4) between
slack adjuster and left
and right brake pistons at slack adjuster end.

2.
Slack adjuster
Remove mounting bolts, then remove slack adjuster (5).
t
There is little space, so be careful when working.
INSTALLATION
ADJUSTER
1.
OF SLACK
Slack adjuster
Set slack adjuster
(5) in mounting position, then tighten
mounting bolts.
*
Tighten
the mounting
bolts partially,
then tighten
fully after connecting the piping.

2.
Brake piping
1) Connect tube (4) between slack adjuster and left and
right brake pistons at slack adjuster end.
2) Connect
tube
(2) between
slack adjuster and brake
chamber at slack adjuster end.

*
Tube (3) at rear.
3) Install cover (1).

3.
Bleeding air
Bleed air from brake system, and check that there is no
leakage of oil from connections.
*
For details
of bleeding
air, see 52 TESTING
AND
ADJUSTING.
t
Bleed the air from the brake end and slack adjuster
end.
53620
WA500-
DISASSEMBLY
1.
OF SLACK
ADJUSTER
Bleeder
Remove bleeder (2) from body (1).
2.
Cylinder
Remove mounting
cylinder
bolts, then disconnect
body (1) and
(4) together with bracket (3).

There
is spring tension
hold the contact
inside the cylinder,
so
surfaces and be careful when
removing.
3.
Piston
1) Remove spring (5) and O-ring (6).
2) Remove piston (7), then remove O-ring.

*
Use a rod of 10 mm diameter
and push out the
piston slowly.
*
Be careful not to damage the thread with the rod.
423F451
4.
Poppet
._ ji
1) Remove
cover (8) from
cylinder
(4),
then
remove
plug (9), spring (10) and poppet (11).

When removing the poppet,
blow in air from the
oil hole in the cylinder.

Hold the oil port of the cylinder
by hand, and do
not pump in air suddenly.

Be careful
not
to
change
the
combination
of
poppet (11) and cylinder (4).

When replacing, replace the poppet and cylinder as
an assembly.
2) Remove O-ring (12) from poppet.
WA500-1
53-21
ASSEMBLY
1.
OF SLACK
ADJUSTER
Poppet
1) Fit O-ring (12) on poppet (11 ).
2) Install poppet
(II),
spring (IO),
(8). then assemble cylinder
2.
plug (9) and cover
(4).
Piston
1) Install O-ring (13) on piston (7).
2) Insert piston (7) in cylinder
*
3.
(4).
Check that the piston moves smoothly.
Cylinder
1) Install O-ring (6) and spring (5) in cylinder.
*
Installed road of spring: 4.4 kg
2) Install
body
(1)
and
cylinder
(4)
together
with
bracket (3).
4.
Bleeder
Install bleeder (2).
WA500-
REMOVAL
OF BRAKE ASSEMBLY
Special tool
Part name
Part No.
A
793-520-I
A.
Stop
Qty
Fixture
910
the machine

1.
Tire, wheel
Jack up axle, put stand under axle, then lift off tire and
,,,,,,
,,,
wheel (1).
Tire, wheel:
2.
600 kg
Draining oil
Remove drain plugs (2) and (3), and drain oil from axle
assembly.
t
Set with the drain plug at the bottom.

- :
3.
Axle assembly:
30 Q
Cover
Remove
bolts
mounting
(4),
then
remove
final
case
cover (5).
4.
Axle shaft assembly

Using forcing screw
01
Pitch =
1.75 mm), pull out alxe shaft assembly (6).
5.
Remove
mounting
(Thread
dia.
bolts
= 12 mm,
(7),
and
Pitch
using eye-bolts @
= 1.75
mm),
lift
off
planetary carrier assembly (8).

*
Since the balance
is bad, adjust center of gravity
with
a bar and remove.

Planetary
WA500-
carrier assembly:
90 kg
53-23
0
6.
Ring gear assembly

Using tool
A,
hold wheel
hub
(9) and brake
(IO)
in
position.
t
Install tool
A to points on opposite
sides, and use
washers to adjust clearance.
7.
Remove
mounting
bolts
(11)
of
retainer
(121, then
remove ring gear assembly (13).

*
There are shims between the retainer and axle housing, so check the number and thickness of the shims,
and use for reference when installing.
Ring gear assembly:
50 kg
8.
Remove brake hose (14).
9.
Sling brake an wheel hub assembly (161, remove mounting bolts (15). then lift off assembly.
Brake, wheel hub assembly:
IO.
270 kg
Axle housing
Remove bearing
(18) and retainer
(19) from axle hous-
ing (17).
53-24
WA500-1
INSTALLATION
OF BRAKE ASSEMBLY
Special tool
Part No.
793-520-I 910
1.
Qty
Part name
~I
Fixture
Axle housing
Press fit retainer
(17).
* After
(19) and bearing (18) on axle housing
press fitting
the retainer and housing, and the
retainer and bearing, check that there is no clearance

425P689
at any point.
2.
Brake, wheel hub assembly

Use tool
A to hold brake assembly and wheel hub in
position.
+
As far as possible, install tool A to points at diametrically
opposite
positions
and adjust clearance
using
with washer.
3.
Raise brake and wheel hub assembly (16), set in position

on axle
housing mount,
(15).
* Be careful
zontally,
then tighten
mounting
of the center of gravity,
bolts
and sling hori-
then install it.
&
Mounting bolt:
Thread tightener
Mounting bolt:
56+
6 kgm
4.
Install brake hose (14).
5.
Wheel bearing adjusting method

1) Raise ring gear assembly
housing and, tighten
425P866
(LT-2)
(131, then
retainer
insert in axle
(12) temporarily
with 3
bolts, then remove tool A.

*
*
Measure thickness lb of retainer first.

Do not insert shims in the retainer when tightening
temporarily.
Rotate
the wheel hub to settle the bearing, then
tighten to a uniform torque.

D
Mounting bolt of retainer:
12
8 f 0.5 kgm
425F293
425P645
WA500-
53-25
0
2) Insert a depth micrometer through measuring hole of

retainer
(20), and measure clearance a between end
face of housing and end face of retainer.

*
Measure at 2 places and take the average.
0.3
mm
c = a -
added
to
measured
value
b, becomes shim thickness.
difference
(Round off
fraction to next highest decimal 0.1 mm,)

*
Use the smallest number of shims which gives the

required thickness.
3) Install tool A to brake assembly and wheel hub, and

remove retainer.
Install requried thickness of shims,
then install retainer again.

f
Always install tool A before assembling the shims.
Rotate
the wheel hub and tighten
bolts uniformly
the mounting
to the specified tightening torque.
&
Mounting bolt:
Thread tightener
Mounting bolt:
28.25 f 3.25 kgm
(LT-2)
425F297
6.
Planetary carrier assembly

Fit
O-ring,
mm,
and using eye-bolts @
(Thread
Pitch = 1.75 mm) sling planetary
dia.
= 12
carrier assembly
(8) and set in mounting position, then tighten mounting

bolts (7).
*
Since the balance is bad, adjust the center of gravity

with a bar and install.
7.
Axle shaft assembly

Install
bolt @
to axle shaft and install axle shaft as-
sembly (6).
*
If the position of the sun gear does not match, rotate

the wheel hub to align.
8.
Cover
Fit O-ring in groove in cover, then install cover (5) with
bolt (4).
53-26
0
WA500-
9.
Refilling with oil

Tighten drain plug (3) and (2) and add oil through level
plug (21) to the specified level.
*
Set the
machine so that the drain
plug of the final

Axle assembly:
approx. 30 Iz
(Width across flats: 30 mm)
10. Tire, wheel

Install tire and wheel (I), then remove stand.
w
11.
Mounting nut:
48 + 5 kgm

*
For details
of bleeding
air, see 52 TESTING
AND
ADJUSTING.
WA500-
53627
DISASSEMBLY
OF BRAKE ASSEMBLY
(Front, rear)
Special tool
Part No.
A
1.
Part name
793-502-1910
1 Fixture
Cylinder
A_
Using eye-bolts u
mm), lift out cylinder
I Qtv
Pitch = 2.0
(1).
Disassemble cylinder with following
steps:
1) Screw in eye-bolts @ (Thread dia. = 16 mm, Pitch

= 2.0 mm), push in spring with bar @ , then pull
out pin (2).
2) Remove spring (3) and shaft (4).
3) Remove piston (5).
53-28
0
WA500-1
2.
Plate, disc
1) Remove plate (6).
2) Remove disc (7).

*
When
removing
marks
on the inner
the
disc and
plates,
put
match
gear and disc, and outer
gear
and plate before removing.

*
The discs are made of soft material,
so be careful
not to damage them when removing.

*
3.
Remove discs and plates alternately.
Outer drum
*
Remove tool A.
1) Using eye-bolts
(Thread
1.75 mm), lift out outer drum
WA500-
dia. = 12 mm,
Pitch =
(8).
53-29
0
2) Remove outer race (9).

3) Remove retainer (IO).
4) Remove floating seal (11).
5) Remove oil seal (12).

6) Remove floating seal (13).
53-30
0
WA500-
ASSEMBLY
Special
OF BRAKE ASSEMBLY
tools
Part name
Part No.
1.
(Front, rear)
793-502-1910
792-520-21
Bl
792-530-l
Outer
IO
600
Qty
Fixture
Installer
Push puller
drum
1) Using
tools B and
BI,
install
floating
seal (13)
to hub.
425F298
&
Seal contact
Assemble
Using
face: Engine
O-ring
alcohol,
Remove
contact
Tighten
tool BI
of the O-ring
press fitting,
uniformly
measure
between
so that there
height
the
seal
of the hub.
of the floating
the circumference,
difference
within
powder
from the floating
surface
twisting
around
seal.
all the white
surface.
all the grease
and O-ring
to floating
remove
from the O-ring

*
(13A)
oil (E030-CD)
is no
seal. After
t at four places
and check that the

measurements
is
1 mm.
425FO1807
425FO1808
2) Install oil seal (12).

&
Seal contact face: Grease
Mating
surface
(G2-LI)
of oil seal and hub:
Thread
tightener
(Loctite
#648)
425FO1809
53-30-2
0
WA500-1
3) Using
tools B and BI,
in retainer
&
install
floating
Seal contact face: Engine

Ir Assemble
*
Using
O-ring
alcohol,
Remove
+- Tighten
contact
powder
from the floating
measure
between
so that there
height
the
seal
of the retainer.
of the floating
the circumference,
difference
seal.
all the white
surface
of the O-ring
press fitting,
within
to floating
tool BI uniformly
twisting
oil (E030-CD)
surface.
all the grease
and O-ring
around
(1 IA)
remove
from the O-ring

f
seal (1 1)
(IO).
is no
seal. After
t at four places
425FO1806
and check that the

measurements
is
1 mm.
11A
t
::-p:l
425FO1811
11A
11
425FO1810
WA500-
53631
4) Match
retainer
(IO)
with
dowel
pin and install re-
tainer.
5) lnstal outer race (9).
425P707
6) Using eye-bolts @
(Thread
dia. = 12 mm,
Pitch =
1.75 mm), lift and install outer drum (8).
7) Install tool A.
425P705
2.
Disc, plate
1) Install disc (7).
5322
WA500-
2) install plate (6).

*
Align notched portion
of outer teeth of plate and
assemble.
*
Align the match marks on the disc and inner gear,

and plate and outer gear, then assemble the plates
and discs in turn.
3.
CyliQder
*
Assemble cylinder with following
steps:
1) Set piston (5) at bottom.
2) Install shaft (4) and spring (3).

3) Screw in eye-bolts @
2.0 mm), push in spring with bar @
Pitch
, then install
pin (2).
4) Fit O-ring, and using eye-bolts @

16 mm,
(Thread dia. =
Pitch = 2.01, match with guide bolt @
and lift and install cylinder assembly (1).

&
Mounting bolt:
Thread tightener
Mounting bolt:
18 f 2 kgm
(LT-2)
425P710
WA500-
53iif3
REMOVAL
a
Stop the
OF SPRING
machine
CYLINDER



1.
Cover
Remove cover (1) at front of front frame.
2.
Linkage
1) Turn adjusting bolt (2) in counter clockwise direction
and check that there is play in the linkage (3).
2) Remove
pin
(4)
and
disconnect
linkage
(3) from
adjuster (5).
Air piping
Disconnect air piping (6) of spring cylinder.
*
Drain the air.
After
removing,
cover to prevent dust or dirt from
engine.
4.
Spring cylinder
Remove mounting nut, then remove spring cylinder
53634
(7).
WA500-
INSTALLATION
1.
CYLINDER
Spring cylinder
Set spring cylinder
w
2.
OF SPRING
(7) in mounting position, and install.
Mounting nut:
28.5 + 3 kgm
Air piping
Connect air piping (6) to spring cylinder.
3.
Linkage
1) Connect linkage (3) to adjuster (5) with pin (4).
2) Turn adjusting bolt (2) in clockwise direction,
and at
point adjusting bolt cannot be tightened further, turn

back 180 or 3 or 4 notches.
*
For details of adjusting the linkage, see 52 TEST-
Check the operation of the parking brake.
ING
4.
AND
ADJUSTING.
Cover
Install cover (1) at front of front frame.
WA500-
1.
2.
Remove boot (3).

Support
rod (4) with
press and remove bolt
(5), then
slowly raise press and separate.

3.
Remove
cover
from cylinder
(7), spring (8) and piston assembly
(9)
(6).
4.
Remove rings (11) and (12) from piston (10).
5.
Remove ring (13) and (14) from cylinder.
ASSEMBLY OF SPRING
CYLINDER ASSEMBLY
1.
Assemble rings (14) and (13) to cylinder
2.
Assemble rings (12) and (11) to piston (10).
3.
Assemble
spring
(8), piston assembly
(6).
(9) and cylinder
(6) to cover (7), then set in press.

*
Coat sliding portion with grease.

Grease:
4.
G30M
Push rod section with press and slowly compress spring.

Then align bolt holes of cylinder and cover, and tighten
mounting bolt (5).
w
5.
Mounting bolt:
11 f 1 kgm
Assemble boot (3).
53-36
0
WA500-
REMOVAL
Stop
OF PARKING
the
safety
machine
brake
Lower

and put
the machine
1.
on level ground
bar on the frame.
ground
blocks
from
BRAKE
and install
the bucket
the
to the
under
moving.
Drive shaft
Disconnect
front
drive
shaft
(I)
from
differential,
and
remove disc cover (2).

Drive shaft:
2.
Air hose
Disconnect
3.
44 kg
air hose (3) from spring cylinder.
Linkage
Remove pin (4) and disconnect
*
For
details
ADJUSTING
4.
on adjusting
linkage.
screw,
see TESTING
section.
Spring cylinder
Remove nut, then remove spring cylinder
5.
Caliper
1) Remove plate (6).
*
Remove pad.
WA500-
(5).
AND
2) Remove caliper (7).

*
Use two men to remove caliper.
m
6.
Caliper:
32 kg
Disc
Remove disc (8)
7.
Disassembly of caliper
1) Remove snap ring (9) and pull out adjuster (IO).
425P720
2) Remove washer (11) and (12) and seal (13).
3) Remove
bolt,
then
remove
caliper
(14) and gasket
(15).
425P322
53638
WA500-1
4) Remove
piston shaft
(16)
and thrust
bearing
(17)
,
,,
,,
from piston.
,, \ ,,
5) Remove piston (19) and piston seal (20) from caliper
,,
(18).
WA500-
,,
i*
, ,j,
,,
INSTALLATION
1.
OF PARKING
BRAKE
Assembly of caliper
1) Install
piston seal (20)
in caliper
(18).
then insert
position (19).
&
Piston, piston seal: Grease (G2-LI)
4253724
2) Screw in piston shaft
(16)
into piston, then install
thrust bearing (17).

*
Be careful
of
direction
of thrust
bearing,
then
install.
&
Thrust bearing:
Grease (G2-LI)
3) Fit gasket (15), then install cap (14).

w
Mounting bolt:
18 f 2 kgm
d25P722
4) Install seal (13) and washers (11) and (12).

*
a
53-40
0
Insert seal in groove completely.

Seal:
Grease (G2-LI)
WA500-
5) Assemble adjuster (IO) and secure with snap ring (9).
425P720
2.
Disc
Install disc (8).
3.
&
Mounting bolt:
Thread tightener
Mounting bolt:
28.5 + 3 kgm
(LT-2)
Caliper
1) Set caliper (7) in mounting position.
*
Check that pad is assembled.
2) Install plate (6).

+
Raise the caliper slightly and align the caliper and

the groove of the pad, then assemble.
Insert the pin of the plate completely.
&
Mounting bolt:
Thread tightener
Mounting bolt:
95 t 10 kgm
(LT-2)
4.
36 mm)
Spring cylinder
Set spring cylinder
(5) in mounting position and tighten
nut.
w
WA500-
Nut:
28.5?
3 kgm
5.
Linkage
Assemble
*
6.
pin (4) and connect
For details, see TESTING
linkage.
AND
ADJUSTING.
Air hose
Connect
53-42
0
air hose (3) to spring cylinder.
WA500-
REMOVAL
Stop the
OF PARKING
machine
BRAKE
PAD

*
1.
Release the parking brake.
Turn the adjusting bolt (1) in a counter clockwise direction, and increase the clearance between the pad and the
disc.
2.
Remove cover (2), then remove plate (3).

*
3.
Remove either the right or left plate (3).
Raise the parking brake caliper slightly and remove pad

(4).
INSTALLATION
BRAKE PAD
1.
OF PARKING
Insert pad (4) between caliper and disc.

*
Since the pad is new, turn the adjusting bolt further

in
counter clockwise
direction
to
increase
the
clearance.
*
Lift the caliper up slightly and the pad will be able to

be smoothly
2.
inserted.
Fit plate (3) and install ocver (2).

*
Align the caliper and groove of the pad completely

with the left and right plates.
&
Mounting bolt of plate: Thread tightener
Mounting bolt of plate:
95 + IO kgm

3.
Turn
the adjusting
bolt
(LT-2)
(1) clockwise
36 mm)
and adjust pad
clearance.
*
For
details
of
adjusting,
see 52
TESTING
AND
ADJUSTING.
WA500-
53-43
0

54 MAINTENANCE
STANDARD
Brake valve. . . . .
Brake chamber
.
Slack adjuster . .
Brake...........
Parking brake
..
Spring cylinder . .
WA500-
.
.
..
..
.
.
.
.
.
..
.
..
..
.
..
..
..
.
.
..
54-2
54-4
54-5
54-6
54-8
. . 54-9
54-1
BRAKE VALVE
425F156
54-2
WA500-
Unit:
No.
Check item
Criteria
I
1
mm
Remedy
Tolerance
Clearance between pedal mounting

pin and mount plate
10
-0.015
-0.050
+0.036
0
0.086 0.015
Pin:
Hole:
10
-0.015
-0.050
+0.058
0
0.015 0.108
Pin:
9.85
Hole: 10.1
26.5
-0.020
-0.160
+0.033
0
0.020 0.193
Plunger:26.16
Hole: 26.65
9.85
10.1
Crearance between roller and pin
Clearance between mount plate

and plunger
Clearance between primary piston

and upper body
60
+0.150
+0.050
+0.401
+0.325
0.175 0.351
Clearance between relay piston

and lower body
66.5
0
-0.10
+0.76
+0.10
O.lO0.86
Outside diameter of roller
Standard size
14.4
Free height of rubber spring
26.0
+0.2
-0.2
Piston return spring
Free
length
65.3
Repair limit
Installation
length
lnstallatioin
load
Free
length
14.6
10.5 kg
54
Primary valve spring
Replace
12.0
Standard size
Repair limit
+0.1
-0.1
26.2
Tolerance
Installation
load
4.5 kg
10
Inner stem spring
35.6
16.0
2.8 kg
30
11
Outer stem spring
41 .o
16.0
4.0 kg
34
12
Relay piston spring
39.5
12.1
4.7 kg
33
13
Secondary valve spring
16.5
10.2
3.0 kg
14
14
WA!iOO- 1
0.55 * 0.15
kgm
Retighten
54-3
BRAKE CHAMBER
Section A - A
425F157
Unit:
NO.
Check item
Criteria
Remedy
Tolerance
Clearance between cylinder and

piston
Standard
size
Standard
clearance
Clearance
limit
Shaft
Hole
68
-0.030
-0.076
+0.046
0
0.030
0.122
0.15
69.6
+0.500
-0.300
+0.046
0
0.346
0.500
1 .o
Replace
Outside diameter of oil seal
Air piston stroke
14.0 ? 3.0 kgm
4.4 F 0.6 kgm
Min. 133.5 (Normal pressure: Max. 9.5 kg/cm21
Retighten
54-4
WA500-
SLACK
ADJUSTER
421F150
Unit:
Remedy
Criteria
Check item
NO.
Tolerance
Clearance between body and

piston
Standard
size
55
Shaft
Hole
-0.030
-0.076
+0.074
0
Free
length
Spring
Installation
length
Clearance
limit
0.03 0.15
0.03 0.25
Repair limit
Standard size
Standard
clearance
Installation
load
198
38
4.4 kg
39.2
33
6.8 kg
Spring
Tightening
torque
of bolt
6.7 t 0.7 kgm
Tightening
torque
of plug
5.7 ? 0.7 kgm
WA500-
Free
length
Replace
Installation
load
Retighten
mm
BRAKE
.--T--J
,
Detail
425F158-1
WA500-
Unit:
No
Check item
Criteria
Remedy
Standard size
1
Return spring
Repair limit
Free
length
Installation
length
Installation
load
Free
length
Installation
load
96.9
80.6
74 kg
95.3
66.6 kg
Standard size
Repair limit
2.4 f 0.1
2.0
5.1 i: 0.1
4.6
47.4 t 1.3
41.6
Thickness of plate
Thickness of disc
Total thickness of plate and disc
Wear of contact surface of seal
Standard size
Tolerance
430
Repair limit
-EL55
Wear of surface in contact with piston

seal
420
Wear of surface in contact with piston

sea I
455
Deformation of friction surface of

plate and disc
Backlash between outer gear and plate
0.28 - 0.61
10
Backlash between inner gear and disc
0.16 - 0.52
11
12
13
18 f 2 kgm
14
56 f 6 kgm
mm
+;.097
I
+0.097
0
Max. 0.4
18+2
Il.52
kgm
1.0 kgm
Retighten
WA500- 1
5&7
PARKING
BRAKE
View Z
425F160
Unit:
Check item
Criteria
Standard size
Wear
of pad
Remaining thickness
of friction material
22.7
Including backing plate
31.7
Tolerance
Remedy
Repair limit
Replace
3.7
-
12.7
0.8
Face runout of disc
Wear of rod connecting pin
12
-0.10
-0.17
Wear of disc
(Thickness of disc plate)
22.0
to.5
Rebuild
Thickness of plate
must be under 20 mm.
Replace
Less than 20 mm
Clearance between pad and disc

(Total of both sides)
1.06
+0.18
2.3
Clearance between brake body

and plate
1.25
kO.85
94.5 * 10.5 kgm
28.5 f 3.0 kgm
10
Adjust
7.25 i 1.75 kgm
Retighten
-
54-8
28.5 f 3.0 kgm
mm
WASOO- 1
SPRING
CYLINDER
425F159
Unit:
NO.
Check item
Criteria
Remedy
Tolerance
Standard
size
Clearance between cylinder and

piston
2
-
Standard
clearance
Shaft
Clearance between piston insert

center boss
Hole: 159
Shaft :I 58.65
0.35
Hole: 38.8
Shaft 138.04
0.76
Free
length
Piston spring
Replace
Repair limit
Installation
length
I
260
Clearance
limit
Hole
Standard size
Installation
load
I
Free
length
I
Installation
load
I
560+50
Play of rod in axial direction
2.1
Installed dimension of rod
65
Tightening torque of rod, lock nut
Adjust
WA500-
mm
7.25 * 1.75 kgm
Retighten
60 WORK EQUIPMENT
SYSTEM
WORK EQUIPMENT SYSTEM

61 STRUCTURE
AND
General
FUNCTION
............................
................
Hydraulic circuit diagram ................
Work equipment lever linkage ............
Hydraulictank
.......................
- Oil filter bypassvalve ................
- Breather .........................
Hydraulic pumps .....................
- Hydraulic pump ....................
- Switch pump ......................
- POCpump
.......................
POC valve ..........................
Main control valve ....................
* Reliefvalve .......................
- Safety valve (with suction valve) .........
- Suction valve ......................
- Float selector valve and unloader valve .....
Hydraulic cylinder
....................
Bucket positioner and boom kick-out ........
Bucket linkage .......................
Bucket ............................
Accumulator
........................
Hydraulic
WA500-1
circuit system
61-
61- 4
61-
61-5-1
61-
61-
61-
61-
61-
61-
61-
61-10
61-18
61-20
61-21
61-22
61-23
61-30
61-32
61-34
61-36
61-37
61-1
8
GENERAL
The work equipment
system consists of the hydraulic
circuit and steering circuit.
The hydraulic circuit con-
The
maximum
regulated
pressure of the
hydraulic
circuit
is
by the relief valve inside the main control

There
are two
safety
valves (with
suction
trols the operation of the bucket and attachment.
valve.
The
valve) and an unloader valve in the dump cylinder cir-
oil in hydraulic
tank
(5) is sent by hydraulic
pump (71, to main control valve (1).

and
lift
HOLD,
spools
of the
main
When the dump
control
valve are at
the oil passes through the drain circuit of
the main control valve. It is then filtered
by the filter
in the hydraulic tank, and returns the tank.

The dump or lift spool in POC valve is activated
operating
the work equipment
control
each spool in the work equipment

lically activated.
Thereby,
from the work equipment

dump cylinder
cuit to protect the circuit.

Even when engine is at rest, the lift arm can be lowered to the ground because accumulator
Hydraulic
by
lever, causing
valve to be hydrau-
(3) is pro-
vided in the circuit.

tank
has a breather
(5) is a pressurized,
with a relief valve.
sealed type and

This acts to pres-
surize the tank and at the same time prevents negative

pressure. This protects the pump from cavitation.
the oil is allowed to flow

valve to lift cylindertll
)or
(21, thus operating the lift arm or the
bucket.
61-2
WA500- 1
425FlOO
1. Main control valve

2. Dump cylinder
3. Accumulator
4. POC valve
5. Hydraulic
tank
6. Switch pump
7. Hydraulic pump
8. Steering, POC pump
9. Steering valve
10. Steering cylinder
11.
WASOO-1
Lift cylinder
61-3
HYDRAULIC
CIRCUIT
SYSTEM
Engine running, hydraulic control lever in HOLD
,
I?$//
21
425F114A
WA500- 1
HYDRAULIC
CIRCUIT
DIAGRAM
19
Float
Lower
Raise
Dump
Tilt
Hold
425Fl 15A
1) Volume
Note
of nitrogen gas: 300 cc

Minimum actuating pressure: 12 kg/cm*
Note 2) Relief valve setting pressure

Serial No. 10001-10153:
30 kg/cm,at
33Q/min
Serial No. 10154 and up: 40 kg/cm, at 33Q/min
1. Hydraulic tank
12.
Steering valve
23.
POC lift spool
Hydraulic filter
13.
Check valve
24.
Relief valve
2.
3.
Breather
14.
Demand spool
25.
Dump spool
4.
Switch pump
15.
Relief valve
26.
5.
Hydraulic pump
16.
Steering spool
27.
Lift spool
28.
Float selector valve
6.
Steering pump
17.
7.
POC pump
18.
29.
Unloader valve
8.
Pilot oil filter
19.
Steering cylinder
30.
Suction valve
9.
Check valve
20.
Oil cooler
31.
Lift cylinder
10.
Accumulator
21.
POC valve
32.
Dump cylinder
11.
Relief valve
22.
POC dump spool
WA500-1
61-5
0
WORK
EQUIPMENT
Section
LEVER LINKAGE
A - A
421FO65
1.
Lock lever
2.
Lift control lever
3.
Dump control lever
4.
Solenoid valve for boom kick-out
5.
Solenoid valve for bucket positioner
6.
POC valve
61-5-l
0
WA500-
HYDRAULK
TAWU
Outline
- The oil from the hydraulic
is sent from
the
pump through the control valve to the cylinders.
In
the return
tank
The hydraulic filter (2) filtersall

If the hydraulic
of
through
the
oil
is cooled
hydraulic
in the
filter
oil
cooler,
the oil in the.circuit.
(2) becomes clogged:, a bypass
valve (1) acts to allow the oil to return directly to the
circuit, the oil from various parts merges.
A part
filter
tank (4).
passes
This prevents damage to the filter (2).
The.
bypass valve (1) is also actu.ated when negative pres-
(2) and returns to the
sure is generated in the circuit.
tank (4).
l-
2-
Section A-A
425F101
61-6
1.
Filter bypass valve
4.
Hydraulic
2.
Hydraulic
5.
Drain valve
3.
Breather
6.
Oil level sight gauge
filter
tank
WAXIO- 1
OIL
FILTER
BYPASS
VALVE
When the filter is clogged.

Bypass valve (1) opens and the oil returns directly to the
tank without
passing through the filter.
Bypass valve set pressure:
From main
control valve
1.27 kg/cm
423Fl31
When negative pressure is formed in the return circuit.
Valve (2) moves up and acts a check valve.
Check valve set pressure: 0.26 kg/cm2
c3 To main
control valve
423F132
BREATHER
.
Preventing negative pressure inside the tank
The tank
is a pressurized, sealed type, so negative pres-
sure is formed
inside the hydraulic
level drops during operations.

difference
atmospheric
tank when the oil
When this happens, the
in pressure between the tank and the outside

pressure opens the poppet (3), and air from
the outside is let into the tank to prevent negative pressure.

Preventing rise in pressure inside the tank
When the hydraulic
in the hydraulic
rises.
cylinder
circuit
If the hydraulic
are being used, the oil level
changes and the temperature
pressure rises above the set pres-
sure, sleeve (4) is actuated to release the hydraulic

sure inside the tank.
pres2.
Filter element
3. Poppet
4.
Sleeve
423F133
WASOO-1
61-7
HYDRAULIC PUMPS
-
HYDRAULtC
* SWtTCH
PUMP
PUMP
SectionA-A
425FO12
1.
2.
Front cover
Model
Gear case
Theoretical
3.
61-8
4.
Rear cover
5.
Specifications
SAR(331-100
discharge
1:00.5 c&w.
Max. pressure
210
Max. pump speed
2,500
kg/cm2
rpm
wA500- 1
POC PUMP
Steering pump
POC pump
SAR(3bO80
SAR(1)-014
425F103
1.
Specifications
2.
Front cover
POC pump
3.
4.
Gear case
5.
Rear cover
6.
WA500- 1
Model
Theoretical
SAR(1 J-014
discharge
14.5 cc/rev
Max. pressure
210 kg/cm
Max. pump speed
3500 rpm
61-9
pOC VALVE (Pilot operated control valve)
View 2
421 Fe69
61-10
1.
Port A,
(To lift cylinder bottom)
(PA,)
2.
Port B,
(To lift cylinder head) (PB,)
3.
Port P (From POC pump)
4.
Port A, (To dump cylinder bottom)
5.
Port B, (To dump cylinder head) (PB,
(PA,
6.
Port T (Drain)
WA!XO- 1
Section A-A
section B-B
421FO70
7.
Spool with variable throttle valve

(for operating lift arm)
8.
Lever
equipment
9.
Spool (for operating lift arm)
control
Function
* The POC valve is installed at the bottom
Spool (for operating bucket)
11.
Lever
control
12.
Return spring
the
Return spring
14.
Spool with variable throttle valve
lever,
and
of the work
is connected
to
the
lever by a linkage.
* The oil from the POC pump is supplied to the spool
10.
13.
control
end of the control
valve according
lever is moved.
operating
force
to the amount
the
This oil actuates the spool, so
needed
small, and as a result, operator
for
the control
fatigue
lever is
is reduced.
(for operating bucket)
WA500-
61-11
POC RELIEF
VALVE
1.
Main valve
2. Valve seat
3.
Pilot poppet
4.
Spring
5.
Adjustment screw
421 F071
Function
* The POC relief valve is between the POC pump and

the
POC valve.
actuated,
When the
or when abnormal
POC valve is not being

pressure is generated, the
oil sent from the pump is relieved through this valve

to protect the pump and circuit from damage.
(Sets maximum
pressure in the circuit)
Operation
* Port A is connected to the pump circuit, and port C is
Fig. 1
421 F072
connected to the drain circuit.

The oil passes through
and fills port B.
with valve seat (2).
the orifice
of main valve (1)
Pilot poppet (3) is in close contact

(Fig. 1)
* If the pressure at ports A and B reach the pressure set

by the poppet spring, pilot poppet (3) opens and the
pressure oil at port B flows through port D to port C.
As a result, the pressure at pot-t B drops.
(Fig. 2)
* If the pressure at port B drops, a pressure difference

is generated between ports A and B due to the orifice
in main valve (1).
Main valve (1) is pushed open by
the pressure at port A, and the oil at port A is relieved.
(Fig. 3)
Fig. 3
61-12
421 F074
WASOO-1
FUNCTION
LIFT AND
OF POC VALVE
DUMP LEVERS AT HOLD
Lift lever
POSITION
Dump lever
0
0
0
Hold
From pump
To tank
F42101008
Operation
* The oil from the pump enters port a, but the circuit is
closed by spool (I),
valve (3).
so the oil is drained from relief
The oil at port B2 of the main control
valve is connected to the drain circuit through port j

and k of spool (I);
the oil at port A2 is connected to
the drain circuit through port i and k of spool (1).
WASOO-1
61-13
DUMP LEVER AT DUMP

LIFT LEVER AT LOWER
Lift lever
(I)
(Intermediate position)
Dump lever
Dump
cower
Hold
Frompump
To tank
F42101069
Operation
* When the control levers are moved to the left, POC
control
valve.
The oil of chamber E passes from port
spool (1) for lift lever moves up and spool (2) for it
j of spool (1) to port k, and flows to the drain circuit.
moves down,
Therefore,
and spools (I)
and (2) for dump lever
the pressure oil acting on ,port A2 of the
main control
move conversely.
- The oil from the pump enters port a, passes through
valve is constant, so a difference
sure is generated at port Bz.
chambers C and F, and flows to port Bs of the main
the main control
control
portion to the movement of the control lever.
valve.
In addition,
ber F passes through

from
61-14
chamber
the pressure oil at cham-
in pres-
As a result, the spool of
valve only moves an amount in pro-
port h of spool (2) and flows
E to the port A2 circuit c. the main
WASOO- 1
DUMP LEVER AT DUMP

LIFT LEVER AT LOWER
(2) (End of travel)

Dump lever
Lift lever
@
0
0
0
0
Dump
Lower
Hold
From pump
To tank
F42101010
Operation
- When the control levers are moved further to the left,

port h closes a little at a time, and the pressure acting
on port A2 of the main control valve drops a little at
a time.
Therefore,
and A2
the pressure difference
between ports B2
increases more, and the spool of the main
control valve moves to its specified stroke.
WA500- 1
61-15
DUMP LEVER AT TI LT
LIFT 1-EVER AT RAISE
(I 1 (Intermediate
position)
HQIcI
Raise
Tilt
From pump
F4210107
To tank
Operation
When the control
RAISE),
lever is moved to the right (TILT
POC spool
moves down
and spool
moves up, and spools (1) and (2)
for
or
(2) for it
dump
lever
move conversely.
The oil from
chambers
control
the pump
In addition,
ber E passes through

from
61-16
enters port a, passes through
chamber
port
F to the
to port Az of the main
valve.
* Therefore,
main
B and E, and flows

valve.
control
The oil at port 8s passes from
spool (I) to port k, and flows to the&r&n

control
main control
the pressure
valve
valve only
tion to the movement
oil acting
is constant,
on port
patii of
circr13t.
Bs of
moves an amount
in propor-=
of the cantra4~ rever.
the pressure oil at chamg of spool
port
B2 circuit
the
so the sprk@ of the
(2) and flows

cL the main
WAS
DUMP LEVER AT T I LT
LIFT LEVER AT RAISE
(2) (End of travel)
Hold
Raise
Tilt
From pump
To tank
~42101012
Operation
* When the control
port
lever is moved
further
to the left,
g closes a little at a time, and the pressure acting
on port
B2 of the main control
valve drops a little at
a time.
Therefore,
and
A2
control
the pressure
increases
more,
difference
valve moves to its specified
WA500- 1
between
and the spool
ports
of the
B2
main
stroke.
61-17
MAIN
CONTROL
VALVE
MBir
1.
Main relief valve
MA1
2.
Dump spool return spring
MA2:
3.
Lift spool return spring
4.
Lift spool
5.
Dump spool
Body
7.
8.
9.
MB1
MB2:
Al
6.
61-18
From PA1 of POC valve

From PA2 of POC valve
From PBl of POC valve

From PB2 of POC valve
To dump cylinder bottom side.
A2:
To lift cylinder bottom side
Bl :
To dump cylinder rod side
Suction valve
82:
To lift cylinder rod side
Unloader valve
P:
Pump port
T:
Dl
10.
425f104
MB2
Float selector valve
D2:
Drain port (to hydraulic tank)
Drain port
Drain port
WASOO-1
section
A-A
Section D-D
Section B-B
Section E-E
425F105
Outline
*
The main control valve controls the actuation

attachments
and the bucket
It has a tandem
circuit
in the hydraulic
of the
system.
which gives priority
to the
bucket circuit.
pressure is set by the main relief valve (1).
passes through
the circuit
if abnormal
ated in the bucket circuit.
pressure is gener-
If one of the two safety
a suction valve to make up any lack of oil.
The oil
the bypass circuit of dump spool (5)
and lift spool (4).

the tank.
to protect
valves is acting as a relief valve, the other valve acts as
- The oil from the pump enters port P. The maximum
drain circuit,
* There are two safety valves (with suction valves) (9)
It then flows from port T to the
passes through the filter and returns to
If the dump and lift spools are actuated,
the oil flows to the dump and lift cylinders.

However,
the circuit
gives priority
to the bucket, so
when the dump spool is being operated,
even if the
lift spool is operated, the lift arm will not move.
WANO- 1
61-19
RELIEF
VALVE
1.
Main valve
2.
Valve seat
3.
Pilot poppet
4.
Pilot poppet spring
5.
Adjustment screw
6.
Locknut
,,
42 1 FO80
Function
* The relief valve is installed

control
valve.
at the inlet
of the main
When the oil goes above the set pres-
sure, the relief valve drains the oil to the tank.

way,
it sets the
circuit
maximum
and protects
pressure
In this
in the hydraulic
the circuit.
Operation
* Port A is connected
connected
the
to the pump circuit
orifice
of
Pilot poppet
main
valve
and port C is
The oil passes through
(1) and flows
(3) is in close contact
with
to port
B.
Fig. 1
421 FO61
Fig. 2
421 FOB2
Fig. 3
42 1 PO83
valve seat (2).
(Fig. 1)
* When the hydraulic

A and
port
poppet
spring
pressurized
pressure in the circuit
B reaches the set pressure

(4).
oil from
pilot
poppet
port
B flows from
C, so the pressure at port
inside port
of the pilot
(3) opens,
B drops.
port
and the
D to port
(Fig. 2)
* When the pressure at port C drops, the orifice effect

of main
valve
between
port A and port
open
(1) generates
and the oil from
a difference
in pressure
B. The main valve is pushed

port
and flows
to the drain circuit
pressure.
(Fig. 3)
A passes through
port
to release the abnormal
* The set pressure can be varied by changing the tension of pilot

pressure,
turn
61-20
poppet
remove
adjustment
spring
cap nut,
(4).
To change the set
loosen
lock
nut
(6) and
screw (5) as follows.
WAMO- 1
SAFETY
VALVE
(with suction valve)
1.
Suction valve
2.
Main valve
3.
Main valve spring
4.
Pilot piston
5.
Suction valve spring
6.
Valve body
Function
. The safety valve (with suction

cylinder
circuit
abnormally
high
pressure
main valve is at neutral,

valve)
from
If shock causes any
in the cylinder
when
the safety valve (with
releases the abnormal
cylinder
valve) is in the dump
in the main valve.
the
suction
pressure and protects
the
damage.
Operation
As a safety valve
* Port A is the cylinder
circuit
and port
B is the drain
circuit.
The pressure oil in port
hole
in the pilot
through
an orifice
the pilot
piston
The pilot
lock
sectional
d,.
to port
D through
(4).
It also flows
to port
consisting
of the main
valve and
(4).
piston
nut.
A flows
piston
(4) is secured to the suction
The diameter
valve by
of the cross section
area) gives a relationship
(cross-
of ds > dI > ds >
(Fig. 1)
Fig. 1
If abnormally
high oil pressure occurs
suction
valve (1) is not actuated
tionship
d2 > dI.
However,
A and C, the hydraulic

is equivalent
d,.
in port
A, the
because of the relad3 > d4 in port
pressure on the main valve (2)
between
d,
and
If this pressure goes up to the main valve spring
force
(set pressure),
the main
and the oil in port A flows
valve
(2) is actuated,
into port B. (Fig. 2)
Fig. 2
WASOO- 1
61-21
As a suction valve
If negative
has negative
pressure,
nected with
each other.
is applied
to port E.
Hydraulic
pressure
ence between
in port A, port D also
because port
The tank
equivalent
ds and dI
D and A are con-
pressure in port 6
to the area differ-
is applied
to the safety valve
because of the tank pressure in port E.

Therefore,
hydraulic
pressure
valve and hydraulic

tion
pressure a
acts to open
the
acts to close the suc-
valve (1).
* If the pressure in port A drops, (approaching

pressure)
hydraulic
pressure
becomes
negative
smaller
than oil pressure e.

When oil pressure
sure a
opens,
A.
becomes
larger than oil pres-
+ valve spring (5) force, the suction

causing the oil to flow
This prevents
negative
from
port
pressure from
421FO48
valve (1)
B into
building
port
up
in port A.
SUCTION
VALVE
1. Main poppet
2. Sleeve
3.
Spring
421 F088
Operation
If negative
in port
A (lift cylin-
der rod end) (if the pressure is lower than in port

the tank
circuit),
the main poppet
oil then flows
from
at the cylinder
port end.
port
B in
(1) opens because
B at the tank end to port A
421 F089
61-22
WA500- 1
FLOAT
SELECTOR
VALVE
AND
UNLOADER
VALVE
Function
* The float selector valve and unloader valve are installed inside the main control valve.
trol
lever is placed in FLOAT,
When the lift conthe float selector
valve detects pressure oil from the POC valve and acts
to actuate the unloader
spool in the FLOAT
TO POC valve
Fro
valve, which places the lift
position.
Operation
- When the lift lever is placed at FLOAT,

valve is set to LOWER.
the POC
Port A becomes high pres-
sure, and port B becomes low pressure.
- The oil from the steering valve fills chambers E and F.

421 F094
LIFT
LEVER
AT
FLOAT
Operation
* If the difference in pressure between port A and port

B exceeds the standard pressure, flow selector valve
To POC valve
A
(2) is moved to the right, and port C and port D are

connected.
* Port D is open, so the hydraulic
pressure at port E
drops and unloader valve (4) moves to-t
and the oil
flows from the steering valve to the drain circuit.
At
the same time, the oil also flows to the rod end of the
lift cylinder,
and the oil at the bottom
nected to the drain circuit,
end is con-
so the lift arm is set at
FLOAT.
4
From steering valve
42 1 F095
WA500- 1
6&23
LIFT
AND
DUMP
SPOOLS AT
HOLD
Dump
Float
Hold
Lower
qaise
Tilt
0
@
Hydraulic tank
Oil cooler
(ZJ
Steering valve
To steering cylinder
Filter
69
Check valve
Accumulator
Switch pump
Hydraulic pump
Steering pump
POC pump
Operation
- The oil from the pump enters port A and the maximum pressure is set by the relief valve (11).
* Dump spool (1) is at HOLD, so the bypass circuit is

open.
The oil in chamber A passes around the spool
and flows to port B.
Lift spool (2) is also at HOLD,
so the bypass circuit is open.
The oil in chamber B
passes around the spool and flows to chamber C in

the drain
circuit.
From
here it passes
rough the
filter and returns to the tank.
61-24
WA500- 1
LIFT
SPOOL AT
RAISE
Dump
Float
Hold
Lower
Raise
Tilt
Hydraulic tank
Oil cooler
Steering valve
Filter
Check valve
Accumulator
Switch pump
Hydraulic pump
Steering pump
POC pump
425F107
Operation
-
When
the
lift
lever (3) is pulled,
pressure oil from
port L of the POC valve flows to ports N and S. The

oil in port T passes through
drain circuit.
port M and flows to the
The pressure oil in port S pushes the
by the spool, so the oil pushes up check valve (IO).

The oil then flows from port H to port I, and goes to
the bottom end of the cylinder.
* At the same time, the oil at the rod end of the cylin-
push piston against the force of the spring and moves
der flows from port K to drain port C, and returns to
lift spool (2) to the RAISE
the tank.
position.
Therefore,
the lift arm rises.
* The oil flows from the pump through the bypass circuit of the dump spool, and then flows to the bypass
circuit
of lift spool (2).
WA500- 1
The bypass circuit is closed
61-25
LIF T SPOOL AT
LOWER
Dump
FIoat
Hold
0
8
0
0
@
Lower
Raise
Titt
Hydraulic tank
Oil cooler
Steering valve
Filter
Check valve
0
@
8
Accumulator
Switch pump
Hydraulic pump
Steering pump
POC pump
425F108A
Operation
-
When
the
lift
lever
(3) is pushed,
pressure
oil
port L of the POC valve flows to ports M and T.

oil in chamber
S is connected
from
The
The pressure oil in chamber T pushes the push piston

against the force of the spring and moves lift spool
(2) to the LOWER
position.
by the
spool,
so the
oil pushes
up check valve (10).
The oil then flows from port J to port K, and goes to

the rod end of the cylinder.
* At the same time, the oil at the bottom end of the

cylinder flows from port I to drain port C, and returns to the tank.
Therefore,
the lift arm goes down.
* The oil flows from the pump through the bypass circuit of the dump spool, and then flows to the bypass
circuit
of lift spool (2).
6626
The bypass circu;
is closed
WA500- 1
LIFT
SPOOL AT
FLOAT
Dump
Float
Hold
Lower
Raise
Tilt
0
@
Hydraulic tank
Oil cooler
Steering valve
Filter
@
0
8
8
8
@
Check valve
Accumulator
Switch pump
Hydraulic pump
Steering pump
POC pump
425F109
Operation
When the lift lever (3) is pushed to the FLOAT
posi-
right and opens ports C1 and C to connect them to
tion, the spool of the POC valve moves further
from
the drain circuit.
the LOWER
Pres-
drain circuit,
position
to the FLOAT
position.
sure oil from port M of the POC valve flows to port M

and also to ports T and W.
At the same time, pres-
When port C1 is connected to the
valve (8) moves up, and the oil from the
pump flows to the drain circuit.

Therefore,
the oil at the rod end of the cylinder flows
sure oil from port S of the POC valve flows to port N.
from
K, and then flows from unload valves (8)
The pressure oil in chamber T pushes the push piston
against the force of the spring and moves lift spool
bottom
12) to the LOWER
C, and then flows to the drain circuit.
position.
If the pressure difference
between port W and port X
port
At the same time, the oil at the
I to
port
Therefore,
the
end of the cylinder flows from port
lift arm floats.
goes above the specified level, valve (7) moves to the
WA500- 1
61-27
DUMP
SPOOL AT
TILT
BACK
@I
Dump
F,koet
Hold
Luwer
Raise
0T
TiPt
Hydraulic tank
Oil cooler
Beefing uehve
To steeringqlinder
Filter
Check valve
.@
Accufnulator
Switch
pump
Hydraulic .pump
Steehg
WC pump
pump
425Flll
Operation
-
When the dump lever (4) is pulled, pressure oil from
from
port
goes to the bottom end of the cylinder.
L of the POC valve flows to port R via port P.
The oil in port V is connected

The
pressure oil in port
R pushes the push piston
against the force of the spring and moves dump spool

(1) to the TILT
port A then flows from port !D to pol;t E, and
* At the same time, the oil at the rod end of the q&-tder flows from port G to drain port C, -and returns to
the tank.
Therefore,
the bucket is-tilted.
position.
* The bypass circuit is closed by the spool (I), so the

oil from port A pushes up check valve (1C
61-28
The oil
WASOO-1
DUMP
SPOOL AT DUMP
Dump
Float
Hold
Lower
Raise
Tilt
Hydraulic tank
@
@
0
Oil cooler
Steering valve
Filter
Check valve
Accumulator
Switch pump
Hydraulic pump
Steering pump
POC pump
425FllO
Operation
*
When the dump lever (4) is pushed, pressure oil from

port
L of the POC valve flows to port V via port 0.
The oil in chamber

cuit.
R is connected to the drain cir-
The pressure oil in port U pushes the push pis-
ton against the force of the spring and moves dump
enters port G, and goes to the rod end of the cylinder.
- At the same time, the oil at the bottom end of the

cylinder
flows from
turns to the tank.
port D to drain port C, and re-
Therefore,
the bucket is dumped.
spool (1) to the DUMP position.
* The bypass circuit is closed by the spool (1). so the

oil from
from
port
check
WA500-1
pushes
up check valve (9).
valve (9) then
flows
from
port
The oil
F and
61-29
HYDRAULIC
LIFT
CYLINDER
CYLINDER
1.
Head
2.
Rod
3.
Cylinder
4.
Piston
5.
Lock ring
Specificatim
Cylinder bore
Rod diameter
Cylinder max. length
2334.5 -Jzwal
Cylinder min. bngth
jI
35m mm-l
Stroke
61-30
DUMP
CYLINDER
425Fll3
1.
Head
2.
Rod
3.
Cylinder
4.
Piston
5.
Lock ring
WA500- 1
Specifications
Cylinder bore
225 mm
Rod diameter
120 mm
Cylinder max. length
1817 mm
Cylinder min. length
1252 mm
Stroke
565 mm
61-31
BUCKET
61-32
POSITIONER
1.
Contact switch
2.
Contact switch
3.
Dump cylinder rod
4.
Lever
5.
Plate
AND
BOOM
KICK-OUT
Bucket positioner
-
The bucket
positioner
is electrically
obtain
used to automatically
actuated and is
the optimum
digging
angle for the bucket.

When the bucket is moved from the DUMP
to the TILT
the
from
the
Lever (4) is secured by bolts to dump cylinder
rod
TILT
(3).
dump
position
position, and it reaches the desired angle,

lever
is automatically
moved
position to the neutral.

A proximity
switch (1) is fixed by bolts to the
cylinder.
* When the bucket is moved from the DUMP position

to the TILT
to the left.
the left.
position,
the dump cylinder
rod moves
At the same time, lever (4) also moves to
When it reaches the desired position,
(4) separates from proximity
lever
switch, and the bucket
lever returns to neutral.

421Flll
Boom kick-out
* The boom kick-out
is electrically
to stop the lift arm.
operated
and acts
When the lift arm reaches the
desired position before the maximum
height, the lift
arm lever is returned to neutral.
* Plate (5) is secured to the lift arm.

switch (2) is fixed to the frame.
A proximity
When the lift arm is
moved from the LOWER
position to the RAISE
tion,
When it reaches the desired
the lift arm rises.
position,
the proximity
posi-
switch and lever come into
contact and the lift arm lever is returned to neutral.
421F112
WASOO- 1
61-33
BUCKET
LINKAGE
_....
r
__.
I=__-,
425Fl I8
1. Bucket
5.
Lift arm
8.
Cord ring
2.
Tilt lever
6.
Bucket link
9.
Cord ring
3.
Dump cylinder
7.
Bucket hinge pin
4.
Liftcylinder
(Serial No. 10001-11463:
oil type)
(Serial No. 11484 and up : grease type)
61-34
0
WASOO- 1
SerialNo. 10001-11463
SerialNo.11464andup
Section A - A
Section A - A
Section
B -
9
Section C - C
Section F -
Section D - D
Section G - G
Section E - E
Section H - H
Section J - J
425F119-1
WA500-
61-35
BUCKET
B-i
A-i
SectionA-A
Section B - B
Section C - C
425Flrn
1.
Bucket
2.
Corner teeth
3.
Teeth
61-36
0
WA500- 1
ACCUMULATOR
Function
The accumulator
is installed between the hydraulic
pump and the POC valve.

raised, and the control
engine
stopped,
nitrogen
the
gas inside
When the lift arm is left
levers are operated with the

pressure of the
the
pressure to the control
accumulator
compressed
sends pilot
valve to actuate it and allow
the lift arm and bucket to come down under their

own weight.
After operation
Before operation
421 F077
421 F076
1.
cap
2.
Nut
Operation
After
the engine is stopped,
at neutral,
3.
Body
4.
Bladder
5.
Oil port
6.
Nut
hydraulic
and the POC valve is
bladder chamber A is compressed by the

pressure in chamber B.
If the POC valve is operated,
the hydraulic
in chamber B goes below 40 kg/cm,
pressure
and the pres-
sure of the nitrogen gas in chamber A expands the

bladder.
As a result, the oil in chamber B becomes
the pilot pressure and actuates the control valve.
WA500-1
61-37
8
WORK EQUIPMENT SYSTEM 0

62 TESTING
AND
ADJUSTING
..
.
Measuring dump and lift control levers . .
Adjusting dump and lift control levers .
...
. . _. . .
.
Measuring hydraulic
work equipment
..
.
..
..
...
.. ...
.. ..
...
...
Measuring hydraulic drift of work equipment

Adjusting bucket positioner
Adjusting boom kick-out
The following
62- 4
62-
pressure of
Measuring work equipment
Troubleshooting
62- 2
62-
.
...
. .. , .
.
.
......
..
..
.
62- 6
62s 9
62-10
62-11
62-12
62-13

1.
2.
are estimated
values based on the
3.
In addition,
do not use
WA500-
62-1
0
STANDARD
. Serial No. 10001
*
serial
No.
VALUE TABLE
-
10001
10186
10146
(Except D sPeo.1
(b SPoo.)
Standard
value
Permissible
value
(Hold 3 Raise1
2.7 - 3.5
Max. 5.3
(Raise--e Hold)
2.7 - 3.5
Max. 5.3
(Hold -
2.7 - 3.5
Max. 5.3
Dump
and lift control
,.
levers
Lift arm control lever operating force
Lower)
(Lower + Hold)
(Lower -
Float)
kg
(Float + Hold)
Dump control lever operating force

(Hold + Dump)
(Hold + Tilt)
(Tilt + Hold)
* Lift
. Hydraulic temperature:
45 -55Oc
* Engine speed: Low idling

. Coolant temperature:
4.0 - 5.5
Max. 8.3
2.7 - 3.5
Max. 5.3
3.0 - 3.5
Max. 5.3
3.0 - 3.5
Max. 5.3
3.0 - 3.5
Max. 5.3
arm control lever travel

(Hold + Raise)
32 -62
17-777
(Hold + Lower)
25 - 55
lo;70
42-72
27 - 87
(Hold -* Float)
mm
Dump control lever travel

(Hold -
Dump)
(Hold -t Tilt)
3;4-64
19-79
34 - 64
19-79
Relief oil pressure

* POC valve
. Main control valve
30+3
0
45-55Oc
21.0+1Q
210+;
* Engine speed: High idling
30M
Operating speed
- Lift arm lifting time

- Lift arm lowering time
- Bucket dumping time
. Bucket tilt back time
(Full stroke)
6.8 - 7.4
45-55C
. Engine speed: High idling

. Steering position: Neutral
. Bucket: unloaded
sec.
Bucket tilt back time

(Horizontal position of bucket)
Max. 8.9
3.0 - 4.0
Ma %..4 B
1.4 - 2.0
Max. 2.4
1.9 - 2:5
Man. 3.0
1.3 - 1.3
r&x. 2.3
Hydraulic drift of lift arm and bucket
Retraction of lift cylinder rod
- Retraction of dump cylinder rod
* Stop engine, leave for 5 minutes,

then measure for next 15
minutes,
.
.
Lift arm horizontal
,Max
Max.,40
Max. 20
Max. 20
3 -.5
Bucket horizontal
Bucket positioner
40
mm
Clearance of switch
45 -55C
Boom kick-out
- Clearance of switch
62-2
0
3-5
WA%Xb 1
Serial No. 10187 and up (Except
D spec.)
- Serial No. 10147 and up (D spec.)

Tasting and measuring item
Unit
Permissible
value
Standard
value
Dump and lift control levers
Lift arm control lever operating force

(Hold -)- Raise)
2.7 - 3.5
Max. 5.3
(Raise -+ Hold)
2.7 - 3.5
Max. 5.3
(Hold -+ Lower)
Max. 5.3
(Lower + Hold)
2.7 - 3.5
-
(Lower * Float)
4.0 - 5.5
Max. 8.3
2.7 - 3.5
Max. 5.3
kg
(Float -+ Hold)
45 -55C
* Dump control lever operating force

(Hold + Dump)
Engine speed:
(Hold + Tilt)
(Tilt * Hold)
3.0
3.5
Max. 5.3
3.0
3.5
Max.
5.3
3.0
3.5
Max.
5.3
Low idling
* Lift arm control lever travel

(Hold -r Raise)
50 - 80
(Hold -r Lower)
33 - 63
18-78
(Hold + Float)
50 - 80
35 - 95
(Hold -t Dump)
42 - 72
27 - 87
(Hold -f Tilt)
42 - 72
27 - 87
40+;
40:;
210+05
21o+O
35 - 95
mm
* Dump control lever travel
Relief oil pressure
* POC valve
- Main control
45 -55c
* Engine
valve
kg/cm
speed: High idling
Operating speed
* Lift arm lifting time

- Lift arm lowering time
* Bucket dumping time
* Bucket tilt back time
45-55OC
- Engine speed: High idling

- Steering position: Neutral
* Bucket: unloaded
(Full stroke)
sec.
Bucket tilt back time

(Horizontal position of bucket)
6.8
7.4
Max. 8.9
3.0
4.0
Max. 4.8
1.4
2.0
Max. 2.4
1.9
2.5
Max. 3.0
1.3
1.9
Max. 2.3
--
Hvdraulic drift of lift arm and bucket

. Hydrru/i;&perature:
* Retraction
of lift
cylinder
* Retraction of dump
cylinder
. Stop engine, leave for 5 minutes,

then measure for next 15
minutes.
rod
rod
Max. 40
Max. 40
Max. 20
Max. 20
mm
Lift arm horizontal

Bucket horizontal
Bucket positioner
- Clearance
3-5
of switch
45-55Oc
mm
Boom kick-out
* Clearance of switch
WA500-
3-5
62i2-
No.
Testing end measuring item
AND
ADJUSTING
Part number
Tool name
Remarks
Hydraulic pressure
Hydraulic tester
799-l 01-5000
0 - 300 kg/cm2
Oil temperature
Thermistor
799-l 01-6000
o-1000c
Engine speed
Tachometer
799-203-8000
60 - 19999 rpm
Dump lever and lift lever

operating force
Push-pull scale
79A-262-0020
0 - 25 kg
Measuring travel
Convex scale
Measuring operating time of

work equipment
Stop watch
kit
1 /lO second
When carrying
cut testing, adjusting or troubleshooting,
stop the machine on level ground, install the safety
bar on the frame, lower the bucket to the ground, and stop the engine.
Do not allow unauthorized
When measuring the engine speed, one worker

operators seat to operate the controls.
should measure the engine speed while the other sits in the
Always check that the operation
is safe, and use agreed signals.
WA500-
62-3
0
MEASURING
DUMP
*
.
.
Engine speed:
AND
LIFT CONTROL
LEVERS
Hydraulic oil temperature:
45 - 55C
Low idling
Unit:
kg (mm)
Item
Float
Dum
423F324
Special tool
Part No.
79A-262.0020
Part Name
Push-pull scale
~~/ &y
I
Install the safety bar on the frame.
Measuring procedure
1.
Operating force of dump and lift control levers
Fit push-pull scale A on dump and lift control

levers and measure operating force.
*
Hook the push-pull scale A on the center of

the knob.
Operate
measure
at the same speed as normal

the
minimum
force
needed
and
to
operate the knob.

2.
Travel of dump and lift control levers

.
Measure the travel of the dump and
lift control
levers at each position.

*
Mark the knob of the lever and use a scale to

measure.
62-4
0
WA500-1
ADJUSTING
1.
2.
AND
LIFT CONTROL
LEVERS
Remove cover (1).
Place bucket lever and lift lever in HOLD.

*
3.
DUMP
Apply
lever lock to hold in position.
Loosen nut, then adjust length of rod (2) so that

POC valve is in HOLD.
*
If the plate (3),
roller
(4) and spring (5) are
damaged, replace them.

+
Operate
that
the
DUMP,
the bucket
lever
RAISE
and lift levers, and check
is held
and
in position
at
TILT,
FLOAT.
421
WA500-
F205
MEASURING
Ir
Conditions
Engine
HYDRAULIC
PRESSURE
OF WORKEQUIPME,NT
of measurement
coolant
temperature:
Within
operating
range
.
Hydraulic
oil temperature:
45 -
55T
Special
tool
Part No.
1.
799-101-5000
Measuring
1) Raise
POC
the
Part Name
Qty
Hydraulic tester
relief valve
lift arm,
then
the lift arm and remove
pressure.
put a support
front frame
under
inspection
cover (1).
Loosen the oil filler cap slowly to release
the pressure
inside
Operate
control
release
the
the
the pressure
hydraulic
levers
tank.
slowly
to
in the accumulator
completely.
2)
Remove
plug (2) for measuring
in dump cylinder
3) Install hydraulic
Install a 90
pressure
of oil
circuit of main control
valve.
test kit A in measuring
port.
elbow
kit in the measuring
for the
hydraulic
port, then connect
test
the
hose.
Check
that there
is no leakage
of oil from
any joint.
Use a hydraulic
the operators
hose long enough
to reach
comppartment.
4) Start the engine, operate the control lever to

lower the lift arm, and measure the pressure
when
the relief valve is actuated.
Set the bucket
Do
not
hydraulic
*
A4
& When
gauge,
apply
pressure
removing
release
way as when
62-6
0
horizontal
suddenly
to the ground.
pressure
to
the
gauge.
the hydraulic
the pressure
installing
pressure
in the same
the gauge.
WA500-
Adjustment
Always
hydraulic
1.
Stop engine and remove cover (1).
2.
Remove cap nut (2) of relief valve.
3.
adjusting
the
pressure.
Loosen locknut
(3), then turn adjustment
screw (4)
to adjust.
*
One turn of the adjustment
screw changes the
425PO87
pressure by about 9.78 kg/cm2.
Turn the adjustment
screw to adjust as follows.
To INCREASE
pressure, TIGHTEN
screw.
To DECREASE
pressure, LOOSEN
screw.
If it is impossible to measure the relief pressure

exactly, do not try to adjust the pressure.
425PO88
423F315A
WA500-
62-7
0
2.
Method
for measuring work equipment
relief valve
pressure.
Loosen the oil filler

pressure
inside
operate
the
cap slowly to release the

Then
hydraulic
tank.
the
control
levers
release the remaining
several
times
to
piping.
1)
Remove
plug
(1)
for
measuring
pressure of
oil in dump cylinder circuit.
2)
Install hydraulic
*
test kit A in measuring port.
Check that there is no leakage of oil from

any joint.
Use a hydraulic
hose long enough to reach
the operators compartment.

3)
Start
400
the engine and raise the lift arm about

Then
mm.
operate
the control
lever to
tilt the bucket back and actuate the relief valve.

Measure the pressure when the valve is relieved.
*
Do
not
hydraulic
When
suddenly
apply
pressure
to
the
pressure gauge.
removing
the
hydraulic
pressure gauge,
release the pressure in the same way as when

installing the gauge.
Adjusting
Always
hydraulic
adjusting
1.
2.
Remove locknut (3) of relief valve (2).
3.
the
pressure.
Turn adjustment screw (4) to adjust.

*
One turn
of the adjustment
screw changes the
pressure by about 52.9 kg/cm2.
*
3
Turn the adjustment
screw to adjust as follows.
To INCREASE
pressure, TIGHTEN
screw.
To DECREASE
pressure, LOOSEN
screw.
If it is impossible to measure the relief pressure

exactly, do not try to adjust the pressure.
4
421
S8
F206A
WA500-
MEASURING
WORK
Measurement
.
.
.
.
EQUIPMENT
condition
Steering position:
n Lifting time of lift arm

Neutral
Engine speed:
45 - 55C
High idling
Unit:
sec.
Item
Standard
value
Permissible
value
Lift arm lifting time
6.8 - 7.4
Max. 8.9
Lift arm lowering time
3.0 - 4.0
Max. 4.8
Bucket dumping time
1.4 - 2.0
Max. 2.4
Bucket tilt back time (Full stroke)
1.9 - 2.5
Max. 3.0
Bucket tilt back time (From horizontal position of bucket)
1.3 - 1.9
Max. 2.3
423F327
Lowering time of lift arm

r>
Special tool
Part No.
A
Part Name
Qty
Stop watch
Measuring procedure
423F328
Lifting time of lift arm
Dumping time of bucket
Set the bucket near the maximum
tilt back position
and at the lowest position on the ground.

bucket
and measure the time taken
reach the maximum
Raise the
for bucket
to
height of the lift arm.
Lowering time of lift arm

Set the bucket
maximum
horizontal
with the lift arm at the
height, lower the bucket and measure the
time taken for the bucket to reach the lowest position on the ground.
Dumping time of bucket
Raise the lift arm to the maximum
height and meas-
ure the time taken for the bucket to move from the
maximum
tilt back position to the maximum
dump
423F329
Tilt back time of bucket
position.
Tilt back time of bucket
1)
Raise the lift arm to the maximum
height and
measure the time taken for the bucket to reach

the maximum
2)
tilt back position.
Set the bucket horizontal

taken
and measure the time
for the bucket to move from the hori-
zontal position to the maximum
tilt back posi-
tion.
423F330
WA500-
62-9
0
MEASURING
HYDRAULIC
Measurement
.
.
.
EQUIPMENT
condition
Stop engine,
DRIFT OF WORK
45 - 55Oc
leave for 5 minutes, then measure for
next 15 minutes.
Lift arm horizontal
Bucket horizontal
Unloaded
(operating load)
Unit:
mm
Standard
value
Permissible
value
Retraction of lift cylinder rod
Max. 40
Max. 40
Retraction of dump cylinder rod
Max. 20
Max. 20
Part No.
Part Name
Qty
Convex scale
Item
Special tool
423F331
Fit the safety locks on the control levers.

Do not go under the work equipment.
Measuring procedure
1)
Set the lift arm and bucket horizontal,
then stop the
engine.
2)
Stop
the
engine,
wait
for
5 minutes,
then
start
measuring.
3)
Measure the amount the lift B and dump A cylinder

rods retract during 15 minutes.
62-10
0
A:
Retraction of dump cylinder rod.
B:
Retraction
423F332
of lift cylinder rod.
WA500- 1
ADJUSTING
BUCKET
POSITIONER
Testing
1.
Check that
angle
(2)
the clearance
with
the
between
engine stopped
switch
(1) and
is within
the
standard value.
2.
Start
the engine and check the actuating
position
at low idling.
(Check three times and take the average.)
Adjusting
1.
Lower the bucket to the ground, operate the bucket

to the desired digging angle, then return the lever to
the HOLD
2.
position and stop the engine.
Secure switch protector

bracket
(3) to the dump
cylinder
so that the center of the switch is aligned
with the end face of angle (2).

3.
Adjust
from
nut (6) of switch
so that clearance a
(1)
the end face of switch
protector
(3) to the
switch response surface is within the standard value,

then lock in position.
*
Clearance a:
m
4.
5.
0.5 -
\\
1 .O mm
Switch mounting nut:
,;::_
u
1.8 f. 0.2 kgm
Remove cover (4) of the switch.
425FO1343
Using washer, adjust so that clearance b between

the response surface of switch
(1) and angle (2) is
within the specified value, then lock in posiiton.

Using washer, adjust the angle so that the clearance between the response surface of the switch
and the angle is within
the specified value over
the whole stroke of the angle, then lock in.position.

Check
that
neither
the
response face
of
the
switch nor the angle are off center before locking

in position.
After
that
adjusting,
the
operate
positioner
the bucket lever, check
is actuated
position, then lock in position.

Clearance lb:
3 - 5 mm
Install cover (4) of the switch.
WA500- 1
at the desired
425FO1344
ADJUSTING
BOOM
KICK-OUT
Unit:
Standard
value
Item
Clearance between switch
and plate
1.
Inspection
1)
3-5
procedure
With the engine stopped,

ante
mm
Permissible
value
between
switch
check that the clea-
(1) and plate
(2) is the
standard value.
2)
Start the engine, run at high idling and check

the actuation
position.
(Measure three times
and take the average.)

2.
Adjusting
11
Raise the lift arm to the desired position,

mark
the
lifr arm at the position
center of the switch
then
where
is at the bottom
the
edge of
the plate.
2)
Lower the lift arm and stop the engine.
3)
Align the marks, adjust the position of the plate

so that the center of switch (1) is level with the
bottom
of
plate
(21, then
lock the
plate
in
position.
4)
Remove switch cover (3).
5)
Adjust the switch so that the clearance between

the sensing surface of the switch and plate (2)
!:
423F335-1
is the standard value.

*
Clearance a.
Mounting
3 - 5 mm
nut of switch:
1.8 + 0.2 kgm
After
adjusting,
operate
the
lift
lever and
check that the lift arm stops at the desired

position.
62-12
0
WASOO- 1
TROUBLESHOOTING
Troubleshooting table . . . . . . .
.. .
l.Liftarmdoesnotrise
. . . . . . .._..__.....
2. Lift arm moves slowly or does not have
sufficient lifting power . . . . . . . .
3. Lift arm movement becomes slow after it
reaches a certain height.. . . .
..
4. Bucket cannot be held down with lift
cylinder . . . . . . . . . . . . . . . . . . . . . . . . ..___.
5. Lift arm has large hydraulic drift .
..
6. Lift arm movement is unsteady
duringwork . . . . ..___..........__.....
7. Lift arm descends momentarily
when control lever is shifted
from Hold to Raise . . . . . .
8. Bucket does not tilt back .
.. . ...
9. Bucket moves slowly or has insufficient
tilt back power . . . . . . . . . . . . . . .
10. Bucket movement becomes slow during
tiitback . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 1. Bucket cannot be held down by the
bucket cylinder . .
.
. . ..
12. Bucket has large hydraulic drift
.
13. Bucket moves unsteadily when
machine travels under load
...
.
(Main control valve in Hold)
14. Bucket dumps momentarily when
control lever is shifted from
Hold to Tilt back . . . . . .
.. .
1 5. Control levers of lift arm and dump
move stiffly and sluggishly . . . . _ .
Before carryinq out the troubleshooting in this section,

page 22-12,
RENCE
WA500-
METHOD
OF TROUBLE
OF READING
page 22-16.
TROUBLESHOOTING
read PRECAUTIONS
TABLE
WHEN
62-l 6
62-l 6
52-l 7
52-l 8
52-l 8
62-l 8
62-18
62-18
62-l 9
62-20
62-21
62-2 1
62-21
62-21
62-21
62-22
TROUBLESHOOTING
RECUR-
TROUBLESHOOTING
1.
TABLE
Lift arm does not rise.

questions
Did the boom suddenly fail to rise? + Seizure

or damage to various units.
Was an unusual noise produced?
(Where did it
emanate from?)
Were there previous signs of the boom slowing
down. + Wear of parts of flattening of spring.
.
.
Is oil level in hydraulic tank correct?

Is stroke of lift control lever and spool correct?
Tank -pump
Problems
No.
I6 ucket
I
cannot operate and lift arm is unable to ascend.
l0lOl0lOl0l0i
I
The machine body can be lifted up by the lift arm however,

the lift arm is unable to ascend. Alternatively, the bucket
operates but the lift arm is unable to ascend.
The lift arm can ascend under no load but cannot ascend
under load.
The hydraulic pump produces an unusual noise.
Lift cylinder has large amount of hydraulic drift.
When the engine is at high idling, steering action is light and

excessively fast.
When the engine is at high idling, steering action is heavy

and slow.
idO/ I
I
0
0
~
IMO
0
0

X : Repalce
A: Repair
A : Adjust
C : Clean
62-14
0
WA500- 1
8.
Bucket does not tilt back.

Did the bucket
suddenly
questions
ceases to move? +
Seized or damaged equipment.

Was any
unusual
noise emitted
(where did it
emanate from)?
Were there previous signs of the bucket slowing

down? + Worn parts of flattened
spring.
.
.
Is amount of oil in hydraulic tank satisfactory?

Is the stroke of the bucket
control
lever and
spool correct?
Lrft arm cannot operate and bucket is unable to tilt back.
The machine can be lifted up by the bucket but the bucket

cannot tilt back. Alternatively, the lift arm operates but the
bucket cannot tilt back.
The bucket can tilt back under no load but cannot excavate
or scoop.
The hydraulic pump produces an unusual noise.
Bucket cylinder has large hydraulic drift.
Steering action is light and excessively fast when the engine

is at high idling.
Steering action is heavy and slow ,when the engine is at

high idling.
I I
lolololololol
0
I I I I I I I MO
0
0

X : Repalce
A:
Repair
A : Adjust
C : Clean
WASOO- 1
62G7
9.
Bucket moves slowly or has insufficient tilt

back power.
Is the oil quantity in the hydraulic tank and the

type of oil satisfactory?
Is the stroke of the bucket control lever and the

main control valve spool correct?
Seizure of bushing in bucket linkage.

(Does emits unusual noise)
Fault checks
Check the amount

by performing
of deficient
titlt
back force
actual work.
Measure the operating
speed of the bucket and
check it against the judgement criterion table to

determine
whether or not it is normal.
No.
lol I I I
Lift arm lifting force and lifting speed are abnormal and also
bucket tilt back force and tilt back speed are abnormal.
Lift arm lifting force and lifting speed are normal but bucket
tilt back force and tilt back speed are abnormal.
Phenomena of item 1 become particularly bad when the oil

temperature increases.
The hydraulic pump emits an unusual noise.
Steering action is light and excessively fast when the engine

is at full throttle.
Steering action is heavy and slow when the engine is at full

throttle.
The dump cylinder has a large amount of hydraulic drift.
The relief pressure of relief valve of main control valve is

also low.
I I I- I I IMoldd
The discharge volume of the hydraulic pump is low.
lolololol
000
0
0
0
0
000
iol

62&8
WA500- 1
10. Bucket movement becomes slow during tilt

back.
13. Bucket moves unsteadily when machine

travels under load. (Main control valve in
Hold).
External deformation
of dump cylinder.
.
.
Swollen
Is oil
level in hydraulic
tank and type of oil
correct?
Cause
or internally
damaged dump
cylinder
Regarding
Excessive play
equipment
tube.
other
faults which
occur when the
in pin
and
bushing
of
work
linkage.
Was an unusual noise produced?
bucket operates, refer to item 9 Bucket moves

slowly or has insufficient
Cause
tilt back power.
.
.
11. Bucket cannot be held down by the bucket
cylinder.
Faulty piston seal of dump cylinder.

Faulty
If the
other
Refer to item 9 Bucket
moves slowly
safety valve with suction
valve for the
bottom side of dump cylinder.

above
symptoms
symptoms,
occur together
with
refer to the problems
items
corresponding to each fault.
or has in-
sufficient tilt back power.

.
.
Is oil level in the hydraulic tank satisfactory?

Is the stroke of the main control
14. Bucket dumps momentarily when control

lever is shifted from Hold to Tilt back.
valve dump
The
spool correct?
bucket
wieght
when
dumps
momentarily
the dump
control
under
its own
lever is gradually
Cause
shifted from the Hold
Faulty seat of safety with suction valve of con-
position while the engine is at low idling.
trol valve for the bottom side of dump cylinder.
When the control
Oil leakage from seal of dump cylinder piston.
Tilt back position, the bucket behaves normally.
position to the Tilt back
lever is put completely
into the
Cause
12. Bucket has large hydraulic drift.
Faulty
seating
of
main
control
valve dump
spool check valve.

Did the hydraulic
questions.
drift suddenly become large?
+ Dirt lodged in valve or damaged parts.
Did the hydraulic
drift gradually become large?
+ Worn parts.
Is the type and temperature
of the oil in the
hydraulic tank correct?
Is the dump spool in the neutral
position? --f
Seized link bushing, faulty spool detent.

Fault check
Use the
judgement
whether
or
not
criterion
the
table
hydraulic
to
drift
check
of the
bucket is actually large.
If hydraulic drift is large.

Cause:
Oil leakage in dump cylinder.
If hydraulic drift returns to normal.

Cause:
Faulty
seating of overload relief valve
or suction valve on rod side.

Faulty
oil sealing on spool of dump
control valve.
WA500- 1
62-19
a
15. Control levers of lift arm and dump move

stiffly and sluggishly.
Fault check
Using the judgement
criterion
table, check whether
or not the operating force of the lever is large.
load is applied and oil pressureincreases.
Movement of lift arm and bucket becomes p
when the link of the control lever is disconnected at

WASOO- 1
WORK EQUIPMENT SYSTEM 0

63
HYDRAULIC
DISASSEMBLY
TANK
DUMP
.......................
tnstallation
.............. ...... .
Removal
HYDRAULIC
HYDRAULIC
Removal
63-
Installation
63- 4
Installation
Disassembly
63-
Assembly
63-
Removal
63-
Installation
63-
POC VALVE
63-20
......
......
63-24
......
63-27
......
63-29
......
......
63-32
......
......
63-41
63-22
63-25
CYLINDERS
...... ......
.
. . . . _. .
EQUIPMENT
.............
............
63-36
COUNTERWEIGHT
.......................
Installation
.....................
Disassembly .....................
Assembly
......................
Removal
MAIN
DUMP
WORK
.... ..... .... ........ .

Installation
... .......... .... ...
AND
.,............
..........,.
63-
PUMP
......
......
CYLINDER
Removal
LIFT
Removal
.............
...... ......
63- 4
FILTER
.......................
Installation
.....................
u!
CYLINDER
LIFT
Removal
ASSEMBLY
63-
PUMP
........... .. .........
Installation
.................. ..
Removal
SWITCH
AND
CONTROL
...... .......
............
Installation
63-41
63-12
63-12
VALVE
.......................
Installation
.....................
Removal
Disassembly and assembly
Removal
63-10
Take
63-13
63-l 5
...........
the following
63-18
method
hydraulic
cylinders after reassembling cylinders, pumps and pipings.

1.
2.

Operate hydraulic
cylinder 4 -
stroke end.
3.
Continue to operate cylinder 3 - 4 cycles until stroke end.
4.
After finishing above steps, keep normal engine speed.

NOTE:
WA500-
After long storage, same procedure is required.
63-1
0
REMOVAL
Qt
OF HYDRAULIC
Stop the
machine
TANK
ground and stop the engine. Then apply the parking

0!
control
tank.
Then operate the

piping.
filter,
and
plugs (3)
and (4) of the
pump
piping to

1.
Hood
Lift off tank hood (5).
2.
Hydraulic
piping
piping as follows:
1) Disconnect tube (6) between hydraulic tank and steering + POC pump, from tank.
2) Disconnect
tube
(7)
switch and hydraulic

3) Disconnect
between
hydraulic
tank,
and
pump, from tank.
tube (8) between main control
valve and
hydraulic tank, from tank.

t
3.
Loosen tube clamp.
Hydraulic
tank
Temporarily
sling hydraulic
tank
(9). remove mounting
bolts and lift out.

*
Be careful that tubes (6) and (8) do not cause interference with tank.
Hydraulic
63-2
0
tank:
290 kg
WA500-
INSTALLATION
1.
Hydraulic
Set
OF HYDRAULIC
TANK
tank
hydraulic
tank
(9)
in
mounting
position,
then
tighten mounting bolt.

*
Be careful that tubes do not cause interference
with
tank.
m
Mounting bolt:
56 * 6 kgm
2.
Hydraulic
30 mm)
piping
Connect hydraulic
piping as follows:
I) Connect tube (8) between main control
valve and
hydraulic tank, to tank.

*
Install tube clamp.
2) Connect tube (7) between hydraulic tank, and switch

and hydraulic
pump, to tank.
3) Connect tube (6) between hydraulic tank and steering

+ POC pump, to tank.
3.
Hood
Install hood (5).
4.
Refilling with oil

Tighten
of
pump

piping,
then
add
tank filter,
hydraulic
and plugs
oil through
oil
filler to the specified level.

*
Run the engine to circulate hydraulic
oil and water.
Then check the oil and water levels again.

m
WA500-
1.2 + 0.1 kgm
REMOVAL
n
!
OF HYDRAULIC
Stop the
safety
machine
PUMP
bar on the frame.

*
See REMOVAL
OF SWITCH
PUMP and remove switch
pump.
1.
Hydraulic
piping
Disconnect hydraulic piping as follows:
* Disconnect
tube
(I)
between
hydraulic tank, from hydraulic
* Disconnect
tube
(2)
between
steering valve, from hydraulic

2.
Hydraulic
pump
and
hydraulic
pump
and
pump.
pump
Remove hydraulic
*
hydraulic
pump.
The working
pump (3).
space is restricted,
so be careful when
working.
Hydraulic
pump:
15 kg
INSTALLATION
OF
HYDRAULIC
PUMP
Hydraulic
1.
pump
Set hydraulic
pump (3) in mounting position and tighten
mounting bolts.
2.
Hydraulic
piping
Connect hydraulic
piping as follows:
* Connect tube (2) between hydraulic pump and steering valve, to hydraulic
* Connect
tube
(1)
pump.
between
hydraulic tank, to hydraulic

*
See INSTALLATION
hydraulic
pump
and
pump.
OF SWITCH
PUMP
and installa-
tion switch pump.
63-4
WA500-
REMOVAL
a
1.
OF HYDRAULIC
FILTER
Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
Cover
Loosen
plug
(1)
and
remove
mounting
bolts,
then
remove cover (2).

The tension of the spring is pushing the cover,
!
Q
*
so be careful when removing.
Be careful
not to damage the O-ring (3) on the con-
tact faces of the cover and tank.

2.
Filter
Remove
spring (4)
and bypass valve (5), then remove
filter (6).
INSTALLATION
OF
HYDRAULIC
FILTER
1.
Filter
Install filter
(6). then install bypass valve (5) and spring
(4).
2.
Cover
Fit O-ring (3) in groove of cover, then intall cover (2) to
tank and tighten plug (1).
+
*
Replace the O-ring with a new part.

Fit the O-ring securely in the groove, and make sure
@Kl
WA500-
Plug:
1.2 f 0.1 kgm
63-5
0
REMOVAL
n!
OF SWITCH
Stop the machine
PUMP

G!
control
tank.
Then operate the
piping.
filter,
and
plugs
(3) and
(4) of the pump
piping to
1. Cover
Remove cover (5).
2.
Hydraulic
piping
Disconnect
hydraulic
piping from switch and POC pump
as follows:
* Tube (6) between hydraulic tank and switch pump.

* Tube (7) between switch pump and steering valve.
*
3.
Remove clamp of tube (7) and let it remain free.
Switch pump
Remove switch pump (8).
*
The working
so be careful when
working.
Switch pump:
15 kg
425P738j
WA500-
INSTALLATION
1.
OF SWITCH
PUMP
Switch pump
Set switch pump
(8) in
mounting bolts.
3.
Cover
Install cover (5).
4.
Refilling with oil

Tighten
of pump piping, then add hydraulic
tank filter,
and plugs
oil through oil filler

WA500-
1.2 2 0.1 kgm
REMOVAL
OF POC VALVE
Stop the
A!
machine

_$;
!

control
tank.
Then operate
the
piping.
filter,
and plugs (3) and
(4) on the pump
piping to

1.
Cover
Remove cover (5) under cab and cover (6) of console
box on right side of operators seat.
2.
Hydraulic
piping
- Disconnect
hoses (7) and
(8) of lift spool at POC
valve end.
* Disconnect hose (9) between POC valve and hydraulic

tank at POC valve end.
* Disconnect hose (10) between POC pump and POC

valve at POC valve end.
- Disconnect hoses (11) and (12) of dump spool at

POC valve end.
*
After
disconnecting
the
hoses, mark
with
a tag to
distinguish when installing.

425P74S
425?342
63-8
2
WA500-
3.
4.
(L
Linkage
Remove
cotter
connect
linkage
pin and loosen
locknut
(131, then
dis-
(14).
POC valve
Remove plate (15). then remove POC valve (16).
*
The working
so be careful
when
working.
*
There
is a washer between
console box, so be careful

*
the plate and valve and the

not to lose it.
Lift out POC valve.
WA500-
63-9
0
INSTALLATION
2.
OF POC VALVE
Linkage
Set linkage
(14)
in mounting
position,
tighten
locknut
(13), then secure with cotter pin.

t
For details of adjusting
linkage, see TESTING
AND
ADJUSTING.
3.
Hydraulic
piping
* Connect hoses (11) and (12) of dump spool at POC

valve end.
* Connect hose (10) between POC pump and POC valve

at POC valve end.
- Connect hose (9) between POC valve and hydraulic

tank at POC valve end.
* Connect hoses (7) and (8) of lift spool at POC valve

end.
425P742
63-10
0
WA5bO- 1
4.
Cover
install cover (5) under cab and cover (6) of console box
on right side of operators seat.
5.
Refilling with oil

Tighten
tank filter,
and plugs
of pump piping, then add hydraulic oil through oil filler

w
WA500-
plug at top for filter:
1.2 + 0.1
kgm
63-11
0
DISASSEMBLY
1.
OF POC VALVE ASSEMBLY
Loosen nipple (1). then remove bottom cover (2).

*
It is only necessary to loosen the nipple if it catched

on the lower cover.
2.
3.
Remove bracket (3).

Remove
plug
(4),
then
remove shim
springs (7), (El), (9) and (lo),

*
(5). spacer (6),
and spacer (11).
Make match marks to prevent
mistakes in the com-
bination of spool and spring.

4.
5.
Remove case assembly (12).

Remove
set screw
(13),
207P432
and pull out
levers (14)
207P433
and
(15), then remove spools (16) and (17).
ASSEMBLY
ASSEMBLY
1.
OF POC VALVE
Make spools (17) and (16) into a set, then install levers
(15) and (14). and tighten set screw (13).
*
2.
3.
Lock securely with wire.
2072434
Fit O-ring and install case assembly (12).

Assemble
spacer
(1 I),
springs (IO),
(9),
(8) and
(7),
spacer (6) and shim (5), then install plug (4).

+
Be careful
not to mistake the combination
of spool
and spring.
4.
5.
Install bracket (3).

Fit O-ring
and install
bottom
cover
(2), then tighten
loosened nipple (1).
207P435
207P436
63-12
0
207P438
207P437
WA500-
REMOVAL
OF MAIN
Stop the
safety
machine
CONTROL
VALVE
bar on the frame.

Q
!

control

tank filter,
tank.
Then operate
the

piping.

Cover
Dump cylinder
1) Disconnect electric wiring (6) from connector.
2) Disconnect grease tube (7) from front frame.
*
Remove clamp of grease hose.
3) Disconnect hydraulic
piping (8) and (9).
4) Sling cylinder
remove
(10).
pin
(ll),
then remove
cylinder.
*
Be careful
to check the center
of gravity when
attaching the lifting tool.

*
There are shims at the mounting
pins, so check the
number and thickness of the shims, and keep in a

safe place.
Hydraulic
wiring
* Disconnect hoses (12), (13), (14) and (15) between

POC valve and main
control
valve at main control
valve end.
*
Remove the tube clamp.
After
disconnecting
the tube, move it toward
the
between
and
rear of the machine.

*
Disconnect
hose
(16)
hydraulic
tank
main control valve at main control valve end.
WA500-
63-13
0
Remove tubes (17) and hose between
main control
valve and dump cylinder.
Remove tubes (18)
between
main control
valve and
lift cylinder.
Disconnect tube (19) from manifold
Remove tube bracket (20).
Remove
hose (21)
between
end.
main control
valve and
steering valve at main control valve end.

l
Remove tube (22) between hydraulic
tank and main
control valve at main control valve end.
Remove
tube
(23)
and hose between
main control
valve and dump cylinder at main control valve end.
* Disconnect
tube
(24)
between
main
control
valve
and lift cylinder at main control valve end.

*
4.
Loosen the tube clamp first.
Main control valve

1) Remove mounting
bolts and turn main control
valve
(25) 90.
2) Using eye-botls, lift out main control valve (25).
*
Be careful of bleeder screw of slack adjuster and

remove.
Main control valve: 88 kg
6 3-l 4
0
WA500-
INSTALLATION
1.
OF MAIN
CONTROL
Main control valve

1) Using eye-bolts, set main control valve (25) in mounting position.
*
When
setting
in the mounting
position,
operate
the hoist to maintain
the balance
interference
bleeder screw of the slack
with
the
and to avoid
adjuster.
2) Turn main control valve (25) 90 and tighten mounting bolts.

+
The
lift
cylinder
tube
will cause interference
so
push the tube upward.
2.
Hydraulic
piping
Connect hydraulic
piping as follows:
* Connect tube (24) between main control valve and

lift cylinder, to main control valve.
+
Tighten tube clamp.
* Install tube (23), together with hose, between main

control valve and dump cylinder.
*
Be careful of angle of tube when installing clamp.
* Connect tube (22) between hydraulic tank and main

control valve, to main control valve.
* Connect hose (21) between steering valve and main

control valve. to main control valve.
WA500-1
VALVE
Install
tube
(18)
between
main
control
valve and
lift cylinder.
+
Install tube (19) to manifold.
Install tube clamp (20).
* Install tube (17), togehter with hose, between main

control valve dump cylinder.
* Connect hose (16) between hydraulic tank and main

control valve, to main control valve.
- Connect
tubes
(12),
(13).
POC valve and main control
(14)
and
(15)
between
valve, to main control
valve.
3.
Dump cylinder
1) Set cylinder
hole.
uniform
(10) in mounting
Adjust
with
position,
shims so that
and align pin
clearance
on left and right, then drive in pin (11
is
) and
lock the pin.

Q
Use a bar to align the pin hole.
Never use
your fingers.
*
Clearance a = 1.5 mm
425F299
WA500-
4.
Cover
Install inspection cover (5) of front frame.
5.
Refilling with oil

Tighten
plugs at the top of hydraulic
plugs of pump piping, then add hydraulic
tank filter,
and
oil through oil
filler to the specified level.

m
WA500-
1.2 i 0.1 kgm
63-17
0
DISASSEMBLY
AND
jo
ASSEMBLY
OF MAIN
!
20
CONTROL
VALVE
il
0
0
425F301
425F300
63-18
0
WA500-
ASSEMBLY
DISASSEMBLY
1.
Spool assembly
1) Remove
1.
sleeve
(I)
(3), spring
2) Remove
piston
3)
Remove
springs
(6),
4)
Remove
spools
(10)
Assemble
body
and case (2).

(4) and retainer
(7) and (8),
valve
(30),
Main
relief
2) Loosen
(9).
2.
relief
valve assembly
main
nut
3) Remove
(13),
relief
then
snap
ring
3.
(12).
holder
(14)
and
(18)
is any defect
If there
whole
from
then
sleeve
assembly.
remove
valve
(17)
(19).
in spool
These
or valve,
4.
valve assembly
with
Remove
safety
Suction
valve assembly
Remove
suction
Fit O-ring
replace
parts are not avail-
suction
valve assembly
w
5.
valve
valve assembly
Remove
selector
6.
(21).
valve
(22).
Main
plate
(23),
(30).
remove
spring
(24)
4)
flange
and unload
(26),
then
valve
(29).
Do not disassemble
pressure
installed
cannot
remove
the safety
be adjusted
on the machine.
spring
(27).
valve further
after
the
seal
as the
valve
is
nut
Spool
valve assembly
(20).
19 + 1 kgm
(17)
and
spring
(18)
in sleeve
backup
ring
and
assemble
seat
fit O-ring
and
(19).
(13)
into
holder
in sleeve
(19),
and
backup
O-ring
valve assembly
Main
(14).
then
tighten
ring,
nut (13).
then
install
main
(12).
relief
valve:
33 t 4.5 kgm
assembly
1) Assemble
2) Install
spools
retainer
3) Assemble
fit O-ring
WA500- 1
(21).
snap ring (16).
and
in sleeve
Fit
safety
valve
O-ring
B
7.
valve assembly
19 + 1 kgm
valve:
and install
assemble
and
(25).
(22).
valve assembly
3) Screw
then
valve assembly
suction
and install
relief
2) Fit
valve assembly
Remove
(28)
in body
7 * 1 kgm
valve:
Safety
relief
7.
(24)
Safety valve assembly with suction valve
(19),
valve assembly
valve:
Suction
(15)
Remove
in
(23).
selector
and install
Fit O-ring
(20).
valve assembly
Selector
Check
(27)
Suction valve assembly
1) Assemble
6.
(26).
spring
plate
and install
Selector
5.
spring
Selector valve assembly
able individually.
4.
(25) and
and install
Fit O-ring
valve assembly.
remove
(16),
and spring
Safety
and
flange
Check valve assembly

Assemble valve
and (1 I).
seat (15).
3.
(28)
valve assembly
I) Remove main
* Disassemble
the
seal
and install
(5).
and retainer
fit O-ring
2.
(29).
fit O-ring
(11)
and (10)
(9) and springs
retainer
and install
(5),
spring
in body.
(8),
(7) and (6).
(4) and
case (2) and sleeve
piston
(3),
(1).
63-19
0
REMOVAL
OF DUMP
Stop the
machine
CYLINDER

control

1.
tank.
Then operate
the

piping.
Bucket positioner wiring

Disconnect wiring (1) from connector.
2.
Grease tube
Disconnect tube (2) from bottom pin end.
*
3.
Remove clamp and move tube.
Hydraulic
piping
1) Disconnect hose (3) at rod end from cylinder.

2) Disconnect
hose (4) of bottom
end from
cylinder
end.
4.
Rod pin
Sling cylinder,
*
remove lock bolt, then remove pin (5).
When raising the cylinder,
sling at two places and be
careful to maintain the balance.
425P759
63-20
0
WA500- 1
5.
Dump cylinder
1) Remove
lock bolt,
then
remove pin (6) at bottom
end.
*
There are shims installed, so check the number and

thickness of the shims, and keep in a safe place.
2) Remove dump cylinder

*
(7).
Be careful not to damage the cylinder rod.
_,.- ._.~
Dump cylinder: 283 kg

_ -~ ^._._..__~__.. .__ _.. -
WA500- 1
_ --
63-21
0
INSTALLATION
1.
OF DUMP
CYLINDER
Dump cylinder
1) Raise dump
cylinder
(7) and set in mounting
posi-
tion.
25P761
2) Align pin hole at bottom
end, assemble shim so that
clearance a between cylinder and frame on left and

right is within specified range, then install pin (6) and
lock with bolt.
Clearance a + b = Max. 1.0 mm
425F299A
2.
Rod pin
Align
pin hole at rod end, then install pin (5) and lock
with bolt.
Never use your
fingers.
425P759
6322
WA500- 1
3.
Hydraulic
piping
1) Connect hose (4) at bottom end.

2) Connect hose (3) at rod end.
4.
Fit the O-ring securely in the grooves.
Install the hose without
twisting or interference.
Grease hose
Connect hose (2) to front frame.
5.
Bucket positioner wiring

Connect wiring (I) to connector.
WA500-
63623
REMOVAL
OF LIFT CYLINDER
Stop the
machine

1.
Fender
Remove fender (I ).
Fender:
2.
48 kg
Rod pin
1) Sling lift cylinder
(2). remove lock bolt, then remove
pin (3).
2) Start
engine, and operate
control
levers to retract
cylinder rod on side where pin has been removed.

Loosen the oil filler cap slowly to release the
pressure inside the hydraulic
operate
the control
tank.
Then
levers several times to
release the remaining pressure in the hydraulic piping.
3.
Hydraulic
piping
1) Disconnect hose (4) at rod end from connector.

2) Disconnect hose (5) at bottom end from connector.
4.
Lift cylinder
1) Place lever block under lift cylinder
rear of machine with lever block @
2) Using forcing screw (Ml2
(2) and pull to
x 50 mm), remove pin (6)
of bottom end.
*
There are shims installed, so check the number and

thickness of the shims, and keep in a safe place.
3) Remove lift cylinder (2).

*
/
Be careful not to damage the cylinder rod.

Lift cylinder:
---i
425P7645
280 kg
425P765
63-24
0
WA500- 1
INSTALLATION
1.
OF LIFT CYLINDER
Lift cylinder
1) Raise lift cylinder
2) Sling cylinder,
(2) and set in mounting position.
then align pin hole using lever block
0.
3) Assemble
shim so that clearance a between cylin-
der and frame
on left and right is within
specified
range, then install pin (6) and lock with bolt.
Use bar to align the pin holes.
Never use
your fingers.
Clearance a + b = Max. 1 .O mm
425F302A
425P768
WASOO- 1
63625
2.
Hydraulic
piping
1) Connect hose (5) at bottom end.

2) Connect hose (4) at rod end.
3.
Fit the O-rings securely in the grooves.
Install the hoses without
twisting or interference.
Rod pin
Start engine and operate
control
levers to extend
rod.
Align pin hole, install pin (31, then lock with bolt.
4.
Fender
Install fender (1).
63-26
0
WA500-
DISASSEMBLY
OF LIFT AND
DUMP
CYLtNDERS
ASSEMBLY
Special tool
Part No.
Part name
790-502-1001
Cylinder repair stand
1.
Set cylinder assembly (1) in tool A.
2.
Remove mounting bolts (2) of cylinder head.
1 Qtv
1
207P490
3.
Pull cylinder
cylinder
*
head and piston rod assembly (3) out from
(4). then lift off.
Oil will come out when the piston rod assembly is

removed from the cylinder, so catch it in a container.
207P49
4.
Remove piston bolts (51, then remove spacer (61, piston

assembly (7) and cylinder head assembly (8).
-.
419Pl254
9
5.
Remove O-ring
(IO)
and backup
ring (11) from piston
rod (9).
423F484
WA500-
63-27
0
6.
,, ,

Remove wear ring (12) and piston ring (13) from piston
(14).
_,
iZOXF24
7.
IB
Disassembly of cylinder assembly

1) Remove O-ring (15) and backup ring (16).
2) Remove snap ring, then remove dust seal (17).
207P494A
207P495A
3) Remove rod packing (18).

4) Remove bushing (19).
207P496A
63-28
0
18
19
207P497A
WA500-
ASSEMBLY
OF LIFT AND
DUMP
CYLINDERS
ASSEMBLY
Special tools
A--
Part No.
Part name
~~
Cylinder repair stand
Expander
790-502-1001
~790-720-1000
1 Ring
796-720-1690
796-720-I
Cl
Oty
720
Ring
Clean all parts, and check for dirt or damage.
Coat the
sliding surfaces of all parts with engine oil before installing.
Be careful not to damage the U-packings, dust seals
or O-rings when assembling.

Assembly of cylinder head assembly
1) Using push tool @
, press fit bushing (19) on cyl-
inder head (20).

t
Be careful
not to deform
the bushing when press
fitting.
9n
207P498A
207P497A
2) Assemble rod packing (18).

*
Be careful to install the rod packing facing in the

correct direction.
200F240A
3) Install backup ring (16) and O-ring (15).

t
Do not try to force the backup ring into position.

Warm it in warm water
(50 - 60C)
before fitting
it.
207P499A
WA500-
207P494A
63-29
0
, install dust seal (17) to cylinder
4) Using push tool @
head, then secure with snap ring.
,.
2.
a-
207P495A
-S207P500

1) Using tool B, expand piston ring (13).
*
Set the piston ring on the expander
and turn the
handle 8 - 11 times to expand the ring.

2) Remove
piston
ring from
tool
B, and assemble on
piston (14).
3) Fit tools C and C1 on piston ring, then using clamp
@
, compress piston ring.
Part No. of clamp:
Part No. of clmap:
07281-02169
07281-02429
(for lift cylinder)

13
(for dump cylinder)
207P502A
4) Assemble wear ring (12) on piston.
C
207P503
3.
Assemble
O-ring
(10)
and backup
ring (11) on piston
rod (9).
423F484
63-30
0
WA500- 1
4.
Assemble cylinder
head assembly (8) and piston assem-
bly (7) on piston rod.

*
Coat backup ring (11) with grease so that it does not

stick out, and assemble carefully.
5.
Assemble spacer (6), then tighten piston bolts (5).

Piston bolt:
18.0 f 2.0 kgm

&
6.
Mounting
Set cylinder
bolt:
22 mm)
Adhesives (LT-2)
(4) in tool A, then raise piston rod and head
assembly (3), and assemble in cylinder
(4).
207P49
Tighten cylinder head mounting bolts (2).

m
Cylinder head mounting bolt:

47.5 ? 14.5 kgm (Lift cylinder)
117.5 f 12.5 kgm (Dump cylinder)
Remove cylinder assembly (1) from tool A.
207P490
WA500-
632
REMOVAL
Q
7
OF WORK
Stop the machine
EQUIPMENT

1.
Bucket link
1) Remove mounting pin (1) of bucket link.
*
Remove cord ring.
Tie the bucket link to the tilt lever with wire.
2) Remove
mounting
bolt
(5A)
of flange (4 pieces at
left and right).

3) Remove mounting pin (2) of bucket hinge.
*
Before removing pin (2), loosen retainer mounting

bolts, remove retainer (3) and shim (3A).
Remove lock bolt and cam, then pull out pin (2)
at left and right.
P425C1197
4) Move machine to rear and disconnect bucket (4).
2.
Flange
1) Remove flange (5) from lift arm.
425P811
63-32
0
WA500-
2) Remove
seal (6), oil seal (6A)
and O-ring (7) from
flange (5).
*
Serial No. 11464 and up: seal (6) only
Serial
No.
Serial
10001-11463
No.
11464
and up
5
6
7
._
425F401
FO425C1130
3.
425P81i
,.
Dump cylinder pin

Temporarily
sling dump cylinder
(8), pull pin (9), then
disconnect cylinder rod and tilt lever.

+
Attach
lifting tool to dump cylinder and secure in the
rear.
Dump cylinder:
285 kg
4.
425P813
Lift cylinder pin

Attach
lever
block @
to
lift
cylinder
(10).
pull ma-
chine to rear and remove mounting pin (11).

+
Secure other end of lever block @
to hole of front
frame.
Lift cylinder:
280 kg
425P814
,,
5.
Tilt lever, bucket link

1) Temporarily
sling tilt
remove mounting
lever and
bucket
link
(12),
pin (13), then lift out from lift arm
(14).
* 3 men should be used for removal of mounting
pin operation.
2-s
~92
Tilt lever and bucket link:
A
cig2
Mounting pin:
480 kg
59 kg
425P815
WA500-
63-33
0
2) Temporarily
sling bucket
link (75).
remove mount-
ing pin (16). then lift out from tilt lever (17).
*
Remove cord ring.

Bucket link:
95 kg
There are shims installed, so check the number of

shims for reference when installing.
425P816
6.
Lift arm
1) Remove boom kickout switch (18).
2) Temporarily
sling lift arm (14). pull out mounting pin
of lift arm, then lift out lift arm.

*
Shims are installed
at connecting
point of front
frame and lift arm, so check the number of shims.

Lift arm:
7.
2,000 kg
Dust seal, bushing

1) Pull out bushing (19) from lift arm (14).
19
19
425F31/
63-34
0
425P819
WA500- 1
2) Pull out dust seal (20)
and bushing (21)
from tilt
lever (17).
3) Pull out dust seal (22) and bushing (23) from bucket
link (15).
*
After
using for
makes
it
a long time,
difficult
to
remove
it wear of the pin

a
15
and use it to
the
jig such as the one shown below,
pin,
make
23
remove the pin.
pump
425F319
426F384A
3-l6x2Depth30
Perforation depth 40
(circumference of equal parts)
-Y
i
\
-_--
\
Dimension of pin hole
(For adapter mounting bolt)
427F2053
WA500-
INSTALLATION
a
1.
OF WORK
EQUIPMENT
Never
use your
fingers.
Dust seal, bushing

Using a press, press fit bushing
(19) in bucket
link,
tilt
lever, and lift arm.

*
Assemble dust seal only
R??K
Bushing:
in bucket
lever.
Grease (G2-LI)
Hydraulic
arm
Lift
link and tilt
cylinder
425P819
419F471
419P1063
2.
Lift arm
1) Sling
lift
arm
and
set in mounting
assemble mounting
pins and lock with
holes of front
Align
mounting
and insert shims so that
position,
frame
clearance
then
bolt.
and lift
arm
on left and
right are equal.

*
Clearance
After
a:
less than 1.5 mm
installing
the pin,
set a support
under
the
tip of the lift arm.
425F320
2) Install boom kickout

*
For
details,
switch
(181.
see TESTING
AND
.-\DJUSTING
section.
63-36
ii
WA500-
3.
Tilt lever, bucket link

1) Assemble cord rings on bucket link (151, align hole of
tilt lever (17), assemble mounting pin (16). then lock
with bolt.
*
Secure bucket link to tilt lever with wire.
Be careful not to get cord ring caught.
Insert shims so that clearance b on left and right

is equal.
Clearance b:
16
less than 1.5 mm
425P816
425F321
425P815
2) Align holes of tilt lever (12) and lift arm (14), assemble mounting pin (13), then lock with bolt.
4.
Lift cylinder pin

While adjusting lever block @
mounting
position,
then
, set lift cylinder (10) in
assemble mounting
pin (11).
and lock with bolt.

*
Remove lever block 0.
:,425P?14
5.
Dump cylinder pin

Temporarily
sling dump
cylinder
(8), adjust operating
levers, align pin hole, assemble mounting
pin (9). then
lock with bolt.
WA500-
63-37
0
6.
Serial No. 10001-10123
Flange
1) Assemble dust seal (6), oil seal (6A) and O-ring (7) in
Do not make
flange (5).
*
Press dimension
clearance
Serial No. 11464 and up: seal (6) only.
Press fit seal uniformly
Check that there is no clearance between dust seal
on circumference.
Check that seal is not sticking out from the side of
and oil seal. (Serial No. 10001-11463)

the flange face.
6
*
Seal lip space, O-ring: Grease (G2-LI)

Dimension of press fit dust seal
(Serial No. 10001-11463):
O-O.5
mm
: 0.25-0.8
Serial No. 10124-I
Dimension of press fit oil seal

(Serial No. 10001-l
1463):
FO425C1131
mm
1463
8 mm
Press dimension
2) Assemble flange (5) to pin (2). and insert in lift -7:~.

t
&
Do not make
clearance
Insert pin slowly, until flange seal touches bushing.

Bushing: Grease (G2-LI)
F42501005
Serial No. 11464 and up
Serial No. 10001-l
Press dimension
0.25-0.8
1463
Seal contacts bushing
427F2069
425F402
Seal contacts bushing
..25F403
5
425P820
425P812
63-38
0
WA500-
3) Using pin as a guide, while rotating flange to left and

right by hand, insert lift arm.
*
After
inserting,
rotate
flange
1 to 2 times with
hand to settle in with seal.

+
Pull the flange out about 5 mm from the lift arm

and check that there is no abnormality
in the dust
seal.
*
Insert the flange until
the inside surface contacts
the end face of the bushing, then tilt the mounting

bolt hole part of the flange about 25 towards the
FO425C1132
rear of the lift arm.

*
*
Never strike flange with hammer.

Follow the same steps for the flange on the other
side.
7,
Bracket
1) Bring bucket
and lift arm together,
lever to align bucket mounting
operate
control
pin holes, then insert
pin.
When doing this, be careful not to let the bucket
hit the flange.
When installing the pin, check that the air bleed
hole on the pin is at the top.
Align the flange bolt holes and the mounting
bolt
holes of the bucket flange.
2) Select shim
(Serial No. 10001-l
1463)
Push flange evenly towards boss of lift arm and measure clearance cl. Assemble shims so that clearance is
within standard value.
*
Clearance c: Max. 0.2 mm
When
both
selecting
the top
the shim,
and bottom
the most suitable
measure clearance
for
split shims, assemble
shim for each, and be careful
that the flange is not at an angle.

425F323
WA500-
Flange mounting
bolt: 23 + 8 kgm
63if9

*
After
selecting
clearance
the number
at the
lift
of shims to make the
arm boss (*
mark)
less than
0.5 mm, remove two 0.5 mm shims and install flange

so that the clearance (* mark) is 1.5 mm.
*
When selecting the shim, measure clearance for both

the top and bottom
split shims, assemble the most
suitable shim for each, and be careful that the flange

is not at an angle.
425F404
3) Tighten
bolt
(24)
temporarily
so that
cam
(24A)
contacts mounting pin.

*
Tighten fully after installing retainer (3).
4) Install
retainer
(3),
and
measure
Assemble shims so that clearance
clearance
is within
d.
standard
425P824
425P825
value.
t
Clearance d: Max. 0.2 mm
After
installing the retainer,
fix the flange to the
bucket.
Clearance
425F324
5) Adding oil (Serial No. 10001-11463)

Remove bolts (27) and (28) of bucket pin and add oil
until
*
oil comes out from hole of air bleed bolt (27).
After
adding
fitted
to bolts (27) and (28). then install the bolts.
aL
oil,
Check
that
there
are O-rings
Pin oil: Gear oil (G0140)

Pin oil: Approx.
3ifo
50 cc
WA500-
6) Greasing (Serial No. 11464 and up)

Add
grease from
the
central
grease fitting
of the
bucket pin until grease comes out from the dust seal.
a,,
8.
Bucket pivot portion:
Grease (G2-LI)
Bucket link
1) Sling bucket link, align hole of mounting pin (I) and
assemble, then lock bolt.
*
Be careful not to get the cord ring caught.
2) When exchanging only cord ring:

i) Insert cord ring (25) in groove.
*
Stretch
cord
ring slightly
while
inserting
in
groove.
ii) Insert bolt (26) in cord ring and secure.
*
Tighten
the bolt
enough
so that
it does not
change shape of cord ring.

9.
Refilling with oil

Refill each pin with oil or grease.
WA500-1
63-40-l
0
REMOVAL
Stop the
OF COUNTERWEIGHT
machine

1.
Radiator
grille
Lift off radiator grille (1).
2.
Counterweight
Sling counterweight
(2), remove mounting bolts, then lift
off counterweight.
*
When slinging the counterweight,
be careful to main-
tain the balance.

*
When removing the counterweight,
be careful not to
let it hit the lamps.

Counterweight:
880 kg
(Serial No.lOOOl--10452)
: 1465 kg
425P829
INSTALLATION
OF
COUNTERWEIGHT
1.
Counterweight
Raise counterweight
(21, set in mounting
position, then

*
When installing the counterweight,
be careful not to
let it hit the lamps.

m
Mounting bolt:
160 Itr 20 kgm

2.
Set radiator grille (1) in mounting
position,
46 mm)
42513830
and tighten
mounting bolts.
WA500-1
63641
WORK EQUIPMENT SYSTEM

64 MAINTENANCE
STANDARD
Main control valve .................

Dump cylinder .....................
Lift cylinder .......................
Bucket linkage .....................
Bucket positioner and boom kick-out
Bucket ............................
Hydraulic and switch pump .........
POCpump ........................
POCvalve ........................
WA500-
0
E
..
..
.
..
.
.
.
.
.
.
.
.
.
64- 2
64- 4
64- 5
64- 6
64- 8
64- 9
64-10
64-l 1
64-12
64-1
MAIN
CONTROL
VALVE
Section A-A
Section
C-C
16
Section 0 -
section B-B
Section
E-
425F163
64-2
WA500-
Unit:
Remedy
Criteria
Check item
No.
Repair limit
Standard size
Spool return spring
Installation
load
Free
length
Installation
length
Installation
load
Free
length
83.8
82.0
7.7 kg
83.4
6.2 kg
Spool return spring
84.1
82.0
9.9 kg
83.7
7.9 kg
Spool return spring
63.0
60.5
23.5 kg
62.5
18.8 kg
Spool return spring
25.1
17.5
23.5 kg
23.6
18.8 kg
Main valve spring
52.3
38.0
2.8 kg
Check valve spring
78.2
52.0
1.92 kg
Suction valve spring of safety valve
27.9
18.1
0.69 kg
Suction valve spring
27.9
19.0
0.65 kg
Float selector valve spring
44.4
35.6
9.85 kg
10
Unloader valve spring
82.7
47.0
5.0 kg
11
Relief valve poppet spring
49.3
43.3
21.4 kg
12
Tightening torque of check valve bolt
13
Tightening torque of suction valve
14
Tightening torque of main relief valve
15
Tightening torque of float selector valve
16
Tightening torque of safety valve
19.0 i- 1 .O kgm
17
Tightening torque of nipple
2.25 t 0.25 kgm
18
15.5 + 2.5 kgm
WA500-
mm
Replace
9.0 i 1 .O kgm
19.0 + 1.0 kgm
32.75 * 4.75 kgm
7.0 2 1 .O kgm
Retighten
64-3
DUMP
CYLINDER
425F165
Unit:
No.
Check item
Criteria
Remedy
Tolerance
Clearance between
bushing
rod and
Standard
size
Standard
clearance
Clearance
limit
Shaft
Hole
120
-0.120
-0.207
a.277
+0.062
0.484 0.182
0.784
Clearance between piston rod

mounting pin and bushing
120
-0.036
-0.090
+0.307
+2.220
0.256 0.397
1 .o
Clearance between cylinder

bottom mounting pin and bushing
120
-0.036
-0.090
f0.307
f2.220
0.256 0.397
1 .o
Cylinder bore
225
+0.46
0
Tightening torque of cylinder

head mounting bolt
Tightening torque of piston

mounting bolt
Replace
buhsing
Replace
117.5 i 12.5 kgm
64-4
mnl
Retighten
16.0 ?:2.0 kgm
WA500- 1
LIFT CYLINDER
425F164
Unit:
No.
:1
Check item
Clearance between rod and bushing

I
Criteria
-_-__---_-_c----
110
-_.
~
~
1
to.274
+0.060
-0.036
-0.090
io ,307
+0.220
0.2560.397
0.481 0.180
Clearance
between
piston
pin
and inside
diameter
of rod
holemounting
120
Clearance between cylinder bottom

mounting pin and bushing
120
~
/
-0.036
-0.090
+0.307
+0.220
0.256 0.397
Cylinder bore
200
+0.45
0
Tightening torque of cylinder head

mounting bolt
Tightening torque of piston mounting

bolt
Remedy
-0.120
-C.207
WA500-
mm
0.81
Replace
bushing
1 .o
1 .o
Replace
47.5 f 14.5 kgm
. Retighten
18.0 t 2.0 kgm
64-5
0
BUCKET LINKAGE
425F169
(Oil type)
Serial No. 10001-11463
Serial No. 7 1464 and up (Grease type)
12
/
Section A-A
SectionA-A
9
/
Section B - B b
14
15
/
Section C - C
Section D - D
Section E - E
10
a
Section F - F
d
Section - - G
b
Section H - H
---L.-f
SectionJ-J
425F! 70-l
64-6
0
WANO- 1
Clearance between pin and bushing at

boss ends of bucket link
n and bushing at
between pin and bushing at

cylinder bottom and frame
Joint of lift armand bucke

on both sides
to make clearance on both
sides less than
16
Joint of lift cylinder and lift arm
125
122
3.0
17
Joint of lift cylinder and frame
123
120
3.0
WA500-
64-7
BUCKET
POSITIONER
AND
BOOM
KICK-OUT
r---1
425F172
Unit:
Criteria
Check item
No.
Clearance of bucket positioner switch
5-8
Clearance of boom kick-out switch
5-8
Remedy
Adjust
I
4
64-8
Tightening torque of mounting bolt for

adiuster
switch
I
I
9.0 f 3.5 kgm

Retighten
1.8 ? 0.2 kgm
WA500- 1
mm
BUCKET
Section A - A
Section B-B
Section C - C
425FlJl
Unit:
No.
Check item
Criteria
Remedy
Standard size
Repair limit
61
23
Wear of bucket tooth
Thickness of shims for tooth

(Clearance between tooth and bucket)

bucket tooth
180?20kgm

corner tooth
180+
Max. 0.5
mm
Replace
Adjust
Retighten
WA500-
20 kgm
64-9
HYDRAULIC
AND
Hydraulic pump SAR(3)-100

Switch pump SAR(SI-100
SWlfCH
PUMP
>
Section A - A
425F134
Unit:
Check item
No.
Clearance between gear case and side

plate gear
Clearance between inside diameter of plain

bearing and outside diameter of gear shaft
Remedy
Criteria
I___
mm
Rep,ace
0
l4 -0.5
0.7 -
1.2 kgm
25.2 f 1.7 kgm
Retighten
Discharge
64-10
Oil:
EOlO-CD
Temperature:
45 - 55C
WA500-
POC PUMP
SAR(l)-014
425F162
Unit:
Remedy
Criteria
Check item
No.
mm
Clearance limit
Standard clearance
Clearance between gear case and side
plate gear
0.19
0.10-0.15
Replace
2
Clearance between inside diameter of plain

bearing and outside diameter of gear shaft
0.06 - 0.144
0.20
0.2 - 0.5 kgm
11.2 f 1.2 kgm
Retighten
Revolution
(rpm)
Discharge
6
Oil:
EOlO-CD
Temperature:
lo -:.5
Standard
discharge
(Q/min)
Repair limit
discharge
(Q/min)
210
47
43
45 - 55Oc
3,500
WA500- 1
Discharge
pressure
(kg/cm )
64-11
POC VALVE (Pilot operated control valve)
3
421F155
Unit:
No.
Remedy
Criteria
Check item
Repair limit
Standard size
Spool return spring
Free
length
Installation
length
Installation
load
57.3
33
8.0 kg
installation
load
Free
length
6.4 kg
Spool return spring
157.3
33
8.0 kg
Spool return spring
33.8
31
1.5 kg
1.2 kg
Spool return spring
33.8
31
1.5 kg
1.2 kg
0.75 * 0.15 kgm
0.75 + 0.15 kgm
Tightening torque of set screw
2.25 t 0.25 kgm
2.25 * 0.25 kgm
0.75 + 0.15 kgm
Main valve spring
11
Poppet spring
Free
length
Installation
length
47
26
33.6
30.5
6.4 kg
Replace if
damaged or
deformed.
Retighten
Repair limit
Standard size
10
Free
length
Installation
load
Installation
load
Replace
if damaged
or deformed.
2.1 kg
5.97kg
33
4.8 kg
Replace
Adjust
6422
mm
WA500- 1
ELECTRIC AND ELECTRONIC

SYSTEM
81 STRUCTURE
AND
FUNCTION
Electric and electronic
system
.............
...........
Electrical wiring diagram circuit
81-
81- 3
Electrical circuit diagram for
..................
.................
Engine stop circuit ....................
Preheating circuit .....................
* Preheating and after-heating with
heater switch ......................
* Preheating with starting switch ..........
- Automatic preheating ................
Combination switch ...................
............
Electrical transmission control
* Transmission cut-off switch ............
- Transmission cut-off selector switch .......
* Neutralizer relay ....................
Electrical parking brake control ............
intermittent
wiper.
Engine starting circuit
Electronic vehicle monitoring
WA500-1
81-
81-
81-
81-
81-10
81-11
81-12
81-13
81-14
81-15
81-16
system
..........................
* Monitor panel .....................
* Indication on monitor panel ............
- Controller ........................
. Wiring harness .....................
* Sensor ..........................
* Contact switch .....................
Operation of proximity switch ............
(EVMS)
81-6-1
.81-6-2
81-25
81-25
81-27
81-29
81-30
81-32
81-37
81-38
8&-
ELECTRICAL
Serial No. 11249
CIRCUIT
DIAGRAM
FOR INTERMITTENT
WIPER
and up
To air conditioner
unit
Relay
unit for intermittent
wiper
/^ ^_^CN4zL
Wiper
switch
connecting
II
7-d06
table
--
F42501010
WA500-1
*it-
ENGINE
Serial
STARTING
No. 10001
CIRCUIT
- 10388
Transmission
F-R lever
Starti
Starting motor
421F118A
Function
Operation
* To ensure safety when starting the engine, the system
* When the directional lever is placed at the N
is equipped with a neutral safety circuit.
position,
This marks it impossible for the engine to start if the
switch
are closed.
switch
is turned
directional
lever is not at the N (Neutral)
position.
In this condition,
to
the
flows in the following

@
Battery
starting motor
In
position,
current
circuit.
C + starting motor terminal
terminal
E -+ directional
C +
lever switch
N + ground.
addition,
terminal
battery
START
lever
if the starting
(+I --f starting switch terminal B +,start-
ing switch terminal

terminal
(Neutral)
the neutral contacts of the directional
current
BR -+ battery
flows
starting
switch
relay coil + ground,
from
so the
relay switch is closed. This forms the follow-
ing circuit.
@
Battery
terminal
(+)
If the directional
(Neutral),
battery
relay
-+ starting
circuit
lever is at any position other than N

@
is not formed,
and the engine
does not start.
*it2
motor
B, and the engine starts.
WA500-1

End
.--
Start
Engine stop motor

k
(hatched area)
Transmission
F-R lever
Battery relay
Battery
421 FO1047
Function
When
* To ensure safety when starting the engine, the system
the same time.
is equipped with a neutral safety circuit.
the motor
terminal
reaches
This marks it impossible for the engine to start it the
terminal
directional
from the battery
lever is not at the N (Neutral)
position.
rotates,
terminal
D also rotates at
When the non-conductive

terminal
A to B is opened,
B,
the
portion
circuit
of
from
and the flow of current
to the motor is shut off. The motor
tries to continue to rotate under inertia, but when the

Operation
conductive
* When the directional lever is placed at the N (Neutral)
both poles of the motor are discharged to the ground.
position, the neutral contacts of the directional

switch
are closed.
switch
is turned
In this condition,
to

@
Battery
ing switch terminal
(2) current
position,
current
circuit.
C + starting motor terminal
terminal
BR
current
+
E + directional
C +
lever switch
flows
through
from
starting
switch
relay terminals
so the relay coil is excited

relay terminals
(3) and
and
(5).
- The current from the battery flows from engine stop

motor terminals
motor,
A -
B,
the motor stops rotating.
Under this condition,

fully,
D contacts terminal
the stop motor
and the fuel injection

position,
cable extends
pump stop lever is set to
so the circuit is set to operating
condition.
In
addition,
terminal
current
BR +
battery
flows
starting
switch
relay coil + ground,
from
so the
battery relay switch is closed.

flows
engine stop motor
(1) + ground,
Therefore,
the FULL
6 + start-
N -+ ground.
* In addition,
terminal
START
(+) + starting switch terminal
starting motor
terminal
the
lever
if the starting
portion of terminal
B + relay terminals
(5) - (3)+
This forms the following

Battery
+ battery
circuit.
relay + starting motor terminal
B,
and the engine starts.

If the directional
N (Neutral),
circuit
lever is at any position other than

@
is not formed,
and the engine
does not start.
and rotates the motor (the cable is extended).
WA500-1
*z3
ENGINE
STOP CIRCUIT
Serail No. 10001 - 10388
Fuel cut solenoid
To starting motor
424FO72
Operation
.
W
When the starting switch

rent flows in following
(1)
Battery
is turned
ON, electric cur-
(+) + starting switch terminal
ing switch terminal
B + start-
BR + fuel cut solenoid + ground
voltage
flows to the fuel cut solenoid,
but the engine is rotating,

at terminal
reason, the following

(2)
connection,
When electric current
When the starting switch is turned OFF, circuit (1) is

shut off,
circuit.
Alternator
BR aground
the fuel governor is put in the FREE position by the
The battery
fuel control linkage.
diode
Fuel flows to the fuel injection
pump and the engine
so there
R of the alternator.
is still
For this
circuit is formed.
terminal
R + battery
relay terminal
connection.
relay is maintained,
inserted
into the circuit,
but because of the

no electric
current
flows to the fuel cut solenoid, so the engine stops.
starts.
WA500- 1
81-7
8
Start
Engine stop motor
@a-
Non-conductive
parts (hatched area)
Alternator
Starting motor
421 FO1048
. When the motor rotates, terminal
Function
* Ease of operation is improved by the use of an elec-
the same time.
trically
operated fuel cut system (engine stop motor).
terminal
which
enables the engine to be started and stopped
terminal
by turning
reaches
continues
positions.
ductive
terminal
A to C is opened,
from the battery
the starting switch to the ON and OFF
D also rotates at
When the nonconductive

C,
the
portion
circuit
and the flow of current
to the motor is shut off. The motor
to retate under inertia, but when the con-
portion
of terminal
D contacts
terminal
C,
both poles of the motor are discharged to the ground.
Operation
* When the starting switch

switch terminals
is turned
OFF,
B, BR and C are opened.
the starting switch, so the coil is deactivated,

circuit between terminals
Therefore,
starting
- The coil for the engine stop motor relay is shut off by
and the
the motor stops rotating.
Under this condition,

ed fully,
the stop motor cable is retract-
and the fuel injection
pump stop lever is set
to the STOP position, so the engine stops.
(3) and (6) closes.
- The current from the battery flows from engine stop

motor terminals
motor,
of
from
A -
C + relay terminals
(6) -
(3) +
and rotates the motor (the cable is retracted).
81-7-1
0
wA500-1
WITH
PREHEATING
STARTING
SWITCH
Preheat switch
timer
I1
I
.I
Electrical air intake heater
To electronic vehicle
monitoring system
(for pilot display)
424FO74
Operation
* If the starting switch is turned one stage to the left

from
the
electric
OFF
position
current
to the HEAT
from terminal
circuit.
(1)
terminal
Starting
switch
BR +
battery
the
B flows to terminals
The electric current from terminal
BR and R,.
terminal
position,
BR
The
electric current
BR
battery
relay
relay coil + ground connec-
from
Starting switch terminal

-t heater
relay
RI + heater relay signal
coil + ground connection,
and the heater relay is CLOSED.

Because of circuits
(1) and (2), the electric
from battery flows through the following
terminal
(3)
Battery
electrical
(+) +
battery
relay +
current
circuit.
heater
relay +
air intake heater + ground connection,
and
the engine is preheated.
tion, and the battery relay is closed.

following
(2)
terminal
RI
flows in the
circuit.
WA500- 1
81-9
AUTOMATIC
PREHEATING
Preheating
Preheat switch
c vehicle
monitoring system
(for pilot display)
Running
vehicle
stem
W
424FO75
In cold areas, when the starting switch is turned to
(4)
ON, the bimetal
electrical
timer
is at low temperature,
so the
As a result, electric
current
(+) -f starting switch terminal
ing switch terminal
B + start-
BR --f bimetal timer terminal
Bimetal
timer
terminal
ground
connec-
heater
relay +
and
(2) sends electric current
the resistor inside the bimetal timer,
resistor heats up and the bimetal
so the
between
bimetal
, timer terminal 2 and terminal 1 is heated.

bient
temperature)
the
bimetal
bends (opens)
and
circuit (3) is shut off.
tion.
(3)
relay +
As a result, after a time (the time depends on the am-
+ (2) and (3).

(2)
When this happens, circuit

through
circuit.
Battery
(+) -+ battery
air intake heater + ground connection,
the engine is preheated.
contacts are closed.
(1)
Battery
Bimetal timer terminal
nal 3
1 + glow switch termi-
+ glow switch terminal
signal terminal
2 + heater relay
+ heater relay coil + ground connec-
of electric
stops.
electric
relay.
current
in circuit
(3) closes the heater
As a result, electric current flows in the follow-
ing circuit.
current
to the heater relay coil
Even after the preheating stops, electric cur-
rent continues
tion.
The
The flow
stops, so the heater relay is opened and preheating
of the
heated.
straight
to flow
bimetal
Therefore
until
between
timer,
the
terminals
so the bimetal
bimetal
the starting switch
does not
is turned
become
OFF,
after the engine is started, there is no preheating.
81-10
and
is kept
wA500-1
so
COMBINATION
.. .
SWITCH
677
423F188
Outline
-
The FORWARD-REVERSE
the speed control
lever has three contacts;
lever switch has four contacts.
switch alone has no detent

mechanism
mechanism.
is in the combination
The detent
switch itself.
switch is held at two places by pins.
The
In addiiton,
switch is secured to the base by three screws.

When the lever is moved to the desired position, the
switch,
which
is connected
by a shaft,
moves and
Each
electric current flows in only that circuit to move the
each
machine.
Function
\
1
FORWARD-REVERSE
Speed control lever switch
Selecting machine speed range
Speed control lever stopper
Prevents speed control lever from going into 3rd or 4th speed
during operations
1 Direction indicator lamp
Selecting FORWARD,
lever switch
Self cancel
I
I
indicates direction
REVERSE
or NEUTRAL
when turning left or right
Returns direction indicator

after turning left or richt
lamp lever to neutral automatically
Lamp switch
Selects clearance lamps, headlamps, parking lamps
Dimmer switch
Selects travel beam, low beam
Emergency flasher switch
Makes left and right winkers flash at the same time
Emergency flasher pilot lamp
Lights up when emergency flasher lamp is ON.
WASOO-1
81-11
ELECTRICAL
TRANSMISSION
CONTROL
Transmission cut-off
sele
Combination switch
FORWARD-REVERSE
Floor wiring harness
lev
Speed control le
Circuit breaker
Transmission cut-off switch
Transmission wiring harness
IW
423F189
Function
Selection of FORWARD,
REVERSE
and NEUTRAL
/ Selection of travel speed range
Transmission cut-off function
FORWARD-REVERSE
lever
Speed control lever

Transmission returned to neutral when left brake pedal is
operated.
c
Transmission cut-off selection function
Selects if transmission cut-off function is used or not used.

With this function, the left brake pedal can be used to get even
better performance than conventional loaders in digging operations or ease of steering when loading on to trailers.
Neutralizer
To prevent the operator from driving off when the parking brake
is still applied and causing seizure of the parking brake, the transmission is returned to neutral when the parking brake is applied.
Neutral safety function
function
The engine can only be started if the FORWARD-REVERSE

lever is in neutral. In any other position the engine will not
start. This prevents the machine from starting suddenly.
(For details, see STARTING
Warning function
CIRCUIT)
When the machine is driven in reverse, a back-up lamp lights up

and a back-up horn sounds to warn people standing near the
machine.
81-12
WASOO-1
TRANSMISSION
-
CUT-OFF
SWITCH
When the left pedal is operated,
the switch detects
the air pressure in a brake circuit.

power
supply
of the solenoid
FORWARD-REVERSE
It shuts off the
valve circuit
for the
clutch, and returns the trans-
mission to neutral.
From rear air tank
Two-way check valve

Stop-lamp switch
From rear brake tank
Two-way check valve
To rear brake
Transmission
From front brake tank

-
To front brake
From front air tank
Diaphragm
\
To transmission
power supply
0
00
To transmission
directional circuit
IDFF
Restored
Low voltage -
Actuated
High voltage
421F123
WA500- 1
81-13
TRANSMISSION
CUT-OFF
SELECTOR
SWITCH
Outline
*
Operation
The transmission cut-off

waterproof
toggle switch.
the transmission
side
of
selector switch is a L-circuit
the
cut-off
It is installed in series with

switch at the power supply
transmission
When
the
turned
to OFF
transmission
selector
switch
is
(switch points in contact),
cut-off
(+)24V
is
applied through this switch to the circuit of the sole-
FORWARD-REVERSE
noid valve for the directional
circuit.
pedal then
clutch.
operates as a normal
The left brake
brake in the same
way as the right brake pedal.

.
When the transmission cut-off switch is turned to ON

(switch points not in contact),
if the left brake pedal
is depressed, it will act as a normal brake, and at the

same time the transmission will be placed in neutral.
r----I
--__-
~.v-
Neutralizer relay
(battery power source)
Transmission
cut-off selector
switch (manual)
Transmission
cut-off selector
switch (manual)
~,----t
-.-
i:
2-i
4 k&
Neutralizer relay
(battery power source)
;wy;gission
_-.
cut-off
(actuated by air pressure)
TrlY;;nission cut-off
(actuated by air,pressure)
If
To Buck-up
lamp relay
Machine monitor
system neutral
terminal
To Buck-up
lamp relay
Machine monitor
system neutral
terminal
421 F124
81-14
WASOO-1
NEUTRALIZER
*
RELAY
When the parking
brake
is being used, no electric
current flows to the relay coil.

connected to output terminal
The input terminal
is
6.
WARD-REVERSE
circuit
of the transmission which
is connected to output terminal
5.
When the park-
ing brake is being used, the transmission
For this reason, no electric current flows to the FOR
Parking brake
switch (manual)
neutral.
is kept
in
Machine will not start.
Parking brake Parking brake

relay
safety relay
Neutralizer relay.
OFF
Battery relay
Battery
Startingswitch
~_
-.__
_-
switch (manual)
ion cut-off switch
Starting motor
(terminal E)
Machine monitor system

natural terminal
Back-up lamp
power source
Back-up lamp
relay
421 F125
WA500- 1
81-15
ELECTRICAL
PARKING
_-
BRAKE CONTROL
Outline
- When electric current flows to the parking brake valve

(solenoid
tank)
valve), air pressure from the air tank
(wet
is applied to the spring cylinder and the parking
brake is released.
When the electric current
is stopped, the air pressure
from the air tank is cut off.

the spring cylinder
The air pressure inside
passes through the parking brake
valve and is released.
The parking brake is then actu-
ated by the force of the spring.
425F510
1. Neutralizer
relay
2.
Parking brake valve
3.
Parking brake switch
4.
Parking safetv relay
5.
Parking brake relay
6.
Air tank (wet)
7.
Emergency brake switch
8.
Spring cvlinder
WA500- 1
Function
Actuation
2
and release of parking brake
Automatic
Parking brake switch used.

Parking brake is automatically
applied when engine is stopped
(starting switch is turned to OFF).
This prevents the machine
parking brake
from running away when the operator

3
leaves his seat.
The parking brake is automatically applied when it is impossible

to maintain braking power because of a drop in the air pressure
inside the tank caused by damage to the air circuit. In this way,
Emergency brake
the parking brake acts as an emergency brake.

4
After the automatic parking brake is actuated, it is dangerous if

the parking brake can be released simply by turning the starting
Parking brake safety
switch to ON.
Therefore, after the starting switch has been turned ON, the parking brake switch must be operated to release the brake.
This
ensures safety.
If the machine is driven with the parking brake still applied, the
parking brake will seize up.
Therefore, the caution lamp lights up and the caution buzzer
sounds to warn the operator of this mistake in operation. At the
same time, when the parking brake is applied, the transmission is
moved to neutral, so it is impossible for the machine to move.
However, when the parking brake is used as an emergency brake,
if the transmission is returned to neutral, the braking distance will
Neutralizer
increase and the machine may stop in a dangerous place (for

example, on a railroad crossing).
For this reason, the circuit is
designed so that the transmission is not returned to neutral when
the emergency brake is applied.

Large size multi-pin connector
? pole blue) with lock
Connection table
1
ON (actuated)
3
YSY
Water proof O-ring
for panel face
2
View Z
423F195
WA500-
81-17
PARKING
BRAKE
VALVE
Valve actuation table
chamber
Exhaust
port No.1
Port No.3
423F196
PARKING
BRAKE RELAY
PARKING SAFETY RELAY
NEUTRALIZER
RELAY
Relayconnectionchart
Relay actuation table
Terminal No.1
Terminal No.5
Terminal No.2
ierminal
Black/
No.6
423F197
EMERGENCY
BRAKE
SWITCH
Diaphragm
Contact
~
423F198
*2*
WA500- 1
._
1. STARTING
SWITCH OFF
* When the starting switch is turned OFF, the battery
relay is opened, so no electricity
the parking brake circuit.

starting
switch
flows to
For this reason, if the
is OFF, no electricity
flows to the
parking
brake
valve regardless of whether
parking
brake
switch is ON
(released).
tuated.
(actuated)
the
or OFF
As a result, the parking brake is ac-
(Automatic
parking brake)
Parking brake
switch (manual)
r$ing
--
OFF
Parking brake
safety relay
---
brake
___-
ON
Neutralizer
relay
Battery
---&-c__-+
Battery
relay
----
--__2+
Starting switch
24-l
To transmission
*.
.
spew cwcun
Emergency
cwitrh
brake
..,._.,
(with wet tank)
421F126
WA500- 1
81-19
2.
STARTiNG
2-1. When
SWITCH
parking
brake
ON
switch
is turned
ON
relay terminal
before
3 + parking safety relay termi-
starting switch is turned ON.
nal 5
+ parking safety
- Elecrric current flows as follows.
parking
safety
(1)
Battery
The
so the battery relay is
circuit
of the parking
CLOSED.
closed because of circuit
Electric current also flows as follows.
switch is turned OFF.
(2)
Battery
(+) + battery
switch terminal
In this condition,
relay -+ parking brake
parking
3 --f parking brake switch ter-
minal 2 + parking safety relay terminal

parking safety relay terminal
brake
until the starting
no electric current flows to the

valve, so the
Also, in this condition,
1 + ground con-
actuated
and circuit
following
circuit is formed.
Battery
parking safety
is closed.
I+) + battery
so no electric current
relay is
Therefore,
2 +
ground
safety relay remains

3
parking
brake
REVERSE
the
circuit
relay is open,
flows to the FORWARD-
of the transmission,
and the
transmission is kept in neutral.

relay + parking safety
Parking brake
relay
Parking brake
switch (manual)
---1
Parking brake
safety relay
---1
Neutralizer relay
----
Battery relay
----
Battery
----
Alternator
terminal R
To transmission
clrcun
is
the circuit between termi-
nal 3 and 5 of the neutralizer
When this happens, the
actuated.
2 +
nection.
(3)
relay terminal
terminal
connection.
(+) + starting switch + battery relay
coil + ground connection,
relay
Emergency brake
switch
(with wet tank)
421F127
WA500- 1
-.
2-2. Parking brake switch turned
OFF
(released) before
actuated.
the
starting switch is turned ON.

Electric current flows as follows.
automatic
(I)
starting
Battery
(+) + starting switch + battery relay
coil -* ground connection,
so the battery relay is
OFF
in this case, the parking brake switch is
(released), so the parking safety relay is not
Parking brake
switch (manual)
brake valve.
parking
switch
is turned
no electric
FORWARD-REVERSE
Therefore,
flows to
after
the
brake is actuated, even if the
brake is not automatically

In addition,
CLOSED.
However,
For this reason, no electricity
parking
to
ON,
the
parking
released.
current
circuit
flows
to
the
of the transmis-
sion, so the machine does not move.
Parking brake
relay
Parking brake
safety relay
Neutralizer
relay
Starting switch
To transmission
FORWARD-REVERSE
circuit
To transmission
speed circuit
;c
U
Emergency brake
switch
(with wet tank)
421F128
WA500- 1
81-21
2-3. Parking brake OFF
(released), after starting switch
is turned ON.
*
ing circuit if formed.
If the parking
leased), circuits
brake switch
is turned
OFF
1 and 2 of the parking
switch are connected.
(re-
brake
When this happens, elec-
tric current flows as follows.

(1)
Battery
(+) + battery
Emergency
brake
switch
parking
brake
relay coil + ground connection.

(3)
Neutralizer
(4)
Battery
relay terminal
relay + parking brake
3 + parking brake relay terminal
parking
relay are
circuit is formed.
(5)
(+I
Battery
relay terminal
battery
relay -+ neutralizer
3 + neutralizer
relay terminal
When
WARD
the transmission
or REVERSE,
switch
5+
circuit.
is put to
FOR-
the machine will move.
actuated, and the circuit between terminals 3 and
Parking brake
switch (manual)
a-
Parking brake
relay
Parking brake
safety relay
Neutralizer relay
----
Battery relay
Starting switch
To transmission
speed circuit
Emergency brake
switch
(with wet tank)
421 F129
81-22
brake is released, and at the same
the following
transmission FORWARD-REVERSE
relay coil -+ ground connection.
The parking brake relay and neutralizer
(+) + battery
+ parking brake valve + ground connection.

The
relay + parking safety
relay + parking brake switch -+ (2) and (3).

(2)
5 of each relay is closed. As a result, the follow-
WA!NO-1
24.
Parking brake switch ON (operated)
* After operating with the parking brake switch at

OFF
(released),
if the
turned to ON (operated),
No electric
current
At
the same time,
the neutralizer
restored,
so the circuit
the circuit becomes as
and 5
is OPEN.
brake switch
between
flows to the parking
brake
circuit
mission, so the transmission
valve, so the air pressure from the air tank acting
In this way, when the parking
the neutralizer
time,
At the same
the air pressure inside the spring cylinder
of the trans-
is placed in neutral.
on the spring cylinder
is shut off.
relay is also
terminals
No electric current flows to
the FORWARD-REVERSE
shown below.
*
is
parking
brake is operated,
relay shuts off the electric current
to the transmission
solenoid valve and puts the
passes through the parking brake valve and is re-
transmission
leased, so the parking
no seizing of the parking brake caused by the ma-
brake is actuated
by the
force of the spring.
chine
in neutral.
being driven
As a result, there will be
with the parking
brake still
applied.
Parking brake
switch (manual)
--
Parking brake
relay
---
Parking brake
safety relay
Neutralizer
relay
-__
-
Starting switch
To transmission
circuit
Speed
Emergency brake
switch
(with wet tank)
421 F130
WAXKb 1
81-23
2-5. When air pressure drops (emergency brake actuated)

Operation
* If the air pressure drops, the emergency brake
For this
reason,
electric
FORWARD-REVERSE
switch installed to the wet tank is opened.
current
circuit
flows to the
of the transmis-
For this reason, no electric current flows to the
sion, and it is possible to connect the transmis-
coil
sion clutch.
of the
parking
brake
brake relay is restored,

terminals
3 and 5
tric current
relay.
The
parking
becomes OPEN.
is re-
leased and the parking brake is actuated.
How-
ever, this case is different

brake
switch
is turned
the same time,

ated,
the emergency
if the emergency
brake is actu-
and it is necessary to move the machine
(for example,
if the emergency
brake was actu-
ated on a railroad crossing), the machine can be
from when the parking

ON (operated).
when
the engine also acts as a brake.
This makes the braking distance shorter, and at
No elec-
flows to the parking brake valve, so
the air pressure inside the spring cylinder
Therefore,
brake is actuated,
and the circuit between
driven by operating the transmission lever.
In this
case, there is electric current flowing to the coil

of the neutralizer
relay.
Parking brake
switch (manual)
r__pi
To transmission
speed circuit
Parking brake
relay
Parking brake
safety relay
----
Neutralizer relay
---
To transmission
FORWARD-REVERSE
circuit
Emergency brake
switch
(with wet tank)
421 F131
81-24
WAMO- 1
ELECTRONIC
VEHICLE
MONITORING
SYSTEM
(EVMS)
1
Serial No. 10001
- 10662
MONITOR
Outline
PANEL
. The electronic vehicle monitoring system is a system

to inform
chine.
the operator
of the condition
The
of the ma-
of the machine,
machine
which observe the condition
and process the information
display the situation on the monitor
TION
of the
speedily,
module
and
panel, sensors, controller,
items (1) and CAUTION

play warnings
chine;
(including
Each module
into
module
gauge module
(5),
service meter),
(21, CAU-
speedometer
the case, and vari-
(excluding
the service meter)
has its
which processes the signals from
The panel uses a liquid crystal display.
CHECK
CHECK
items (2) and (3), which dis-
and gauges (5). speedometer
(3).
components.
CAUTION
the sensor and gives a display.
divided
if any abnormality
module
(l),
own microcomputer
warning buzz-
er, warning lamp and power source.
. The displays can be broadly
consists of the following
module
ous other components.
panel.
. The electronic vehicle monitoring system consists of

the monitor
monitor
CHECK
It consists of sensors installed in various parts
and CAUTION
The microcomputer
(7). and service
meter (9), which always display the condition
(I),
(2) and (3) modules all
use common parts.
arises in the ma-
judges which module
it is from
the wiring harness to which it is connected.
of the
machine.
Warning lamp
Warning buzzer
Do0
a:
c
,.:::.
::.:
::.
.A..
...I
:..::
Battery
-
24V
Buzzer signal
421F116A
WA500- 1
8(i25
SB
1A
5A
2A
28
1B
30
3E
48
View 2
423F170-1 K
1.
Check
38.
Engine oil pressure
1 A.
Brake oil level
3c.
Coolant level
5A.
Air pressure
1 B.
Engine oil level
3D.
Air pressure
58.
Coolant temperature
Coolant level
3E.
Coolant temperature
5C.
Torque converteroil
Caution (Warning)
3F.
Torque converter oil

temperature
5D.
Fuel level
1 C.
2.
2A.
Battery charge
28.
Fuel level
4.
3.
2C.
Transmission oil filter
2D.
Emergency steering
Pilot indicator
4A.
48.
Parking brake
4C.
Work lamp
4C.
Preheat monitor
Caution (Emergency warning)

3A.
Brake line failure
8626
5.
Gauge
6.
Turn signal pilot lamps
7.
Speedometer
8.
Head lamp (High beam)
temperature
9
_. Service meter
10.
Service meter indicator
11.
Night lighting lamp
WASOO-1

Outline
. The electronic vehicle monitoring system is a system

to
inform
machine.
the
operator
of
the
condition
It consists of sensors installed
of the
in various
parts of the machine, which observe the condition

the machine
and process the
and
the
display
The electronic
the monitor
situation
information
on the
vehicle monitoring
of
speedily,
monitor
panel.
system consists of
panel, sensors, warning buzzer, warning
lamp and power source.

The
displays
items
(1)
display
machine,
can be broadly
and CAUTION
warnings
if
any
divided
items
into
CHECK
(2) and (3), which
abnormality
arises in the
and gauges (51, speedometer
(7). and service
meter (91, which always display the condition
of the
machine.
Warning lamp
Warning buzzer
Battery
Sensor
425FO1198
WA!NO- 1
*-2-l
1A
18
5i
io
210
ic
425FOll99
View Z
4.
1. Check
1A.
Brake oil level
4A.
1 B.
Engine oil level
48.
Parking brake
IC.
Coolant level
4C.
Work lamp
40.
Preheat monitor
2. Caution (Warning)
3.
Pilot indicator
5.
Gauge
2A.
Battery charge
2B.
Fuel level
5A.
Air pressure
2C.
Transmission oil filter
5B.
Coolant temperature
2D.
Emergency steering
5C.
Caution (Emergency warning)
5D.
Fuel level
3A.
Brake line failure
6.
Turn signal pilot lamps
38.
Engine oil pressure
7.
Speedometer
3c.
Coolant level
6.
Head lamp (High beam)
3D.
Air pressure
Service meter
3E.
Coolant temperature
3F.
*-e2
IO. Service meter indicator
WA500-
_,
ON MONITOR
INDICATION
Catf
!JOP
Symbol
PANEL
Indication
item
I Indication range
Brake oil level
Description
Below low mark

Displayed when starting switch is turned
Engine oil level
Below low mark

I
IIaJ
Display goes out when normal.

Display flashes when abnormal.
Coolant level
Below low mark
Battery charge
When charging is
defective.
Fuel level
to ON with engine stopped.
Below low mark
Displays when engine is running.

Display goes out when normal.
Display flashes when abnormal and lamps
flash at same time.
.
(0?
Brake line failure
When stroke is
over.
Engine oil pressure
Below specified
pressure
Displays when engine is running.
Coolant level
Below low mark

I
I=
Dispaly goes out when normal.

Display flashes when abnormal;
buzzer
and lamp actuated.

Below specified
pressure
4ir pressure
-I
Zoolant temperature
Above lb2C
I
:emperature
Above 102C
arking brake
When operated
work lamp
When operated
Displays when starting switch is turned ON.

Lights up when operated
rransmission cut-off
When operated
REHEAT
When preheating
WA500-
Displays when starting switch is turned ON;

lights up during preheating.
81-27
Category
Indication
Symbol
---
item
Indication
Description
range
l-ravel speed
I-
iigh beam
Nhen operated
Digital display
100 km/h
Displays when starting switch is turned ON;

lights up when operated.
QD
Winkers (right, left)
Nhen operated
aD
iazard
Nhen operated
0
0
jervice meter
I-
Lights up when operated.
Actuated
99999/h
when engine oil pressure is normal.
Advances 1 for every hour of operation.
Iisplayed
jervice meter indicator
Flashes when service meter is operating.
Air pressure
One lamp lights up to indicate level.
Coolant temperature
One lamp lights up to indicate level.
H
Red
13oT
El
12OC
110-C

temperature
GWIJ
WC
One lamp lights up to indicate level
70L
5oC
FULL
I&
*if*
Fuel level
All lamps light up below indicated level.
WA500- 1
CONTROLLER
Serial No.10081
-10662
Function
* The auxiliary controller acts as the power source box

and provides electric power to the panel.
The
power
source (battery,
chine has a large difference

controller
alternator)
for the ma-
in voltage, so the auxiliary
converts this to a stable voltage and sup-
plies it to the panel.

Even if excessive voltage is generated by failure in the
alternator
or regulator,
it is cut by the auxiliary
con-
troller.
Controller
Lamp
Buzzer
Battery
_-_--_
Battery relay
terminal E
WA500- 1
423F172A
WIRING
HARNESS
Serial No. 10001 - 10662
W-P8
(16P)
CWPB
(16P)
CN-PO
(SP)
CN.PZ
(1E.P)
CN.P4
(16P)
423F182A
Operation
of monitor panel
If the monitor
the monitor
panel is working
normally,
the lamps on
panel will work as follows.
1) When the starting switch is turned to ON.

a) All monitor lamps will light up for 3 seconds.
b) The warning buzzer will sound for 1 seconds.
2) CHECK
MONITOR
a) All monitor
if there is any abnormality

(About
in any check item, that
0.8 seconds ON, then 0.8
seconds OFF repeated.)

b) If the outside air temperature
-lOC),
CHECK
engine
running
the flashing interval will change slightly,
lamps will
go out
(Judge whether
when the
the engine is
by the rise in the engine oil pressure, or

is a voltage of over
1OV from
MONITOR
a) All monitors
GROUPS
are working from the time the engine
starts to the time the engine stops and the starting

switch is turned to OFF.
is any abnormality
in the machine,
the
lamp for that item will start to flash (0.8 seconds

ON, 0.8 seconds OFF).
but this is not an abnormality.
81630
the
alternator.)
If there
is low (below about
item
is started.
see if there
3) CAUTION
GROUP
lamps will light up for 3 seconds, then
item will flash.
c) The
WASOO- 1
Serial No. 10663
and up
CNPl
(16P)
CNP4
(12P)
CNP3
(16P)
To sensor
U41901066
Operation
of monitor
If the monitor
the monitor
panel
panel is working
normally,
the lamps on
panel will work as follows.
1) When the starting switch is turned to ON.

a) All monitor
lamps will light up for 3 seconds.
b) The warning buzzer will sound for 1 seconds.

2) CHECK
MONITOR
a) All monitor
GROUP
if there is any abnormality
in any check item, that
0.8 seconds ON, then 0.8
seconds OFF repeated.)

b) If the outside air temperature
-
IOC),
engine
running
the flashing interval will change slightly,
lamps will
go out when
(Judge whether
the engine
the
is
by the rise in the engine oil pressure, or

is a voltage of over 10 V from
the
alternator.)
MONITOR
a) All monitors
GROUPS
are working from the time the engine
starts to the time the engine stops and the starting

switch is turned to OFF.
If there
is low (below about
item
is started.
see if there
3) CAUTION
lamps will light up for 3 seconds, then
item will flash. (About
cl The CHECK
is any abnormality
in the machine,
the
lamp for that item will start to flash (0.8 seconds

ON, 0.8 seconds OFF).
but this is not an abnormality.
WASOO- 1
*(i3
SENSORS
FUNCTION
*
There are three types of sensor: contact type, resistor
If the contact
type, and solenoid type.
rectly
* With contact type sensors, one end of the wiring is
is closed, the monitor
If the contact
the signal from the sensor directly
the monitor
or
sends it through a relay.
of the sensor that sends the signal to
through
a relay is opened, the monitor
judges the signal tob normal.
(The signal is reversed
by the relay.)
Sensor actuation table
1 Sensor type
1 When normal
Enaine oil level
Contact
ON
Brake oil level (Serial No. 10001-10565)
Contact
ON
Check item
1 When abnormal
I
I
OFF
OFF
Brake oil level (Serial No. 10566 and up)
Contact
OFF
ON
Coolant level
Contact
ON
OFF
Fuel level
Resistor
Engine oil pressure (Serial No. 10001-10243)
Contact
ON
OFF
Engine oil pressure (Serial No. 10244 and up)
Coolant temoerature
Toroue converter oil temperature
Contact
Resistor
Resistor
I
I
OFF
I
I
ON
Travel speed
Solenoid
Brake line failure
Contact
ON
OFF
Transmission oil filter cloaaina
judges
the signal to be normal.
grounded at the chassis end, and the other end sends

to the monitor
of the sensor that sends the signal di-
to the monitor
Contact
ON
OFF
WA500-1
.._
COOLANT
TEMPERATURE,
TORQUE
CONVERTER
OIL
TEMPERATURE
SENSOR
1.
Connector
2.
Wire
3.
Tube
4.
Plug
5.
Thermistor
0P
(beat type)
---tY
Circuit structure
423FlJ6
Function
These
sensors are installed
block and transmission
case.
on the engine cylinder

They use a thermistor
to detect the temperature,
and when the temperature
goes above the specified
temperature,
monitor
ENGINE
the machine
lamp lights up to indicate the abnormality.
OIL
PRESSURE,
PARKING
BRAKE
SENSOR
:
0@
1.
Connector
2.
Wire
3.
Switch
4.
Diaphragm
5.
Plug
Oil
Circuit StruCtWe
423F177
Function
-
These are installed on the engine block and parking

brake solenoid
valve.
The diaphragm detects the oil
and air pressure, and when the pressure goes over the
specified
pressure, the machine
monitor
lamp lights
up to indicate the abnormality.
WA500- 1
81-33
ROTATIONAL
SPEED
SENSOR
Function
The
rotational
mission
the
output
rotation
the
speed
sensor
gear.
A pulse
of the
machine
is installed
voltage
gear teeth,
monitor,
and
is generated
a signal is then
this
Section A-A
on the trans-
displays
by
sent to
the
travel
speed.
1. Connector
2.
Magnet
3.
Case
t
Circuit structure
423F178
FUEL
GAUGE
SENSOR
Function
The
fuel
The
float
level.
gauge
The
is installed
moves
movement
of the
gear to actuate
a variable
to the machine
monitor
When
the display
certain
ules
level,
inside
on top
up and down
the
float
resistor.
the
is sent through
the fuel
monitor
machine
monitor,
tank.
This sends a signal
machine
is generated
fuel
to the fuel
to display
on the
a signal
of
according
level.
drops to a
between
and
the
the
mod-
warning
lamp lights up.
1.
Connector
2.
Variable resistor
3.
Float
4.
Gear
5.
Contact
.!Y
Emtw
Circuit structure
423F179
81-34
WA500- 1
4) FUEL GAUGE SENSOR

FUNCTION
* The fuel gauge is installed on top of the fuel tank.

The float
moves up and down according to the fuel
level. The movement
of the float
is sent through
arm to actuate a variable resistor. This sends a signal

to the machine monitor to display the fuel level.
When the display on the machine monitor drops to a
certain level, a signal is generated between the
modules inside the machine monitor,
and the warning
lamp lights up.
1. Connector
2.
Variable resistor
3.
Arm
4.
Float
Emptv
423F179C
5) ENGINE
01 L PRESSURE SENSOR
Serial No. 10001-10243
:
@
0
1.
Connector
2.
Wire
3.
Switch
4.
Diaphragm
5.
Plug
Oil
Circuit structure
423F177A
1. Contact ring
2.
Contact
3.
Diaphragm
4.
Spring
Circuit structure
427FO1023
FUNCTION
- The engine oil pressure sensor is installed on the

engine block.
The diaphragm
detects the oil and air
pressure, and when the pressure goes below the specified
pressure, the machine
monitor
lamp lights up
to indicate the abnormality.
WA500- 1
81-35
0
6) PARKING
BRAKE SENSOR
Air
1.
Connector
2.
Wire
3.
Switch
4.
Diaphragm
5.
Plug
((E+=@
Circuit structure
423F177A
FUNCTION
- The parking
brake sensor is parking
valve. The diaphragm
brake solenoid
detects the oil and air pressure,
and when the pressure goes below the specified pressure, the machine monitor
lamp lights up to indicate
the abnormality.
7) AIR PRESSURE SENSOR

FUNCTION
- The air pressure sensor is installed to the wet air tank.
It acts through
a diaphragm
sistor according
to changes in the air pressure. This
to actuate
sends signals to the machine monitor
a sliding re-
to indicate the
air pressure. If the air pressure drops below the specified level, it generates a signal to the module inside
the machine
monitor,
and the warning lamp flashes.
1. Connector
2.
Ventilation
tube
3.
Wire
4.
Resistor
5.
Resistor selector contact
Circllit structure
423F181
8&36
WA500-1
_CONTACT
SWITCH
To battery relay
Contact switch
for bucket positioner
10A
lot----
2
3
2o.p
30.7
Positioner relay
AI
Contact switch
for boom kickaut
II
Kick-out relay
Solenoid for kick-out
421F117
Function
l
Contact switches are installed by a support to the lift

and dump
and
the
match
tions
cylinders.
TILT
BACK position
the operating
are
reached,
WA500- 1
The lift arm RAISE position

conditions.
can be selected to
When these posi-
a pulse is generated
from
the
switch, the electric current flows to a magnet and the

lift or dump lever is returned to the neutral position.
When this happens,
the main control
returned
and the
to
neutral
movement
valve is also
of the
lift
arm or bucket stops.
81-37
OPERATION
LIFT
ARM
OF CONTACT
SWITCH
RAISE
Contact switch for
boom kick out
* When the lift arm is lower than the set position for
the boom kick-out,
the detection
unit (steel plate) is
not on the sensing surface of the contact switch.

relay switch is at OFF
The
and the electric current of the
solenoid is shut off.

Kick-out relay
Solenoid for kickout
Lift lever
Contact switch
Lift arm
Cjetection unit
425F122
When the lift control
lever is moved to the
position, the lever cam and the cam follower

lift spool in the RAISE
position,
RAISE
Contact switch for
boom kick-out
keep the
so the lift arm goes

_~--~a-
UP.
Battery relay
/ !
Kick-out relay
Solenoid for kick-out
,Lift
lever
Lift arm
Contact switch
Cjetection unit
425F123
81-38
WASOO-1
.. When the lift arm goes up and reaches the set position
for
the
plate)
kick-out
(that
is in contact
is, the
detection
unit
(steel
to the sensing surface of the con-
tact switch), the contact switch and relay circuit act

to send electric current to the solenoid.
This actuates
the magnet, the cam is pulled out of the cam detent,

and the lift spool is returned to the neutral position
by the return spring.
Contact switch for

boom kick-out
Kick-out relav
Solenoid for kickaut

V
Lift lever
Cam
Detection unit
Contact switc
\
LIPOC
Solenoid
valve
425F124
Movement
of contact switch
Position
Contact switch display
Contact switch load circuit

(relay switch circuit)
Relay switch load circuit
(solenoid circuit)
WA500- 1
Sensing surface of contact switch

is in contact with detection
ON
unit.

separated from detection unit.
OFF
Current flows
Current shut off
Current flows
Current shut off
81-39
BUCKET
TILT
When the bucket is lower than the set position for the
bucket
leveler, the detection
unit (steel plate) is on
the sensing surface of the contact switch.

flows through the contact switch.
at OFF
and the electric
Contact switch for

bucket positioner
current
Electricity
The relay switch is

from the battery
is
shut off.
Positioner relay
Bucket lever
n
Cam
/
Detection unit
When the bucket control
Contact switch
lever is moved to the TILT
position, the lever cam and the cam follower

dump spool in the TILT
keep the
Contact switch for

bucket positioner
position, so the bucket tilts.
_a;--j :
Battery relay
i I
Solenoid for positioner
Bucket lever
/I
Detection unit
Contact switch
hi--
81-40
POC valve
425F126
WA500- 1
. When the bucket tilts and reaches the set position for
the bucket
plate)
contact
leveler (that
is separated
switch),
is, the detection
from
unit (steel
the sensing surface of the
the contact switch and relay circuit
act to send electric
current
to the solenoid.
This
actuates the magnet, the cam is pulled out of the cam

detent,
and the dump spool is returned to the neutral
position by the return spring.

Contact switch for
bucket positioner
---
Battery relay
1
j
,
Positioner relay
Bucket lever
Detection unit
id
Contact switch
4-d\
Movement
POC valve
425F127
of contact switch
Position
Contact switch display
Contact switch load circuit

(relay switch circuit)
Relay switch load circuit
(solenoid circuit)
WA500- 1

is in contact with detection unit.
ON

separated from detection unit.
OFF
Current flows
Current shut off
Current shut off
Current flows
81-41
ELECTRIC AND ELECTRONIC

SYSTEM
82 TESTING
AND
ADJUSTING
Standard value table for electrical system

Adjusting speedometer
machine monitor
..
. . 82-2
module of
. . . . . . . . . . . . . . . . . . . 82-2-3
in fuel level sensor . . 82-2-5
. . . . . . . . . . . . . . 82-3
Checking for abnormality

Troubleshooting
The following
..

1.
2.
are estimated
values based on the
3.
In addition,
do not use
WA500- 1
82-l
0
STANDARD
Serial No. 10663
Systen
VALUE TABLE FOR ELECTRICAL

and
SYSTEM
up
Name of component
:onnectol
Measurement
conditions
Judgement table
No.
If the condition is as shown in the table below,

the sensor is defective
Radiatorwater
sensor
level
Starting
switch ON
Short connector connected
Monitor OFF
CN278 disconnected
Monitor ON
CN278
the sensor is normal
Starting
switch OFF
il
Oil level, water level abnormal

CN299
(female) grounded
Monitor OFF
Monitor ON
CN299 disconnected
Engine oil level sensor
Air pressure sensor

temperature sensor,
engine water temperature
sensor
Starting
switch ON
CN299
Starting
switch OFF

Starting
switch OFF
CN92
Air pressure 1 kg/ems
Approx.
1 kn
Air pressure 5 kg/cm
Approx. 600 51

Starting
switch OFF
If thecondition is as shown in the table below,

Starting
switch OFF
When engine is running (l/2

27.5 - 29.5%
Start engine
CN84
CNlO 1
Fuel level sensor
Alternator
throttle or above):
If the battery is old, or after starting

in cold areas, the voltage may rise
for some time.
WA500-1
Name of component
Zonnector
No.
nspection
nethoc
Measurement
conditions
Judgement table

Starting
switch ON
$1
Transmission filter
sensor
CN153
Starting
switch OFF
ni

Brake stroke limit

switch
Monitor OFF
CN87.88
Monitor ON
disconnected
Starting
switch ON
CN87
CN88
Starting
switch OFF
ni

Engine oil pressure

sensor
WA500- 1
Terminal wiring harness disconnected
Monitor OFF
Terminal wiring harness grounded
Monitor ON
Starting
switch ON

Engine
started

Starting
iwitch ON
f the condition is as shown in the table below,

:he sensor is normal
Starting
witch OFF
:N36
822-1
InsrJecti&
method
b
5
E
E
z
,o
v)
Brake oil level sensor
Measurement
conditions
Judgement table

MonitorOFF
CN86 disconnected
Monitor ON
Starting
switch ON
CN86
822-2

Starting
switch OFF
WA500-1
ADJUSTING
MONITOR
The speedometer
SPEEDOMETER
on the machine
monitor
MODULE
OF MACHINE
is common
for all models, but the input signals for the travel speed
differ
according
to
the
model,
so it is necessary to
adjust to make the speedometer applicable to the model

on which it is being used.
the diameter
of the tires differs according
to the type of tires fitted,
In addition,
so it is necessary to adjust the
travel speed to match this.

Turn
starting
(Serial No. 10001-10662)
switch OFF.
Remove the machine moni-
tor, and adjust at the adjustment
portion at the rear of
the speedometer.
1) Remove
rubber
caps II
and III
at the
rear of the
speedometer.
2) Inside
the
rubber
caps there
Using a flat-headed
are rotary
screwdriver,
switches.
turn the switch to
adjust as shown in the diagram on the right.

*
Switch
1 has no connection
speedometer,
with
adjustment
of the
Driver (-)
423F336
so do not touch it.
I
Switch I
Tire size
Switch II
I (reference) I
Rotary
Switch
Switch III
P
423F337
3) After
completing
adjustment,
fit
the
rubber
caps
securely, and install the machine monitor.

Suitable setting for switch III
Reference
Switch
position
Suitable
setting
-14
-12
-10
-8
-6
-4
-2
Switch
position
1 +2
1 +4
1 +6
$?;e
WA500- 1
+8
/ +lO
1 t12
1 +14
82z-3
Turn
starting
monitor,
switch
Remove
OFF.
and adjust at the adjustment
the
machine
portion
CNpl
at the
CIjP4
CFP5
rear of the speedometer.

1) Remove
rubber
caps 1 and 2 at the rear of the
speedometer.
2) Inside the rubber
caps there are rotary
Using a flat-headed
screwdriver,
switches.
P3
turn the switch
to adjust as shown in the table.

*
Switch
3 has no connection
the speedometer,
with
adjustment
of
Rotary switch
Switch 1
Tire size
Km/h
MPH
Switch 2
26.5-25-20PR
7 (or 8)
29.5-25-22PA
3) After
428FO1416
so do not touch it.
completing
adjustment,
fit the rubber caps
securely, and install the machine monitor.
Reference
Suitable setting for switch 2

F41E01113
Switch
position
Suitable
setting
+14
+12
+I0
+8
+6
+4
+2
Switch
position
Suitable
setting
-2
-4
-10
-12
-14
82:-4
-6
-8
WA500-1
CHECKING
FOR ABNORMALITY
If there
is any
displayed
and the amount
marked
fuel tank (for example,

gauge does not indicate
difference
between
of fuel remaining
the
IN FUEL LEVEL SENSOR
level
inside the
the fuel tank is full but the fuel

FULL),
measure the resistance
at the five positions of the float shown in the diagram

on the right with the fuel level sensor as an individual
part.
Method of measuring
l
Connect
one
pole to terminal
other pole against terminal
(11, and touch
the
(2) to measure the resist-
ance.
Resistance value of fuel level sensor at each point

Unit:
.zqzqzF
2
View
425FO1009
The standard values are only a guide.
WA500-1
82-2-5
0
TROUBLESHOOTING

Method of using YES-NO
. . . _ . . . . . . . . . 82- 4
Troubleshooting
......... .........
numbers. . . . . . . .
Precaution when handling connector
..
Electrical wiring diagram . . . . . . . . . .
Electrical circuit system . . . . . . . . . . .
flow chart
Connector terminal
Troubleshooting
monitoring
Troubleshooting
(Electronic
Before carrying
page 22-12,
RENCE
out the troubleshooting
METHOD
OF TROUBLE
WA500-1
OF READING
page 22-16.
in this section,
TROUBLESHOOTING
.
.
.
.
.
.
.
.
.
.
.
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.
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.
.
82-
82- 7
82-11
82-13
82-14
. . . . . . . . . . . . . . . . . . . . . . 82-19
chart for electronic vehicle
system (M-l to M-l 1)
. . . . . . . . 82-42
table
vehicle monitoring
read PRECAUTIONS
TABLE
.
.
.
.
.
chart for electric system
(E-1 to E-15)
Troubleshooting
.
.
.
.
.
WHEN
system)
. . . . . 82-44
TROUBLESHOOTING
RECUR-
CHECK
BEFORE TROUBLESHOOTING
Item
Standard value
1. Check fuel level
Remedy
Add fuel
2.
Check for dirt or water in fuel
Clean, drain
3.
Check hydraulic oil level
Add oil
4.
Check hydraulic oil strainer
Clean, drain
5. Check brake oil level
Add oil
6.
Add oil
Check engine oil level (Level of oil in oil pan)
7. Check cooling water level
Add water
a.
Check condition of dust indicator
Clean or replace
9.
Check air pressure
Refer to troubleshooting
IO.
Check for loose or corroded battery terminals
Tighten or replace
Il.
Check for loose or corroded alternator terminals
Tighten or replace
12. Check for loose or corroded starting motor terminals
Tighten or replace
13. Check for abnormal noise or smell
Repair
14. Check for oil leakage
Repair
15. Bleed air from system
16. Check battery voltage (engine stopped)

17. Check level of battery electrolyte
23 - 26V
Replace
Add or replace
Repair
18. Check for discolored, burnt, or bare wiring

19. Check for missing wiring clamps, hanging wires
Bleed air
Replace
!O. Checks for water leaking onto wiring (check carefully water
leakage at connectors and terminals)
Disconnect connector
and dry connection
!l Check for broken or corroded breaker
Replace
!2. Check alternator voltage

(engine running at overhalf throttle)
!3. Noise when battery relay is operated
(switch starting switch from on to off)
27.5 - 29.5V
Replace
Replace
WA500- 1
\_
OF USING
METHOD
CHART
YES-NO
TROUBLESHOOTING
FLOW
The electric system can be broadly divided into the following two parts.
1.
2.
Starting system, transmission electrical control system, brake system.

ELECTRONIC
VEHICLE
MONITORING
SYSTEM.
The charts for these systems are marked as E-xx, and M-xx respectively.
TrogMe$h$gting
1.
Item
E-xx
Troubleshooting of starting system, transmissionelectrical control n/stem. brake system.
M-XX
Troubleshooting of electronic vehicle monitoring system.
Method for troubleshooting

.
Check or measure the items inside the rectangle
YES
[-H-I
NO
According
to the result, follow the YES arrow or the NO arrow and proceed to the next rectangle.
The number given at the top right of the rectangle is a reference number.
(Note:
It does not indicate the order for
troubleshooting.)
.
If the result of the check or measurement

action given in the REMEDY
leads directly
The value for the check and the measurement

the answer is yes, follow the YES arrow;
to the CAUSE
column,
note the cause and take the
column.
method
Below the rectangle, there is a list giving preparatory

values needed for checking and measuring.
ing or handling is used, or the judgement
always read the procedure carefully
is given inside the rectangle.
If the value is correct, or
if the value is not correct, or the answer is no, follow the NO arrow.
work, methods of operating and handling, and judgement
If the preparatory
work is ignored, or the wrong method of operat-
is wrong, this could result in damage to the equipment.
before starting the check or measurement,
Therefore,
and carry out the operations
in the order given.
2.
Precautions when carrying out troubleshooting

The precautions to be followed
tion of the failure.
3.
when carrying out troubleshooting
for each failure is marked *under
the descrip-
Always follow these precautions when making measurements.
Tools needed for troubleshooting

The tools needed for troubleshooting
Troubleshooting
tools
foreach
I
I
problem are listed as follows.
I
I
Prepare these tools before starting troubleshooting.
4.
Place to install connectors, connector pin numbers

When troubleshooting
some problems,
step during the troubleshooting

connector
the YES -
pin number)
measurements have to be made of continuity,
procedure.
The location
is shown in a photograph or diagram.
NO type troubleshooting
for measurement
voltage and resistance at each
at each step (location
of connector,
For this reason, use these photographs together with
flow charts to carry out troubleshooting
quickly and accurately.
WA500- 1
82-5
0
Example
*
When disconnecting
or connecting the T-adapter
(or socket adapter)
or short socket adapter, or when disconnect-
ing the connector for checking, turn the starting switch OFF to prevent accidents.
*
When connecting the T-adapter
When disconnecting
(ro socket adapter), connect to the connector specified.
(CNxx(
connectors or connecting T-adapters, return them to the orifiganl condition
))
immediately
after
checking, then go to the next check.

a)
($1
(BRAKE
OIL
LEVEL)
FLASHES.
Remedy
Defective
brake oil level
Replace
SeWOr
ES
w
1 I Connect short
socket adapter
to CN86
(female) (brake
oil level sensor)
7JTum starting
switch ON.
Defective CHECKES
STARTING module
BEFORE
I
1 )Connect short
socket adapter
1 )Connect
T-adapter (or
socket adapter)
to CN66
(female).
2)Turn starting
switch OFF.
socket adapter)
to CNP4 (female).
,
Troubleshooting
tools
POSITION
Short socket adapter
T-adapter
T-adapter or socket adapter

(for Econoseal)
(for DLI)
After inspection,
repair Mean) or
repalce
Disconnection in wiring
harness between CN86
(female) (2) - CN91 (5) chassis ground.
After inspection.
repair (clean) or
repalce
CONNECTOR
Procedure No. 1 and No. 2

CN86
OF
Tester
harness, or defective COntSCt
between CN86 (female) (1)
CN91 (6) - CN64 (11)
- CNP4 (female) 14)
(female)
Procedure No. 3
CN4 (female)
82-6
0
WA500- i
CONNECTOR
TERMINAL
NUMBERS
.-
Connector
ECONOSEAL
CONNECTOR
Female terminal (Socket)
Male terminal (Pin)
CN21, CN92
CN35, CN96
CN36, CNl 01
CN83, CN163
CN84, CN201
CN86, CN202
CN87, CN204
CN88, CN266
CN41
142F401
142F400A
CN42
Y
142F403A
CN43
KDI
2
142F402A
1
142F405A
142F404A
CN63
31
25
142F406A
142F407A
CN15
CN16
CN39
CN60
CN97
ii
142F409A
WA500-1
26
142F408A
*&
Connector
-r
DLI
CONNECTOR
(For monitor panel)
Male terminal (Pin)
CNPl
CNP3
CNPB
CNP7
a
0
142F418
CNPZ
12
'6
142F420
142F419
12
142F421
CNP4
CNP6
CNP8
CNPIO
142F422
82-8
0
142F423
WASOO- 1
Connector
N-SLC
CONNECTOR
Male terminal (Pin)
CN12
a!
CN17
CN26
CN76
1
423F349
CNll
CN13
-
CN48
423F351
423F352
423F353
423F354
423F355
423F356
CN18
CN40
II
423F357
WA500-1
423F358
*zT9
MIC
CONNECTOR
Male terminal (Pin)
Female terminal (Scoket)
CNP9
142F410
742F411
BENDIX
CONNECTOR
CN85
I
N
FM
423F347
423F346
RELAY
CONNECTOR
CN51
CN52
CN53
CN54
8220
WA500- 1
PRECAUTION WHEN HANDLING CONNECTOR

1.
If the connector
has a lock, always release the lock
before disconnecting the connector.
When connecting, align

this arrow and push in.
Be sure to fit rubber
cover tightly.
When removing, press

this part and pull
the connector out.
F142A092
2.
When removing, press in

on both sides and pull
the connector out.
F142A093
Never pull the cord to disconnect the connector.
F142AO94
3.
When connecting, align

the guide inside the
connector and push in.
If the connector
is difficult
to disconnect,
F142A095
do not
try to pull it out.

-
(If it is difficult
to reach by hand, remove the clamp
and move the wiring harness.)
This must be removed.
F142A096
WA500-1
82-l 1
0
4.
After
pulling out the connector,
cover with a vinyl
bag to protect the contacts from dirt or oil.
F142A097
5.
When
cleaning
the connector,
agents such as trichloroethane

If the connector
agent.
After
immediately.
never use cleaning

or trichloroethylene.
is very drity, use a neutral cleaning
cleaning wash well and dry completely

(Do not use any connector which has
deposits left on it after drying.)

Coat with contact restorer.
(When drying, be particularly
careful to dry the gaps
in the rubber.)
6.
When assembling the connector,
be sure to fit it
F142A098
correctly.
(For connectors with locks, it should be possible to
heat
the
locks click
as they
fit
completely
into
position.)
F142A099
F142AlOO
Correct any protrusion of the boots.
82-12
m
WANO- 1
ELECTRICAL
WIRING
DIAGRAM
1, Preheating
CN65
CN52
CN58
CN!
lamp switch
3. Parking
brake switch
4. Starting
W<
CN55\
switch
2. Working
switch
5. Transmission
6. Circuit
cut-off
breaker
7. Air conditioner
CN130
CNll
View
CN13
N4g \
CN88
CN87
9. Warning
buzzer
10. Lift proximity
relay
8. Controller
(Serial No. 10001-10662)
CN163
\
I /
/
CN131
Y
CN86
CN12
-. _- .^
vim;~?I/L*278
switch
switch
11. Brake oil level sensor
CN2
CN83
12. Heater
relay
13. Engine
oil level sensor
14. Coolant
CN20
\
water
level sensor
15. Alternator
16. Breaker
17. Battery
Serial No. 10001 -
18. Fuel level sensor
10662
CNPlO
CNP6
ZNP8
relay
CNP2
CNP4
19. Starting
motor
20. Brake chamber
CN254
21. Engine
oil pressure
22. Torque
converter
sensor
oil temperature
sensor
23. Emergency
24. Air pressure
CNP;
kNP9
CNP;
View
bNP3
bNP1

CNP2
CNPl
FNP4
CNP5
I
Ii 1
i,,
View X
WA500-1
26. Parking
brake display
27. Parking
brake solenoid
28
24
,NP/
sensor
25. Speed meter sensor

/
brake sensor
23
Bucket
proximity
switch
valve
switch
CN204
CN92
15
425FOlOll-1K
82i3
ELECTRICAL
1.
ENGINE
CIRCUIT
STARTING
Serial No. 10001
Transmission
control switch
CIRCUIT
SYSTEM
SYSTEM
10388
II
Main braker
425F210
2.
ENGINE
STOP CIRCUIT
Serial No. 10001
SYSTEM
10388
425F211
WA500-
ENGINE STARTING
Serial
No. 10389
AND STOP CIRCUIT
SYSTEM
and up
Starting switch
CN95
CN14
-01
---a2
L-03
04
CN254
ccc0
relay
Transmission
control switch
Banery
To transmission
control valve
I
Main breaker
-
To circuit breaker
I
Main fuse
Alternator
CN97
To monitor panel -
Engine stop motor

_.
fuse
CN29,
Engine stop motor relay
Engine stop motor
42 1 FOl 1 ZOA-K
WA500-1
82-A4-1
3.
TRANSMISSION
CONTROL,
TRANSMISSION
CUT-OFF
CIRCUIT
SYSTEM
Parking
brake valve
CN 15
Parkzng brake relay
To wiper
switch
Meter panel
Tranrmirrlon
select switch
cut-off
Main
braker
L-
To battery
relay
425F212-1
WA500-1
82d5
4.
PARKING
BRAKE
CIRCUIT
SYSTEM
Parking
425F213-1
5.
PREHEATING
): Serial
CIRCUIT
No.
10663
SYSTEM
and
up
425F214A-K
82P
WA500-
C158
A/C camprerror
7.
VEHICLE
Serial
MONITOR
No. 10001-I
SYSTEM
0662
---warninglamp
CN
1,
._
425F218
WA500- 1
Serial No. 10663
and UP
w-L.H. head lamp

421FO1127A-1K
WA500-1
82-18-1
n
TROUBLESHOOTING
E-
CHART FOR ELECTRIC

(E-l. to E-l 5.)
1. Engine does not start (Serial No. 10001-10388)
.............................
82-20
............
E- IA.
Engine does not start (Starting motor rotates) (Serial No. 10389 and up)
E-
2.
Engine does not stop
E-
3.
Engine stop when traveling
E-
4.
.....................
b) Parking brake does not work (Air pressure less than 2.0 kg/cm)
................
Parking brake is not released ...........................................
Parking brake is released when starting siwtch is turned to ON ....................
Transmission is not returned to Neutral when parking brake is applied ...............
Machine does not travel Forward ........................................
Machine does not travel Reverse ........................................
Transmission does not shift gear (F-R direction normal) .........................
Machine travels when transmission cut-off switch is ON .........................
Transmission cannot be cut-off .........................................
Transmission does not return to Neutral ...................................
Preheating display does not go out .......................................
Preheating does not work .............................................
E-
5.
E-
6.
E-
7.
E-
8.
E-
9.
E- IO.
E- 11.
E- 12.
E- 13.
E- 14.
E- 15.
a)
WA500- 1
SYSTEM
...............................................
............................................
Parking brake does not work (Parking brake switch ON)
82-21-I
82-21-4
82-22
82-24
82-24
82-26
82-28
82-28
82-30
82-32
82-34
82-36
82-37
82-38
82-40
82-41
TROliJBLESHOOTlNG
CHART
Serial No. 10001-I

0388
,Failure mode: ENGINE DOES NOT
*
When disconnecting
or connecting
No. E-l.
START.
the T-adapter
(or socket adapter)
*
When
disconnecting
the original
(or socket adapter), connect to the connector specified.
connectors
condition
or connecting
immediately
after
T-adapters,
checking,
then
(CNxx
))
return them to
go to the next
Cause
Remedy
check.
*
If the head lamps and other
electrical
parts are not working
normally,
check battery - battery relay - starting switch first.

(a)
Checking starting circuit
YES
Defective starting motor

assembly.
YES
1)
3)Turn starting
switch OFF.
CN102 (female) (1)

chassis ground
and
1) Measure with
starting switch
at START.
2) Disconnect
CN102 (starting
motor assy).
continuity
between CN14 (3)
(female) and (1 I?
1) Connect
T-adapter (or
socket adapter)
toCN14.
2) Measure with
starting switch
at START.
Tester
Troubleshooting
tools
After checking,
repair or replace
F-R switch.
L
NO
Defective
starting switch
After checking,
repair or replace
(1)
Replace

(for Econoseal)
CONNECTOR

CN102
OF
Defective
Defective contact or
disconnection in wiring
(female) - CN97 (4) CN63 (5) - CN14 (3).
Isthere
.
After checking,
repair or replace
NO
4 r
POSITION
Connect
T-adapter (or
socket adapter)
toCN16.
2) Place F-R lever al
N.
3)Turn starting
switch OFF.
harness between CN102 (3)
(female) - CN97 (7) CN64 (9) - CN16 (9)
(female) ordefective contact
or disconnection in wiring
harness between F-R switch
and chassis ground.
(female)
Procedure No. 3
* Procedure No. 4
CN14 (female)
- Battery relay
* Starting switch
CN16 (male)
10 12
11
425F217
425F216
82-20
WA500-
Cause
(b)
Remedy
Checking battery - battery relay - starting switch

YES
Is voltage between
both thick
terminals of battery
relay and chaws
around 20 - 3OV?
YI
1) Turn starting
switch ON.
2)Measure voltaae
between two terminals
connected by
thick insulated
cable.
Is there sound of
1 )Turn starting
switch ON OFF.
NO
harness between battery
relay and starting motor
assembly.
After checking,
repair or replace
If NO for both terminals

defective contact or
harness between battery and
battery relay.
If NO for one terminal
defective battery realy.
After checking,
repair or replace
ReplaCe
YFS
Defective
YES
Is voltage between
N
harness between grand battery relay CN254 (3) (female) - CN95 (1) (diode) - CN95 (2) CN63 (21 - CN14 (2) starting switch terminal BR
51
YES
chassis ground 20
NO
terminal Band
chassis ground 20
11 Turn starting
battery relay
switch ON.
Replace
After checking,
repair or replace
Defective starting switch

switch
ON.
1I connect
T-adapter (or
socket adapter)
toCN14
(female).
2)Turn starting
switch OFF.
Tester
Troubleshooting
tools
POSITION
JO

(for Econoseal)
>efective contact or
jisconnection in wiring
wness between battery
,elay - CN254 (21 - CN63
17) - CN58 (1) - fuse
ZN58 (2) - CN14 (1) starting switch terminal B.
After checking,
repair or replace
I
OF
CONNECTOR
CN58
* Procedure No. 3
CN254
(female)
CN63

CN14 (female)
CN97
WASOO- 1
82-21
0
TROUBLESHOOTING
CHART
No. E-IA

Failure mode: ENGINE DOES NOT START. (STARTING
*
When
disconnecting
disconnecting
or connecting
the connector
When
connecting
When
disconnecting
after checking,
the
for checking,
the T-adapter
connectors
T-adapter
(or socket
turn the starting
(or socket adapter),

or connecting
MOTOR ROTATES)
connect
T-adapters,
adapter)
switch
or short
OFF to prevent
to the connector
return
socket
adapter,
specified.
them to the original
(CNxx
condition
( ))
immediately
then go to the next check.
YI
11
1
Does engine stop
motcn move?
I)
Turn starting
switch ON OFF and check
visuallv.
2
4
YES
I
Is voltagebetween
NO
chassis 20 -
2)
voltage
Is
bvetween
CN 293 (4) and
chassis 20 - 3OV?
YI
3OV?
T-adapter to
CN293 @-pin)
Turn starting
switch ON.
1)
connect
T-adapter
CN293.
to
NO
(Stays OFF1
1) Connect
T-adapter to
CN293.
2) Continuous
when starting
switch is OFF,
and cut when
switch is ON.
Go to appropriate
stem
YES
57
(Stays continuous1
7
2)
T-adapter
stop relay).
Turn starting
switch ON.
NO
or socket adapter
(for Econoseal)
Tester
82-%
-
or when
accidents.
WA500-1
Cause
Defective adjustment between

engine stop motor and lever.
Defective engine stop motor, or

defective contact, or
disconnection in wiring harness
between CN293 (8) - CN290
(3) - chassis ground.
Defective engine stop motor, or

defective contact. or
between CN292 (5) - CN293
(5).
Broken fuse (CN291). or

- disconnection in wiring
harness between CN293 (4) CN291 (2).
Defective contact, or
between engine stop motor
relay (CN292) or CN293 (7) CN292 (3). CN292 (6) - CN293
Remedy
Adjust
After
inspection,
repair or rep,ace
Afterinspection,
repair or replace
After inspection,
repair or replace
After isw,_tion,
repair or replace
(31.
WA500-1
Defective engine stop relay. or

between CN292 (2) (female) chassis ground.
After inspection,
repair or replace
Defectwe circuit between

battery and starting switch.
Check accroding to E-l-(b).
After inspection,
repair or replace
CN293 (For engine stop motor)

ECONOSEAL connector 8 pins.
CN293
Engin s&p motor

425FO1362A-K
82-&1
-3
WA500-1
TROUBLESHOOTING
Failure
Sr
mode:
When
ENGINE
disconnecting
disconnecting
*
When
connecting
When
disconnecting
after checking,
No. E-2
NOT STOP.
or connecting
the connector
CHART
DOES
the
for checking,
the T-adapter
T-adapter
(or socket
turn the starting
connectors
or connecting
connect
T-adapters,
adapter)
switch
or short
OFF to prevent
to the connector
return
or when
specified.
( ))
(CNxx
condition
immediately
Cause
Remedy
Defective adjustment of linkage

between fuel cut solenoid and
governor
4djust
Defective fuel cut solenoid
%?plXX
YFS
Does spool of fuel

cut solenoid work,
Turn starting
visually.
adapter,
accidents.
Serial No. 10001-10388
1)
socket
?I
ls voltage between
both terminals of
fuel Cut solenoid
ND
approx.
Contact or disconnected wiring

between + 24V and wiring
harness between CN14 (male)
(2) - CN63 (2) - CN97 (male)
YES
OV?
Wer inspection,
.epair or replace
(11).
I)
Turn starting
switch OFF.
Is voltage between
starting switch BR
- chassis approx.
OV?
b
NO
1)
Turn starting
switch OFF.
NO
Serial No. 10389
and up
Defective adjustment between

engine stop motor and stop
4djust
IWW
ES
Defective engine stop motor
Does engine stop
1)
Turn starting
1)
2)
Connect
T-adapter to
CN293 (engine
stop motor
coector)
(B-pin).
Turn starnng
switch OFF.
YES
disconection in wiring harness
between CN293 (3) (female) CN292 (6) (female). or CN292
(3) - CN293 (7) (female), or
defective relay (CN292).
4fter mspectio.
repair or replace
Defective engine stop motor
?eplace
Isvoltage
1)
2)
between
CN293 (3) and (8)
20 - 3OV
connect
T-adapter to
CN293.
Turn starting
switch OFF.
YEE
Is voltage between
1) Connect
T-adapter
CN293.
to
I
NI
disconnection in wiring harnes
between CN293 (4) (female) CN291 (2) (female). or broken
fuse (CN291).
After inspection.
repair or replace
Tester
Troubleshooting
tools
WA500-1
82-&
-4
TROUBLESHOOTING CHART NO. ~-3

Failure mode: ENGINE STOPS WHEN TRAVELING
*
When
disconnecting
disconnecting
+
When
connecting
It
When
disconnecting
after checking,
Serial
or connecting
the connector
the
for checking,
the T-adapter
T-adapter
(or socket
turn the starting
connectors
or connecting
connect
T-adapters,
adapter)
switch
or short
OFF to prevent
to the connector
return
socket
adapter,
or when
accidents.
specified.
( ))
(CNxx
condition
immediately
No. 10001-l
Remedy
Cause
0388
3efective adjustment
of linkage
letwee
fuel cut solenoid and
YE:
4
between both
terminals
of fuel
cut-off solenoid
Does spool of fuel

cut solenoid work?
1)
1)
Turn staning
visually.
Is voltage between
starting swtch
terminal
BR and
chassis ground 20
- 3OV?
YES
-
1)
Is voltage between
starting switch
terminal
B and
chassis ground 20
- 3OV?
L
NO
1)
2)
Disconnect
wiring of fuel
cut-off
solenoid.
Turn starting
switch OFF.
I
NO
Serial
*
No.
10389
fuel cut solenoid
Defective
starting
switch
Xsconnection
in wirina
wrness or defective c&act
Jetween starting switch
terminal 8 and battery relay
after inspection,
Defective adjustment
between
engine stop motor and stop
lever
idjust
Defective
engine
stop motor
leplace
Defective
engine
stop relay
teDlace
epke
and up
Check if the starting

check accroding
motor rotates.
to E-l A (Engine
If it does not rotate,
does not start).
YES
Does engine stop

motor work?
Defective
6fter inspection,
eptace
Turn staning
switch ON.
Turn starting
switch OFF.
Disconnection
in wiring
harness or defective contact
between starting switch
terminal BR - CN14 (2) CN63 (2) - CN97 (11). or fuel
cut solenoid - CNS7 (12) chassis ground
YES
_
2
1)
Turn starting
visually.
L
NO
Does voltage
between CN293 (7)
and (8) switch
between OV and 20
- 3OV?
1)
2)
connect
T-adapter to
CN293.
Turn starting
switch ON OFF.
YES
3
Is voltage between
CN292 (2) (female)
and (1) (female) 20
- 3OV?
_
NO
1)
2)
Troubleshooting
tools
82-22
Disconnect
CN292 (engine
stop relay).
Turn starting
switch ON.
NO
Defective circuit between

battery and starting switch.
Check according tQ E-l -(bJ.
\fter inspection,
epair or replace

(for Econoseal)
Tester
WA500-1
Serial No. lOOQl-10388
Fuel cut-off
solenoid
No. 10001-10388
Serial
STARTING
SWITCH
425F217
CN97
(Intermediate
ECONOSEAL
connector)
connector
12 pins
425P105
Serial
CN293
Serial
(For engine
No. 10389
ECONOSEAL
No.
10389
and
UD
stop motor)
and up
connector
8 pins
/
CN293
Engin
st&
motor
425F01362A.K
WA500-1
82:3
TROUBLESHOOTING
Failure mode: a) PARKING
*
When disconnecting
CHART
BRAKE
or connecting
No. E-4.
DOES NOT WORK.
the T-adapter
(PARKING
(or socket adapter)
BRAKE
SWITCH
ON)
*
When disconnecting
connectors

or connecting
connect to the connector specified.
T-adapters,
(CNxx
return them to the original condition
( 1)
immediately
after

*
Parking brake lamp does not light up.
Even when air pressure drops, parking brake does not work.
YES
,
YES
CN35
(1) (male)
j Connect
T-adapter (or
socket adapter)
to CN35.
PITurn parking
brake switch ON
(parking).
3) Start engine (air
charge).
b
Is there continuity
between CN 11
(male) (1) and (2)
as shown in table?
YES
L
1) Replace CN54
(back-up lamp
relay) and CN51
(parking brake
relay).
2)Turn parking
brake switch ON
(parking).
pressure gauge).
1) Disconnect
CNll.
2)Turn starting
switch OFF.
NO
1 )Disconnect
CN51.
2)Start engine (air
pressur<gauge).
Failure mode: b)PARKlNG

BRAKE
2.0 kg/cm2 1
DOES
NO
NOT
WORK.
(AIR
PRESSURE
LESS
THAN
YES
Is work parking
brake when
disconnect
CN204?
NO
1) Starting switch
ON.
21 Parking brake
switch OFF.
,
Troubleshooting
tools

(for Econoseal)
Tester
82Li?4
WA500- 1
Cause
YES
Remedy
Defective
solenoid
parking
brake
RE$bX
Defective
parking
brake relay
ReplaCe
Abnormal
contact or
mistaken wiring between
CNl 1 (male) (1) - CN63 (41
- CN204 (1). (21 - CN63
(6) - CN51 (2).
After inspection,
repair or replace
Defective
switch
Replace
NO
WASOO- 1
perking
brake
Abnormal
contact or
CN51 (5) (male) - CN39
(11) - CN35 11).
After inspection,
repair or replace
Defective
switch.
emergency
Replace
Defective
parking
brake
brake.
Repair
CNl 1 (Parking brake switch)

N-SLC
CN35
connector
(Parking
ECONOSEAL
3 pins
brake solenoid
connector
valve)
2 pins
solenoid
CN39
(Intermediate
ECONOSEAL
valve
425P108
connector)
connector
12 pins
connector
8 pins
CN63
ECONOSEAL
82-$5-1
WA500-1
serial No. 10001-10662

CN51
(Parking
brake relay)
CN54
(Back-up
lamp relay)
RELAY connector
5 pins
CN297
WY
l&V
I4
Warning buzzer
CN5<
CN5b
CN53
CIj52
dN51
kN50
425F551
CN204
(Emergency
ECONOSEAL
brake switch)
connector
WA500-1
2 pins
82-F2
TROUBLESHOOTING
Failure mode:
*
PARKING
When disconnecting
ing the connector
CHART
BRAKE
or connecting
No. E-5.
IS NOT
RELEASED.
the T-adapter
(or socket adapter)
for checking, turn the starting switch OFF to prevent accidents.
When disconnecting
connectors
or connecting
T-adapters,
(CNxx
( ))
immediately
after

f
*
Parking brake lamp does not light up.

Even when air pressure drops, parking brake does not work.
1
Y ES
YES
Is there continuity
between CN35 (2)
(male) and chassis ground?
NO
1
Y
CN35 (1) (male)

and chassis ground
1 )Connect
T-adapter (or
socket adapter)
to CN35.
2)Stari engine (air
pressure charge).
1) Connect Tadapter (or

W&OW;papter)
2) Turn starting
switch OFF.
1
JO
iS
Is problem
removed when
relays are
interchanged?
1) Interchange
CN54 (back-up
lamp relay) and
CN5 1 (parking
brake relay).
2)Start engine (air
press&charge).
BITurn parking
brake switch ON
- OFF.
rl
Is air pressure in
reservoir normal I7
- 8.3 kg/cm2)
YE
Is voltage between
CN5 1 (2) (male)
and chassis ground
20 - 3OV?
1 )Disconnect
CN51.
pressure charge).
3)Turn parking
brake switch ON
- OFF.
Is voltage between
CN51 (31 (female)
and chassis ground
1 )Start engine (air

pressure charge).
1I
NO
1 )Connect short
socket adapter
to CN204
(fern&).
2)Start engine lair
pressure charge).
3)Turn parking
brake switch ON
- OFF.
NO
NO
giiynect
2)Turn starting
switch ON.
1) Interchange
CN54 (back-up
lamp relay) and
CN52 (parking
brake relay).
2) Stan engine (air
pressure charge).
3) Turn parking
brake switch ON
- OFF.
IO
t
Troubleshooting
for air circuit
Table 1
Troubleshooting
tools

(for Econoseal)
WAMO- 1
Cause
Defective parking
solenoid valve
Remedy
brake
Disconnection
in wiring
harness, or defective contact
between CN25 (2) (male)
and chassis ground
Defective
parking
4fter inspection,
.eplace
brake relay
Disconnection
in wiring
between CN51 (5) (male) CN39 (11)
CN35 (1).
After inspection,
reolace
Defective
switch
emergency
Replace
Defective
parking
safety
Defective
switch
parking
brake
brake
YES
relay
Replace
1)Disconnect
CNll.
2)Turn starting
switch OFF.
YES
HI
NO
Disconnection
in wiring
between CNll
(1) (female) CN63 (4) - CN204 (1). (2) CN63 (6) - CN51 (2). or
braker - CN60 (4) - CN51,
52 (3) or CN51 (2) - CN52 l5L
(2) - CNl 1 (2).
Disconnection
in wiring
between braker - CN60 (4)
- CN51 (31.
WA500- 1
Replace
After inspection,
replace
8227
CNl 1 (Parking brake switch)

N-SLC connector 3 pins
CN35 (Parking brake solenoid valve)

ECONOSEAL connector 2 pins
solenoid valve
425P108
CN39 (Intermediate connector)

CN63
ECONOSEAL connector
82-F
8 pins
WA500-1
Serial No. 10001-10662
CN51
(Parking
brake
relay)
CN54
(Back-up
lamp
relay)
RELAY
connector
5 pins
CN297
I
T\K
h&v
I
I
7
I?
Y-f-T-e 1
CN55 CN54
CN53 Ci52
dN51 CN50
425F551
CN204
(Emergency
ECONOSEAL
WA500-1
brake
connector
switch)
2 pins
82-$7-2
TROUBLESHOOTING
Failure mode:
*
PARKING
TO ON.
When disconnecting
ing the connector
CHART
BRAKE
or connecting
IS RELEASED
the T-adapter
WHEN
STARTING
(or socket adapter)
SWITCH
IS TURNED
or short socket adapter, or when disconnect.
When disconnecting
the original
No. E-6.
connectors
condition

or connecting
immediately
after
T-adapters,
checking,
then
return
(CNxx
( ))
them to
go to the next
check.
Remedy
Defective parking brake

safety relay
1 )Interchage
parking brake
relay (CN51) and
back-up lamp
relay (CN54).
2) Start engine and
charge air
pres?.ure.
3)Turn starting
switch ON.
back-up lamp
relay (CN54).
2)Start engine and
charge air
pressure.
3)Turn starting
switch ON.
TROUBLESHOOTING
Failure mode:
Defective
parking brake relay
Defective
switch
parking brake
l---_l
I__1) Disconnect
CNll.
2) Start engine and
charge air
pressure.
3)Tum starting
switch OFF ON.
CHART
TRANSMISSION
IS NOT
BRAKE IS APPLIED.
YES
Replace
Is problem
removed when
CNll
is
disconnected?
&connection
in wiring
lerness. or defective confect
Jetwee +24V terminal and
:N35 (1) - CN39 (11)
CN51 (5) or CNll (1)
CN51
2).
4fter inspection,
replace
No. E-7.
RETURNED
TO NEUTRAL
1
1
Replace
WHEN
PARKING
Cause
Defective neutralizer
Remedy
relay
Is problem removed
when relay is
replaced?
1) Interchange
neutralizer relay
(CN53) and backup lamp relay
(CN54).
2) Stan engine and
charge air
pressure.
3) Turn staning
switch ON.
82-28
a
NO
1 Disconnection in wiring
between + 24V terminal and
CN53 (5) - CN21 (l), (2) CN75 (8) - CN85 (A).
After inspection,
replace
WA500- 1
CNl 1 (Parking
N-SLC
CN35
brake
connector
(Parking
ECONOSEAL
switch)
3 pins
brake
solenoid
connector
valve)
2 pins
-_
solenoid
CN39
(Intermediate
ECONOSEAL
connector
valva
display switch
425Pt08
connector)
connector
CN85 (For transmission

BENDIX
-.)
,,,,,,,,
12 pins
control
valve)
14 pins
425P112
WA500-1
8229
CN51
(Parking
brake relay)
CN52
(Parking
brake safety
CN53
(Neutralizer
CN54
(Back-up
Serial No. 10001-10662
relay)
relay)
relay)
RELAY connector
5 pins
CN297
CN55 CN54
CN53 CN52 CN51 CN50

425F551
82-E-1
WA500-1
TROUBLESHOOTING
Failure mode:
*
MACHINE
When disconnecting
CHART
No. E-8.
DOES NOT TRAVEL
or connecting
the T-adapter
FORWARD.
(or socket adapter)
*
When disconnecting
connectors
or connecting
T-adapters,
(CNxx
( 1)
immediately
4
YES
3 Is there continuity
between CN16
(female) (1) and
chassis ground?
Is there continuity
between CN16
(male) (1) and (2)?
1) place F-R lever in

REVERSE.
socket adapter)
to CN16.
3) Turn starting
switch OFF.
NO
1)Connect
T-adapter (or
socket adapter)
to CN16
(female).
2)Turn starting
switch OFF.
YES
1
NO
YIES
Is parking brake
chassis ground?
YES
YES
CN85 (A) (female)

and chassis ground
1 I Disconnect CN85
2) Turn starting
switch ON. (Do
not start
3) Parking brake
switch ON-OFF
(release).
engine.)
Troubleshooting
tools
8220

(for Econoseal)
ES
1) Place F-R lever in

FORWARD.
2) Disconnect
CN85.
3) Turn starting
switch OFF.
I
YES
Is problem
removed when
relay is replaced?
1
1) Interchange
neutralizer relay
(CN53) and backup lamp relay
(CN54).
2) start engjne.
3) Parkmg brake
switch ON - OFF
(released).
removed when
short socket
11 Connect short
socket adapter to
CN21 (female).
2) Start engine.
3) Parking brake
switch ON -OFF
(release).
Tester
WASOO- 1
after
Cause
between CN16 (2) (female)
- CN75 (5) - CN85 0) CN85 (A) (female)
After inspection,
repairorreplace
Defective
Replace
F-R switch
between CN16 (8) (male)
and chassis ground
WA500-1
Defective
forward
Defective
neutralizer
After inspection,
repair or replace
solenoid
relay
Replace
Defective transmission
cut-off switch
Replace
betweenmain breaker CN59
(8) - CN53 (3) orCN53
(5)
- CN21 (1 j, (2) - CN75 (8)
- CN85 (AL
After inspection,
repair or replace
CNll (Parking brake switch)

CN16 (Speed lever, directional lever)

CN21 (Transmission cut-off switch)

CN85 (For transmission control valve)

BENDIX connector 14 pins
82-$
-
WASOO-1
Serial
CN53
(Neutralizer
CN54
(Back-up
No. lOOOl--10662
relay)
relay)
RELAY connector
5 pins
Semi
No. 10663
and LID
CN297
CN55CN5k
CNj3
&52
dN51 bN50
425F551
WA500-1
82-E
-2
TROUBLESHOOTING
Failure mode:
*
MACHINE
When disconnecting
ing the connector
CHART
No. E-9.
DOES NOT TRAVEL
or connecting
the T-adapter
REVERSE.
(or socket adapter)
When disconnecting
connectors
or connecting
T-adapters,
(CNxx
( ))
immediately
YES
-
(rIO
Refer to E-5
CN18
chassis
ground?
II
I
(1)
Jconnect
T-adapter
(or
socket adapter)
toCN16
(femaleI.
2lTurn starting
switch OFF.
Is there continuity
between CN85 (Cl
(female) and
chassis ground?
YES
between
Is there continuity
between CN16
(male) (1) and (3)?
1) Place F-R never I

REVERSE.
socket adaoter)
to 0416 (fdmaie).
3) Turn starting
switch OFF.
rJO
ND
1) Place F-R lever in

REVERSE.
2)Turn starting
switch OFF.
'ES
voltage
Is
between
CN85 IA) Ifemale)
and chassis ground
3OV?
i zo-
1) Disconnect
CN85.
2) Turn starting
switch ON. (Do
not start engine.)
3) Parking brake
switch ON-OFF
Irelease).
2) Start engine.
3) Parking brake
switch ON -OFF
(release).
Troubleshooting
tools
8222
T-adapter
or socket
(for Econoseal)
Tester
Short
socket adapter to
CN21 (female).
2) Start engine.
3) Parking brake
switch ON - OFF
(release).
socket
adapter
adapter
WA500- 1
after
Cause
Remedy
- CN75 (6) - CN85 (C) CN85 (A) (male)
After inspection.
repair or replace
Defective
Replace
F-R switch
between CN16 (male) (1)and
chassis ground.
After inspectIOn.
repair or replace
Defective
reverse solenoid
ReplaCe
Defective
neutralizer
Replace
relay
cut-off switch
Disconnection
in wiring harness
between main breaker CN59
(8) - CN53 (31 or CN53 (5)
- CN21 (1). (2) - CN75 (8)
- CN85 (Al.
WA500-1
Replace
After insPection.
repair or replace
CNll
(Parking
N-SLC
brake switch)
connector
3 pins
B
CN16
(Speed
ECONOSEAL
CN21
lever, directional
connector
(Transmission
ECONOSEAL
CN85
cut-off
connector
(For transmission
BENDIX
connector
82-33-l
0
lever)
12 pins
switch)
2 pins
control
valve)
14 pins
WA500-1
Serial No. 10001 -
10662
CN53 (Neutraliter relay)

CN54 (Back-up relay)
RELAY connector 5 pins
3
CN55kkh
CNk3 Cd!52 dN51 bN50

425F551
WA500-1
82-33-2
/;\
TROUBLESHOOTING
Failure mode:
*
CHART
TRANSMISSION
When disconnecting
ing the connector
No. E-l 0.
DOES NOT SHIFT
or connecting
the T-adapter
GEAR
(or socket adapter)
(F-R
DIRECTION
NORM,CLL).
When disconnecting
connectors
or connecting
T-adapters,
(CNxx
( ))
immediately
after

Remedy
Cause
YES
Defective
1 st solenoid
pi-
NO
1) Disconnect
CN85.
2) Turn starting
switch OFF.
3) Speed control
lever 1 st.
YES
2nd
between CN85 (HI (female)
and CN 16 (4). or defective
speed switch
After inspection,
repair or replace
=r
Defective
Replace
2nd solenoid
2
Is there continuity
between CN16 IS)
(female) and
chassis ground?
ES
Is voltage between
CN85 (8) (female)
and chassis ground
20 - 3OV?
1) Connect
T-adapter (or
socket adapter)
to CN16
(female).
2)Tum starting
switch OFF.
between CN85 (G) (female)
and CN16 (5). or defective
speed switch
2) Turn starting
switch OFF.
3) Speed control
lever 2nd.
pizgiqYES
1) Disconnect
CN85.
2) Turn starting
switch OFF.
3) Speed control
lever 3rd.
1) Disconnect
CN85.
2)Turn starting
switch ON.
3)Parking brake
switch ON-OFF
(release).
NO
YES
LTzgzgi:ig,
INO
1) Disconnect
CN85.
2) Turn starting
switch OFF.
3) Speed control
lever 4th.
NC
Troubleshooting
tools
Tester
82634
Defective
After inspection.
repair or replace
3rd solenoid
harness. or defective COntaCt
between CN85 (F) (female)
speed switch
Defective
After inspection.
repair or replace
4th solenoid
*
Disconnection in Wiring
between CN85 (E) (female)
speed switch
After inspection,
repair or replace
harness, or defective Contact
and chassis ground
After inspection.
repair or replace
Disconnection in Wiring
between main breaker CN75 (1) - CN85 (8)
(female)
After inspection.
repair or replace

(for Econoseal)
WA500- 1
POSITION
OF
CONNECTOR
. Procedure No. 1, No. 3, No. 4, NO. 5 and No. 6

CN85 (female)
1 Procedure No. 2
CNI 6 (female)
WA500- 1
TROUBLESHOOTING
Failure mode:
*
MACHINE
When disconnecting
CHART
TRAVELS
or connecting
No. E-l 1.
WHEN
the T-adapter
TRANSMISSION
(or socket adapter)
CUT-OFF
SWITCH
IS ON.
ing the connector for checking turn the starting switch OFF to prevent accidents.
*
When disconnecting
connectors
or connecting
T-adapters,
(CNxx
( ))
immediately
after
Cause
YES
- [)isconnection
in wiring
lamess, or defective contact
letwee CN21 (1) - CN18
l),orCN21
(21 - CN18 (21.
II1
t
f
EiNO
_
IDefective transmission
,cut-off switch
21 Turn starting
switch ON.
* DO not press the
left brake pedal.

(for Econoseall
Troubleshooting
tools
rfter inspection.
eplace
Ieplace
POSITION
OF
CONNECTOR
- Procedure No. 1
CN21 (female)
WA500-1
TROUBLESHOOTING
Failure mode:
TRANSMISSION
CHART
CANNOT
No. E-l 2.
BE CUT-OFF.
Cause
YES
1) Disconnect
CN18.
21 Start engine.
between CN76
(male) (1 and (2)
as shown in table?
1 Disconnect
CN76.
2) Turn starting
switch OFF.
Procedure
OF
Procedure
%zplace
cut-off selector switch
ReDlace
Abnormal contact, or
f24V
terminal and wiring
harness of main breaker CN53 (3). (51 - CN21 cl),
(2) - CN85 (AL
&fter inspection,
.epair or replace
Replace
CONNECTOR
No. 1
CN21
cut-off switch

(for Econoseal)
Troubleshooting
to015
POSITION
NO
Remedy
Procedure
No. 3
CN76 (male)
No. 2
CN18
WA500- 1
82-37
0
TROUBLESHOOTING
Failure mode:
*
CHART
TRANSMISSION
When disconnecting
ing the connector
No. E-l 3.
DOES NOT
for checking,
When disconnecting
turn the starting
TO NEUTRAL.
(or socket adapter)

switch
connectors or connecting
RETURN
OFF to prevent accidents.
T-adapters,
(CNxx
( ))
immediately
YES
3
YES_
Is there continuity
between CN16
(male) (9) and (2).
(9) and (3)?
1)Connect
T-adapter (or
socket adapter)
to CN 16 (male)
2)Turn starting
switch OFF.
Yl
1 )Turn starting
switch ON.
2)Turn
transmission
cut-off selector
switch ON.
Is transmission
returned to
NEUTRAL when
left brake is
aoolied?
NO
Is there continuity
between CN85 0)
(female) and
chassisground,
CN85 CC) (female)
and chassis
ground,
1) Disconnect
CN85.
2)Turn starting
switch OFF.
YES
between CN76
(male) (1 and 121
as shown in table?
Is transmission
returned to
NEUTRAL when
parking brake is
applied?
YES
1)
Connect
T-adapter (or
socket adapter)
to CN76 (male).
2)Turn starting
switch OFF.
N0
1 )Turn starting
switch ON.
2)Tum
transmission
cut-off selector
switch OFF.
3)Turn parking
brake switch ON
- OFF.
Table
~1
Troubleshooting
tools
8228

(for Econoseal)
WA500- 1
after
POSITION
Cause
Remedy
OF
Procedure
CONNECTOR
No. 3
CN16 (male)
7
Defective F-R switch
Seplace
4bnormal contact, or
nistaken wiring between
:hassis ground and CN85 ID1
(female) - CN75 (5) EN1 6 (2). or CN85 (C)
lfemalel - CN76 (1). (2) CN16 (3).
4fter inspection,
epair or replace
4bnormal contact, or
nistaken wiring between
:hassis ground and CN 16 I21
(male) - CN75 (5) - CN85
ID) (female), or CN 16 (3)
(male) - CN75 (6) - CN76
I1 ), (2) - CN85 ICI (female).
4fter inspection,
epair or replace
11
12
10
Procedure
No. 4
CN85 (female)
Procedure
No. 5
CN76 (male)
teplace
See E-7 Transmission is not

returned to NEUTRAL when
parking brake is applied.
See E-l 2 Transmission

cannot be cut-off.
WA500- 1
82-39
0
TROUBLESHOOTING
PREHEATING
Failure mode:
*
CHART
When disconnecting
ing the tonnector
DISPLAY
or connecting
No. E-l 4.
DOES NOT
the T-adapter
GO OUT.
(or socket adapter)
When disconnecting
connectors or connecting T-adapters,
(CNxx
( 1)
immediately
Cause
YES
44
Is there continuity
between CN13
Imale) I1 and (2)?
- ckfective
preheating
switch
I 1
1 )Turn preheating
siwtch OFF
(AUTO).
2) Disconnection
CN13 (nxilel.
Troubleshooting
tools
POISITON
*
NO
heater relav
Tester
OF
w - ckfective
CONNECTOR
Procedure No. 1
CN13 (male)
82-40
0
WA500-
after
TROUBLESHOOTING
Failure mode:
*
CHART
PREHATING
When disconnecting
ing the connector
No. E-l 5.
DOES NOT WORK.
or connecting
the T-adapter
(or socket adapter)
When disconnecting
connectors
or connecting
T-adapters,
(CNxx
( ))
immediately
after
checking, then go to the next check

Cause
1s
YES
Defectwe
Is there continuity
between CN 13
(male) (1) and (2)7
1) Turn preheating
switch OFF
(AUTO).
2) Disconnection
CN13 (male).
_
NO
4
-
,~
Is there continuity
between CN48 (3)
NO
Is there continutty
between heater
relay Input termmal
and wtpt
terminal?
YES
3
ReplSCe
Oefective automatic
preheating
timer
R+%?
Defective
RepiW2
NO
OF
CONNECTOR
- Procedure No. 1
CN13 (male)
Procedure No. 2
CN48 (female)
Procedure No. 3
Heater relay
relay
Disconnection
in wiring
harness, or defectwe contact
between CN43 (3) and chasss
ground.
NO
Tester
Troubleshooting
heater
Contact between wiring

harness of +24V terminal
and
heater relay output terminal
- input terminal
of electrical
Intake a,r heater or CN13 (2)
- heater relay, CN13 (3) automatic
preheating
timer
1) Turn starting
switch OFF
~~~~cnhda,is
1) Turn starting
swtch OFF.
YES
rc
tools
WA500-
switch
2
Is voltage bdtween
CN48 (female) 11)
and (3) 20 - 3OV
flWSSE
preheating
YES
1) Turn preheating
switch OFF
(AUTO).
2) Turn starting
switch ON, wait
for approx. 30
minutes, then
POSITION
Remedy
Afrer inspection.
repaIr or replace
After ~nspect,on.
repaIr or replace
TROUBLESHOOTING
CHART FOR ELECTRONIC
VEHICLE MONITORING
SYSTEM
(Serial
No. 10001-l
0662)
M- 1. When starting switch is turned ON (do not start engine), and there is no abnormality
in machine,
check before starting itme flashes.
.................................................
................................................
c) Coolant level ..................................................
M- 2.
a) Brake oil level
82- 46
b) Engine oil level.
82-
47
82- 48
When starting switch is turned ON (do not start engine), and there is no abnormality
in machine,
caution item flashes.

a) Battery charge .................................................
82- 49
....................................................
c) Clogging in transmission oil filter .....................................
82-
50
82-
51
a) Failure in brake line
82-
52
b) Engine oil pressure
82-
53
c)
82-
54
b) Fuel level
M- 3.
When starting switch is turned ON (engine started), and there is no abnormality
in machine,
emergency items flashes.
d)
e)
f)
M- 4.
.............................................
..............................................
Coolant level ..................................................
Drop in air pressure. .................................
Coolant temperature
.............................................
....................................
When starting switch is turned ON (do not start engine), and there is no abnormality
pilot item lights up abnormally,
55
82-
56
82-
57
in machine,
or does not light up.
..................................
.................................
Working lamp display does not go out .................................
Working lamp display does not light up. ................................
Preheat display lights up ..........................................
Preheat display does not light up .....................................
Failure in main steering dispaly light up (If equipped) .......................
Failure in main steering display does not light up (If equipped) .................
Emergency steering normal display lights up (If equipped) ....................
Emergency steering normal display does not light up (If equipped)
..............
Transmission cut-off display lights up ..................................
Transmission cut-off display does not light up ............................
82-
58
b) Parking brake display does not light up
82-
59
c)
82-
60
82-
61
82-
62
82-
63
e)
f)
g)
h)
i)
j)
k)
I)
Turn signal lamps, high beam light up abnormally,
82 . 64
82-
65
82 . 66
82 . 67
82 . 68
82 . 69
or do not light up.
...........................
...........................
c) Pilot display of turn signal lamp (right) does not light up .....................
d) Pilot display of turn signal lamp (left) does not light up ......................
e) HIGH BEAM pilot lamp does not light up ...............................
f) HIGH BEAM pilot lamp does not work normally ..........................
M- 6. Speedometer display does not work normally
..............................
M- 7. Servicemeter does not work normally ....................................
M- 8.
82-
a) Parking brake display does not go out
d)
M- 5.
_ ...........
a) Pilot display of turn signal lamp (right) lights up
82- 70
b) Pilot display of turn signal lamp (left) lights up
82 . 70
Abnormality
in monitor
a) None of monitor
b) Part of monitor
82- 71
82- 72
82- 73
82- 74
82-
75
82-
76
panel.
.......................................
..................................
panel works
82- 78
panel does not work
82- 80
c) Even when engine is stopped, engine oil pressure flashes, caution buzzer sounds and
warning lamp also lights up.
........................................
d) Even when engine is stopped, battery charge flashes and warning lamp lights up
e) No lamps on monitor
(immediately
after turning starting switch to ON,
displays no abnormal;/,
engine stopped)
.............
but central warning lamp lights up intermittently
g) Central warning lamp lights up continuously
.............................
but central warning buzzer sounds intermittently
i) Central warning buzzer sounds continously
82642
82-
81
82-
82
82-
82
82-
83
82-
84
lights up
f) Monitor displays no abnormality,

h) Monitor
......
..............................
...
. 82- 85
82- 86
WA500-
M- 9.
Abnormality
in panel lamps on monitor.
a.) No panel lamps light up even when only small lamp in combination
b) No panel lamps light up even working
c) Panel lamps of gauge module do not light up . . .

d) Panel lamps of CHECKS,
CAUTION
1 and 2, speedometer
e) Panel lamps of service meter do not light up

M-10.
Abnormality
...
...... .
lamp is switched on
..
.. ....... ... ...
82- 91
82- 92
.. ...
..
82- 93
....
........
..
82- 94
item is flashing, but warning lamps does not flash
82- 96
in gauge.
a) Fuelgauge..................................................
... .... .. .......................... .

c) Coolant temperature gauge . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . .
d) Torque converter oil temperature gauge . . . . . . . . . . . . . . . . . . . . . . _ . . . . . .
b) Air pressure gauge.
WASOO- 1
82- 88
82- 90
in alarm buzzer or warning lamp.
b) Emergency item or non-emergency

Abnormality
...
..
..
module do not light up .
a) Emergency item is flashing, but alarm buzzer does not sound

M-l 1.
lamp is used
.. . ....
.
. .... ..
..
82- 98
82-100
82-102
82-104
82-43
0
TROUBLESHOOTING
TABLE
(ELECTRONIC
VEHICLE
Module
I
NO.
Trouble
Even when engine

level) flashes.
is stopped,
and there
is no abnormality
in machine,
Even when engine

level) flashes.
is stopped,
and there
is no abnormality
in machine,
Even when engine

level) flashes.
is stopped,
1 10 ) (Battery
r@l
(Fuel
level)
( a 1(Clogging
(Engine
oil
LQi
charge)
;_
group
phenomenia
and there
is no abnormality
flashes at engine
in machine,
(Coolant
running,
flashes.
transmission
oil filter)
flashes.
0
(Drop
air pressure)
Even when
temperaturel
11
17
.-
flashes.
engine is stopped,
flashes.
13
(Parking
14
l5
c2
16
lamp)
lights UP abnormally.
or does not light
up.
(Preheat)
lights
Turn
signal lamps,
20
Speedometer
meter
steering)
steering
23
Even when engine

charge) flashes.
up abnormally,
up abnormally,
does not work
does not work
All or part of monitor

after checking.
light
panel
does not work
Central
warning
lamp does not go out.
26
Central
warning
buzzer
27
None
of panel
lamps
28
Some
of panel
lamps on monitor
29
Emergency
item
is flashing,
30
Emergency
item
or non-emergency
32
Abnormality
in
34
Abnormality
light
up (Immediately
0
0
or does not light
up.
up.
up.
If any fuse is broken,
oil pressure)
flashes,
replace
(Battery
or
after
turning
starting
switch
to ON
does not stop.
on monitor
light
but alarm
(Air
pressure
in
1.
ic
_&
(Coolant
in
ir-
k@_
(Torque
buzzer
item
gauge)
up.
do not light
1 (Fuel
82$4
Llll
25
in
up. (lf equipped
or does not light
or does not light
normally.
(Engine
No lamps on monitor
enaine stoooedl
Abnormality
-A--L-l
or does not light
IGI
31
normally.
is stopped,
F@
E
normally.
24
Abnormality
up abnormally,
lights up abnormally,
lights
high beam
22
lights
normal)
cut-off)
display
up abnormally.
in main
19
~~
(T orque
L1IL!
(Working
I (Transmission
Service
IAl
up.
(Failure
(Coolant
is no abnormaf$inmachine,
or does not light
in maohine,
lights up abnormally,
18
33
is no abnormality
brake)
(Emergency
(If equipped)
21
and there
1 Even when engine is stoppe$and

there
1 converter
011 temperature)
tlasnes.
in
up.
does not sound.
is flashing,
but warning
lamp does not flash.
gauge)
temperature
converter
gauge)
oil temperature
gauge)
WA500- 1
MONITORING
Electrical
Alternator
Working
lamp
switch
Transmission
cut-off
switch
SYSTEM)
parts group
Sensor
group
Torque
Clog-
Electricd air
intake
heater
Diode
conver-
Lamp
buzzer
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
WA500-
82-45
0
TROUBLESHOOTING
CHART
No. M-l.
(Fluid level of CHECKS BEFORE STARTING items are correct)

Failure mode: WHEN STARTING
SWITCH IS TURNED ON (DO NOT START ENGINE),
AND THERE IS NO ABNORMALITY
IN MACHINE,
CHECK BEFORE
STARTING
ITEM FLASHES.
*
When disconnectiong or connecting the T-adapter (or socket adapter) or short socket adapter, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents.
*
When disconnecting
(CNxx
( 1)
immediately
after

Remedy
YES
>
1
Does(0
I
Defective
sen*or
brake oil level
Defective CHECKS BEFORE

STARTING
module
Replace
harness. or defective contact
CN91 - CN64 (11)
cNP4 (female) (4)
After inspectin.
repair (clean) or
replace
(female) (2) - CN91 (5) chassis ground
After inspectin.
repair (clean) or
replace
YE
goout?
/
1 )Connect short
socket adapter
to CN86
(female1 (brake
oil level sensor)
2)Turn starting
switch ON.
1 )Connect
T-adapter (or
socket adapter)
to CN86
(female).
P)Turn starting
switch OFF.
POSITION
T-adapter
OF
JO
4
Tester
Troubleshooting
tools
to CN86
(female).
2) Connect
T-adapter (or
socket adapter)
to CNP4 (female)
3)Turn starting
switch OFF.
(for DLI)

(for Econoseal)
CONNECTOR
- Procedure No. 1 and No. 2

CN86 (female)
Procedure No. 3
CNP4 (female)
82if6
WA500- 1
b)
($
(ENGINE
OIL
LEVEL)
FLASHES.
cl
Cause
Remedy
Y ES
4)
Defective
sensor
engine oil level
YES
31

STARTING module
Replace
)isconnection in wiring
lames% or defective contact
>etween CN96 (female) (1)
- CN97 (5) - CN62 (1) 3NP3 (female) (3)
4fter inspection.
,epair (clean) or
eplace
Iisconnection in wiring
Iamass, or defective contact
)etween CN96 (female) (2)
- CN97 (12) chassis ground
4fter inspection,
.epair (clean) or
wlace
Is there continuity
between CNP3
(female) (3) and
chassis ground?
11Connect
short
socket adapter
to CN96
(female) (engine
oil level sensor).
PITurn starting
switch ON.
1) Connect short
socket adapter
to CN96
(female).
2)Connect
T-adapter to
CNP3 (female).
3)Turn starting
switch OFF.
m
NO
1)
Connect
T-adapter (or
socket adapter)
to CN96
(female).
2) Turn starting
switch OFF.
Troubleshooting
tools
POSITION
OF
Tester
T-adapter

(for Econoseal)
(for DLI)
CONNECTOR
* Procedure No. 1 and No. 2

CN96 (female)
Procedure
No. 3
CNP3 (female)
WA500- 1
82-47
0
C)
Q
L-l
(COOLANT
LEVEL)
FLASHES.
Cause
defective radiator water level

sensor
YES
>efective CHECKS BEFORE

STARTING module
3eDlace
)isconnection in wiring
larness, or defective contact
oet~ee CN278 (female) tl)
- CNllO(l)-CN62(2)
- CNP3 (female) (5)
4fter inspection,
.epair (clean) or
.eplace
- CN106 (2) - chassis
ground
After inspection.
repair Wean) Or
YI
Does
8
go out?
rl
i
1
1 )Connect short
socket adapter
to CN278
(female) (radiator
water level
sensor).
PITurn starting
switch ON.
1
10
Is
1
there continuity
between CN278
(female) (2) and
chassis ground?
1 I Connect
T-adapter (or
socket adapted
to CN278
(female).
2)Tum starting
switch OFF.
Troubleshooting
tools
POSITION
OF
socket adapter
to CN278
(female).
21 connect
T-adapter to
CNP3 (female).
3)Turn starting
switch OFF.
NO
Tester
T-adapter

(for Econoseall
(for DLII
CONNECTOR
- Procedure No. 1, No. 2 and No. 3

CN278
(female)
Procedure
No. 3
CNP3 (female)
82-48
0
WA500-
TROUBLESHOOTING
CHART
No. M-2.
(Fluid level of CHECKS BEFORE STARTING

items)
SWITCH IS TURNED ON (DO NOT START
IN MACHINE,
CAUTION
FLASHES.
When disconnecting
or connecting
the T-adapter
(or socket
ing the connector
for checking,
turn the starting
When connecting
the T-adapter
When disconnecting
checking,
/_
connectors
or connecting
switch
adapter)
OFF to prevent
connect
T-adapters,
or short socket adapter,
them
or when disconnect-
accidents.
to the connector
return
ENGINE),
ITEM
specified.
to the original
(CNxx
( ))
condition
immediately
after
(BATTERY
CHARGE)
FLASHES.
Remedy
/
YES
w
Defective
1
CAUTION
module
harness, or defective Cont.32
between alternator terminal
R-CN97(1l-CN64~1~
- CNP5 (1)
Defective
Replace
2
Isvoltage
YES
1 c
IS voltage at
alternator terminal
R 20 - 3OV?
between
CNP5 (female) and
chassisground 20
- 3OV?
Connect
T-adapter to
CNP5 (female).
2)Turn starting
switch ON.
1 )Turn starting
switch ON. Start
engine.
2)Measure voltage
between
alternator
terminal R and
chassis ground.
NO
After inspection,
repair (clean) or
replace
alternator
NO
Troublleshooting
tools
POSITION
OF
Tester
T-adapter

(for Econoseal)
(for DLI)
CONNECTOR
- Procedure No. 1
CNP5 (female)
WA500- 1
82-49
0
b,
l@l(
FUEL
LEVEL)
FLASHES.
Cause
YES
Remedy
See M-l 1 -a) Abnormality

in, fuel gauge.
Replace
Defective
1
CAUTION
Replace
Defective
gauge module
1
Does fuel gauge
display show
EMPTY?
1.
1ITurn
Starti%
switch ON.
a Does2
I
.~.
YES
g,,,,Ut,-
NO
Isvoltage
1) Interchange
CAUTlON
modules 1 and 2.
2)Turn starting
switch ON.
Na
between
CNP 15) and
chassis ground less
than4V?
POSITION
OF
NO
Tester
T-adapter

lfor Econoseall
(for DLI)
After inspection.
repair (clean) or
replace
1)connect
T-adapterto
CNP5 (female).
Z)Turn starting
switch ON.
Troubleshooting
tools
module
between CNPZ (female) (3)
and CNP5 (female) (6).
After inspection.
repair (clean) or
replace
CONNECTOR
- Procedure No. 2
Module I,2
Procedure No. 3
CNP5 (female)
82-50
0
WA500-
cl
(CLOGGING
IN TRANsMlssl0N
OIL FILTER)
FLASHES.
Remedy
Cause
filter clogging sensor
Defective
1.
(female)
(transmission
filter clogging
sensor).
2)Tur starting
switch ON.
3)Start engine.
module
Reolace
Repke
to CN153
CAUTION
oil
I- _,
oil
between CN153
(2) (female) and
1 )Connect
T-adapter
(or
socket adapter)
to CN153
(female).
2)Turn starting
switch ON.
2)Connect
T-adapterto
CNP5 (female).
3)Turn starting
switch OFF.
NO
NO
Disconnection
in wiring
between CNl 53 (11 (female)
- CN64 (2) - CNP5 (7)
(female).
4fter inspection,
.epair (clearn) or
.eolace.
Disconnection
in wiring
harness, or defective
contact
and chassis gruund.
prfter inspection,
.epair Meam) or
.eplace.
.
Troubleshooting
tools
Tester
Short socket
T-adapter
T-adapter
or socket
(for Ecooseal)
(for DLI)
adapter
adapter
POSITION OF CONNECTOR
* Procedure No. 2
- CN64
Module 1
Procedure No. 3
CNP5 (female)
WA500-
- CN153
(female)
82-51
0
TROUBLESHOOTING
CHART
No. M-3.

SWITCH IS TURNED ON (ENGINE STARTED),
AND
THERE IS NO ABNORMALITY
IN MACHINE,
EMERGENCY
ITEMS
FLASHES.
*
When disconnecting
or connecting the T-adapter (or socket adapter) or short socket adapter, or when disconnecting the connector
for checking,
turn the starting
When connecting
the T-adapter
When disconnecting
checking,
connectors
or connecting
switch
OFF to prevent
connect
T-adapters,
accidents.
to the connector
return
specified.
(CNxx
( ))
condition
immediately
after

Cause
(FAILUR
E IN
BRAKE
LINE)
FLASHES.
YES
defective
ES
ES
Troubleshooting
tools
OF
1 I Connect
T-adapter
(or
socket adapter)
to CN87 (male).
PITurn starting
switch OFF.
1) connect
T-adapter
(or
socket adapter)
to CN88 (male).
Z)Tum starting
switch OFF.
POSITION
Is there continuity
between CN87
(male) (1 and (2)?
YES
_
Is there continuity
between CN87
(female) (2) and
chassis ground?
1 )Connect short
socket adapter
to CN88
(female).
PIConnect
T-adapter
(or
socket adapter)
to CN87
(female).
3)Turn starting
switch OFF.
Is there continuity
between CNPE
(female) (1 1) and
chassis ground?
l)Coect
T-adapter to
CNP8 (female).
2)Turn startina
switch OFF.-
rr
NO
Iisconnection
in wiring
larness, or defective contact
letween CN87 (female) (1)
- CN91 (8) - CN64 (12)
- CNPE (female) (1 1)
After inspection,
repair (clean) or
replace
Iisconnection
in wiring
lamess, or defective contact
Detween CN87 (female) (2)
- CN88 (female) (1). or
ZN88 (female) (2) - CN91
15) chassis ground
After inspection,
repair (clean) or
replace
Defective
brake line failure
Reolace
3efective
sensor
brake line failure
NO
Short
T-adapter
T-adapter
or socket
(for Econoseal)
(for DLII
module
Tester
socket
CAUTION
adapter
adapter
CONNECTOR

CN87
* Procedure No. 4
CNP8 (female)
(female)
Procedure
No. 3
CN88
(male)
82-52
Co
WA500-
b)
16
/ (ENGINE
OIL
PRESSURE)
FLASHES.
Cause
YES
Remedy
Defective
sensor
engine oil pressure
Defective
2
CAUTION
module
YI ES
Iz$%J--;
1 I Connect short
socket adapter
to CN163
(female) (engine
oil pressure
seosor1.
Z)Turn starting
switch ON.
31 Start engine.
to CN163
(engine oil
pressure sensor).
21 Connect
T-adapter to
CNP7 (female).
3)Turn starting
switch OFF.
2
Is there continuity
between CN163
(female) (2) and
1 I Connect
T-adapter (or
socket adapter)
toCN163
(femaleI.
2)Turn starting
switch OFF.
(Engine stopped.)
NC
Note:
flashes
If
when the engine is
stopped. is I_)
defe&ive.
/WI
- CN97 (8) - CN64 (6) CNP7 (female) (2)
After inspection.
epair Wean) or
eplace
ground
4fter inspection.
.epair (clean) or
.eplace
See M-7-b) Even when

engine is stopped, engine oil
pressure lamp or battery
charge lamp flashes.
Wter inspection.
repair (clean1 or
replace
1
Troubleshooting
tools
T-adapter
POISTION
OF
Tester
(for DLI)

(for Econoseall
CONNECTOR
* Procedure No. 1
CN163
(female)
Procedure
No. 3
CNP7 (female)
WA500- 1
82-53
0
C)
e
L-.
(COOLANT
LEVEL)
FLASHES.
Cause
3
(female) (2) and
chassis ground?
YES
*
level sensor
I
1) Connect T-adapter
(or socket adapter)
to CN278 (female).
2)Turn starting
switch OFF.
CN278 (female).
2)Turn starting
switch ON.
3)Start engine.
1) Connect short
socket adapter
to CN278
(female).
2) Connect
T-adapterto
CNP7 (female).
BITurn starting
switch OFF.
NO
Tester
T-adapter
OF
Defective
module
CAUTION
Replace
(female) (1) - CNl 10 (1) CN62 (2) - CNP7 (female)
(6).
After inspection,
repair (clean) or
replace
Defective contact. or
(female) (2) - CNl 10 (2) chassis ground
After inspection.
repair (clean) or

(for DLI)
&
POSITION
N0
Troubleshooting
tools
coolant level sensor
I
-
Defective

(for Econoseal)
CONNECTOR
* Procedure No. 1, No. 2

CN278
(male)
Procedure
No. 3
CNP7 (female)
82-54
0
WA500-
d Ial
(DROP
IN AIR
PRESSURE)
FLASHES.
(AT
ENGINE
RUNNING)
Cause
ES
Remedy
See M-l 1 -b) Abnormality

air pressure gauge.
in
Replace
1
Does air pressure
gauge move to red
level?
YES
1 )Turn starting
switch ON.
1) Interchange
1
CAUTION
NC
modules 1 and 2.
2lTurn starting
switch ON. (Start
engine.)
Tester
Troubleshooting
tools
T-adapter
POSITION
OF
1) Connect
T-adapter to
CNP7 (female).
2)Turn starting
switch ON.
Defective
2
CAUTION
module
Defective
gauge module
between CNP2 (female) (7)
and CNP7 (female) (3)
NO
Replace
After inspection,
repair (clean) or
replace

(for DLII

(for Econoseall
CONNECTOR
- Procedure No. 2
CNP2
Module 1 and 2
I2
Procedure No. 3
CNP7 (female)
WA500-
82-55
0
e)
(COOLANT
TEMPERATURE)
FLASHES.
Remedy
Cause
YES
L
See M-l l-cl Abnomality

coolant temperature.
Defective
2
CAUTION
Defective
gauge module
in
module
Replace
Repkace
Does coolant
temperature gauge
move to red level?
1)Turn
starting
switch ON.
ND
Replace
and chassis ground
1 I connect
T-adapter to
CNP7 lfemalel.
2)Turn starting
switch ON.
Tester
1Troubleshooting
tools
T-adapter
POSlTlON
-
OF
and CNP7 (female) (71
NO
After inspection,
repair (clean) or

(for DLI)

lfor Econoseal)
CONNECTOR
Procedure No. 2
CNP2
Module 1 and 2
Procedure No. 3
CNP7 (female)
82656
WA500-1
(TORQUE
CONVERTER
OIL
TEMPERATURE)
FLASHES.
Remedy
YES
See M-l 1 -d) Abnormality
torque converter oil
temperature
gauge
Y
1)lnterchange
CAUTION
modules 1 and 2.
2)Turn starting
switch ON.
Ih
I
,
Irl0
3
I
Is voltage between
CNP7 (female) 151
and chassis ground
less than 3.5V?
YES
POSITION
OF
Short socket
T-adapter
T-adapter
or socket
(for Econoseal)
adapter
adapter
CNP2
1 and 2
Procedure
No. 3
CNP7 (female)
WA500-
module
Defective
gauge module
Disconnection
in wirino
and CNP7 (female) (51
CONNECTOR
* Procedure No. 2
Module
Tester
(for DLI)
CAUTION
?eplace
Replace
Replace
1 )Connect
T-adapterto
CNP7 (female).
2)Turn starting
switch ON.
Troubleshooting
tools
Defective
2
in
12
After inspection,
repair Wean) or
replace
TROUBLESHOOTING
CHART
No. M-4.

SWITCH Is TURNED ON (DO NOT START ENGINE),
IN MACHINE,
PILOT ITEM LIGHTS
ABNORMALLY,
OR DOES NOT LIGHT UP.
*
When disconnecting
or connecting
the T-adapter
(or socket
ing the connector
for checking,
turn the starting
When connecting
the T-adapter
When disconnecting
checking,
connectors
or connecting
switch
adapter)
or short socket adapter,
OFF to prevent
connect
T-adapters,
them
or when disconnect-
accidents.
to the connector
return
specified.
to the original
(CNxx
condition
( ))
immediatelv
(P
101
DOES
NOT
GO OUT.
1)Connect
short
ND
1 )Turn starting
switch ON.
Defective
sensor.
parking brake
Defective
2
CAUTION
Is there continuity
between CNP8
(female) (2) and
chassis ground?
YI
3
there continuity
between CN36
(female) (21 and
chassis ground?
1) connect
T-adapter (or
socket adapter)
to CN36
(female) (parking
brake sensor).
2)Turn starting
switch OFF.
1) CO~WZCt short
connector to
CN36 (female)
(parking brake
NO
After inspection.
repair (clean) or
replace
between CN36 (female) (21
and chassis ground
After inspection,
repair (clean) or
replace
2) connect
T-adapter to
CNP8 (femaleI.
OF
Tester
T-adapter

(for Econoseal)
(for DLI)
module
CN38 (4) - CNPS
(female) (2)
See troubleshooting
machine
Troubleshooting
tools
Replace
4 YES
Is
when parking brake

switch is turned to
Remedy
YES
POSITION
for
CONNECTOR

CN36 (female)
Procedure
No. 3
CNP8 (female)
82-58
0
after

Cause
a)
UP
WA500- 1
Id ~@ ~DOES
NOT
LIGHT
UP.
Remedy
Cause
YES
c
Defective
sensor
parking
brake
Replace
2
YES
3when parking brake

switch is turned to
1 )Turn starting
switch ON.
1)Disconnect
connector
CN36.
2)Turn starting
switch ON.
_
NO
YES
Short circuit between

chassis ground and wiring
(female1 (1) - CN38 141 CNP8 (female) (21
IS there continuity
between CNP8
-
;,e~;;;~;$!!,
I)connect
T-adapter
to
CNP8 (female).
2) Disconnect
CN36.
3)Turn starting
switch OFF.
I
NO
NO
Troublleshooting
tools
POSITION
OF
CN36 (female)
Procedure
No. 3
CNP8 (female)
WASOO- 1
Short socket
T-adapter
T-adapter
or socket
(for Econoseal)
(for DLI)
CONNECTOR
* Procedure No. 2
Tester
adapter
adapter
defective
2
CAUTION
See troubleshooting
machine
module
for
After inspection,
epair l&an)
or
eplace
Note:
lf all working
lamp bulbs are broken, or there is defective contact or
a disconnection
q
c)
,,g
in the wiring harness of the working lamp,
(working lamp) will stay on.

DOES
NOT
GO OUT.
Cause
ES
>
*
3
between CNP8
(female) (10) and
CN40 (female) 1517
1) Connect
T-adapter to
CNP8 (female).
21 Turn starting
switch OFF.
Tester
T-adapter
OF
After inspection,
repair (clean) or
replace
Defective
switch
working
RePlace
Defective
2
CAUTION
Disconnection
in wiring
and CN40 (female1 (5)
Table
1 IDisconnect
CN12 (male).
2)Turn starting
switch OFF.
3)Dperate
working
lamp switch.
1) Disconnect
CN40.
PITurn starting
switch ON.
POSITION
Contact between f24V

terminal and working lamp
switch assembly RN1 2 (211
- CN40 (female) (1)
Is there continuity
between CN12
(male)(l)
and (2)
es shown in table?
YI
Troubleshooting
tools
Remedy
YES
1
I
NO
Short socket
(for DLI)
lamp
module
Replace
After inspection,
repair (clean) or
replace
adapter
T-adapter
or socket
(for Econoseal)
adapter
CONNECTOR
- Procedure No. 1
CN40 (female)
82ii60
- Procedure No. 2
CN12 (male)
. Procedure No. 3
CNP8 (female)
16
WA500- 1
d)
,,g
L_i
DOES
NOT
LIGHT
UP.
Cause
Remedy
4 YES
YES
p
3
Isvoltage
between
CN40 (female) (1)
end chassis ground
20 - 3OV!
1)Control
T-adapter
to
CNP8 (female).
2)Turn starting
switch ON.
3)Turn working
lame switch ON.
El
between CN 12
(male)11 and (2)
as shown in table?
1 ITurn starting
switch ON.
Z)Turn working
lamp switch ON.
CN60 (male) (1)

and chassis ground
1)Disconnect
CN 12 (male).
2)Tum starting
switch OFF.
3)Turn working
lamp switch OFF
- ON.
1)connect
T-adapter
(or
socket adapter)
to CN60 Imale).
ZlTurn starting
switch ON.
Defective
2
Disconnection
in wiring
between CN40 (male1 (11
CN40 (5) - CNP (8)
(female) (101
After inspection,
repair (clean1 or
Disconnection
in wiring
contact
fuse - CN60 (2) cN12 - CN40 (female) (1)
After inspection,
repair (clean) or
replace
Is voltage between
CNP8 (female) (10)
and chassis ground
20 - 3OV?
NO
Defective
switch
Replace
working
KSpkNX
lamp
Disconnection
in wiring
between main breaker and
CN60 imale) (1)
module
NIO
CAUTION
After inspection,
repair (clean) or
replace
Table
Working
lamp switch
I
Troubleshooting
tools
T-adapter
POSITION
OF
Procedure
I2
II
i
*
i
Procedure
j
No. 2
CN 12 (female)
WA500-
No. 3
CN40 (female)
CN60 (female)
Procedure
CNP8
adapter
T-adapter or socket
(for Ecooseal)
(for DLII
CONNECTOR
- Procedure No. 1
IO
Short socket
Tester
No. 4
adapter
e)
m
El
LIGHTS
UP.
Cause
VIES
Defective
2
CAUTION
Remedy
module
Replace
2
VI
between CNP8
(female) (31 and
chassis ground less
than lOR?
1
Is resistance
between electrical
1) Connect
T-adapter to
CNP8 (female).
2)Turn starting
switch OFF.
L_.
between electrical intake air
heater - heater relay
terminal - CN97 (9) CN64 (7) - CNPS (female)
(3)
1 ITurn starting
switch ON.
Troubleshooting
tools
POSITION
OF
Tester
T-adapter
T-adapter or socket
(for Econoseall
(for DLI)
Defective
heater
After inspection.
repair (clean) or
replace.
electrical intake air
adapter
CONNECTOR
- Procedure No. 1
Electrical
intake air heater, heater relay
Procedure
No. 2
CNP8 (female)
8222
WA500-
f)
-@jr-7
Note:
DOES
NOT
LIGHT
UP.
If the engine oil pressure and battery

preheating
charge are abnormal,
the
will not work.
I
1
YES
-1Remedv
Cause
Refer to E-l 5
Does
m
rIl
lightup?
1) Disconnect
electrical intake
air heater (+I
terminal.
_
NO
YES
Is there continuity
between CNP8
(female) (3) and
chassis ground?
1 Disconnect
electrical intake
air heater (+)
terminal.
2) Connect
T-adapter
to
CNP8 (female).
C
NO
Contact between +24V

terminal and electrical intake
air heater (+) - CN97 (9) CN64 17) - CN98 Ifemale)
(3)
After inspection,
repair (clean) or
replace.
Defective
2
Replace
CAUTION
POSITION
Short socket
Tester
Troubleshooting
tools
T-adapter
OF
(for DLI)
module
adapter
T-adaotet or socket
(for Econoseal)
adapter
CONNECTOR
* Procedure No. 1
* Electrical
intake air heater
CNP8 (female)
WA500-
82-63
0
g)
l_t0
(FAILURE
IN
MAIN
STEERING)
LIGHTS
UP.
(IF
EQUIPPED)
Remedy
Cause
Defective main steering

failure sensor
3elace
Defective
t
Ieplace
YES
31
ES
1 )Connect short
socket adapter
to CNZOO
(female) (main
steering sensorl.
21 Turn starting
switch ON.
module
_
NO
Is there continuity
between CNZOO
CAUTION
CNP6 (female).
2)Connect short
socket adapter
to CNZOO
(female).
3)Turn starting
switch OFF.
- CN150 (connector) CN45 (female) 11) - CN45
(female) (2) - CNP6
(female) (2). or defective
diode CN145 (male).
After inspection,
repair or replace
between CNZOO (female) (2)
and chassis ground.
After inspection.
repair (clean) or
replace
1 )Connect
T-adapter (or
socket adapter)
to CNZOO
(female).
2)Tum starting
switch OFF.
Troubleshooting
tools
Tester
T-adapter
T-adaoter or socket adapter

(for Econoseal)
(for DLI)
POSITION
CN200
OF
CONNECTOR

(female)
Procedure No. 3
CNP6 (female)
WA500-
h)
(FAILURE
IN
MAIN
STEERING)
DOES
NOT
LIGHT
UP.
(IF
EQUIPPED)
Cause
Does
71
cl
light
up?
YES
_
2
1)Disconnect
CNZOO (female)
(main steering
sensor).
P)Turn starting
switch ON.
OF
Replace
Short circuit between

chassis ground and CNZOO
(female) (1) - CN150
(connector)
- CN45 (1). (2)
- CNP6 (female) (2).
After inspection,
repair (clean) or
replace
Defective
1
Replace
NO
Short socket
Tester
T-adapter
POSITION
Defective main steering

failure sensor
1
1)Connect
T-adapter
to
CNP6 (female).
Z)Turn starting
switch OFF.
Troubleshooting
tools
Is there continuity
between CNP6
(female) (2) and
chassis ground?
Ng
Remedy
(for DLI)
CAUTION
module
adapter
T-adapter
or socket
(for Econoseal)
adapter
CONNECTOR
* Procedure No. 1
CN200
(female)
Procedure
No. 2
CNP6 (female)
WA500- 1
82665
i)
cl
(EMERGENCY
STEERING
NORMAL)
LIGHTS
UP. (IF
EQUIPPED)
l-
Cause
Remedy
Emergency steering
NORMAL sensor defective
Replace
YES
YlES
11Disconnect
CN201 and
CN202
2) Connect CN201
(female) and
CN202 (male1
3)Turn starting
switch ON.
NO
Is there continuity
between CN202
(male connector)
and chassis
ground?
4
1) Turn starting
switch OFF.
Tester
Troubleshooting
tools
T-adapter
POSITION
OF
Defective
1
31
I
T-adapter to
CNP6 (male).
2)Connect CN201
(female) and
CN202 (male).
3)Turn starting
switch OFF.
NO
L
NO
CAUTION
module
c
between chassis ground CN202 (male) - CN201
(female) - CN149
connector - CNP6 (female)
(3)
After inspection,
repair (clean1 or
replace
between CN202 (male)
connector and chassis
ground
After inspection,
repair (clean) or
replace
I
(for DLI)

,fnr Frnnosrall
CONNECTOR
- Procedure No. 1 and No. 2

CN202,
CN201
(female)
-
(male)
Procedure No. 3
CNP6 (female)
82-66
WA500- 1
i)
IV/
u
EMERGENCY
STEERING
NORMAL)
DOES
NOT
LIGHT
UP. (IF
EQUIPPED)
Cause
Remedy
Emergency steering
UORMAL sensor defective
Does V
light
up,
:ontact between chassis

around and CN201 (female)
CN149 (connector)
ENP6 (female) (3)
9
I
1) Disconnect
CN201.
2)Turn starting
switch ON.
4fter inspection.
.epair (clean) Or
replace
Is there continuity
between CNPG
(female) 13) and
chassis ground?
~~~~~me),
Iti_
Defective
NO
CAUTION
module
2)Turn starting
switch OFF.
3)Disconnect
CN201.
Tester
Troubleshooting
tools
T-adapter
POSITION
OF
(for DLI)
T-adapter
or socket
(for Econoseal)
adapter
CONNECTOR
- Procedure No. 2
CNP6
WA500- 1
82-67
0
k, /@I(TRANSMISSION
CUT-OFF)
LlGHTS
UP.
Remedy
Cause
ES
w
Et
Does
go out?
1) Short-circuit
CN18 (female)
(3) and (4).
Z)Turn starting
switch ON.
Is there continuity
between CN18
leplace
YES
STARTING module
31
)
NO
Cut-off switch
ON.
Z)Connect
T-adapter to
CNP4 (femaleI.
3)Turn starting
switch OFF.
and CNP4 (female) (10)
After inspection.
,epair (clean) or
,eplace
between CN 18 (female) (4)
and chassis ground
After inspection.
repair (clean) or
replace
chassis ground?
1 )Turn starting
switch OFF.
Tester
Troublleshooting
took
T-adapter
POSITION
OF
CNI 8 (female)
Procedure

(for Econoseal)
CONNECTOR
* Procedure No. 1
(for DLII
Procedure
No. 3
CNP4 (female)
No. 2
CN18 (male)
82-68
0
WA500-
/Q
I)
(TRAN~MI~~I~N
cm-0~)
0013
NOT
LIGHT
UP.
Cause
Remedy
YES
c
1
YES
light up? _
Does
2
Isthere
1) Disconnect
CN18.
2)Turn starting
switch ON.
N;
continuity
between CNP4
(female) I101 and
chassis ground?
1)Connect
T-adapter to
CNP4 (female).
2)Turn starting
switch ON.
NO
Tester
POSITION
T-adapter
OF
CONNECTOR
* Procedure No. 1
CN18
Procedure No. 2
CNP4 (female)
WA500- 1
(for DLI)
Replace
Contact between chassis

ground and CN18 (female)
(3) - CNP4 (female) (10)
After inspection.
repair (clean) or
replace

STARTING module
Replace
Troubleshooting
tools
cut-off switch

(for Econoseal)
TROUBLESHOOTING
Failuremode:
CHART
No. M-5.
TURN SIGNAL LAMPS, HIGH

OR DO NOT LIGHT UP.
When disconnecting
or connecting
the T-adapter
BEAM
LIGHT
(or socket adapter)
UP ABNORMALLY,
*
When disconnecting
connectors

or connecting T-adapters,
(CNxx
( ))
immediately
after

a)
PILOT
DISPLAY
OF
TURN
SIGNAL
LAMP
(RIGHT)
LIGHTS
UP.
Cause
connect
I)
T-adapter to
CNPlO (female).
2lTurn starting
switch ON.
SITurn turn signal
switch OFF.
b)
PILOT
NO
DISPLAY
OF
TURN
SIGNAL
LAMP
(LEFT)
LIGHTS
1
I
After inspection,
repair (clean) or
replace
Defective speedometer
nodule
Replace
:ontact between +24V

line
md wiring harness between
:NPlO
(female) (I
and
:N15 (male) 6)
After inspection.
repair (clean) Or
UP.
replace
1 )Connect
T-adapter to
CNPlO (female).
2)Turn starting
switch ON.
3)Turn turn signal
switch OFF.
nodule
NO
Tester
Troubleshooting
tools
POSITION

line
and wiring harness between
:NPlO
(female) (3) and
:Nl!i
(male) (3)
1)
Doesvoltage
between CNPlO
(female) (11 and
chassis ground
change between
OV and 20 - 3OV?
Remedy
T-adapter
OF
(for DLI)

(for Econoseal)
CONNECTOR
- Procedure No. 1
CNPIO
82-70
0
(female)
WA500- 1
c)
PILOT
DISPLAY
OF
TURN
SIGNAL
LAMP
(RIGHT)
DOES
NOT
LIGHT
UP.
Cause
2
Does voltage
between CNPlO
(female) (3) and
chassis ground
chanoe between
OV acd 20 - 30V.
1) connect
T-adapter
to
CNPlO (female)
2)Starting
switch
turn ON.
3)Turn signal
switch turn ON.
1 )Operate right
turn signal lamp.
2)Starting
switch
turn ON.
T-adapter
OF
CONNECTOR
* Procedure No. 2
CNPIO
WASOO-
(for DLI)
- [defective
speedometer
7eplace
I nodule
I
NO
Tester
Troubleshooting
tools
POSITION
YES
T-adapter
or socket
(for Econoseal)
adapter
IIefective
contact, or
cjisconnection
in wiring
I?amess between CNPlO
/[female) (3) and CN15 (male)
,13).
&fter inspection.
,epair (clean) or
.eplace
Defective
Replace
turn signal
d)
PILOT
DISPLAY
TURN
0~
SIGNAL
LAMP (LEFT)
DOES NOT LIGHT
YES
voltage
YES
,
_
DO front and rear

turn signal lamps
normally?
work
1)
Operate left turn

signal lamp.
2)Starting
switch
turn ON.
Does
between CNPlO
(female) (3)and
chassis ground
change between
OV and 20 - 30V.
Defective
module
speedometer
Remedy
Replace
*
NO
disconnection
in wiring
harness between CNPl 0
Ifer$;g\l
and CNl5
m
After inspection.
repair (clean) or
replace
1)
Defective
turn signal
Tester
Troubleshooting
to015
POSITION
Cause
1)~~~~~~~
T-adapter
to
CNPlO (femaleI.
2)Starting
switch
turn ON.
SITurn signal
switch turn ON.
UP.
T-adapter
OF
(for DLII
T-adaoter or socket adapter

(for Econoseal)
CONNECTOR
- Procedure No. 2
CNPlO
82-72
0
(female)
WASOO- 1
e)
HIGH
BEAM
PILOT
LAMP
DOES
NOT
LIGHT
UP.
Cause
nodule
1 ;;dch;&&ground
JL
Do both left and

right head lamps
1)Connect
NO
Tester
Troubleshooting
tools
T-adapter
OF
(female)
WA500-
(for DLI)
CONNECTOR
* Procedure No. 2
CNPIO
3efective contact, or
jisconnection in wiring
?arness between CNPlO
[female) (4) and CN39
(female) (1 I.
bulbs broken in both head

amps (low beam lamps) (If
he low beam bulb is broken,
he pilot lamp will not light up
?ven if the switch is turned to
iIGH BEAM.)
T-adapterto
CNPlO (female).
2)Turn starting
swtch ON.
3)Turn
combination
switch to head
lamp position.
4)Turn dimmer
;&My
to HIGH
1 )Turn starting
switch ON.
Z)Tllrn
combination
switch to head
lamp position.
3)Turn dimmer
switch to LOW
BEAM.
POSITION

lfor Fmnos~al~
4fter inspection,
.epair (clean) or
f)
HIGH
BEAM
PILOT
LAMP
DOES
NOT
GO OUT.
Cause
Defective
module
disconnection in wirina
harness between CN 1%
(female) (9) and dimmer
switch
After inspection.
repair (clean) or
replace.
harness between CNlb
(female) (12) and dimmer
switch
After inspection.
repair (clean) or
replace.
1
Do both left and
right head lamps
light up?
speedometer
Replace
YES
I
1 )Turn startino
switch ON. 2)Turn
combination
switch to head
lamp position.
3)Turn dimmer
switch to LOW
BEAM.
YES
N
Is there continuity
between CN 15
(male) (12) and
chassis ground?
I
1 )Turn starting
switch ON.
2lTurn
combination
switch to head
lamp position.
3)Turn dimmer
switch to HIGH
BEAM.
h
I
1 I connect
T-adapter (or
socket adapter)
to CN15 (male).
2)Starting switch
turn OFF.
I
NO
(male) (12) and chassis
ground
After inspection,
repair (clean) or
replace.
Tester
Troubleshooting
tools
T-adapter
POSITION
Remedy
OF
(for DLII

(for Econoseall
CONNECTOR
- Procedure No. 2
CNI 5 (male)
82-74
0
WA500-
TROUBLESHOOTING
CHART
Failure mode: SPEEDOMETER
DISPLAY
When disconnecting
or connecting
No. M-6.
DOES NOT WORK
the T-adapter
(or socket adapter)
NORMALLY.
*
When disconnecting
T-adapters,
(CNxx
( ))
immediately
after
Cause
Remedy
4 YE:
Is resistance
between CN22
(female) (3) and (4)
3OOfl - lkfi?
between CN83
(male) (1) and (2)
3OOfI - lkfi?
1) Connect
T-adapterto
CNPlO (femaleI.
21 Turn starting
switch OFF.
1) Connect
T-adapter (or
socket adapter)
to CN22 (female)
2)Turn starting
switch OFF.
1) Connect
T-adapter (or
socket adapter)
to CN83 (male).
2)Turn starting
switch OFF.
* Loosen the lock nut

of the speed sensor.
and turn the sensor
clockwise. If it
contacts the gear
within one turn. the
gap is within 1.5 mm.
L
N
NO
Defective
module
speedometer
ReDlace
Defective
mount
speed sensor
Adjust
between CNPlO (female)
(101. (2) - CN22 (3). (4) CN83 (female) I1 ), (2).
lfter inspection,
.epair (clean) or
aplace
Iisconnection in wiring
Barnes% or defective contact
retween CN22 lfemalel (31.
41 - CN83 (11, (2).
jfter inspection.
,epairor
,eplace.
Defective speed sensor
Tester
Troubleshooting
tools
T-adapter
POSITION
OF
WA500- 1

(for Econoseall
CONNECTOR
* Procedure No. 1
CN83 (male)
(for DLI)
Procedure No. 2
CNPlO
(female)
TROUBLESHOOTING
Failure mode: SERVICE
*
When disconnecting
CHART
METER
or connecting
No. M-7.
DOES NOT WORK

the T-adapter
NORMALLY.
(or socket adapter)
*
When disconnecting
(CNxx
( 1)
immediately
after
Cause
ES
.
Defective engine oil pressure

sensor.
E
.
Defective
module.
service meter
Does service meter

move, or display
1)Connect
short
socket adapter
to CN163
(female) (engine
oil pressure
sensor).
21 Turn starting
switch ON.
1 2
II
YE
'ES
IO
k there continuity
CN163 (female)
(21 and chassis
ground?
Is there continuity
CNP9 (female) (4)
and chassis
1)connect
T-adapter CNPg
(female).
2)Turn starting
switch ON.
1)Connect
short
socket adapter
to CN163
(female).
2)5onect
I -aaaprer to
CNP9 Ifemale).
3JTurn starting
swtch UFF.
-__
Is voltage between
CNP9 (female) (1)
and (3) 20 - 3OV?
.,
IN
NO
Troublleshooting
tools
Tester
T-adapter
82-76
0
NC
Disconnetion in wiring
between CN43 (male) (1)
and CNP9 (female) (1). (3).
After inspection,
.epair (clean) or
oetween CN163 (female) (1)
- CNg7 (8) - CN64 (11)
CNP9 (female) (4).
After inspection.
repair (clean) or
replace.
- CNg7 (male) (1 7) chassis ground
After inspection,
vepair (clean1 or
replace.

(for DLI)

(for Econoseal)
WA500- 1
POSITION
OF
CONNECTOR
- Procedure No. 2
CN43 (female)
Procedure No. 3
CNP9 (female)
Procedure No. 4
CNI 63 (female)
WA500-
82677
TROUBLESHOOTING
CHART
Failure mode: ABNORMALITY
IN MONITOR
When disconnecting
No. M-8.
PANEL.
(or socket adapter)
ing the connector for checking turn the starting switch OFF to prevent accidents.
*
When
connecting
the
T-adapter
(CNxx
When
connectors
disconnecting
to the original condition
(or socket
adapter),
connect
to the
( ))
connector specified.
or connecting
immediately
T-adapters,
return them
Cause
after checking, then go to the next
Remedy
check.
a)
NONE
OF
MONITOR
d-
-_
PANEL
-Y
T-adapter
WORKS.
YES
\IES
I
YES
Is voltage between
CN43 (female) (1)
and (4) 20 - 3OV?
Is voltage batwaa
CN41 (female) (1)
and (2) 20 - 3OV7
1 I Connect
T-adapter (or
socket adapter)
to CN43
(female).
2lTurn starting
switch ON.
1) Connect
T-adapter (or
socket adapter)
to CN41
(female).
2)Turn starting
switch ON.
\fter inspection,
apair (clean) or
One of modules defective.

(Contact connactors in turn.
lf there is no voltage for any
module, check it.)
after inspection,
epair (clean) or
eplace
Short circuit batwean CN43

connector (1) and (4) (Power
shut off to protect controller).
ifter inspection,
epair (clean) or
- all
Is voltage between
CN43 (male) (1)
and (4) 20 - 3OV?
2
1
Imale) (1)
modules
(+24),
and CN43 (male) (4)
- all modules (ground
connection).
Is voltage between
CN43 (male) (1)
and (4120 - 3OV7
1) Connect
T-adapter to
CN43 kaleL
2)Turn starting
switch ON.
T-adapter to
CN43 (male).
2) Disconnect
connectors
(CNPl, P4. P6,
P8, Pg and
3)Tum starting
switch ON.
i1
.._
Nb
1
I
Pl0).
II
P_
--
Auxiliary controller defective
YES
NO **
1) Connect
T-adapter (or
socket adapter)
to CN41
(female).
P)Turn starting
switch OFF.
NO
Socket adapter
I
YES;
c
I
--
Is there continuity
betweenCN43
(male) (1) and (4)?
1) Disconnect
connectors
(CNPl, P4, P6,
PS, P9 and Pl 01.
2)Connect socket
to CN43 (male).
3)Turn starting
switch OFF.
Table 1
CNPl
CN43 connector
(male1 (4)
- (8)
CN43 connector
(female) (1)
82-78
a
(4)
CNP4
CNP6
- (8)
- (8)
-(161
i 6)
CNP8
NO
-
rfter inspection,
epair (clean1 or
eplace
3ne of modules defective

Iconnect connectors one at a
:ime to check)
CNP9
CNPlO
- (8)
- (3)
-cl61
-(16)
-_(l)
- (8)
rfter inspection,
epair (clean) or
eplace
Connect
to NP
CN43 connector.
Connect sockets
to CNP
coectors.
--_
between CN41 (female) (21
ground
Is the continuity
between CN43
(male) connector
(4) and (1) and all
connectors in table
b&W?
1)
tfter inspection,
epair (clean) or
eplace
(female) (1) and (4).
YES
between CN41 - (female)
(1) - CN60 (6) - fuse CN60 (5) - fuse - main
breaker.
&
(male) 11)
all modules
(+24).
and CN43 (male1 (41
all modules (ground
connection)
,fter inspection.
.epair (clean) or
.eplace
c)
EVEN
SURE)
LAMP
WHEN
ENGINE
FLASHES,
ALSO
IS STOPPED,
CAUTION
LIGHTS
BUZZER
(ENGINE
ke.
SOUNDS
AND
OIL PRESWARNING
UP.
Cause
Remedy
YES
w
Defective
alternator
Reolace
YES
terminal
R.
2lTum starting
Switch ON. (Do
POISITON
OF
)~%%%?
2)CHECKS.
CAUTION
1 and
CAUTl6N
2
modules are
interchangeable,
so interchange
them.
BITurn starting
switch ON.
(Leave terminal R
disconnected)
not start engine.1
-_

terminal and alternator
terminal R - CN97 (1) CNP3, P5, P7
EF; (
After inspection,
repair (clean) or
replace
CONNECTOR
- Procedure No. 2
Module 1,2
WA500- 1
82-81
0
d)
EVEN
WHEN
FLASHES
ENGINE
AND
STOPPED,
WARNING
LAMP
I(BATTERY
L-J
LIGHTS
UP.
CHARGE)
Cause
Remedy
YES
c
Defective engine oil pressure

sensor
ReplaCe
Defective
Replace
---z--II
jC_I!goout?
H
YES
module
does
1)Disconnect
CN163 (engine
oil pressure
sensor).
2)Turn starting
switch ON.
POSITION
-
OF
Is problem
removed when
modules are
interchanged?
NO
,
1) Turn starting
switch OFF.
2)CHECKS.
CAUTION 1 and
CAUTION 2
modules are
interchangeable,
so interchange
them.
3)Turn starting
switch ON.
NO
NO
Procedure No. 2
Module I,2
LAMPS
ON,
(1)
After inspection.
repair (clean) Or
replace
CONNECTOR
Procedure No. 1
CN163
e)
contact
between chassis
ground and CN163 (female)
(1) - CN97 (8) - CN64 (6)
CNP3 (2). CNP5 (2).
cNP7 (2).
ON
ENGINE
MONITOR
LIGHTS
UP (IMMEDIATELY
AFTER
TURNING
STARGING
SWITCH
TO
STOPPED.)
No lamps on any module light up when starting switch is turned ON.

All lamps go out when engine is started.
See M-8-a).
(2)
b). cl. d)
Lamps on some modules do not light up.
Defective
8222
module
WA500- 1
f)
MONITOR
DISPLAYS
WARNING
LAMP
NO ABNORMALITY,
LIGHTS
BUT
CENTRAL
UP INTERMITTENTLY.
Remedy
Cause
warning
2)Start
1) Disconnection
CN43.
2)Start engine.
Tester
(for Econoseal)
POSITION
OF
CONNECTOR
* Procedure No. 1
CN43
Procedure
No. 2
CNP7
WA500-
Defective
module
CAUTlON
Defective
auxiliary
lepkG3
engine.
T-adapter
CAUTION
lamp go
in
Troubleshooting
tools
Defective
nodule
* CN17
controller
Replace
Replace
g)
CENTRAL
WARNING
LAMP
LIGHTS
UP CONTINUOUSLY.
Remedy
Cause
YES
2
Does Central
warning lampgo
out?
YES
-
1 Disconnection
CNP7.
PIStart engine.
Defective
module
CAUTION
Replace
Defective
module
CAUTION
ReplaCe
in
NO

ground and wiring harness
and CN17 (female) (2)
After inspection,
repair Wean) or
replace
Defective
Replace
1)Connect
T-adapter (or
socket adapter)
to CN42 (male).
2)Turn starting
switch OFF.
Tester
Troubleshooting
tools
POSITION
-
Procedure
T-adapter
OF
Procedure
auxiliary controller
I
(for Econoseal)
CONNECTOR
No. 1
CN43
NO
Procedure
No. 3
CN42 (male)
No. 2
CNP7
82b84
WA500- 1
h)
MONITOR
DISPLAYS
WARNING
BUZZER
NO ABNORMALITY,
SOUNDS
BUT
CENTRAL
INTERMITTENTLY.
Cause
ES
1 )Disconnectlon
CN43.
21 Start engine.
CAUTION
lefective
auxiliary
Replace
in
L
IO
controller
Replace
Tester
Troubleshooting
tools
POSITION
defective
nodule
Remedy
T-adapter
or socket
(for Econoseal)
OF
adapter
CONNECTOR
- Procedure No. 1
CN43
WA500-
82-85
0
i)
CENTRAL
WARNING
BUZZER
SOUNDS
CONTINUOUSLY.
Remedy
Cause
YES
Defective
2
1
Does central
warning buzzer
stop?
1)lI~I3~tion
YES

and CN131 (malel.
Defective
continuity
between CN42
(male) (3) and
chassis ground?
Nt
2)Start
engine.
module
Isthere
in
CAUTION
Replace
After inspection,
repair (clean) or
replace
1 Connect
T-adapter
(or
socket adapter)
to CN42 (male).
2)Turn starting
switch OFF.
Tester
POSlTlON
-
Procedure
T-adapter
or socket
(for Econoseal)
OF
Procedure
controller
adapter
CONNECTOR
No. 1
CN43
auxiliary
Troubleshooting
t001.5
*
NO
Module
Module
No. 2
CN42 (male)
82-86
0
WA500-
TROUBLESHOOTING
CHART
IN PANEL
When disconnecting
No. M-9.
LAMPS
ON MONITOR.
(or socket adapter)
ing the connector for checking,
turn
When disconnecting
the starting
OFF to prevent accidents.
switch
(CNxx
( ))
immediately
after

Cause
a)
NO
IN
PANEL
LAMPS
LIGHT
COMBINATION
UP EVEN
LAMP
WHEN
ONLY
SMALL
IS USED.
YES
(female) (1)
CNPl (female) (3).
CNP4 (female) (15).
CNP6 (female) (15).
CNP8 (female) (15).
CNP9 (female) (2).
CNPlO (female) (15).
in a rare case, all panel
lamps may be broken)
After
inspection,
repair (clean)
or replace
contact between CN15
(male) (8) - CN58 (1 1 I,
(12) - CN26 (female)
(2). or defective diode
assembly
After
inspection.
repair (clean)
Disconnection in wirina
harness, or defective contact between CN15
(female) 14) - front
lamp and parking lamp
switch - CN15
(female) (8). or
defective switch
After
inspection,
repair (clean)
or replace
Defective contact of
front lamp and parking
lamp switch
Replace
contact between
batWrY relay output CN59 (1). (2) - CN15
(male) (4)
After
inspection,
repair (clean)
or replace
Defective front lamp

and parking lampswitch
Replace
and chassis ground
_--
T-adapter
YES
I
1
dI
1 Connect
T-adapter (or
socket adapter)
to CN15 (male).
21 Turn starting
switch ON.
Hi
--II
1)Connect
ground with
diode assembly
still connected.
3)Twn starting
switch ON.
YES
Is there continuity
between T-adapter
CN15 (female) (4)
I!
NO
and chassis
~.-
T-adapter to
CN15 (male).
2)Turn starting
switch ON.
3) Turn
combination
lamp switch to
side lamps.
Is voltage between
CN15 knale) (2)
and chassis ground
20 - 3ov7
2)Check voltage
between CN26
(female) wiring
harness end (1)
.-,
Is voltage between
CNlf
Imalel ISI
L
and cnass~s
y-round
203ov7
Remedy
LAMP
CN15 (female).
2)Turn starting
switch OFF.
Combinatuon
lamp switch
continuity
1
I
w
NO
Combitiona
switch
lamp
1
Continuity
p$q-y--,,
Table 1
YES
Socket adapter
CN15 (female)
and (8)?
1 )Connect
Tostep
(4)
I
socket
Tester
Troubleshooting
tools
T-adapter
82-88
CD
:,
or socket adapter
(for DLII

ifor Econoseal)
WA500-
POSITION
OF
CONNECTOR
- Procedure No. 1
Procedure No. 2
When using T-adapter.
When using socket adapter.

CN15 (female)
Procedure No. 3
CN26 (female)
WASOO-
Procedure No. 4
CNI 5 (female)
CNI 5 (male)
b)
NO
PANEL
LAMPS
SWITCHED
LIGHT
UP EVEN
WORKING
LAMP
IS
ON.
Cause
Remedy
YES
After inspection,
repair (clean) or
replace
harness between CNf5
(female) (1)
CNPl
(female) (3). CNP4
(female) (I 5). CNPG
(female) (15). CNPB
lfemalel I1 5); CNP9
(female) 12). CNPlO
(female) (15)
3
YES
2 1
YES
1
CN 12 (female) (1)
and chassis ground
20 - 3OV?
1 )Turn starting
switch ON.
2) CN 1 2 still
connected.
Is voltage between
CN12 (female) (2)
and chassis ground
20 - 3OV?
1 )Turn starting
switch ON.
2)Turn working
lamp switch ON.
3)CNl 2 still
IS VOltage betV4e.S
CN25 (female) (1)
and chassis ground
203OV?
(In a rare case. all panel lamps

may be broken)
11
Turn working
lamp switch ON.
2)Check voltage
between CN25
(female) wiring
harness end (1)
>
NO
between CN12 (female) 121
- CN40 (11 - CN40 15) CN25 (female1 (2). or
defective diode assembly.
After inspection,
repair (clean) Or
replace
working lamp switch CN12 (male) (2). or defective
working lamp switch
After inspection,
repair (clean) or
replace
between battery relay output
- CN60 (1). (2) - CN12
(female) (1
After inspection,
repair (clean) or
replace
Table 2
Tester
Troubleshooting
tools
POSITION
-

lfnr Ernnncrall
OF
CONNECTOR

CNI 2 (female)
82$o
Procedure No. 3
CN25 (female)
WA500- 1
c)
PANEL
LAMPS
OF
GAUGE
MODULE
DO
NOT
LIGHT
UP.
Cause
YE
Remedy
IIefective
lamp
qeplace
Defective
gauge module
Replace
Is lamp bulb
bracken?
Is voltage between
CNPl (female) (3)
and chassis ground
20 - 3OV
1) Remove lamp
Socket
tl
Ot rrIOdule
and check
resistance of
small bulb.
If it is over
1000,
bulbis
broken.
1 I Connect
T-adapter to
CNPl (female).
2)Turn starting
switch ON.
3) Turn light switch
NO
Tester
Troubleshooting
tools
T-adapter
POSITION
-
CNPI
OF
CONNECTOR
(female)
WA500-
(for DLI)

(for Econoseal)
- CN25 (female) (1) CNPl (female) (3) - CNP4
(female) (15) - CNPG
(female) (151 - CNP
(femalej il51 - 6NP9
(female) (2) - CNPlO
(female) (151
After inspection,
repair (clean) or
replace
d)
PANEL
LAMPS
MODULE
DO
OF
NOT
CHECKS,
LIGHT
CAUTION
1 AND
2, SPEEDOMETER
UP.
Remedy
Cause
YES
*
Iefective
lamp
Defective
module
Gplace
2
1
chassis ground and
COeCtOr Of
module which does
not light up 20 3OV? (Refer to
1)
1) Remove lamp
socket of module
and check
resistance of
small bulb. If it is
over 1000,
bulb
if broken.
Connect
T-adapter
to
cOectOr of
module which
does not light up.
2)Turn starting
switch ON.
3)Turn light switch
ON.
Procedure
Iisconnection
in wiring
wness, or defective contact
)etween CN26 (female) (1)
CN25 (female) (1) :NPl (female) (3) - CNP4
female) (15) - CNP6
female) (15) - CNP8
female) (15) - CNP9
female) (2) - CNPl D
female) (15)
4fter inspectlon,
.epair (clean) or
Tester
Troubleshooting
took
POSITION
?eplace
T-adapter
OF
(for DLI)
CONNECTOR
No. 1
CNP4 (female)
CNP8 (female)
CNP6 (female)
CNPI 0 (female)
82zf2
WA500-
e)
PANEL
LAMPS
OF
SERVICE
METER
DO
NOT
LIGHT
UP.
Cause
Is voltage between
CNP9 (female) (2)
and chassis ground
20 - 3ov7
1)
Is lamp bulb broken?
lamp
Defective
IllodlJle
service meter
Disconnection
in wiring
CN25 (female) (1)
CNPl (female) 13) - CNP4
(female) (15) - CNP6
(female) I1 5) - CNPS
(female) (15) - CNPs
(female) (2) - CNPlO
(female) (15)
l----4
YES
,
Defective
1)Remove
lamp
socket of module
and check
resistance of
small bulb.
If it is over
10021,bulbis
broken.
connect
T-adapter
to
CNP (female).
2)Turn starting
switch ON.
3)Turn light switch
ON.
NO
NO
Tester
Troubleshooting
tools
POSITION
T-adapter
OF
CONNECTOR
- Procedure No. 1
CNP9 (female)
CNPl
WA500-
(for DLI)
T-adapter
or socket
(for Econoseal)
adapter
Replace
After inspection,
repair (clean) or
replace
TROUBLESHOOTING
CHART
No. M-10.
Failure tiode:
IN ALARM
BUZZER
ABNORMALITY
When disconnecting
OR WARNING
(or socket adapter)
LAMP.
ing the connector for checking, turn the starting switch OFF to prevent accidents,
*
When disconnecting
connectors
or donnecting
T-adapters,
(CNxx
( ))
immediately
after

a)
EMERGENCY
NOT
ITEMS
IS FLASHING,
BUT
ALARM
BUZZER
DOES
SOUND.
Remedy
Cause
YES
defective
buzzer
leplace
Does voltagebeJw_Een
YES CN130 (female) and
- CN13 1 %naieI
change between
OV and 20 - 3OV?
1 )Disconnect
CN130.131
(buzzer
connector).
2) Disconnect
CN107 (coolant
level).
3)Turn starting
switch ON.
(Start engine.)
Does voltage
between CN42
change between
OV and 20 - 3OV?
1
L
NO
lfter inspection,
,epair (clean) or
eplace
Defective module
qeplace
)Connect
T-adapter
(or
socket adapter)
to CN47.
(female).
21 Disconnect
CN107 (coolant
level).
3)Turn starting
switch ON.
4) Start engine.
YES
YES
NO
Does caution
buzzer sound when
CN43 (female) (1)
and (2) are
short-circuited?
1 IStop engine.
2)Short-circuit
when CN43
(female) (1) and
(2).
3)Turn starting
switch ON.
Iisconnection
in wiring
aarness, or defective contact
IN1 30 (female), or CN42
male) (2) - CNl 31 (male)
4-
removed when
modules are
replaced?
1 )Interchange
emergency
display item
CAUTION
module and
CHECK module.
ilTuro
starting
switch ON.
The voltage, can be checked in parking, FORWARD
Xsconnection
in wiring
Tarness, or defective contact
oetween CNP7 (female) (8)
and CN43 (male) (2)
ifter inspection,
epair (clean) or
replace
Defective auxiliary controller

or contact between CN42
(CN42 (female) (1) and (2)
are in contact, so protection
device in auxiliary controller
is actuated.)
Replace
(repair or replace)
and REVERSE
positions, and when the power is ON (starting switch at ON).
Short socket
Tester
Troubleshooting
tools
82z4
T-adapter
(for DLI)
adapter
T-adapter
or socket
(for Econoseal)
adapter
WA500-1
POSITION
-
Procedure
OF
CONNECTOR
No. 1
CN42 (female)
Procedure
No. 2
CN130.131
WA500- 1
Procedure
No. 3
CN43 (female)
b)
EMERGENCY
BUT
ITEM
WARNING
OR
LAMPS
NON-EMERGENCY
DOES
NOT
ITEM
IS FLASHING,
FLASH.
Remedy
Cause
YI
lefective lamp
YI
between CN17
change between
OV and 20 - 3OV?
1 )Turn starting
switch ON.
2)Disconnect
CN107 (coolant
level).
3)Start engine.
D isconnection in wiring
h;arnes?., or defective contact
bletween CN42 (male) (1)
C N17 (female) (1). or CN43
ale) (3) - CN17 (female)
Iz!I
4fter inspection.
epair (clean) or
eplace
D efective module
+olace
ClDntact with chassis ground.

h;>rness between CNP7
emale) (4) - CNP5
1::emale) (4) - CNP3 (male)
(?I)
A .uxilian/ controller defective

0 rcontact between CN42
(f emale) (1) and (3)
NO
voltage
Does
between CN42
lfemalel (1) and (3)
change between
OV and 20 - 3OV?
1 )Connect
T-adapter (or
socket adapter)
to CN42
(female).
2) Disconnect
CNlO?
(coolant
levell.
3)Turn starting
switch ON.
41 Start engine.
4YES
3
I
NC
Does warning lamp

light up?
YES
Is problem
removed when
modules are
replaced?
1 jinterchange
module which
does not light up
with other
module.
2)Turn starting
switch ON.
1 )Stop engine.
2)Connect
T-adapter (or
socket adapter)
to CN43
(femaleI.
3) Short-circuit
CN43 (female)
(1) and (3).
7eolace
The voltage can be checked
0,
&fter inspection,
.epair (clean) or
replace
(CN42 (female) (1) and (3)

are in contact, so protection
device in auxiliary controller
is actuated.)
I
when the power is ON (starting
switch
at ON).
Troubleshooting
tools
**iY
Tester
(for Econoseal)
WA500-
pOSITION
OF
CONNECTOR
Procedure
No. 1
CN42 [female)
Procedure No. 2
CN17 (female)
WA500-1
Procedure
No. 3
CN43 (female)
TROUBLESHOOTING
CHART
IN GAUGE.
When disconnecting
No. M-l 1.
(or socket adapter)
*
When disconnecting
T-adapters,
(CNxx
( ))
immediately
after

(FUEL
a)
i)
GAUGE)
Nothing shown in display area.
Cause
ES
1
Does fuel gauge
show FULL?
YES
there continuity
between CNP2
;f,e2~;le) 16) and
1 )Connect
T-adapter to
CNP2 (female).
2) Connect short
connectore to
CN266 (female).
3)Turn starting
switch OFF.
T-adapter
OF
Defective gauge module
CN64 (4) - CNP2
liemale) (6). or CN105
(female) (1)
CN64 (3) CNPP (female) (12)
I
NO
After inspection.
repair (clean) or
replace
(for DLI)
CONNECTOR
* Procedure No. 1
CN266
Ieplace
level sensor
Tester
Troublleshooting
tools
POSITION
Defective
fuel
Is
_
short
socket adapter
to CVN266
(female) (fuel
level sensor).
2)Tum starting
switch ON.
NO
1)Connect
Remedy
Procedure No. 2
CNP2 (female)
(female)
8228
WA500- 1
ii)
Stays at FULL and does not move.

Cause
Does all of display

area for fuel gauge
NO
Is
there continuity
between CNP2
r2y;lel
(61 and
1 Disconnect
CN266 (fuel
level sensor).
2)Turn starting
switch ON.
Taster
Troubleshooting
tools
T-adapter
OF
(female)
Procedure
No. 2
CNP2 (female)
WASOO-
(for DLI)
CONNECTOR
. Procedure No. 1
CN266
>efective fuel level sensor
teplace

jround and wiring harness
letwean CNP2 (female1 (6)
- CN64 (4) - CN266
female) (2). CNP2 (female)
121CN64 (31CN266
female) (1)
Sfter inspectiOn.
epair (clean) or
xplace
defective gauge module
Replace
3)Turn starting
switch OFF.
POSITION
Remedy
i)

Cause
Does air pressure

gauge display top
position?
1)Connect short
connector to
CN92 (air
pressure sensor)
2)Turn starting
switch ON.
T-adapter
to
CNPZ (fernaM.
2)Connect
short
socket adapter
to CN92
(female).
3)Turn starting
switch OFF.
POSITION
T-adapter
OF
Defective
air pressure
Sensor
Defective
gauge module
Disconnection
in wiring
between CN92 Ifemale) (1)
CN63 11)
CNPZ
(female) (9). or CN92
(female) 12) - CN62 I1 0) CNP2 (female) (4)
NO
Short socket
Tester
Troubleshooting
tools
Remedy
teplace
+aplace
4fter inspection.
.epair Wean) or
.eplace
adapter
(for DLI)
CONNECTOR
- Procedure No. 1
- Procedure No. 2
CN92 (female)
CNPZ (female)
82200
WA500-
ii)
Stays at top level and does not move.
Cause
YES
Does all of display

area for air
pressure
gauge90
NO
IS there continuity
between CNP2
Kyle)
(41 and
1)Disconnect
CN92 lair
pressure sensor1
2)Turn starting
switch ON.
Remedy

Iround and wiring harness
)etween CNP2 (female) (91
- CN63 (1) - CN92
female) (1). or contact
between chassis ground and
viring harness between
:NP2 (female) (4) - CN62
10) - CN92 (female) (2)
After inspection.
repair (clean) or
Replace
1) Connect
T-adapter to
CNP2 (female).
2);W;oyction
3)Turn starting
switch OFF.
Tester
Troubleshooting
tools
T-adapter
POSITION
OF
NV
(for DLI)
CONNECTOR
- Procedure No. 1
CN92
WA500-
- Procedure No. 2
CNP2 (female)
82-101
0
c)
i)
(COOLANT
TEMPERATURE
GAUGE)
Nothing shown in display area

Cause
Remedy
lefective coolant
5mperature sensor
I
YES
COOLant
Does
temperature gauge
display bottom
position?
1 )Disconnect
CNl 01 (coolant
temperature).
2)Turn starting
switch ON.
NO
Is there continuity
between CNPZ
(female) (41 and
(lOI?
11 Connect
T-adapter to
CNP2 (female).
2) yu&yct
SITurn starting
switch OFF.
POSITION
T-adapter
OF
82-102
0
Iefective
3eDlace
gauge module
NO
(for DLII
CONNECTOR
- Procedure No. 1
CNIOI
after inspection.
epair (clean) or
eplace
Tester
Troublleshooting
tools
:ontact with wiring harness

between CNl 01 (female) (1)
- CN97 (3)CN62 (9):NP2 (female 1 (101 and
:NlOl
(female) (2) - CN97
2) - CN62 (lOICNP2
female) (4)
(female)
- Procedure No. 2
CNP2 (female)
WA500-
ii)
Stays at bottom
position and does not move.
Cause
YES
11
Does all of display
area for coolant
temperature gauge
YES
goout?
1)Connect
Remedy
Defective coolant
temperature sensor
Replace
Defective
Replace
gauge module
Is
short
socket adapter
toCNlO1
,1._._1_1
there continuity
betweenCNP2
(female) (4) and
(lo)?
_
NO
\TWdll,.
2)Turn starting
switch ON.
-------I1) connect
T-adapter to
CNPP (female).
21 Connect short
connector to
CNI 01 (female)
3lTurn starting
switch OFF.
POSITION
T-adapter
OF
(female)
WA500-
(for DLll
CONNECTOR
- Procedure No. 1
CNlOl
After inspection,
repair (clean) or
replace
Tester
Troubleshooting
tools
between CNP2 Ifemale) I1 0)
- CN62 (9) - CN97 (3) CNlOl
(female) (l),orCN92
(female) 14) - CN62 (10) F2y9? (2) - CNl 01 (female)
NO
Procedure
No. 2
CNP2 (female)
82iAo3
d)
i)
w
b
(TORQUE
CONVERTER
OIL
TEMPERATURE
GAUGE)
Cause
Remedy
temperature gauge
display bottom
I
1)
After inspection,
repair (clean) or
reolace
Replace
T-adaoter
NO
Tester
OF
Contact with wiring harness

Detween CN84 (female) 11)
CN22 (1)
CNP2
(female) (1 1). or CN84
(female) (2) - CN22 (2) ENP2 (female) (5)
connect
T-adapter to
CNP2 (female).
2)Disconnection
CN84.
3)Turn starting
switch OFF.
Troubleshooting
tools
POSITION
Replace
Is there continuity
between CNP2
(female) (5) and
converter oil
temperature).
2)Turn starting
switch ON.
Iefective torque converter

%I temperature sensor
(for DLI)
CONNECTOR
* Procedure No. 1
Procedure No. 2
CNP2 (female)
CN84 (femakj
12
822
O4
WA500-
,ii)
Stays at bottom
position and does not move.
Cause
Remedy
Defective torque convert3

oil temperature
*ensOr
bOk.2
Defective
?epIace
Does
allof
display
area fortorque
I I
1)connect
2)i&
starting
switch ON.
T-adapter
to
CNPP (female).
2) Connect short
socket adapter
to CN84
(female).
3)Turn starting
switch OFF.
T-adapter
OF
Disconnection
in wiring
- CN22 (1) - CN84
(female) (1 I, or CNP2
(female) (51 - CN22 (2) CN84 (female) (2)
NO
Short socket
Tester
Troubleshooting
toots
POSITION
After inspection.
repair (clean) or
replace
adapter
lfor DLI)
CONNECTOR
* Procedure No. 1
- Procedure No. 2
CN84 (female)
CNP2 (female)
WA500-
gauge module
82-105
0
TROUBLESHOOTING
CHART FOR ELECTRONIC
VEHICLE MONITORING
SYSTEM
(Serial No. 10663
and UP)
. . . . _. . . . . . . . . . .
. 82-108-l
82-110
..........................
82-110
M- 2. (ENGINE OIL LEVEL) flashes when engine is stopped .........................
WATER LEVEL) flashes when engine is stopped ....................
82-112
M- 3. (RADIATOR
CHARGE) flashes when engine is running. .........................
82-112
M- 4. (BATTERY
OIL FILTER CLOGGING)
flashes when engine is running ..........
82-114
M- 5. (TRANSMISSION
82-116
M- 6. (FUEL LEVEL) flashes when engine is running ..............................
flashes when engine is running .......................
82-116
M- 7. (BRAKE LINE FAILURE)
flashes when engine is running
82-118
M- 8. (ENGINE OIL PRESSURE)
......................
WATER LEVEL) flasheswhen engine is running ....................
82-118
M- 9. (RADIATOR
(DROP IN Al R PRESSURE) flashes when engine is running ......................
82-120
M-10.
flasheswhen engine is running ................
82-120
M-l 1. (ENGINE WATER TEMPERATURE)
(TORQUE CONVERTER
OILTEMPERATURE)
flasheswhenengine
is running ........
82-120
M-12.
BRAKE) lights up abnormally, or does not light up ...................
M-l 3. (PARKING
82-122
a) If stays lighted up ................................................
82-122
b) If does not light up ...............................................
82-122
(WORKING
LAMP) lights up abnormally, or does not light up ....................
M-14.
82-124
a) If stays lighted up ................................................
82-124
b) If does not light up ...............................................
82-124
(PREHEATING)
lights up, or does not light up ..............................
M-15.
82-126
a) (Preheating) lights up .............................................
82-126
b) (Preheating) does not light up ........................................
82-126
CUT-OFF)
lights up, or does not light up. .....................
M-l 6. (TRANSMISSION
82-128
a) Lightsup
82-128
.....................................................
b) Does not light up ................................................
82-128
M-17. Turn signal Hi beam light up, or do not light up ..............................
82-130
a) Turn signal (right) pilot display lights up .................................
82-130
b) Turn signal (left) pilot display lights up. .................................
82-131
c) Turn signal (right) pilot display does not light up ...........................
82-132
d) Turn signal (left) pilot display does not light up ............................
82-132
e) Hi beam pilot does not light up .......................................
82-133
f) Hi beam pilot stays lighted up ........................................
82-133
M-18. Turn signal does not flash even when hazard switch is turned ON ...................
82-135
M-19. Speedometer display does not work normally
82-136
...............................
Hourmeter does not work normally ......................................
M-20.
82-137
M-21. When starting switch is turned ON, monitor panel does not work, or only part work ......
82-138
a) None of monitor panel lights up ......................................
82-138
b) Except for speedometer module, none of monitor panel lights up ................
82-138
Connector types and location of components.
M- 1.
(BRAKE
01 L LEVEL)
c) None of CAUTION
. ._ ......
flashes when engine is stopped
items light up
82-139
.....................................
d) Some other parts do not light up ......................................

M-22.
When starting switch is turned ON, all monitor
M-23.
(ENGINE
01 L PRESSURE)
when engine is stopped
82-139
panel lights up, but does not go out
flashes or (BATTERY
CHARGE)
..............................................
b) (Battery charge) flashes, and warning lamp lights up
82-139
82-140
a) (Engine oil pressure) flashes, and alarm buzzer and warning lamp are actuated
WA500-
......
flashes
.........................
........
82-140
82-140
82-107
0
M-24.
None of machine monitor

a) Even when combination
panel lighting lights up, or part does not light up

lamp is placed at SMALL,
............
none of panel lighting lights up
82-142
.....
..........
c) Even when starting switch is turned ON, none of monitor panel lights up ...........
d) Part of panel does not light up .......................................
b) Even when working
M-25.
M-26.
M-27.
lamps is switched ON, none of monitor
When starting switch is turned to on position (ENGINE
M-29.
M-30.
M-31.
82-146
buzzer does not sound
item is flashing but buzzer does not sound ....................

is shown on monitor display, but alarm buzzer sounds ...............
When starting switch is turned to ON position (ENGINE STOPPED), warning lamp does not
82-148
No abnormality
82-148
No abnormality
..........
.............
item is flashing but warning lamp does not flash
is shown on monitor display, but warning lamp lights up
...................................
...................................
........................................
b) If indicator remains at FULL
in (AIR PRESSURE GAUGE) system. ...........................
Abnormality
a) If nothing is displayed in display area ...................................
b) If indicator remains at maximum level ..................................
82-150
82-151
system
82-152
a) If nothing is displayed in display area
82-152
Abnormality
Abnormality
in (FUEL
GAUGE)
in (ENGINE
WATER
TEMPERATURE
GAUGE)
system
82-152
82-154
82-154
82-154
...............
82-156
...................................
b) If indicator remains at minimum level ...................................
82-156

~-32.
82-146
for 1 sec. CAUTION
light up for 2 sec. CAUTION

M-28.
STOPPED),
82-142
82-144
panel lights up
Abnormality
in (TORQUE
CONVERTER

b) If indicator remains at minimum
82i08
level
OIL TEMPERATURE
...................................
...................................
82-156
GAUGE)
system
........
82-158
82-158
82-158
WA500- 1
CONNECTOR
TYPES AND
LOCATION
OF COMPONENTS
COMBINATION SWITCH
DIMMER SWITCH
428FO144C
STARTING SWITCH
425F217
BATTERY RELAY
425F216
CNPl
DLI connector
WA500-1
16 pins
82-l 08-l
0
CNP2
DLI connector
CNP2
8 pins
CNPl
GNP4
q
oooo
000
CNP3 (CHECK module)

DLI connector 16 pins
CNP4 (CHECK module)

12
CNP5 (CHECK module)

llizl
oooo
000
82-:8-2
WA500-1
CNPS
CNP6
MIC connector
CN,P2
5 pins
CNf'l
CNP4
CNP5
P3
428FO1416
CNI 2 (Warking lamp switch)

brake
switch
Working
lamp
LB
CNi3
CN13 (Preheater switch)

CN14 (For starting switch)

WA500-1
EB
cN12
428F01427B-K
CN15 (Lamp switch)

Econoseal
CN17
N-SLC
12 pins
(Central
warning
connector
lamp)
Transmission
selector yh
2 pins
cut-off
PE
Central warning lamp
CNI 8 (Transmission
N-SLC
CN22
connector
(Intermediate
ECONOSEAL
cut-off
selector
(317
425FO14( 12-K
switch)
4 pins
connector)
connector
4 pins
82-$8-4
WA500-1
CN25 (Diode)
CN26 (Diode)
N-SLC connector
2 pins
CN36 (Parkin brake display switch)

ECONESEAL connector 2 pins
Parking bra
solenoid va Ive
display switch
425P108A.K
CB38 (Intermediate connector)

CN38
425P104

82-18-5

CN58 (Circuit breaker 4)

CN60 (Circuit breaker 2)

CN63 (intermediate connector)

82-z8-6
WA500-1
CN64
(Intermediate
ECONOSEAL
connector)
connector
12 pins
CN62
CN38
425P104
CN83 (Speedometer
ECONOSEAL
CN84
(Torque
ECONOSEAL
CN86 (Brake
ECONOSEAL
sensor)
connector
converter
connector
2 pins
oil temperature
sensor)
2 pins
oil level sensor)

connector
2 pins
425F555
WA500-1
CN87 (Brake stroke sensor)

CN88 (Brake stroke sensor)

425P123
CN92 (Air pressure sensor)

CN97 (Intermediate
connector)
82-1:8-8
WA500-1
CNl 01 (Engine
ECONOSEAL
water
temperature
connector
2 pins
sensor)
Engine water
temperature
sensor
42527
CN130
(Warning
buzzer)
CN131
(Warning
buzzer)
Male-female
connector
Warning
131
CNI 53 (Transmission
ECONOSEAL
oil filter
connector
426F503A-K
sensor)
2 pins
WA500-1
clogged
buzzer
ission oil filter

clogged sensor
,, *%+,y
,L,
82-1:8-9
CN163 (Engine oil pressure sensor)

Terminal
CN229 (Engine oil level sensor)

Econoseal 1 pins
Serial No. 10001
10973
Serial No. 10974 and
\T
UP
425F557
CN266 (Fuel level sensor)

82-1Fo
WA500-1
CN278
(Radiator
ECONOSEAL
water
level sensor)
connector
2 pins
Radiator water
level sensor
CN289
(Engine
CN297
(Caution
RELAY
connector
oil pressur
lamp
relay)
CN297
relay)
5 pins
CN55
CN5b
CN53
Ctj52
dN51
kN50
425F551
WA500-1
82-k8-1
(BRAKE OIL LEVEL) FLASHES WHEN ENGINE

IS STOPPED.
When
disconnecting
disconnecting
+
or connecting
the connector
When
connecting
connect
to the connector
When
the
disconnecting
return
them
checking,
to
T-adapter
specified.
connectors
the
the
for checking,
original
(or
T-adapter
socket
(CNO A
or connecting
condition
(or socket
turn the starting
switch
adapter)
continuity
between CN86
(female)(Z)
and
chassis ground
YES
1
Is there continuity
between CN86
(male) (1 and (217
1) Connect
_
T-adapters,
immediately
after
Cause
YES
Iefective
NO
Remedy
oanel
disconnection
in wiring
:female) (2) - CN91 (5) chassis ground.
T-
adapter) to CN86
(male) (brake oil
level sensor 1).
2) Turn starting
switch OFF.
monitor
disconnection
in wtrmg
harness between CNP3
(female) (1)
CN64 (11)
CN91 (6) - CN86 (1).
adapter (socket
adapter) to CN86
(female).
2) Turn starting
switch OFF
T-
aaapter ,soc*et
defective
NO
After inspection,
repair (clean) or
replace
After inspection.
repair (clean) or
replace
brake oil level sensor
(ENGINE OIL LEVEL) FLASHES WHEN ENGINE

IS STOPPED.
Remedy
Cause
YES
YES
(female), then
connect to
chassis ground.
2) Turn starting
switch ON.
Trouble-
when
adapter),
fH_
or
ISthere
M-2:
connector,
accidents.
1)
1) Connect
or short
OFF to prevent
Is there continuity
between CNP3
(female) (2) and
chassis ground?
1) Connect CN229
(engine oil level
SellSOr).
2) Connect Tadapter to CNP3
(female).
3) Turn starting
switch OFF.
T-adapterorsocket
adapter
(for Econoseall
shooting
-I
Iefect1ve
eng,ne 011level sense
-c
lefective
monitor
panel
IIefective contact, or
,disconnection
in wirlno
7aress
between CN2i9
female) - CN97 (5) - CN62
(11 - CNP3 (female) (2).
NO
T-adapter
After inspection,
repair (clean) or
replace
(for DLI)
I
Short
82iA10
connector
WA500-1
.C..
M-l
Related electrical circuit drawing
CNP3
Monitor
panel
CN64
CNQI
-mm
CN66
Brake oil
level sensor
rI7-l
n/L
425F511
M-2
CNP3
Monitor
panel
CN62
CN97
CN 229
Engine oil
level sensor
425F512
WA500-
M-3:
(RADIATOR
0
I -
ENGINE
When
disconnecting
necting the connector

*
When
connecting
When
disconnecting
return
them
checking,
to
WATER
FLASHES
WHEN
IS STOPPED.
or connecting
the T-adapter
(or socket
adapter)
or short connector,
or when discon-
for Checking, turn the starting switch OFF to prevent accidents.
the T-adapter
the
LEVEL)
connectors
original
or connecting
condition
connect
to the connector
specified.
(CN 0 A
1)
T-adapters,
immediately
after

Cause
YES
Defective
SeSOr
radiator water level
RWkX
YES
-II
ES
Connector
to
1) Connect Tadapter (socket

adapter) to
CN278 (female).
2) Turn start,g
swtch OFF
/ _
el
3
II
Is voltage between
CNP4 (female) 15)
and chassis ground
normals
1
1)
2)
31
2)
,
Turn starting
swtch ON.
Measure voltage
between
alternator
termmal Rand
chaws ground.
Is reading 20 3ov7
Troubleshooting
tools
WHEN
mspectlon.
wer
epair (clean) or
@ace
ENGINE
flashes when the engine is stopped, go to M-8. Engine oil pressure abnormal.)
YES
_
Is voltage Of
alternator terminal R normal?
FLASHES
4fter inspection.
*pair (clean) or
qlace
disconnectmn in wirmo
harness between CN2i9
(female) (2) and chass!s
ground.
NO
short
connector to CN278
(female).
2) Connect T-adapter to
CNP3 (female).
31 Turn startang switch
OFF.
(BATTERY
CHARGE)
IS RUNNING.
(If 3
(female) (1) - CN62 (2) CNP3 (female) (3).
1) Connect
CN278 (female)
(radiator water
level sensor).
2) Turn starting
swfch ON.
M-4:
IS there continuity
between CNP3
(female) (3) and
chassis ground?
3)
NO
YES
Defectwe
Connect
T-adapter to
CNP4 (female).
Turn starting
switch ON. (Start
eng1ne.l
Is reading 20 3ow

(for Econoseal)
monitor panel
Replace
_
Defectwe contact, or
dwonnection
in wring
harness between alternator
terminal R - CN97 (1) CN64 (1)
CNP4 (5).
After inspection,
repau (clean) or
replace
Defectwe
wace
T-adapter
alternator
(for DLI)
8222
Short connector
WA500-1
M-3
Related electrical cirw it drawing
CN 278
CN 62
CNP 3
Monitor
panel
Radiator water
level sensor
425F513
M-4
Related electrical cirarit
CNP4
Monitor
panel
drawing
CN64
CN 97
Alternator
O terminal R
425F514
WA500-
82ih3
(TRANSMISSION
OIL FILTER CLOGGING)
FLASHES WHEN ENGINE IS RUNNING.
*
When
disconnecting
disconnecting
When
connecting
connect
or connecting
the connector
the T-adapter
to the connector
When
disconnecting
return
checking,
the .T-adapter
for checking,
switch
adapter)
or short
OFF to prevent
connector,
or when
accidents.
(CNOA (
specified.
connectors
(or socket
turn the starting
or connecting
condition
immediately
))
T-adapters,
after
Remedy
Cause
YES
Defective
transmission
filter clogging sensor
YES
Defective
monitor
or1
panel
Replace
Replace
WH_
1) Connect
short
CN153
(female)
(transmission
oil
filter clogging
sensor)
2) Turn starting
swtch
ON.
M-5
1) Connect short
connector
to
CN153 (female)
2) Connect
Tadapter to CNP3
(female).
3) Turn starting
swtch
OFF
to
connector
Is there
between
cont~~ty
CN 153

adapter) to
CNi53
ifemale).
2) Turn starting
switch OFF.
NO
txl8-l
._
Defective
contact, or
disconnection
in wirmg
harness between
CN153
[female) (1) - CN64 (2) CNP3 (female) (10).
Uter inspection,
epair (clean) or
Defective
contact. or
disconnection
in wiring
harness between
CN153
(female) (2) and chassis
ground.
4fter
%PkCt?
.epa,r
.eplXZ
CN 153
CN64
CNP3
Monitor
panel
Transmission
clogging
filter
sensor
425F515
Troubk-
T-adapter
or socket adapter
(for Econoseall
Short
82ii14
T-adapter
(for DLI)
connector
wA500- 1
inspection,
(clean) or
FLASHES
M-6:
When
disconnecting

*.
When
connecting
When
disconnecting
return
them
checking,
or connecting
to
the
ENGINE
the T-adapter
for checking,
the T-adapter
WHEN
(or socket
turn the starting
switch
connectors
original
or connecting
condition
.-
adapter)
or short connector,
OFF to prevent
connect
or when discon-
accidents.
to the connector
specified.
(CNOA
1)
T-adapters,
immediately
after

Remedy
Cause
YES
See M-29 (Abnormality

level gauge)
in fuel
Does fuel gauge

display EMPTY 7
1)
Defective
Turn starting
switch ON
lepkx!
monitor panel
NO
(BRAKE
LINE FAILURE)
FLASHES
WHEN
ENGINE
IS RUNNING.
*
Check that there is no abnormality
with the chassis.
I
Is there continuity
between CNP3
(female) Wand
chassis ground?
YES
2
Yl
Is there continuity
each sensor7
2)
of
[total:

adapter) to each
sensor (male).
2) Turn starting
watch OFF.
31 connector
numbers are
CN87 and 88.
82ii6
Is there cotm~ty
between CN87
(female) (2) and
chassis ground,
adapter) to CN87
(female).
2) Turn starting
switch OFF.
r
1)
-
Connect
T-adapter to
CNP3 (female).
YES
I I
Defective monitor panel
harness between CNS7
(female) (1) - CNSl (8) CN64 (12) - CNP3 (female)
14).
p
NO
3eplaC.3
disconnection in wring
:female) (2) - CNS8 (female)
Il), or CN88 (female) (2) CNSl I51 - chassis ground
Non-continuous
defective
sensor is
After inspection.
epair (clean) or
@ace
ift8r inspection,
epair (cleanJ or
edace
teplace
WA500-1
N6
CNP4
CN64
CN 266
Monitor
panel
Fuel level sensor
425F516
M-7
CN87
CNP3
Monitor
panel
CN 64
4
CN91
Brake stroke
El---
425F517
WA500-
8227
M-8:
,
43
I
When
(ENGINE
OIL PRESSURE)
disconnecting
Whenconnecting
or connecting
When
return
specified.
disconnecting
them
checking,
to
(or socket
original
(or socket
turn the starting
ENGINE
switch
adapter).
adapter)
or short connector,
OFF to prevent
or when discon-
accidents.
connect
1)
(CN 0 A
connectors
the
the T-adapter
for checking,
the T-adapter
to the connector
WHEN
IS RUNNING.

+
FLASHES
or connecting
condition
T-adapters,
immediately
Cause
after
Remedy
YES
. Defective
sensor
engine
oil pressure
Replace
1
3
.Does
&,goout,
Is there continultv
between CNP3
(female) (9) and
chassis ground
YES
1) Disconnect
CN163.
2) Turn stafling
switch ON.
3) start eng,ne.
_
Is voltage between
CN163andchassis
fllXl?lal?
NO
1)
2)
Turn starting
swttchON
(Start
engme.)
IS reading 20 3ov7
1)
2)
YES
Defective
p
NO
Connect
T-adapter to
CNP3 lfemalel
Turnstarting
switch OFF
NO
M-9:
0
CI-
If w&:
flashes
when engine
IS stopped.
1s defectwe.
(RADIATOR
WATER LEVEL)
ENGINE IS RUNNING.
FLASHES
ES
panel
Replace
disconnection
m wiring
harness between chassis
ground - CN289 (3). (6) CNP3 (female) (9). or defective
engine oil pressure sensor
relay
After inspection.
repair (clean) or
replace

between CN163 - CN97 (8)
- CN64 (6) - CN289 (2).
After inspection,
repaw (clean1 or
replace
Go to M-23 (Engine oil

pressure or battery charge
flashes when engine is
stopped.)
r
Note)
monitor
YES
WHEN
Defective
sensor
radiator
water
Defectwe
monitor
panel
level
Replace
YI
iH-1) Connect short
connector to
radiator water
level sensor
CN278 (female).
2) Turn starting
swtch ON.
3) Start engme.
hIO
\ -l
Is there continuity
between CN278
(female) (2) and
chassis ground?

adapter) to
CN278 (female)
2) Turn startmg
swtch OFF
82-118
0
1) Connect short
ccannector to
CN278 (female).
(female).
3) Turn startmg
switch OFF.
NO
Defectwe contact. or
disconnection
m wiring
(female) (1)
CN62 (2) CNP3 (female) (3)
After mspection.
repair (clean) or
replace
4fter inspectvan.
spair (clean) or
eDlaCe
WA500-1
M-8
Engine oil pressure
relay
Engine oil
pressure sensor
425F518
M-9
Related electrical cirwit
CNP3
Monitor
panel
drawing
CN 62
CN 278
Radiator water
level sensor
7
J
425F519
WA500-1
82-2
9
M-10:
(DROP IN AIR PRESSURE) FLASHES WHEN
49
0
When
ENGINE IS RUNNING.
disconnecting
disconnecting
*
When
connecting
connect
When
return
or connecting
the connector
the
to the connector
disconnecting
them
checking,
to
the
T-adapter
specified.
connectors
original
the
for checking,
(or
T-adapter
socket
(CN 0 A
or connecting
condition
(or socket
turn the starting
switch
adapter)
or short
OFF to prevent
or when
adapter),
1)
T-adapters,
immediately
after
Cause
Remedy
YES
Is air pressure gauge

withm red level

pressure gauge)
m air
Defectwe
7)
connector,
accidents.
hsplace
monitor panel
NO
Turn starbng
Swtch ON
i
(ENGINE WATER
M-II:
rer
TEMPERATURE)
FLASHES
WHEN ENGINE IS RUNNING.
1 YES
Is engine water
temperature gauge
wlthm red level
1
See M-31 (Abnormality in

engine water temperature
gauge)
Ikfectwe
M-l 2:
monitor panel
3eplace
NO
Turn starting
swtch ON
(TORQUE CONVERTER OIL TEMPERATURE)

FLASHES WHEN ENGINE IS RUNNING.
YES

torque converter oil
temperature gauge)
in
Is torque conwrter 011

temperature gauge
wthm red level?
1)
Defectue
Turn starting
switch ON.
monitor panel
NO
82-A20
WA500-
M-IO
CNP4
..~
_.__
I,OllOT
CN 63
CN92
I,\
--
panel
t
P\ t
2
CN62
425F520
M-l 1
CNP4
panel
425F521
Ml2
CNP4
Monitor
CN 22
CN84
Torque converter
oil temperature sensor
panel
425F522.K
WA500-1
82-ih21
M-13: [/A\]
j
(PARKING
w /OR
When
disconnecting
disconnecring
*
When
When
return
a)
the
disconnecting
to
connectors
the
original
checking,
then go tothe
If
stays
b1
lighted
the
(or
specified.
UP ABNORMALLY,
UP.
for checking,
T-adapter
to the connector
them
LIGHTS
or connecting
the connector
connecting
connect
BRAKE)
DOES NOT LIGHT
T-adapter
socket
(CN 0 A
or connecting
condition
(or socket
turn the starting
adapter)
switch
or short
OFF to prevent
connector,
or when
accidents.
adapter),
1)
T-adapters.
immediately
after
Cause
Remedy
next check.
up
YES
1) Connect
short
connector to
CN36 (female)
(parkmg brake
SWWX).
2) Turn startmg
swtch
1I
ON.
COeCtOr
NO
Is there continuity
between CN36
(female)(Z)
and
chassis ground,
Turn starbng
switch ON.
I
NC
11 Connect Tadapter (socket

adapter) to CN36
(female) (parking
brake sensor).
21 Turn start,na
switch OFF.
parkmg
brake sensor
)efecwJe
monltoi
panel
to
)efectlve contact. or
iisconnection
in wiring
wrness between CN36
female) (1)
CN38 (4) :NP3 (female) (5)
TPlZlC.3
NO
)efectwe contact. or
lisconnectlon
m wiring
female) (2) and chassis
Iround
ice Troubleshootmg
If
4fter InspectIon,
repax (clean) or
CN36 (female)
(parkmg brake
sensor).
(female).
3) Turn starting
switch OFF.
NO
b)
After mspectnon.
repall Iclean) or
replace
for
hass1s
does not light up
Iefectwe
YE
parklng
brake sensor

(female).
2) Disconnect
CN36.
3) Turn starting
swtch OFF.
Turn starting
swtch ON.
IO
NO
Replace
:ontact between chassis

,etween CN36 (female) (1)
:N38 (4) - CNP3 (female) (51.
After Inspectlo,
epalr (clean) or
wace
Iefectw
leplace
1I
Re0k.e
I1
Iefectwe
monitor
See Troubleshootmg
:hasss
panel
fat
WA500-1
M-13
CNP3
Monitor
panel
CN 38
CN 36
Parking brake
sensor
425F523
WA500-1
82iA23
(WORKING
M-14:
LAMP)
ABNORMALLY,
*
When
disconnecting
adapter)
or short
connector
for
or connecting
connector,
checking,
turn
the
accidents.
When
connecting
-k
When
disconnecting
connectors
return
them
original
to
(or socket
disconnecting
starting
UP.
switch
the
OFF
to
Note)
the
to the connector
checking,
UP
the T-adapter
or when
prevent
connect
LIGHTS
OR DOES NOT LIGHT
the
T-adapter
(or
specified.
KN
socket
0 A (
Even is all the working

are
)I
or connecting
condition
adapter),
broken,
contact
wiring
T-adapters,
immediately
after
or there
or a disconnection
harness
lamp,
lamp bulbs
is defective
for
the
will stay lighted up.
jAl

Cause
a)
If m
1) Remove CN12.
2) Turn starting
switch ON.
working
lamp swtct
Defective
momtor panel
_
NO
YES
IS voltage between
CNP3 (female) (14)
and chassis ground
normal7
(female).
2) Turn starting
watch ON.
3) Remove CN 12.
4) Is reading O1w
Contact between t24V and

wiring harness between CN12
(female) (2) - CN40 (1) CN40 (4) - CNP3 lfemalei
(14)
NO
After mspection,
repair Mean1 or
does not light up

3
YES
Defectwe
{mH--
1)
Is contmuity
between CN12
(male) (1) and (2) as
shown in Table?
Is voltage between
CN60 (male) (1) and
chassis ground
nCX!llal?
adapter) to CN60
(male).
2) Turn starting
swttch ON.
3) Is reading 20 3OV
Defective
If m
Remedy
stays lighted up
Doesiglgoout?
b)
in the
working
1) Disconnect CN12
(male).
2) Turn startmg
swtch OFF.
3) Turn working
lamp switch ON
- OFF.
21
3)
4)
Connect
T-adapter to
CNP3 (female).
Turn starting
swtch ON
Turn workmg
lamp switch ON
IS readmg 20 3ov7
monitor panel
harness between CN 12
(female) (2) - CN40 (1)
CN40 (4) - CNP3 (female)
(14) or CN12 (female) (1) CN60 (male) (2).
After inspection,
wair (clean) or
NO
Defective
workmg
WhX
lamp switch
NO
disconnection in wirmg
harness between main
breaker - CN60 (male) (1)
leplace
ifter inspection,
epair (clean1 or
epkKe
Table
I
T-adapter
Troubleshootmg
tools
Workmg
lamp switch
Tester
(for DLI)
ON
OFF
Continutty
No continuoty
CN12 (male)
82-124
0
(l)-_(2)
WA500-1
M-14
Fuse box
CN26
l.L
CNPI
Head lamp switch
e
CNP6
CN 25
Service meter
CNP 3
M&ypj-
Working
lamp
425F524
WA500-1
82225
M-l 5:
(PREHEATING)
0
*
When
disconnecting
or connecting

*
When
connecting
to the connector
When
return
LIGHTS
OR DOES NOT LIGHT
the T-adapter
disconnecting
them
checking,
to
the T-adapter
for checking,
specified.
original
(or socket
turn the starting
(or socket
(CN 0 A
connectors
the
UP,
UP.
adapter),
adapter)
or short connector,
OFF to prevent
or when discon-
accidents.
connect
1)
or connecting
condition
switch
T-adapters,
immediately
after
Cause
a)
7S
G
(Preheating)
lights
up
YES
SeeE-14.E-15
I I
I
11
21
3)
b)
NO
Connect
T-adapter to
CNP3 (fern&l.
Turn startmo
switch ON. _
Is readang 20 3ov7
(Preheating)
21
3)
connect
toois
monitor panel
E;eeE-14.E-15
NO
T-adapter
Trouble-
kfect1ve
YES
T-adapter to
CNP3 (female)
Turn starting
switch ON
Is reading 20 3ov7
shooting
monitor panel
does not light up
Is voltage between
CNP3 (female1 I1 51 _
and chasss ground
normal)
I
I
1)
kfectw
(for DLII
82-ik26
WA500-1
M-15
To batt
CN48
Starting switch
&metal time1
425F525
WA500-1
82-ik27
M-16:
(TRANSMISSION
CUT-OFF) LIGHTS UP,
DOES NOT LIGHT UP.
1$/
*
When
disconnecting
or connecting

*
When
connecting
to the connector
or
When
return
the T-adapter
specified.
disconnecting
them
checking,
to
the T-adapter
for checking,
(or socket
(CNO A
connectors
the
original
(or socket
turn the starting

adapter),
adapter)
or short connector,
OFF to prevent
or when discon-
accidents.
connect
1)
or connecting
condition
switch
T-adapters,
immediately
after

Cause
a)
@
El
lights
Is there continuity
between CNP3
(female1 (1 11 and
chassis ground
YES
r
1)
2)
Short circuit
between CN18
Enale)
(3) and
Turnstarting
swtich ON.
It
IS there continuity
betweenCN18
(female) (4) and
chassis ground
.
N
Turn
transmission
cut-off selector
:=
1)
NO
Turn stanlng
swtch OFF.
YES
I I
cut-off
monitor oanel
replace
teplace
)efectwe contact, or
lisconnection in wiring harness
letween CN18 (female) (3) an<
:NP3 ifemale) (1 1)
rfter IspeCtIO.
?pair (clean) or
eplace
Iefectwe contact, or
lkconnectlon in winng harness
between CN18 (female1 (4) aoc
hassls ground
ifter Inspection.
pair Iclean) or
aplace
transmission
cut-off
:ontact between chaws

round and wring harness
stween CN18 (female) (31
nd CNPJ (female) (1
,fter uxqection.
rpair Iclean or
)efectwe
:epkXe
1)
I Remove
CN18.
!plaCe
11 connect
T-adapter to
CNP3 (female)
2) Turn starting
switch OFF.
T-adapter
Trouble-
)efectlve
jefective
witch
shooting
took.
transmisston
YES
Turnstarting
svwtch ON.
Iefective
witch
1
21
Remedy
up
(for OLll
monitor panel
NO
Tester
82-A28
WA500-1
M-16
CNP3
\
1
CNl8
I
425F526-K
WA500-1
82ii29
M-l
7: TURN
SIGNAL
HI BEAM
OR DO NOT LIGHT
*
When
disconnecting
When
connecting
When
return
checking,
a)
specified.
disconnecting
them
to
(or socket
(CN 0 A
connectors
the
original
(or socket
turn the starting
adapter),
switch
adapter)
or short connector,
OFF to prevent
or when discon-
accidents.
connect
1)
or connecting
condition
T-adapters,
immediately
after
Turn signal
(right)
pilot display
lights
2
Is voltage between
CN15 (male1 (5) and
chassus ground
normal 7
YE
3)
Does voltage switch repeatedly
.
F
1)
2)
3)
4)
Connect
T-adapter to
CNPl (female)
Turn starting
switch ON.
Turn right turn
slgnal switch ON
Does voltage
switch
repeatedly
between 0 - 20
- 3OV?
Contactbetween +24V and

wnng harness between CN 15
Ifemalel 131 - rtght turn signal
swtch. or between CN15
lfemalel 151 and turn slgnal
4fter tnspectlo,
.epa,r or replace
swtch
2)
Is voltage between
CNPl (femalel (71
and chassis ground
normal,
Remedy
Remove CN15.
Turn startmg
swttch ON.
up
YES
NO
Connect
T-adapter to
CNl 5 Imale)
Turn starbng sw,tch ON
11
Does turn signal go
1)
21
the T-adapter
for checking,
the T-adapter
to the connector
UP,
UP.
or connecting

*
LIGHT
YES
between
0 -
20 -
Contact between t24V line

and wrmg harness between
CNl5 (male) (5) and CN55
(female) (4).
4fter Inspection,
,epair or replace
Defectwe
Replace
30V
monitor panel
NO

and
wring harness between CNPl
ifemalel (71 and CN15 (male)
4fter inspection.
.epa,r or replace
(31
T-adapter
shooting
to015
(for DLI)
82-130
a

(for Econoseal)
WA500-
b)
Turn signal (left) pilot display lights up
2
Is voltage between
CN15 (male1 (5) and
chassis ground
normal
11
IL
Does turn signal go

outs
1)
21
Remove CN15
Turn startmg
switch ON.
21
31
I
3)
41
NO
Connect
T-adapter to
CN15 (m&l.
Turn starting switch ON.
Does voltage switch repeatedly
between
0 -
20 -
Afternspecton.
repair or replace
Contact between +24V line.

and wirmg harness between
CN15 (male) (5) and CN55
(female) (4).
After inspectlon,
repair or replace
3OV7
monitor panel
voltage
connect
T-adapieror
socket adapter
(for Econoseal)

and
wiring harness between CNPl
(female) 16) and CNl 5 bnale)
NO
Afterinspectlon,
repair or replace
(6)
T-adaoter to
CNPl (female)
Turn stanma
swtch ON. Turn left turn
sgnal switch ON.
Does voltage
watch
repeatedly
between 0 - 20
- 3ov7
T-adapter
WA500-
Contact between +24V and

wirmg harness between CN15
Ifemale) (61 - left turn signal
switch, or between CN15
(female) (5) and turn signal
switch
Defective
2)
Trouble-
YES
Remedy
Is
between
CNPl Ifemale) 16)
;;;;:,yis
ground
II
Cause
(for DLII
82-ii31
Cause
c)
&
1)
connect
T-adapterto
CNPl (femalel.
Turn starting
switch ON.
Turn turn sional
switch ON. Does voltage
switch
repeatedly
between 0 - 20
- 3OV?
1
Do front and rear turn
signal lamps work
2)
3)
4)
1)
YES
Is voltage between
CNPl (female) (71
and chassis ground
normal?
YES
-
21
Operate right
turn signal.
Turn starting
swtth ON.
NO
YE
IS voltage between
CNPl lfemalel (61
and chassis ground
normal?
1)
2)
31
41
21
monitor panel
ieplace
lefective contact. or
letween CNPl (female) 17) ant
:N15 hnale) (31
After inspection.
epair l&an) or
eolace
of
Turn signal (left) pilot display does not light up
1)
Iefectwe
:arry out troubleshooting

urn signal
10
d)
Remedy
Turn signal (right) pilot display does not light up
operate left turn

SIgnal.
Turn starting
switch ON.
Trouble-
Connect
T-adapter to
CNPl Ifemale)
Turn stanlng
switch ON.
Turn turn slgnal
swttch ON
Does voltage
switch
repeatedly
between 0 - 20
- ?O,
YES
)efectwe
mon!tor panel
wace
NO
lefectwe contact, or
isconnection in wring harness
atwee CNPl Ifemalel (61 ant
:N15 Imale) (6)
:arry out troubleshoovng

urn SIgnal
After 8nspection.
epeir (clean) or
ephe
of

(for Econoseal)
T-adapter
82-k32
lfor DLI)
WA500- 1
e)
Hi beam pilot does not light up

If the head lamp does not switch to Hi beam, check the head
lamp system.
11
1
21
Do both left and right
front lamps lkght up7
3)
4)
1)
2)
3)
f)
Turn starttng
swtch ON.
Place
combination
swtch at HEAD.
Place dimmer
switch at Lo
beam
5)
YES
Cause
Iefective
monitor panel
jefective contact, or
lisconnection in wiring
larness between CNPl
female) (5) and CN39 (male)
1).
_..
connect
I -aoapter 10
CNPl (female).
Turn starting
switch ON
Place
combination
switch at HEAD
Place dimmer
switch at Hi
beam.
Is reading 20 3ov7
\
NO
Remedy
7eplace
ifter inspectlon.
epair (clean) or
eplace
10th head lamp bulbs (Lo beam

wnps) broken
If the Lo beam bulb is broken,
he Hi beam pilot will not light
!p even if the lamp is switched
ol+ beam.)
qeplace
Iefective
leplace
Hi beam pilot stays lighted up
lefectnve contact, or
letween CN15 (female) (9) ant
ombinatton swtch
Do both left and right

front lamps lkght up?
1)
2)
3)
Turn starting
switch ON
Place
combination
switch at HEAD
Place dimmer
switch at Lo
beam.
monitor panel
Does head lamp light
1)
21
31
Turn startmg
switch ON.
Place
combinatloo
swtch at HEAD
Place dimmer
switch at Hi
beam.
11
2)
T-adapter
Connect
T-adapter
(socket adapter)
to CN15 (male).
Turn starting
switch OFF.
NO
rfter inspection.
epair (clean) or
eplace
lefective contact. or
disconnection in winng harnes
between CN15 (fernaLe) (12)
and combination switch
After Inspactlon.
repair (clean) or
replace
Iefectwe contact, or
iisconnectlon in wiring hernest
>etween CN15 (male) (12) ant
:hassis ground
After Inspection.
repair (clean) or
replace
ifor DLI)
shooting
tools

(forEconoseal1
WA500-1
82-ih33
M-17
a), b), c), d) related electrical circuit drawing
+24
CNPI
1
Hazard
Monitor
panel
/a
e--
CN55
Turn slgnal swtch
425F52?-K
M-17
e), f) related electrical circuit drawing
CN201
CN28
Right head
lamp Lo
Left head
lamp Lo
425F528
82-iA34
WA500-1
M-l 8: TURN SIGNAL DOES NOT FLASH EVEN WHEN

HAZARD SWITCH IS TURNED ON.
+
When
disconnecting
disconnecting
*
When
connecting
connect
When
return
or connecting
the connector
the
to the connector
disconnecting
them
checking,
to
T-adapter
specified.
connectors
the
the
for checking,
original
(or
EN0
T-adapter
socket
A
adapter)
switch
or short
OFF to prevent
connector,
adapter),
T-adapters,
immediately
after

Cause
2
Is voltage between
CNPl Ifemale) (6).
(7) and chassts
ground normal
YE
YES
Defective
Connect T-adapter to CNPl (female).

Does voltage switch repeatedly between
21
0 -
20 -
3)
CN15 (female1 12)

and chassis ground
I
1)
2)
3)
1
Connect
T-adapter to
CN15 (female).
Turn hazard
switch ON.
Is reading 20 3ov7
e-
YES
AI
2)
3)
T-adapter or
of turn signal
Iefective contact. or
jlsconnection in wiring harnes!
wztween CNPl (female) (3) EN1 5 (male) (21
Prfter inspecW9n.
apair (clean) or
.eplace
disconnection in wiring harnes!
wawx
CN15 lfemalel (1)
Ind hazard switch, or between
:Nl5
(female) 12) and hazard
witch, of defective hazard
witch
4fter inspection.
Fpair (clean1 or
eplace
)efecttve contact, or
disconnection in wiring harnesr
,et*een CN15 (m&l
(11 and
+24V line
NO
Trouble-
RepkCe
3OV?
monitor panel
See M-l 7 c), d)

Troubleshooting
CNPl (female1 (3)

and chassis ground
connecr
T-adapter to
CNPl (femalei.
Turn hazard
switch ON.
Is reading 20 3ov7
Remedy
NO
1I
21
3)
1)
or when
accidents.
1)
or connecting
condition
(or socket
turn the starting
CN15 (male).
Turn hazard
switch ON.
lssy,ding 20 -
\fter inspection.
epair (clean1 or
EplaCe
socket adapter
(for Econoseall
shooting
I
I mdsI
T-adapter
M-l 8
electrical
Related
(for DLII
circuit
drawing
+24
1
CNl5
I
425F527.K
WA500-1
82-A35
M-l 9: SPEEDOMETER
DISPLAY
DOES NOT WORK NORMALLY.
or When disconnecting or connecting the T-adapter

t
(or socket adapter) or short connector, or when

disconnecting the connector for checking, turn the starting switch OFF to prevent accidents.
(or socket adapter).
connect to the connector specified. (CN 0 A ( 1)
When disconnecting connectors or connecting T-adapters,
return them to the original condition immediately after
Cause
4
YES
-
Is resistance
between CNPl
3OOfI-1
kQ?
YE
Is
1
resistance
between CN83
(male) (1) and (2)
3OOfI-1
kQ?
1) Connect
Tadapter (socket
adapter) to CN83
(speed sensor)
(male).
2) Turn starting
switch OFF.
M-19
adapter (socket
adaoterl to CN22
(female;.
2) Turn starting
swtch OFF.
Rf@CZ
Loosenspeed
tensor locknut
and turn speed
sensor clock-
3efectlve
speed sensor mount
Replace
NO
NO
NO
harness between CNPl (9).
10) (female) - CN22 (3). (4).
4fter mspection.
.epair (cleanl Or
aplace
3efenive contact. or
disconnection in wwng
:female) (4). (3) - CN83 (1).
2).
4fter inspection,
epanr or replace
Defective
Replace
I
speed senspr
NO

(for Econoseal)
Troubleshootmg
to015
T-adapter tp
CNPl (female)
Turn starting
swatch OFF
monitor panel
wise If it
Contacts the 9%~
within one turn.
the distance is
wthm 1.5 mm.
1 connect
YE
Oefectwe
IS proximity settmg of
speed sensor 0.5 1.5 mm,
YE:
Remedy
T-adapter
(for DLI)
CNPI
CN22
CN83
Speed
sensor
425F530.K
82-A36
WA500- 1
M-20:
*
*
+
HOURMETER
DOES NOT WORK NORMALLY.
When disconnecting or connecting the T-adapter (or socket

adapter) or short connector, or when disconnecting the
connector for checking, turn the starting switch OFF to prevent accidents.
When connecting the T-adapter (or socket adapter), connect
to the connector specified. (CNO A ( 11
Cause
Iefecttve
#ensor
YES
engme oil pressure
YES
Remedy
ReplaCe
Replace
Br
Yf
I) Remove CN163.
2) Turn starting
switch ON.
2
NO
21
CNP3 (female).
Turn starting
switch OFF.
Troubke-
M-20
switch ON. IStart

engine.)
IS reading 20 3OV?
IO

(for Econoseal)
shooting
toots
After inspectIon.
repair (clean1 or
replace

between CN163 - CN97 18)
- CN64 (6) - CN289 (2).
After Inspectlo.
*pair kzleanl or
replace
1I Turn starting
2)
Defective contact, or disconsection I wiring harness

,etween chassis around 3N289 (3), (6) - eNP3
female) (9). or defectwe
.elay
Short connector
T-adapter
T-adapter
(for DLI)
or socket adapter
(for MIC)
Engine
oil pressure
relay
CNP 3
CN 163
&TJ
CN 64
Engine oil
pressure sensor
CN 97
1,
425F518
WA500-1
82-ih37
M-21:
WHEN STARTING SWITCH IS TURNED ON,

MONITOR PANEL DOES NOT WORK,
OR ONLY PART WORKS.
When
disconnecting
or connecting

*
When
connecting
the T-adapter
to the connector
specified.
When
disconnecting
return
them
checking,
to
the T-adapter
for checking,
(or socket
(CN 0 A
connectors
the
original
(or socket
turn the starting

adapter),
adapter)
or short connector,
OFF to prevent
or when discon-
accidents.
connect
)I
or connecting
condition
switch
T-adapters,
immediately
after

Cause
a)
None of monitor
panel
lights
2
YI
Is voltage between
CNPl Ifemale) (11
and (2120 - 3OV7
11
CN60 (male) (5) and
chassis ground 20
2)
1 J Connect Tadapter to CN60

(male).
2~ Turn starting
switch ON.
b)
Except
lights
YES
Defectwe
monitor panel
leplace
connect
T-adapter to
CNPl
Turn stantng
swtch ON
NO
IO
for speedometer
Remedy
up
module,
none of monitor
,are?.s between CN60 (6) :NPl (1). or between CNPl (2)
- CN64 (5) - chassis ground.
&an (defective
ontact) or replal
Abnormality in wiring harness

between battery terminal (f)
- battery relay - main
breaker - CN146 - CN60
(male) (5).
rfter inspection,
epar or replace
aefective
leplace
panel
up
I
-
YES
IS voltage between
CNP5 (female1 (1)
and (7) 10 - 2OV
15voltage between
12) and 17) approx
5V?

(for Econoseal)
T:ouble-
NO
connect
T-adapter to
CNP5 (femaleI.
Turn starting
switch ON.
2)
II
)efectwe contact or
jisconnection in wirng harness
ztween
CNP2 (1)
CNP5
1). CNP2 (2) - CNP5 (21.
:NP2 (7) -CNPS
(71, or
jefective monitor panel
1)
,_
monitor panel
lean (defective
ontact) or repiac
Tester
...=
tools
T-adapter
82-&38
(for DLI)
WA500-
Remedy
Cause
c)
None of CAUTION
items light up
YES
Is there disconnection
in wiring harness
between CNPP
(female) and CNP5
(female)?
1)
2)
d)
NO
Connect
T-adapter
to.
CNP2 and CNP5
.(femak).
Turn starting
switch OFF.
)efectivecotact.
or
lisconnectwx
in wiring harnas
#etween CNP2 ifemale) and
:NP5 (female)
San (defectwe
ontact) or replac
Iefectwe
nwmt0r
panel
ledace
Iefective
monitor
panel
meplace
sefectlve monitor
panel
eplace
Some other parts do not light up
M-22:
WHEN STARTING SWITCH IS TURNED ON,

ALL MONITOR PANEL LIGHTS UP,
BUT DOES NOT GO OUT.
T-adapter
Troubkshooting
or socket
adapter
Tester
(for Econoseal)
T-adapter
(for DLI)
Related electrical
M-21.22
circuit drawing
Fuse
box
Main
breaker
Battery
relay
CNPl
\
CN156
CNl57
CNl54
CNl55
CN148
CN60
Battery
Monitor
terminal
(+)
panel
CN64
WA500- 1
Nf
425F531
-K
82-A39
(ENGINE
M-23:
OIL PRESSURE)
BATTERY
FLASHES
*
When
disconnecting
disconnecting
*
WHEN
When
connecting
connect
to the connector
the
When
disconnecting
return
them
checking,
to
the
for checking,
T-adapter
specified.
connectors
the
CHARGE)
ENGINE
or connecting
the connector
original
FLASHES
IS STOPPED.
T-adapter
(or
socket
(CN 0 A
or connecting
condition
(or socket
turn the starting
switch
adapter)
or short
OFF to prevent
connector,
adapter),
1)
T-adapters,
immediately
after
Cause
a)
or when
accidents.
(Engine
oil pressure)
warning
flashes,
and alarm
buzzer
Remedy
and
lamp are actuated.
YES
r ~.
DoesB& goout) 11 RWWWe
wiring
of
_
ND
alternator
terminal R.
21 Turn starting
swtch ON.
(Do not start
engIn%)
2
IS voltage of CNP4
lfemalel 15) normal7
1)
2)
31
b) rml
(Battery
charge)
Reolace
Iefectwe
monitor panel
R&SCe
Contact between f24V and

Nirmg harness between
#ernator terminal R - CN97
l)-CN64(1)-CNP4
female) (5).
NO
flashes,
alternator
YES
Connect
T-adapter to
CNP4 (female0
Turn startmg
switch ON.
(With wrmg at R
termmal
removed)
is reading 0 lV,
Defectw
and warning
lamp lights
After inspectuq
repair (clean) or
eplace
up
ES
Defective
sensor
engine oil pressure
Defectwe
monitor panel
Replace
1
3,
Is voltage
between
YES_
1) Connect CN 163
to chassis
ground.
2) Turn starting
switch ON.
CNP3 (female) (9)

and chassis ground
normal?
Is voltage between
CN163 and chassis
Orlal?
1)Turn
starting
switch ON. (Start
1)
Trouble-
NO
Replace
Connect T-adapNO
ter to CNP3
(female).
2) Turn starting switch ON,
31 Connect CN163 to chassis
ground.
4) Is reading 20 - 3OV?
engine.)
2) Remove CN163.
3) Is reading 20 3OV?
YES

ground and tiring harness
between CN289 (3). (6) CNP3 (female) (9). or defective
relay.
After inspection,
repau Ml?al or
replace
harness between CN 163 CN97 (8) - CN64 (6) CN289 (21. (1) - +24V line.
After inspection,
*pair (clean) or
@ace

(for Econoseall
shooting
T-adapter
82-140
0
(for DLI)
wA!500-1
M-23 a) Related electrical circuit drawing
CN64
CNP4
CN 97
Alternator
O terminal A
Monitor
panel
425F514
M-23
b) Related electrical circuit drawing
Engine oil pressure relay

CNP 3
Engine oil
pressure sensor
CN 64
CN97
425F518
WA500-1
82-A4
M-24:
NONE OF MACHINE
LIGHTS
When
disconnecting
disconnecting
*
When
When
return
or connecting
the connector
connecting
connect
the
to the connector
disconnecting
them
checking,
MONITOR
PANEL
LIGHTING
UP, OR PART DOES NOT LIGHT
to
T-adapter
(or
specified.
original
T-adapter
socket
or connecting
condition
(or socket
turn the starting
KN 0 A
connectors
the
the
for checking,
UP.
switch
adapter)
or short
OFF to prevent
connector,
or when
accidents.
adapter),
1)
T-adapters,
immediately
after

L
Cause
a)
Even when
placed
lighting
combination
at SMALL,
lights
lamp
none of panel
up.
ES
5
Is voltage between
CNPl (female) (15)
andCNP6
(female)
12) - chassis ground
nromal?
YES
-
..
3m
1)
Is voltage between
CN26 (1) and
chassis ground
normal?
2)
3)
1)
Is voltage between
CN15 (8) and chassrs
ground normal?
YE
1)
2)
IS voltage between
CN15 ,malel (41 and
31
4)
11
connect
T-adapter
(socket adapter)
to CN15 (male).
21 Turn starting
switch ON.
31 Is reading 20 3ov7
Remedy
is
Connect
T-adapter
to
CN15
Turne.tarting
swtch ON
Place
combination
switch at SMALL.
Is reading 20 3ov7
Place
comb,nat,on
switch st SMALL
21 Measure voltage
between CN26
(female) (1) and
chassis ground
with CN26 still
connected.
3) Turn starting
switch ON.
4) Is readmg 20 3OV?
4)
NO
YES
t
Is continuitv
between
CN 15 (fen&e)
(4)
end (8) es shown ,n
Table 1 7
1J
Disconnect
CN15.
Turns starbng
switch OFF
2)
Connect T-adapter
L
to CNPl (female1
NO
and CNP6 (female)
Turn starting switch
ON.
Place combination
switch at SMALL
Is reading 20 - 30V 7
--t
t
I
NO
_c
0
Table
4bnormality
in momtor panel, (
311lamp bulbs broken, or
defective contsct. or
~lsconnection
in wring harries!
Ibetween CNPl (female) ,161 Iamp connector. or between
ainp connector. CNP6 (female
I 3) - chassis ground
IDefective contact. or
disconnection
in wiring
1Ifemale) (1) - CNPl (female)
I:15), CNP6 (female) (2).
disconnection
m wiring
Iharness between CN15 (male)
I18l- CN58 (11). (12) - CN26
Ifemale) (2). or defective diode
tissv.
After ,nspectlon.
repsIr Wean) or
replace
lfter inspection,
epsir (clean) or
YSpl&X
4fter inspection,
epair (clean) Or
WhCZe
C)efective contact, or
clisconnection
1-1wiring harness
Between CN 15 (female) (4) t lead lamp and parking tamp
s witch - CN15 (female1 I81
tfter inspection,
apair (clean) or
?olace
cdefective contact of head lamp

a nd parklng lamp switch
leplace
I)efective
contect, or
tisconnection
in wiring
trarness between betterY

<utpuf - CN59 (1 J, (2) (:N16 (male) (4).
relay
ifter inspectlon.
rpew (clean) or
aplace
i]
Trouble-
T-adapter or
socket adapter
(for Econoseall
82-i42
OFF
No
WA500-
.-
b)
Even when working lamp is switched

panel lights up
ON, none of monitor
YES
5 +
Isvoltagn
between
YES CNPl
r
4
Is voltage between
CN25 (1) and
chassis ground
normal?
Turn working
lamp switch ON.
YE
2
Is voltage between
CN12 (2) and
chassis ground
r-l
YES
connected.
IS voltage between
CN12 (female) (1)
and chassis ground
connected.
2) Turn starting
switch ON.
3) Is reading 20 3OV?
3) Turn working
lamp switch ON
4) Is reading 20 -
CN40 (male) (4) and
2)
c
31
Turn workmg
lamp witch
ON.
Measure voltage
between connect
T-adapter to
CN40 (male) and
chassis ground
Is reading 20 3ov7
(female) (16)
andCNP6
(fern&l
(21 - chassis ground
normals
1I
2)
3)
4)
. -
Connect T-adsvter
/
toCNP1
lfemab)
NO
and CNP6 ~femabJ.
Place combiMtii
switch at SMALL.
Is reading 20 - 3OV?
b=etvmnCN25NO
(female) (1) and
chassis ground
with CN25 still
connected.
Is reading 20 - 3OV?
0
1
NO
Table 2
Working
swtch
82-i44
lamp
Continuity
WA500-1
Cause
Abnormality in monitor panel,

or all lamp bulbs broken, or
defective contact, or
harness between CNPi
Ifemale) (16) - IamP
COnneCtor
(1).or between
lamp connector (2). CNP6
(female) (3) - chassis ground.
harness between CN2;
(female) (1) - CNPl (female)
(15). CNP6 (female) (2).
(female) (4) - CN25 (female)
(2) or defective diode a&y.
(female) (2) - CN40 (1) CN40 (male) (4).
disconnection in &ring
harness between CNl2 (male)
(1) -working
lamp swi<ch -
CN12 lmale) (2). or defective
workmg lamp switch.
disconnectton in wiring
harness between battery relay
output - CN60 (1). (2) CN12 (female) (1).
WA500-1
Remedy
After inspectvx,
repair (clean) or
replace
After inspection.
repair (clean) or
replace
After inspecton,
repar (clean) or
replace
After inspection,
repair (clean) or
T?place
After inspection,
repair (clean1 or
replace
4fter inspection,
*pair (clean) or
aPlace
82-245
-_
Cause
c)
Remedy
Even when starting switch is turned ON, none of monitor

panel lights up
41lamps broken. or defectwe
ontact. or disconnection in
rv!ng ham&s between CNPl
iemalet (161 - lamp connectoN
lamp connector (2) hassls ground
After wlspect,on,
repair (clean) or
replace
Xsconnect10n in lamp wirmg
Replace
jefective contact, or
)etwean CNPl (famalel (16) amp connactor (1 I, 121 :hassis ground
After mspection.
repair Mean) or
replace
1J.
1)
21
3)
d)
NO
connect
T-adapter to
CNPl (female).
Turn stirtins
switch ON.
Is reading 20 3ov7
Part of panel does not light up
YES
II
Is lamp bulb broken?
1)
NO
Remove lamp
and check
visually.
Trouble-
T-adapter
(for DLII
shooting
tools
82i46
WA500-1
M-24
Fuse box
+24V
CN 26
CNPI
:N58
1 1
p,
F)
Head
I I
I
lamp
switch
+24V
CN 12
25
0
*
I
CNP 3
Working
Working
switch
IamD
lamp
Monitor
panel
425F524
WA500-
82-147
0
M-25:
WHEN STARTING SWITCH IS TURNED TO ON

POSITION (ENGINE STOPPED),
BUZZER DOES NOT SOUND FOR 1 SEC.
CAUTION ITEM IS FLASHING BUT BUZZER
DOES NOT SOUND.
When
CkSCOnneCting or connecting

When
connecting
the T-adapter
to the connector
specified.
When
disconnecting
return
them
checking,
(or socket
(CNO A
connectors
the
original
(or socket
turn the starting

adapter),
adapter)
T-adapters,
immediately
after
Cause
does not sound for charge
Defective monitor panel
Connect CNP4
(female) (8) and
chassis ground. Does
alarm buzzer sound,
31
Connect
T-adapter to
CNP4 (female)
Connect CNP4
(81 to chassis
ground.
Turn starbng
switch ON.
YES
2l
Connect CNl30
(male) and chassis
ground. Does alarm
buzzer sound?
ND-
Turn starting
swttch ON.
3
Is voltage between
CN131 andchassis
growd normal?
ND
YES
1I
2)
Turn starbng
switch ON.
Is reading 20 3ov7
The alarm
buzzer
sounds
when
the parking
is in any position except

2
NO
Disconnect CNP4
(female).
Turn starting
switch ON.
Troubleshooting
defective
qeplace
alarm buzzer
Safective contact. or
clisconnection in wiring
harness batwae CN131
:male) - +24V line.
4fter inspection,
epair Mean) or
eplace
brake is applied
NEUTRAL.
YES
Defective
1i
:lean (defective
:otactl or replac e
NO ABNORMALITY
IS SHOWN ON MONITOR
DISPLAY, BUT ALARM BUZZER SOUNDS.
and the transmission
21
harness between CNl30
[female) - CNW (female) (8)
II
M-26:
Remedy
level and fuel level of
items.
21
or when discon-
accidents.
connect
YES
1)
or short connector,
OFF to prevent
1)
or connecting
condition
switch
The buzzer
CAUTION
to
the T-adapter
for checking,
NO

lfor Econoseall
T-adapter
82iA48
alarm buzzer
Replace
Contact batwean chassis

ground and wiring hamess
between CNP4 (female) (8) CN130.
After inspection.
repair Mean) or
replace
Defectwe
Replace
monitor panel
Wiring harness with

crocodile clip
(for DLI)
w&500-1
M-25,
25 Related electrical circuit drawing
+24V
Monitor
panel
CNl30
425F533
WA500- 1
82-149
@
M-27:
WHEN STARTING SWITCH IS TURNED TO ON

POSITION (ENGINE STOPPED),
WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC.
CAUTION ITEM IS FLASHING BUT WARNING LAMP
DOES NOT FLASH.
When
disconnecting
or connecting

*
When
connecting
the T-adapter
to the connector
+J When
return
specified.
disconnecting
them
checking,
to
the T-adapter
for checking,
switch
(CNOA (
connectors
the
(or socket
turn the starting
original
or short connector,
or when discon-
accidents.
connect
1)
or connecting
condition
adapter)
OFF to prevent
T-adapters.
immediately
after
Cause
Defective
1
Doeswam~ng
lamp
YES
light up?
YE
1)
2)
31
connect
T-adapter
to
CNP4 (female).
ConnectCNP4
(female) (7) to
chassis ground.
Turn starting
swtch ON
2
Is voltage between
CNl 7 (female) (1
and chassis ground
orma,,
No
2)
3)
Troubleshootmg
tools
M-27
Connect
T-adapter
to
CN17 (female)
Connect CNP4
(female) (71 to
chassis ground
Turn starting
swtch ON
panel
Replace
urarn!ng lamp bulb broken. or

jefectiie
contact. or
disconnection
an wirmg harness
lamp. or CN17 (male) (2) lamp
After mspectn%
repau (clean) or
replace
)efective contact. or
jisconnsction
in wmng harness
between CN17 (female) (2) :hassIs ground
After mspection.
repaw (clean1 or
replace
mH--
1)
2)
1)
monitor
Remedy
Connect
T-adapter
to
CN17 (female).
Turn starting
swtch OFF.
IO
NO
Defectwe contact. or
disconnection
in wiring
harness between CNP4
(female) (7) - CN297 (female)
(2). (1)
+24V line. or
between CN17 (female) (1) CN297 (female) (3). (5) +24V line. or defective lamp
relay.
After inspection.
repatr (clean) or
reolace
T-adapter
or socket adapter
(for Econoseal)
T-adapter
(for DLII
Related electrical
circuit drawing
Warning
lamp
panel
425F534-K
82ii50
WA500-1
M- 28: NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY,

BUT WARNING LAMP LIGHTS UP.
*
*
When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when
disconnecting the connector for checking, turn the starting switch OFF to prevent accidents.
(or socket adapter).
connect to the connector specified. (CN 0 A ( 1)
Remedy
YES
Defective
T-adapter
21
I
T-adapter
Troubleshooting
tools
M-28
to
CNP4 (female)
Turn starting
switch OFF.
monitor panel
Replace

between CNP4 (female) (7) CN297 (female) (2).
After inspection.
repair (clean) or
replace
Contact between +24V line

and wiring harness between
CN17 (female) (1) - CN297
(female) (3). or defective lamp
relay.
After inspection.
repair (clean) or
replace
(for DLI)
Short connector
1
Related electrical
circuit drawing
mp
panel
425F534-K
WA500-1
82251
M-29:
ABNORMALITY
IN
: &J
(FUEL GAUGE)
SYSTEM
I-J
*
When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents.
When connecting the T-adapter (or socket adapter), connect to the connector specified. EN0 A ( 1)
Cause
a)
If nothing is displayed in display area
YES
I
Does fuel gauge
show FULL?
2
IS there continuity
between CNP4
(femele) (4) and
Chassis ground7
A
1) Connect short
connector to
CN266 (female)
(fuel sensor).
2) Turn starting
switch ON.
b)
_
NO
fuel sensor
Iefectwe
monitor panel
YES
NO

(female).
21 Connect short
connector to
CN266 (female).
31 Turn stating
Swtch OFF.
Defective
Replace
kfective contact, 0,
1ares-s between ,I266
female) (2) - cN64 (4) :hassis ground, or between
X266 (female) (1) - CN64
3) - CNP4 (female) (4).
After inspection,
repair (clean) 0,
replace
efectlve fuel sensor
kplace
If indicator remains at FULL

YES
1
Does whole display

z:; of fuel gauge go -
1) Disconnect
CN266 (fuel
_
NO
SellSOr).
2)
Turn starting
switch ON.
ifter inspection,
weir kleanj 0,
eplace
Clefectlve

(female).
2) Remove CN266.
3) Turn starting
switch OFF.
T-adapter
Trouble-
monitor panel
(for DLll
shooting
tools
IS there continuity
betweenCNP4
(female) (4) and
chassis ground?
ontact between chassis

round and wiring harness
etween CNP4 (female) (4) .N64 (3) - CN266 (female)
1).
YES
Short connector
I
82ii52
WASOO-1
M-29
CNP4
Monitor
panel
CN64
CN 266
Fuel level sensor
425F516
WA500-1
82ii53
M-30:
*
ABNORMALITY
IN
;$i&
cl
(AIR PRESSURE
GAUGE) SYSTEM
When disconnecting or connecting the T-adapter (or socket adapter) or short connector, 1;rv;t?sn disconnecting the connector for checking, turn the starting switch OFF to prevent accidents.
to the connector specified. (CNO A ( 1)
checking, then go tothe next check.
a*
Remedy
Cause
a)
YES
gauge show
maximum level?
cot!wty
between CNP4
(female1 (1 and
Troubleshootmg
tools
Defective
monitor panel
Replace
rJO
Is there continuity
between CNP4
(female1 (1) and
chassis ground,
(female).
2) Disconnect
CN92.
3) Turn starting
switch OFF.
T-adapter
YES
dosconnection in wiring
harness behwen CN92
(female1 HI - CN63 (1
kNP4 (f&n&e) (1). orbetween
CN92 (female) (2) - CN62
(10) -chassis
ground.
After inspection,
repaIr (clean) or
replace
Defective
Replace
b-
NO

(female).
7.1 Connect short
COnnectOr to
CN92 (female).
3) Turn starting
switch OFF.
2
1) Disconnect CN92
(air pressure
sensorl.
21 Turn s;artmg
switch ON.
Replace
If indicator remains at maximum
air pressure sensor
YES
ISthere
1) Connect short
COnnectOr to
CN92 (air
pressure sensor).
2) Turn starting
switch ON.
b)
Defective
level
air pressure sensor

between CNW (female) (1)
CN63 (1) - CN92 (female) (1).
4fter inspection.
lpair Mean) or
.eolace
NO
Defective
monitor panel
(for DLI)
.
Short connector
82ii54
WA500-1
M-30
CNP4
CN 63
CN92
Monitor
panel
1
425F520
WA500-1
82-155
@
M-31
CNP4
CN 62
CN 97
CNIOI
Engine water
temperature sensor
Monitor panel
425F521
WA500- 1
82ii57
M-32:
ABNORMALITY
IN
(TORQUE CONVERTER OIL
TEMPERATURE GAUGE) SYSTEM

*
When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents.
to the connector specified. (CN 0 A ( 1)
Cause
a)
Remedy
oil
9fectwe torque converter

mperature sensor
temperature gauge
show minimum
level 7
1) Disconnect CN84
(torque converter
oil temperature).
2) Turn starting
switch ON.
b)
Intact between chassis

ound and wiring harness
ween
CN84 (female) (1)
U22 (1) - CNW (female) (3).
YES
Is there continuitv
between CNP4
(female) 13) and
chassis ground,
ND-

(female).
2) Remove CN84.
3) Turn Starting
switch OFF.
Dlefective monitor panel
Replace
After inspection.
repair (clean) or
replace
Replace
If indicator remains at minimum level
YES
De fective torque converter oil

ter nperature semor
1 r
De!fective monitor panel
7eplace

(female).
2) Connect short
connector to
CN84 (female).
3) Turn starting
switch OFF.
T-adapter
Troubkshooting
tOOIS
factive contact, or
;connaction in wiring
mess batwaen CNP4
male) (3) - CN22 (1)
I84 (female) (11, or Mv.wan
184 (female) (2) - CN22 (2)
chassis ground.
NO
ifter Inspection,
epair Mean1 or
eplace
(for DLII
Short connector
82iA58
WASOO-1
M-32
Monitor
425F522.K
WA500-1
82-159
0
ELECTRICAND ELECTRONIC
SYSTEM
83
DISASSEMBLY
AND
ASSEMBLY
MACHINE MONITOR
(Serial
No. 10001-10662)
Removal
Installation
(Serial
No. 10663
Removal
Installation
WA500-
. . . . . . . . . . . . . . . . . . . . . . . . 83- 2
. . . . . . . . . . . . . . . . . . . . . . . 83- 2
and up)
. . . . . . . . . . . . . . . . . . . . . . . . 83- 3
. . . . . . . . . . . . . . . . . . . . . . . 83- 4
83-l
0
REMOVAL
OF MACHINE
MONITOR
Serial No. 10001-10662

Stop the
safety
machine
bar on the frame.
ment to the ground

apply the parking
Lower the work
and stop the
equip-
engine.
Then
Disconnect
the cable from the negative (-)
terminal
of
the battery.
1.
Covers
Remove covers (I) and (2) of machine monitor.
2.
Wiring
Disconnect the following wirings from connector.
*
.
*
*
Connectors (3) and (4) for CAUTION
2 module
Connectors
1 module
(5) and (6) for CAUTION
Connector
(7) for speedometer module
Connector
(8) for service meter
Connectors
(9) and (10) for gauge module
Connectors
(11) and (12) for check module
After
disconnecting
the connectors,
mark with a tag
to distinguish when installing.

3.
Machine monitor
Remove mounting
bolts, then remove machine monitor
(13).
t When removing the machine monitor,
be careful not
to give it any sudden shock.
INSTALLATION
MONITOR
OF MACHINE
Serial No. 10001-10662

1.
Machine monitor
Set machine
monitor
(13)
in mounting
position
and
install.
*
2.
Be careful not to tighten the screw too much.
Electric wiring
Connect
the
following
electric
wirings
to
machine
monitor.
*
*
*
*
t
Connectors
Connectors
(11) and (12) for check module

(9) and (10) for gauge module
Connector
(8) for service meter
Connector
(7) for speedometer module
Connectors
1 module
Connectors
2 module
After
inserting the connectors,
lock securely.
apply the connector
Assemble so that there is no strain on
the wiring.
3.
Covers
Install covers (1) and (2) of machine monitor.
*%
WA500-1
REMOVAL
Serial
OF MACHINE
No. 10663
and up
Stop the machine

safety
MONITOR
bar
on
equipment
the
to the
Then
apply
under
the wheels
the
frame.
ground
parking
Lower
the
work

brake
to prevent
and
put
blocks
the machine
from
moving.
Disconnect
the cable from the negative
(-) terminal
of the battery.
1.
Covers
Remove
2.
covers (1) and (2) of machine
monitor.
Wiring
Disconnect
the following
wirings
from
connector.
Connector
(3) for CNPl
Connector
(4) for CNP2
Connector
(5) for CNP3
Connector
(6) for CNP4
Connector
(7) for CNP 5
Connector
(8) for CNP6
Connector
(9) for CNP7 (Night lighting
Connector
lamp)
Connector
lamp)
429FOIl397
After
disconnecting
a tag to distinguish
3.
Machine
Remove
monitor
*
When
the connectors,
when
mark
with
installing.
monitor
mounting
bolts,
then
remove
machine
monitor,
be careful
(12).
removing
the machine
not to give it any sudden
WA500-1
lamp)
shock.
11
INSTALLATION
Serial
1.
No.
10663
OF MACHINE
MONITOR
and up
Machine monitor
Set machine
monitor
(12) in mounting
position
and
install.
*
2.
Be careful
not to tighten
the
screw
too much.
Electric wiring
Connect
the following
electric
wirings
to machine
monitor.
0
Connector
lamp)
Connector
lamp)
Connector
Connector
(8) for CNP6
Connector
(7) for CNP5
Connector
(6) for CNP4
Connector
(5) for CNP3
Connector
(4) for CNP2
Connector
(3) for CNPl
After
inserting
connector
is no strain
3.
the
lamp)
-28FO
connectors,
lock securely.
Assemble
apply
I I397
11
the
so that there
on the wiring.
Covers
Install covers (1) and (2) of machine
*g4
monitor.
WA500-1
91 OTHERS
Cab ..........................
Air conditioner (Option) ........
. Piping ......................
. Air conditioner wiring diagram
- Air conditioner electric circuit .
. Air conditioner unit ..........
+ Compressor ................
. Condenser .................
. Dry reservoir ................
WA500-
......
......
......
......
......
......
......
......
......
..
..
..
..
..
..
..
..
..
91-2
. 91-3
. 91-3
. 91-4
. 91-4
. 91-5
. 91-6
. 91-6
. 91-7
91-1
CAB
--__._.
,._
_---3--_
423F159
1. Front glass
II
I!
Front wiper
3.
Rear wiper
4.
Door
L-l
View
91-2
2.
WAMO- 1
AIR CONDITIONER
PIPING
425F128
1.
Air vent
2.
Dry reservoir
3.
Condenser
4.
Compressor
5.
Hot water inlet port
6.
Hot water outlet port
7.
Air conditioner
WA500- 1
unit
91-3
0
AIR
CONDITIONER
WIRING
DIAGRAM
\ir conditioner unit
\
Screw 718.14UNF
Screw 5/8-18UNF
Screw 7/8-14UNF
Screw 5/8-18UNF
423F165-K
WA500-1
AIR
CONDITIONER
For DAIKIN
ELECTRIC
CIRCUIT
air conditioner
Blower box
temperature
..__
Cab unit
Therm0 protector
&
Condensor fan motor
Compressor
F42501011
For DENS0
air conditioner
(Condenser
(Relay end)
Air-conditioner
(Relay end)
relay
Condenser
r------7
L-
relay
Blower switch
A/C switch
____-
end)
Condenser
r-------______
.~.
~.
.-_-.I
,
I
El
(Resistor end)
(Motor end)
IAir condemner unit end)
WA500-1
AIR
CONDITIONER
For DAIKIN
UNIT
air conditioner
Cooling
Function
* The air conditioner acts to reduce operator fatigue by

providing
the operator
with a comfortable
* The refrigerant gas is compressed and pressurized in

air conditioner
operating
conditioner
environment.
compressor.
It then
enters the air
condenser where it is cooled, and goes to
air conditioner
unit.
Heating
The fan blows out cold air, the temperature
- The heating system uses the engine cooling water.
refrigerant gas rises and it returns to the compressor.
Hot
water
enters the air conditioner
unit from
hot
A fan blows hot air out.
The
water outlet
port (2).
temperature
of the cooling water
turns to
inlet
engine cooling
port
goes down,
it re-
(1) and then flows back to the
circuit.
423F161
91-6
0
1.
Hot Wdter inlet port
5.
2.
Hot water cutlet port
6.
Refrigerant gasoutlet port
3.
Electrical wiring
7.
Condensation drain port
4.
Outside air intake filter
Refrigerant gas inlet port
WA500- 1
of the
For DENS0 air conditioner
423F630
1. Temperature
regulator lever
11. Refrigerant gas inlet port
6. Connector
7. Air conditioner
3. Air conditioner switch
8. Condenser relay
13.
4. Blower switch
9. Hot water pick-up port
14. Heater coil assy
5.
RECIfWFRESH
WA500- 1
selector cable
relay
12. Refrigerant gas out let port
2. Mode selector lever
10. Hot water return port
Drain pipe
15. Evaporator assy
91-7
0
COMPRESSOR
For DAIKIN
air conditioner
1.
Charge valve
2.
Clutch
3.
Front head
4.
Case
A.
Air outlet port
B. Air inlet port
423F163
For DENS0
air conditioner
1.
Discharge service valve
2.
Suction service valve
3.
Clutch
4.
Oil plug
423F632
91-8
0
WA500- 1
CONDENSER
For DAI KIN air conditioner
Condensor motor
1.
Electrical wiring
2.
Fan
3.
Refrigerant gas inlet

port
4.
Refrigerant gas outlet

Port
1.
Refrigerant
poat
2.
Electrical wiring
423F162
For DENS0
air conditioner
3.
Fan
4.
Refrigerant
port
gas inlet
gas outlet
423F631
WA500- 1
9&9
DRY RESERVOIR
For DAIKIN
air conditioner
1.
Body
2. Sight glass
View
3.
Drier
4.
Filter
423F164
For DENS0
air conditioner
1.
Body
2. Sight glass
3.
Drier
4.
Drier
View Z
423F633
WA500- 1
OTHERS
93
DISASSEMBLY
AND
CAB
Removal
installation
ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . 93- 2
. . . . . . . . . . . . . . . . . . . . . . . 93- 3
AIR CONDITIONER
UNIT (If equipped)
. . . . . . . . . . . . . . . . . . . . . . . . 93- 4
Installation
. . . . . . . . . . . . . . . . . . . . . . . 93- 6
Removal
AIR CONDITIONER
CONDENSER
. . . . . . . . . . . . . . . . . . . . . . . . 93- 8
Installation
. . . . . . . . . . . . . . . . . . . . . . . 93- 8
Removal
DRY RESERVOIR
Removal
Installation
COMPRESSOR
(For DAIKIN
Removal
Installation
(For DENS0
. . . . . . . . . . . . . . . . . . . . . . . . 93- 9
. . . . . . . . . . . . . . . . . . . . . . . 93- 9
FOR AIR CONDITIONER
air conditioner)
. . . . . . . . . . . . . . . . . . . . . . . . 93-10
. . . . . . . . . . . . . . . . . . . . . . 93-l 0
air conditioner)
. . . . . . . . . . . . . . . . . . . . . . . . 93-l 1
Installation
. . . . . . . . . . . . . . . . . . . . . . 93-12
Removal
WASOO-
REMOVAL
n!
OF CAB
Stop the
safety
machine
bar on the frame.

1.
Electric wiring
1) Remove mounting bolt, then remove arm rest (-1,).

2) Remove mounting screw, then remove cover (2):
3) Disconnect electric wiring from connector
2.
(3).
Cab
1) Remove cap, then remove mounting bolts (4);.(5)
(6).
* There
are 2 mounting
and
bolts on both sides of, the
rear of the cab, so do not forget to remove them.
2) Lift off cab (7).

*
Lift off the cab evenly.

Cab:
9%2
305 kg
WA500- 1
INSTALLATION
1.
OF CAB
Cab
1) Sling cab (7) and set in mounting position.
*
Coat the seal evenly with adhesive compound.
&
2) Tighten
Seal: Adhesive compound
(cemedine 366E)
mounting bolts (61, (5) and (41, and assemble
cap.
2.
Electric wiring
1) Connect electric wiring at connector
(3).
2) Tighten mounting screw and install cover (2).

3) Install arm rest (1).
WA500-
REMOVAL
OF AIR CONDITIONER
Stop the
A.
safety
machine
UNIT
(If equipped)
bar on the frame.

Disconnect
the cable from the negative (-1 terminal
of
the battery.
Remove the cover under the cab.
Loosen air conditioner
hoses (I) and (2), and drain the
gas from the air conditioner.

*
Do not disconnect
the hose completely.
Loosen a
little, and drain.

Air conditioner,
1) Disconnect
After
heater hoses
air conditioner
bottom of air conditioner

*
42fP3580
- _
disconnecting
hoses (1) and
(2) from
unit.
the
air
conditioner
hoses,
cover the openings to prevent dirt and water from

entering.
2) Loosen clamps of heater hoses (3) and (4), then disconnect hoses.
Operators seat
Remove operators seat.
Operators seat: 40 kg
Arm rest, covers and seat support
1) Remove
arm rests (5) and (6), then remove covers
(7) and (8).

2) Remove cover (9) and seat support (IO).
Electric wiring
Disconnect the following
*
electric wiring from connector.
Wiring (11) for cab
- Wirings (12), (13). (14) and (15) for front and rear.
*
Remove the plate inside the tool box and push to

the front, then disconnect wiring.
5.
Circuit breaker
Remove circuit breaker (16).
*
Check that the wiring
connector
does not hit other
parts when removing.
93-4
0
WA500-
6.
Filter, blower box

1) Disconnect
VENTILATION-SELECTOR
cable
(17)
from lever.
2) Disconnect
electric
wirings
from
connectors
(18),
(19), (20) and (21).

*
Remove the clamp of cab wiring

it towards the air conditioner
3) Remove
mounting
bolts,
(22), then move
unit.
then
remove
filter
and
blower box (23).

*
Be careful
not to damage the seal at the contact
surface with the air conditioner
Air conditioner
1) Disconnect
unit.
unit
connectors
(24),
(25)
and (26) for cab
wiring and wiring (27) for radio antenna.
2) Remove mounting
bolts, then remove air conditioner
unit (28).
*
Move the air conditioner
unit outside the cab, then
lift off.
*
Be careful not to damage the connector

conditioner
hose.
Air conditioner
WA500-
unit:
115 kg
of the air
24
/
INSTALLATION
1.
Air conditioner
OF AIR CONDITIONER
UNIT
(If equipped)
unit
1) Set air conditioner
unit (28)
in mounting
position,
and tighten mounting bolts.
2) Connect
connectors
(24).
(25)
and
(26)
for
cab
wiring and wiring (27) for radio antenna.
2.
Filter, blower box

1) Set filter and blower box (23) in mounting
position,

*
Be careful
not to damage the seal at the contact
surface with the air conditioner
unit when instal-
ling.
2) Connect
connectors
(IS),
(19),
(20)
and
(21)
of
electric wiring.
t
Install clamp of wiring (22) for cab.
3) Connect
VENTILATION-SELECTOR
cable
(17) to
lever.
93-6
0
WA500-
3.
Circuit breaker
Install circuit breaker (16).
4.
Electric wiring
Connect the following
electric wirings to connector.
* Wirings (12), (13), (14) and (15) for front and rear
* Wiring (I I) for cab
*
5.
Install the plate inside the tool box.
Arm rests, covers, seat support

I) Set
seat
support
(10)
in mounting
position,
and
install cover (9).

2) Fit covers (7) and (8), then install arm rests (5) and
(6).
6.
Operators seat
Install operators seat.
7.
Air conditioner,
heater hoses
I) Connect heater hoses (3) and (4), then tighten clamp.

2) Connect air conditioner
of air conditioner
+
hoses (I) and (2) to bottom
unit.
To prevent water or dirt and dust from entering,

do not remove the covers from the hoses until just
before installing them.
Hold the hoses securely with a wrench to prevent

them from twisting when they are tightened.
Hose connector,
flared part: Compressor
Hose (I) nut: 3.7 f 0.4 kgm
Hose (2) nut: 5.6 f 0.6 kgm
Hose (1) nut: 1.35 + 0.15 kgm
Hose (2) nut: 3.25 & 0.25
(DAIKIN
air conditioner)
(DAIKIN
(DENS0
air conditioner)
air conditioner)
kgm
(DENS0
8.
air conditioner)
Filling with gas

Fill with air conditioner
gas.
* Connect cable to negative (-) terminal of battery.
WA500-
oil
REMOVAL
OF AIR CONDITIONER
Stop the
safety
ment
machine
CONDENSER
bar on the frame.

to the ground
apply the parking
Lower the work
and stop the
engine.
equipThen
1.
Remove cover (1).
2.
3.
Loosen air conditioner

conditioner
*
hoses (3) and (4). and drain air
gas.
Do not disconnect
Loosen it
slightly to drain the gas.

*
After
draining
the
air conditioner
gas, disconnect
hoses (3) and (4).

*
After
disconnecting
the hoses, fit covers to the con-
nectors and hoses to prevent water or dirt and dust

from entering.
4.
Remove
mounting
bolts, then
remove
air conditioner
condenser (7) from bracket (6).
INSTALLATION
CONDITIONER
1.
Set air conditioner
OF AIR
CONDENSER
condenser (7) in mounting
position,

2.
Connect air conditioner

*
hoses (3) and (4).
To prevent water or dirt and dust from entering, do

not
remove
the
covers from
the
hoses until
just
before installing them.

*
Hold
the
hoses securely
with
a wrench
to prevent
them from twisting when they are tightened.

4
Hose connector,
flared part:
Hose (3) nut:
5.6*
Hose (4) nut:
3.7 + 0.4 kgm
Compressor oil
0.6 kgm
3.
Connect electric wiring (2) to connector.
4.
Install cover (1).
5.
Fill air conditioner
9$8
with gas.
WA500-
REMOVAL
OF DRY RESERVOIR
Stop the machine

safety
ground
and
parking
brake
to prevent
1.
2.
on level ground
bar on the frame.

stop
the
Lower
engine.
Then
and put blocks
the machine
from
and install
the bucket
under
the
to the
apply
the
the wheels
moving.
Remove
cover (1)
Remove
bolt (2), and move air conditioner
condenser
to front.
3.
4.
Disconnect
Loosen
electric
air conditioner
air conditioner
+
wiring
hoses
After
connector.
(4) and (5). and drain
gas.
Do not disconnect
slightly
(3) from
Loosen
it
to drain the gas.

draining
the air conditioner
gas, disconnect
hoses (4) and (5).

*
After
disconnecting
connectors
the
hoses,
fit
and hoses to prevent
covers
water
to the
or dirt and
dust from entering.

5.
Remove
clamp,
then
remove
INSTALLATION
RESERVOIR
1.
Set dry reservoir
dry reservoir
(6).
OF DRY
(6) in mounting
position,
and tighten
clamp.
2.
Connect
+
hoses (4) and (5).
To prevent
water
do not remove
before
+
installing
Hold the hoses

them
or dirt
with a wrench
when
Hose connector,
flared
part:
Hose (4) nut: 3.7 * 0.4 kgm
Hose (5) nut: 3.7 + 0.4 kgm
Hose (4) nut: 1.35 i- 0.15
Hose (5) nut: 1.35 * 0.15
(DAIKIN
(DAIKIN
Set air conditioner
electric
then secure
5.
Install
6.
Fill with
with
wiring
Compressor
p3593
oil
air conditioner)
air conditioner)
air conditioner)
kgm
(DENS0
Connect
to prevent
kgm
(DENS0
3.
entering,
they are tightened.
4.
from
from the hoses until just
them.
securely
from twisting
&
and dust
the covers
air conditioner)
(3) to connector.
condenser
in mounting
position,
bolts (2).
cover (1).
WA500-1
air conditioner
gas.
9%9
FOR AIR
REMOVAL
OF COMPRESSOR
(For DAIKIN air conditioner)
Stop the
safety
machine
on level ground
bar on the frame.
CONDITIONER
and install the
ground and sto the engine.

1.
2.

Loosen hoses (2) and (3), and drain gas from air conditioner.
+
When draining the gas, do not completely
disconnect
the hoses. Loosen them slightly.

*
After draining the gas, disconnect hoses (2) and (3).
After
disconnecting
the hoses, cover the operatings
to prevent dirt and water from entering.

3.
Remove
bolts
(4).
(5)
and
(61, remove
V-belt,
then
remove compressor (7) of air conditioner.

*
There is little space, so be careful when working.
INSTALLATION
COMPRESSOR
CONDITIONER
(For DAIKIN
1.
OF
FOR AIR
air conditioner)
Set compressor
(7) of air conditioner
tion,
(8). then secure with bolts (4), (5) and
fit V-belt
(6).
t Clearance
a between
air conditioner:
*
in mounting
posi-
bracket ancd compressor for
a = Within 0.6 mm.
For details of adjusting V-belt, see 12 TESTING
AND
ADJUSTING.
w
2.
Mounting bolt of bracket:
5.5 f 0.5 kgm
Connect hoses (2) and (3).

*
To prevent
dirt and water
from
entering
the hoses,
do not remove the covers until just before installing.

*
To prevent the hoses from twisting,
hold them secure-
ly with a wrench when tightening.

&,
Hose connector thread, flare:
Hose (2) nut:
5.6 + 0.6 kgm.
Hose (3) nut:
7.0 f 0.7 kgm
3.
Connect electric wiring (I) at connector,
4.
Fill air conditioner
Compressor oil
with gas.
u
421 F3060
93io
WA500- 1
REMOVAL OF COMOPRESSOR
(For DENS0 air conditioner)
Stop the machine

safety
ground
and
parking
brake
to prevent
1.
Electric
stop
and install
the bucket
engine.
Then
blocks
the machine
electric
Air conditioner
Loosen
the
and put
Lower
under
from
the
to the
apply
the
the
wheels
moving.
wiring
Disconnect
2.
on level ground
bar on the frame.
FOR AIR CONDITIONER
wiring
(1) from connector
hose
hoses
(2) and
(3). and
drain
gas from
air
conditioner.
+
When
draining
disconnect
+
After
(3).
After
the
gas,
the hoses.
draining
not
to
the
prevent
dirt
completely
them
the gas, disconnect
disconnecting
operatings
do
Loosen
slightly.
hoses
hoses,
and
(2) and
cover
water
the
from
entering.
3.
425FO1959
Air compressor
1) Loosen
bolts (4) and
2) Remove
bolts
compressor
Sr The
(5), and remove

and
(5).
then
V-belt.
remove
air
so carry
out
(6).
working
the work
(4)
space
is confined,
carefully.
425F558
WA500-1
932
INSTALLATION OF COMPRESSOR
(For DENS0 air conditioner)
1.
FOR AIR CONDITlOlVER
Air compressor
1) Set air compressor
secure
+
with
position,
and
bolts (4) and (5).
Ti.ghten bolts (4) and (5) temporarily.
2) Install
+
(6) in mounting
mounting
V-belt,
Adjust
and secure
with
bolts (4) and (5).
the V-belt.
For details,
see TESTING
ADN
ADJUSTING.
2.
Air conditioner
Connect
*
To
425F558
hose
hoses (2) and (3).
prevent
dirt
and
hoses, do not remove
water
from
entering
the
the covers until just before
installing.
*
To prevent
securely
&
the
hoses from
with a wrench
Hose connector
twisting,
when
thread,
hold them
tightening.
flare:
Compressor
3.
4.
Hose (2) nut: 2.25
& 0.25
kgm
Hose (3) nut: 3.25
f 0.25
kgm
Electric
wiring
Connect
electric
Fillair conditioner
+
For details,
wiring
oil
(1) at connector.
with gas.
see the separate
AIR CONDITIONER
volume.
WA500-1
GEAR PUMP
97
SA SERIES
Structure
.........................

Disassembly
Assembly
Maintenance
GEAR
PUMP
.................
.......................
.........................
standard
.................
97-102
97-105
97-108
97-112
97-117
97-101
STRUCTURE
SA SERIES
STRUCTURE
:ide plate
FEATURES
The gear pump is a high quality,
specially
designed
for
reliable product that is
use in construction
equipment
which works under severe conditions.

0
The side plate, given surface treatment

its matching
alloy,
characteristics
ensures minimum
to improve
with the special copper
torque
loss and excellent
wear resistance.
l
With
the
the improved
pump
offers
hydraulic
stable
balance
performance
mechanism,
and
high
durability.
2OOF132
STRUCTURE
5
9,lO
1. Drive gear
2. Driven gear
3. Snap ring
4. Oil seal
5. Plate
6. Bracket
7. O-ring
8. Side plate
9. Back-up ring
IO.
Seal ring
11. Gear case

12. Side plate
13. Back-up ring

14. Seal ring
15. Cover
16. O-ring
17.
Bolt
18.
Dowel pin
21 F023
97-102
GEAR
PUMP
SA-1 Series single pump

-I
30.4 p
06.4 -I
I-- 1-l
22.2
+L -2
/
z
&
H
1:
Delivery
(The drawing above shows a pump of the counter-clockwise
port
rotation type. In a clockwise
rotation pump, the positions of the suction and delivery ports are reversed.)
SA-2 series single pump

0
Side port type
p-174
!--,_-_-____-146,
--
-H
Delivery
(The drawing above shows a pump of the counterclockwise
port
0
Rear port type

;__
/
._.- -,
,-_.__,
7446- -I
-,
-.H
GEAR
PUMP
97- 103
STRUCTURE
SA SERIES
SA-3 series single pump

0
Side port type
Delivery port
I*__. _.
_B-
.._
\ 4-E, Depth: - F
__-_I
0
Rear port type
,&_
*,I -.--.-_
,-pm
---I
,8,_-_____,
14.5----i
j---48---
44-8
i-75-1-88-i
SA-4
series single pump

--213--
y,
1

rotation
(Note)
i/i
?
\ 4-t.
LB-4
4kl, Depth: H
_
Delivery port
Uepth: F
pump, the positions of the suction and delivery ports are reversed.)
Dimensions A through H in the drav.ings vary with the pump capacity.
97-104
GEAR
PUMP
TESTING
SA SERIES
TESTING
AND ADJUSTING
Measure the pump delivery
5% See
No.
with
a test bench or flow meter kit (790-303-1001).

The capacity
Note on page 97-107.
Check item
Series
No.
erformance
Hydraulic oil:
EOIO-CD
Oil temperature:
50C
:apacity
code
Delivery
pressure
(kg/cm* )
Rqtation
(rpm)
Rotation
(rpm)
Delivery
(literslmin)
32
29
012
38
34
014
210
3500
47
23
3500
43
016
52
48
020
66
61
025
83
76
l 016
44
40
l 020
55
50
*025
67
62
77
71
88
82
036
100
92
040
111
103
045
121
Ill
050
138
128
l 020
45
42
l 025
55
51
032
210
3000
*040
90
82
l050
112
102
210
2500
129
2500
II9
063
145
134
071
158
146
080
184
170
100
231
214
212
140
2000
112
125
2200
140
160
210
236
192
2000
213
233
215
253
234
287
266
328
303
336
310
200
373
345
224
411
250
460
180
PUMP
Delivery
(literdmin)
010
125
operating
Repair limit
25
112
For SA pumps
* are for triple pumps.
008
056
No. 2. (Examples:
codes marked
Standard
028
GEAR
AND ADJUSTING
at a service pressure of 50 kg/cm2
Pumps for power traines and servo-hydraulic
2000
385
425
or less, see the standard and the repair limit in Table,

pumps for excavators)
97-105
TESTING
SA SERIES
No.
Check item
Series
No.
:apacity
code
Performance
Hydraulic oil:
EOl O-CD
Oil temperature:
Repair limit
Standard
Rotation
(rpm)
ADJUSTING
Delivery
(liters/min)
Rotation
(rpm)
Delivery
(literslmin)
008
27
25
010
33
30
012
40
37
014
50c
Delivery
pressure
(kg/cm2 1
AND
xl
3500
48
3500
44
016
54
50
020
68
63
025
86
79
23
21
*016
47
43
* 020
59
53
* 025
72
66
008
74
80
028
2
30
3000
032
92
84
036
104
95
040
115
106
045
126
115
2
050
144
132
* 020
49
44
* 025
60
55
l 040
96
88
119
* 050
3
056
30
134
109
2500
123
063
151
138
071
164
150
080
192
176
100
241
221
217
198
125
240
220
112
242
222
125
264
112
30
242
2200
140
160
4
97-106
300
275
342
314
30
180
350
321
200
389
357
2000
2000
224
434
398
250
480
440
GEAR
PUMP
SA SERIES
TESTING
AND ADJUSTING
Note 1.) If it is impossible to raise the pump speed to

the value shown in the table because of limitations of the test bench, calculate the allowance
for the delivery from the following
formula:
-(No -N)Qth
Q=Qo
1000
however, N -2
N:
1000 rpm
where,
RPM of test bench
0:
Repair
limit
for
delivery
at
rpm
(liters/min)
No:
RPM in the table
Qo:
Repair
limit
for delivery
in the table
(liters/min)
Capacity code
Qth:
Note 2.) If the test bench allows the pump to raise its
delivery
above
pressure above
210 kg/cm2,
140
kg/cm2
but not
use the repair limit
for
delivery given in Table, No. 1.

Note 3.) For
pumps
50 kg/cm2
whose
in
service
operation,
pressure
use
Table,
exceeds
No. 1.
(Do not use Table, No. 2)

Note 4). The volumetric
efficiency
of a pump decreases
after the pump is reassembled. After reassembly,

therefore,
perform
the following
test bench or flow-meter
tests with
kit (790-303-1001).
(1) Shock test

20 times
252 kg/cm max.
E
3
I
t
Time
(2) Performance test (measure the delivery)
GEAR
PUMP
97- 107
DISASSEMBLY
SA SERIES
DISASSEMBLY
(I)
Match mark
Single pump
*
Cautions before disassembly

To avoid confusion
in the reassembly,
match marks on connecting
stamp
sections of bracket
(6) to gear case (11) and gear case (11) to cover

(15).
I OOPO50
1)
Put the pump assembly on a work bench with

the
bracket
side
facing
down,
and
loosen
mounting bolts (17) for cover (15).
Use the bracket mounting
bolt holes to secure
the pump assembly.
__I00P051
2)
*
Remove cover assembly (15).

Place the internal
parts in line in the order of
removal, taking care not to damage the contacting surfaces or sliding surfaces of the parts.
*
Pull out cover assembly (15),
taking
care not
to damage the hole for the dowel pin. Do not

pry the cover.
I OOP052
3)
Remove O-ring (16) from the cover.
I OOPO53
97-108
GEAR
PUMP
SASERIES
4)
DISASSEMBLY
Pull out side plate (12) on the cover side.
I OOPO54
5)
Remove backup ring (13) and seal ring (14).
23OF221
6)
*
Remove drive gear (1) and driven gear (2).

Pull
out
the
gears by
hand.
Do
not
use a
hammer.
*
If the oil seal is not replaced, tape the drive gear

and the spline section
to protect
the oil seal
from damage.
I OOPO55
7)
Remove bracket (6) from gear case (I?).
When removing bracket (6) from gear case (11).

take care not to let side plate (8) on the bracket
side fall down and leave the side plate-installed
as is to the gear case.
Do not hit the side plate surface.
I OOP056
GEAR
PUMP
97- 109
DISASSEMBLY
SA SERIES
8)
Pull out side plate (8) from gear case (111.
fOOPO57
9)
Remove backup ring (13) and seal ring (14).
:
-
_,,
lOOPO58
10)
Remove O-ring (7) from the bracket.
I OOPO59
97-110
GEAR
PUMP
SA SERIES
(2)
DISASSEMBLY
Tandem pump
1)
Stamp match marks.
2)
Put the pump on a work
bench with the front
pump bracket surface facing down, and remove

the four bolts that connect the front pump to
the rear pump.
3)
4)
Disconnect the front pump from the rear pump.
For the disassembly
of single pumps, see the
section on single pumps.
(3)
P7050
I 003
Triple pump
Follow the same procedure for tandem pumps.
GEAR
PUMP
97-111
ASSEMBLY
SA SERIES
ASSEMBLY
(1)
Single pump
t
When
a used gear case is assembled,
burrs
from
plate
can be slided
Make
the
sure
case and make
the
the side
smoothly.
that
has specified
remove
sure that
the
length
dowel
pin
on
the
case
(II).
I g+Length
of dowel
2
pin
3
::- I OOPO60
1)
Put cover
(15)
on a work
bench.
FOOPO6
2)
Install
side
plate
the seal groove

*
Do
not
install
side plate
*
Do
plate
gear case (11)
backup
the
with
ring and the seal to
suction
the delivery
damage
especially
into
outside.
at this stage.
confuse
with
Do not
the
(12)
not
(12)
facing
the
around
side
of
the
side
side.
periphery
of the side plate,
the seal section.
I OOP062
Measurement
of side clearance
Temporarily
assemble
as shown
a work
stack
in the
bench
height
bracket
drawing
and
measure
including
and (12)
and the height
Measure
with
a depth
(6)
at right.
drive
the
and
Place
gear
the
difference
gear
(I),
case
assembly
between
side
plates
(11)
on
the
(8)
of gear case (11).

dial gauge or depth
micrometer.
Judgement criteria
Confirm
clearance
that
the measurements
given in the Maintenance
97-112
conform
to the standard
Standard
T, ble.
GEAR
PUMP
SA SERIES
3)
Install
ASSEMBLY
gear case (11)
to cover
(15)
with the
match marks aligned.
4)
Install drive gear (1) and driven gear (2).
IOOPO64
5)
Install side plate
(8) with the backup and seal
ring grooves facing upward.
IOOP065
10
6)
*
Dischargepen
Install backup ring (9) and seal ring (10).

Install them with care to prevent gaps between
the ring and the gear case as shown in Fig. P.
If it is impossible to eliminate
the gap, replace
the seal ring and the backup ring.
-Gap
23OF223
GEAR
PUMP
97-113
SA SERIES
7)
ASSEMBLY
Apply
some hydraulic
oil to the shafts of gears
(1) and (2) and also to the sliding section of

the side plate.
*
Take care to keep the gear case free from oil.
8)
Install O-ring (7) to bracket (6).
9)
Install bracket (6).
Align
the
match
marks
when
installing
the
bracket.
*
Before
installing
the bracket,
make sure that
the seal and backup rings are properly installed

according to the precautions in item 6.
t
Make sure O-ring (7) is fit properly.
Confirm
that the contact
surface is free from
dirt and dust.
10)
Carefully
turn the gear pump assembly upside
down so that the bracket side will face downward,
and put the gear pump assembly on a
work bench.
*
When turning the pump upside down, take care

not to let the contact surfaces open out and not
to let the O-ring and seal come off.
97-114
GEAR
PUMP
SASERIES
ASSEMBLY
11)
Remove the cover (15) and install O-ring (16).
12)
Install
backup
ring and seal ring to side plate
(12) in the manner described in item 6).

13)
Install cover (15).
*
*
Align the match marks when installing thecover.
Make sure O-ring (16) is fit properly.
42
Before installing the cover, make sure backup

ring and seal ring are properly installed according to the precautions given in item 6).
lOOP053A
14) Tighten mounting bolts (17).

*
Use a torque wrench and tighten
to the specified
torque
the
bolts
in the order shown in
the drawing.
For the tightening
torque,
see the Maintenance
Standard Table on page 97-l 17.
M
3
Tightening order
15) After
assembly;check
the pump
the rotational
torque of
shaft to see if it conforms
to the
value given in the table.

*
After
the
pump
performance
with
a test
303-1001).
is assembled,
carry
out the
test (measure the pump delivery)

bench
Confirm
or
flow
that
meter
kit
(790-
the performance
l.O-
1.5 ksm
is
with the repair limits.
GEAR
PUMP
97-115
ASSEMBLY
SA SERIES
3)
ddupling
Install the coupling to the front pump.
4)
Fit the O-ring to the rear pump bracket.
5)
Put the rear pump on top of the front pump.
Take care not to let the O-ring come off.
Align the match marks.
6)
Tighten four mounting bolts.
Tighten
O-ring
/
P7050
the
bolts
with
a torque
wrench
I006
to
the specified torque in the order shown in the

drawing below.
[I]
I$-$]
Tightening order
*
After
the
pump
performance
with
a test
303-1001).
is assembled,
carry
out the
Match mark
test (measure the pump delivery)

bench
Confirm
or
flow-meter
that
the
kit
(790-
performance
is within the repair limits.
3)
Triple pump
Follow
the same assembly procedure
as for the
tandem pump.
97-116
GEAR
PUMP
MAINTENANCE
SA SERIES
MAINTENANCE
STANDARD
STANDARD
2
Unit:
mm
Criteria
NO.
Check item
Series No.
Standard clearance
Clearance
limit
0.10 - 0.15
0.19
Remedy
Clearance between the

gear case and the gear
plus the side plate
Replace the side plate

or the pump assembly
Replace
-1
0.06 - 0.140
Tightening torque for

the case mounting
bolts.
4
GEAR
PUMP
15 -
18 kgm
97-117
Komatsu America international Company

440 North Fairwav Drive
I
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications
Fax No. (847) 970-4186
PROPOSAL
FOR MANUAL
REVlslON
FOR INTERNAL USE ONLY -- No. PMR

2
NAME OF COMPANY:
PHONE NO:
:
S
DEPARTMENT:
E
R
NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
Attach photo or sketch.

If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY

CORRECTIVE ACTION:
PFMRl 081696
LOCATION:
DATE:

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SEBM04250107

Series Engine Shop Manual.

(THIS SECTION IS NOT USED IN THIS MANUAL)

50 BRAKE AND AIR SYSTEM

are indicated by the use of the

It is requested that necessary actions

are those previously revised

Proper service and repair is extremely

and repair techniques

manual are both effective

safety, and take the necessary

Some of these operations

by Komatsu for the purpose.

for the safe operation

and safe methods

quire the use of tools specially designed

are used to mark safety pre*

arises or may possibly arise, first consider

actions to deal with the situation.

keep tools and removed

and parts in their correct

sure that there is no dirt or oil on the floor.

out any greasing

keep the work area clean and make

Never smoke while working.

decals which are fixed to the machine.

wear safety shoes and helmet.

loose work clothes,

always wear welding

gloves, apron, glasses,

out any operation

controls in the operators

on hard, level ground, and

stands before starting work.

safety pin or use blocks to prevent the work

the correct way to use them.

or any other work equipment

repairs are needed, always have a

machine from moving.

grinding parts with a grinder, etc.

park the machine

parts with a hammer.

all mud and oil from

use the handrails,

Never jump on or off the machine.

ladders or steps, use a stand to provide safe

the oil filler

are free from

out. If any fuel or oil drips on to

the bolts to remove.

even start fires.

use -only the miniwashing

parts such as guards,

not to get your

may cause electrical

by the hoist or crane.

part still raised

that they are installed

the leads from

use the specified

not to get burned.

chine is being operated.

the oil from

end of the track.