SEBM009014

MACHINE MODEL SERIAL NUMBER

WA500-3 50001 and up

• This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may re-
quire.
Materials and specifications are subject to change without notice.

• WA500-3 mounts the S6D140E-2 or SA6D140E-3 engine.

For details of the engine, see the 6D140-2 or 140-3 Series Engine Shop Manual.

© 2005 1
All Rights Reserved 00-1
Printed in Japan 02-05(02) (14)
 CONTENTS

No. of page

01 GENERAL ............................................................................................................ 01-1

10 STRUCTURE AND FUNCTION ........................................................... 10-1

20 TESTING AND ADJUSTING ................................................................ 20-1

30 DISASSEMBLY AND ASSEMBLY ..................................................... 30-1

40 MAINTENANCE STANDARD ............................................................... 40-1

90 OTHERS ............................................................................................................... 90-1

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30-109 (3) 30-159 (3) 40-11-2 (8) 90-9 (8)
30-110 (3) 30-160 (3) 40-11-3 (8) 90-11 (8)
30-111 (3) 30-161 (3) 40-11-4 (8) 90-11-2 (8)
30-112 (3) 30-162 (3) 40-12 90-13 (8)
30-113 (3) 30-163 (3) 40-13 90-15 (8)
30-114 (3) 30-164 (3) 40-14 (8) 90-17 (8)
30-115 (3) 30-165 (3) 40-15 90-19 (8)
30-116 (3) 30-166 (3) 40-16 90-20-1 (8)
30-117 (3) 30-167 (3) 40-17 90-20-3 (8)
30-118 (3) 30-168 (3) 40-18 90-20-5 (8)
30-119 (3) 30-169 (3) 40-19 90-20-7 (8)

WA500-3 00-2-5
(13)
 INITIAL TEACHING METHOD FOR
TESTING AND ADJUSTING TRANSMISSION CONTROLLER

INITIAL TEACHING METHOD FOR

TRANSMISSION CONTROLLER
fl The transmission controller is equipped with a
learning function to self compensate so that it pro-
vides a constant gearshifting feeling to match the
changes in the transmission clutches occurring
with the wear.
If the transmission is overhauled or replaced, the
transmission controller keeps the control com-
mand values learned to match the previous trans-
mission. For this reason, transmission shock or
abnormal noise may occur. After operating the
machine for a short time, the controller will learn
to match the condition of the new transmission
and will gradually return to the normal condition,
but if it is desired to reset the condition quickly
and to carry out learning again, it is possible to
reset the learning data and to carry out initial
learning as follows.

1. Method for resetting learning control data

fl Do as follows to return all the previously
learned control data in the controller to the
default values.
1) Check that the starting switch is at the OFF
position.
2) Remove the cover at the right side of the work
equipment control box.
3) Disconnect wiring connector (C3A) (1) and
connect T-adapter P.
4) Turn the starting switch ON.
fl Do not start the engine.
5) From the free condition, short circuit between
terminals No. (1) to (16) for at least one sec-
ond, then return them to free condition.

2. Initial learning method

fl To adjust the controller learning control data
for each clutch from the default settings to
the optimum values, first carry out the above
Step 1 “Method of resetting learned control
data”, then do as follows.
1) Stall the torque converter. For details, see
MEASURING ENGINE SPEED.
2) Operate the speed lever and directional lever
as follows.
N→F1→F2→F3→F4→N→R1→N
fl Operate the levers with the engine running at
low idling, the transmission cut-off selector
switch at OFF, and the manual switch at ON.

WA500-3 20-147
(12)
 INITIAL TEACHING METHOD FOR
TESTING AND ADJUSTING TRANSMISSION CONTROLLER

fl It is possible to carry out this operation

with the left brake pedal depressed fully,
so there is no need to travel.
3) When the torque converter oil temperature
gauge rises to the 2nd level on the mainte-
nance monitor, return the engine to low idling.
fl Target value for torque converter oil tem-
perature: 40 – 50°C
fl There is no problem if the oil temperature
gauge goes down to the 1st level.
4) Operate the speed lever and directional lever
as follows twice in succession.
N→F1→F2→F3→F4→F3→F2→F1→N→R1→
N
fl Operate the levers with the engine run-
ning at low idling, the transmission cut-
off selector switch at OFF, and the manual
switch at ON.
fl Hold for the following periods of time for
each speed range.
• Speed range 4 only: 3 seconds
• Other speed ranges: 2 seconds
fl After carrying out the gearshifting opera-
tion in Step 2), if the engine is stopped
before carrying out the gearshifting op-
eration in Step 4), repeat Step 2) again.
fl It is possible to carry out this operation
with the left brake pedal depressed fully,
so there is no need to travel.
¤ Check that the area around the machine
is safe and depress the left brake se-
curely when shifting gear.

20-148 WA500-3
9
TESTING AND ADJUSTING ADJUSTING MAIN MONITOR

ADJUSTING MAIN MONITOR

(SPEEDOMETER MODULE)
Serial No.: 50001 – 52000
• The speedometer on the main monitor is a com-
mon part for all machines, and the input signal
for the travel speed differs according to the ma-
chine, so it is necessary to adjust the monitor for
use with the particular model.
• In addition, the tire diameter also differs accord-
ing to the type of tire fitted, so it is necessary to
adjust to give the correct travel speed.
• It is also necessary to change the switches if the
optional E.C.S.S. (Electronically Controlled Sus-
pension System) is installed.

Adjustment procedure
• Turn off the power, then remove the machine
monitor and adjust the switches at the back of
the speedometer.
1. Setting machine model
1) Remove the rubber caps from DIP switches (1),
(2) and (3) at the back of the speedometer.
2) When the rubber cap is removed, a rotary
switch can be seen inside. Using a flat-headed
screwdriver, turn this switch to adjust it to the
settings in the table below.
• When using the main monitor as the
speedometer, set DIP switch (3) to posi-
tion 0. When using the former as the ta-
chometer, set the latter to position 1.
Switch (3)
Switch (1) Switch (2) (tachometer
Tire size (model (speed- input selection)
selection) ometer cor- Speed- Tachom-
rection)
ometer eter
26.5-25-20PR
5 7 0 1
(STD)
29.5-25-22PR 5 4 0 1
(If equipped)

3) When the cap is removed from DIP switch (4)

at the back of the speedometer, an ON/OFF
switch can be seen.
Adjust the setting if the E.C.S.S. (Electronically
Controlled Suspension System) is installed.
DIP switch (4) Reference
Switch
No. Without With Amount of correction for DIP switch (2)
E.C.S.S. E.C.S.S.
1 ON ON Switch position 0 1 2 3 4 5 6 7

2 ON ON Amount of
correction (%) +14 +12 +10 +8 +6 +4 +2 0
3 ON OFF
4 OFF OFF
Switch position 8 9 A B C D E F
4) After completing the adjustment, fit the rub-
ber caps securely and install the main moni- Amount of
correction (%) 0 –2 –4 –6 –8 –10 –12 –14
tor.

WA500-3 20-153
(14)
TESTING AND ADJUSTING ADJUSTING MAIN MONITOR

Serial No.: 52001 and up

• The speedometer on the main monitor is a com-
mon part for all machines, and the input signal
for the travel speed differs according to the ma-
chine, so it is necessary to adjust the monitor for
use with the particular model.
• In addition, the tire diameter also differs accord-
ing to the type of tire fitted, so it is necessary to
adjust to give the correct travel speed.

Adjustment procedure
• Turn off the power, then remove the machine
monitor and adjust the switches at the back of
the speedometer.
1. Setting machine model
1) Remove the rubber caps from DIP switches (1),
(2) and (3) at the back of the speedometer.
2) When the rubber cap is removed, a rotary
switch can be seen inside. Using a flat-headed
screwdriver, turn this switch to adjust it to the
settings in the table below.
• When using the main monitor as the
speedometer, set DIP switch (3) to posi-
tion 0. When using the former as the ta-
chometer, set the latter to position 3.
Switch (3)
Switch (1) Switch (2) (tachometer
Tire size (model (speed- input selection)
selection) ometer cor- Speed- Tachom-
rection)
ometer eter
26.5-25-20PR
5 7 0 3
(STD)
29.5-25-22PR 5 4 0 3
(If equipped)

3) After completing the adjustment, fit the rub-

ber caps securely and install the main moni-
tor.
Reference 1.
Amount of correction for DIP switch (2)

Switch position 0 1 2 3 4 5 6 7
Amount of
correction (%) +14 +12 +10 +8 +6 +4 +2 0

Switch position 8 9 A B C D E F
Amount of
correction (%) 0 –2 –4 –6 –8 –10 –12 –14

Reference 2.
DIP switch (4) is set as shown in the figure at right
when delivered.
If it is changed, travel damper will not work nor-
mally. Accordingly, do not change it.
When the main monitor is replaced, check the set-
ting of DIP switch (4).

20-154 WA500-3
(14)
 TROUBLESHOOTING OF MAIN MONITOR
SYSTEM
(M MODE)

Trouble data display ................................................................................................................................ 20-453

Electrical circuit diagram for machine monitor system ....................................................................... 20-456
Electrical circuit diagram for lamp and horn system ........................................................................... 20-458
Electrical circuit diagram for turn signal and hazard system .............................................................. 20-459
M- 1 Main monitor does not work ................................................................................................... 20-460
M- 2 When starting switch is turned ON and engine is started immediately, all lamps stay
lighted up .................................................................................................................................. 20-461
M- 3 Speedometer display does not work properly ...................................................................... 20-462
M- 4 Abnormality in shift indicator ................................................................................................. 20-463
a) Displays N even when directional lever is at F ................................................................ 20-463
b) Displays N even when directional lever is at R ................................................................ 20-463
c) Does not display N even when directional lever is at N, and displays R when
directional lever is at F ....................................................................................................... 20-463
d) Does not display N even when directional lever is at N, and displays F when
directional lever is at R ....................................................................................................... 20-464
e) Does not display 1st – 4th ................................................................................................... 20-464
M- 5 High beam does not light up ................................................................................................... 20-465
M- 6 Turn signal display does not light up ..................................................................................... 20-466
a) L.H. turn signal display does not light up ......................................................................... 20-466
b) R.H. turn signal display does not light up ........................................................................ 20-466
M- 7 Abnormality in parking display ............................................................................................... 20-467
a) Parking lamp display does not light up ............................................................................ 20-467
b) Parking lamp display stays lighted up .............................................................................. 20-467
M- 8 Abnormality in preheating system ......................................................................................... 20-468
(1) Abnormality in preheating system (QHS) (Serial No.: 50001 – 52000) ................................ 20-468
a) Does not carry out preheating ........................................................................................... 20-468
b) Always carries out preheating for 45 seconds ................................................................. 20-469
c) Preheating stays on ............................................................................................................ 20-469
d) Preheating time becomes shorter, or there is variation .................................................. 20-470
(2) Abnormality in preheating system (Serial No.: 52001 and up) ......................................... 20-470-1
a) Does not carry out preheating ........................................................................................ 20-470-1
b) Preheating stays on ......................................................................................................... 20-470-1
M- 9 Night lighting does not light up .............................................................................................. 20-471
M-10 Abnormality in front working lamp ........................................................................................ 20-472
a) Neither monitor display nor front working lamp light up ............................................... 20-472
b) Working lamp lights up but monitor display does not light up ...................................... 20-472
c) Monitor display lights up but working lamp does not light up ...................................... 20-472
M-11 Abnormality in rear working lamp ......................................................................................... 20-474
a) Neither monitor display nor rear working lamp light up ................................................ 20-474
b) Working lamp lights up but monitor display does not light up ...................................... 20-474
c) Monitor display lights up but working lamp does not light up ...................................... 20-474

WA500-3 20-451
(12)
M-12 Abnormality in transmission cut-off ....................................................................................... 20-476
a) When monitor switch (transmission cut-off switch) is pressed, cut-off function is
not switched and display does not change ...................................................................... 20-476
b) When monitor switch (transmission cut-off switch) is OFF, monitor display goes out
but cut-off function is actuated when pedal is depressed .............................................. 20-476
c) When monitor display is turned off (transmission cut-off switch turned OFF),
cut-off function is always actuated ................................................................................... 20-476
d) Cut-off function is always actuated regardless of monitor display
(transmission cut-off switch ON or OFF) .......................................................................... 20-476
e) Monitor display lights up (transmission cut-off switch turned ON),
but cut-off function is not actuated ................................................................................... 20-477
M-13 Abnormality in parking brake dragging warning .................................................................. 20-478
a) When parking brake is applied, buzzer sounds (intermittently) and caution lamp
flashes even when directional lever is at N ...................................................................... 20-478
b) When parking brake is applied, buzzer does not sound and caution lamp does not
light up even when directional lever is at position other than N ................................... 20-478
M-14 When parking brake dragging warning is given, buzzer and caution lamp are actuated
continuously, or they are not actuated ................................................................................... 20-480
a) Actuated continuously ....................................................................................................... 20-480
b) Not actuated ........................................................................................................................ 20-480
M-15 Abnormality in buzzer .............................................................................................................. 20-481
a) Buzzer does not sound when starting switch is at ON (for 3 seconds)
(during self-check) .............................................................................................................. 20-481
b) Buzzer always sounds ........................................................................................................ 20-481
M-16 Condition of monitor switches is not stored in memory ...................................................... 20-482
M-17 Abnormality in failure display mode ................................................................................... 20-482-2
a) Does not enter failure display mode .............................................................................. 20-482-2
b) Count for time elapsed since failure in failure display mode does not advance ....... 20-482-2
M-18 Buzzer is not made to sound by transmission controller ..................................................... 20-484
M-19 Abnormality in emergency steering normal display ............................................................ 20-485
a) Emergency steering normal display does not light up ................................................... 20-485
b) Emergency steering normal display stays lighted up ..................................................... 20-485
M-20 Abnormality in emergency steering actuation display ......................................................... 20-486
a) Emergency steering actuation display does not light up ................................................ 20-486
b) Emergency steering actuation display stays lighted up .................................................. 20-486
M-21 Abnormality in auto-greasing system .................................................................................... 20-487
a) Forced greasing cannot be carried out ............................................................................. 20-487
b) Monitor display flashes rapidly (2 times/sec) ................................................................... 20-487
c) When no more grease remains, monitor display flashes rapidly (2 times/sec) ............ 20-487
d) Monitor display flashes slowly (1 time/sec) ..................................................................... 20-488
e) Monitor display goes out ................................................................................................... 20-488

20-452 WA500-3
(12)
M-22 Abnormality in ECSS system [*] ............................................................................................. 20-489
a) Display does not change when switch is pressed ........................................................... 20-489
b) Monitor display lights up but ECSS function does not work .......................................... 20-489
M-23 Failure code is not sent to main monitor (abnormality in network) .................................... 20-490

fl: Referring to TESTING AND ADJUSTING, Adjusting main monitor (speedometer module),
check that DIP switch 4 on the back side of the main monitor is set correctly.

WA500-3 20-452-1
(12)
TROUBLESHOOTING M-7

M-7 Abnormality in parking display

fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on to the next step.

a) Parking lamp display does not light up

Cause Remedy

3 YES
Defective main monitor Replace
Is resistance
YES between CN19
(female) (2) and
2 chassis ground Defective contact or discon-
Is voltage between normal? nection in wiring harness Repair or
YES L06 (11) and between CN19 (female) (1) replace
• Max. 1 Ω NO
chassis ground • Turn starting switch and chassis ground
1 normal? OFF.
Is resistance Defective contact or discon-
• 20 – 30 V • Disconnect CN19. nection in wiring harness Repair or
between CN19
(male) (1) and (2) • Turn starting switch NO between L06 (female) (11) – replace
normal? ON. TM2 (7) – CN19 (female) (1)
• Turn parking switch
• Max. 1 Ω ON.
• Disconnect CN19. Defective parking brake Replace
• Turn starting switch NO indicator switch
ON.
• Turn parking switch
ON.

b) Parking lamp display stays lighted up

Cause Remedy

2 YES
Defective main monitor Replace
Is voltage between
YES CN19 (1) and
1 chassis ground
Short circuit with power
Is resistance normal? Repair or
source in harness between
between CN19 •0–2V NO L06 (female) (11) – TM2 (7) replace
(male) (1) and (2) • Turn starting switch – CN19 (female) (1)
normal? ON.
• Max. 1 Ω • Turn parking switch OFF. Defective parking brake
• Disconnect CN19. NO Replace
indicator switch
• Turn starting switch
ON.
• Turn starting switch
OFF.

M-7 Related electrical circuit diagram

WA500-3 20-467
2
TROUBLESHOOTING M-8

M-8 Abnormality in preheating system

(1) Abnormality in preheating system (QHS)
Serial No.: 50001 – 52000
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on to the next step.

a) Does not carry out preheating

fl Check that the water temperature is below 5˚C.
(1) Monitor display also does not light up
Cause Remedy

2 YES
Defective monitor panel Replace
Is resistance bet-
YES ween L05 (female)
1 (7) and chassis
Short circuit with power
Is resistance bet- ground normal? Repair or
source in harness between
ween E05 (male) • Min. 4 kΩ NO L05 (female) (7) – LR4 (2) – replace
(1) and chassis • Turn starting switch ER1 (8) – E05 (female) (1)
ground normal? OFF.
• Min. 4 kΩ • Disconnect L05. Defective engine water
• Turn starting switch NO Replace
temperature sensor
OFF.
• Disconnect E05.

(2) Only monitor display lights up

Cause Remedy

YES Defective electrical intake

Replace
air heater
2
Is voltage between
YES 3 YES
E07 and chassis Defective heater relay Replace
1 ground normal? Is voltage between
Is voltage E08 and chassis
• 20 – 30 V NO ground normal? Defective contact or discon-
between E09 and nection in wiring harness
• Turn starting switch Repair or
L56 (3) normal? between E08 and slow
ON. • 20 – 30 V NO replace
blow fuse
• 20 – 30 V • Turn starting switch
ON. Defective contact or discon-
• Turn starting switch nection in wiring harness
ON. between L56 (female) (3) – Repair or
NO LR4 (7) – ER1 (4) – E09, or replace
between L56 (female) (1)
and chassis ground

20-468 WA500-3
(12)
TROUBLESHOOTING M-8

b) Always carries out preheating for 45 seconds

fl Check that the water temperature is above -10˚C.

Cause Remedy

2 YES
Defective monitor panel Replace
Is resistance bet-
YES ween L05 (female)
1 (7) and chassis Defective contact or discon-
Is resistance bet- ground normal? nection in wiring harness Repair or
ween E05 (male) between L05 (female) (7) –
• Max. 9 kΩ NO LR4 (2) – ER1 (8) – E05
replace
(1) and chassis • Turn starting switch (female) (1)
ground normal? OFF.
• Max. 9 kΩ • Disconnect L05. Defective engine water
• Turn starting switch NO Replace
temperature sensor
OFF.
• Disconnect E05.

c) Preheating stays on

Cause Remedy

YES
Defective main monitor Replace

Does preheating 3 YES Defective preheating

Replace
stop? relay
Is voltage between
YES L06 (4) and chassis
• Turn starting switch ground normal? Short circuit with power
2
ON. source in harness between Repair or
• Disconnect L06. L06 (female) (4) and L56 replace
• 20 – 30 V NO (female) (2)
Does preheating
• Turn starting switch
NO stop? ON. Short circuit with power
source in wiring harness Repair or
• Turn starting between L56 (female) (3) –
NO LR4 (7) – ER1 (male) (4), or replace
switch OFF.
between L56 (female) (3)
• Remove preheating and L05 (female) (19)
relay.

WA500-3 20-469
(12)
TROUBLESHOOTING M-8

d) Preheating time becomes shorter, or there is variation

Cause Remedy

3 YES
Defective main monitor Replace
YES Is voltage between
L05 (3) and chassis
2 Defective contact of wiring
ground normal?
Is resistance harness between L05 (3) – Repair or
YES between L05 LR5 (3) – R11 – chassis replace
(female) (7) and
• Max. 0.1 V NO
• Turn starting switch ground
1 chassis ground as
shown in Table 1? ON. Short circuit with chassis
Is resistance ground or defective contact
between E05 (male) • See Table 1 Repair or
• Turn starting switch NO of wiring harness between
(1) and chassis replace
ground as shown in
L05 (female) (7) – LR4 (2) –
OFF.
Table 1? ER1 (8) – E05 (female) (1)
• See Table 1
• Turn starting switch Defective engine water
Replace
OFF. NO temperature sensor

Table 1 (Tolerance ± 0.5 kΩ)

Temperature (˚C) -30 -20 0 20 40 60 80 90
Resistance value (kΩ) 19.5 12.1 5.11 2.39 1.21 0.695 0.381 0.295

M-8 (1) Related electrical circuit diagram

20-470 WA500-3
(12)
TROUBLESHOOTING M-8

(2) Abnormality in preheating system

Serial No.: 52001 and up
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on to the next step.
fl Check that error codes E-51 and E-6A are not displayed.

a) Does not carry out preheating

fl Check that the water temperature is below 5˚C.

Cause Remedy

YES Defective electrical intake

Replace
air heater
3

YES Is voltage between 4 YES

E07 and chassis Defective heater relay Replace
ground normal? Is voltage between
2 E08 and chassis
• 20 – 30 V NO ground normal? Defective contact or discon-
Is voltage nection in wiring harness
YES between HT and • Turn starting switch Repair or
ON. between E08 and slow replace
chassis ground • 20 – 30 V NO blow fuse
1 normal? • Turn starting switch
ON. Defective contact or discon-
• 20 – 30 V nection in wiring harness
Does monitor • Turn starting switch between L56 (female) (3) – Repair or
display lights up? ON. NO LL2 (6) – LR7 (11) – ER2 replace
(11)– HT, or between L56
(female) (1) and chassis
• Turn starting switch ground
ON. Defective monitor panel Replace
NO

b) Preheating stays on

Cause Remedy

2 YES Defective preheating Replace

Is voltage between relay
YES
L06 (4) and chassis
1 ground normal? Short circuit with power
source in harness between
Repair or
• 20 – 30 V NO L06 (female) (4) and L56 replace
Does preheating
stop? • Turn starting switch (female) (2)
ON. Short circuit with power
• Turn starting source in wiring harness Repair or
switch OFF. NO between L56 (female) (3) – replace
LR4 (7) – ER1 (male) (4), or
• Remove preheating between L56 (female) (3)
relay. and L05 (female) (19)

WA500-3 20-470-1
(12)
TROUBLESHOOTING M-8

M-8 (2) Related electrical circuit diagram

20-470-2 WA500-3
(12)
TROUBLESHOOTING M-22

M-22 Abnormality in ECSS system

fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on to the next step.
fl Referring to TESTING AND ADJUSTING, Adjusting main monitor (speedometer module), check that
DIP switch 4 on the back side of the main monitor is set correctly.
fl ECSS : Electronic Controlled Suspension System.

a) Display does not change when switch is pressed Cause Remedy

Defective main monitor Replace

b) Monitor display lights up but ECSS function does not work

Cause Remedy

2 YES Go to Troubleshooting
for ECSS controller —
Is voltage between system (D MODE)
YES
C3B (9) and chassis
1 Defective contact or
ground normal?
Is voltage between disconnection in wiring Repair or
• Max. 3 V NO harness between L06 (7) replace
L06 (7) and chassis
• Turn starting switch and C3B (9)
ground normal?
ON.
• Max. 3 V
Defective main monitor Replace
• Turn starting switch NO
ON.

c) Display does not light up Cause Remedy

Defective main monitor Replace

M-22 Related electrical circuit diagram

WA500-3 20-489
(12)
TROUBLESHOOTING M-23

M-23 Failure code is not sent to main monitor (abnormality in network)

fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on to the next step.
fl Set dipswitch 3 at the rear of the main monitor to “F”.
fl MDC : Multiple Display and Condition.

Cause Remedy

2 YES Applicable controller is

defective Replace
Is voltage normal
YES between pins of
1 connectors in table Defective contact or discon-
below? nection in wiring harness
Is voltage between Repair or
between L08 (female)
L08 (male) (1) and • Repeats 0V and NO (1)(3), L08 (female) (2)(4) – replace
(2) normal? 12V? applicable connector pins
• Turn starting switch ON.
• Repeats 0V and • Disconnect connector to be measured.
Defective main monitor Replace
12V? NO
• Turn starting switch
ON.
• Disconnect L08.

Table
Connector Pin No.
L34 (female) Between (1) – (2)
LM1 (male) Between (5) – (6)

M-23 Related electrical circuit diagram

20-490 WA500-3
2
TROUBLESHOOTING H-32

H-32 ECSS does not work, and there is pitching and bouncing
[machines with ECSS]
Serial No.: 50001 – 52000
Ask the operator the following questions.
• Did the problem suddenly start?

ator
Yes = Related equipment broken

or
ulat
L2)

mul
3)
• Was there any abnormal noise when this hap-

SOL
(SO

cum
pened? Where did the noise come from?

accu
(
-pre OL5)
alve

e ac
• Did the problem gradually appear?

lve
L1)

e
ssur
a
v
Yes = Wear of related parts, defective seal

ssur
(SO

(S
v
noid
oid
v e

-pre
alve

l
olen

a
sole
Checks before troubleshooting

id v
high
low
id v
ses

s
• Is operation of ECSS switch correct?

o
sure

e
n
leno

m
rom
ssur
Cau

sole
• Is DIP switch 4 on the back side of the main

o
pres

r
r

olle
as f
as f
f so

-pre
monitor set correctly.

rge
igh-

ontr
g
of g
e

w
(See TESTING AND ADJUSTING, Adjusting

cha
i

f
l

ge o
of re

of lo
of h

sor
of c
e
main monitor (speedometer module).)

g
o
eaka
eaka

sen
ion
ion
tion

tion
i o
tuat
tuat

eed
al, l
al, l
a

ctua
actu

Defe ve actu
e ac

e sp
e ac

e se
e se
a
e

e
ctiv
ctiv
ctiv

ctiv
ctiv
ctiv
ctiv
cti
Defe
Defe
Defe

Defe
Defe

Defe
Defe
Accumu- Cont- Sen-
Solenoid valve lator roller sor

a b c d e f g h
Remedy d0 d1 d2 d3 — — — —
No.
Problems
Speed (5 km/h) for start of actuation of ECSS is greatly out of
1 adjustment
2 ECSS does not work when traveling loaded
3 ECSS does not work when traveling unloaded
When ECSS is actuated when traveling loaded, boom drops
4 greatly (more than 30 cm)
5 ECSS does not work at all

WA500-3 20-641
(12)
TROUBLESHOOTING H-32

Serial No.: 52001 and up

Ask the operator the following questions.
• Did the problem suddenly start?
Yes = Related equipment broken

ator
• Was there any abnormal noise when this hap-

or
ulat
pened? Where did the noise come from?

mul
cum
• Did the problem gradually appear?

accu
Yes = Wear of related parts, defective seal

e ac
sure
ssur
pres
Checks before troubleshooting

L1)

-pre
(SO
• Is operation of ECSS switch correct?

igh-
low
ses
• Is DIP switch 4 on the back side of the main

alve
mh
m
Cau
monitor set correctly.

o
o
id v

er
r
r
f
f
(See TESTING AND ADJUSTING, Adjusting

troll
eaka of gas
s
eno

a
of g
main monitor (speedometer module).)

con
o l
of s

sor
age
e
f
g
o
sen
ion

tion
leak
tuat

eed
al, l
ctua
a l ,

e sp
e se
e se
e ac

e a
ctiv
ctiv
ctiv

ctiv
ctiv
Defe
Defe
Defe

Defe
Sol-
enoid Defe
Accumu- Cont- Sen-
valve lator roller sor

a b c d e
Remedy d0 — — — —
No.
Problems
Speed (3 km/h) for start of actuation of ECSS is greatly out of
1 adjustment
2 ECSS does not work when traveling loaded
3 ECSS does not work when traveling unloaded
When ECSS is actuated when traveling loaded, boom drops
4 greatly (more than 30 cm)
5 ECSS does not work at all

20-641-1 WA500-3
(12)
 TROUBLESHOOTING OF ECSS
(ELECTRONICALLY CONTROLLED
SUSPENSION SYSTEM)
(D MODE)
Judgement table for controller electrical system ................................................................................. 20-652
Electrical circuit diagram for ECSS ........................................................................................................ 20-654
D-1 ECSS does not work ....................................................................................................................... 20-656
a) Error code [d0] is displayed .................................................................................................... 20-658
b) Error code [d1] is displayed (Serial No.: 50001 – 52000) ...................................................... 20-658
c) Error code [d2] is displayed (Serial No.: 50001 – 52000) ...................................................... 20-659
d) Error code [d3] is displayed (Serial No.: 50001 – 52000) ...................................................... 20-659
e) No abnormality display is given ............................................................................................. 20-661
D-2 ECSS cannot be canceled .............................................................................................................. 20-664

fl Referring to TESTING AND ADJUSTING, Adjusting main monitor (speedometer module), check
that DIP switch 4 on the back side of the main monitor is set correctly.

WA500-3 20-651
(12)
TROUBLESHOOTING JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM

JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM

ECSS CONTROL SYSTEM
Serial No.: 50001 – 52000

Failure code Abnormal system Nature of abnormality

1) Defective sol 1 & sol 14 relays

2) Short circuit with power source, short circuit with ground,
defective contact, or disconnection in wiring harness be-
tween transmission controller C1 (female) (3) and ECSS re-
lay L90 (1)
d0 sol 1 (relief) & sol 14 relay 3) Defective contact or disconnection in wiring harness be-
tween sol 1 & sol 14 relay L90 (female) (2) and chassis ground
4) Defective transmission controller

1) Defective sol 2
2) Short circuit with power source, short circuit with ground,
defective contact, or disconnection in wiring harness between
transmission controller C1 (female) (10) – ECSS (2) – AF2 (1)
3) Defective contact or disconnection in wiring harness between
d1 sol 2 (high pressure) sol 2 connector AF2 (female) (2) and chassis ground
4) Defective transmission controller

1) Defective sol 3
2) Short circuit with power source, short circuit with ground,
defective contact, or disconnection in wiring harness between
transmission controller C1 (female) (5) – ECSS (3) – AF3 (1)
3) Defective contact or disconnection in wiring harness between
d2 sol 3 (low pressure) sol 3 connector AF3 (female) (2) and chassis ground
4) Defective transmission controller

1) Defective sol 5
2) Short circuit with power source, short circuit with ground,
defective contact, or disconnection in wiring harness between
transmission controller C1 (female) (9) – ECSS (7) – AF5 (1)
3) Defective contact or disconnection in wiring harness between
d3 sol 5 sol 5 connector AF5 (female) (2) and chassis ground
4) Defective transmission controller

20-652 WA500-3
9
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR ECSS

Serial No.: 52001 and up

WA500-3 20-655
9
TROUBLESHOOTING D-1

D-1 ECSS does not work

Serial No.: 50001 – 52000
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on to the next step.
fl Carry out troubleshooting with the starting switch ON.
fl Check that the ECSS switch on the main monitor is ON.
fl Referring to TESTING AND ADJUSTING, Adjusting main monitor (speedometer module), check that
DIP switch 4 on the back side of the main monitor is set correctly.

Cause Remedy

Displa ying [d0]. Go to Item a) —

Displaying [d1]. Go to Item b) —

2 5

YES Which code is

monitor Displaying [d2]. Go to Item c) —
displaying?

1
6
Is there an
abnormality
Displaying [d3]. Go to Item d) —
display?

Go to Item e) —
NO

20-656 WA500-3
(12)
TROUBLESHOOTING D-1

Serial No.: 52001 and up

fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on to the next step.
fl Carry out troubleshooting with the starting switch ON.
fl Check that the ECSS switch on the main monitor is ON.
fl Referring to TESTING AND ADJUSTING, Adjusting main monitor (speedometer module), check that
DIP switch 4 on the back side of the main monitor is set correctly.

Cause Remedy

YES
Displa ying [d0]. Go to Item a) —
1
Is there an
abnormality
display?

Go to Item e) —
NO

WA500-3 20-657
(12)
TROUBLESHOOTING D-1

a) Error code [d0] is displayed

Cause Remedy

4 YES
Defective ECSS controller Replace
Is resistance
YES between L90
3 (female) (2) and Defective contact or discon-
Is resistance chassis normal? nection in wiring harness Repair or
YES between L90 • Max. 1 Ω NO between L90 (female) (2) replace
(female) (1) and • Turn starting and chassis
2 chassis normal? switch OFF. Short circuit with ground in
Is resistance between
• Min. 1 MΩ • Disconnect L90. wiring harness between C1 Repair or
YES L90 (female) (1) and
chassis normal when • Turn starting NO (female) (3) and L90 replace
C1 (male) (3) is switch OFF. (female) (1)
1 grounded to chassis?
• Disconnect L90 and
Is troubleshooting • Max. 1 Ω Defective contact or discon-
C1.
code displayed when • Turn starting nection in wiring harness Repair or
L90 is replaced with NO between C1 (female) (3) replace
other relay of same
switch OFF.
and L90 (female) (1)
type? • Disconnect L90 and
C1.
• Turn starting
switch OFF. Defective ECSS relay Replace
• Interchange with NO
other relay of same
type.
• ECSS switch: ON

b) Error code [d1] is displayed

Serial No.: 50001 – 52000

Cause Remedy

4 YES
Defective ECSS controller Replace
Is resistance
YES between AF2
3 (female) (2) and Defective contact or discon-
Is resistance chassis normal? nection in wiring harness Repair or
YES between C1 • Max. 1 Ω NO between AF2 (female) (2) – replace
(female) (10) and • Turn starting ECSS (5) – chassis
2 chassis normal? switch OFF. Short circuit with ground in
Is resistance between
• Min. 1 MΩ • Disconnect AF2. wiring harness between C1 Repair or
YES C1 (female) (10) and
chassis normal when • Turn starting NO (female) (10) – ECSS (2) – replace
AF2 (female) (1) is switch OFF. AF2 (female) (1)
1 grounded to chassis?
• Disconnect AF2 and
Is resistance • Max. 1 Ω C1. Defective contact or discon-
between AF1 • Turn starting nection in wiring harness Repair or
(male) (1) and (2) switch OFF. NO between C1 (female) (10) – replace
normal? ECSS (2) – AF2 (female) (1)
• Disconnect AF1 and
C1.
• 30 – 80 Ω
• Turn starting Defective solenoid 2
Replace
switch OFF. NO (high pressure)

20-658 WA500-3
9
 TROUBLESHOOTING OF ENGINE
CONTROLLER SYSTEM
(ENG MODE)

Serial No.: 52001 and up

Table of error codes ................................................................................................................................ 20-903
Action taken by controller and condition of machine when error code is displayed ........................ 20-904
Error code displays and points to remember when troubleshooting ................................................. 20-912
Electrical circuit diagram for engine controller system ....................................................................... 20-916
ENG-1 Error code E-1b [Abnormality in Ne speed sensor system] ............................................... 20-919
ENG-2 Error code E-1c [Abnormality in G speed sensor system].................................................. 20-920
ENG-3 Error code E-22 [Overrun] ..................................................................................................... 20-921
ENG-4 Error code E-31 [Abnormality in throttle sensor system] ................................................... 20-922
ENG-5 Error code E-3c [Abnormality in boost pressure sensor system] ...................................... 20-924
ENG-6 Error code E-3d [Abnormality in fuel temperature sensor system] ................................... 20-927
ENG-7 Error code E-51 [Abnormality in preheater relay coil system] ........................................... 20-928
ENG-8 Error code E-54 [Short circuit in starting switch C signal system] ..................................... 20-929
ENG-9 Error code E-56 [Abnormality in power supply system 1] .................................................. 20-930
ENG-10 Error code E-57 [Abnormality in power supply system 2] .................................................. 20-931
ENG-11 Error code E-5A [Abnormality in Q adjustment switch signal] ........................................... 20-932
ENG-12 Error code E-6A [Abnormality in low water temperature sensor system] ......................... 20-933
ENG-13 Error code E-70 [Overcurrent in fuel supply pump PCV1 system] ..................................... 20-934
ENG-14 Error code E-71 [Overcurrent in fuel supply pump PCV2 system] ..................................... 20-935
ENG-15 Error code E-74 [Disconnection in fuel supply pump PCV1 system] ................................. 20-936
ENG-16 Error code E-75 [Disconnection in fuel supply pump PCV2 system] ................................. 20-937
ENG-17 Error code E-77 [Abnormality in common rail fuel pressure sensor system] ................... 20-938
ENG-18 Error code E-79 [Abnormality in high common rail fuel pressure 1]
Error code E-7A [Abnormality in high common rail fuel pressure 2] ................................. 20-942
ENG-19 Error code E-7b [No-pressure feed by fuel supply pump 1]
Error code E-7c [No-pressure feed by fuel supply pump 2] ............................................... 20-944
ENG-20 Error code E-7d [Abnormality in common rail high fuel pressure] .................................... 20-947
ENG-21 Error code E-80 [Defective controller] .................................................................................. 20-948
ENG-22 Error code E-81 [Disconnection in No. 1 fuel injector system] ........................................... 20-949
ENG-23 Error code E-82 [Disconnection in No. 2 fuel injector system] ........................................... 20-950
ENG-24 Error code E-83 [Disconnection in No. 3 fuel injector system] ........................................... 20-951
ENG-25 Error code E-84 [Disconnection in No. 4 fuel injector system] ........................................... 20-952
ENG-26 Error code E-85 [Disconnection in No. 5 fuel injector system] ........................................... 20-953
ENG-27 Error code E-86 [Disconnection in No. 6 fuel injector system] ........................................... 20-954
ENG-28 Error code E-8A [Short circuit in No. 1, No. 2, No. 3 fuel injector systems] ...................... 20-955
ENG-29 Error code E-8b [Short circuit in No. 4, No. 5, No. 6 fuel injector systems] ...................... 20-956

WA500-3 20-901
(11)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION

2. Precautions when carrying out installation work

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

fl When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and
other hydraulic equipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times,
stopping the cylinder 100 mm from the end of its stroke.
3. Next, operate the steering, bucket, and boom cylinders to the end of their stroke 3 - 4 times, stop
the engine, loosen air bleed plug (1), bleed the air from the hydraulic tank, then tighten plug (1)
again.
4. Raise the engine speed, repeat Step 3 to bleed the air, and repeat this operation until no more air
comes out from the plug.
5. After doing this, run the engine at normal speed.
fl When using the machine for the first time after repair or
long storage, follow the same procedure.

3. Precautions when completing the operation

• If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
fl For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.

WA500-3 30-5
3
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

SPECIAL TOOL LIST

fl Tools with part number 79cT-ccc-cccc cannot be supplied (they are items to be locally manu-
factured).
fl Necessity: : .......... Cannot be substituted, should always be installed (used)
b : .......... Extremely useful if available, can be substituted with commercially avail-
able part
New/remodel: N : .......... Tools with new part numbers, newly developed for this model
R : .......... Tools with upgraded part numbers, remodeled from items already available
for other models
Blank: .... Tools already available for other models, used without any modification
fl Tools marked c in the Sketch column are tools introduced in special sketches (See SKETCHES OF
SPECIAL TOOLS).

Nece- New/ Ske-

Component Symbol Part No. Part Name re-
ssity Q’ty model tch Nature of work, remarks
Installation of engine Wrench 1 Tightening of head assem-
cylinder head 1 790-331-1110 bly

1 795-521-1110 Push tool 1

2 790-101-5221 Grip 1
2 Press fitting of front seal
3 01010-51225 Bolt 1
Installation of engine 4 01050-31640 Bolt 3
front seal, rear seal 1 795-931-1210 Sleeve jig 1
A
2 795-931-1220 Sleeve jig 1
3 Press fitting of rear seal
3 01050-31625 Bolt 3
4 01050-31645 Bolt 3
795-471-1700 Remover 1

Removing fuel supply 1 795-471-1520 • Block 1 Removal of fuel supply

4
pump 2 795-471-1530 • Bolt 1 pump assembly

3 01435-01085 • Bolt 2
1 793T-615-1230 Push tool 1 N c
2 793T-615-1240 Spacer 1 N c
Assembly of damper 1 Press fitting of oil seal and
3 790-101-5421 Grip 1 dust seal
4 01010-51240 Bolt 1

2 790-102-1871 Wrench 1 Removal, installation of

round nut

B 1 790-201-2730 Spacer 1
2 791-520-4140 Screw 1
Disassembly, 3 02215-11622 Nut 2
assembly of PTO
Washer 2 Press fitting of PTO gear
3 4 01643-32780 bearing inner race

5 790-101-2102 Puller 1
(294.2 kN {30 ton})

6 790-101-1102 Pump 1
1 790-501-5200 Repair stand 1
Disassembly,
assembly of torque C 2 790-901-2110 Bracket 1
converter assembly
3 793-310-2160 Plate 1

30-6 WA500-3
(11)
DISASSEMBLY AND ASSEMBLY FUEL SUPPLY PUMP

REMOVAL OF FUEL SUPPLY

PUMP
Serial No.: 52001 and up

1. Align 1.6 TOP line a on damper (2) with pointer

(1).

2. Remove breather tube (3).

3. Remove plugs (4) (2 places, at the upper and lower

part), then check that forcing tap holes of the fuel
supply pump drive gear can be seen through
holes. 1

4. Remove cover (5). Remove gear mounting nut

(6) and washer (7) with care not to fall them in the
engine. 2

5. Set gear forcing jig A4.

6. Tool bolt A4 must be mounted at the forcing tap

hole (2 places) of gear (21).

7. Remove fuel hose (9), then remove fuel tube (10),

fuel supply tube (11), oil tube (12) , and overflow
tube (13). 3
fl Install masking at the joints and the joint por-
tions of piping to keep dust and debris out.

8. Remove harness connectors (14) and (15).

fl Install masking the connector parts to keep
dust and debris out.

WA500-3 30-19
(11)
DISASSEMBLY AND ASSEMBLY FUEL SUPPLY PUMP

9. Loosen bracket mounting bolts (16) and nuts (17)

and fuel supply pump mounting bolts (18) (4
places on the front and rear sides).

10. Clockwise rotate tool bolt A4 to pull out the fuel

supply pump drive gear (21).
fl There is key (19) inside. Be careful not to drop
it.

11. Remove bolts (16) and nuts (17) loosened at Step

9, then remove fuel supply pump assembly (20).

30-19-1 WA500-3
(11)
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL GEAR

DISASSEMBLY OF DIFFERENTIAL
GEAR ASSEMBLY
1. Set differential assembly (1) on special tools H2-
1, H2-2, and H-3.
4 Differential assembly : 230kg

2. Differential gear case assembly

1) Remove left and right locks (6), and with a bar,
turn nut (7) until it become loose.

2) Remove mounting bolts (9) of cap (8).

3) Remove nut and lift out differential gear case

assembly(10).

WA500-3 30-77
(12)
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL GEAR

3. Pinion assembly
1) Remove case (2).

2) Remove oil seal (3) and dust seal (3A) from

case.

3) Screw in forcing screw 1 (Thread dia. = 18

mm, Pitch = 1.75 mm), and fit out pinion as-
sembly (4).
fl Check number of shims (5).

30-78 WA500-3
(12)