WD600 6

SEN04979-11
WHEEL DOZER WD600 -6

SERIAL NUMBERS 55001 and up
SEN04981-11
WHEEL DOZER
WD600-6
Machine model Serial number

WD600-6 55001 and up
00 Index and foreword 00
100 Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
WD600-6 00-100 1
100 Index
SEN04981-11 Composition of shop manual
Composition of shop manual 1
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs ..................................................................... SEN04979-11
00 Index and foreword .................................................................................................................... SEN04980-11

100 Index .................................................................................................................................. SEN04981-11 q
200 Foreword and general information ..................................................................................... SEN04982-01
01 Specification ............................................................................................................................... SEN04983-01

100 Specification and technical data......................................................................................... SEN04984-01
10 Structure, function and maintenance standard........................................................................... SEN04985-03

100 Engine and cooling system ................................................................................................ SEN04986-00
201 Power train, Part 1 ............................................................................................................. SEN04987-00
202 Power train, Part 2 ............................................................................................................. SEN04988-00
300 Steering system ................................................................................................................. SEN04989-00
400 Brake system ..................................................................................................................... SEN04990-00
500 Undercarriage and frame ................................................................................................... SEN04991-00
601 Hydraulic system, Part 1 .................................................................................................... SEN04992-00
602 Hydraulic system, Part 2 .................................................................................................... SEN04993-00
700 Work equipment................................................................................................................. SEN04994-00
800 Cab and its attachments .................................................................................................... SEN04995-00
901 Electrical system, Part 1 .................................................................................................... SEN04996-02 q
902 Electrical system, Part 2 .................................................................................................... SEN04997-00
903 Electrical system, Part 3 .................................................................................................... SEN04998-02 q
20 Standard value table................................................................................................................... SEN04999-02

100 Standard service value table.............................................................................................. SEN05044-02
30 Testing and adjusting ................................................................................................................. SEN05000-07

101 Testing and adjusting, Part 1.............................................................................................. SEN05045-03
104 Testing and adjusting, Part 4.............................................................................................. SEN05048-05 q
40 Troubleshooting.......................................................................................................................... SEN05001-03
100 Failure code table and fuse locations ................................................................................ SEN05049-01
200 General information on troubleshooting............................................................................. SEN05050-01
301 Troubleshooting by failure code (Display of code), Part 1 ................................................. SEN05051-01
00-100 2 WD600-6
100 Index
Composition of shop manual SEN04981-11
302 Troubleshooting by failure code (Display of code), Part 2..................................................SEN05052-02

310 Troubleshooting by failure code (Display of code), Part 10................................................SEN05060-01
400 Troubleshooting of electrical system (E-mode) ..................................................................SEN05061-01
500 Troubleshooting of hydraulic and mechanical system (H-mode)........................................SEN05062-01
600 Troubleshooting of engine (S-mode) ..................................................................................SEN05063-00
50 Disassembly and assembly ........................................................................................................SEN05002-05

100 General information on disassembly and assembly...........................................................SEN05141-00
201 Engine and cooling system, Part 1.....................................................................................SEN05142-01
202 Engine and cooling system, Part 2.....................................................................................SEN05143-02
301 Power train, Part 1..............................................................................................................SEN05144-01
400 Brake system......................................................................................................................SEN05148-01
500 Undercarriage and frame ...................................................................................................SEN05149-01
600 Hydraulic system ................................................................................................................SEN05150-01
700 Work equipment .................................................................................................................SEN05151-00
800 Cab and its attachments.....................................................................................................SEN05152-02
900 Electrical system ................................................................................................................SEN05153-00
90 Diagrams and drawings ..............................................................................................................SEN05003-03

100 Hydraulic diagrams and drawings ......................................................................................SEN05004-00
200 Electrical diagrams and drawings.......................................................................................SEN05005-03
WD600-6 00-100 3
100 Index
SEN04981-11 Table of contents
Table of contents 1
00 Index and foreword

100 Index SEN04981-11
Composition of shop manual......................................................................................................................... 2
Table of contents ........................................................................................................................................... 4
200 Foreword and general information SEN04982-01
Safety notice ................................................................................................................................................. 2
How to read the shop manual ....................................................................................................................... 7
Explanation of terms for maintenance standard............................................................................................ 9
Handling of electric equipment and hydraulic component............................................................................. 11
Handling of connectors newly used for engines............................................................................................ 20
How to read electric wire code ...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
01 Specification
100 Specification and technical data SEN04984-01
Specification dimension drawing ................................................................................................................... 2
Specifications ................................................................................................................................................ 3
Weight table .................................................................................................................................................. 6
Table of fuel, coolant and lubricants.............................................................................................................. 8
10 Structure, function and maintenance standard

100 Engine and cooling system SEN04986-00
Engine mount and transmission mount......................................................................................................... 2
Damper ......................................................................................................................................................... 4
Cooling system.............................................................................................................................................. 6
Cooling fan pump .......................................................................................................................................... 10
Cooling fan motor.......................................................................................................................................... 18
201 Power train, Part 1 SEN04987-00
Power train .................................................................................................................................................... 2
Power train system diagram.......................................................................................................................... 3
Torque converter and transmission piping diagram ...................................................................................... 4
Torque converter ........................................................................................................................................... 6
Modulation clutch .......................................................................................................................................... 15
Torque converter regulator valve................................................................................................................... 16
Transmission ................................................................................................................................................. 18
Transfer ......................................................................................................................................................... 38
Transmission control valve............................................................................................................................ 40
ECMV............................................................................................................................................................ 42
Main relief valve and torque converter relief valve........................................................................................ 49
Lubrication relief valve .................................................................................................................................. 51
Torque converter oil cooler............................................................................................................................ 2
Torque converter oil filter............................................................................................................................... 3
Drive shaft ..................................................................................................................................................... 5
Center support .............................................................................................................................................. 8
Axle ............................................................................................................................................................... 10
Differential ..................................................................................................................................................... 14
Limited slip differential................................................................................................................................... 23
Final drive...................................................................................................................................................... 28
300 Steering system SEN04989-00
Steering piping diagram ................................................................................................................................ 2
Steering column ............................................................................................................................................ 4
00-100 4 WD600-6
100 Index
Table of contents SEN04981-11
Joystick steering lever linkage....................................................................................................................... 5

Joystick EPC valve ........................................................................................................................................ 6
Lock valve...................................................................................................................................................... 7
Steering valve ................................................................................................................................................ 8
Rotary valve................................................................................................................................................... 11
Steering control valve .................................................................................................................................... 14
Two-way restrictor valve ................................................................................................................................ 30
Stop valve ...................................................................................................................................................... 31
Steering pump ............................................................................................................................................... 32
Steering cylinder ............................................................................................................................................ 46
Emergency steering piping diagram .............................................................................................................. 47
Diverter valve................................................................................................................................................. 48
Emergency steering pump............................................................................................................................. 56
400 Brake system SEN04990-00
Brake piping diagram..................................................................................................................................... 2
Brake ............................................................................................................................................................. 4
Brake valve.................................................................................................................................................... 8
Accumulator charge valve ............................................................................................................................. 16
EPC relief valve ............................................................................................................................................. 22
Accumulator (for brake) ................................................................................................................................. 24
Slack adjuster ................................................................................................................................................ 26
Parking brake ................................................................................................................................................ 30
Parking brake solenoid valve......................................................................................................................... 32
Emergency parking brake release valve ....................................................................................................... 34
Brake cooling pump....................................................................................................................................... 35
500 Undercarriage and frame SEN04991-00
Axle mount..................................................................................................................................................... 2
Center hinge pin ............................................................................................................................................ 7
601 Hydraulic system, Part 1 SEN04992-00
Hydraulic piping diagram ............................................................................................................................... 2
Work equipment control lever linkage ........................................................................................................... 4
Hydraulic tank................................................................................................................................................ 6
Work equipment pump .................................................................................................................................. 8
602 Hydraulic system, Part 2 SEN04993-00
Control valve.................................................................................................................................................. 2
CLSS ............................................................................................................................................................. 16
Functions and operation by valve.................................................................................................................. 20
Accumulator (for PPC circuit) ........................................................................................................................ 30
Triple pump.................................................................................................................................................... 31
700 Work equipment SEN04994-00
Work equipment linkage ................................................................................................................................ 2
Cutting edge and end bit ............................................................................................................................... 5
Work equipment lubrication ........................................................................................................................... 7
Hydraulic cylinder .......................................................................................................................................... 10
800 Cab and its attachments SEN04995-00
ROPS cab...................................................................................................................................................... 2
Air conditioner................................................................................................................................................ 4
901 Electrical system, Part 1 SEN04996-02
Machine monitor system................................................................................................................................ 2
Machine monitor ............................................................................................................................................ 8
Work equipment control system .................................................................................................................... 2
Transmission controller system ..................................................................................................................... 28
Electric transmission control.......................................................................................................................... 2
Engine starting/stopping circuit...................................................................................................................... 4
Parking brake circuit ...................................................................................................................................... 7
WD600-6 00-100 5
100 Index
Sensor........................................................................................................................................................... 11
VHMS controller related ................................................................................................................................ 32
Electric lever (Work equipment) .................................................................................................................... 37
20 Standard value table

100 Standard service value table SEN05044-02
Standard service value table for engine ........................................................................................................ 2
Standard service value table for chassis ....................................................................................................... 3
30 Testing and adjusting

101 Testing and adjusting, Part 1 SEN05045-03
Tools for testing, adjusting, and troubleshooting ........................................................................................... 3
Sketches of special tools............................................................................................................................... 8
Measuring engine speed............................................................................................................................... 9
Measuring exhaust gas color ........................................................................................................................ 11
Measuring exhaust temperature ................................................................................................................... 12
Adjusting valve clearance ............................................................................................................................. 14
Testing compression pressures..................................................................................................................... 16
Measuring blow-by pressure ......................................................................................................................... 19
Measuring engine oil pressure ...................................................................................................................... 20
Testing EGR valve and bypass valve drive oil pressure ............................................................................... 21
Measuring intake air (boost) pressure........................................................................................................... 23
Handling fuel system equipment ................................................................................................................... 24
Releasing residual pressure in fuel system................................................................................................... 24
Testing fuel pressures ................................................................................................................................... 25
Testing return rate and leakage..................................................................................................................... 26
Bleeding air from fuel circuit.......................................................................................................................... 29
Testing leakage in fuel system ...................................................................................................................... 31
Handling reduced cylinder mode operation................................................................................................... 32
Handling no-injection cranking operation ...................................................................................................... 32
Handling controller voltage circuit ................................................................................................................. 33
Replacing and adjusting alternator and air conditioner compressor belt tension.......................................... 34
Adjusting modulation clutch speed sensor and speed sensor ...................................................................... 35
Measuring directional lever and gear shift lever (Steering wheel specification)............................................ 37
Testing and adjusting power train oil pressure .............................................................................................. 38
Flushing procedure for torque converter and transmission hydraulic circuit ................................................. 52
Method of moving machine when transmission valve is broken ................................................................... 54
Moving method of machine disabled by short-to-power failure in work equipment potentiometer................ 56
Adjusting steering stop valve ........................................................................................................................ 58
Measuring operating effort of AJSS lever (AJSS specification) .................................................................... 3
Testing and adjusting AJSS lever angle sensor and frame angle sensor (AJSS specification) .................... 4
Testing and adjusting steering stopper bolt (AJSS specification).................................................................. 6
Testing and adjusting steering wheel (Steering wheel specification) ............................................................ 8
Testing steering oil pressure ......................................................................................................................... 10
Bleeding air from steering cylinder circuit ..................................................................................................... 14
Testing hydraulic drive fan............................................................................................................................. 15
Bleeding air from hydraulic drive fan circuit .................................................................................................. 18
Measuring brake pedal.................................................................................................................................. 20
Measuring brake performance ...................................................................................................................... 21
Testing and adjusting accumulator charge pressure..................................................................................... 22
Testing of accumulator nitrogen gas pressure and procedure for charging brake
accumulator with nitrogen gas ................................................................................................................ 24
Testing wheel brake oil pressure................................................................................................................... 32
Measuring wear of wheel brake disc............................................................................................................. 34
Bleeding air from wheel brake circuit ............................................................................................................ 35
Releasing residual pressure in brake accumulator circuit............................................................................. 36
00-100 6 WD600-6
100 Index
Testing parking brake performance ............................................................................................................... 37

Measuring parking brake oil pressure ........................................................................................................... 38
Testing wear of parking brake disc ................................................................................................................ 41
Method of releasing parking brake manually................................................................................................. 42
Measuring and adjusting work equipment control lever ................................................................................ 43
Measuring work equipment oil pressure........................................................................................................ 44
Bleeding air from work equipment circuit....................................................................................................... 49
Moving machine for removing operator cab .................................................................................................. 50
Preparations for work on troubleshooting of electric system ......................................................................... 52
Procedure for testing diodes.......................................................................................................................... 56
Machine monitor-based adjustment at replacement, disassembly and assembly,
and additional installation for each sensor and controller........................................................................ 2
Special functions of machine monitor (EMMS).............................................................................................. 5
VHMS controller initial setting procedure (ORBCOMM installation specification) ......................................... 2
VHMS controller initial setting procedure (IRIDIUM installation specification) .............................................. 24
Precautions for replacing VHMS controller.................................................................................................... 46
Pm-clinic inspection table .............................................................................................................................. 52
40 Troubleshooting
100 Failure code table and fuse locations SEN05049-01
Failure codes list............................................................................................................................................ 2
Fuse locations ............................................................................................................................................... 14
200 General information on troubleshooting SEN05050-01
Points to remember when performing troubleshooting.................................................................................. 2
How to proceed in troubleshooting ................................................................................................................ 4
Checks before troubleshooting...................................................................................................................... 6
Classification and procedures of troubleshooting.......................................................................................... 7
Information in troubleshooting table .............................................................................................................. 11
Troubleshooting method for disconnecting wiring harness of pressure sensor system ................................ 13
Phenomena looking like troubles and troubleshooting Nos........................................................................... 16
Connection table for connector pin numbers................................................................................................. 18
T- branch box and T- branch adapter table ................................................................................................... 54
301 Troubleshooting by failure code (Display of code), Part 1 SEN05051-01
Failure code [1500L0] TORQFLOW transmission: Double meshing ............................................................. 3
Failure code [15B0NX] Transmission Oil Filter Clogging............................................................................... 4
Failure code [15SAL1] ECMV F clutch: When command current is OFF, fill signal is ON ............................ 6
Failure code [15SALH] ECMV F clutch: When command current is ON, fill signal is OFF ........................... 8
Failure code [15SBL1] ECMV R clutch: When command current is OFF, fill signal is ON ............................ 10
Failure code [15SBLH] ECMV R clutch: When command current is ON, fill signal is OFF ........................... 12
Failure code [15SEL1] ECMV (1): When command current is OFF, fill signal is ON..................................... 14
Failure code [15SELH] ECMV (1): When command current is ON, fill signal is OFF.................................... 16
Failure code [15SFL1] ECMV (2): When command current is OFF, fill signal is ON..................................... 18
Failure code [15SFLH] ECMV (2): When command current is ON, fill signal is OFF.................................... 20
Failure code [15SGL1] ECMV (3): When command current is OFF, fill signal is ON .................................... 22
Failure code [15SGLH] ECMV (3): When command current is ON, fill signal is OFF ................................... 24
Failure code [15SHL1] ECMV (4): When command current is OFF, fill signal is ON .................................... 26
Failure code [15SHLH] ECMV (4): When command current is ON, fill signal is OFF ................................... 28
Failure code [15W0NT] Transmission modulation clutch: Overheating......................................................... 30
Failure code [2F00MA] Parking brake: Malfunction....................................................................................... 31
Failure code [2G42ZG] Front Accumulator Oil Pressure Low ....................................................................... 34
Failure code [2G43ZG] Rear Accumulator Oil Pressure Low........................................................................ 4
Failure code [A000N1] (or VHMS_LED display: “n2” → “01”) Engine: Overrun ............................................ 7
Failure code [AA1ANX] Air Cleaner Clogging ............................................................................................... 8
Failure code [AB00L6] Alternator: Signal disagrees with run and stop of engine.......................................... 10
WD600-6 00-100 7
100 Index
Failure code [AB00MA] Alternator: Malfunction ............................................................................................ 12

Failure code [B@BAZG] Engine oil pressure: Low error............................................................................... 14
Failure code [B@BAZK] Eng Oil Level Low .................................................................................................. 15
Failure code [B@BCNS] Engine coolant temperature: Overheating............................................................. 16
Failure code [B@BCZK] Engine coolant level low ........................................................................................ 18
Failure code [B@C7NS] Brake oil overheating ............................................................................................. 20
Failure code [b@CENS] Torque converter oil overheating ........................................................................... 21
Failure code [B@CENS] Torque converter oil overheating ........................................................................... 22
Failure code [B@GAZK] Low Battery Fluid Level ......................................................................................... 23
Failure code [B@HANS] Hyd Oil Overheat................................................................................................... 24
Failure code [CA111] Abnormality in engine controller.................................................................................. 26
Failure code [CA115] Engine Ne or Bkup speed sensor error ...................................................................... 29
Failure code [CA122] Charge (boost) pressure sensor high error ................................................................ 30
Failure code [CA123] Charge (boost) pressure sensor low error.................................................................. 32
Failure code [CA131] Throttle sensor high error ........................................................................................... 34
Failure code [CA132] Throttle sensor low error ............................................................................................ 37
Failure code [CA135] Engine oil pressure sensor high error ........................................................................ 40
Failure code [CA141] Engine oil pressure sensor low error.......................................................................... 42
Failure code [CA144] Coolant temperature sensor high error ...................................................................... 44
Failure code [CA145] Coolant temperature sensor low error........................................................................ 46
Failure code [CA153] Charge (boost) temperature sensor high error........................................................... 48
Failure code [CA154] Charge (boost) temperature sensor low error ............................................................ 50
Failure code [CA187] Sensor power supply 2 low error................................................................................ 52
Failure code [CA212] Engine oil temperature sensor high error ................................................................... 54
Failure code [CA213] Engine oil temperature sensor low error .................................................................... 56
Failure code [CA221] Atmospheric pressure sensor high error .................................................................... 58
Failure code [CA222] Atmospheric pressure sensor low error...................................................................... 60
Failure code [CA227] Sensor power supply 2 high error .............................................................................. 62
Failure code [CA234] Engine overspeed ...................................................................................................... 3
Failure code [CA238] Ne speed sensor power supply error ......................................................................... 4
Failure code [CA263] Fuel Temp Sensor High Error..................................................................................... 6
Failure code [CA265] Fuel Temp Sensor Low Error...................................................................................... 8
Failure code [CA271] PCV1 Short circuit ...................................................................................................... 10
Failure code [CA272] PCV1 Disconnection .................................................................................................. 11
Failure code [CA273] PCV2 Short circuit ...................................................................................................... 12
Failure code [CA322] Injector #1 open/short error ........................................................................................ 14
Failure code [CA342] Calibration code inconsistency................................................................................... 26
Failure code [CA351] Injectors drive circuit error .......................................................................................... 27
Failure code [CA352] Sens Supply 1 Volt Low Error..................................................................................... 28
Failure code [CA431] Idle validation switch error.......................................................................................... 31
Failure code [CA432] Idle validation action error .......................................................................................... 34
Failure code [CA441] Battery voltage low error ............................................................................................ 37
Failure code [CA442] Battery voltage high error ........................................................................................... 38
Failure code [CA449] Common rail pressure high error 2............................................................................. 39
Failure code [CA451] Rail Press Sensor High Error ..................................................................................... 40
Failure code [CA452] Rail Press Sensor Low Error ...................................................................................... 42
Failure code [CA554] Common rail pressure sensor in range error.............................................................. 45
Failure code [CA559] Supply pump pressure very low error 1...................................................................... 46
Failure code [CA689] Engine Ne speed sensor error ................................................................................... 50
00-100 8 WD600-6
100 Index
Failure code [CA731] Engine Bkup speed sensor phase error ..................................................................... 52
Failure code [CA757] All continuous data lost error ...................................................................................... 53
Failure code [CA778] Engine Bkup speed sensor error ................................................................................ 54
Failure code [CA1228] EGR valve servo error 1 ........................................................................................... 56
Failure code [CA1625] EGR valve servo error 2 ........................................................................................... 57
Failure code [CA1626] (Bypass valve solenoid current high error) ............................................................... 58
Failure code [CA1627] (Bypass valve solenoid current low error)................................................................. 60
Failure code [CA1628] Bypass Valve Servo Error 1 ...................................................................................... 62
Failure code [CA1629] Bypass Valve Servo Error 2 ...................................................................................... 63
Failure code [CA1631] (Bypass valve lift sensor high error).......................................................................... 64
Failure code [CA1632] (Bypass valve lift sensor low error) ........................................................................... 66
Failure code [CA1633] KOMNET datalink timeout error................................................................................ 68
Failure code [CA2185] Throttle sensor supply voltage high error ................................................................. 4
Failure code [CA2186] Throttle sensor power supply low error..................................................................... 6
Failure code [CA2249] Supply pump pressure very low error 2 .................................................................... 8
Failure code [CA2271] EGR valve lift sensor high error................................................................................ 10
Failure code [CA2272] EGR valve lift sensor low error ................................................................................. 12
Failure code [CA2351] EGR valve solenoid operation short circuit............................................................... 14
Failure code [CA2352] EGR valve solenoid operation disconnect ................................................................ 16
Failure code [CA2555] Intake air heater relay open circuit error ................................................................... 18
Failure code [CA2556] Intake air heater relay short circuit error ................................................................... 20
Failure code [D191KA] AJSS neutral safety relay open circuit...................................................................... 22
Failure code [D191KB] AJSS neutral safety relay short circuit...................................................................... 24
Failure code [D198KA] Transmission oil pressure bypass solenoid: Disconnection ..................................... 26
Failure code [D198KB] Transmission oil pressure bypass solenoid: Short circuit......................................... 27
Failure code [D198KY] Transmission oil pressure bypass solenoid: Short circuit with power supply line..... 28
Failure code [D5ZHKA] Terminal C signal open circuit.................................................................................. 30
Failure code [D5ZHKB] Terminal C signal short circuit.................................................................................. 32
Failure code [D5ZHKZ] Terminal C signal open or short circuit..................................................................... 34
Failure code [D5ZHL6] Terminal C signal disagrees with run and stop of engine ......................................... 36
Failure code [DA80L4] Auto-greasing controller disagrees with ON/OFF signal........................................... 38
Failure code [DAF3KK] Machine monitor: Source voltage low (input)........................................................... 40
Failure code [DAF5KP] Machine monitor: Output voltage low ...................................................................... 42
Failure code [DAFRKR] CAN communication with machine monitor: Communication error (Abnormality in tar-
get component system) ........................................................................................................................... 44
Failure code [DAQ0KK] Transmission controller: Source voltage low........................................................... 45
Failure code [DAQ0KT] Transmission controller: Defect in controller ........................................................... 48
Failure code [DAQ2KK] Transmission controller load power supply line: Source voltage low (Input)........... 50
Failure code [DAQ9KQ] Transmission controller model selection: Model selection signal disagreement..... 53
Failure code [DAQRKR] CAN communication with transmission controller: Communication error (Abnormality
in target component system) ................................................................................................................... 54
Failure code [DAQRMA] Transmission controller (Option setting): Malfunction ............................................ 59
Failure code [DB2RKR] CAN communication from engine controller: Communication error (Abnormality in tar-
get component system) ........................................................................................................................... 4
Failure code [DB90KK] Work equipment controller: Source voltage low (input)............................................ 7
Failure code [DB90KT] Work equipment controller: Defect in controller ....................................................... 10
Failure code [DB92KK] Work equipment controller load power supply line: Source voltage low (input) ....... 11
Failure code [DB95KX] Work equipment controller power supply output: Out of range ................................ 14
Failure code [DB99KQ] Work equipment controller model selection: Model selection signal disagreement. 16
Failure code [DB9RKR] CAN communication with work equipment controller: Communication error (Abnormal-
ity in target component system)............................................................................................................... 17
Failure code [DB9RMA] Work equipment controller (Option setting): Malfunction ........................................ 18
Failure code [DB9RMC] CAN communication with transmission controller: Malfunction .............................. 19
Failure code [DBB0KK] or change of VHMS_LED display from "n9" to "01" (VHMS controller: Source voltage
low (input))............................................................................................................................................... 20
WD600-6 00-100 9
100 Index
Failure code [DBB0KQ] or change of VHMS_LED display from "nF" to "11" (VHMS controller: Disagreement of
model selection signals).......................................................................................................................... 22
Failure code [DBB3KK] or change of VHMS_LED display from "n9" to "05" (VHMS controller battery power
supply: Source voltage low (input)) ......................................................................................................... 24
Failure code [DBB5KP] or change of VHMS_LED display from "n9" to "04" (VHMS controller 5 V power supply
output: Output voltage low) ..................................................................................................................... 26
Failure code [DBB6KP] or change of VHMS_LED display from "n9" to "02" (VHMS controller 24V power supply
Failure code [DBB7KP] or change of VHMS_LED display from "n9" to "03" (VHMS controller 12V power supply
Failure code [DBBQKR] or change of VHMS_LED display from "n8" to "02" (CAN communication of VHMS
controller: Communication error (Abnormality in target component system)) ......................................... 32
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time ............................. 34
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time............................. 36
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time .............................. 38
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time .............................. 40
Failure code [DDA7L4] RPM set ON/OFF switch: ON-OFF signals disagree............................................... 4
Failure code [DDA8KB] RPM set idle-up/down selector switch (idle-up): Short circuit ................................. 6
Failure code [DDA9KB] RPM set idle-up/down selector switch (idle-down): Short circuit ............................ 9
Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF signals disagree ................................ 12
Failure code [DDD1LD] Pitch operation switch: Switch is kept pressed for long time .................................. 16
Failure code [DDDBKA] Traction adjustment dial: Disconnection................................................................. 18
Failure code [DDDBKB] Traction adjustment dial: Short circuit .................................................................... 20
Failure code [DDE5MA] Emergency steering drive switch: Malfunction ....................................................... 22
Failure code [DDK4KA] AJSS FNR switch: Disconnection ........................................................................... 24
Failure code [DDK4KB] AJSS FNR switch: Short circuit............................................................................... 26
Failure code [DDK5L4] AJSS shift-up/down switch: ON/OFF signals disagree ............................................ 28
Failure code [DDK6KA] FNR lever switch: Disconnection ............................................................................ 31
Failure code [DDK6KB] FNR lever switch: Short circuit................................................................................ 34
Failure code [DDP5KA] Lock detection pressure switch of steering lock lever: Disconnection .................... 36
Failure code [DDT0L4] Shift mode selector switch: ON/OFF signals disagree............................................. 38
Failure code [DDW9LD] Kick-down switch: Switch is kept pressed for long time ......................................... 40
Failure code [DDWLLD] Hold switch: Switch is kept pressed for long time .................................................. 42
Failure code [DF10KA] Transmission shift lever switch: Disconnection........................................................ 44
Failure code [DF10KB] Transmission shift lever switch: Short circuit ........................................................... 48
Failure code [DGE5KX] (or VHMS_LED display: “n4” o “01”)
(Atmospheric temperature sensor: Out of input signal range) ................................................................ 50
Failure code [DGF1KA] Transmission oil temperature sensor: Disconnection ............................................. 52
Failure code [DGF1KB] Transmission oil temperature sensor: Short circuit ................................................. 54
Failure code [DGH2KX] Hydraulic oil temperature sensor: Out of input signal range................................... 4
Failure code [DGR2KA] Rear brake oil temperature sensor: Disconnection ................................................ 6
Failure code [DGR2KX] Rear brake oil temperature sensor: Out of input signal range................................ 8
Failure code [DGT1KA] Torque converter oil temperature sensor: Disconnection........................................ 10
Failure code [DGT1KB] Torque converter oil temperature sensor: Short circuit ........................................... 12
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range)...................... 14
Failure code [DGT4KA] (or VHMS_LED display: "n3" → "12") Exhaust gas temperature sensor (F): Disconnec-
tion .......................................................................................................................................................... 16
Failure code [DGT4KB] (or VHMS_LED display: "n3" → "11") Exhaust gas temperature sensor (F): Short cir-
cuit........................................................................................................................................................... 19
Failure code [DGT5KA] (or VHMS_LED display: "n3" → "22") Exhaust gas temperature sensor (R): Discon-
nection..................................................................................................................................................... 22
Failure code [DGT5KB] (or VHMS_LED display: "n3" → "21") Exhaust gas temperature sensor (R): Short cir-
cuit........................................................................................................................................................... 25
Failure code [DH21KA] Work equipment pump oil pressure sensor: Disconnection .................................... 28
Failure code [DH21KB] Work equipment pump oil pressure sensor: Short circuit ........................................ 30
Failure code [DHE5KB] (or VHMS_LED display: “n3” → “32”) Blow-by pressure sensor: Short circuit........ 32
00-100 10 WD600-6
100 Index
Failure code [DHE5KY] (or VHMS_LED display: “n3” → “31”) Blow-by pressure sensor: Short circuit with
power supply line..................................................................................................................................... 34
Failure code [DHT2L6] Transmission filter clogging sensor: Signal disagrees with operating state of engine 36
Failure code [DHT8KX] (or VHMS_LED display: “n5” → “33”) Steering oil pressure sensor: Out of input signal
range ....................................................................................................................................................... 38
Failure code [DHTBKA] Modulation clutch oil pressure sensor: Disconnection ............................................ 42
Failure code [DHTBKB] Modulation clutch oil pressure sensor: Short circuit................................................ 44
Failure code [DHU2KX] (or VHMS_LED display: “n7” → “11”) Front brake oil pressure sensor (F): Out of input
signal range ............................................................................................................................................. 46
Failure code [DHU3KX] (or VHMS_LED display: “n7” → “12”) Rear brake oil pressure sensor (R): Out of input
signal range ............................................................................................................................................. 48
Failure code [DK30KA] AJSS lever angle sensor: Disconnection ................................................................. 50
Failure code [DK30KY] AJSS lever angle sensor: Short circuit with power supply line ................................ 52
Failure code [DK59KA] Lift EPC lever potentiometer (Main): Disconnection ................................................ 3
Failure code [DK59KY] Lift EPC lever potentiometer (Main): Short circuit with power supply line................ 6
Failure code [DK59L8] Lift EPC lever potentiometer (Main): Analog signals disagree ................................. 8
Failure code [DK5AKA] Lift EPC lever potentiometer (Sub): Disconnection ................................................. 11
Failure code [DK5AKY] Lift EPC lever potentiometer (Sub): Short circuit with power supply line................. 14
Failure code [DK5BKA] Tilt & pitch EPC lever potentiometer (Main): Disconnection .................................... 16
Failure code [DK5BKY] Tilt & pitch EPC lever potentiometer (Main): Short circuit with power supply line ... 20
Failure code [DK5BL8] Tilt & pitch EPC lever potentiometer (Main): Analog signals disagree ..................... 22
Failure code [DK5CKA] Tilt & pitch EPC lever potentiometer (Sub): Disconnection ..................................... 25
Failure code [DK5CKY] Tilt & pitch EPC lever potentiometer (Sub): Short circuit with power supply line..... 28
Failure code [DKD0KA] Frame angle sensor: Disconnection........................................................................ 30
Failure code [DKD0KY] Frame angle sensor: Short circuit with power supply line ....................................... 32
Failure code [DKD0KZ] AJSS lever and frame angle sensor: Disconnection or short circuit........................ 34
Failure code [DLFAKA] Modulation clutch output shaft speed sensor: Disconnection .................................. 38
Failure code [DLFALC] Modulation clutch output shaft speed sensor: Speed signals disagree.................... 40
Failure code [DLT3KA] Transmission output shaft speed sensor (2): Disconnection .................................... 42
Failure code [DLT3LC] Transmission output shaft speed sensor (2): Speed signals disagree ..................... 44
Failure code [DLT4KB] Transmission output shaft speed sensor (1): Short circuit ....................................... 46
Failure code [DLT4KX] Transmission output shaft speed sensor (1): Out of input signal range ................... 48
Failure code [DV00KB] Alarm buzzer: Short circuit....................................................................................... 50
Failure code [DW4PKA] Blade raise EPC solenoid: Disconnection .............................................................. 52
Failure code [DW4PKB] Blade raise EPC solenoid: Short circuit.................................................................. 54
Failure code [DW4PKY] Blade raise EPC solenoid: Short circuit with power supply line.............................. 55
Failure code [DW4QKA] Blade lower EPC solenoid: Disconnection ............................................................. 56
Failure code [DW4QKB] Blade lower EPC solenoid: Short circuit................................................................. 57
Failure code [DW4QKY] Blade lower EPC solenoid: Short circuit with power supply line ............................ 58
Failure code [DW4RKA] Tilt & pitch EPC solenoid: Disconnection ............................................................... 59
Failure code [DW4RKB] Tilt & pitch EPC solenoid: Short circuit ................................................................... 60
Failure code [DW4RKY] Tilt & pitch EPC solenoid: Short circuit with power supply line............................... 61
Failure code [DW4SKA] Tilt & pitch EPC solenoid: Disconnection................................................................ 62
Failure code [DW4SKB] Tilt & pitch EPC solenoid: Short circuit ................................................................... 63
Failure code [DW4SKY] Tilt & pitch EPC solenoid: Short circuit with power supply line ............................... 64
Failure code [DW7BKA] Fan reverse solenoid: Disconnection ..................................................................... 66
Failure code [DW7BKB] Fan reverse solenoid: Short circuit ......................................................................... 68
Failure code [DW7BKY] Fan reverse solenoid: Short circuit with power supply line..................................... 70
Failure code [DWM1KA] Work equipment neutral lock solenoid: Disconnection .......................................... 4
Failure code [DWM1KB] Work equipment neutral lock solenoid: Short circuit .............................................. 6
Failure code [DWM1KY] Work equipment neutral lock solenoid: Short circuit with power supply line .......... 8
Failure code [DWN7KA] Blade float magnet detent solenoid: Disconnection ............................................... 10
Failure code [DWN7KB] Blade float magnet detent solenoid: Short circuit ................................................... 12
Failure code [DWN7KY] Blade float magnet detent solenoid: Short circuit with power supply line............... 14
Failure code [DWNFKA] Modulation clutch cut-off release solenoid: Disconnection .................................... 16
Failure code [DWNFKB] Modulation clutch cut-off release solenoid: Short circuit ........................................ 18
WD600-6 00-100 11
100 Index
Failure code [DWNFKY] Modulation clutch cut-off release solenoid: Short circuit with power source line .... 20
Failure code [DX16KA] Fan pump EPC solenoid: Disconnection ................................................................. 22
Failure code [DX16KB] Fan pump EPC solenoid: Short circuit..................................................................... 23
Failure code [DX16KY] Fan pump EPC solenoid: Short circuit with power supply line ................................ 24
Failure code [DXA1KA] Pump PC-EPC solenoid: Disconnection ................................................................. 25
Failure code [DXA1KB] Pump PC-EPC solenoid: Short circuit..................................................................... 26
Failure code [DXF0KA] AJSS EPC solenoid: Disconnection ........................................................................ 27
Failure code [DXF0KB] AJSS EPC solenoid: Short circuit............................................................................ 28
Failure code [DXH1KA] Lockup ECMV solenoid: Disconnection .................................................................. 30
Failure code [DXH1KB] Lockup ECMV solenoid: Short circuit...................................................................... 32
Failure code [DXH1KY] Lockup ECMV solenoid: Short circuit with power supply line ................................. 34
Failure code [DXH4KA] 1st clutch ECMV solenoid: Disconnection .............................................................. 36
Failure code [DXH4KB] 1st clutch ECMV solenoid: Short circuit .................................................................. 38
Failure code [DXH4KY] 1st clutch ECMV solenoid: Short circuit with power supply line.............................. 40
Failure code [DXH5KA] 2nd clutch ECMV solenoid: Disconnection ............................................................. 4
Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short circuit................................................................. 6
Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short circuit with power supply line............................. 8
Failure code [DXH6KA] 3rd clutch ECMV solenoid: Disconnection .............................................................. 10
Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short circuit.................................................................. 12
Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short circuit with power supply line ............................. 14
Failure code [DXH7KA] R clutch ECMV solenoid: Disconnection................................................................. 16
Failure code [DXH7KB] R clutch ECMV solenoid: Short circuit .................................................................... 18
Failure code [DXH7KY] R clutch ECMV solenoid: Short circuit with power supply line ................................ 20
Failure code [DXH8KA] F clutch ECMV solenoid: Disconnection ................................................................. 22
Failure code [DXH8KB] F clutch ECMV solenoid: Short circuit..................................................................... 24
Failure code [DXH8KY] F clutch ECMV solenoid: Short circuit with power supply line ................................ 26
Failure code [DXHHKA] 4th clutch ECMV solenoid: Disconnection.............................................................. 28
Failure code [DXHHKB] 4th clutch ECMV solenoid: Short circuit ................................................................. 30
Failure code [DXHHKY] 4th clutch ECMV solenoid: Short circuit with power supply line ............................. 32
Failure code [DXHJKA] RH pitch REAR EPC solenoid: Disconnection ........................................................ 34
Failure code [DXHJKB] RH pitch REAR EPC solenoid: Short circuit............................................................ 35
Failure code [DXHJKY] RH pitch REAR EPC solenoid: Short circuit with power supply line ....................... 36
Failure code [DXHKKA] RH pitch FORWARD EPC solenoid: Disconnection ............................................... 37
Failure code [DXHKKB] RH pitch FORWARD EPC solenoid: Short circuit................................................... 38
Failure code [DXHKKY] RH pitch FORWARD EPC solenoid: Short circuit with power supply line .............. 39
Failure code [DXHPKA] Modulation clutch solenoid: Disconnection............................................................. 40
Failure code [DXHPKB] Modulation clutch solenoid: Short circuit ................................................................ 42
Failure code [DXHPKY] Modulation clutch solenoid: Short circuit with power source line............................ 44
Failure code [DXHPMA] Modulation clutch solenoid: Malfunction ................................................................ 46
Failure code [F@BBZL] (or VHMS_LED display: “n3” → “38”) Blow-by pressure: High error ...................... 48
Failure code [F@BYNR] (or VHMS_LED display: “n3” o “62”)
(Exhaust gas temperature (F): Abnormal heat)....................................................................................... 50
Failure code [F@BYNS] (or VHMS_LED display: “n3” → “61”) Exhaust gas temperature (F): Overheat..... 52
Failure code [F@BZNR] (or VHMS_LED display: “n3” o “72”)
(Exhaust gas temperature (R): abnormal heat)....................................................................................... 54
Failure code [F@BZNS] (or VHMS_LED display “n3” → “71”) Exhaust gas temperature (R): Overheat ..... 56
400 Troubleshooting of electrical system (E-mode) SEN05061-01
Before carrying out troubleshooting of electrical system............................................................................... 2
Information in troubleshooting table .............................................................................................................. 5
E-1 Engine does not start.............................................................................................................................. 6
E-2 Wiper does not operate .......................................................................................................................... 16
E-3 Windshield washer does not operate ..................................................................................................... 24
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off................................... 30
E-5 Working lamp does not light up or go off. ............................................................................................... 46
E-6 Step lamp does not light up or go off ...................................................................................................... 54
E-7 Turn signal lamp and hazard lamp do not light up or go off.................................................................... 56
E-8 Brake lamp does not light or it keeps lighting up. ................................................................................... 66
00-100 12 WD600-6
100 Index
E-9 Backup lamp does not light or it keeps lighting up.................................................................................. 70

E-10 Backup buzzer does not sound or it keeps sounding. .......................................................................... 74
E-11 Horn does not sound or it keeps sounding............................................................................................ 78
E-12 Alarm buzzer does not sound or it keeps sounding .............................................................................. 82
E-13 Air conditioner does not operate or stop ............................................................................................... 84
E-14 Electric priming pump does not operate or does not stop automatically............................................... 86
E-15 When starting switch is turned to ON position, machine monitor displays nothing ............................... 88
500 Troubleshooting of hydraulic and mechanical system (H-mode) SEN05062-01
Method of using troubleshooting chart .......................................................................................................... 4
Table of failure modes and causes ................................................................................................................ 6
H-1 Machine does not start ........................................................................................................................... 10
H-2 Torque converter lockup is not switched (engine stalls) ......................................................................... 12
H-3 Torque converter lockup is not turned on................................................................................................ 13
H-4 Travel speed is slow, thrusting force is weak, uphill traveling power is weak, and gear is not shifted.... 14
H-5 Shocks are large at the times of starting and shifting gear ..................................................................... 16
H-6 Time lag is large at the times of starting and shifting gear...................................................................... 18
H-7 Torque converter oil temperature is high ................................................................................................ 20
H-8 Steering does not turn [machine with steering wheel] ............................................................................ 21
H-9 Steering does not turn [machine with AJSS]........................................................................................... 22
H-10 Turning, response of steering is poor [machine with steering wheel] ................................................... 23
H-11 Turning, response of AJSS is poor [machine with AJSS] ..................................................................... 24
H-12 Steering is heavy [machine with steering wheel] .................................................................................. 25
H-13 When machine turns, it shakes or makes large shocks [machine with steering wheel] ....................... 26
H-14 When machine turns, it shakes or makes large shocks [machine with AJSS]...................................... 27
H-15 Wheel brake does not work or does not work well ............................................................................... 28
H-16 Wheel brake is not released or it drags ................................................................................................ 29
H-17 Parking brake does not work or does not work well ............................................................................. 30
H-18 Parking brake is not released or it drags (including emergency release system)................................. 31
H-19 Blade does not rise ............................................................................................................................... 32
H-20 Blade speed is low or rising force of lift is insufficient ........................................................................... 33
H-21 When rising, blade comes to move slowly at specific height ................................................................ 34
H-22 Lift cylinder cannot hold down blade (Blade floats)............................................................................... 34
H-23 Hydraulic drifts of blade occur often...................................................................................................... 34
H-24 Blade wobbles during operation ........................................................................................................... 34
H-25 Blade does not tilt and pitch.................................................................................................................. 35
H-26 Blade speed is low or tilt and pitch force is insufficient ......................................................................... 36
H-27 Blade comes to operate slowly in the midst of tilt and pitch ................................................................. 37
H-28 Tilt & pitch cylinder cannot hold down blade......................................................................................... 37
H-29 Hydraulic drifts of blade occur often...................................................................................................... 37
H-30 Blade wobbles during travel when loaded (Work equipment valve is set to “HOLD”)........................... 37
H-31 During operation of machine, engine speed lowers remarkably or engine stalls.................................. 38
H-32 Large shocks are made when work equipment starts and stops .......................................................... 38
H-33 When work equipment circuit is relieved singly, other work equipment moves .................................... 38
H-34 Fan speed is abnormal (Fan sound and vibration are abnormally large or engine overheats)............. 39
600 Troubleshooting of engine (S-mode) SEN05063-00
Method of using troubleshooting chart .......................................................................................................... 2
S-1 Engine does not start easily. ................................................................................................................... 6
S-2 Engine does not start .............................................................................................................................. 8
S-3 Engine does not pick up smoothly .......................................................................................................... 12
S-4 Engine stops during operation ................................................................................................................ 13
S-5 Engine does not rotate smoothly (Hunting occurs) ................................................................................. 14
S-6 Engine lacks output (or lacks power) ...................................................................................................... 15
S-7 Exhaust smoke is black (Incomplete combustion) .................................................................................. 16
S-8 Oil is consumed much (or exhaust gas color is blue) ............................................................................. 18
S-9 Engine oil becomes contaminated quickly .............................................................................................. 19
S-10 Fuel consumption is excessive ............................................................................................................. 20
S-11 Coolant contains oil (blows back or reduces)........................................................................................ 21
S-12 Oil pressure drops................................................................................................................................. 22
WD600-6 00-100 13
100 Index
S-13 Oil level rises (Water, fuel in oil) ........................................................................................................... 24

S-14 Coolant temperature rises too high (Overheating) ............................................................................... 26
S-15 Abnormal noise is made ....................................................................................................................... 27
S-16 Vibration is excessive ........................................................................................................................... 28
S-17 Air cannot be bled from fuel circuit ....................................................................................................... 30
50 Disassembly and assembly

100 General information on disassembly and assembly SEN05141-00
How to read this manual ............................................................................................................................... 2
Coating materials list..................................................................................................................................... 4
Special tools list............................................................................................................................................. 7
Sketches of special tools............................................................................................................................... 11
201 Engine and cooling system, Part 1 SEN05142-01
Removal and installation of engine assembly ............................................................................................... 2
Removal and installation of radiator assembly.............................................................................................. 6
Removal and installation of air aftercooler .................................................................................................... 11
Removal and installation of cooling fan and fan motor assembly ................................................................. 12
Removal and installation of damper assembly.............................................................................................. 14
Disassembly and assembly of damper assembly ......................................................................................... 16
Removal and installation of fuel tank assembly ............................................................................................ 20
Removal and installation of engine hood assembly ...................................................................................... 22
Removal and installation of bulkhead assembly ........................................................................................... 24
202 Engine and cooling system, Part 2 SEN05143-02
Removal and installation of fuel supply pump assembly............................................................................... 2
Removal and installation of cylinder head assembly .................................................................................... 8
Removal and installation of fuel injector assembly ....................................................................................... 24
Removal and installation of engine front seal ............................................................................................... 28
Removal and installation of engine rear seal ................................................................................................ 31
Removal and installation of parking brake assembly .................................................................................... 2
Removal and installation of torque converter and transmission assembly ................................................... 4
Disassembly and assembly of torque converter assembly ........................................................................... 2
Disassembly and assembly of transmission assembly ................................................................................. 29
Disassembly and assembly of transfer assembly ......................................................................................... 56
Disassembly and assembly of parking brake assembly................................................................................ 72
Removal and installation of front axle assembly ........................................................................................... 2
Removal and installation of rear axle assembly............................................................................................ 4
Removal and installation of center support assembly ................................................................................... 6
Disassembly and assembly of center support assembly .............................................................................. 8
Disassembly and assembly of differential assembly ..................................................................................... 12
Removal and installation of final drive carrier assembly ............................................................................... 2
Disassembly and assembly of final drive carrier assembly........................................................................... 4
Removal and installation of front final drive brake assembly ........................................................................ 5
Disassembly and assembly of final drive assembly ...................................................................................... 7
400 Brake system SEN05148-01
Disassembly and assembly of brake assembly ............................................................................................ 2
Removal and installation of brake valve assembly ....................................................................................... 10
Disassembly and assembly of accumulator and charge valve assembly ..................................................... 11
Disassembly and assembly of slack adjustor assembly ............................................................................... 14
500 Undercarriage and frame SEN05149-01
Removal and installation of center hinge pin ................................................................................................ 2
Removal and installation of counterweight assembly ................................................................................... 9
00-100 14 WD600-6
100 Index
600 Hydraulic system SEN05150-01

Removal and installation of hydraulic tank assembly .................................................................................... 2
Removal and installation of hydraulic pump assembly.................................................................................. 4
Removal and installation of control valve assembly ...................................................................................... 8
Disassembly and assembly of control valve assembly.................................................................................. 10
Removal and installation of steering valve assembly .................................................................................... 15
Disassembly and assembly of hydraulic cylinder assembly .......................................................................... 16
700 Work equipment SEN05151-00
Removal and installation of work equipment assembly................................................................................. 2
800 Cab and its attachments SEN05152-02
Removal and installation of operator's cab assembly.................................................................................... 2
Removal and installation of operator's cab glass (stuck glass) ..................................................................... 6
Removal and installation of floor frame assembly ......................................................................................... 14
Disassembly and assembly of operator’s seat assembly .............................................................................. 17
Removal and installation of air conditioner unit assembly............................................................................. 50
Removal and installation of AJSS lever switch assembly ............................................................................. 53
900 Electrical system SEN05153-00
Removal and installation of engine controller assembly................................................................................ 2
Removal and installation of transmission controller assembly ...................................................................... 4
Removal and installation of loader controller assembly ................................................................................ 4
Removal and installation of VHMS controller assembly ................................................................................ 5
Removal and installation of machine monitor assembly................................................................................ 6
90 Diagrams and drawings
100 Hydraulic diagrams and drawings SEN05004-00
Power train hydraulic circuit diagram............................................................................................................. 2
Brake hydraulic circuit diagram ..................................................................................................................... 3
200 Electrical diagrams and drawings SEN05005-03
Air conditioner electrical circuit diagram ........................................................................................................ 3
Electrical circuit diagram (1/10) ..................................................................................................................... 5
Electrical circuit diagram (10/10) ................................................................................................................... 23
Connector list and stereogram ...................................................................................................................... 25
WD600-6 00-100 15
SEN04981-11
WD600-6 Wheel dozer

Form No. SEN04981-11
©2019 KOMATSU
All Rights Reserved
Printed in Japan 10-19 (01)
00-100 16
SEN04982-01
WHEEL DOZER
WD600-6

WD600-6 55001 and up
00 Index and foreword 00
200 Foreword and general information

Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
WD600-6 00-200 1
SEN04982-01 Safety notice
Safety notice 1
Important safety notice

Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before w elding work, alw ays wear welding
operating the machine. In addition, gloves, apron, shielding goggles, cap and
read this manual and understand its other clothes suited for welding work.
contents before starting the work. 8) Before starting work, warm up your body
1) Before carrying out any greasing or thoroughly to start work under good condi-
repairs, read all the safety labels stuck to tion.
the machine. For the locations of the 9) Avoid continuing work for long hours and
safety labels and detailed explanation of take rests at proper intervals to keep your
precautions, see the Operation and Main- body in good condition. Take rests in
tenance Manual. specified safe places.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always Safety points
keep the tools and parts in their correct
places. Always keep the work area clean 1 Good arrangement
and make sure that there is no dirt, water, 2 Correct work clothes
or oil on the floor. Smoke only in the areas 3 Following work standard
provided for smoking. Never smoke while
working. 4 Making and checking signs
3) When carrying out any operation, always Prohibition of operation and handling by
5
wear safety shoes and helmet. Do not unlicensed workers
wear loose work clothes, or clothes with 6 Safety check before starting work
buttons missing.
Wearing protective goggles
q Always wear safety glasses when hit- 7
(for cleaning or grinding work)
ting parts with a hammer.
q Always wear safety glasses when Wearing shielding goggles and protectors
8
grinding parts with a grinder, etc. (for welding work)
4) When carrying out any operation with 2 or 9 Good physical condition and preparation
more workers, always agree on the oper- Precautions against work which you are
ating procedure before starting. Always 10
not used to or you are used to too much
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, fork-
lift, service car, etc.
00-200 2 WD600-6
Safety notice SEN04982-01
2. Preparations for work

1) Before adding oil or making any repairs,
park the machine on a hard and level
ground, and apply the parking brake and
block the wheels or tracks to prevent the
machine from moving.
2) Before starting work, lower the work
equipment (blade, ripper, bucket, etc.) to
the ground. If this is not possible, insert
the lock pin or use blocks to prevent the
work equipment from falling. In addition,
be sure to lock all the control levers and
hang warning signs on them.
3) When disassembling or assembling, sup-
port the machine with blocks, jacks, or
stands before starting work. 5) When raising a heavy component (heavier
4) Remove all mud and oil from the steps or than 25 kg), use a hoist or crane. Before
other places used to get on and off the starting work, check that the slings (wire
machine. Always use the handrails, lad- ropes, chains, and hooks) are free from
ders or steps when getting on or off the damage. Always use slings which have
m a c h i n e . N e v e r j u m p o n o r o ff t h e ample capacity and install them to proper
machine. If it is impossible to use the places. Operate the hoist or crane slowly
handrails, ladders or steps, use a stand to to prevent the component from hitting any
provide safe footing. other part. Do not work with any part still
raised by the hoist or crane.
3. Precautions during work 6) When removing a cover which is under
1) Before disconnecting or removing compo- internal pressure or under pressure from a
nents of the oil, water, or air circuits, first spring, always leave 2 bolts in diagonal
release the pressure completely from the positions. Loosen those bolts gradually
circuit. When removing the oil filler cap, a and alternately to release the pressure,
drain plug, or an oil pressure pickup plug, and then remove the cover.
loosen it slowly to prevent the oil from 7) When removing components, be careful
spurting out. not to break or damage the electrical wir-
2) The coolant and oil in the circuits are hot ing. Damaged wiring may cause electrical
when the engine is stopped, so be careful fires.
not to get scalded. Wait for the oil and 8) When removing piping, stop the fuel or oil
coolant to cool before carrying out any from spilling out. If any fuel or oil drips
work on the oil or water circuits. onto the floor, wipe it up immediately. Fuel
3) Before starting work, stop the engine. or oil on the floor can cause you to slip
When working on or around a rotating and can even start fires.
part, in particular, stop the engine. When 9) As a general rule, do not use gasoline to
checking the machine without stopping wash parts. Do not use it to clean electri-
the engine (measuring oil pressure, cal parts, in particular.
revolving speed, temperature, etc.), take 10) Be sure to assemble all parts again in their
extreme care not to get rolled or caught in original places. Replace any damaged
rotating parts or moving parts. parts and parts which must not be reused
4) For the machine equipped with a bat- with new parts. When installing hoses and
tery disconnct switch, turn the battery wires, be sure that they will not be dam-
disconnect switch to the OFF (O) posi- aged by contact with other parts when the
tion, before starting the work. For machine is operated.
machines without a battery disconnct 11) When installing high pressure hoses,
switch, remove the cable from the battery, make sure that they are not twisted. Dam-
before starting the work. Always remove aged tubes are dangerous, so be
the cable from the negative (-) terminal extremely careful when installing tubes for
first. high pressure circuits. In addition, check
t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
installed.
WD600-6 00-200 3
12) When assembling or installing parts, 7) Limit the hanging angle to 60°, as a rule.
always tighten them to the specified Do not sling a heavy load with ropes form-
torques. When installing protective parts ing a wide hanging angle from the hook.
such as guards, or parts which vibrate vio- When hoisting a load with 2 or more
lently or rotate at high speed, be particu- ropes, the force subjected to each rope
l ar l y c a r e f u l t o c h e c k t h a t t h e y a r e will increase with the hanging angle. The
installed correctly. table below shows the variation of allow-
13) When aligning 2 holes, never insert your able load in kN {kg} when hoisting is made
fingers or hand. Be careful not to get your with 2 ropes, each of which is allowed to
fingers caught in a hole. sling up to 9.8 kN {1,000 kg} vertically, at
14) When measuring hydraulic pressure, various hanging angles. When the 2 ropes
check that the measuring tools are cor- sling a load vertically, up to 19.6 kN {2,000
rectly assembled. kg} of total weight can be suspended.
15) Take care when removing or installing the This weight is reduced to 9.8 kN {1,000
tracks of track-type machines. When kg} when the 2 ropes make a hanging
removing the track, the track separates angle of 120°. If the 2 ropes sling a 19.6
suddenly, so never let anyone stand at kN {2,000 kg} load at a lifting angle of
either end of the track. 150°, each of them is subjected to a force
16) If the engine is operated for a long time in as large as 39.2 kN {4,000 kg}.
a place which is not ventilated well, you
may suffer from gas poisoning. Accord-
ingly, open the windows and doors to ven-
tilate well.
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
8) When installing wire ropes to an angular
load and guide the operator safely.
load, apply pads to protect the wire ropes.
q Do not stand under the load.
If the load is slippery, apply proper mate-
q Do not step on the load.
rial to prevent the wire rope from slipping.
2) Check the slings before starting sling
9) Use the specified eyebolts and fix wire
work.
ropes, chains, etc. to them with shackles,
3) Keep putting on gloves during sling work.
etc.
(Put on leather gloves, if available.)
10) Apply wire ropes to the middle portion of
4) Measure the weight of the load by the eye
the hook.
and check its center of gravity.
q Slinging near the tip of the hook may
5) Use proper sling according to the weight
cause the rope to slip off the hook
of the load and method of slinging. If too
during hoisting. The hook has the
thick wire ropes are used to sling a light
maximum strength at the middle por-
load, the load may slip and fall.
tion.
6) Do not sling a load with 1 wire rope alone.
If it is slung so, it may rotate and may slip
out of the rope. Install 2 or more wire
ropes symmetrically.
k Slinging with 1 rope may cause
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
00-200 4 WD600-6
Safety notice SEN04982-01
6. Precautions for using overhead hoist crane

k When raising a heavy part (heavier
than 25 kg), use a hoist, etc. In Disas-
sembly and assembly, the weight of a
part heavier than 25 kg is indicated
after the mark of 4.
1) Before starting work, inspect the wire
ropes, brake, clutch, controller, rails, over
wind stop device, electric shock preven-
tion earth leakage breaker, crane collision
prevention device, and power application
warning lamp, and check safety.
2) Observe the signs for sling work.
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east,
west, south, and north) and the directions
11) Do not use twisted or kinked wire ropes.
of the control buttons without fail.
12) When lifting up a load, observe the follow-
5) Do not sling a load slantingly. Do not move
ing.
the crane while the slung load is swinging.
q Wind in the crane slowly until wire
6) Do not raise or lower a load while the
ropes are stretched. When settling
crane is moving longitudinally or laterally.
the wire ropes with the hand, do not
7) Do not drag a sling.
grasp them but press them from
8) When lifting up a load, stop it just after it
above. If you grasp them, your fingers
leaves the ground and check safety, and
may be caught.
then lift it up.
q After the wire ropes are stretched,
9) Consider the travel route in advance and
stop the crane and check the condi-
lift up a load to a safe height.
tion of the slung load, wire ropes, and
10) Place the control switch on a position
pads.
where it will not be an obstacle to work
q If the load is unstable or the wire rope
and passage.
or chains are twisted, lower the load
11) After operating the hoist, do not swing the
and lift it up again.
control switch.
q Do not lift up the load slantingly.
12) Remember the position of the main switch
13) When lifting down a load, observe the fol-
so that you can turn off the power immedi-
lowing.
ately in an emergency.
q When lifting down a load, stop it tem-
13) If the hoist stops because of a power fail-
porarily at 30 cm above the floor, and
ure, turn the power switch OFF. When
then lower it slowly.
turning on a switch which was turned OFF
q Check that the load is stable, and
by the electric shock prevention earth
then remove the sling.
leakage breaker, check that the devices
q Remove kinks and dirt from the wire
related to that switch are not in operation
ropes and chains used for the sling
state.
work, and put them in the specified
14) If you find an obstacle around the hoist,
place.
stop the operation.
15) After finishing the work, stop the hoist at
5. Precautions for using mobile crane
the specified position and raise the hook
a Read the Operation and Maintenance
to at least 2 m above the floor. Do not
Manual of the crane carefully in advance
leave the sling installed to the hook.
and operate the crane safely.
WD600-6 00-200 5
7. Selecting wire ropes 2) Connection

1) Select adequate ropes depending on the 1] When installing the air conditioner cir-
weight of parts to be hoisted, referring to cuit hoses and tubes, take care that
the table below. dirt, dust, water, etc. will not enter
them.
Wire ropes 2] When connecting the air conditioner
(Standard “Z” twist ropes without galvanizing) hoses and tubes, check that O-rings
(JIS G3525, No. 6, Type 6X37-A) (1) are fitted to their joints.
Nominal 3] Check that each O-ring is not dam-
Allowable load
diameter of rope aged or deteriorated.
mm kN ton 4] When connecting the refrigerant pip-
10 8.8 0.9 ing, apply compressor oil for refriger-
12 12.7 1.3 ant (R134a) (DENSO: ND-OIL8,
14 17.3 1.7 VA L E O T H E R M A L S Y S T E M S :
16 22.6 2.3 ZXL100PG (equivalent to PAG46))
18 28.6 2.9 to its O-rings.
20 35.3 3.6
a Example of O-ring (Fitted to every joint of
25 55.3 5.6
hoses and tubes)
30 79.6 8.1
40 141.6 14.4
50 221.6 22.6
60 318.3 32.4
a The allowable load is one-sixth of the

breaking strength of the rope used
(Safety coefficient: 6).
8. Precautions for disconnecting and con-

necting hoses and tubes in air conditioner
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the a For tightening torque, see the precautions for
refrigerant (air conditioner gas: installation in each section of "Disassembly
R134a) which has fewer factors of and assembly".
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
00-200 6 WD600-6
How to read the shop manual SEN04982-01
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

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

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

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

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

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
WD600-6 00-200 7
SEN04982-01 How to read the shop manual
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
00-200 8 WD600-6
Explanation of terms for maintenance standard SEN04982-01
Explanation of terms for maintenance standard 1
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
–0.022
120
–0.126
a The tolerance may be indicated in the text

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

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
WD600-6 00-200 9
SEN04982-01 Explanation of terms for maintenance standard
2. Standard clearance and standard value 5. Clearance limit

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

able dimension
q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit, it must
be replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value which
the product can be used without causing a
problem is called the “allowable value” or
“allowable dimension”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
00-200 10 WD600-6
Handling of electric equipment and hydraulic component SEN04982-01
Handling of electric equipment and hydraulic component 1
To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
Points to remember when handling electric

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

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

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
WD600-6 00-200 11
SEN04982-01 Handling of electric equipment and hydraulic component
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

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

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
00-200 12 WD600-6
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

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

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

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
WD600-6 00-200 13
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
00-200 14 WD600-6
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
WD600-6 00-200 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oil and water from the com-
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
00-200 16 WD600-6
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
WD600-6 00-200 17
Points to remember when handling hydraulic equipment

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

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

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
00-200 18 WD600-6
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
WD600-6 00-200 19
SEN04982-01 Handling of connectors newly used for engines
Handling of connectors newly used for engines 1
a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 – 170, 12V140 engines
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 – 170, 12V140 engines tor (2) outward.
q Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE (95 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
00-200 20 WD600-6
Handling of connectors newly used for engines SEN04982-01
3. Push lock type

q 95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engines

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
WD600-6 00-200 21
SEN04982-01 Handling of connectors newly used for engines
q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
00-200 22 WD600-6
How to read electric wire code SEN04982-01
How to read electric wire code 1
a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

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

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
automobile
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
WD600-6 00-200 23
SEN04982-01 How to read electric wire code
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
00-200 24 WD600-6
How to read electric wire code SEN04982-01
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
WD600-6 00-200 25
SEN04982-01 Precautions when carrying out operation
Precautions when carrying out operation 1
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

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

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
00-200 26 WD600-6
Precautions when carrying out operation SEN04982-01
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
WD600-6 00-200 27
SEN04982-01 Precautions when carrying out operation
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.
00-200 28 WD600-6
Method of disassembling and connecting push-pull type coupler SEN04982-01
Method of disassembling and connecting push-pull type coupler 1
k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
WD600-6 00-200 29
SEN04982-01 Method of disassembling and connecting push-pull type coupler
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
00-200 30 WD600-6
Method of disassembling and connecting push-pull type coupler SEN04982-01
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
WD600-6 00-200 31
SEN04982-01 Standard tightening torque table
Standard tightening torque table 1
1. Table of tightening torques for bolts and nuts

a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a The following table applies to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

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

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 12 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 17 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
00-200 32 WD600-6
Standard tightening torque table SEN04982-01
2. Table of tightening torques for split flange bolts

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

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diameter Width across flats Tightening torque Nm {kgm}

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

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
WD600-6 00-200 33
SEN04982-01 Standard tightening torque table
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

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

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

diameter across Nominal No. – Thread diameter
of pipe flats Range Target Number of threads, (mm)
(mm) (mm) type of thread (Reference)
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
00-200 34 WD600-6
Standard tightening torque table SEN04982-01
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
WD600-6 00-200 35
SEN04982-01 Conversion table
Conversion table 1
Method of using the conversion table

The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

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

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-200 36 WD600-6
Conversion table SEN04982-01
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
WD600-6 00-200 37
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-200 38 WD600-6
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
WD600-6 00-200 39
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-200 40 WD600-6
WD600-6 00-200 41
SEN04982-01
WD600-6 Wheel dozer

©2012 KOMATSU
All Rights Reserved
Printed in Japan 02-12
00-200 42
SEN04984-01
WHEEL DOZER
WD600-6

WD600-6 55001 and up
01 Specification 01
100 Specification and technical data

Specification dimension drawing..................................................................................................................... 2
Specifications .................................................................................................................................................. 3
Weight table .................................................................................................................................................... 6
Table of fuel, coolant and lubricants................................................................................................................ 8
WD600-6 01-100 1
SEN04984-01 Specification dimension drawing
Specification dimension drawing 1
01-100 2 WD600-6
Specifications SEN04984-01
Specifications 1
Machine model name WD600-6

Serial number 55001 and up 55001 and up
Standard For NORTH AMERICA
Operating weight kg 48,100 48,400
Weight
Distribution
Front wheel kg 22,560 22,710
Rear wheel kg 25,460 25,610
Data inside the parentheses
P-mode E-mode P-mode E-mode
represents a value when locked up
Travel speed F1 km/h 6.7 6.3 6.7 6.3
Travel speed F2 km/h 11.7 (12.4) 11.1 (11.8) 11.7 (12.4) 11.1 (11.8)
Travel speed R1 km/h 7.3 6.9 7.3 6.9
Travel speed R2 km/h 12.8 (13.5) 12.1 (12.8) 12.8 (13.5) 12.1 (12.8)
Performance
Max. drawbar pull, forward kN{kg} 429.53{43,800} 357.94{36,500} 429.53{43,800} 357.94{36,500}
Max. drawbar pull, reverse kN{kg} 387.36{39,500} 354.02{36,100} 387.36{39,500} 354.02{36,100}
Gradeability deg. 25 25
Min. turning radius
Center of outside tire mm 7,075 7,075
Outside of chassis
with straight end bit mm 8,610 8,610
with angle end bit mm 8,630 8,630
Overall length
Overall width (chassis) mm 3,570 3,570
Blade width mm 5,100 5,100
Overall height (ROPS cab top) mm 4,460 4,460
Dimensions
Blade clearance mm 1,500 1,500

Max. drop below ground mm 450 450
Max. tilt mm 1,430 1,430
Wheelbase mm 4,500 4,500
Tread mm 2,650 2,650
Minimum ground clearance mm 525 525
Front overhung
WD600-6 01-100 3
SEN04984-01 Specifications

Standard For NORTH AMERICA
Name SAA6D170E-5
4-cycle, water-cooled, direct injection type with
Type
turbocharger, aftercooler and water-cooled EGR
Number of cylinders – Bore × Stroke mm 6 – 170 x 170
Total piston displacement l {cc} 23.15 {23,150}
P-mode E-mode
Hosepower
Gross [SAE J1995] kW{HP}/rpm 396 {530}/1,800 384 {515}/1,700

ISO 14396 kW{HP}/rpm 396 {530}/1,800 -
Engine
Net [ISO 9249/SAE J1349] kW{HP}/rpm 393 {527}/1,800 382 {513}/1,700

Nm/rpm
Max. torque 2,594/1,000 {264.5/1,000}
{kgm/rpm}
g/kWh
Rated fuel consumption 227 {169} (In P-mode only)
{g/HPh}
High idle speed rpm 2,000
Low idle speed rpm 800
Starting motor 24 V, 11 kW × 2
Alternator 24 V, 90 A
Battery 12 V, 200 Ah × 2 pcs
Torque converter 3-element, 1-stage, 2-phase (with lockup clutch)
Planetary type, multiple disc type, and forward-reverse
Power train
Transmission
4 stages
Reduction gear unit Spiral bevel gear type and splash lubrication type
Differential system Straight bevel gear type
Final drive Single-stage planetary gear and splash lubrication type
Drive method Front and rear wheel drive
Front axle Fixed frame, full floating type
Wheel and axle
Rear axle Center pin supporting, full floating type

Tire 35/65-33-36PR(L-4)
Wheel rim 28.00 x 33WTB
kPa
Tire inflation pressure Front wheel: 434 {3.5} and rear wheel: 392 {4.0}
{kg/cm2}
Independent front and rear wheel brake system of closed
Foot brake multiple wet disc type
Brake
Fully hydraulic type

Drive shaft braking system of wet disc type
Parking brake
Hydraulically released spring-driven brake
01-100 4 WD600-6
Specifications SEN04984-01

Steering system Standard for NORTH AMERICA
Steering
system
Type Articulated steering

Structure Fully hydraulic power steering
182 + 182 (Variable displacement type piston pump
l/min
Hydraulic pump delivery
Work equipment pump

HPV125+125)
Steering pump l/min 163 (Variable displacement type piston pump HPV125)
Cooling fan pump l/min 57 (Variable displacement type piston pump LPV45)
Torque converter and
l/min 294 (Gear pump SAL(4)160)
transmission pump
Hydraulic oil cooling pump l/min 182 (Gear pump SAL(3)100)
EPC and brake pump l/min 58 (Gear pump SAL(2)32)
Hydraulic system
Control valve
Set pressure for work equipment MPa {kg/cm2} 3-spool type (with HI valve) 24.5 {250}
Set pressure for steering system MPa {kg/cm2} Spool valve type 34.3 {350}
Number of lift cylinders – Bore x

mm Double-acting piston type, 1 – 160 x 1,080
Stroke
Cylinder
Number of pitch and tilt cylinders

mm Double-acting piston type, 2 – 180 x 236.5
– Bore x Stroke
Number of steering cylinders –
mm Double-acting piston type, 2 – 130 x 510
Bore x Stroke
Motor
Fan motor Fixed displacement piston type LMF110 (55)
WD600-6 01-100 5
SEN04984-01 Weight table
Weight table 1
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Serial number 55001 and up
Engine (Dry weight) 3,098
Radiator (Dry weight) 433
Torque converter (Dry weight) 486
Transmission (Dry weight) 1,290
Upper drive shaft 29.6
Center drive shaft 60.5
Front drive shaft 65
Rear drive shaft 62.8
Center support 46.4
Front axle 3,635
Rear axle 3,532
Front differential 551
Rear differential 586
Planetary carrier assembly (1 unit) 191
Wheel hub (1 piece) 182.5
Axle pivot (Front) 136.2
Axle pivot (Rear) 190
Wheel (1 piece) 409
Tire (Standard: 35/65-33-36PR L-4) (1 piece) 1,085
Steering valve 66
Steering cylinder (1 unit) 97.8
Hydraulic tank (Dry weight) 492
Work equipment pump 180
Steering pump 103
Fan pump 25
Torque converter, transmission + Cooling + Brake, EPC 48.3
Oil cooler 59.5
Torque converter oil cooler 75
Fan motor 25
Fan 62
01-100 6 WD600-6
Weight table SEN04984-01
Unit: kg
Serial number 55001 and up
Work equipment valve 150
Lift cylinder 218
Pitch and tilt cylinder 184
Engine hood (top hood, front/rear) 33.4 / 42.4
Engine hood (a side hood) 50.5
Radiator guard 354
Front frame 4,880
Rear frame 4,320
Front frame top cover 23
Blade assembly 2,894
End bit (1 piece)
For straight end bit 31.6
For angle end bit 37
Edge (1 piece) 60.6
H linkage 482
Y linkage 584
Counterweight 616
Fuel tank 426
Battery (1 piece) 64
Cab 1,095
Air conditioner unit 9.8
Operator's seat 50.2
Floor frame 116.3
WD600-6 01-100 7
SEN04984-01 Table of fuel, coolant and lubricants
Table of fuel, coolant and lubricants 1
a For details of the notes (e.g.,Note. 1, Note. 2 …) in the table, see the Operation and Maintenance Man-
ual.
Refill points Engine oil Transmission Hydraulic oil Cooling

Front axle Rear axle Pins Fuel tank
Capacity pan case system system
Specified capacity l 97 120 592 155 155 — 718 182
Refill capacity l 86 83 443 155 155 — — 147
01-100 8 WD600-6
Table of fuel, coolant and lubricants SEN04984-01
WD600-6 01-100 9
SEN04984-01
WD600-6 Wheel dozer

©2012 KOMATSU
All Rights Reserved
01-100 10
SEN04986-00
WHEEL DOZER
WD600-6

WD600-6 55001 and up
10 Structure, function and

maintenance standard 10
100 Engine and cooling system

Engine mount and transmission mount........................................................................................................... 2
Damper ........................................................................................................................................................... 4
Cooling system ............................................................................................................................................... 6
Cooling fan pump.......................................................................................................................................... 10
Cooling fan motor.......................................................................................................................................... 18
WD600-6 10-100 1
SEN04986-00 Engine mount and transmission mount
Engine mount and transmission mount 1
Unit: mm
No. Check item Criteria Remedy
Clearance between stopper and
1 Min. 1 Adjust
support
10-100 2 WD600-6
Engine mount and transmission mount SEN04986-00
Unit: mm
Standard shim thickness of 1.2 (Parallelism of center support coupling and
2 Adjust
mount transmission coupling is 0.1 mm)
WD600-6 10-100 3
SEN04986-00 Damper
Damper 1
1. Breather Function
2. Flywheel (shaft side) q The damper reduces torsional vibration due to
3. Breather torque fluctuation and protects vibration in the
4. Cover drive system after the engine from torsional
5. Outer body vibration.
6. Inner body
7. Rubber cushion (large) Operation
8. Rubber cushion (small) q Power from the engine is transmitted to outer
9. Shaft body (5) via the flywheel. Rubber cushions (7)
and (8) absorb torsional vibration of the
engine, and the power is transmitted to the
upper drive shaft between the torque converter
through shaft (9) via inner body (6).
10-100 4 WD600-6
Damper SEN04986-00
Unit: mm
Standard Tolerance Standard Clearance
Clearance between bearing size Shaft Hole clearance limit
10
and shaft +0.015 –0.000 –0.035 –
85 0.005
+0.003 –0.020 –0.003
Replace
Clearance between bearing –0.000 –0.008 –0.033 –
11 150 0.018
and housing –0.018 –0.033 –0.010
Clearance between inner body –0.012 +0.110 0.042 –
12 85
and shaft –0.034 +0.030 0.144
Standard size Tolerance Repair limit
Wear of oil seal contact surface Finish with
13 –0.000
of shaft 100 –0.18 grinder or replace
–0.087
after chrome-
Wear of oil seal contact surface –0.000 plating repair
14 120 –0.18
of sleeve –0.087
15 Backlash at spline section 0.068 – 0.262 Replace
WD600-6 10-100 5
SEN04986-00 Cooling system
Cooling system 1
10-100 6 WD600-6
Cooling system SEN04986-00
WD600-6 10-100 7
SEN04986-00 Cooling system
1. Radiator upper tank

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

B: Aftercooler inlet port
C: Coolant inlet port
D: Hydraulic oil cooler inlet port
E: Hydraulic oil cooler outlet port
F: Coolant port
Specifications
Torque converter Brake oil cooler
Radiator Oil cooler Aftercooler
oil cooler (if equipped)
Triangle and
Type of core GF68-5 PTO-OL straight, 15-hole PTO-LS CF40-1
pipe type
*1) 100 × 558 × 150 × 620 × 25
Fin pitch (mm) 4.0/2P 4.0/2P 4.0/2P
20 stages stages
Total heat dissipation
59.04 2.1512 53.64 4.065 2.90
surface (m2)
Cross sectional area
156.96 — — — —
of flow (m2)
Pressure valve
70 ± 15
cracking pressure — — — —
{0.7 ± 0.15}
(kPa{kg/cm2})
Vacuum valve
0–5
cracking pressure — — — —
{0 – 0.05}
(kPa{kg/cm2})
*1): Size of element
10-100 8 WD600-6
Cooling system SEN04986-00
WD600-6 10-100 9
SEN04986-00 Cooling fan pump
Cooling fan pump 1
Type: LPV45
General view
P1 : Pump discharge port

PAEPC : EPC output pressure pickup plug
PEPC : EPC valve basic pressure input port
PS : Pump suction port
TO : Drain port
1. Servo valve
2. Air bleeder
10-100 10 WD600-6
Cooling fan pump SEN04986-00
Sectional view
1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
WD600-6 10-100 11
Function q Cylinder block (7) seals the pressurized oil to

q The pump converts the engine rotation trans- valve plate (8) and carries out relative rotation.
mitted to its shaft to oil pressure and delivers q This surface is designed so that the oil pres-
pressurized oil corresponding to the load. sure balance is maintained at a suitable level.
q It is possible to change the discharge amount q The oil inside each cylinder chamber of cylin-
by changing the swash plate angle. der block (7) is suctioned and discharged
through valve plate (8).
Structure
q Cylinder block (7) is supported to shaft (1) by
spline (11).
q Shaft (1) is supported with front and rear bear-
ings (12).
q The end of piston (6) has a spherical hollow
and is combined with shoe (5).
q Piston (6) and shoe (5) form a spherical bear-
ing.
q Shoe (5) is kept pressed against plane (A) of
rocker cam (4) and slid circularly.
q Rocker cam (4) slides around ball (13).
q Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (7).
10-100 12 WD600-6
Operation of pump q With the condition of center line (X) of rocker

q Cylinder block (7) rotates together with shaft cam (4) has swash plate angle (a) to axial
(1), and shoe (5) slides on flat surface (A). direction of cylinder block (7), flat surface (A)
q Rocker cam (4) slants around ball (13). As a functions as cam against shoe (5).
result, angle (a) between center line (X) of q Piston (6) slides on the inside of cylinder block
rocker cam (4) and the axis of cylinder block (7), so a difference between volumes (E) and
(7) changes. (F) is created inside cylinder block (7).
q Angle (a) is called the swash plate angle. q A single piston (6) sucks and discharges the oil
by the amount (F) – (E).
q As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
q On the other hand, the volume of chamber (F)
grows larger and, in this process, the oil is suc-
tioned.
WD600-6 10-100 13
q As center line (X) of rocker cam (4) matches Control of delivery

the axial direction of cylinder block (7) (swash q If the swash plate angle (a) becomes larger,
plate angle (a) = 0), the difference between the difference between volumes (E) and (F)
volumes (E) and (F) inside cylinder block (7) becomes larger and pump delivery (Q)
becomes 0. increases.
q Suction and discharge of pressurized oil is not q Swash plate angle (a) is changed with servo
carried out in this state. Namely pumping piston (10).
action is not performed. (Actually, however, the q Servo piston (10) reciprocates straight accord-
swash plate angle is not set to 0) ing to the signal pressure of the servo valve.
q This straight motion is transmitted to rocker
cam (4).
q Rocker cam (4) supported with ball (13) slides
around ball (13).
q Swash plate angle (a) is in proportion to the

pump delivery.
10-100 14 WD600-6
Servo valve
P : EPC valve basic pressure

PE : Control piston pressure
PH : Pump discharge pressure
T : Drain port
1. Plug
2. Lever
3. Retainer
4. Seat
5. Spool
6. Piston
7. Sleeve
8. Spring
WD600-6 10-100 15
Function q The land of the servo piston pressure passage

q The servo valve controls the current input to is connected to the pump discharge passage
the EPC valve and pump delivery (Q) so that by the notch of spool (5) and the discharge
they will be related as shown in the diagram. pressure is led to the servo piston.
q When the rocker cam is pushed up by the
servo piston, a position feedback is applied
and lever (2) moves to compress spring (8).
q When spool (5) is pushed back, the pump dis-
charge circuit and the servo piston circuit are
cut off.
q Pressure in the servo piston chamber drops
and the rocker cam returns in the direction of a
maximum swash plate angle.
q These processes are repeated until the swash
plate is fixed to a position where the EPC out-
put pressure is balanced with spring (8) force.
q The greater the EPC output pressure, the
smaller the swash plate angle. Conversely, the
q The output pressure of the EPC valve flows in smaller the EPC output pressure, the greater
the piston chamber to push piston (6). the swash plate angle.
q Piston (6) pushes spool (5) until it is balanced
with the spring.
10-100 16 WD600-6
WD600-6 10-100 17
SEN04986-00 Cooling fan motor
Cooling fan motor 1
Type: LMF110 (55)

General view
P : From fan pump

T : From cooler to tank
TC : To tank
Specifications
Type : LMF110 (55)
Capacity : 55.0 cc/rev
Rated speed : 980 rpm
Rated flow : 53.9 l/min
Check valve cracking pressure : 78.5 kPa {0.8 kg/cm2}
10-100 18 WD600-6
Cooling fan motor SEN04986-00
Sectional view
1. Output shaft 7. End cover

2. Case 8. Center spring
3. Thrust plate 9. Check valve
4. Piston assembly 10. Pilot valve
5. Cylinder block 11. Spool for reversible valve
6. Valve plate 12. Safety valve
Unit: mm
Standard size Repair limit
Free length
Installed Installed Installed
x Outside Free length
13 Spool return spring length load load If damaged or
diameter
deformed,
62.66 x 146 N 117 N replace spring
53.5 —
19.8 {14.90 kg} {11.9 kg}
13.7 N 11.0 N
14 Check valve spring 16.4 x 8.9 11.5 —
{1.4 kg} {1.12 kg}
WD600-6 10-100 19
Hydraulic motor unit
Function
q This hydraulic motor is called a swash plate-
type axial piston motor. It converts the energy
of the pressurized oil sent from the hydraulic
pump into rotary motion.
Principle of operation
q The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
q This oil can flow on only one side of the (Y-Y)
line connecting the top dead center and bottom
dead center of the stroke of piston (4).
q The oil sent to one side of cylinder block (5)
presses pistons (4) (2 or 3 pieces) and gener-
ates force (F1).
q Force F1 (F1 kg = P kg/cm2 x xD2/4 cm2)
q This force is applied to thrust plate (2).
q Since thrust plate (2) is fixed to a certain angle
(“a” degrees) to output shaft (1), the force is
divided into components (F2) and (F3).
q Radial component (F3) generates torque [T =
F3 x ri] against the (Y - Y) line connecting the
top dead center and bottom dead center.
q The result of this torque [T = s(F3 x ri)] rotates
cylinder block (5) through the piston.
q This cylinder block (5) is coupled to output
shaft (1) with the spline.
q Output shaft (1) rotates and torque is transmit-
ted.
10-100 20 WD600-6
Suction valve
Function When stopping

q When the fan pump stops rotating, hydraulic oil q When the engine stops, the fan pump input
does not flow into the motor. revolution becomes 0 rpm.
q Since the motor is revolved by the force of q Hydraulic oil from the pump is not supplied to
inertia, the pressure rises on the outlet side of port (P).
the motor. q As the hydraulic oil does not flow to (MA) side
q When the oil stops flowing in from inlet port (P), of the motor, the motor speed decreases grad-
suction valve (1) sucks in the oil on the outlet ually to stop.
side and supplies it to port (MA) where there is q If the motor shaft is revolved by the force of
not sufficient oil. inertia while the oil flow to port (P) decreases,
q Cavitation is prevented from being generated the oil in port (T) on the outlet side is sent by
accordingly. suction valve (1) to (MA) side.
q Cavitation is prevented from being generated
Operation accordingly.
When starting
q When the hydraulic oil from the pump is sup-
plied to port (P) and the pressure on (MA) side
rises.
q When starting torque is generated in the motor,
the motor starts revolution.
q The oil on outlet (MB) side of the motor returns
through port (T) to the tank.
WD600-6 10-100 21
Operation of reversible valve
When solenoid valve is de-energized When solenoid valve is energized

q When solenoid valve (1) is “de-energized”, q When solenoid valve (1) is “energized”, selec-
hydraulic oil from the pump is cut off by selector valve (2) switches.
tor valve (2). q Hydraulic oil from the pump flows through port
q Port (C) is connected to the tank circuit. (C) into spool chamber (D).
q Accordingly, spool (3) is pressed by spring (4) q Hydraulic oil in chamber (D) compresses
to the right. spring (4).
q As a result, motor port (MA) opens and the q Spool (3) moves to the left.
hydraulic oil flows into the motor to revolve it in q Motor port (MB) opens and the hydraulic oil
normal direction (clockwise). flows into the motor to revolve it in reverse
(counterclockwise).
10-100 22 WD600-6
Safety valve
Function
q When the engine is started, the pressure in
port (P) of the fan motor is heightened in some
cases.
q Safety valve (1) is installed to protect the fan
system circuit.
Operation
q If the pressure in port (P) rises above the
cracking pressure of safety valve (1), valve (2)
of safety valve (1) opens to release the pres-
surized oil into port (T).
q Accordingly, abnormally high pressure is pre-
vented from being generated in port (P).
WD600-6 10-100 23
SEN04986-00
WD600-6 Wheel dozer

©2009 KOMATSU
All Rights Reserved
10-100 24
SEN04987-00
WHEEL DOZER
WD600-6

WD600-6 55001 and up

201 Power train, Part 1

Power train...................................................................................................................................................... 2
Power train system diagram ........................................................................................................................... 3
Torque converter and transmission piping diagram ........................................................................................ 4
Torque converter ............................................................................................................................................. 6
Modulation clutch .......................................................................................................................................... 15
Torque converter regulator valve .................................................................................................................. 16
Transmission................................................................................................................................................. 18
Transfer......................................................................................................................................................... 38
Transmission control valve............................................................................................................................ 40
ECMV............................................................................................................................................................ 42
Main relief valve and torque converter relief valve........................................................................................ 49
Lubrication relief valve .................................................................................................................................. 51
WD600-6 10-201 1
SEN04987-00 Power train
Power train 1
1. Center drive shaft Outline

2. Transfer (output) q Power from engine (8) is transmitted through
3. Transmission the flywheel of engine to damper (7). The
4. Torque converter damper output shaft is connected to modula-
5. Transfer (input) tion clutch (9) via upper drive shaft (6). The
6. Upper drive shaft output of the modulation clutch is connected to
7. Damper pump of torque converter (4). The turbine of
8. Engine the torque converter is connected to input shaft
9. Modulation clutch of transmission (3).
10. Rear axle q The transmission has 6 hydraulic clutches to
11. Rear drive shaft set itself to 4 forward gear speeds and 4
12. Center support reverse gear speeds, which is operated
13. Front drive shaft through selection of one of them using an elec-
14. Front axle trically controlled switch.
q The output shaft of the transmission is con-
nected to gear of transfer (2) and the power is
transmitted to the output shaft. The power
from the transfer output shaft is transmitted
through center drive shaft (1), center support
(12), front drive shaft (13) and rear drive shaft
(11) to front axle (14) and rear axle (10), and
then transmitted through the wheels to the
tires.
10-201 2 WD600-6
Power train system diagram SEN04987-00
Power train system diagram 1
15. Front differential 23. Hydraulic oil cooling pump

16. Front brake 24. Power train pump
17. Front final drive 25. Work equipment pump
18. Front tire 26. Steering pump
19. Emergency steering pump (Only machine with 27. Cooling fan pump
emergency steering system) 28. Rear differential
20. Parking brake 29. Rear brake
21. Brake cooling pump (if equipped) 30. Rear final drive
22. Brake and EPC pump 31. Rear tire
WD600-6 10-201 3
SEN04987-00 Torque converter and transmission piping diagram
Torque converter and transmission piping diagram 1
1. Transmission
2. Power train, hydraulic oil cooling, brake and EPC pump
3. Transfer (input)
4. Torque converter
5. Transfer (output)
6. Transmission oil level gauge
7. Torque converter oil cooler
8. Torque converter oil filter
10-201 4 WD600-6
Torque converter and transmission piping diagram SEN04987-00
WD600-6 10-201 5
SEN04987-00 Torque converter
Torque converter 1
(Input transfer, PTO, modulation clutch, and torque converter)
10-201 6 WD600-6
Torque converter SEN04987-00
A: Modulation clutch oil pressure pickup port Specifications

B: From transmission control valve
C: From brake valve (Left)
D: To torque converter regulator valve
E: From lockup clutch ECMV
F: From main relief valve
G: From oil cooler
H: To transfer case
1. Steering, cooling fan pump mounting port

2. Work equipment pump mounting port
3. Modulation clutch output shaft speed sensor
4. Torque converter
5. Input transfer and PTO
6. Modulation clutch
7. Power train, hydraulic oil cooling, brake and Type 3-element, 1-stage, 2-phase
EPC pump mounting port 2.113 (T3/T1)
8. Brake cooling pump (If equipped) mounting Stall torque ratio
2.654 (T3/T2)
port
WD600-6 10-201 7
1. Modulation clutch output shaft 11. Stator shaft

2. Modulation clutch piston 12. Transmission input shaft
3. Modulation clutch outer drum 13. Free wheel
4. Modulation clutch gear (Number of teeth: 43) 14. Race
5. Torque converter input shaft 15. Boss
6. Lockup clutch housing 16. Lockup clutch disc
7. Turbine 17. Lockup clutch plate
8. Drive case 18. Lockup clutch piston
9. Stator 19. Modulation clutch disc
10. Pump 20. Modulation clutch plate
10-201 8 WD600-6
1. Coupling
2. PTO gear (Number of teeth: 51)
3. Drive gear (Number of teeth: 54)
4. Input shaft
5. PTO gear (Number of teeth: 51)
WD600-6 10-201 9
Unit: mm
Inside diameter of cover seal
1 +0.050 Repair by hard
ring contact surface 60 60.5
+0.000 chromium-plat-
Inside diameter of retainer seal +0.040 ing or replace
2 140 140.5
ring contact surface +0.000
Backlash between drive gear
3 and modulation clutch inner 0.198 – 0.506
drum
Thickness of modulation clutch
2.8 ±0.08 2.3
disc
Thickness of modulation clutch
4 2.6 ±0.05 2.3
plate
Replace
Total assembly thickness of
40.4 ±0.25 37.1
modulation clutch
Thickness of lockup clutch disc 5.0 ±0.1 4.5
Thickness of lockup clutch
5.0 ±0.1 4.5
5 plate
Total assembly thickness of
15.0 ±0.17 13.9
lockup clutch
10-201 10 WD600-6
Unit: mm
Standard size Tolerance Repair limit Repair by hard
Outside diameter of coupling oil
1 –0.000 chromium-plat-
seal contact surface 95 94.8
–0.087 ing or replace
Backlash between drive gear
2 0.198 – 0.506
and PTO gear
Tolerance
Standard size
Shaft Hole
Tolerance for fitness Outside –0.000 –0.012
3 130
of input shaft bearing diameter –0.020 –0.052
Inside +0.039 –0.000
75
diameter +0.020 –0.015
Outside –0.000 +0.026
Tolerance for fitness diameter 140
–0.018 –0.014 Replace
4 of PTO gear bearing
(rear) Inside +0.030 –0.000
80
diameter +0.011 –0.015
Outside –0.000 –0.010
Tolerance for fitness diameter 100
–0.015 –0.045
5 of PTO gear bearing
(front) Inside +0.030 –0.000
55
diameter +0.011 –0.015
Standard clearance Clearance limit
Clearance between cage and
6 1.05 – 1.70
case —
(Standard shim thickness: 1.2)
WD600-6 10-201 11
Power transmitting route

When lockup clutch is “disengaged”
Drive case (11) is disconnected from boss (15) and turbine (14) and lockup torque converter works as an
ordinary torque converter.
The power from engine o (from left bottom)

O O
Damper Outer drum (7)
O O
Universal joint Output shaft (8)
O O
Coupling (1) Input shaft (9)
O O
Input shaft (2) Clutch housing (10), drive case (11) and pump (13)
O rotate together
Drive gear (3) O
O Oil is used as medium
Clutch gear (5) O
O Turbine (14) and boss (15)
Modulation clutch (6) O
O Transmission input shaft (16)
(To right top) o
q The power being transmitted to coupling (1) is then transmitted through input shaft (2), drive gear (3)
and PTO gear (4) and then used as the pump driving power.
10-201 12 WD600-6
When lockup clutch is “engaged”
Drive case (11) is connected to boss (15) and turbine (14) and lockup torque converter is locked up.
The power from engine o (from left bottom)

O O
Damper Outer drum (7)
O O
Universal joint Output shaft (8)
O O
Coupling (1) Input shaft (9)
O O
Input shaft (2) Clutch housing (10), drive case (11) and pump (13)
O rotate together
Drive gear (3) O
O Lockup clutch (12)
Clutch gear (5) O
O Boss (15)
Modulation clutch (6) O
O Transmission input shaft (16)
(To right top) o
q The power being transmitted to coupling (1) is then transmitted through input shaft (2), drive gear (3)
and PTO gear (4) and then used as the pump driving power.
WD600-6 10-201 13
Oil flow
q The oil flows through the main relief valve and

its pressure is regulated by the torque con-
verter relief valve, and then it flows to the
pump (4) through inlet port (A) and the oil pas-
sage of housing (1), stator shaft (2) and guide
(3).
q The oil is given a centrifugal force by pump (4),
and then it enters turbine (5) to transmit its
energy to turbine (5).
q The oil from turbine (5) is sent to stator (6), and
then returned to pump (4). Part of this oil is
sent to the oil cooler through stator (6), oil pas-
sage of stator shaft (2) and outlet port (B).
10-201 14 WD600-6
Modulation clutch SEN04987-00
Modulation clutch 1
Outline
q The modulation clutch is installed between the
input transfer and torque converter.
q Regulating the clutch oil pressure by use of
ECMV allows adjusting the clutch connection.
q Sliding the clutch allows reducing the power to
be transmitted to the torque converter.
When clutch is “engaged” (fixed)

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

q As the low clutch oil pressure signal from the
controller is received, the modulation clutch
ECMV reduces the clutch oil pressure.
q As the clutch oil pressure goes low, pressing
force of piston (3) is weakened, causing slip-
page of disc (4) and plate (5). As the result,
speed of outer drum (7) becomes slower than
clutch gear (6).
Thus, the power to be transmitted to outer
drum (7) is reduced.
q Magnitude of the power to be transmitted is
determined by the ratio between the clutch slip
ratio and torque converter's speed.
Slip ratio (%) = (1 – Output shaft speed/Input
shaft speed) x 100
WD600-6 10-201 15
SEN04987-00 Torque converter regulator valve
Torque converter regulator valve 1
Unit: mm
Clearance between spool and size Shaft Hole clearance limit
1
valve body –0.050 +0.025 0.050 –
32 0.111
–0.066 +0.000 0.091
Standard size Repair limit Replace
Free length Free length
2 Valve spring length load load
328 N 312 N
126.6 94.5 122.8
{33.5 kg} {31.8 kg}
3. Torque converter outlet port oil pressure pickup Outline

port q This valve is provided at the torque converter
4. Spool outlet circuit in order to secure an optimum
5. Valve body performance of the torque converter by adjust-
ing its set oil pressure.
A: From torque converter Set pressure:
B: To oil cooler 0.57 ± 0.05 MPa {5.8 ± 0.5 kg/cm2}
C: Drain
10-201 16 WD600-6
Torque converter regulator valve SEN04987-00
Operation
q The oil from the torque converter is conducted

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

(D) becomes larger than the tension of spring
(1), spool (2) is pressed rightward, opening
port (A) and port (B).
WD600-6 10-201 17
SEN04987-00 Transmission
Transmission 1
(Transmission, transfer and parking brake)
10-201 18 WD600-6
Transmission SEN04987-00
A: From torque converter 1. Transmission control valve

B: To torque converter 2. Lubrication relief valve
C: To lockup clutch 3. Drain valve
D: From power train pump 4. Drain plug
E: From oil cooler 5. Transfer
F: From parking brake emergency release valve 6. Parking brake
G: From lockup clutch ECMV 7. Transmission
H: From main relief valve 8. Torque converter drain tube mounting port
J: From R clutch ECMV 9. Transmission lubrication temperature sensor
K: From F clutch ECMV 10. Speed sensor
L: From 4th clutch ECMV 11. Emergency steering pump mounting port
M: From 2nd clutch ECMV 12. Oil filler tube mounting port
N: From 3rd clutch ECMV 13. Torque converter regulator valve
P: From 1st clutch ECMV 14. Parking brake oil pressure pickup port
R: From torque converter relief valve 15. Strainer
WD600-6 10-201 19
10-201 20 WD600-6
1. Transmission input shaft Outline

2. R ring gear (Hub) q The transmission employed consists of the
3. Tie bolt united planetary gear mechanism and disc
4. Clutch disc clutch that provides “4 forward gear speeds
5. Clutch plate and 4 reverse gear speeds”.
6. R planetary pinion (Number of teeth: 28) q The transmission selects a single rotating
7. R clutch housing direction and a single speed by fixing the plan-
8. R ring gear (Number of inside teeth: 86) etary gear mechanism and 2 of 6 disc clutches
9. F ring gear (Number of inside teeth: 90) by use of ECMV.
10. F planetary pinion (Number of teeth: 24) q The transmission transmits the power being
11. F clutch housing transmitted to the transmission input shaft to
12. 4th planetary pinion (Number of teeth: 24) the output shaft after selecting a single speed
13. 4th clutch housing from the 1st to 4th speeds both in the forward
14. 2nd hub and reverse travel. In this case, the gear speed
15. 2nd clutch housing change is done by F and R clutches plus com-
16. 2nd clutch piston housing binations of 4 speed clutches.
17. 3rd clutch housing
18. 3rd ring gear (Number of inside teeth: 90)
19. 3rd planetary pinion (Number of teeth: 20) Number of plates and discs used
20. 1st clutch housing
Clutch No. Number of plates Number of discs
21. 1st ring gear (Number of inside teeth: 90)
22. 1st planetary pinion (Number of teeth: 20) R clutch 5+1 6
23. Transfer input gear (Number of teeth: 46) F clutch 5+1 6
24. Transmission output shaft 4th clutch 3+1 3
25. 1st sun gear (Number of teeth: 50)
2nd clutch 7 8
26. 1st carrier
27. 1st clutch piston 3rd clutch 3+1 3
28. 3rd sun gear (Number of teeth: 50) 1st clutch 3+1 3
29. 1st piston return spring
30. 3rd carrier
31. 3rd clutch piston Combinations of clutches at respective gear
32. 3rd piston return spring speeds and reduction ratio
33. 2nd clutch piston
34. 2nd piston return spring Gear speed Clutch used Reduction ratio
35. 4th ring gear (Number of inside teeth: 90) Forward 1st F x 1st 5.622
36. 4th clutch piston Forward 2nd F x 2nd 3.143
37. 4th sun gear (Number of teeth: 42)
Forward 3rd F x 3rd 1.765
38. 4th piston return spring
39. F clutch piston Forward 4th F x 4th 1.000
40. F and 4th carrier Neutral — —
41. F sun gear (Number of teeth: 42) Reverse 1st R x 1st 5.128
42. F piston return spring
Reverse 2nd R x 2nd 2.866
43. R clutch piston
44. R carrier Reverse 3rd R x 3rd 1.610
45. R piston return spring Reverse 4th R x 4th 0.912
46. Washer spring
47. R sun gear (Number of teeth: 30)
48. Housing
WD600-6 10-201 21
1. Transfer idler gear (Number of teeth: 41)

2. Transfer output gear (Number of teeth: 42)
3. Output shaft
4. Front coupling
5. Rear coupling
6. Parking brake
10-201 22 WD600-6
WD600-6 10-201 23
Unit: mm
1 R clutch spring (12 springs) length load load
78.5 N 66.7 N
68 61.0 63.9
{8.0 kg} {6.8 kg}
72.9 N 61.8 N
2 F clutch spring (12 springs) 68 61.5 63.9
{7.4 kg} {6.3 kg}
85.3 N 72.6 N
3 4th clutch spring (12 springs) 41 34.7 38.5
{8.7 kg} {7.4 kg}
1,627 N 1,380 N
4 2nd clutch spring (5 springs) 6 4.9 5.64
{166 kg} {141 kg}
85.3 N 72.6 N
5 3rd clutch spring (12 springs) 41 34.7 38.5
{8.7 kg} {7.4 kg}
85.3 N 72.6 N
6 1st clutch spring (12 springs) 41 34.7 38.5
{8.7 kg} {7.4 kg}
Total assembled thickness of 6 Standard size Tolerance Repair limit
7
discs and 6 plates for R clutch 53.4 ±0.35 50.2
Total assembled thickness of 6
8 53.4 ±0.35 50.2
discs and 6 plates for F clutch
9 30.8 ±0.26 28.4
discs and 4 plates for 4th clutch
10 discs and 7 plates for 2nd 62.4 ±0.39 58.1
clutch
Replace
11 30.8 ±0.26 28.4
discs and 4 plates for 3rd clutch
12 30.8 ±0.26 28.4
discs and 4 plates for 1st clutch
F, R 5.4 ±0.1 4.9
Thickness of 4th, 3rd,
13 5.4 ±0.1 4.6
clutch disc 1st
2nd 5.0 ±0.1 4.5
F, R, 4th, 3.2 ±0.1 2.9
Thickness of 3rd, 1st
14 5.0 ±0.1 4.5
clutch plate
2nd 3.2 ±0.1 2.9
–0.01
Wear of input shaft Width 2.56 2.30
15 –0.03
seal ring
Thickness 1.7 ±0.1 1.55
–0.01
16 –0.03
seal ring
Thickness 2.5 ±0.1 2.35
–0.01
17 –0.03
seal ring
Thickness 3.3 ±0.1 3.15
–0.01
18 –0.03
seal ring
Thickness 1.9 ±0.1 1.75
10-201 24 WD600-6
Unit: mm
Wear of R spacer –0.01
19 Width 4.5 4.05
seal ring –0.03
Thickness 6.0 ±0.15 5.85
–0.01
Wear of housing Width 4.0 3.60
20 –0.04
seal ring
Thickness 5.0 ±0.15 4.85
Wear of 4th spacer –0.01
21 Width 4.0 3.60
housing seal ring –0.03
Wear of seal ring
21 of 4th spacer Thickness 5.1 ±0.12 4.95
housing
Wear of 2nd clutch –0.01
Width 5.0 4.50
22 piston housing –0.03
seal ring Thickness 6.0 ±0.15 5.85
–0.01
Wear of output Width 3.0 2.70
23 –0.03
shaft seal ring
Thickness 1.9 ±0.1 1.75
Backlash between R 0.13 – 0.31
24 sun gear and F, 4th, Replace
planetary pinion 0.14 – 0.35
3rd, 1st
Backlash between R 0.15 – 0.38
25 planetary pinion F, 4th,
and ring gear 0.15 – 0.39
3rd, 1st
Backlash between input gear
26 0.190 – 0.486
and idler gear
Tolerance
Standard size
Tolerance for Shaft Hole
fitness of input Outside –0.000 –0.014
27 200
gear bearing diameter –0.030 –0.060
(Rear)
Inside +0.045 –0.000
110
diameter +0.023 –0.020
Tolerance for Outside –0.000 –0.022
190
fitness of input diameter –0.030 –0.051
28
gear bearing Inside +0.045 –0.000
(Front) 105
diameter +0.023 –0.020
29 0.85 – 1.70
case —
WD600-6 10-201 25
10-201 26 WD600-6
Unit: mm
Outside diameter of coupling oil
1 –0.000 Repair by hard
seal contact surface (Rear) 105 104.8
–0.087 chromium-plat-
Outside diameter of coupling oil –0.000 ing or replace
2 125 124.8
seal contact surface (Front) –0.087
Backlash between idler gear
3 0.190 – 0.486
and output gear
Tolerance
Standard size
Shaft Hole
Tolerance for fitness Outside –0.000 –0.014
4 200
of idler gear bearing diameter –0.030 –0.060
Inside +0.045 –0.000
110
diameter +0.023 –0.020
Outside –0.000 –0.014
Tolerance for fitness 190
diameter –0.030 –0.060
5 of output shaft
Inside +0.059 –0.000 Replace
bearing (Rear) 105
diameter +0.037 –0.020
Outside –0.000 –0.022
Tolerance for fitness 190
diameter –0.030 –0.051
6 of output gear
bearing (Front) Inside +0.059 –0.000
105
diameter +0.037 –0.015
7 0.63 – 1.37
case —
Clearance between cover and 0.38 – 1.23
8 —
cage (Standard shim thickness: 0.5)
WD600-6 10-201 27
Disc clutch
Structure Operation
When clutch is “engaged” (fixed)
q Disc clutch is used for fixing ring gear (1). It q The oil from ECMV is sent with pressure to the
consists of piston (2), plate (3), disc (4), pin (5), rear side of piston (2) through oil the passage
return spring (6) and washer spring (8). of housing (7) and pushes piston (2) leftward.
q Inside teeth of disc (4) are engaged with out- q Piston (2) contacts plate (3) closely against
side teeth of ring gear (1). disc (4) to stop rotation of disc (4) by use of the
q Plate (3) is assembled to clutch housing (7) friction force generated between them.
with pin (5). q Since inside teeth of disc (4) are engaged with
outside teeth of ring gear (1), move of ring gear
(1) is stopped.
When clutch is “disengaged” (released)
q As the oil from ECMV is stopped, piston (2) is

pushed back rightward by return spring (6).
q Plate (3) and disc (4) are released from the
frictional force and ring gear (1), as the result,
is also released.
q Washer spring (8) is installed between plate
(3). This spring quickens return of piston (2) as
the clutch is disengaged by providing smooth
separation of plate (3) and disc (4). At the
same time, it is used for preventing the drag-
ging.
10-201 28 WD600-6
WD600-6 10-201 29

Forward 1st gear speed
10-201 30 WD600-6
F ring gear (4) of F clutch and 1st ring gear (17) of 1st clutch are fixed hydraulically.
The power from torque converter

O
Input shaft (1)
O
F sun gear (2)
O
F planetary pinion (3)
O
F and 4th carrier (10)
O
4th planetary pinion (11)
O
4th ring gear (12) 4th sun gear (23)
O
2nd clutch piston housing (13)
O
3rd carrier (14)
O
3rd planetary pinion (20)
O
3rd ring gear (21) 3rd sun gear (22)
O
1st sun gear (15)
O
1st planetary pinion (16)
O
1st carrier (18)
O
Output shaft (24)
WD600-6 10-201 31
Forward 2nd gear speed
F ring gear (4) of F clutch and 2nd hub (19) of 2nd clutch are fixed hydraulically.

O
Input shaft (1)
O
F sun gear (2)
O
O
O
O
O
2nd hub (19)
O
Output shaft (24)
10-201 32 WD600-6
Forward 3rd gear speed
F ring gear (4) of F clutch and 3rd ring gear (21) of 3rd clutch are fixed hydraulically.
O
Input shaft (1)
O
F sun gear (2)
O
O
O
O
O
O
3rd carrier (14)
O
O
3rd sun gear (22)
O
Output shaft (24)
WD600-6 10-201 33
Forward 4th gear speed
F ring gear (4) of F clutch and 4th ring gear (12) of 4th clutch are fixed hydraulically.

O
Input shaft (1)
O
F sun gear (2)
O
O
O
O
4th sun gear (23)
O
Output shaft (24)
10-201 34 WD600-6
WD600-6 10-201 35
Reverse 1st gear speed
10-201 36 WD600-6
R ring gear (7) of R clutch and 1st ring gear (17) of 1st clutch are fixed hydraulically.

O
Input shaft (1)
O
R sun gear (5)
O
R planetary pinion (6)
O
R ring gear (9)
(R carrier (8) is fixed with R ring gear (7) =
R ring gear (9) rotation direction is opposite to
input shaft (1))
O
O
O
O
O
3rd carrier (14)
O
O
3rd ring gear (21) 3rd sun gear (22)
O
1st sun gear (15)
O
1st planetary pinion (16)
O
1st carrier (18)
O
Output shaft (24)
WD600-6 10-201 37
SEN04987-00 Transfer
Transfer 1
Outline
q The transfer is installed in the output side of
the transmission and fixed to the transmission
case with the bolt.
Operation
Transmission output shaft (1)

O
Transfer input gear (2)
O
Transfer idler gear (3)
O
Transfer output gear (4)
O
Output shaft (5)
O
Center drive shaft
O
Front drive shaft Rear drive shaft
O O
Front axle Rear axle
10-201 38 WD600-6
Transfer SEN04987-00
WD600-6 10-201 39
SEN04987-00 Transmission control valve
Transmission control valve 1
Serial No.: (Transmission No. 100091) and up
A: R clutch oil pressure pickup port P: To parking brake emergency release valve
B: F clutch oil pressure pickup port (To parking brake piston)
C: 4th clutch oil pressure pickup port
D: 2nd clutch oil pressure pickup port
E: 3rd clutch oil pressure pickup port
F: 1st clutch oil pressure pickup port
G: Lockup clutch oil pressure pickup port
H: Modulation clutch oil pressure pickup port
J: From power train pump
K: Main relief oil pressure pickup port
L: Torque converter relief pressure pickup port
M: To input transfer lubrication
N: To parking brake emergency release valve
(Pilot pressure)
10-201 40 WD600-6
Transmission control valve SEN04987-00
1. R clutch ECMV Outline

2. F clutch ECMV q The oil from the pump flows to the transmis-
3. 4th clutch ECMV sion control valve via the oil filter and then oil
4. 2nd clutch ECMV flow is divided into the main relief circuit and
5. 3rd clutch ECMV clutch actuation circuit.
6. 1st clutch ECMV q The pressure of the oil sent to the clutch actua-
7. Lockup clutch ECMV tion circuit is regulated by the main relief valve,
8. Modulation clutch ECMV and then used to actuate the clutch and park-
9. Parking brake solenoid valve ing brake through the last chance filter. The oil
10. Last chance filter relieved from the main relief valve is supplied
11. Main relief valve and torque converter relief to the torque converter.
valve q When the transmission gear is shifted, the
12. Check valve ECMV increases the clutch oil pressure
smoothly according to the command current
Operation table of ECMV from the transmission controller to reduce the
gear shifting shocks. The ECMV also keeps
ECMV the clutch pressure constant during travel.
F R 1st 2nd 3rd 4th L/U M/C
Gear speed q If the F, R, or 1st to 4th ECMV is selected, the
F1 Q Q Q regulated oil pressure is supplied to the
selected clutch to set the transmission in the
F2 Q Q Q Q
desired gear speed.
F3 Q Q Q Q q In the 2nd, 3rd and 4th speed travel, the lockup
F4 Q Q Q Q clutch ECMV operates at a speed higher than
R1 Q Q Q the speed being specified from the transmis-
sion controller.
R2 Q Q Q Q
q The modulation clutch ECMV operates at every
R3 Q Q Q Q gear speed.
R4 Q Q Q Q
L/U: lockup clutch ECMV
M/C: modulation clutch ECMV
WD600-6 10-201 41
SEN04987-00 ECMV
ECMV 1
a ECMV: Abbreviation for Electronic Control Modulation Valve
For F, R, 1st, 2nd, 3rd, and 4th clutch

a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch
*1:
P: From pump
T: Drain Clutch used Printing on name plate
Dr: Drain F, R, 1st, 2nd, 3rd, 4th D*******
P1: Clutch oil pressure pickup port
1. Fill switch connector

2. Proportional solenoid connector
3. Flow rate pickup valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate (*1)
10-201 42 WD600-6
ECMV SEN04987-00
Outline of ECMV ECMV and proportional solenoid

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

teristics of proportional solenoid
Range A: Before shifting gear (When draining)

Range B: During filling ECMV and fill switch
Range C: Pressure regulation q For each ECMV, 1 fill switch is installed.
Range D: During filling (During triggering) If the clutch is filled with oil, the fill switch is
Point E: Start of filling turned “ON” by the pressure of the clutch. The
Point F: Finish of filling oil pressure is built up according to this signal.
a The logic is so made that the controller will not

recognize completion of filling even if the fill
switch is turned “ON” during triggering (Range
D).
WD600-6 10-201 43
SEN04987-00 ECMV
Operation of ECMV Before shifting gear (when draining)

q ECMV is controlled with the command current (Range A in chart)
sent from the controller to the proportional
solenoid and the fill switch output signal.
The relationship between the proportional
solenoid command current of ECMV, clutch
input pressure, and fill switch output signal is
shown below.
q While no current is flowing in proportional sole-

noid (1), pressure control valve (3) drains the
oil from clutch port (A) through drain port (T).
At this time, since no oil pressure is applied to
flow rate pickup valve (4), fill switch (5) is
turned “OFF”.
Range A: Before shifting gear (When draining)
Range B: During filling
Range C: Pressure regulation
Range D: During filling (During triggering)
Point E: Start of filling
Point F: Finish of filling
a The logic is so made that the controller will not

recognize completion of filling even if the fill
switch is turned “ON” during triggering (Range
D).
10-201 44 WD600-6
ECMV SEN04987-00
During filling (Range B in chart) Pressure regulation (Range C in chart)
q If a current is given to proportional solenoid (1) q If a current flows in proportional solenoid (1),
while there is no oil in the clutch, a hydraulic the solenoid generates thrust in proportion to
force balanced with the solenoid force is the current. This thrust of the solenoid is bal-
applied to chamber (B) and it pushes pressure anced with the sum of the thrust generated by
control valve (3) to the left. This conducts oil the oil pressure in clutch port and the tension
through pump port (P) and orifice (a) of flow of pressure control valve spring (2), and then
rate pickup valve (4) to start filling the oil to the the pressure is settled.
clutch chamber. At this time, differential pres-
sure is generated between the upper stream
and down stream of orifice (a) of flow rate
pickup valve (4). This differential pressure
pushes flow rate pickup valve (4) leftward.
As the clutch chamber is filled up with oil and
oil flow from pump port (P) to clutch port (A) is
stopped, differential pressure before and after
orifice (a) of flow rate pickup valve (4) disap-
pears. As the result, flow rate pickup valve (4)
is pushed rightward, turning “ON” fill switch (5).
WD600-6 10-201 45
SEN04987-00 ECMV
ECMV for lockup and modulation clutch

a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch
*1:
P: From pump
T: Drain Clutch used Printing on name plate
Dr: Drain Lockup, modulation K*******
P1: Clutch oil pressure pickup port
1. Proportional solenoid connector

2. Sleeve
3. Proportional solenoid
4. Pressure control valve
5. Nameplate (*1)
10-201 46 WD600-6
ECMV SEN04987-00
Outline ECMV for modulation clutch

ECMV for lockup clutch q This valve is used for regulating the clutch oil
q This valve is used to switch the clutch in order pressure to the set pressure.
to regulate the clutch oil pressure to the set It controls oil pressure by employing the pro-
pressure. portional solenoid for adjusting slip ratio of the
Since the modulation waveform is used for the clutch.
pressure application characteristics to the Responding to the command current from the
clutch, ECMV is capable of connecting the controller, the valve controls oil pressure by
lockup clutch smoothly, thereby reducing applying the thrust generated on the propor-
shocks resulting from gear shift. Above also tional solenoid to the pressure control valve
prevents generation of peak torque in the spool.
power train. These arrangements make the In order to control the oil pressure, this valve
machine comfortable to operator and enhance changes levels of the thrust applied to the
durability of the power train. pressure control valve by controlling the com-
mand current.
When changing from torque converter travel to
direct travel Oil pressure control of modulation clutch
At gear shift (in direct travel)
WD600-6 10-201 47
SEN04987-00 ECMV
Operation
When clutch is “disengaged” (released) When clutch is “engaged” (fixed)
q While no current is flowing in to proportional q As current is conducted to proportional sole-

solenoid (1), pressure control valve (3) drains noid (1), the oil pressure being balanced with
the oil from clutch port (A) through drain port the solenoid force is applied to chamber (B),
(T). pushing pressure control valve (3) leftward.
Above opens pump port (P) and clutch port (A)
to start filling oil to the clutch.
q As the clutch is filled with oil, the solenoid
thrust is balanced with the sum of the thrust
generated from oil pressure of the clutch port
and the tension of the pressure control valve
spring (2), and then the pressure is settled.
10-201 48 WD600-6
Main relief valve and torque converter relief valve SEN04987-00
Main relief valve and torque converter relief valve 1
Unit: mm
Clearance between main relief size Shaft Hole clearance limit
1
valve and valve body –0.035 +0.013 0.035 –
28 0.078
–0.045 +0.000 0.058
Clearance between torque con-
–0.035 +0.013 0.035 –
2 verter relief valve and valve 22 0.078
–0.045 +0.000 0.058
body
Replace
Main relief valve spring Free length Free length
3 length load load
(Outside)
479.1 N 456 N
128 78.3 124.2
{48.9 kg} {46.5 kg}
365.5 N 347 N
4 Main relief valve spring (Inside) 108 78.3 104.8
{37.3 kg} {35.4 kg}
Torque converter relief valve 162.5 N 154 N
5 50 41.5 48.5
spring {16.5 kg} {15.7 kg}
6. Body A: Drain (Torque converter relief)

7. Piston B: Drain
8. Torque converter relief valve C: From pump
9. Piston D: Drain
10. Main relief valve E: To torque converter
P1: Main relief oil pressure pickup port
P2: Torque converter relief pressure pickup port
(Serial No.: 60001 – (Transmission No. 100090))
WD600-6 10-201 49
SEN04987-00 Main relief valve and torque converter relief valve
Outline Operation of main relief valve
Torque converter relief valve

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

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

the set pressure, the oil conducted to chamber
(F) pushes piston (2) and the resulting reaction
force pushes main relief valve (1) leftward,
q The oil relieved through the main relief valve opening ports (C) and (E).
flows through port (E) into the torque con- Above operation conducts the oil from port (E)
verter. It also flows through orifice (b) of torque to the torque converter.
converter relief valve (3) into chamber (G).
q As the oil pressure to the torque converter
rises beyond the set pressure, the oil con-
ducted to chamber (G) pushes piston (4) and
the resulting reaction force pushes torque con-
verter relief valve (3) rightward, opening ports
(E) and (A).
As the result, the oil in port (E) is drained to the
oil tank through port (A).
10-201 50 WD600-6
Lubrication relief valve SEN04987-00
Lubrication relief valve 1
Unit: mm
Clearance between spool and size Shaft Hole clearance limit
1
valve body –0.035 +0.013 0.035 –
22 0.078
–0.045 +0.000 0.058
2 Valve spring length load load
97.4 N 92.6 N
59.7 37 57.9
{9.94 kg} {9.44 kg}
3. Valve body Function

4. Spool q The lubrication relief valve is installed to the
transmission valve and used for maintaining
A: From oil cooler the pressure of the lubrication circuit below the
B: Drain set pressure.
C: Lubrication pressure pickup port Set pressure: 0.26 MPa {2.7 kg/cm2}
(Cracking pressure)
WD600-6 10-201 51
SEN04987-00
WD600-6 Wheel dozer

©2009 KOMATSU
All Rights Reserved
10-201 52
SEN04988-00
WHEEL DOZER
WD600-6

WD600-6 55001 and up


Torque converter oil cooler.............................................................................................................................. 2
Torque converter oil filter................................................................................................................................. 3
Drive shaft ....................................................................................................................................................... 5
Center support ................................................................................................................................................ 8
Axle ............................................................................................................................................................... 10
Differential ..................................................................................................................................................... 14
Limited slip differential .................................................................................................................................. 23
Final drive ..................................................................................................................................................... 28
WD600-6 10-202 1
SEN04988-00 Torque converter oil cooler
Torque converter oil cooler 1
1. Torque converter oil cooler Outline

Oil from the torque converter is heated by power
A: Inlet port transmitting energy. This torque converter oil cooler
B: Outlet port enters the torque converter oil cooler through inlet
C: Coolant inlet port (A) to be cooled by engine coolant. Then it
D: Coolant outlet flows into the transmission lubrication system
through outlet port (B).
10-202 2 WD600-6
Torque converter oil filter SEN04988-00
Torque converter oil filter 1
1. Relief valve
2. Element
3. Drain plug
A: Outlet port
B: Inlet port
WD600-6 10-202 3
SEN04988-00 Torque converter oil filter
Specifications
q Filtering area: 8,900 cm2 x 3
q Relief pressure: 0.29 – 0.34 MPa
{3 – 3.5 kg/cm2}
(Bypass pressure)
Operation
q Oil from the torque converter charge pump
enters filter inlet port (A). It passes from out-
side to inside of element (2), and flows to outlet
port (B).
q When element (2) is clogged with foreign mat-

ters, or when low oil temperature has caused
pressure at inlet port (A) to increase, oil from
inlet port (A) opens relief valve (1) to flow to
outlet port (B) directly, preventing the pump
and element (2) from being damaged.
10-202 4 WD600-6
Drive shaft SEN04988-00
Drive shaft 1
1. Front drive shaft 4. Rear drive shaft

2. Center support 5. Upper drive shaft
3. Center drive shaft
k Precautions for tightening torque of spider a The specified torque for the new bolt is
mounting bolts lower than that for the old bolt. Accord-
1. There are 2 types (new and old types) of the ingly, if the new bolt is tightened to the
spider mounting bolts which have the same torque for the old bolt, it may be broken
part No. during operation and the machine may not
a Different tightening torques are specified able to travel.
for the new bolt and old bolt.
3. For the above reason, when "retightening",
2. Since the new and old bolts cannot be distin- "removing" or "installing", be sure to replace
guished from each other by appearances, the the existing bolts with new bolts and tighten
existing spider mounting bolts cannot be them to the torque specified for them.
reused.
WD600-6 10-202 5
SEN04988-00 Drive shaft
a A new part No. is set for the new bolt. For

the new part No., see the parts book.
3 *Spider mounting bolts (A, C, E):

215 – 255 Nm {21.9 – 26 kgm}
3 Shaft mounting bolts (B, D, F):
245 – 309 Nm {25 – 31.5 kgm}
3 *Spider mounting bolts (G):
107 – 127 Nm {10.9 – 13 kgm}
3 Shaft mounting bolts (H):
98 – 123 Nm {10 – 12.5 kgm}
*: Bolts of new tightening torque (New bolt val-
ues).
Upper drive shaft
Front drive shaft
10-202 6 WD600-6
Drive shaft SEN04988-00
Center drive shaft
Rear drive shaft
Outline
q Power from the engine is transmitted from the q When the machine is articulated or when it
damper through upper drive shaft (5), torque receives traveling impacts or working impacts,
converter, transmission and transfer to rear the distances between the engine, transmis-
axle through rear drive shaft (4), and also to sion and the front and rear axles change. The
front axle from center drive shaft (3) through drive shafts absorb the fluctuation of the angle
center support (2) and front drive shaft (1). and length with the universal joints and slip
q The drive shafts have the following purpose joints so that the power will be transmitted
besides simple power transmission. without damaging the parts even when the
positions of the components change.
WD600-6 10-202 7
SEN04988-00 Center support
Center support 1
1. Front coupling Outline

2. Case q The center support is installed between the
3. Breather center drive shaft and the front drive shaft
4. Rear coupling mounted on the front frame.
q With the articulating frame, this part is con-
stantly twisting from side to side, so there is lia-
ble to be large stress on the drive shaft.
Therefore, the center support is used to trans-
mit the power smoothly, to reduce the stress
on the drive shafts, and in this way improve the
durability of the drive shafts.
10-202 8 WD600-6
Center support SEN04988-00
Unit: mm
Clearance between case and size Shaft Hole clearance limit
5
bearing –0.000 –0.036 –0.018 –
130 –0.015
–0.018 –0.061 –0.061
Clearance between coupling +0.051 –0.000 –0.032 – Replace
6 75 –0.029
shaft and bearing +0.032 –0.015 –0.066
Clearance between case and –0.000 –0.036 –0.018 –
7 140 –0.015
bearing –0.018 –0.061 –0.061
Clearance between coupling +0.051 –0.000 –0.032 –
8 80 –0.029
shaft and bearing +0.032 –0.015 –0.066
9 Wear of oil seal contact surface Finish with
–0.000
95 –0.18 grinder after
–0.087
chrome-plating
–0.000 repair or replace
10 Wear of oil seal contact surface 105 –0.18
–0.087
Max. 0.22
11 End play of coupling shaft Adjust
(Free rotational torque: Not exceeding 3.9 Nm{0.4 kgm})
WD600-6 10-202 9
SEN04988-00 Axle
Axle 1
Front axle
1. Front axle 8. Oil filler plug

2. Front differential 9. Level plug (front axle)
3. Final drive 10. Level plug (final drive)
4. Front brake 11. Slack adjuster
5. Drain plug (differential)
6. Drain plug (front brake)
7. Drain plug (final drive)
10-202 10 WD600-6
Axle SEN04988-00
Front axle
(with forcible brake cooling system)
1. Front axle 8. Drain plug (front brake)

2. Front differential 9. Drain plug (final drive)
3. Final drive 10. Oil filler plug
4. Front brake 11. Level plug (front axle)
5. Block 12. Level plug (final drive)
6. Strainer 13. Slack adjuster
WD600-6 10-202 11
SEN04988-00 Axle
Rear axle
1. Rear axle 7. Drain plug (final drive)

2. Rear differential 8. Oil filler plug
3. Final drive 9. Level plug (rear axle)
4. Rear brake 10. Level plug (final drive)
5. Drain plug (differential) 11. Slack adjuster
6. Drain plug (rear brake)
10-202 12 WD600-6
Axle SEN04988-00
Rear axle
1. Rear axle 8. Drain plug (rear brake)

2. Rear differential 9. Drain plug (final drive)
3. Final drive 10. Oil filler plug
4. Rear brake 11. Level plug (rear axle)
5. Block 12. Level plug (final drive)
6. Stainer 13. Slack adjuster
WD600-6 10-202 13
SEN04988-00 Differential
Differential 1
Front differential
1. Pinion (Number of teeth: 12)

2. Bevel pinion (Number of teeth: 9)
3. Shaft
4. Side gear (Number of teeth: 24)
5. Bevel gear (Number of teeth: 42)
10-202 14 WD600-6
Differential SEN04988-00
Front differential

3. Shaft
WD600-6 10-202 15
Rear differential

3. Shaft
10-202 16 WD600-6
Rear differential

3. Shaft
WD600-6 10-202 17
a This diagram shows the front differential mechanism.
10-202 18 WD600-6
Unit: mm
No Check item Criteria Remedy
Clearance in side bearing outer size clearance limit
Shaft Hole
1 race of differential gear
assembly –0.000 +0.013 0.028 –
225 —
–0.015 –0.016 –0.016
Clearance in side bearing inner
+0.090 –0.000 0.065 –
2 race of differential gear 150 —
+0.065 –0.025 –0.115
assembly
Clearance between differential –0.018 +0.057 0.018 –
3 360 —
carrier and gauge –0.075 –0.000 –0.132
Clearance in outer race of +0.025 +0.020 0.020 –
4 250.825 —
pinion shaft bearing +0.000 –0.027 –0.052
Clearance in inner race of +0.069 +0.025 0.022 –
5 101.6 —
Clearance in outer race of –0.000 +0.033 –0.003 –
6 215 —
pinion shaft bearing –0.030 –0.079 –0.079
Clearance in inner race of +0.035 –0.000 –0.013 –
7 100 —
pinion shaft bearing +0.013 –0.020 –0.055 Replace
8 End play of pinion gear 0.290
9 Backlash of differential gear 0.25 – 0.33
Clearance between spider and size Shaft Hole clearance limit
10
differential pinion bushing –0.13 +0.03 0.021 –
46 —
–0.18 –0.02 –0.11
Clearance between spider and –0.13 +0.03
11 52 0.21 – 0.11 —
differential pinion bushing –0.18 –0.02
12 Backlash of bevel gear 0.41 – 0.56
Free rotational torque of bevel
13 6.28 – 18.74 (0.64 – 1.91 kgm)
gear
14 Bevel gear preload 9.81 – 19.61 kN (1,000 – 2,000 kg)
15 Rear runout of bevel gear 0.1
Clearance between bolt and
16 0.08 – 0.13
cap
WD600-6 10-202 19
10-202 20 WD600-6
Unit: mm
1 Thickness of side gear washer
4.0 ±0.05 3.5
2 Thickness of pinion gear washer 3 ±0.08 2.8 Replace
–0.00
3 Wear of oil seal contact surface 110 2.8
–0.08
(1) Press the end of the bolt against the rear of the cap.
(2) In state indicated in (1), turn back the bolt by 20 to 30°.
(3) In the position cited in (2), tighten the nut to fix it in
4 Tightening torque of mounting nut Retighten
place.
Tightening torque of fixed nut:
343 – 441 Nm {35 – 45 kgm}: After adjusting clearance
WD600-6 10-202 21
Outline While machine is turning

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

q While the machine is traveling straight, the
right and left wheels rotate at the same speed.
Accordingly, pinion gears (4) in the differential
assembly do not rotate and the power of car-
rier (6) is transmitted through pinion gears (4)
and side gears (3) to right and left axle shafts
(2) evenly.
10-202 22 WD600-6
Limited slip differential SEN04988-00
Limited slip differential 1
(if equipped)
1. Washer
2. Disc
3. Plate
4. Pressure ring
5. Cover
6. Shaft
7. Side gear
8. Shaft
9. Case
10. Pinion
11. Bevel gear
WD600-6 10-202 23
SEN04988-00 Limited slip differential
10-202 24 WD600-6
Unit: mm
Clearance in side bearing outer size clearance limit
Shaft Hole
1 race of differential gear
assembly –0.000 +0.013 0.028 –
225 —
–0.015 –0.016 –0.016
Clearance in side bearing inner
+0.090 –0.000 0.065 –
2 race of differential gear 150 —
+0.065 –0.025 –0.115
assembly
Clearance between differential –0.018 +0.057 0.018 –
3 360 —
carrier and gauge –0.075 –0.000 –0.132
Clearance in outer race of +0.025 +0.020 0.020 –
4 250.825 —
Clearance in inner race of +0.069 +0.025 0.022 –
5 101.6 —
Clearance in outer race of –0.000 +0.033 –0.003 –
6 215 —
Clearance in inner race of +0.035 –0.000 –0.013 –
7 100 —
8 End play of pinion gear 0 – 0.290
9 Backlash of differential gear 0.25 – 0.33
Replace
10 Backlash of bevel gear 0.41 – 0.56
Free rotational torque of bevel
11 6.28 – 18.74
gear
12 Rear runout of bevel gear 0.1
Clearance between stop bolt
13 0.08 – 0.13
and cap
14 Thickness of plate 3.4
±0.02 3.3
3.5
15 Thickness of disc 3.2 ±0.07 3.1
Clearance between disc and
16 0.2 – 0.8
plate (end play)
3.75
17 Thickness of washer
4.0 ±0.05 3.55
4.25
–0.000
18 Wear of oil seal contact surface 110 —
–0.087
(1) Press the end of the bolt against the rear of the cap.
(2) In state indicated in (1), turn back the bolt by 20 to 30°.
Tightening torque of mounting
19 (3) In the position cited in (2), tighten the nut to fix it in place. Retighten
nut
Tightening torque of fixed nut:
343 – 441 Nm {35 – 45 kgm}: After adjusting clearance
WD600-6 10-202 25
SEN04988-00 Limited slip differential
Operation of limited slip differential While machine is traveling straight

The power from the transmission is transmitted 1. When drive forces of right and left wheels
through bevel gear (11), case (9), pressure rings are balanced
(4), shaft (8), pinion (10) to side gears (7), and then [When the road conditions (coefficients of friction)
distributed to the right and left shafts (6). Brake under both wheels and the wheel loads are even
mechanism consisting of disc (2) and plate (3) is and the center of load is at the center of the bucket]
installed to back side of each side gear (7). It gen- The power from the transmission is distributed
erates braking torque in proportion to the torque evenly by the differential gears to the right and left.
transmitted from pressure rings (4) to shaft (8). Under this condition, the slip limits of the right and
Since the brake torque restricts the rotation of side left wheels are the same. Accordingly, when the
gears (7) and case (9), right and left side gears (7) power from the transmission exceeds the slip limits,
cannot rotate freely, thus the operation of the differ- both wheels slip and the differential does not work.
ential is restricted. No load is applied to the brake on the back side of
each side gear.
Mechanism of generation of braking torque by
right and left side gears (7)
Shaft (8) is supported on the cam surfaces made
on the surfaces of pressure rings (4) which are fac-
ing each other. The power (= torque) transmitted
from pressure rings (4) to shaft (8) is transmitted on
the cam surfaces. Force (Fa) to separate both pres-
sure rings (4) is generated by inclination of the cam
surfaces in proportion to the transmitted torque.
Separating load (Fa) acts on the brake on the back
side of each side gear (7) to generate braking
torque.
10-202 26 WD600-6
2. When drive forces of right and left wheels Difference of wheel drive force in each type of dif-
are unbalanced ferential when either wheel slips
[When the road conditions (coefficients of friction)
Wheel drive force
under both wheels and the wheel loads are uneven
(Drive force of slipping wheel is 1)
and either wheel slips more easily]
Example 1: When either wheel is on soft ground in Slipping Locked Total
wheel wheel (Ratio)
digging work
Example 2: When either wheel is on snow and the Limited slip differential 3.64
1 2.64
other one is on asphalt in snow remov- (if equipped) (1.82)
ing work Ordinary differential 1 1 2 (1)
Example 3: When the right and left wheel loads are
unbalanced in travel on a slope On a road where either wheel slips easily, the drive
force of the limited-slip differential is 1.82 times as
The power from the transmission is distributed large as that of the ordinary differential.
evenly by the differential gears to the right and left.
If the distributed drive force limits the wheel slip
limit on the slipping side, the excess of the drive
force is transmitted through the brake on the back
side of the side gear and the case to the brake on
the opposite side (locked side) and given to the
locked wheel.
Only when the excessive drive force exceeds the
braking force, the differential starts working.
While machine is turning

The differential gears in the limited slip differential
operate similarly to those in the ordinary differential.
Accordingly, a difference in rotation speed between
the outer and inner tires necessary for turning is
generated smoothly.
WD600-6 10-202 27
SEN04988-00 Final drive
Final drive 1
1. Axel shaft
2. Sun gear (Number of teeth: 18)
3. Ring gear (Number of teeth: 81)
4. Planetary carrier
5. Planetary gear (Number of teeth: 30)
6. Wheel
10-202 28 WD600-6
Final drive SEN04988-00
Unit: mm
Clearance between planetary size Shaft Hole clearance limit
1
shaft and bearing +0.015 –0.000 –0.020 –
60 —
+0.002 –0.015 –0.030
Clearance between ring gear +0.066 +0.025 –0.009 –
2 266.7 —
hub and bearing +0.034 –0.000 –0.066
Thickness of ring gear mount- Standard size Tolerance Repair limit
3 Replace
ing retainer 22 ±0.1 21.6
Backlash of planetary gear and
4 0.19
sun gear
Backlash of planetary gear and
5 0.20
ring gear
Standard shim thickness of
6 2.3
wheel hub
WD600-6 10-202 29
SEN04988-00 Final drive
Unit: mm
62.8±4.9 Nm {6.4±0.5 kgm}
Tightening torque of 1st time
7 (Preload 7,845 – 27,459 N {800 – 2,800 kg}) Retighten
mounting bolt
2nd time 279±29.4 Nm {28.5±3.0 kgm}
Clearance between wheel hub size Shaft Hole clearance limit
8
and bearing +0.051 –0.042 –0.042 –
355.6 —
–0.000 –0.078 –0.129
Replace
Clearance between tube and –0.015 +0.130 0.174 –
9 215.9 —
bearing –0.044 +0.015 0.030
Clearance between wheel hub +0.025 –0.037 –0.037 –
10 285.75 —
and bearing –0.000 –0.069 –0.094
10-202 30 WD600-6
Final drive SEN04988-00
Outline
q Final drive is reduced by the planetary gear
unit in order to gain increased force, and then
drive force is transmitted to the tires.
Operation
q Power transmitted from the differential mecha-
nism to sun gear (2) through axle shaft (1) is
transmitted to planetary gear (5). The plane-
tary gear rotates inside fixed ring gear (3) to
transmit reduced rotation to planetary carrier
(4) and the power is transmitted to wheel (6)
mounted onto the planetary carrier.
WD600-6 10-202 31
SEN04988-00
WD600-6 Wheel dozer

©2009 KOMATSU
All Rights Reserved
10-202 32
SEN04989-00
WHEEL DOZER
WD600-6

WD600-6 55001 and up

300 Steering system

Steering piping diagram .................................................................................................................................. 2
Steering column .............................................................................................................................................. 4
Joystick steering lever linkage ........................................................................................................................ 5
Joystick EPC valve ......................................................................................................................................... 6
Lock valve ....................................................................................................................................................... 7
Steering valve ................................................................................................................................................. 8
Rotary valve ...................................................................................................................................................11
Steering control valve.................................................................................................................................... 14
Two-way restrictor valve ............................................................................................................................... 30
Stop valve ..................................................................................................................................................... 31
Steering pump............................................................................................................................................... 32
Steering cylinder ........................................................................................................................................... 46
Emergency steering piping diagram ............................................................................................................. 47
Diverter valve ................................................................................................................................................ 48
Emergency steering pump ............................................................................................................................ 56
WD600-6 10-300 1
300 Steering system
SEN04989-00 Steering piping diagram
Steering piping diagram 1
(Steering wheel specification)
1. Steering cylinder (right) 6. Stop valve (left)

2. Stop valve (right) 7. Steering cylinder (left)
3. Hydraulic tank 8. Accumulator charge valve
4. Steering and fan pump 9. Steering valve (Orbit-roll valve)
5. Steering control valve
10-300 2 WD600-6
300 Steering system
Steering piping diagram SEN04989-00
AJSS (Advanced Joystick Steering System) specification
1. Steering cylinder (right) a See the “Work equipment hydraulic circuit dia-
2. Hydraulic tank gram”; the steering hydraulic circuit diagram is
3. Steering and fan pump included in the diagram of the work equipment
4. Steering control valve circuit.
5. Steering cylinder (left)
6. EPC valve
7. Accumulator charge valve
8. Rotary valve
WD600-6 10-300 3
300 Steering system
SEN04989-00 Steering column
Steering column 1
1. Steering wheel
2. Steering column
3. Joint
4. Steering valve (Orbit-roll valve)
Unit: mm
Clearance between steering size clearance limit
Shaft Hole
5 shaft and steering column bear- Replace
ing –0.08 +0.15 –0.05 –
19 0.4
–0.08 –0.05 0.23
10-300 4 WD600-6
300 Steering system
Joystick steering lever linkage SEN04989-00
Joystick steering lever linkage 1
1. Joystick (steering lever)

2. Potentiometer (lever operating angle)
3. Upper joint
4. Universal joint
5. Lower joint
6. Rotary valve
7. Potentiometer (frame angle)
8. Rod (follow up link)
9. Bracket
10. Steering lock lever
11. Rod
12. Lock valve (steering)
13. Front frame
WD600-6 10-300 5
300 Steering system
SEN04989-00 Joystick EPC valve
Joystick EPC valve 1
1. Minimum pressure assurance pressure reduc- Function

ing valve q EPC valve controls oil supply to the rotary
2. Proportional solenoid valve valve by means of a proportional solenoid
valve controlled by command current from the
machine controller.
C: To rotary valve q Also, the minimum pressure assurance pres-
D: To hydraulic tank sure reducing valve ensures supply of mini-
P1: From EPC pump mum pressure to the rotary valve even if the
P2: From diverter valve proportional solenoid valve fails due to failure
of the controller system.
10-300 6 WD600-6
300 Steering system
Lock valve SEN04989-00
Lock valve 1
AJSS (Advanced Joystick Steering System)

specification
1. Lever
2. End cap
3. Ball
4. Seat
5. Body
Outline
q The lock valve is installed between the EPC
valve and rotary valve. When the steering lock
lever is set in the “LOCK” position, the lock
valve, interlocked with the steering lock lever,
operates to shut off the oil in the EPC circuit
and disables steering operation.
WD600-6 10-300 7
300 Steering system
SEN04989-00 Steering valve
Steering valve 1
1. Neutral position spring L: To steering cylinder

2. Valve body (To Pb port of steering valve)
3. Check valve P: From PPC pump
4. Spool R: To steering cylinder
5. Sleeve (To Pa port of steering valve)
6. Gear rim T: To hydraulic tank
7. Gear
8. Cover
9. Drive shaft
10. Center pin
10-300 8 WD600-6
300 Steering system
Steering valve SEN04989-00
Outline Structure
q The steering unit is directly connected to the q Spool (4) is interconnected with the drive shaft
shaft of the steering wheel. The oil from the of the steering wheel and is connected to
PPC pump passes through the steering control sleeve (5) by neutral position spring (1) and
valve, and is switched to the left and right center pin (10) (when the steering wheel is at
steering cylinders to determine the direction of neutral, it does not contact the spool).
travel of the machine. q The top of drive shaft (9) is meshed with center
q The steering unit can be broadly divided into pin (10) and forms one unit with sleeve (5).
the following: spool (4) and sleeve (5), which The bottom is meshed with the spline of gear
have a rotor type direction selection function, (7) of the gear set.
and the gear set (combination of gear (7) and q Valve body (2) has four ports. These are con-
gear rim (6)), which acts as a hydraulic motor nected respectively to the pump circuit, tank
when the steering is operated. circuit, and pilot circuit of the steering demand
valve.
In addition, the port at the pump end and the
port at the tank end are connected by check
valve (3) inside the housing. If there is any fail-
ure in the PPC pump, oil is sucked in directly
from the tank end by the check valve.
WD600-6 10-300 9
300 Steering system
SEN04989-00 Steering valve
Operation
When turning
q When the steering wheel is turned, spool (4) overcomes neutral position spring (1) and turns slightly in
relation to sleeve (5). Because of this rotation, the ports of sleeve (5) and spool (4) overlap, so a pas-
sage is formed for the oil to flow, and the oil flows to gear (7).
q When the steering wheel is turned, the oil inside gear (7) flows, passes inside sleeve (5) and spool (4),
operates the spool of the steering control valve, and actuates the steering cylinders.
At neutral
q When the turning of the steering wheel is stopped (the rotation of the spool is stopped), the return force
of neutral position spring (1) returns spool (4) and sleeve (5) to the neutral position, so the oil passage is
shut off and the oil stops flowing.
q When the non-reaction type steering valve is at the neutral position, the steering cylinder and spool (4)
and sleeve (5) are blocked, so the reaction from the machine is not transmitted to the steering wheel.
10-300 10 WD600-6
300 Steering system
Rotary valve SEN04989-00
Rotary valve 1
1. Neutral position spring T: To hydraulic tank

2. Valve body L: To Pb port of steering control valve
3. Check valve R: To Pa port of steering control valve
4. Spool P: From EPC pump
5. Sleeve
6. Feedback spool
7. Feedback sleeve
8. Loose spring
9. Drive shaft
10. Center pin
11. Body
WD600-6 10-300 11
300 Steering system
SEN04989-00 Rotary valve
Outline
q With a steering lever connected on the top, the Structure
rotary valve switches the flow of oil supplied q Spool (4) connects to sleeve (5) through center
from the EPC pump through the EPC valve to pin (10) (which is out of contact with the spool
move the spool of the steering demand valve. when the steering lever is in “neutral“) and
This movement of the spool operates the neutral position spring (1).
steering cylinder to steer the machine. q The top and the bottom of drive shaft (9) are
q On the other hand, the link installed on the engaged with center pin (10) and combined
front frame is connected to the underside of with sleeve (5) and feedback sleeve (7) in one
the rotary valve, which feeds back the steering body.
angle of the machine. q Feedback spool (6) is connected to feedback
This mechanism ensures that the position of sleeve (7) through center pin (10) (which is not
the steering lever always matches the steering in contact with the spool while the steering
position of the machine. wheel is in “neutral“) and loose spring (8).
q Valve body (2) has 4 ports, which are con-
nected to the pump circuit, tank circuit and the
pilot circuit of the steering demand valve
respectively.
10-300 12 WD600-6
300 Steering system
Rotary valve SEN04989-00
Operation
When turning
q When the steering lever is operated, spool (4) overcomes neutral position spring (1) and turns slightly in
relation to sleeve (5). Because of this rotation, the ports of spool (4) and sleeve (5) overlap, so a pas-
sage is formed for the oil to flow, and the oil flows to the steering control valve to steer the machine.
At neutral
q When application of the operating effort on the steering lever is stopped, the return force of neutral posi-
tion spring (1) returns spool (4) and sleeve (5) to the neutral position, so the oil passage is shut off and
the oil stops flowing.
q When the steering lever is held at a certain angle and the machine is steered to the angle equivalent to
the operating angle of the steering lever (since sleeve (5) turns according to the steering angle of the
machine), spool (4) and sleeve (5) are also returned to the neutral position, and the oil stops flowing.
WD600-6 10-300 13
300 Steering system
SEN04989-00 Steering control valve
Steering control valve 1
1. Relief valve A: To steering cylinder

2. Flow control spool B: To steering cylinder
3. Main relief valve P: From steering pump
4. Steering spool Pa: From stop valve
5. Overload relief valve Pb: From stop valve
Pr: To PB port of steering pump
T: To hydraulic tank
Ts: To PLS port of steering pump
Tp: To hydraulic tank
10-300 14 WD600-6
300 Steering system
Steering control valve SEN04989-00
1. Relief valve A: To steering cylinder

2. Flow control spool B: To steering cylinder
3. Main relief valve P: From steering pump
4. Steering spool Pa: From rotary valve
5. Overload relief valve Pb: From rotary valve
Pr: To PB port of steering pump
T: To hydraulic tank
Ts: To PLS port of steering pump
Tp: To hydraulic tank
WD600-6 10-300 15
300 Steering system
(Steering wheel specification) AJSS (Advanced Joystick Steering System)

specification
10-300 16 WD600-6
300 Steering system
Unit: mm
Steering spool return spring Free length Free length
1 length load load
(Steering wheel specifications)
94.1 N 74.3 N
41.8 37 —
{9.6 kg} {7.6 kg}
Steering spool return spring 94.1 N 74.3 N
1 39.8 35 —
(AJSS specification) {9.6 kg} {7.6 kg}
8.8 N 7.0 N Replace
2 Load check valve spring 20.9 13.2 —
{0.9 kg} {0.71 kg}
372.7 N 297.6 N
3 Flow control valve return spring 85.1 83 —
{38 kg} {30.4 kg}
182.4 N 145.1 N
4 Main relief valve spring 24.0 22.19 —
{18.6 kg} {14.8 kg}
8.8 N 7.0 N
5 Check valve return spring 20.9 13.2 —
{0.9 kg} {0.71 kg}
WD600-6 10-300 17
300 Steering system
Operation of flow amplifier

When spool is at neutral
(When Orbit-roll valve is not in operation)
q Since both ports (Pa) and (Pb) are connected through the Orbit-roll valve, steering spool (1) is kept at
neutral by right and left return springs (2).
When spool is in operation

(When oil flows in port (Pa))
q The pressure in port (Pa) rises and steering spool (1) compresses left return spring (2) and moves to the
left.
q The oil in port (Pa) flows through the hole of spring seat (3) and orifice (a) of steering spool (1) to port
(Pb).
q Since port (Pb) is connected through the Orbit-roll valve to the drain circuit, the oil in port (Pb) is drained.
q Since the pressure generated in port (Pa) is in proportion to the flow rate of the oil, steering spool (1)
moves to a position where the oil pressure reduced by orifice (a) is balanced with the repulsive force of
return spring (2).
10-300 18 WD600-6
300 Steering system
When spool is returned

(When steering wheel is stopped)
q Since both ports (Pa) and (Pb) are connected through the Orbit-roll valve to the drain circuit, steering
spool (1) is driven back to neutral by left return spring (2).
WD600-6 10-300 19
300 Steering system
Operation of flow control spool

When steering spool is at neutral position
q The oil from the steering pump flows in port q If the oil pressure in port (Pr) rises above the
(P). set pressure, the swash plate angle of the
q Since notch (e) is closed, the oil pressure in steering pump is reduced to reduce the deliv-
port (P) is increased and then led through ori- ery.
fice (a) to pressure receiving chamber (X) to q If the oil pressure in port (P) keeps rising after
move flow control spool (1) to the left. the delivery of the pump is minimized, flow
q The oil in pressure receiving chamber (Y) is control spool (1) moves to the left further.
drained from port (T1) through orifice (b), notch q If the oil pressure in pressure receiving cham-
(f) and port (T). ber (X) rises above the set pressure, notch (d)
q If the oil pressure in pressure receiving cham- opens and the oil in port (P) is drained through
ber (X) rises above the set pressure, flow con- notch (d) and port (T).
trol spool (1) moves to the left to open notch
(c).
q The oil in port (P) flows through notch (c) and
port (Pr) to the LS valve of the steering pump.
q Port (Pr) is connected through orifice (j) to port
(Tp) and (Ts).
q The oil pressure in port (Pr) is set between the
pump pressure and drain pressure of port (Tp)
because of the passing resistance of notch (c)
and orifice (j).
10-300 20 WD600-6
300 Steering system
When steering spool operates
q If steering spool (2) operates, notch (f) closes q The excessive oil from the steering pump is
and pressure receiving chamber (Y) and port drained through notch (d) and port (T).
(T) are disconnected and notch (e) opens. q The oil returning from the steering cylinder is
q The oil pressure in pressure receiving chamber drained through orifice (g) and port (T1).
(Y) rises and flow control spool (1) moves to q Even after flow control spool (1) moves to the
the right and the open area of notch (d) right to close notch (d), it moves further to the
reduces. right, as long as the pressure before notch (e)
q The oil before notch (e) is led to pressure is below the set pressure.
receiving chamber (X) and the oil after notch q Since the open area of notch (c) reduces, the
(e) is led to pressure receiving chamber (Y). oil flow into port (Pr) is reduced and the oil
q If the oil pressure in pressure receiving cham- pressure in port (Pr) lowers.
ber (Y) rises higher than that in port (A), the oil q If the oil pressure in port (Pr) lowers, the LS
flowing from orifice (h) pushes and opens load valve of the steering pump increases the deliv-
check valve (3) to the left. ery of the pump to keep the oil pressure in port
q Since the oil from notch (e) flows through port (Pr) to the set pressure.
(A) to the steering cylinder, a pressure differ- q Flow control spool (1) is held at a position
ence is made between before and after notch where the pressure in port (P) is balanced with
(e). the pressure in port (Pr), thus the delivery of
q Since flow control spool (1) works to keep the the pump is kept constant.
differential pressure between before and after q If the open rate of notch (e) changes, the steer-
notch (e) to the set pressure, the oil is dis- ing pump delivery changes according to it to
charged to the steering cylinder according to keep the oil pressure in port (Pr) constant.
the open rate of notch (e).
WD600-6 10-300 21
300 Steering system
Operation of steering valve

At neutral
q Since the steering wheel is not operated,

steering spool (1) does not move.
q The oil from the steering pump flows in port
(P).
q If the oil pressure in port (P) rises, flow control
spool (2) moves to the left and the oil from the
steering pump is drained through notch (a) and
port (T).
10-300 22 WD600-6
300 Steering system
Turning left
q If the steering wheel is turned to the left, the

output pressure from the Orbit-roll valve enters
port (Pa) and steering spool (1) is pushed to
the right.
(P), and then flows through flow control spool
(2) to steering spool (1).
q Load check valve (3) is pushed to the left and
opened, conducting oil to the head side of the
left steering cylinder and to the bottom side of
the right steering cylinder to turn the machine
to the left.
q The oil returning from the right and left steering
cylinders is drained through load check valve
(4) and port (T).
WD600-6 10-300 23
300 Steering system
Turning right
q If the steering wheel is turned to the right, the

output pressure from the Orbit-roll valve enters
port (Pb) and steering spool (1) is pushed to
the left.
(P), and then flows through flow control spool
(2) to steering spool (1).
q Load check valve (4) is pushed to the right and
opened, conducting the oil flows to the head
side of the right steering cylinder and to the
bottom side of the left steering cylinder to turn
the machine to the right.
q The oil returning from the right and left steering
cylinders is drained through load check valve
(3) and port (T).
10-300 24 WD600-6
300 Steering system
Main relief valve

1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat
Function
q The main relief valve is installed to the steering
valve. It maintains the oil pressure in the steer-
ing circuit to the set pressure during the steer-
ing operation.
WD600-6 10-300 25
300 Steering system
Operation of main relief valve
q If the oil pressure in the steering circuit rises to

the level being set with adjustment screw (1)
and spring (2), pilot poppet (3) opens and the
oil is drained through port (T).
q Pressure balance between receiving chambers
(X) and (Y) is lost and flow control spool (4)
moves to the left.
q As flow control spool (4) operates, the oil from
the steering pump is drained and the pressure
in the steering circuit is kept below the set
pressure.
10-300 26 WD600-6
300 Steering system
Overload relief valve Operation

Operation as relief valve
q Port (A) and port (B) are connected to the cyl-

inder circuit and drain circuit, respectively.
q The oil flows through the hole of poppet (1) to
the inside of relief valve poppet (2).
q Check valve poppet (3) and relief valve poppet
(2) are seated securely by the area difference
between diameters (d1) and (d2).
1. Poppet
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring
Function
q The overload relief valve is installed to the q If the oil pressure in port (A) rises above the
steering valve. It protects the cylinder circuit set pressure of the relief valve, pilot poppet (4)
from abnormally high pressure that can be is pushed and opened to the right.
generated if an impact is applied to the cylinder q The oil flows through pilot poppet (4) and hole
while the steering valve is in neutral. to port (B).
q If abnormally high pressure is generated on
the cylinder side, the overload relief valve
works as a safety valve to prevent breakage of
the cylinder and hydraulic piping.
q If negative pressure is generated on the cylin-
der side, the overload relief valve works as a
suction valve to prevent occurrence of vacuum
in the circuit.
WD600-6 10-300 27
300 Steering system
Operation as suction valve
q As pilot poppet (4) opens, the oil pressure

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

(2) becomes lower than the oil pressure in port
(A).
q The oil pushes and opens relief valve poppet
(2) to the right and flows through port (A) to
port (B), thus the circuit is protected from
abnormally high pressure.
10-300 28 WD600-6
300 Steering system
Relief valve
1. Plug
2. Spring
3. Valve
4. Valve seat
Function
q The relief valve is installed to the steering
valve. If the oil pressure in port (Pr) rises
above the set pressure, the relief valve
relieves the oil to protect the LS circuit of the
steering pump from abnormally high pressure.
WD600-6 10-300 29
300 Steering system
SEN04989-00 Two-way restrictor valve
Two-way restrictor valve 1
Operation
q When the oil is flowing to arrow o, it pushes
spring (2) and flows through the orifice, and
between poppet (1) and the poppet seat.
1. Two-way restrictor valve

2. Steering control valve
Function
q To reduce the shock caused by the inertia of q When the oil is flowing to arrow i, the oil flows
the machine when the steering is operated, an only from orifice (a) inside poppet (1), so the
orifice is installed in the oil line of the return cir- flow is controlled.
cuit from the cylinder. This applies pressure to
the returning oil, and regulates the movement
of the cylinder piston.
1. Poppet
2. Spring
3. Body
10-300 30 WD600-6
300 Steering system
Stop valve SEN04989-00
Stop valve 1
1. Boot A: From steering valve (Orbit-roll valve)

2. Wiper B: To steering control valve
3. Seal DR: Drain
4. Poppet
5. Spring
6. Spool
7. Spring
WD600-6 10-300 31
300 Steering system
SEN04989-00 Steering pump
Steering pump 1
Type: HPV125
General view
10-300 32 WD600-6
300 Steering system
Steering pump SEN04989-00
Outline
q The pump unit is composed of the variable-
capacity swash plate-type piston pump, CO
valve, and LS valve.
PA : Pump discharge port

PB : Pump discharge pressure input port
PC : Pump discharge pressure pick-up port
PD1 : Case drain port
PD2 : Drain plug
PEN : Control pressure pick-up port
PLS : Load pressure input port
PLSC : Load pressure pick-up port
POP : External pilot pressure input port
POPC : External pilot pressure pick-up port
1. Main pump
2. LS valve
3. CO valve
WD600-6 10-300 33
300 Steering system
Sectional view
1. Shaft
2. Cradle
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Servo piston
11. CO valve
10-300 34 WD600-6
300 Steering system
Function q Piston (6) carries out relative movement in the

q The pump converts the engine rotation trans- axial direction inside each cylinder chamber of
mitted to its shaft to oil pressure and delivers cylinder block (7).
pressurized oil corresponding to the load. q Cylinder block (7) seals the pressurized oil to
q It is possible to change the discharge amount valve plate (8) and carries out relative rotation.
by changing the swash plate angle. q This surface is designed so that the oil pres-
sure balance is maintained at a suitable level.
Structure q The oil inside each cylinder chamber of cylin-
q Cylinder block (7) is supported to shaft (1) by der block (7) is suctioned and discharged
spline (12). through valve plate (8).
q Shaft (1) is supported by bearings (13) and
(14).
q Tip of piston (6) is shaped as a concave ball
and shoe (5) is caulked to it to form one unit.
ing.
q Rocker cam (4) has flat surface (A), and shoe
(5) is always pressed against this surface while
sliding in a circular movement.
q Rocker cam (4) conducts high pressure oil to
cylinder surface (B) with cradle (2), which is
secured to the case, and forms a static pres-
sure bearing when it slides.
WD600-6 10-300 35
300 Steering system
Operation of pump
q Cylinder block (7) rotates together with shaft q Suction and discharge of pressurized oil is not
(1), and shoe (5) slides on flat surface (A). carried out in this state. Namely pumping
q When this happens, rocker cam (4) moves action is not performed. (Actually, however, the
along cylindrical surface (B), so angle (a) swash plate angle is not set to 0)
between center line (X) of rocker cam (4) and
the axial direction of cylinder block (7)
changes.
q Angle (a) is called the swash plate angle.
q With center line (X) of rocker cam (4) at swash

plate angle (a) in relation to the axial direction
of cylinder block (7), flat surface (A) acts as a
cam in relation to shoe (5).
q In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between vol-
umes (E) and (F) is created inside cylinder
block (7).
q A single piston (6) sucks and discharges the oil
by the amount (F) – (E).
oil is discharged.
tioned.
q As center line (X) of rocker cam (4) matches

the axial direction of cylinder block (7) (swash
plate angle (a) = 0), the difference between
volumes (E) and (F) inside cylinder block (7)
becomes 0.
10-300 36 WD600-6
300 Steering system
Control of delivery
q If the swash plate angle (a) becomes larger,
the difference between volumes (E) and (F)
becomes larger and pump delivery (Q)
increases.
q Servo piston (12) is used for changing swash
plate angle (a).
q Servo piston (12) reciprocates straight accord-
ing to the signal pressure of CO and LS valve.
q This linear movement is transmitted to rocker
cam (4) through slider (13).
q Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) slides on the surface
while continuing revolving movement.
q Space of the pressure receiving area of servo
piston (12) are not identical on the left side and
right side. Main pump discharge pressure (self
pressure) (PP) is always brought to the pres-
sure chamber of the small diameter piston
side.
q Output pressure (PEN) of the LS valve is
brought to the chamber receiving the pressure
at the large diameter piston end.
q The relationship in the size of pressure (PP) at
the small diameter piston end and pressure
(PEN) at the large diameter piston end, and
the ratio between the area receiving the pres-
sure of the small diameter piston and the large
diameter piston controls the movement of
servo piston (12).
WD600-6 10-300 37
300 Steering system
LS valve
PA : Pump port 1. Sleeve

PDP : Drain port 2. Piston
PLP : LS control pressure output port 3. Spool
PLS : LS pressure input port 4. Spring
PP : Pump port 5. Seat
PPL : Load pressure input port 6. Sleeve
PSIG : Drain port 7. Plug
8. Locknut
Function
q The LS (Load Sensing) valve detects the load
and controls the discharge amount.
q This valve controls the main pump discharge
(Q) with the steering pump signal pressure
(PR).
10-300 38 WD600-6
300 Steering system
Operation
When the control valve is situated at neutral
q LS valve is a 3-way selector valve, and signal q According to the difference in the areas on
pressure (PR) from the steering valve is led to servo piston (12), the pressure moves in to the
port (H) of sleeve (8). direction of minimizing the swash plate angle.
q Position of spool (6) is determined by the size
of force of spring (4) and the force of signal
pressure (PR) from the steering valve.
q Before starting engine, servo piston (12) is
pressed to the left. (See the figure to the right)
q If the control lever is in neutral when starting
engine, steering valve signal pressure (PR)
reads 1.4 MPa {14 kg/cm2}.
q Spool (6) stops at a position where the open-
ings from port (D) to port (C) and from port (D)
to port (E) are approximately equal.
q Shuttle valve output pressure (PPH) enters the
large diameter side of the piston from port (K).
q Pump pressure (PP) is present in port (J) on
the small diameter side of the piston.
WD600-6 10-300 39
300 Steering system
Action for the direction of maximizing the pump delivery
q If signal pressure (PR) from the steering pump

becomes smaller, spool (6) is pressed to the
left by the force of spring (4).
q As a result of the movement of spool (6), ports
(D) and (E) are connected, then to CO valve.
q CO valve is connected to the drain port, and
the pressure between circuits (D) and (K)
becomes equal to drain pressure (PT). (Opera-
tion of CO valve to be described later on)
q The pressure at the large diameter end of
servo piston (12) becomes drain pressure
(PT), and pump pressure (PP) enters port (J)
at the small diameter end, so servo piston (12)
is pushed to the left side. Therefore, the swash
plate is moved in the direction to make the dis-
charge amount larger.
10-300 40 WD600-6
300 Steering system
Action for the direction of minimizing the pump delivery
q If steering pump signal pressure (PR)

becomes larger, spool (6) is pressed to the
right by the force of signal pressure (PR).
q As a result of the movement of spool (6), shut-
tle valve output pressure (PPH) flows from port
(C) to port (D), then from port (K) to the large
diameter side of the piston.
q While main pump pressure (PP) is present in
port (J) of the smaller diameter side of the pis-
ton, servo piston (12) is pressed to the right by
its area difference between the larger and the
smaller diameter sides. As the result, servo
piston (12) moves in the direction to minimize
the swash plate angle.
WD600-6 10-300 41
300 Steering system
When servo piston is balanced
q Let us take the area receiving the pressure at q The force of spring (4) is adjusted to determine
the large diameter end of the piston as (A1), the balanced stop position of this spool (6) at
the area receiving the pressure at the small the center of the standard when (PP) – (PLS) =
diameter end as (A0), and the pressure flowing 1.4 MPa {14 kg/cm2}.
into the large diameter end of the piston as
(PEN).
q Combined force of LS valve steering pump sig-
nal pressure (PR) and spring (4) is balanced
and servo piston (12) stops where it is when a
relation of (A0) x (PP) = (A1) x (PEN) is estab-
lished.
q And the swash plate of the pump will be held in
an intermediate position. [Spool (6) will be
stopped at a position where the distance of the
opening from port (D) to port (E) and the dis-
tance from port (C) to port (D) is almost the
same.]
q At this point, the relationship between the pres-
sure receiving areas across servo piston (12)
is (A0) : (A1) = 3 : 5, so the pressure applied
across the piston when it is balanced becomes
(PP) : (PEN) C 5 : 3.
10-300 42 WD600-6
300 Steering system
CO valve
PA : Pump port 1. Plug

PDP : Drain port 2. Servo piston assembly
PPL : CO control output port 3. Ball
4. Spool
5. Spring
6. Retainer
7. Cover
8. Spring
Function
q When the pump pressure in the hydraulic cir-
cuit reaches the maximum level, CO (Cut Off)
valve minimizes the pump swash plate angle
and protects the circuit by suppressing the rise
of pressure.
q The minimum pump swash plate angle given
reduces the pump suction torque to improve
fuel economy.
WD600-6 10-300 43
300 Steering system
When the actuator load is small and pump discharge pressure (PP) is low
q Spool (3) is positioned closer to the left, and

ports (C) and (D) are connected through inter-
nal passage of spool (3).
q Port (C) of CO valve is connected to port (E) of
LS valve.
q Pump pressure (PP) is present in port (B) and
on the smaller diameter side of servo piston
(9). Port (E) of LS valve has the pressure equal
to that of drain pressure (PT).
q When ports (E) and (G) of LS valve are con-
nected, the pressure on the larger diameter
side of the piston becomes equal to drain pres-
sure (PT), and servo piston (9) moves to the
left.
q The swash plate angle of the pump becomes
larger and the pump discharge increases.
10-300 44 WD600-6
300 Steering system
When the actuator load is large, and pump discharge pressure (PP) reaches the maximum pressure
q When load is large and pump discharge pres- q As the servo piston moves to the direction to
sure (PP) is high, the force pressing spool (3) minimize the pump swash plate angle, the
to the right becomes larger, and spool (3) pump discharge is reduced accordingly.
moves to the position as shown in the diagram
above.
q Port (C) of CO valve is connected to port (E) of
LS valve.
q Pump pressure (PP) is present in port (B) and
on the smaller diameter side of servo piston
(9).
q Pressure flowing from port (C) to LS valve
becomes main pump pressure (PP) from port
(B).
q When ports (E) and (G) of LS valve are con-
nected, main pump pressure (PP) enters the
larger diameter side of servo piston (9).
the smaller diameter side of the piston, servo
piston (9) is pressed to the right by its area dif-
ference between the larger and the smaller
diameter sides.
WD600-6 10-300 45
300 Steering system
SEN04989-00 Steering cylinder
Steering cylinder 1
Installation of steering cylinder
Unit: mm
Clearance between steering size clearance limit
Shaft Hole
1 cylinder rod and bushing of
frame joint and mounting pin +0.036 +0.207 0.156 –
85 0.7
+0.090 +0.120 0.297
Clearance between steering
+0.036 +0.207 0.156 –
2 cylinder bottom and bushing of 85 0.7
+0.090 +0.120 0.297
frame joint and mounting pin Replace
Standard clearance
Width of bushing Width of hinge
Steering cylinder and front (clearance of a + b)
3
frame joint Max. 0.5 (after
101 ± 2 106 ± 1.5
shim is adjusted)
Steering cylinder and rear Max. 0.5 (after
4 96 ± 1.2 101.5 ± 1
frame joint shim is adjusted)
10-300 46 WD600-6
300 Steering system
Emergency steering piping diagram SEN04989-00
Emergency steering piping diagram 1
(Only machine with emergency steering system)
1. Hydraulic tank
2. Steering and fan pump
3. Diverter valve
4. Emergency steering relief valve
5. Check valve
6. Transmission
7. Emergency pump
WD600-6 10-300 47
300 Steering system
SEN04989-00 Diverter valve
Diverter valve 1
(Emergency steering) (Only machine with emergency steering system)
1. Check valve A: From emergency pump

2. Check valve B: From emergency pump
3. Check valve D: To hydraulic tank
4. Check valve L: Sensor mounting port
5. Spool P: From steering pump
6. Valve body S: From hydraulic tank
T: To steering control valve
10-300 48 WD600-6
300 Steering system
Diverter valve SEN04989-00
Function
q In a case where steering is disabled due to
engine stop or pump seizure during machine
traveling, this function enables operation of the
steering wheel, utilizing rotations of the tires
through the transmission to operate the emer-
gency pump.
WD600-6 10-300 49
300 Steering system
Unit: mm
Clearance between body and size Shaft Hole clearance limit
1
spool –0.013 +0.015 0.020 –
40 —
–0.015 +0.007 0.030
Free length Free length Replace
2 Spool return spring length load load
216.7 N 205.9 N
122.6 84 120.7
{22.1 kg} {21.0 kg}
5.6 N 5.3 N
3 Check valve spring 79.2 54.5 77.9
{0.57 kg} {0.54 kg}
4.9 N 4.6 N
4 Check valve spring 79.2 57.5 77.9
{0.50 kg} {0.47 kg}
10-300 50 WD600-6
300 Steering system

Operation
q If the pump and engine are normal
q If the steering pump and engine are operating

normally, the steering pump is operated by the
engine, and oil can be sent to the steering
valve, which enables steering.
The emergency pump is operated by the exter-
nal travel force and pushes check valve (2)
open through port (A) of diverter valve (1) and
supplies the oil to port (B).
Spool (3) is pressed to the left as pressure oil
is flowing from the steering pump toward port
(D).
For that reason, oil at port (B) flows to port (C)
to be drained to the hydraulic tank.
WD600-6 10-300 51
300 Steering system
q If the machine is running and the pump or engine has failed
q In a case where the machine is running and

the pump or engine has failed, rotations from
the tires operate the emergency pump through
the transmission.
No pressure oil appears at port (D) because
the steering pump is not operating. For that
reason, spool (3) is pressed by spring (4) to
the right.
Oil from the emergency pump goes through
port (A) and port (B), and then flows to the
rotary valve and the steering valve, enabling
steering.
a The emergency pump is enabled for normal
and reverse rotations.
10-300 52 WD600-6
300 Steering system

Operation
q If the pump and engine are normal
q If the steering pump and engine are operating

normally, the steering pump is operated by the
engine, and oil can be sent to the steering
valve, which enables steering.
The emergency pump is operated by the exter-
nal travel force and pushes check valve (2)
open through port (A) of diverter valve (1) and
supplies the oil to port (B).
Spool (3) is pressed to the left as pressure oil
is flowing from the steering pump toward port
(D).
For that reason, oil at port (B) flows to port (C)
to be drained to the hydraulic tank.
WD600-6 10-300 53
300 Steering system
q If the machine is running and the pump or engine has failed
q In a case where the machine is running and

the pump or engine has failed, rotations from
the tires operate the emergency pump through
the transmission.
No pressure oil appears at port (D) because
the steering pump is not operating. For that
reason, spool (3) is pressed by spring (4) to
the right.
Oil from the emergency pump goes through
port (A) and port (B), and then flows to the
rotary valve and the steering valve, enabling
steering.
a The emergency pump is enabled for normal
and reverse rotations.
10-300 54 WD600-6
300 Steering system
Emergency steering relief valve

(Only machine with emergency steering sys- q When the pressure inside ports (A) and (B)
tem) reaches the pressure set by the poppet spring
(set pressure), pilot poppet (3) opens and the
hydraulic pressure at port (B) escapes from
port (D) to port (C). This lowers the pressure at
port (B).
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw q When the pressure at port (B) drops, the orifice
Set pressure: 20.6 MPa {210 kg/cm2} of main valve (1) generates a difference in
pressure between port (A) and port (B). Main
Function valve (1) is opened by the pressure at port (A)
Compared to the steering control valve relief pres- and the oil at port (A) is relieved.
sure of 34.3 MPa {350 kg/cm2}, the rated pressure
of the emergency steering pump and diverter valve
are both 20.6 MPa {210 kg/cm2}. Therefore, to pro-
tect the emergency steering pump and diverter
valve, there is a relief valve in the piping from the
diverter valve to the steering valve. When the emer-
gency steering is being operated, and the hydraulic
pressure generated by the steering exceeds 20.6
MPa {210 kg/cm2}, the relief valve is actuated.
Operation
q Port (A) is connected to the pump circuit, and
port (C) is connected to the drain circuit. The
oil passes through the orifice in main valve (1)
and fills port (B). Pilot poppet (3) is in contact
with valve seat (2).
WD600-6 10-300 55
300 Steering system
SEN04989-00 Emergency steering pump
Emergency steering pump 1
(Only machine with emergency steering system)

SAM(3)100
Unit: mm
Standard
Clearance between body and Type Tolerance
1 clearance
spool
SAM(3)-100 0.10 – 0.15 0.19
Clearance between inside
2 diameters of needle bearing SAM(3)-100 0.035 – 0.041 0.075 Replace
and gear shaft
Type Standard size Tolerance Repair limit
3 Driven depth of pin –0.5
SAM(3)-100 14
–0.5
4 Rotation torque of spline shaft 6.8 – 11.8 Nm{0.7 – 1.2 kgm}
Discharge Standard Allowable
Speed pressure
Type discharge discharge
Discharge oil: EO10-CD (rpm) (MPa —
— {kg/cm2}) (l/min) (l/min)
Oil temperature: 45 – 55°C
20.6
SAM(3)-100 2,500 221 203.5
{210}
10-300 56 WD600-6
300 Steering system
Emergency steering pump SEN04989-00
WD600-6 10-300 57
SEN04989-00
WD600-6 Wheel dozer

©2009 KOMATSU
All Rights Reserved
10-300 58
SEN04990-00
WHEEL DOZER
WD600-6

WD600-6 55001 and up

400 Brake system

Brake piping diagram ...................................................................................................................................... 2
Brake............................................................................................................................................................... 4
Brake valve ..................................................................................................................................................... 8
Accumulator charge valve............................................................................................................................. 16
EPC relief valve ............................................................................................................................................ 22
Accumulator (for brake) ................................................................................................................................ 24
Slack adjuster ............................................................................................................................................... 26
Parking brake................................................................................................................................................ 30
Parking brake solenoid valve ........................................................................................................................ 32
Emergency parking brake release valve ....................................................................................................... 34
Brake cooling pump ...................................................................................................................................... 35
WD600-6 10-400 1
400 Brake system
SEN04990-00 Brake piping diagram
Brake piping diagram 1
1. Front brake (right) 8. Rear brake (left)

2. Slack adjuster (front) 9. Front brake (left)
3. Hydraulic tank 10. Accumulator charge valve
4. Brake and EPC pump 11. Accumulator
5. Transmission control valve 12. Brake valve (right)
6. Rear brake (right) 13. Brake valve (left)
7. Slack adjuster (rear)
10-400 2 WD600-6
400 Brake system
Brake piping diagram SEN04990-00
WD600-6 10-400 3
400 Brake system
SEN04990-00 Brake
Brake 1
1. Guide pin
2. Return spring
3. Cylinder
4. Brake piston
5. Outer gear
6. Hub gear
7. Plate
8. Disc
10-400 4 WD600-6
400 Brake system
Brake SEN04990-00
Unit: mm
9 Return spring length load load
725 N 689 N
104.8 91.5 102.7
{73.9 kg} {70.2 kg}
10 Thickness of plate
2.4 — 2.15
11 Thickness of disc 5.1 — 4.6
Assembled thickness of plate
12 84.9 — 79.4
discs
–0.155 Replace
13 Wear of seal contact surface 430 —
–0.155
Wear of piston seal contact sur- +0.097
14 420 —
face +0.097
Wear of piston seal contact sur- +0.097
15 465 —
face +0.097
Strain of plate and disc contact Standard strain Repair limit
16
surface Max. 0.5 0.7
Backlash of outer gear and
17 0.24 – 0.72
plate
18 Backlash of inner gear and disc 0.19 – 0.62
WD600-6 10-400 5
400 Brake system
SEN04990-00 Brake
Function
q All the 4 wheels are equipped with a main
brake, which is a wet-type multi-disc brake.
q When the brake pedal is pressed down, pres-

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

sure on brake piston (4) is released and force
of return spring (2) moves the piston in the
direction shown by an arrow mark to release
the brake.
10-400 6 WD600-6
400 Brake system
Brake SEN04990-00
WD600-6 10-400 7
400 Brake system
SEN04990-00 Brake valve
Brake valve 1
Brake valve (Left)
1. Brake pedals
2. Rod
3. Spool
4. Cylinder
A: To pilot port
P1: From accumulator charge valve
PA: From transmission modulation clutch ECMV
T1: Drain port
T2: To transmission tank
10-400 8 WD600-6
400 Brake system
Brake valve SEN04990-00
Unit: mm
Clearance between bevel size Shaft Hole clearance limit
5
mounting hole and pin –0.01 +0.022 0.112 –
φ10 0.25
–0.09 +0.022 0.01
Clearance between roller and –0.01 +0.022 0.112 –
6 φ10 0.25
pin –0.09 +0.022 0.01
7 Outside diameter of roller
25.5 ±0.1 25.1
Free length Free length Replace
8 Control spring length load load
72 N
27.7 26.5 26.7 —
{7.4 kg}
60.4 N
9 Control spring 42.4 39 41.4 —
{6.2 kg}
19.6 N
10 Control spring 50.4 49.5 49.4 —
{2.0 kg}
57.9 N
11 Return spring 56.9 52.4 51 —
{5.9 kg}
24.5 N
12 Return spring 35.3 17.2 32 —
{2.5 kg}
WD600-6 10-400 9
400 Brake system
Brake valve (right)
1. Brake pedals A: To rear brake

2. Rod B: To front brake
3. Piton and pilot PA: From accumulator charge valve
4. Spool PB: From accumulator charge valve
5. Cylinder, upper PP: From pilot port
6. Spool T: Drain port
7. Cylinder, lower
10-400 10 WD600-6
400 Brake system
Unit: mm
Clearance between bevel size Shaft Hole clearance limit
8
mounting hole and pin –0.025 –0.1 0.025 –
φ10 0.25
–0.075 –0.1 0.175
Clearance between roller and –0.025 +0.1 0.025 –
9 φ10 0.25
pin –0.075 +0.1 0.175
10 Outside diameter of roller –0.5
30 29.2
–0.5
Installed Installed Installed Replace
11 Control spring length load load
7.66 N
34 3.0 33 —
{0.781 kg}
0N
12 Control spring 46 46 45 —
{0 kg}
60.8 N
13 Return spring 86.2 58 78 —
{6.2 kg}
16.7 N
14 Return spring 31.5 19.5 28 —
{1.7 kg}
17.7 N
15 Return spring 17 16.5 16 —
{1.8 kg}
WD600-6 10-400 11
400 Brake system
Outline
q There are 2 brake valves installed in parallel to
front lower part of the operator's seat. They are
operated by pressing the pedal.
q If the right pedal is pressed, the oil is supplied
to the brake cylinder to operate the brake.
q If the left pedal is pressed, the oil is supplied to
the right pedal and the brake is operated simi-
larly to when the right pedal is pressed.
q If the left brake pedal is pressed down, the
modulation clutch pressure is reduced to
reduce the drive force of the tires according to
the pressing angle of the pedal.
Operation
When brake is applied (right brake valve)
Upper section
q If pedal (1) is pressed, the pressing effort is
transmitted through rod (2) and spring (4) to
spool (3). If spool (3) lowers, drain port (a) is
closed and the oil from the pump and accumu-
lator flows through port (A) to port (C) to oper-
ate the rear brake cylinder.
Lower section
q If pedal (1) is pressed, the pressing effort is
transmitted through rod (2) and spring (4) to
spool (3). When spool (3) lowers, the force is
transmitted through plunger (6) to cause spool
(5) to go down. As a result, drain port (b) is
closed and the oil from the pump and accumu-
lator flows through port (B) to port (D) to oper-
ate the front brake cylinder.
10-400 12 WD600-6
400 Brake system
When brake is applied (left brake valve)

q If pedal (7) is stepped down, the stepping force
pushes spool (10) down through rod (8) and
spring (9) to close drain port (c). The oil from
the pump and accumulator flows through port
(E) to port (F).
q Since port (F) of the left brake valve is con-
nected to port (PP) of the right brake valve by
the hose, the oil flowing to port (F) flows further
to pilot port (PP) of the right brake valve.
q The oil flowing to pilot port (PP) flows further
through orifice (d) to port (G) and pushes pilot
piston (11) down. It then pushes down spool
(3) through spring and performs the same
operation as that caused by stepping down the
right brake valve.
q When rod (8) is pushed down, the notch of rod
(8) opens to cause oil for the modulation clutch
to flow from port (L) to port (M), and then is
drained. This lowers pressure of the modula-
tion clutch, and drive force transmitted from the
engine to the tires continuously lowers accord-
ing to the stepping angle of the pedal.
WD600-6 10-400 13
400 Brake system
Operation of brake when upper valve has trouble Lower section

(right brake valve) q At the same time when spool (3) in the upper
q Even if the oil leaks from the piping on the section goes upward and port (A) is discon-
upper side, if pedal (1) is pressed, spool (5) is nected from port (C), the front brake cylinder is
moved mechanically and the brake on the also filled with oil and the oil pressure rises
lower side operates normally. between port (B) and port (D). Then, oil enter-
The upper side brake does not operate. ing port (J) through orifice (f) of spool (5)
pushes up spool (5) as much as the amount of
Operation of brake when lower valve has trouble movement of spool (3) to disconnect the port
(right brake valve) (B) from port (D). Also, as drain port (b)
remains closed and the oil entering the brake
q Even if the oil leaks from the piping on the
cylinder is retrained there to maintain the brake
lower side, the brake on the upper side oper-
in operation.
ates normally.
q The pressure in the upper section is balanced
with the pedal pressing force and the pressure
in the lower section is balanced with the pres-
sure in the upper section. When spools (3) and
(5) move in full stroke, the line is fully open
between ports (A) and (C) and ports (B) and
(D). Thus, the pressure in the upper and lower
sections and the oil pressure in the right and
left brake cylinders become the same as the oil
pressure from the pump.
Therefore, until the piston moves in full stroke,
the effect of the brake can be adjusted by the
degree of stepping on the pedal.
Balancing operation
Upper section
q When the rear brake cylinder is filled with oil
and the oil pressure rises between port (A) and
port (C), oil entering port (H) from orifice (e) of
spool (3) resists spring (4) and pushes up
spool (3) to disconnect port (A) from port (C).
At this time, drain port (a) remains closed and
the oil entering the brake cylinder is retrained
there to maintain the brake in operation.
10-400 14 WD600-6
400 Brake system
When brake is released (right brake valve)

Upper section
q When pedal (1) is released and the stepping
force is removed from the upper section of the
spool, back pressure from the brake cylinder
and the spool return spring raise spool (3) to
release drain port (a). Oil from the brake cylin-
der flows to the hydraulic tank return circuit to
release the rear brake.
Lower section
q When the pedal is released, spool (3) of the
upper section moves upward and at the same
time, back pressure from the brake cylinder
and the spool return spring move spool (5) to
release drain port (b). Then, oil from the brake
cylinder flows to the tank return circuit to
release the front brake.
WD600-6 10-400 15
400 Brake system
SEN04990-00 Accumulator charge valve
Accumulator charge valve 1
A1: To steering valve (steering wheel specification)

A1: To EPC valve (AJSS specification)
A2: To work equipment valve
ACC1: To right brake valve port PB
To left brake valve port P1
ACC2: To right brake valve port PA
P1: From pump
PP1: To right brake valve port PB
To left brake valve port P1
T: Drain
10-400 16 WD600-6
400 Brake system
Accumulator charge valve SEN04990-00
1. Valve body Function

2. Main relief valve (R3) q The accumulator charge valve keeps the oil
3. Relief valve (R1) pressure from the pump to the set pressure
4. PPC relief valve (R2) and stores it in the accumulator.
(steering wheel specification) q If the oil pressure rises above the set pressure,
4. EPC relief valve (R2) (AJSS specification) the oil from the pump is led to the drain circuit
5. Relief valve (H1) to reduce the load on the pump.
WD600-6 10-400 17
400 Brake system

Operation 2. When oil is supplied to accumulator
1. When oil is not supplied to accumulator 1) Cut-in state
(cut-out state) q If the pressure at port (B) drops below the
q Since the pressure at port (B) is higher set pressure of relief valve (R1), piston (2)
than the set pressure of relief valve (R1), is returned downward by the tension of
piston (2) is forced to move upward by the spring (8). This causes valve seat (9) to
hydraulic pressure of port (B). As this closely contact poppet (1) to disconnect
move opens poppet (1), port (C) and port port (C) from port (T).
(T) are shorted. q The right-hand side spring chamber of
q As the rightmost spring chamber of spool spool (6) also gets shuttered off from port
(6) leads to port (C) of relief valve (R1), (T) to increase pressure, leading to pres-
tank pressure prevails. sure at port (P) to rise as well.
q Oil from the pump enters port (P) and q When pressure at port (P) exceeds the
pushes spool (6) to the right with a low pressure at port (B) (accumulator pres-
pressure equivalent to the load of spring sure), oil supply to the accumulator starts.
(5) and then flows from port (A) to the This timing is determined by the area size
EPC valve and the work equipment valve. of orifice (7) and pressure differential
At the same time, it flows to the tank before and after (equivalent to the load of
through orifices (7), (4) and (3). spring (5)). A fixed amount of oil is sup-
plied regardless of the engine speed, and
the remaining amount flows to port (A).
10-400 18 WD600-6
400 Brake system
2) When pressure reaches cut-out pressure 3. Safety relief valve (R3)

q When pressure at port (B) (accumulator q If the pressure at port (P) (pump pressure)
pressure) reaches the set pressure for rises above the set pressure for relief
relief valve (R1), poppet (1) leaves valve valve (R3), the oil from the pump resists
seat (9) to generate a flow of oil, creating spring (10) and pushes ball (11) upward to
relief operation. cause oil to flow into the tank circuit, thus
q The relief operation creates vertical pres- protecting the circuit by defining the maxi-
sure differential for piston (2). Thus, piston mum pressure for the brake circuit.
(2) moves upward to force poppet (1) to
open, shorting ports (C) and (T).
q As the rightmost spring chamber of spool
(6) leads to port (C) of relief valve (R1),
tank pressure prevails.
q Since the pressure at port (P) also drops
to the level equivalent to the load of spring
(5), oil supply to port (B) is stopped as
well.
WD600-6 10-400 19
400 Brake system
AJSS (Advanced Joystick Steering System) 2. When oil is supplied to accumulator

specification 1) Cut-in state
Operation q If the pressure at port (B) drops below the
set pressure of relief valve (R1), piston (2)
1. When oil is not supplied to accumulator
is returned downward by the tension of
(cut-out state)
spring (8). This causes valve seat (9) to
q Since the pressure at port (B) is higher
closely contact poppet (1) to disconnect
than the set pressure of relief valve (R1),
port (C) from port (T).
piston (2) is forced to move upward by the
q The right-hand side spring chamber of
hydraulic pressure of port (B). As this
spool (6) also gets shuttered off from port
move opens poppet (1), port (C) and port
(T) to increase pressure, leading to pres-
(T) are shorted.
sure at port (P) to rise as well.
q When pressure at port (P) exceeds the
pressure at port (B) (accumulator pres-
sure), oil supply to the accumulator starts.
q Oil from the pump enters port (P) and
This timing is determined by the area size
pushes spool (6) to the right with a low
of orifice (7) and pressure differential
pressure equivalent to the load of spring
before and after (equivalent to the load of
(5) and then flows from port (A) to the
spring (5)). A fixed amount of oil is sup-
EPC valve and the work equipment valve.
plied regardless of the engine speed, and
At the same time, it flows to the tank
the remaining amount flows to port (A).
through orifices (7), (4) and (3).
10-400 20 WD600-6
400 Brake system
2) When pressure reaches cut-out pressure 3. Safety relief valve (R3)

q When pressure at port (B) (accumulator q If the pressure at port (P) (pump pressure)
pressure) reaches the set pressure for rises above the set pressure for relief
relief valve (R1), poppet (1) leaves valve valve (R3), the oil from the pump resists
seat (9) to generate a flow of oil, creating spring (10) and pushes ball (11) upward to
relief operation. cause oil to flow into the tank circuit, thus
q The relief operation creates vertical pres- protecting the circuit by defining the maxi-
sure differential for piston (2). Thus, piston mum pressure for the brake circuit.
(2) moves upward to force poppet (1) to
open, shorting ports (C) and (T).
q Since the pressure at port (P) also drops
to the level equivalent to the load of spring
(5), oil supply to port (B) is stopped as
well.
WD600-6 10-400 21
400 Brake system
SEN04990-00 EPC relief valve
EPC relief valve 1
1. Main valve
2. Spring
3. Valve seat
4. Pilot poppet
5. Spring
6. Screw
Function
q The EPC relief valves are located between the
EPC brake pump and the EPC valve and
between work equipment units. When the EPC
valve is not operating, or when any abnormal
pressure has occurred in the EPC circuit, oil
from the pump is relieved from this valve in
order to protect the pump and the circuit from
damage.
a For the steering wheel specification model,
read “EPC” as “PPC”.
10-400 22 WD600-6
400 Brake system
EPC relief valve SEN04990-00
Operation
q The relief valve is installed on the charge q When pressure at port (B) drops, the orifice of
valve. Port (A) is connected to the pump cir- main valve (1) functions so as to allow pres-
cuit, and port (C), to the drain circuit. sure differential to occur at ports (A) and (B),
Oil runs through the orifice of main valve (1) causing main valve (1) to open due to pressure
and fills port (B). from port (A) and oil in port (A) is drained to
Pilot poppet (4) is seated on the valve seat (3). port (C) for relief.
q When pressure at ports (A) and (B) reaches
the set pressure, pilot poppet (4) opens and oil
pressure at port (B) is carried from port (D) to
port (C), causing pressure at port (B) to drop.
WD600-6 10-400 23
400 Brake system
SEN04990-00 Accumulator (for brake)
Accumulator (for brake) 1
1. Valve
2. Top cover
3. Cylinder
4. Piston
Function Specifications
q The accumulator is installed between the Gas used: Nitrogen gas
charge valve and brake valve. The space Amount of gas: 6,000 cc
between cylinder (3) and free piston (4) is filled Charge pressure:
with nitrogen gas. The nitrogen gas absorbs 3.43 ± 0.20 MPa {35 ± 2.0 kg/cm2} (at 50°C)
the hydraulic pulses generated by the hydrau-
lic pump and secures the braking force and
operability when the engine stops by utilizing
its compressibility.
10-400 24 WD600-6
400 Brake system
Accumulator (for brake) SEN04990-00
WD600-6 10-400 25
400 Brake system
SEN04990-00 Slack adjuster
Slack adjuster 1
1. Cylinder Function
2. Check valve q The slack adjuster is installed on the brake oil
3. Piston line leading to the brake piston from the brake
4. Spring valve, and functions to keep the time lag during
5. Bleeder brake operation at a fixed level.
A: Inlet port
B: Outlet port
10-400 26 WD600-6
400 Brake system
Slack adjuster SEN04990-00
Unit: mm
Clearance between body and size Shaft Hole clearance limit
6
piston –0.030 +0.074 0.030 –
55 0.25
–0.076 +0.074 0.150
7 Slack adjuster spring length load load
49 N
198 90 181 —
{5.0 kg}
WD600-6 10-400 27
400 Brake system
SEN04990-00 Slack adjuster
Operation
1. When the brake pedal is pressed down
q Before the brake is pressed down, piston (4) is
restored as much as the amount of stroke (S)
(a full stroke). When the brake pedal is
pressed down, oil discharged from the brake
valve branches into right and left cylinders (2)
from port (P) of the slack adjuster to move pis-
ton (4) as much as the amount of stroke (S) to
the right and the left.
2. When the brake pedal is released

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

ther, oil pressure from the brake valve exceeds
the specified to open check valve (3) and port
(C) is imposed pressure to function as braking
force.
Thus, the time lag when the brake is in opera-
tion is maintained the same.
10-400 28 WD600-6
400 Brake system
Slack adjuster SEN04990-00
WD600-6 10-400 29
400 Brake system
SEN04990-00 Parking brake
Parking brake 1
1. Output shaft Outline

2. Spring (outside) q The parking brake is a wet-type multi-disc
3. Spring (inside) brake, which is operated mechanically with the
4. Piston spring and stops output shaft (1).
5. Parking brake oil port q The tension of springs (2) and (3) presses disc
6. Plate (7) against plate (6) with piston (4) to stop out-
7. Disc put shaft (1).
8. Wave spring q When releasing, the oil pressure from parking
brake oil port (5) operates piston (4) to release
the pressing force being applied to disc (7) and
plate (6).
10-400 30 WD600-6
400 Brake system
Parking brake SEN04990-00
Unit: mm
9 Parking brake spring (outside) length load load
1,266 N 1,203 N
94 72.6 91.2
{129.2 kg {122.7 kg}
662 N 630 N
10 Parking brake spring (inside) 94 72.6 91.2
{67.6 kg} {64.2 kg}
Standard size Tolerance Repair limit Replace
Thick-
11 Plate 4.0 ±0.05 3.9
ness
Strain — 0.05 0.6
Thick-
12 Disc 3.2 ±0.08 2.97
ness
Load of wave spring 626.4 N ±176.5 N 533 N
13
(testing height: 3.2 mm) {63.9 kg} {±18 kg} {54.3 kg}
WD600-6 10-400 31
400 Brake system
SEN04990-00 Parking brake solenoid valve
Parking brake solenoid valve 1
1. Movable core
2. Coil
3. Push pin
4. Spring
5. Spool
6. Block
7. Check valve
10-400 32 WD600-6
400 Brake system
Parking brake solenoid valve SEN04990-00
Operation
When parking brake is applied (when solenoid When parking brake is released (when solenoid
is de-energized) is energized)
q If the parking brake switch is turned “ON”, the q If the parking brake switch is turned “OFF”, the
solenoid is turned “OFF”. As the result, spool solenoid is turned “ON” and spool (1) is moved
(1) is pushed back in the left direction by the rightward. Accordingly, the pressurized oil from
tension of spring (2). Accordingly, pump port the pump flows to the parking brake through
(P) is disconnected from parking brake port port (P), inside of spool (1) and port (A). At the
(A), stopping flow of the pressurized oil from same time, port (T) is closed and the oil is not
the pump to the parking brake. drained. As a result, the spring in the parking
q At the same time, the oil from the parking brake is pushed back by the oil pressure and
brake is drained through ports (A) and (T). As the parking brake is released.
a result, the disc in the parking brake is
pressed by the spring and the parking brake is
applied.
WD600-6 10-400 33
400 Brake system
SEN04990-00 Emergency parking brake release valve
Emergency parking brake release valve 1
Operation
q When parking brake emergency release switch
(1) is turned to “ON”, solenoid valve (2) starts
operating. and oil pressure from accumulator
(3) enters port (P). Then pilot pressure
switches the circuit, and the pressure moves to
the parking brake from port (A) to release the
parking brake.
1. Valve
2. Solenoid valve
A: To parking brake
B: From parking brake valve
C: From pilot circuit
T: Drain
P: From brake (accumulator circuit)
Function
q The emergency release solenoid valve is
installed between the transmission and trans-
mission control. It operates solenoid of the
parking brake release switch installed at the
operator's seat when oil pressure is not avail-
able from the transmission pump due to engine
failure, etc. in order to supply accumulator
charge pressure in the brake circuit to the
parking brake cylinder.
10-400 34 WD600-6
400 Brake system
Brake cooling pump SEN04990-00
Brake cooling pump 1
SAL(1)22+22
(If equipped)
Unit: mm
Type Tolerance Repair limit
Clearance between body
1 SAL(1)-22
and spool 0.10 – 0.15 0.19
SAL(1)-22
Clearance between inside SAL(1)-22
2 diameters of plain bearing 0.06 – 0.119 0.20 Replace
and gear shaft SAL(1)-22
3 Driven depth of pin SAL(1)-22 0
10 —
SAL(1)-22 –0.5
Rotation torque of spline
4 3.9 – 9.8 Nm {0.4 – 1.0 kgm}
shaft
Speed
Type pressure discharge discharge —
Discharge oil: EO10-CD (rpm)
— (MPa {kg/cm2}) (l/min) (l/min)
Oil temperature: 45 – 55°C
SAL(1)-22
3,500 20.6 {210} 73.1 67.5
SAL(1)-22
WD600-6 10-400 35
SEN04990-00
WD600-6 Wheel dozer

©2009 KOMATSU
All Rights Reserved
10-400 36
SEN04991-00
WHEEL DOZER
WD600-6

WD600-6 55001 and up

500 Undercarriage and frame

Axle mount ...................................................................................................................................................... 2
Center hinge pin.............................................................................................................................................. 7
WD600-6 10-500 1
SEN04991-00 Axle mount
Axle mount 1
10-500 2 WD600-6
Axle mount SEN04991-00
1. Front axle Front axle

2. Rear axle q Front axle (1) is directly fixed to front frame (4)
3. Rear frame with axle mount bolt (5) as it is directly sub-
4. Front frame jected to the working force.
5. Axle mount bolt
Rear axle
q Rear axle (2) has swaying structure at the cen-
ter of rear axle to enable each tire to make
contact with the ground during travel on a soft
ground.
WD600-6 10-500 3
10-500 4 WD600-6
Axle mount SEN04991-00
Unit: mm
Clearance between shaft and size clearance limit
Shaft Hole
1 hole on front support side
(before press fitting bushing) –0.062 +0.381 0.128 –
350 1.0
–0.151 +0.066 0.582
Clearance between shaft and
+2.5 +0.089 –0.911 –
2 hole on front support side 360 —
+1.0 –0.000 –2.5
(before press fitting bushing)
–0.056 +0.381 0.117 –
3 hole on rear support side 310 1.0
–0.137 +0.061 0.518
Replace
+2.5 +0.089 –0.911 –
4 hole on rear support side 320 —
+1.0 –0.000 –2.5
5 Thickness of thrust plate –0.25
27.6 —
–0.39
+0.3
6 Thickness of thrust washer 5 1.3
–0.1
7 Thickness of rear bushing 4.9 ±0.1 —
8 Thickness of front bushing 4.9 ±0.1 —
WD600-6 10-500 5
10-500 6 WD600-6
Center hinge pin SEN04991-00
Center hinge pin 1
1. Front axle Outline

2. Front frame q Front frame (2) and rear frame (3) are coupled
3. Rear frame with each other by the bearing with center
4. Rear axle hinge pins (5) and (6).The steering cylinders
5. Upper hinge pin connect the left and right front frame and rear
6. Lower hinge pin frame. They adjust the bending angle of the
frame, or the turning radius of the machine.
WD600-6 10-500 7
SEN04991-00 Center hinge pin
10-500 8 WD600-6
Center hinge pin SEN04991-00
Unit: mm
No. Item Criteria Remedy
Clearance between upper size Shaft Hole clearance limit
7
hinge pin and rear frame –0.25 –0.15
140 0 – 0.15 —
–0.30 –0.25
Clearance between upper –0.101 –0.00 0.051 –
8 108 1.0
hinge pin and spacer (small) –0.152 –0.05 0.152
Clearance between upper –0.051 +0.025 0.051 –
9 107.95 1.0
hinge pin and bearing –0.102 –0.000 0.127
Clearance between upper –0.101 –0.00 0.051 –
10 108 1.0
hinge pin and bushing –0.152 –0.05 0.152
Clearance between rear frame –0.250 –0.150
11 140 0.05 – 0.15 —
and bushing –0.300 –0.200
Clearance between front frame –0.000 –0.077 –0.127 –
12 160 —
and lower hinge bearing –0.025 –0.127 –0.052
Clearance between lower hinge –0.076 +0.025 0.056 – Replace
13 100 —
pin and bushing –0.127 –0.020 0.152
Clearance between lower hinge –0.076 –0.000 0.056 –
14 100 1.0
pin and bearing –0.127 –0.020 0.127
Clearance between front frame +0.025 –0.051 –0.127 –
15 212.725 —
and upper hinge bearing –0.000 –0.102 –0.051
Clearance between lower hinge +0.013 +0.076
16 147 0 – 0.088 —
rear frame and bushing –0.012 +0.013
Clearance in seal fitting part of +0.28 +0.025 –0.310 –
17 117.45 —
lower hinge +0.18 –0.030 –0.155
Clearance in seal fitting part of +0.26 +0.063 –0.260 –
18 180 —
upper hinge pin +0.16 –0.000 –0.097
19 Height of upper hinge bushing
43.9 ±0.1 —
20 Height of upper hinge bushing 89.8 ±0.1 —
Standard thickness of shim
21 between upper hinge and 2.4
retainer
22 between upper hinge and 2.2
retainer
23 between lower hinge and 1.0
retainer Adjustment
Tightening torque of upper 68.8 Nm {7 kgm} (When shim is adjusted)

24
hinge retainer mounting bolt 279±29.4 Nm {28.5 ± 3 kgm} (Final value)
Tightening torque of upper 279±29.4 Nm {28.5 ± 3 kgm} (When shim is adjusted)
25
hinge retainer mounting bolt 279±29.4 Nm {28.5 ± 3 kgm} (Final value)
Tightening torque of lower 34.3 Nm {3.5 kgm} (When shim is adjusted)
26
hinge pin mounting bolt 279±29.4 Nm {28.5 ± 3 kgm} (Final value)
WD600-6 10-500 9
SEN04991-00
WD600-6 Wheel dozer

©2009 KOMATSU
All Rights Reserved
10-500 10
SEN04992-00
WHEEL DOZER
WD600-6

WD600-6 55001 and up

601 Hydraulic system, Part 1

Hydraulic piping diagram ................................................................................................................................ 2
Work equipment control lever linkage ............................................................................................................. 4
Hydraulic tank ................................................................................................................................................. 6
Work equipment pump .................................................................................................................................... 8
WD600-6 10-601 1
SEN04992-00 Hydraulic piping diagram
Hydraulic piping diagram 1
1. Hydraulic tank 7. Steering control valve

2. Triple pump 8. Steering cylinder
(Power train + Hydraulic oil cooling + Brake and 9. Work equipment valve
EPC pump) 10. Pitch and tilt cylinder
3. Tandem pump 11. EPC valve
(Work equipment + Work equipment pump) 12. Accumulator
4. Tandem pump 13. Charge valve
(Steering + Cooling fan pump) (Built-in EPC relief valve)
5. Brake cooling pump (if equipped) 14. Oil cooler
6. Lift cylinder
10-601 2 WD600-6
Hydraulic piping diagram SEN04992-00
A: To right pitch cylinder (bottom side)

B: To right pitch cylinder (head side)
C: To left pitch cylinder (bottom side)
D: To left pitch cylinder (head side)
WD600-6 10-601 3
SEN04992-00 Work equipment control lever linkage
Work equipment control lever linkage 1
1. Work equipment control lever

2. Kickdown switch
3. Hold switch
4. Pitch control selector switch
5. Work equipment lock lever
6. R.H. console forward-reverse slide lever
7. Armrest adjustment lever
8. Armrest
9. Work equipment EPC valve
10-601 4 WD600-6
Work equipment control lever linkage SEN04992-00
WD600-6 10-601 5
SEN04992-00 Hydraulic tank
Hydraulic tank 1
1. Filter bypass valve A: Emergency steering suction port

2. Oil filter B: Emergency steering return port
3. Hydraulic tank C: Hydraulic oil cooler and steering return port
4. Oil level sight gauge D: EPC pump suction port
5. Breather E: Steering drain port
6. Oil filler point F: Pump case drain port
7. Strainer G: Main return port
H: Brake drain port
10-601 6 WD600-6
Hydraulic tank SEN04992-00
Operation of oil filter bypass valve Breather

q In the case the filters are clogged
Bypass valve (1) opens, and oil returns to the
tank bypassing the filters.
Bypass valve set pressure:
0.15 MPa {1.5 kg/cm2}
q In the case the return circuit turns negative
pressure
Whole valve (2) is held up to serve as the
check valve.
Check valve set pressure:
2.36 MPa {24 kg/cm2}
1. Body
2. Filter element
3. Poppet
4. Sleeve
Function
q Prevention of negative pressure in tank
Since the tank is pressurized and enclosed, if
the oil level in it lowers, negative pressure is
generated. At this time, poppet (3) is opened
by the differential pressure between the tank
pressure and the atmosphere pressure to pre-
vent generation of the negative pressure.
q Prevention of pressure rise in tank
If the pressure rises to above a specified level
while the circuit is in operation by an increase
or decrease of oil level and the temperature
rise, sleeve (4) is tripped to relieve pressure in
the hydraulic tank.
WD600-6 10-601 7
SEN04992-00 Work equipment pump
Work equipment pump 1
Type: HPV125+125
General view
10-601 8 WD600-6
Work equipment pump SEN04992-00
Outline
q This pump consists of 2 variable capacity
swash plate piston pumps, PC valve, LS valve,
and EPC valve.
ISIG : PC mode selector current

PAF : Front pump discharge port
PAR : Rear pump discharge port
PBF : Pump pressure input port
PBR : Pump pressure input port
PD1F : Case drain port
PD1R : Air bleeder
PD2F : Drain plug
PD2R : Drain plug
PENF : Front control pressure pick-up port
PENR : Rear control pressure pick-up port
PEPC : EPC basic pressure port
PEPB : EPC basic pressure pick-up port
PFC : Front pump discharge pressure pick-up
port
PLSF : Front load pressure input port
PLSFC : Front load pressure pick-up port
PLSR : Rear load pressure input port
PLSRC : Rear load pressure pick-up port
PM : PC mode selector pressure pick-up port
PRC : Rear pump discharge pressure pick-up
port
1. Front pump
2. Rear pump
3. LS valve
4. PC valve
5. PC-EPC valve
WD600-6 10-601 9
Sectional view
1. Front shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Rear shaft
11. Rear case
12. Servo piston
13. PC valve
10-601 10 WD600-6
Function q Piston (6) carries out relative movement in the

q The pump converts the engine rotation trans- axial direction inside each cylinder chamber of
mitted to its shaft to oil pressure and delivers cylinder block (7).
pressurized oil corresponding to the load. q Cylinder block (7) seals the pressurized oil to
q It is possible to change the discharge amount valve plate (8) and carries out relative rotation.
by changing the swash plate angle. q This surface is designed so that the oil pres-
sure balance is maintained at a suitable level.
Structure q The oil inside each cylinder chamber of cylin-
q Cylinder block (7) is supported to shaft (1) by der block (7) is suctioned and discharged
spline (14). through valve plate (8).
q Shaft (1) is supported by front and rear bear-
ings (15).
q Tip of piston (6) is shaped as a concave ball
and shoe (5) is caulked to it to form one unit.
ing.
q Rocker cam (4) has flat surface (A), and shoe
(5) is always pressed against this surface while
sliding in a circular movement.
q Rocker cam (4) conducts high pressure oil to
cylinder surface (B) with cradle (2), which is
secured to the case, and forms a static pres-
sure bearing when it slides.
WD600-6 10-601 11
Operation of pump q As center line (X) of rocker cam (4) matches

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

plate angle (a) in relation to the axial direction
of cylinder block (7), flat surface (A) acts as a
cam in relation to shoe (5).
q In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between vol-
umes (E) and (F) is created inside cylinder
block (7).
q A single piston sucks and discharges the oil by
the amount (F) – (E).
oil is discharged.
tioned.
10-601 12 WD600-6
Control of pump delivery

q If the swash plate angle (a) becomes larger,
the difference between volumes (E) and (F)
becomes larger and pump delivery (Q)
increases.
q Servo piston (12) is used for changing swash
plate angle (a).
q Servo piston (12) carries out linear reciprocal
movement according to the signal pressure
from the PC and LS valves.
q This linear movement is transmitted to rocker
cam (4) through slider (13).
q Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) slides on the surface
while continuing revolving movement.
q Space of the pressure receiving area of servo
piston (12) are not identical on the left side and
right side. Main pump discharge pressure (self
pressure) (PP) is always brought to the pres-
sure chamber of the small diameter piston
side.
q Output pressure (PEN) of the LS valve is
brought to the chamber receiving the pressure
at the large diameter piston end.
q The relationship in the size of pressure (PP) at
the small diameter piston end and pressure
(PEN) at the large diameter piston end, and
the ratio between the area receiving the pres-
sure of the small diameter piston and the large
diameter piston controls the movement of
servo piston (12).
WD600-6 10-601 13
LS valve
PA : Pump port 1. Sleeve

PDP : Drain port 2. Piston
PLP : LS control pressure output port 3. Spool
PLS : LS pressure input port 4. Spring
PP : Pump port 5. Seat
PPL : Control pressure input port 6. Sleeve
PSIG : Drain port 7. Plug
8. Locknut
Function
q The LS (load sensing) valve detects the load
and controls the discharge amount.
q This valve controls main pump delivery (Q)
according to differential pressure (dPLS) [= PP
– PLS], called the LS differential pressure (the
difference between main pump discharge pres-
sure (PP) and control valve outlet port pres-
sure (PLS)).
q Main pump discharge pressure (PP), pressure
(PLS) (called the LS pressure) coming from
the control valve output, and pressure (PSIG)
(called the LS selector pressure) from the pro-
portional solenoid valve enter this valve.
10-601 14 WD600-6
Operation
When the control valve is situated at neutral
q The LS valve is a 3-way selector valve, with q Pump pressure (PP) is present in port (J) on
pressure (PLS)(LS pressure) from the inlet port the small diameter side of the piston.
of the control valve brought to spring chamber q According to the difference in the areas on
(B), and pump discharge pressure (PP) servo piston (12), the pressure moves in to the
brought to port (H) of sleeve (8). direction of minimizing the swash plate angle.
q Magnitude of the force resulting from this LS
pressure (PLS), force of spring (4) and the
pump delivery pressure (self pressure) (PP)
determine the position of spool (6).
q Before starting engine, servo piston (12) is
pressed to the left. (See the figure to the right)
q If the control lever is at the neutral position
when the engine is started, LS pressure (PLS)
will be set to 0 MPa {0 kg/cm2}. (It is intercon-
nected to the drain circuit through the control
valve spool)
q Spool (6) is pushed to the right, and port (C)
and port (D) will be connected.
q Shuttle valve output pressure (PPH) enters the
large diameter side of the piston from port (K).
WD600-6 10-601 15
Action for the direction of maximizing the pump delivery
q When the difference between the pump dis-

charge pressure (PP) and LS pressure (PLS),
in other words, LS differential pressure (dPLS)
becomes smaller (for example, when the area
of opening of the control valve becomes larger
and pump pressure (PP) drops), spool (6) is
pushed to the left by the combined force of LS
pressure (PLS) and the force of spring (4).
q When spool (6) moves, port (D) and port (E)
are interconnected and connected to the PC
valve.
q The PC valve is connected to the drain port, so
the pressure across circuits (D) and (K)
becomes drain pressure (PT). (The operation
of the PC valve is explained later.)
q The pressure at the large diameter end of
servo piston (12) becomes drain pressure
(PT), and pump pressure (PP) enters port (J)
at the small diameter end, so servo piston (12)
is pushed to the left side. Therefore, the swash
plate is moved in the direction to make the
delivery larger.
10-601 16 WD600-6
Action for the direction of minimizing the pump delivery
q If LS differential pressure (dPLS) becomes

larger (for example, when the area of control
valve opening becomes smaller and the pump
pressure (PP) increases), spool (6) is pressed
to the right by the force of pump pressure (PP).
q As a result of the movement of spool (6), shut-
tle valve output pressure (PPH) flows from port
(C) to port (D), then from port (K) to the large
diameter side of the piston.
port (J) of the smaller diameter side of the pis-
ton, servo piston (12) is pressed to the right by
its area difference between the larger and the
smaller diameter sides. As the result, servo
piston (12) moves in the direction to minimize
the swash plate angle.
WD600-6 10-601 17
When servo piston is balanced
q Let us take the area receiving the pressure at q The force of spring (4) is adjusted to determine
the large diameter end of the piston as (A1), the balanced stop position of this spool (6) at
the area receiving the pressure at the small the center of the standard when (PP) – (PLS) =
diameter end as (A0), and the pressure flowing 1.4 MPa {14 kg/cm2}.
into the large diameter end of the piston as
(PEN).
q If the main pump pressure (PP) of the LS valve
and the combined force of spring (4) and LS
pressure (PLS) are balanced, and the relation-
ship is (A0) x (PP) = (A1) x (PEN), servo piston
(12) will stop in that position.
q And the swash plate of the pump will be held in
an intermediate position. [Spool (6) will be
stopped at a position where the distance of the
opening from port (D) to port (E) and the dis-
tance from port (C) to port (D) is almost the
same.]
q At this point, the relationship between the pres-
sure receiving areas across servo piston (12)
is (A0) : (A1) = 3 : 5, so the pressure applied
across the piston when it is balanced becomes
(PP) : (PEN) C 5 : 3.
10-601 18 WD600-6
PC valve
PA : Pump port 1. Plug

PA2 : Pump pressure pilot port 2. Servo piston assembly
PDP : Drain port 3. Pin
PM : Mode selector pressure pilot port 4. Spool
PPL : Control pressure output port (to LS valve) 5. Retainer
6. Seat
7. Cover
8. Wiring
Function
q PC valve controls the flow to a certain rate cor-
responding to the discharge pressure irrespec-
tive of how much the control valve stroke is
increased, when pump discharge pressure
(PP1) (self pressure) and (PP2) (other pump
pressure) are high.
q If the pump discharge pressure increases due
to increased load during operation, this valve
decreases the pump delivery.
q And if the pump discharge pressure goes low,
it increases the pump delivery.
q In this case, relation between the mean dis-
charge pressure of the front and rear pumps
[(PP1) + (PP2)]/2 and pump delivery (Q) will
become as shown below if the relation is repre-
sented as the parameter of the current value
(X) to be given to PC-EPC valve solenoid.
q The controller continues counting the actual
engine speed.
q During low speed, command current flows
from the controller to PC-EPC valve solenoid
according to the engine speed to reduce the
pump delivery.
WD600-6 10-601 19
Operation
When the actuator load is small and pump pressure (PP1) and (PP2) are low
Action of PC-EPC valve solenoid (1) a Other pump pressure denotes the pressure of
q Command current (X) is being sent to PC-EPC the pump situated on the opposite side.
valve solenoid (1) from the pump controller. For the front pump pressure, the other pump
q This command current acts on PC-EPC valve pressure is that of the rear pump.
to output the signal pressure in order to modify And for the rear pump pressure, the other
the force pushing piston (2). pump pressure is that of the front pump.
q Spool (3) stops at a position where the com-
bined force pressing spool (3) becomes bal-
anced between a set force of spring (4) and
pump pressure (PP1) (self pressure) and
(PP2) (other pump pressure).
q The pressure [port (C) pressure] output from
PC valve is changed depending on the above
position.
q The size of command current (X) is determined
by the nature of the operation (lever opera-
tion), the selected working mode, and the set
value and actual value of the engine speed.
10-601 20 WD600-6
Action of spring q If port (E) and port (G) of the LS valve are con-
q The load of spring (4) at the PC valve is deter- nected, the pressure entering the large diame-
mined by the position of the swash plate. ter end of the piston from port (J) becomes
q Spring load changes as servo piston (9) makes drain pressure (PT), and servo piston (9)
spring (4) elongate or contract. moves to the left side.
q If the command current (X) to PC-EPC valve q The pump delivery will be set to the increasing
solenoid (1) changes, so does the force push- trend.
ing piston (2). q Spring (4) extends as servo piston (9) moves
q The load of spring (4) also changes according and weakens the spring force.
to the PC-EPC valve solenoid command cur- q As the spring force is weakened, spool (3)
rent (X). moves to the right, the connecting between
q Port (C) of the PC valve is connected to port port (C) and port (D) is shut off and the pump
(E) of the LS valve. discharge pressure ports (B) and (C) are con-
q Self pressure (PP1) enters port (B) and the nected.
small diameter end of servo piston (9), and q The pressure on port (C) rises and the pres-
other pump pressure (PP2) enters port (A). sure on the large diameter end of the piston
q When pump pressures (PP1) and (PP2) are also rises. Thus, the leftward move of servo
small, spool (3) will be positioned in the left piston (9) is stopped.
side. q Stop position of servo piston (9) (= pump
q Ports (C) and (D) are connected, and the pres- delivery) is determined by a position where
sure entering the LS valve becomes drain press force generated by pressure (PP1) and
pressure (PT). (PP2) on spool (3) and other press force by
PC-EPC valve solenoid are balanced with the
force of spring (4).
WD600-6 10-601 21
When the actuator load is large, and the pump discharge pressure is high
Outline Operation
q When the load is large and pump discharge q When port (E) and port (G) of the LS valve are
pressures (PP1) and (PP2) are high, the force connected, this pressure from port (J) enters
pushing spool (3) to the right becomes larger the large diameter end of servo piston (9),
and spool (3) will be moved to the position stopping servo piston (9).
shown in above figure. q If main pump pressure (PP2) increases further
q Part of the pressure to be conducted from port and spool (3) moves further to the right, main
(C) to LS valve flows from port (B) to port (C) pump pressure (PP1) flows to port (C) and acts
and (D) through LS valve. At the end this flow, to make the pump delivery the minimum.
level of this pressure becomes approximately q When servo piston (9) moves to the right,
half of main pump pressure (PP2). springs (4) and (6) are compressed and push
back spool (3).
q When spool (3) moves to the left, the openings
of port (C) and port (D) become larger.
q The pressure on port (C) (= J) is decreased
and the rightward move of servo piston (9) is
stopped.
q The position in which servo piston (9) stops at
this time is further to the right than the position
when pump pressures (PP1) and (PP2) are
low.
10-601 22 WD600-6
q The relationship between the average pump

pressure (PP1 + PP2)/2 and average pump
delivery (Q) becomes as shown below.
q If command voltage (X) sent to PC-EPC valve

solenoid (1) increases further, the relationship
between average pump pressure (PP1 + PP2)/
2, and pump delivery (Q) is proportional to the
force of the PC-EPC valve solenoid and moves
in parallel.
q Namely, the force of PC-EPC valve solenoid
(1) is added to the pushing force to the right
because of the pump pressure applied to spool
(3), so the relationship between the average
pump pressure (PP1 + PP2)/2 and pump deliv-
ery (Q) moves from (A) to (B) as command
current (X) is increased.
WD600-6 10-601 23
PC-EPC valve
C : To PC valve
P : From pilot pump
T : To tank
1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger
10-601 24 WD600-6
Function Operation
q The EPC valve consists of the proportional
solenoid portion and the hydraulic valve por- When signal current is 0 (coil is de-energized)
tion. q When there is no signal current flowing from
q On receiving signal current (i) from the control- the controller to coil (2), coil (2) is de-energized.
ler, the EPC valve generates EPC output pres- q Spool (5) is pushed to the left by spring (4).
sure in proportion to the signal current and q Port (P) is closed and the oil from the pilot
outputs it to the PC valve. pump does not flow to the PC valve.
q The oil from the PC valve is drained through
ports (C) and (T) to the tank.
WD600-6 10-601 25
When signal current is very small When signal current is maximum

(coil is energized) (coil is energized)
q When a very small signal current flows to coil q As the signal current flows to coil (2), coil (2) is
(2), coil (2) is energized, and a propulsion force energized.
is generated on the right side of plunger (7). q When this happens, the signal current is at its
q Rod (6) pushes spool (5) to the right, and pres- maximum, so the propulsion force of plunger
surized oil flows from port (P) to port (C). (7) is also at its maximum.
q Pressures on port (C) increases and the force q Spool (5) is pushed toward the right side by rod
to act on spool (5) surface and the spring load (6).
on spring (4) become larger than the propul- q Hydraulic oil from port (P) flows to port (C) with
sion force of plunger (7). maximum flow rate. As the result, the circuit
q Spool (5) is pushed to the left, and port (P) is pressure between the EPC and PC valves
shut off from port (C). becomes maximum.
q Port (C) and port (T) are connected. q Since port (T) is closed, pressurized oil does
q Spool (5) moves up and down so that the pro- not flow to the tank.
pulsion force of plunger (7) may be in balance
with pressure of port (C) + spring load of spring
(4).
q Circuit pressure between the EPC valve and
PC valve is controlled in proportion to the size
of the signal current.
10-601 26 WD600-6
WD600-6 10-601 27
SEN04992-00
WD600-6 Wheel dozer

©2009 KOMATSU
All Rights Reserved
10-601 28
SEN04993-00
WHEEL DOZER
WD600-6

WD600-6 55001 and up


Control valve ................................................................................................................................................... 2
CLSS............................................................................................................................................................. 16
Functions and operation by valve ................................................................................................................. 20
Accumulator (for PPC circuit)........................................................................................................................ 30
Triple pump ................................................................................................................................................... 31
WD600-6 10-602 1
SEN04993-00 Control valve
Control valve 1
Outline
As for outside views and sectional views, only the 4-spool valve is shown.
A1 : To R.H. pitch cylinder head

A2 : To lift cylinder head
A3 : To L.H. pitch, tilt cylinder bottom
B1 : To R.H. pitch cylinder bottom
B2 : To lift cylinder bottom
B3 : To L.H. pitch, tilt cylinder head
CP : Pressure sensor installation port
P1 : From front work equipment pump
P2 : From rear work equipment pump
PA1 : From REAR R.H. pitch controller
PA2 : From lift RAISE controller
PA3 : From FORWARD L.H. pitch, RIGHT tilt controller
PB1 : From FORWARD R.H. pitch controller
PB2 : From lift LOWER controller
PB3 : From REAR L.H. pitch, LEFT tilt controller
PLS : To work equipment pump LS port
PP : From pilot pump
PPS : To work equipment pump
T : To tank
TS : To tank
1. R.H. pitch valve

2. Lift valve
3. Dummy valve
4. L.H. pitch, tilt valve
5. Cover 1
6. Cover 2
7. Lift suction valve
10-602 2 WD600-6
Control valve SEN04993-00
General view
WD600-6 10-602 3
Sectional view
(1/6)
10-602 4 WD600-6
1. Pressure compensation valve (R.H. pitch cylinder head)

2. Pressure compensation valve (Lift cylinder head)
3. Pressure compensation valve (L.H. pitch, tilt cylinder bottom)
4. Pressure compensation valve (L.H. pitch, tilt cylinder head)
5. Pressure compensation valve (Lift cylinder bottom)
6. Pressure compensation valve (R.H. pitch cylinder bottom)
WD600-6 10-602 5
(2/6)
10-602 6 WD600-6
1. Spool (Tilt and L.H. pitch)

2. Spool (Dummy)
3. Spool (Lift)
4. Spool (R.H. pitch)
Unit: mm
Free length
5 Spool return spring length load load
diameter
393 N 315 N
54.5 x 34.8 51.2 — If damaged or
{40.1 kg} {32.1 kg}
deformed,
417 N 333 N replace spring
6 Spool return spring 54.2 x 34.8 51.2 —
{42.5 kg} {34.0 kg}
66.89 x 263 N 210 N
7 Spool return spring 63.5 —
36.1 {26.8 kg} {21.4 kg}
53.16 x 274 N 219 N
8 Spool return spring 33 —
22.3 {27.9 kg} {22.3 kg}
WD600-6 10-602 7
(3/6)
10-602 8 WD600-6
1. Safety-suction valve (REAR L.H. pitch and LEFT tilt cylinder bottom)
2. Safety-suction valve (FORWARD L.H. pitch and RIGHT tilt cylinder head)
3. Suction valve (Lift cylinder bottom)
4. Safety-suction valve (REAR R.H. pitch cylinder bottom)
5. Safety-suction valve (FORWARD R.H. pitch cylinder head)
Unit: mm
Free length
Installed Installed Installed If damaged or
6 Suction valve spring length load load deformed,
diameter
replace spring
5.49 N 4.41 N
46.8 x 7.5 40.6 —
{0.56 kg} {0.45 kg}
WD600-6 10-602 9
(4/6)
1. Unload valve R.H. pitch valve

2. EPC valve (FORWARD R.H. pitch)
3. Pressure compensation valve
(REAR R.H. pitch)
(FORWARD R.H. pitch)
5. EPC valve (REAR R.H. pitch)
6. Suction safety valve (FORWARD R.H. pitch)
7. Spool
8. Suction safety valve (REAR R.H. pitch)
10-602 10 WD600-6
WD600-6 10-602 11
(5/6)
10-602 12 WD600-6
Lift arm valve

1. EPC valve (LOWER and FLOAT)
2. Pressure compensation valve (RAISE)
3. LS shuttle valve
4. Pressure compensation valve (LOWER)
5. EPC valve (RAISE)
6. Suction valve (LOWER and FLOAT)
7. Suction valve (LOWER and FLOAT)
8. Spool
ECSS valve
9. Spool (Dummy)
Unit: mm
Free length
Installed Installed Installed If damaged or
10 Check valve spring length load load deformed,
diameter
replace spring
3.04 N 2.45 N
62.5 x 20 39 —
{0.31 kg} {0.25 kg}
WD600-6 10-602 13
(6/6)
10-602 14 WD600-6
L.H. pitch, tilt valve

1. EPC valve (REAR L.H. pitch, LEFT tilt)
2. Pressure compensation valve (FORWARD L.H. pitch, RIGHT tilt)
3. LS shuttle valve
4. Pressure compensation valve (REAR L.H. pitch, LEFT tilt)
5. EPC valve (FORWARD L.H. pitch, RIGHT tilt)
6. Suction safety valve (REAR L.H. pitch, LEFT tilt)
7. Spool
8. Suction safety valve (FORWARD L.H. pitch, RIGHT tilt)
9. Unload valve
10. Main relief valve
11. LS bypass plug
WD600-6 10-602 15
SEN04993-00 CLSS
CLSS 1
Outline of CLSS 1
Features Structure
CLSS stands for Closed center Load Sensing Sys- q CLSS is configured with a variable capacity
tem, and has the following features: piston pump, control valves, and respective
actuators.
q Fine control not influenced by load q The hydraulic pump is configured with pump
q Controllability enabling digging even with fine body, PC valve and LS valve.
control
q Ease of compound operation ensured by flow
divider function using area of opening of spool
during compound operations
q Energy saving using variable pump control
10-602 16 WD600-6
CLSS SEN04993-00
Basic principle q The pump swash plate angle shifts toward the
maximum position if LS differential pressure
Pump swash plate angle control (dPLS) is lower than the set pressure of the LS
q The pump swash plate angle (pump delivery) valve (when the actuator load pressure is
is so controlled that the LS differential pressure high).
(dPLS), which is the differential pressure q If it becomes higher than the set pressure
between the pump discharge pressure (PPS) (when the actuator load pressure is low), the
and LS pressure (PLS) (the actuator load pres- pump swash plate angle shifts toward the mini-
sure) at the control valve outlet, will be con- mum position.
stant.
q [LS differential pressure (dPLS) = Pump dis- LS differential pressure (dPLS) and pump
charge pressure (PPS) – LS pressure (PLS)] swash plate angle
a For details of functions, see the “Hydraulic

pump” paragraph.
WD600-6 10-602 17
SEN04993-00 CLSS
Pressure compensation control
q A pressure compensation valve is installed to

the outlet port side of the control valve to bal-
ance the load.
q When actuators are operated together, the
pressure difference (dP) between the
upstream (inlet port) and downstream (outlet
port) of the spool of each valve becomes the
same regardless the size of the load (pres-
sure).
q The flow of oil from the pump is divided (com-
pensated) in proportion to the area of opening
(S1) and (S2) of each valve.
10-602 18 WD600-6
CLSS SEN04993-00
WD600-6 10-602 19
SEN04993-00 Functions and operation by valve
Functions and operation by valve 1
Hydraulic circuit diagram and the name of valves
10-602 20 WD600-6
Functions and operation by valve SEN04993-00
1. R.H. pitch valve

2. Lift valve
3. Dummy valve
4. L.H. pitch, tilt valve
5. R.H. pitch spool
6. Lift spool
7. Dummy spool
8. L.H. pitch, tilt spool
10. Suction valve
11. EPC valve
12. Main relief valve
Set pressure: 24.5 ± 0.5 MPa {250 ± 5 kg/cm2}
13. Unload valve
Cracking pressure: 1.96 ± 0.2 MPa {20 ± 2 kg/cm2}
14. Suction safety valve
Set pressure: 26.5 ± 0.5 MPa {270 ± 5 kg/cm2}
WD600-6 10-602 21
Unload valve
When the unload valve is actuating
1. LS circuit 4. Tank circuit

2. Valve 5. Spring
3. Pump circuit
Function Operation
q The unload valve drains an oil discharge for q Pressure of pump circuit (3) is received by the
the portion of the minimum pump swash plate end of valve (2).
angle while all control valves are in the holding. q Since the control valve is in neutral position,
q The pump pressure will correspond to a set pressure of LS circuit (1) is 0 MPa{0 kg/cm2}.
load of spring (5) inside the valve (this pres- q Pressurized oil of pump circuit (3) stops at
sure will be P1). valve (2), and the pressure rises as no relief is
q Since LS pressure is drained from the LS available.
bypass valve, LS pressure C tank pressure C 0 q When this pressure becomes larger than the
MPa{0 kg/cm2}. force of spring (5), valve (2) moves to the left.
q Ports (b) and (c) are interconnected and the
pump pressure flows to tank circuit (4).
q The pressurized oil of LS circuit (1) passes
from orifice (a) through port (c) and is drained
to the tank circuit (4).
q When actuated, LS pressure C tank pressure.
q Since the pump discharge pressure – LS cir-
cuit pressure during unloading is larger than
the pump LS control pressure, the signal is
output to minimize the pump swash plate
angle.
10-602 22 WD600-6
q During operation (a work within a scope of dis- Operation of relief valve

charge by a minimum swash plate angle), the q When the cylinder reaches the stroke end, the
discharge pressure for the portion of minimum main relief valve opens.
pump swash plate angle is set to LS pressure q The pump delivery (Q) is relieved to the tank.
+ P1 pressure. q The pump discharge pressure (PP) and LS
q LS control differential pressure (dPLS) of dis- pressure (PLS) become approximately the
charge for the portion of minimum swash plate same as each has not flow at the upstream
angle will be equal to P1 pressure. and downstream of the spool, and LS differen-
tial pressure (dPLS) becomes 0 MPa {0 kg/
cm2}.
q As LS differential pressure (dPLS) is lower
than the LS set pressure of LS valve, LS valve
is actuated to maximize the pump swash plate
angle.
q Mechanically, operation of PC valve have the
prevalence to that of LS valve.
q The pump is held at a minimum swash plate
angle by the cut-off function of PC valve.
WD600-6 10-602 23
Pressure compensation valve 1
During independent operation and under maximum load pressure

(If the load pressure is higher than other work equipment during a combined operation)
1. Hydraulic pump 4. Piston

2. Valve 5. Spring
3. Shuttle valve 6. LS shuttle valve
Function
q Pressure compensation valve works as the
load check valve.
q If the pump pressure (LS pressure) is lower
than the load at port (c), shuttle valve (3) in
pressure compensation valve piston (4) inter-
connects spring chamber (E) and port (C).
q The force of spring (5) operates piston (4) and
valve (2) to the closing direction.
10-602 24 WD600-6
When compensated
(If the load pressure is lower than other work equipment during a combined operation)
Function
q The pressure compensation valve closes
under LS pressure of port (D), and the spool
meter-in downstream pressure of port (B)
becomes equivalent to the maximum pressure
of other work equipment.
q Since the spool meter-in upstream pressure of
port (A) is the pump pressure, the spool meter-
in differential pressure [upstream pressure port
(A) pressure] – downstream pressure [port (B)
pressure] becomes equivalent to all the spools
in operation.
q Pump flow is divided according to the ratio of
the meter-in opening area.
Operation
q Spring chamber (E) is interconnected to port
(D).
q Piston (4) and valve (2) operate in the closing
direction (to the right) under the LS circuit pres-
sure from other work equipment of port (F).
q Valve upstream pressure (= spool meter-in
downstream pressure) of port (B) is controlled
with LS pressure.
WD600-6 10-602 25
Shuttle valve in the pressure compensation valve
If holding pressure of port (B) > LS pressure in spring chamber (C)
1. Hydraulic pump
2. Valve
3. Shuttle valve
4. Piston
Function
q Shuttle valve (3) is pressed to the right by port
(B) pressure and ports (B) and (D) are cut off.
q Holding pressure of port (B) is led to spring
chamber (C) and piston (4) is pressed to the
left to prevent it from being separated from
valve (2).
10-602 26 WD600-6
Area ratio of pressure compensation valve
Function
q The state of division changes according to the
area ratio of pressure compensation portions
(A1) and (A2). Area ratio = (A2)/(A1)
q Since the area ratio is less than 1, spool meter-
in downstream pressure < maximum load
pressure, and the oil flow is divided greater
than by the area ratio of the opening.
WD600-6 10-602 27
Supply of LS pressure
(LS shuttle valve)
1. Hydraulic pump 5. Check valve

2. Main spool 6. LS circuit
3. Pressure compensation valve 7. LS shuttle valve
4. Valve
Function Operation
q The LS pressure (PLS) means the actuator q If main spool (2) is operated, pump discharge
load pressure on the outlet side of the control pressure (PPS) flows to actuator circuit (B).
valve. q Pump discharge pressure (PPS) is led through
q Pressure compensation valve (3) upstream orifice (a) of main spool (2) to LS circuit (PLS).
pressure (spool meter-in downstream pres- q When actuator circuit (B) rises to necessary
sure) is led through main spool (2) to LS shut- pressure level, pump discharge pressure
tle valve (7). (PPS) rises.
q Connected to actuator port (B) through valve q Check valve (5) in main spool (2) opens and
(4), and makes LS pressure C actuator load the high pressure in LS circuit (PLS) flows out
pressure. to actuator circuit (B).
q Inlet pore (a) inside main spool (2) has a small q Pressure in LS circuit (PLS) becomes approxi-
diameter concurrently serving as a throttle. mately equal to that of actuator circuit pressure
(B).
10-602 28 WD600-6
LS bypass valve 1
1. Hydraulic pump
2. Main spool
4. LS shuttle valve
5. LS bypass valve
6. LS circuit
Function
q The LS bypass valve releases the residual
pressure in LS pressure circuit (6) from orifices
(a) and (b).
q The LS bypass valve slows down the rising
rate of LS pressure to prevent a sudden
change of hydraulic pressure.
q Bypass flow from LS bypass valve (5) causes
a pressure loss to be generated due to the cir-
cuit resistance between throttle (c) of main
spool (2) and LS shuttle valve (4).
q Effective LS differential pressure drops to
improve a dynamic stability of the actuator.
WD600-6 10-602 29
SEN04993-00 Accumulator (for PPC circuit)
Accumulator (for PPC circuit) 1
Operation
q After engine is stopped, chamber (A) in the
bladder is compressed by oil pressure in
chamber (B).
q When work equipment EPC solenoid is tripped
by operating the work equipment EPC lever,
pressure inside nitrogen gas chamber (A)
expands the bladder, and the oil in chamber
(B) operates the work equipment valve as the
pilot pressure.
1. Gas plug
2. Poppet
3. Holder
4. Bladder
5. Film
6. Shell
7. Oil port
Specifications
Type of gas : Nitrogen gas
Amount of gas : 500 cc
Max. operating pressure : 3.92 MPa {40 kg/cm2}
Min. operating pressure : 0 MPa {0 kg/cm2}
Function
q Accumulator is installed between the charge
valve and work equipment valve. In the case
the engine is stopped with the lift arm lifted up,
compressed nitrogen gas pressure in the accu-
mulator feeds the pilot oil pressure to the work
equipment valve for operation. Thus the lift
arm and bucket are enabled to descend under
own weight.
10-602 30 WD600-6
Triple pump SEN04993-00
Triple pump 1
Power train, Hydraulic oil cooling, brake and EPC pump

SAL(4)160+(3)100+(2)32
Unit: mm
Type Tolerance Repair limit
Clearance between body SAL(4)-160 0.11 – 0.16 0.20
1
and spool SAL(3)-100
0.10 – 0.15 0.19
SAL(2)-32
SAL(4)-160 0.069 – 0.14
Clearance between inside
2 diameters of plain bearing SAL(3)-100 0.078 – 0.149 0.20 Replace
and gear shaft
SAL(2)-32 0.073 – 0.125
SAL(4)-160 21
3 Driven depth of pin 0
SAL(3)-100 14 —
–0.5
SAL(2)-32 12
Rotation torque of spline
4 19.6 – 33.3 Nm {2.0 – 3.4 kgm}
shaft
Speed
Type pressure discharge discharge
(rpm) —
(MPa {kg/cm2}) (l/min) (l/min)
Discharge oil: EO10-CD
—
Oil temperature: 45 – 55°C SAL(4)-160 20.6 {210} 328.3 303.3
SAL(3)-100 2,200 30 {2.9} 210 183.5
SAL(2)-32 20.6 {210} 62.7 56.0
WD600-6 10-602 31
SEN04993-00
WD600-6 Wheel dozer

©2009 KOMATSU
All Rights Reserved
10-602 32
SEN04994-00
WHEEL DOZER
WD600-6

WD600-6 55001 and up

700 Work equipment

Work equipment linkage ................................................................................................................................. 2
Cutting edge and end bit................................................................................................................................. 5
Work equipment lubrication ............................................................................................................................ 7
Hydraulic cylinder.......................................................................................................................................... 10
WD600-6 10-700 1
700 Work equipment
SEN04994-00 Work equipment linkage
Work equipment linkage 1
10-700 2 WD600-6
700 Work equipment
Work equipment linkage SEN04994-00
Unit: mm
Clearance between bearing size clearance limit
Shaft Hole
1 and pin at joint of lift cylinder
rod and blade –0.030 +0.046
70 0.03 – 0.12 1
–0.076 –0.000
Clearance between bearing
–0.025 +0.039 0.025 –
2 and pin at joint of support and 50 1
–0.069 –0.000 0.108
blade
Clearance between bushing
–0.5... +0.300
3 and pin at joint of frame and 70 0.5 – 0.9 2
–0.6... –0.000
blade
–0.3... +0.200
4 and pin at joint of tilt, pitch 75 0.3 – 0.6 2
–0.4... –0.000
cylinder and blade
–0.030 +0.285 0.214 –
–0.076 +0.184 0.361
front frame
–0.3... +0.174 0.13 –
6 and pin at joint of tilt, pitch 70 2
–0.5... +0.100 0.674
cylinder and frame
Spherical clearance between –0.5... +0.500
7 195 0.5 – 1.5 —
trunnion cap and trunnion –1.0... –0.000
–0.030 +0.046 0.030 –
8 and pin at joint of lift cylinder 70 1
–0.076 –0.000 0.122
bottom and frame
Clearance between bearing Replace
+0.070 +0.240
9 and bushing at joint of lift 135 0.12 – 0.25 —
–0.010 +0.190
cylinder and blade
+0.070 +0.240
10 and bushing at joint of support 135 0.12 – 0.25 —
–0.010 +0.190
and blade
+0.450
11 and bushing at joint of frame 140 ±0.050 0.30 – 0.50 1
+0.350
and blade
–0.025 +0.039 0.025 –
–0.069 –0.000 0.108
blade
Clearance between pin and
–0.030 +0.100 0.03 –
13 boss at joint of cylinder rod and 70 1
–0.076 –0.000 0.176
blade
–0.025 +0.100 0.025 –
14 boss at joint of support and 50 1
–0.069 –0.000 0.169
blade
Clearance between pin and –0.5... +0.300
15 70 0.5 – 0.9 2
boss at joint frame and blade –0.6... –0.000
–0.3... +0.100
16 boss at joint of tilt, pitch cylinder 75 0.3 – 0.5 2
–0.4... –0.000
and blade
–0.030 +0.100 0.03 –
17 boss at joint of support and 75 1
–0.076 –0.000 0.176
front frame
WD600-6 10-700 3
700 Work equipment
SEN04994-00 Work equipment linkage
Unit: mm
Clearance between pin and size clearance limit
Shaft Hole
18 boss at joint of tilt, pitch cylinder
and frame –0.3... +0.100
70 0.3 – 0.6 2
–0.5... –0.000
Clearance between pin and Replace
–0.030 +0.300 0.230 –
19 boss at joint of lift cylinder 70 1
–0.076 +0.200 0.376
bottom and frame
–0.036 +0.054 0.036 –
20 and boss at joint of support and 82 1
–0.090 –0.000 0.144
blade
Width between Standard clearance
Width of hinge
Joint of lift cylinder rod and bosses (Clearance a + b)
21
frame +0.5 0
110 +0.2 110 –0.2
0.2 – 0.7
+0.8 –0.2
22 Joint of frame and blade 140 +0.3 140 –0.7
0.5 – 1.5
Joint of tilt, pitch cylinder and —

–0.1
23 106 ± 2 100 –0.3
4.1 – 8.3
blade
Joint of tilt, pitch cylinder and 0
24 74 ± 1.5 70 2.5 – 6
frame –0.5
Joint of lift cylinder bottom and +2.0 0

25 110 110 0.5 – 2.2
frame +0.5 –0.2
Adjust with shims

so that clearance
26 Joint of H-link and boss 89 ± 1 86 ± 0.8 1.2 – 4.8 is less than 1.5
mm on both left
and right.
10-700 4 WD600-6
700 Work equipment
Cutting edge and end bit SEN04994-00
Cutting edge and end bit 1
(For angle end bit)
Unit: mm
1 Cutting edge height
254 ± 2.0 215
2 End bit (outside) height 315 235
3 End bit (inside) height 254 215 Replace
4 End bit width 492 392
Tightening torque for mounting
5 862 – 941 Nm {88 – 96 kgm}
bolts
WD600-6 10-700 5
700 Work equipment
SEN04994-00 Cutting edge and end bit
(For straight end bit)
Unit: mm
1 Cutting edge height
254 ± 2.0 215
3 End bit (inside) height 254 215
Replace
4 End bit width 493 392
Tightening torque for mounting
5 902 ± 39.2 Nm {92 ± 4 kgm}
bolts
10-700 6 WD600-6
700 Work equipment
Work equipment lubrication SEN04994-00
Work equipment lubrication 1
1. Lift cylinder A: Center hinge, upper side

2. Front frame B: Lift cylinder, bottom pin side
3. Center support C: Steering cylinder head, left side
4. Steering cylinder D: Steering cylinder head, right side
5. Rear frame E: Center support
WD600-6 10-700 7
700 Work equipment
SEN04994-00 Work equipment lubrication
F: Rear axle, rear side

G: Rear axle, top side
H: Rear axle, front side
10-700 8 WD600-6
700 Work equipment
Work equipment lubrication SEN04994-00
WD600-6 10-700 9
700 Work equipment
SEN04994-00 Hydraulic cylinder
Hydraulic cylinder 1
Steering cylinder
Lift cylinder
10-700 10 WD600-6
700 Work equipment
Hydraulic cylinder SEN04994-00
Tilt, pitch cylinder
Unit: mm
Cylinder Standard Tolerance Standard Clearance

name size Shaft Hole clearance limit
Clearance –0.036 +0.257 0.084 –

Steering 90 0.647
between piston –0.090 +0.048 0.347 Replace
1
rod and bush- bushing
–0.036 +0.257 0.084 –
ing Lift 90 0.647
–0.090 +0.048 0.347
–0.036 +0.257 0.084 –
Tilt, pitch 90 0.647
–0.090 +0.048 0.347
–0.036 +0.188 0.036 –
Steering 85 0.7
Clearance –0.090 80888 0.190
between piston
–0.030 +0.468 0.030 –
2 rod supporting Lift 70 1.0
–0.076 80888 0.122
shaft and bush-
ing –0.388 +0.288
Tilt, pitch 75 0.3 – 0.6 2.0
–0.488 80888 Replace pin
–0.036 +0.207 0.156 – and bushing
Steering 85 0.7
Clearance –0.090 +0.120 0.297
between cylin-
–0.030 +0.046 0.030 –
3 der bottom sup- Lift 70 1.0
–0.076 80888 0.122
porting shaft
and bushing –0.388 +0.174 0.40 –
Tilt, pitch 70 2.0
–0.588 +0.100 0.674
WD600-6 10-700 11
SEN04994-00
WD600-6 Wheel dozer

©2009 KOMATSU
All Rights Reserved
10-700 12
SEN04995-00
WHEEL DOZER
WD600-6

WD600-6 55001 and up

800 Cab and its attachments

ROPS cab ....................................................................................................................................................... 2
Air conditioner ................................................................................................................................................. 4
WD600-6 10-800 1
SEN04995-00 ROPS cab
ROPS cab 1
1. Front glass 3. Door

2. Front wiper 4. Rear wiper
10-800 2 WD600-6
ROPS cab SEN04995-00
WD600-6 10-800 3
SEN04995-00 Air conditioner
Air conditioner 1
Air conditioner piping
1. Air outlet duct

2. Defroster window
3. Air outlet duct
4. Air conditioner unit
5. Dry receiver
6. Compressor
7. Air conditioner condenser
8. Hot water take-out port
9. Hot water return port
10-800 4 WD600-6
Air conditioner SEN04995-00
Air conditioner condenser
A: Refrigerant gas inlet port

B: Refrigerant gas outlet port
WD600-6 10-800 5
SEN04995-00 Air conditioner
Air conditioner compressor
1. Refrigerant gas outlet port

2. Refrigerant gas inlet port
3. Clutch
Specifications
Type : Piston pump type
Specified refrigerant : R134a
10-800 6 WD600-6
Air conditioner SEN04995-00
Air conditioner dry receiver
1. Body
2. Dryer
WD600-6 10-800 7
SEN04995-00
WD600-6 Wheel dozer

©2009 KOMATSU
All Rights Reserved
10-800 8
SEN04996-02
WHEEL DOZER
WD600-6

WD600-6 55001 and up

901 Electrical system, Part 1

Machine monitor system ................................................................................................................................. 2
Machine monitor ............................................................................................................................................. 8
WD600-6 10-901 1
SEN04996-02 Machine monitor system
Machine monitor system 1
Outline
q In the machine monitor system, each monitor 4. In addition to the above, the following can be
on the network monitors and controls the vehi- displayed, set, and adjusted by using the char-
cle condition with the sensors installed to vari- acter display and the machine monitor mode
ous parts of the vehicle, and then sends the selector switch which is the operation switch of
result as network information to the machine the character display.
monitor, which displays the information to
notify the operator of the vehicle condition. 1) Load meter (Not used)
q Loaded/no loaded calibration
q The machine monitor displays the information q Reset of calibration
in the normal mode or service mode. q Display/non-display of load meter
q Printer output format (printer (if equip-
q The normal mode is used to display the infor- ped))
mation to the operator normally. The major 2) Display of odometer
items displayed in this mode are as follows. 3) Reset of filter oil replacement time
4) Input of telephone number
1. Items always displayed 5) Selection of language
q Meters (Speedometer or engine tachome- 6) Adjustment of brightness of the night light-
ter) ing for the machine monitor
q Gauges (Engine coolant temperature 7) Adjustment of time of clock (Load meter (if
gauge, torque converter oil temperature equipped))
gauge, hydraulic oil temperature gauge, 8) Selection of travel speed and engine
and fuel level gauge) speed display
q Pilot indicators 9) Function to display/non-display of travel
q Service meter speed and engine speed on the character
display
The following is displayed according to setting
condition of optional device.
q Load meter calculated weight (Not used)
q Hours
q Display of travel speed/engine speed on
the character display
2. Items displayed when abnormality is detected

q Caution lamps
q Action code (While an action code is dis-
played, if the monitor panel mode selector
switch (>) is pressed and released, the
failure code (6 digits) is displayed.))
3. At the replacement period of a filter or oil, the

character display displays that filter or oil.
(Maintenance monitoring function)
10-901 2 WD600-6
Machine monitor system SEN04996-02
q The service mode function is used for the ease 10. Function of selecting optional device
of troubleshooting for the controllers on the Information of the controller to be used and
network (including the machine monitor itself). optional device are selected.
The major functions used in the service mode
are as follows. 11. Input of machine serial number (No.)
Enter the machine serial number to specify the
1. Display of electrical system failure history machine.
The electrical system failures of each controller
saved in the machine monitor are displayed. 12. Model selection function
The information of those failures is deleted Enter the information of applicable model.
with this function, too.
13. Initialize
2. Display of mechanical system failure history This function is used to set the machine moni-
The mechanical system failures of each con- tor to the state set when delivered.
troller saved in the machine monitor are dis-
played.
3. Real-time monitor
The input and output values recognized by
each controller on the network are displayed in
real time.
4. Reduced-cylinder mode
This function is used to stop fuel injection by
cylinder and specify the cylinder having defec-
tive fuel by shutting off fuel injected from the
fuel injector.
5. No injection cranking
This function is used when lubricating the
engine with the engine stopped when restart-
ing it after a long time of non-operation.
6. Adjustment function
The installation errors and manufacturing dis-
persion of the sensors, solenoid valves, etc.
are corrected and adjusted, and control char-
acteristic data is changed upon request of the
user.
7. Maintenance monitor
The filter and oil replacement period is
changed and its function is stopped.
8. Operating information display function

Fuel consumption per operating hours is dis-
played.
9. Manual snap shot (if equipped)

The direction to take in the snap shot data is
given to the VHMS.
WD600-6 10-901 3
Machine monitor electrical circuit diagram (AJSS specification)
10-901 4 WD600-6
WD600-6 10-901 5
Machine monitor electrical circuit diagram (Steering wheel specification)
10-901 6 WD600-6
WD600-6 10-901 7
SEN04996-02 Machine monitor
Machine monitor 1
1. Torque converter oil temperature gauge 26. Maintenance caution lamp

2. Torque converter oil temperature caution lamp 27. Battery electrolyte level caution lamp
3. Engine coolant temperature gauge 28. Battery charge circuit caution lamp
4. Engine coolant temperature caution lamp 29. Steering oil pressure caution lamp
5. Speedometer or engine tachometer (Not used)
6. Display of the unit of speedometer or engine 30. Emergency steering pilot lamp
tachometer 31. Output mode pilot lamp (Power mode)
7. Turn signal pilot lamp (Left) 32. Preheater pilot lamp
8. Head lamp high beam pilot lamp 33. Semi auto digging pilot lamp (Not used)
9. Turn signal pilot lamp (Right) 34. Auto-grease pilot lamp (If equipped)
10. Hydraulic oil temperature gauge 35. Joystick operation pilot lamp
11. Hydraulic oil temperature caution lamp 36. Directional selector pilot lamp (Not used)
12. Fuel level gauge 37. ECSS pilot lamp (Not used)
13. Fuel level caution lamp 38. Economy operation indicator lamp
14. Central warning lamp 39. Shift position pilot lamp (Forward/reverse)
15. Brake oil pressure caution lamp 40. Shift position pilot lamp (Gear speed)
16. Engine oil pressure caution lamp 41. Shift indicator
17. Fuel filter water detection caution lamp 42. Auto-shift pilot lamp
18. Engine oil level caution lamp 43. Lockup pilot lamp
19. Radiator coolant level caution lamp 44. Shift hold pilot lamp
20. Parking brake pilot lamp 45. Display of bucket loading (Not used)
21. Air cleaner clogging caution lamp 46. Addition mode: Total loading display/Reduction
22. Transmission oil filter clogging caution lamp mode: Display of level (Not used)
23. Brake oil temperature caution lamp 47. Working object display (Not used)
24. Modulation clutch temperature caution lamp 48. Addition/reduction mode display (Not used)
25. Cooling fan reverse rotation pilot lamp 49. Character display
10-901 8 WD600-6
Machine monitor SEN04996-02
1. Machine monitor mode selector switch 2

2. Machine monitor mode selector switch 1
WD600-6 10-901 9
List of items displayed on monitor

During starting the engine, the monitor checks if:
1. Starting motor switch ON has been recorded.
2. Charge level is min. the specified value or more.
3. Engine speed is the specified value (500 rpm) or more
At least two items above are satisfied, or CAN communication error (transmission controller:
DAQRKR) or (engine controller: DB2RKR) and charge level are the specified values or more.
Q: Lighting
w: Flashing (1.6 sec., 50% duty)
A: Intermittent (Period: 240 msec., “ON“: 80 msec., “OFF“: 160 msec.)
E: As per separate setting condition
Operating condition: Engine operating
Operating state
condition included, error detection time
(Starting switch ON)
counted (As indicated at right)
Signal detection controller

Detec-
tion time Engine: Stopped Engine is running
Display color
(SEC)
Category
No. Item Device Remarks
Display of message
Display of message
Individual display
Individual display
Central warning
Central warning
Alarm buzzer
Alarm buzzer
Detection
Reset
Lights when error (E03, E02)
Central warning lamp
occurs on each controller and at
Red
When error is made E E E E E E E E E
the same time displays mes-
sage.
14 Central warning lamp LED
Other than above, see “Oper-
ating condition – Central
— — — — — — — —
warning lamp” column of rele-
vant items.
For night Back light:
White
Back light
Back
light
— lighting of When small lamp is turned — — — — — — Monitor

(various back lights)
LED ON
Indicates “0” if error is made
Switchable to speedmeter
in communication other than
The first digit is fixed at 0.
Engine speed Fixed LCD when engine speed is — — — — — — — Engine
Number of display digits (4-dig-
selected or tilt positioner set
its): 0 – 3990
angle is displayed.
Other than when engine Switchable to tachometer
speed is not selected and tilt Trans- Number of display digits (4-dig-
Speedometer Fixed LCD — — — — — — —
positioner set angle is dis- mission its): 0 – 99 (middle 2 out of 4
Gauges and meters
played digits are used.)

Alarm is issued when infor-
mation of “Overrun preven-
5 Overrun prevention
Remarks
Remarks
tion (in lockup release o

(when lockup release o Trans-
Fixed LCD torque converter mode) alarm w Q w Q —
w
torque converter mode) mission

notice” is obtained from
alarm notice
transmission controller, and is
kept at least 3 minutes.
Note)
Alarm is issued when infor-
mation of “Overrun preven-
Overrun prevention
Remarks
Remarks
tion (in lockup release o

(in lockup release o Trans-
Fixed LCD torque converter mode) alarm w Q w Q —
w
torque converter mode) mission

detecting” is obtained from
alarm
transmission controller, and is
continued at least 3 minutes.
When engine speed is
— — — r/min — — r/min — —
selected
When speed [km/H] is
Unit
6 Unit display LCD — — — km/h — — km/h — — Monitor

selected
When speed [MPH] is
— — — MPH — — MPH — —
selected
Note)
Central
Main part
warning Buzzer Message
(*1)
lamp
Overrun notice Q w w (flashing) —
Overrun Q w w (flashing) Overrun prevention
(*1) When the engine speed is displayed on the center LCD, the display flashes.
When the travel speed is displayed, it is switched to the engine speed and
the display flashes.
10-901 10 WD600-6
Operating condition: Engine operating

Operating state
condition included, error detection time
counted (As indicated at right)

Detec-
Engine: Engine is run-
tion time
Display color
Stopped ning
(SEC)
Category
No. Item Device Remarks
Display of message
Display of message
Individual display
Individual display
Central warning
Central warning
Alarm buzzer
Alarm buzzer
Detection
Reset
Torque converter
Pointer:
1 oil temperature — — — — — — — — —
Movement MAX position: 135°C
gauge Red zone start point: 120°C
DGT1KX B@CENS (b@CENS)
DGT1KX B@CENS (b@CENS)

Level: 110°C
Alarm: Min. 120°C and [No 1/4 of full scale: 80°C
Red
abnormality is detected 10 1 — Q — — Q — (See figures
Min. position 50°C
(DGT1KX is not generated)] below.)
When sensor is grounded: Max.
Monitor of gauge
Torque converter
Indicator: Alarm: Min. 130°C and [No When sensor is disconnected or
2 oil temperature
Red
LED abnormality is detected 10 1 w Q Q w Q Q hot shorted: Min. of gauge
caution lamp
(DGT1KX is not generated)]
When abnormality is
Red
20 5 — — — — — — b@CENS does not display character message.
detected
Engine coolant Pointer:

3 — — — — — — — — —
temperature gauge Movement
Alarm: Min. 102°C and [No
abnormality is detected
Red
3 — Q — — — Q — —
(CA144 and CA145 are not
generated)]
Operation of gauges and meters
MAX position: 135°C

CA145 CA144 B@BCNS
CA145 CA144 B@BCNS

Engine (See figures Level: 85°C
Red
Engine coolant Alarm: Min. 105°C w Q Q w Q Q monitor below.) 1/4 of full scale: 65°C
Indicator:
4 temperature cau- Min. position: 50°C
LED
tion lamp
When abnormality is
— — — — — —
detected
When abnormality is
— — — — — —
detected
Hydraulic oil tem- Pointer: Max. position: 125°C
10 — — — — — — — — —
perature gauge Movement Red zone start point: 100°C
Level: 85°C (green graduations
DGH2KX B@HANS
DGH2KX B@HANS
Alarm: Min. 100°C and [No only)

Red
abnormality is detected 10 1 w Q Q w Q Q 1/4 of full scale: 65°C

(DGH2KX is not generated)] (See figures
Hydraulic oil tem- Monitor (green graduations only)
Indicator: below.)
11 perature caution Min. position: 50°C
LED When sensor is grounded: Max.
lamp
When abnormality is of gauge
20 5 — — — — — — —
detected When sensor is disconnected or
hot shorted: Min. of gauge
Pointer: MAX position: 100%: 10z
12 Fuel level gauge — — — — — — —
Movement 3/4 of full scale: 75%:
Level: 50%: 32z
1/4 of full scale: 25%: 49.5z
Red zone start point:
(See figures See specified LED lighting per-
Monitor
Fuel level caution Indicator: below.) cent or resistance.
Red
13 Min. 61.3 z 10 1 — Q — — Q — Min. position: 0%: 85z

lamp LED
When sensor is disconnected or
hot shorted: Gauge EMPTY
When sensor is grounded:
Gauge FULL
WD600-6 10-901 11
Operating condition: Engine operating condition

Operating state
included, error detection time counted (As indi-

cated at right)
Detec-
Engine: Engine is
tion time
Display color
(SEC) Stopped running
Category
Device
Display of message
Display of message
No. Item Remarks
Individual display
Individual display
Central warning
Central warning
Alarm buzzer
Alarm buzzer
Detection
Reset
[When F is selected] and [Engine is
1 0 A Q Q — — — Green
stopped]
[When R is selected] and [Engine is
1 0 A Q Q — — — Green
stopped]
When F is selected 0 0 — Q — — Q — Green
When N is selected 0 0 — Q — — Q — Green Monitor
39 Shift position When R is selected 0 0 — Q — — Q — Green Trans-
LED
40 pilot lamp
When 4th gear speed is selected 0 0 — Q — — Q — Green mission
When 3rd gear speed is selected 0 0 — Q — — Q — Green
When 2nd gear speed is selected 0 0 — Q — — Q — Green
When 1st gear speed is selected 0 0 — Q — — Q — Green
Actual gear speed
If error is made in communication, display

— — — — — — —
is held until key is turned OFF.
Displayed on right of [Gear speed display].
Upper line: F, N, R
Interlocked with shift valve. In neutral, how-
9-segment Lower line: 1, 2, 3, 4 Trans-
41 Shift indicator 0 0 — — — — — — — ever, gear speed is not displayed.
LCD If error is made in communication, display mission
Displayed on left of [FNR display].
N when F or R solenoid vale is OFF.
When auto-shift is selected 0 0 — Q — — Q — Green
Auto-shift
42 LED If error is made in communication, display
pilot lamp — — — — — — Green
When auto-shift and shift hold is selected 0 0 — Q — — Q — Green
Shift hold
pilot lamp — — — — — — —
When lockup functions 0 0 — — — — Q — Green
Lockup pilot
lamp — — — — — — —
Functions when key is OFF to provide haz-
7 Turn signal When turn signal switch is input
LED 0 0 — Q — — Q — Green Monitor ard function interlocking with turn signal
9 pilot lamp (including when key is OFF)
switch.
Head lamp
When high beam is functioning: Head
8 high beam LED 0 0 — Q — — Q — Blue Monitor
lamp ON and High beam ON
pilot lamp
Normal oil pressure (CLOSED) — — — — — — —
2G43ZG 2G42ZG
Below specified value (F) (OPEN)

(detection time is continued) and in 45 5 1 — Q — w Q Q Red Front
seconds after engine is started
Below specified value (R) (OPEN)
(detection time is continued) and in 45
5 1 — Q — w Q Q Red Rear
seconds after engine is started
(No detection time)
Below specified pressure (F) (OPEN)
Brake (detection time is continued) and 45 sec-
accumulator
15 LED onds after engine is started Monitor
oil pressure (No detection time) 1 1 — Q — w Q Q Red Front
caution lamp * When engine is stopped, condition of
“45 seconds after engine is started” is not
applied.
Below specified pressure (R) (OPEN)
(detection time is continued) and 45 sec-
onds after engine is started
Others
(No detection time) 1 1 — Q — w Q Q Red Rear

* When engine is stopped, condition of
“45 seconds after engine is started” is not
applied.
At normal operation — — — — — — — —
Engine oil
B@BAZG
B@BAZG
16 pressure cau- LED Engine oil pressure reduction error is Engine

tion lamp w Q Q w Q Q Red
received
Normal oil level (CLOSED) — — — — — — —

If alarm is detected when key is turned ON,
Engine oil Low oil level (OPEN) continues 2 sec-
B@BAZK
first information is kept until engine oil

18 level caution LED onds. Monitor
2 1 — Q — — — — Red reaches normal oil level even if engine is
lamp For 300 seconds after engine is stopped, started.
however, no error is detected.
Normal coolant level (CLOSED) — — — — — — —
Radiator
B@BCZK
B@BCZK
19 coolant level LED Monitor

caution lamp Low coolant level (OPEN) 30 1 — Q — — Q — Red
When parking brake is applied (OPEN) — Q — — Q — Red

When parking brake is not applied
Parking — — — — — — —
(CLOSED)
20 brake pilot LED Monitor
lamp Other than when parking brake is applied
and gear shift lever is at “N” position, and 0 0 A Q Q Red
during starting engine
10-901 12 WD600-6

Operating state

cated at right)
Detec-
Engine: Engine is
tion time
Display color
Category
Device
Display of message
Display of message
No. Item Remarks
Individual display
Individual display
Central warning
Central warning
Alarm buzzer
Alarm buzzer
Detection
Reset
Normal (CLOSED) — — — — — — —
Air cleaner
AA1ANX
21 clogging cau- LED Monitor
tion lamp Sensor detects clogging (OPEN) 2 1 — — — — Q — Red
Normal (CLOSED) — — — — — — —
15BONX
Clogging (OPEN) and torque converter
Transmis- 2 1 — — — — Q — Red
oil temperature > 50°C If abnormality is detected while engine is
sion oil filter
22 LED Monitor stopped, alarm is continued even after
clogging cau-
DHT2L6
engine is started.
OFF
tion lamp When abnormality is detected 3 — — — — — — —
— — — — — — Red
Other than below — — — — — — — — —
Temperature increase (Min. 120°C)
5 5 — Q — — — Q — — Red
(notice alarm)
Temperature increase (1 or 2 below)
1. Oil temperature is above 130°C for 5
seconds.
B@C7NS
B@C7NS
2. When travel speed is above 35 km/h
while brake oil temperature, 125°C and 5 5 w Q Q w Q Q Red
Brake oil above, is detected continuously for 5 sec-
23 temperature LED onds. It is released when oil temperature, Monitor
caution lamp 125°C and below, is detected continu-
ously for 5 seconds.
DGR2KX DGR2KA
DGR2KX DGR2KA
When abnormality is detected — — — — — — —
When abnormality is detected — — — — — — —
Other than following — — — — — — — — —

Modulated Temperature rise (Forecast alarm) 0 0 — Q — — — Q — — Red
clutch tem-
24 LED
15W0NT
15W0NT
perature
Others
caution lamp Temperature rise 0 0 w Q Q w Q Q Red
Cooling fan forward drive 0 0 — — — — — — — —

As indicated at right
As indicated at right
Cooling fan reverse rotation state is dis-

Cooling fan
played.
reverse rota- Trans-
25 LED Cooling fan reverse rotation 0 0 — Q — — Q — Orange While fan is reversed, message is dis-
tion pilot mission
played on character display.
lamp
COOLING FAN REVERSE ROTATION
Fan switch and solenoid disagree. 0 0 — w — — — w — — Orange

Simultaneously displays contents on mes-
Ordinary — — — — — — —
Maintenance sage display.
26 LED Monitor
caution lamp 30 h or less before maintenance or main-
— Q — E — Q — E Red
tenance time
Normal — — — — — — —
B@GAZK
B@GAZK
Battery elec-
27 trolyte level LED Sensors: Less than 2 V 10 1 — Q — — — Red Monitor
caution lamp
Option is not applied — — — — — — If abnormality is detected while engine is

Normal voltage (hysteresis on the right stopped, alarm is continued even after
— — — — — — —
figure) engine is started.
Insufficient alternator voltage See figures on alternator terminal R volt-
AB00MA
Battery age.
(Hysteresis on the right figure), no start-
charge cir- 30 1 — — — w Q Q Red
28 LED ing motor C signal input, and during run- Monitor
cuit caution ning of engine
lamp
AB00L6
When abnormality is detected 3 1 w Q Q — — — Red
Not in operation — — — — — — — — — —
Steering oil In operation (CN3-3 = OPEN) — — Q — — Q — Red
DDE5MA
DDE5MA
29 pressure cau- LED Monitor Not used

tion lamp When abnormality is detected — — — — — — —
WD600-6 10-901 13

Operating state

cated at right)
Detec-
Engine: Engine is
tion time
Display color
Category
Device
Display of message
Display of message
No. Item Remarks
Individual display
Individual display
Central warning
Central warning
Alarm buzzer
Alarm buzzer
Detection
Reset
Normal operation
Emergency [Operation of divider
1 1 — Q — — Q — Green
30 steering pilot LED (= Below S/T pressure CN3-3=OPEN)] Monitor
lamp and [Travel speed, min. 1 km/h]
Holds in position — — — — — —
Output mode Power mode = P 0 0 — Q — — Q — Green
pilot lamp Trans-
31 LED Selection of power mode is displayed.
(power Power mode = Other than P — — — — — — — — mission
mode)
Preheating Other than below — — — — — — —
32 LED Engine
pilot lamp In preheating (with signal) 0 0 — Q — — Q — Red
Semi auto When auto digging switch is OFF — — — — — — — Work
33 digging pilot LED When auto digging switch is ON 0 0 — Q — — Q — Green equip- Not used
lamp When error is made in communication — — — — — — — ment
Not in operation and not installed — — — — — — —
Operation 1 1 — Q — — Q — Green Status: Port A: Port B: Panel display
w 2 Hz w 1 Hz
w 2 Hz w 1 Hz
Operation: 0 V: 24 V: Lighting
Auto grease Empty tank 3 1 — — — — Green Monitor Abnormality: 0 V: 0 V: Flashing, 2 Hz
34 LED
pilot lamp
Empty tank: 24 V: 0 V: Flashing, 1 Hz
Others
Abnormality: 24 V: 24 V: OFF
Abnormal 3 1 — — — — Green
Option is not applied — — — — — — — — —

Operation of wheel steering system — — — — — — — — Monitor — When steering wheel option is selected
Operation of AJSS system only when joy- Trans- CAN input signal from transmission con-
0 0 — Q — — — Q — — Green
stick optional setting is made. mission troller
AJSS Work
35 operation LED AJSS lever neutral lock (Output from CAN input signal from work equipment
0 0 A w Q — A w Q — Green equip-
pilot lamp work equipment controller) controller
ment
Operation of FR prohibition function dur-
Trans- CAN input signal from transmission con-
ing locking of AJSS steering only when 0 0 A w Q — A w Q — Green
mission troller
AJSS optional setting is made.
When error is made in communication — — — — — — —
Not operated — — — — — — —
ECSS pilot Trans-
37 LED Operating 0 0 — Q — — Q — Green Not used
lamp mission
When error is made in communication — — — — — — —
Economy Economy mode 0 0 — Q — — Q — Green
operation Trans-
38 LED
indicator Other than above 0 0 — — — — — — — mission
lamp
Priority of sounding of buzzer: Continual (w) > Intermittent (A) > Cancellation of operation > Check of acceptance of operation.
10-901 14 WD600-6
Character display function
Using the character display function, you can change the display and settings on the machine monitor.
For usage of functions for the operator, see the Operation and Maintenance Manual.
The operator can operate the part “Operator disclosure function” below.
(*1) Once you pass on the ID input screen, you can directly move to the function selection screen without
displaying this screen until the starting switch is turned OFF.
WD600-6 10-901 15
Operator mode self-check function
Self-check (0th layer) Select “Displayed” for “10. Engine speed or travel
The self-check function operates 3 seconds after speed display on character display and normal
the key is turned ON. screen” in the optional setting. Then, when the
After the key ON, it automatically starts and ends travel speed is displayed on the LCD at the center
the self-check function operation. of the monitor, the engine speed is displayed on the
After 3 seconds, you are brought to the 2nd layer character display.
automatically. when the engine speed is displayed on the LCD,
In self-check mode, the mode switch is disabled. the travel speed is displayed on the character dis-
play.
For machines of SI specification, the travel speed
unit is km/h and for ones of non-SI specification,
the service optional setting is conformed to.
Normal screen (1st layer)

After the self-check, the following screen is auto-
matically displayed.
Press the U switch to move to the 2nd layer.
10-901 16 WD600-6
Failure code display screen (1st layer)
q Pressing the > switch while the alarm screen is

displayed changes to the failure code display
screen.
q Pressing the > switch again displays the ser-
vice meter for 10 seconds, and automatically
returns to the alarm screen.
q If you do not perform any switch input for 30
seconds with the failure code display screen
displayed or a new error occurs, you are
returned to the alarm screen.
q When multiple errors occur, every pressing of
the > switch displays items in descending
order of priority. Items of the same priority is
displayed in reverse chronological order of
occurrence.
q Example of failure code display screen (When

DLT3KA, DW7BKA and DKA0L0 occur simul-
taneously)
The upper column displays failure code (6-digits) so
that the ECM CODE and space are sandwiched.
The lower column displays the message 2.
For information on the failure code (6-digits), ECM

CODE, and message 2, see the message list.
The example shows the failure code of WA600-6.
In 10 seconds, you are automatically brought to the

alarm screen.
WD600-6 10-901 17
Operator disclosure function
Function opened to the operator (2nd layer and lower)

q If any switch operation is not done at least 60 seconds on the 2nd layer or lower, you are brought to the
1st layer automatically.
q Optional items are not displayed if not selected.
q The language selected by the language selection function is displayed.
q For operation after selecting each menu, see the corresponding menu item.
(Select each menu using the U switch.)
Function opened to the operator (2nd layer and lower)
(*1) This menu is not available when the function to display the travel speed or rpm on the character display
is turned OFF through the option selection of service mode.
10-901 18 WD600-6
Outline of service mode

The service mode function is used for the ease of troubleshooting for the controllers on the network (includ-
ing the machine monitor itself).
When making initial settings and optional settings for the sensors, enter the service mode of the machine
monitor.
Operating method of machine monitor

1. Entering the service mode
1) Operating method
1] Turn the starting switch of the machine ON.
2] When the normal service meter screen or alarm screen is on the character display of the
machine monitor, press the machine monitor mode selector switches 1 (t) and 2 (<) simulta-
neously for 5 seconds. Then, the INPUT ID screen is displayed.
Machine monitor mode display selector switch 1 2) How to input ID

and 2 1] Press the < or > switch. Then, the
value at the cursor position increases
or decreases at the cursor position.
Select a desired value using the U
switch.
2] Completing operations equivalent to 4
digits (1) brings you to the ELECTRIC
FAULT screen.
a If you input an incorrect value,
press t switch to return the cur-
sor to the highest-order digit, and
re-enter values from there.
a If you press the t switch while
the cursor is at the highest-order
digit, the normal service meter
INPUT ID screen
screen or alarm screen is
returned.
a If any switch operation is done at
least 60 seconds during the ID
input, the normal service meter
screen or alarm screen is
returned.
ID to enter the service mode is

“6491”.
Remarks: If the starting switch is
turned OFF in the service mode, the
normal service meter screen or alarm
screen is returned at the next starting
switch ON.
WD600-6 10-901 19
2. Service mode menu
a The service mode menu shows a different

screen by operating the < or >switch. Select a
target operation menu screen with the switch.
a If you press the U when the following screen
(selection screen) is displayed, the menu
screen/operation screen of each function
appears.
a If you press the t when the following screen
(selection screen) is displayed, the normal ser-
vice meter screen or alarm screen is returned
at the next starting switch ON.
Operation menu screen (character display)

1) ELECTRIC FAULT screen 2) MACHINE FAULT screen
[ ] field displays number of the failure history [ ] field displays number of the failure history
currently recorded (up to 20 cases). currently recorded (up to 20 cases).
Outline Outline
This function is used to check the electrical system This function is used to check the mechanical sys-
failure history of each controller saved in the tem failure history of each controller saved in the
machine monitor. For the failure codes displayed in machine monitor. For the failure codes displayed in
the electrical system failure history, see “Trouble- the mechanical system failure history, see “Trouble-
shooting”. After each failure is repaired and the nor- shooting”.
mal operation is confirmed, delete the failure
history.
10-901 20 WD600-6
3) REAL-TIME MONITOR screen 5) NO INJECTION screen
Outline Outline
This function is used to check the input and output This function is used when lubricating the engine
signals, etc. recognized by each controller on the with the engine stopped when restarting it after a
network. long time of non-operation.
For the starting method of engine using this func-
4) CYLINDER CUT-OUT screen tion, see “Testing and adjusting: No injection crank-
ing operation of engine”.
6) TUNING screen
Outline
This function is used to stop fuel injection by cylin-
der and specify the cylinder having defective com-
bustion by shutting off fuel injected from the fuel Outline
injector. The installation errors and manufacturing disper-
For the method of checking using this function, see sion of the sensors, solenoid valves, etc. are cor-
“Testing and adjusting: Operating engine in reduce rected and adjusted, and control characteristic data
cylinder mode”. is changed upon request of the user. Use this func-
tion if you have changed or added sensors, valves
or controllers. For adjustment using this function,
see “Testing and adjusting: Adjustment performed
on the monitor”.
WD600-6 10-901 21
7) MAINTENANCE MONITOR screen 9) MANUAL SNAP SHOT screen
Outline Outline
This function is explained in “Operation and Mainte- The direction to take in the snap shot data is given
nance Manual, Operation, Character display, Dis- to the VHMS.
play of replacement periods of filters and oils”. The This function is used only when the VHMS is
set replacement periods of a filter and oil are installed.
changed and their functions are stopped. For inspection with this function, see “Testing and
adjusting volume, Inspection with VHMS”.
8) OPERATION INFO screen
10) OPTIONAL SELECT screen
Outline
Fuel consumption per operating hours is displayed. Outline
With this function, you can display installation of an
optional device and change the setting of that
device. Use this function after any optional device
is installed or removed. For the method of setting
and changing this function, see “Testing and adjust-
ing: Adjustment performed on the monitor”.
10-901 22 WD600-6
11) Machine serial No. input function screen
Outline
The machine serial No. is displayed and set.
This screen is used for machine management etc.
12) MACHINE screen
a The lower column displays the currently

selected model.
Outline
This function is used to display or select the
machine model.
13) INITIALIZE screen
Outline
This function is used only in the factory. Do not use
it.
WD600-6 10-901 23
Function of displaying electrical system failure history
1) Display of electrical system failure history and selection of clearing entirely the electrical system failure
history
The items are displayed in the sequential order by the latest occurrence time from the latest one.
The items which have not been reset are displayed before the items which have been reset.
Pressing the > switch scrolls the items from the newer ones to the older ones.
Pressing the < switch scrolls the items from the newer ones to the older ones.
After the oldest saved item, the “Electrical system failure history all clear selected” screen is displayed.
Pressing the t switch changes the screen to the “Electrical system failure history selected” screen.
Pressing the U switch changes the screen to the “Electrical system failure history individual cleared” screen
or the “Electrical system failure history all cleared” screen.
2) Selection of electrical system failure history (1st layer)

Pressing the < switch changes the screen to the “Select initialization” screen.
Pressing the > switch changes the screen to the “Select display of mechanical system failure history” screen.
Pressing the t switch changes the screen to the normal screen or alarm screen.
Pressing the U switch changes the screen to the “Display electrical system failure history” screen.
10-901 24 WD600-6
3) Display of electrical system failure history and the electrical system failure history all clear selected (2nd
layer)
Pressing the t switch changes the screen to the “Display electrical system failure history” screen.
Pressing the U switch changes the screen to the “Display electrical system failure history” screen.
q If there is only 1 history, the current screen does not change to the “Electrical system failure history all
clear” screen (Only the “Electrical system failure history individual clear” screen is displayed).
q If the number of the histories exceeds 20, they are deleted in order from the oldest one.
4) Electrical system failure history individual clear and Electrical system failure history all clear (3rd layer)
Select “YES” or “NO” with the < or > switch.
The cursor “_” blinks on the selected item. If “YES” is selected and the t switch is pressed, clearing is exe-
cuted. If “NO” is selected and the t switch is pressed, clearing is cancelled and the display changes as
shown below.
q If clearing is cancelled (NO), the current screen returns to the “Display electrical system failure history”
screen of the corresponding failure.
(Returns to the screen before the “Electrical system failure history individual clear” (Electrical system
failure history all clear) screen).)
q If clearing is executed (YES), the current screen returns to the “Display electrical system failure history”
screen of the corresponding next failure.
After all the failure histories are cleared, the current screen returns to the “Select electrical system fail-
ure history” screen.
By default, the cursor is on NO (cancel) to prevent resetting by an error.
You cannot delete a failure which has not been reset. At this time, the operation cancel peep (for 1 sec) is
heard.
If any failure history is cleared, the operation acceptance peeps (“ON” for 0.1 sec, “OFF” for 0.1 sec, “ON” for
0.1 sec) are heard.
When clearing of all the histories is selected, if there is any history to be cleared, clearing is assumed to be
completed.
WD600-6 10-901 25
Function of displaying mechanical system failure history
1) Display of mechanical system failure history

Pressing the t switch changes the screen to the “Mechanical system failure history selected” screen.
q The mechanical system fault histories cannot be deleted.
2) Selection of mechanical system failure history (1st layer)

Pressing the > switch changes the screen to the “Select real-time monitor” screen.
Pressing the < switch changes the screen to the “Select display of electrical system failure history” screen.
Pressing the t switch changes the screen to the normal screen or alarm screen.
Pressing the U switch changes the screen to the “Mechanical system failure history selected” screen.
10-901 26 WD600-6
3) Display of mechanical system failure history (2nd layer)

Pressing the > switch scrolls the items from the older ones to the newer ones.
Pressing the t switch changes the screen to the “Mechanical system failure history selected” screen.
WD600-6 10-901 27
Function of real-time monitor
The real-time monitor function displays the information saved in the controllers mounted on the machine in
real time.
This function is used for testing, adjusting, or troubleshooting the machine.
This function classifies the items and data by the controllers having them, and then displays the results. It
has 2 display modes of the normal display mode and the 2-item display mode for displaying 2 data simulta-
neously.
Operating procedure
1. Hold the t switch and < switch simultaneously for at least 5 seconds to change the screen to the ID
inputting screen.
2. Input the ID with the < and > switches, and then press the U switch to enter the screen for the service
mode.
3. Using the < and > switches, display “Real-time monitor selection” screen, and then press the U switch.
10-901 28 WD600-6
4. Press the U switch, and the “Monitor panel information display select screen”.
Each time the < switch or > switch is pressed, the screens to select the following information or function
are displayed in order; the transmission controller information, engine controller information, VHMS con-
troller information, work equipment controller information and 2-item display function.
WD600-6 10-901 29
5. Press the U switch while a selection screen is 2] Select a desired digit and press the
displayed, and the screen to select the “1 item U switch.
display” function or “2 item display” function is The cursor moves to the 2nd position.
displayed. Select the digits for the all positions in
1) 1 item display screen the same manner as the previous
The screen to select display of the infor- steps.
mation of the monitor panel, transmission 3] Input a value at the lowest-order digit
controller, engine controller, VHMS con- and press the U switch to move to
troller or work equipment controller or the the screen to select the display of 2nd
“2 item display” function are displayed. item.
q If you press the t switch during the
processing, the screen returns to the
“Select 2 items display information”
screen.
***: Item name

%%%%% : Data and unit (Unit: SI unit)
$$$$ : ID number
q Items displayed on the “Display 1 item” q In display of 2 items mode, input the
screen change in order by pressing < and ID of necessary information and
> switches, displaying information held by press the U switch to display 2 items
the controller. simultaneously.
2) 2 item display function q The ID displayed is the same as the
If the “2 item display function” is selected, ID number displayed on the “Display
2 items are displayed simultaneously. 1 item” screen.
1] How to input ID
“00000” is displayed during screen
transition.
Input a value between 0 and 9 at the
cursor (_) position.
First, the cursor appears at the high-
est-order digit. Each time the > or <
switch is pressed, the digit changes
by 1 between 0 and 9.
10-901 30 WD600-6
WD600-6 10-901 31
List of display contents of the real-time monitor

The state of the controller input and output signals can be checked using the real-time monitor function of the
monitor.
The following table shows the display items and display contents in normal operation of the real-time monitor
in relation to the machine monitor:
No. Item ID No. Display of item Contents of display data Display contents in normal operation Remarks
Monitor software part Part No. of software is dis-
1 20200 VERSION Depends on the software part number
No. played
Application version number is
2 Application version 20221 VERSION (APP) Depends on application version number
displayed
Data version number is dis-
3 Data version 20222 VERSION (DATA) Depends on data version
played
Li: 800 ± 25 rpm
Hi: 2000 ± 50 rpm (P-mode)
4 Engine Speed 01001 ENG SPEED Engine speed is displayed 1900 ± 50 rpm (E-mode)
T/C stall: 1800 ± 100 rpm (P-mode)
1730 ± 100 rpm (E-mode)
F1/R1: 6.7/7.3 km/h ± 5% (P-mode, T/C)
F2/R2: 11.7/12.8 km/h ± 5% (P-mode, T/C)
5 Travel speed 40000 SPEED Travel speed is displayed
F3/R3: 20.3/22.0 km/h ± 5% (P-mode, T/C)
F4/R4: 33.8/37.0 km/h ± 5%(P-mode, T/C)
6 Fuel level 04202 FUEL SENSOR Fuel level is displayed 0 – 100%
Gauge FULL (100%,10 z): 0.32 V When sensor is disconnected or hot
Gauge 1/2 (50%, 32 z): 0.88 V shorted: gauge EMPTY
7 Fuel level 04207 FUEL SENSOR Fuel level is displayed
Caution (61.3 z): 1.45 V When sensor is grounded: gauge
Gauge EMPTY (0%, 85 z): 1.81 V FULL
Coolant temperature, max. 100°C
Engine coolant temper- Coolant temperature is dis-
8 04103 COOLANT TEMP Depends on machine status (°C) Data is obtained from engine con-
ature played
troller.
Torque converter oil Torque converter oil tempera-
9 40100 TC OIL TEMP Depends on machine status (°C) Overheat: 120°C
temperature ture is displayed
When sensor is disconnected or hot
Torque converter oil Torque converter oil tempera- Gauge red zone start point (120°C): 1.62 V shorted: Min. of gauge
10 40101 TC OIL TEMP
temperature ture is displayed (80°C): 2.91 V When sensor is grounded: Max. of
gauge
Hydraulic oil tempera- Hydraulic oil temperature is Hydraulic tank oil temperature: Max.
11 04401 HYD TEMP Depends on machine status (°C)
ture displayed 100°C
When sensor is disconnected or hot
Hydraulic oil tempera- Hydraulic oil temperature is Gauge red zone start point (120°C): 1.62 V shorted: Min. of gauge
12 04404 HYD TEMP
ture displayed (80°C): 2.91 V When sensor is grounded: Max. of
gauge
Brake oil temperature is dis-
13 Brake oil temperature 30202 R BRAKE OIL Depends on machine status (°C)
played
Brake oil temperature is dis- (120°C): 1.62 V
14 Brake oil temperature 30205 R BRAKE OIL
played (80°C) : 2.91 V
15 Charge level 04302 ALTERNATOR R Charge level is displayed Depends on machine status (0.0 – 30 V)
Small lamp voltage is dis-
16 Small lamp voltage 40200 SMALL LAMP Depends on machine status (0.0 – 30 V)
played
Battery electrolyte level Battery electrolyte level is
17 40300 BATTERY A Min. 2 V Only when optional setting is made
A displayed
Battery electrolyte level
18 40301 BATTERY B — — Not used.
B
19 Lift arm angle 06001 BOOM ANG — — Not used.
20 Lift arm angle 06003 BOOM ANG — — Not used.
Lift arm bottom pres- BOOM BTM
21 40400 — 0 – 50 MPa displayed Not used.
sure PRESS
Lift arm bottom pres- BOOM BTM
22 40402 — 0.5 – 4.5 V displayed Not used.
sure PRESS
BOOM HEAD
23 Lift arm head pressure 40500 — — Not used.
PRESS
BOOM HEAD
24 Lift arm head pressure 40501 — — Not used.
PRESS
25 Calibration pressure 40600 CAL PRESS — — Not used.
Load meter calculated weight Only when optional setting is made
26 Classified weight 40800 MES LOAD Load weight [t]
is displayed in load meter
27 Position of rotary switch 30802 SW1, SW2, SW3 — — Not used.
28 Position of DIP switch 30904 SW5-1, SW5-2 — — Not used.
31 Position of DIP switch 30907 SW6-3. SW6-4 — — Not used.
10-901 32 WD600-6
D-IN-0: Head lamp
10000000 (Head lamp = on) D-IN-1: Not used
00000000 (Not used) D-IN-2: Starting motor C
00100000 (Starting motor C = on) D-IN-3: Not used
00000000 (Not used) D-IN-4: Auto grease A
The state of input signal is 00001000 (Auto grease: Empty) (Only when optional setting is made
32 Input signal D_IN_0-7 40900 D-IN--0------7
displayed 00000100 (Auto grease: Operation) in auto grease)
00000000 (Auto grease: Abnormal) D-IN-5: Auto grease B
00001100 (Auto grease: Abnormal) (Only when optional setting is made
00000000 (Not used) in auto grease)
00000000 (Not used) D-IN-6: Not used
D-IN-7: Not used
The state of input signal is 00000000 (Not used) D-IN-11: Not used
33 Input signal D_IN_8-15 40901 D-IN- 8-----15
displayed 00001000 (Right winker on) D-IN-12: Winker right
00000100 (Left winker on) D-IN-13: Winker left
00000010 (Monitor mode SW (U) = on) D-IN-14: Monitor mode SW (U)
00000001 (Monitor mode SW (t) = on) D-IN-15: Monitor mode SW (t)
10000000 (Front brake oil pressure SW = on =
low level) D-IN-16: Brake oil pressure (Front)
01000000 (Rear brake oil pressure SW = on = D-IN-17: Brake oil pressure (Rear)
low level) D-IN-18: Not used
Input signal D_IN_16- The state of input signal is
34 40902 D-IN-16-----23 00000000 (Not used) D-IN-20: Air cleaner clogging
23 displayed
00001000 (Air cleaner clogging SW = on) D-IN-21: Not used
00000000 (Not used) D-IN-22: Parking brake emergency
00000010 (Parking brake emergency release SW release SW
= on) D-IN-23: Not used
00000000 (Not used)
D-IN-24: T/M filter clogging
10000000 (T/M filter clogging SW = on)
(Only when optional setting is made)
00000000 (Not used)
D-IN-25: Not used
00100000 (Parking brake = on)
D-IN-26: Parking brake
00010000 (Coolant level SW = on = low level)
Input signal D_IN_24- The state of input signal is D-IN-27: Coolant level
35 40903 D-IN-24-----31 00000000 (Not used)
31 displayed D-IN-28: Not used
00000100 (Engine oil level SW = on = low level)
D-IN-29: Engine oil level
00000010 (Emergency steering operation SW =
D-IN-30: Emergency steering opera-
on)
tion (Low S/T pressure)
00000000 (Not used)
D-IN-31: Not used
00100000 (High beam = on) D-IN-34: High beam
Input signal D_IN_32- The state of input signal is 00000000 (Not used) D-IN-35: Not used
36 40904 D-IN-32-----39
39 displayed 00001000 (SW for servicing = on) D-IN-36: SW for servicing
00000100 (Monitor mode SW (>) = on) D-IN-37: Monitor mode SW (>)
00000010 (Monitor mode SW (<) = on) D-IN-38: Monitor mode SW (<)
1000 (Buzzer = on) D-OUT-0: Buzzer
Output signal The state of output signal is 0000 (Not used) D-OUT-1: Not used
37 40952 D-OUT-0--3
D_OUT_0-3 displayed 0000 (Not used) D-OUT-2: Not used
0000 (Not used) D-OUT-3: Not used
WD600-6 10-901 33
The following table shows the display items and display contents in normal operation of the real-time monitor
in relation to the VHMS.
–30 – +100°C, depending on ambient tem-
1 Ambient temperature 37501 AIR TEMP Ambient temperature
perature
0.0 – 20.0 kPa
2 Blow-by pressure 42801 BLOWBY PRESS Blow-by pressure
See Pm-clinic check sheet.
Engine oil tempera- 0 – 180°C, depending on engine oil tempera-
3 42703 ENG OIL TEMP Engine oil temperature
ture ture
Check after machine is warmed up.
Exhaust temperature EXHAUST TEMP
4 42610 Exhaust temperature (F) 200 – 950°C
(F) F
Check after machine is warmed up.
Exhaust temperature EXHAUST TEMP
5 42611 Exhaust temperature (R) 200 – 950°C
(R) R
0.00 – 50.00 MPa
6 Brake oil pressure (F) 92800 BRAKE PRESS F Brake oil pressure (F)
BRAKE PRESS 0.00 – 50.00 MPa
7 Brake oil pressure (R) 92801 Brake oil pressure (R)
R See Pm-clinic check sheet.
8 Brake signal 92900 BRAKE SIG Brake signal Brake operation = ON
0.00 – 50.00 MPa
9 Steering oil pressure 93000 S/T OIL PRESS Steering oil pressure
10 Start signal 93100 START SIG Start signal Starting switch ON = ON
00000000 (Unused) D-IN-0: Unused
01000000 (Download switch under cab D-IN-1: Download switch under
ON = on) cab
11 Input signal D_IN_0-7 40944 D-IN--0------7 Input signal state
00000000 (ORBCOMM connection = on) (*1) D-IN-6: ORBCOMM connection (*1)
00000000 (IRIDIUM connection = on) (*2) D-IN-6: IRIDIUM connection (*2)
00000000 (Brake operation = on) D-IN-7: Brake operation signal
0000 (Unused) D_OUT_0: Unused
Output signal 0000 (Unused) D_OUT_1: Unused
12 40948 D-OUT--0--3 Output signal state
D_OUT_0-3 0010 (During VHMS operation = on) D_OUT_2: VHMS operation
0000 (Unused) D_OUT_3: Unused
0000 (Kept at 0) SEL-0: Kept at 0
13 SEL signal 0-3 00248 D-SEL-0--3 SEL signal state
(*1): ORBCOMM installation specification

(*2): IRIDIUM installation specification
10-901 34 WD600-6
Engine reduced-cylinder function

1. Using the < and > switches, display “Reduced
cylinder mode selection (CYLINDER CUT-
OUT)” screen, and then press the U switch.
2. Operating method of reduced-cylinder function

Every pressing the > switch moves the cursor to the right (select a cylinder to issue the reduced-cylinder
command).
Every pressing the < switch moves the cursor to the left (select a cylinder to issue the reduced-cylinder com-
mand).
Press the U switch to issue the monitor reduced-cylinder command. Every pressing this switch repeats out-
put/release of the command.
Press the t switch to return to the “Reduced cylinder mode selection (CYLINDER CUT-OUT)” screen and
the reduced-cylinder commands from the monitor are all released.
Operation example: When the 3rd cylinder stop command is issued
WD600-6 10-901 35
No injection cranking
For the starting method of engine using this function, see “Testing and adjusting: No injection cranking oper-
ation of engine”.
This section describes only the operating method.
10-901 36 WD600-6
Adjustment function
For adjustment using this function, see “Testing and
adjusting: Adjustment performed on the monitor”.
This section describes its outline only.
01: Reset of transmission initial learning

See “Testing and adjusting: Setting of trans-
mission initial learning”.
See “Testing and adjusting: Reset of initial
learning”.
See “Testing and adjusting: Setting of trans-
mission initial learning”.
02: ECMV compensation
See “Testing and adjusting: Adjustment of
transmission ECMV current”.
04: Adjustment of transmission shift point
See “Testing and adjusting: Adjusting a shift
point”.
05: Lift angle adjustment of work equipment con-
troller
a Not used
06: Adjustment of lift raise variations in the dead
zone of EPC
See “Testing and adjusting: Adjusting lift raise
EPC starting current”.
07: Adjustment of lift lower (float) lever and varia-
tions in the dead zone of EPC
See “Testing and adjusting: Adjusting variation
correcting calibration of lift lower (float) EPC
lever”.
See “Testing and adjusting: Adjusting lift lower
EPC starting current”.
08: Adjustment of L.H. pitch and tilt L.H. lever vari-
ations in the dead zone
See “Testing and adjusting: Adjusting variation
correcting calibration of L.H. pitch and tilt L.H.
lever position before detent”.
See “Testing and adjusting: Adjusting bucket
tilt EPC starting current”.
09: Adjustment of L.H. pitch forward and tilt R.H.
lever EPC starting current
See “Testing and adjusting: Adjustment of L.H.
pitch forward and tilt R.H. lever EPC starting
current”.
10: Adjustment of R.H. pitch rear variations in the
dead zone of EPC
See “Testing and adjusting: Adjustment of R.H.
pitch rear EPC starting current”.
WD600-6 10-901 37
11: Adjustment of R.H. pitch forward variations in

the dead zone of EPC
See “Testing and adjusting: Adjustment of R.H.
pitch forward EPC starting current”.
12: Adjustment of AJSS neutral position (AJSS

specification)
AJSS neutral position”.
13: Adjustment of AJSS EPC output current (AJSS

specification)
AJSS EPC output current”.
14: Adjustment of pitch forward left-right speed

See “Testing and adjusting: Pitch forward left-
right speed”.
15: Adjustment of pitch rear left-right speed

See “Testing and adjusting: Pitch rear left-right
speed”.
16: Adjustment of lift raise/lower stop modulation

See “Testing and adjusting: Adjustment of lift
raise/lower stop modulation”.
17: Adjustment of pump cut-off pressure in lift raise

a Not used
18: Adjustment of lift angle sensor (raise) (For load

meter)
a Not used
19: Adjustment of lift angle sensor (lower) (For

load meter)
a Not used
21: Modification of AJSS oil pressure command

table pattern
See “Testing and adjusting: Modification of
AJSS oil pressure command table pattern”.
22: Adjustment of maximum speed limit

maximum speed limit”.
10-901 38 WD600-6
Maintenance monitoring function

1. Selection of display of maintenance monitor function (1st layer)
For the destination you can go to using <, >, and t switches, see “Function 1 for the service person: 2nd
layer transition diagram”.
Pressing the U switch changes the screen to the “Item NO. 1 is displayed” screen.
WD600-6 10-901 39
2. “Select maintenance item” screen

(1) Using the > switch, display items in ascending order of numbers.
a When the last item is selected, the screen is changed to the “Default value is set” screen.
(2) Using the < switch, display items in descending order of numbers.
a When the last item is selected, the screen is changed to the “All item timer stop/all item valid selector” screen.
a. Change of maintenance interval time

How to input interval
(1) Input a value between 0 and 9 at the cursor
position.
(2) The cursor is positioned at the highest-order
digit. Pressing the > or < switch increases or
decreases the value between 0 and 9.
(3) Input a desired value and press the U switch.
(4) The cursor moves to the 2nd position. Select
the digits for the all positions by performing
steps (2) and (3) above.
(5) After selecting the digit for the lowest position,
press the U switch.
a If the input interval time is acceptable, the
screen changes to the check screen.
a If the input interval time is not acceptable, the
time does not change.
(6) Return the cursor to the highest-order digit.
a The lower limit of set value is 50h.
(7) When you have entered a wrong value to a
position succeeding to the highest-order digit,
move to the highest-order digit using t switch
and repeat the procedure from the first.
a In this case, values that had been entered
remain as they are until modified.
(8) When the cursor is at the highest-order digit,
move to the higher layer using t switch.
q Select YES or NO with the < or > switch.
q The cursor (_) is blinking at the selected item. If
you have selected “YES”, press the t switch to
execute the change. If you have selected “NO”,
press it to return to the “Select maintenance
item” screen without executing the change.
a By default, the cursor is set to NO (cancel) to
prevent resetting error.
q When an interval time is changed, the remain-
ing timer time is changed as shown below.
(Interval time being set – Elapsed time from
the last replacement)
10-901 40 WD600-6
b. Selection between enabling or disabling timer 3. Setting of a default value

by item
q Select YES or NO with the < or > switch.

q When “Timer by item” is enabled at present, q The cursor (_) blinks on the selected item. If
“ON o OFF” is displayed at the lower column. “YES” is selected with the t switch, the
q When “Timer by item” is disabled at present, change is executed. If “NO” is selected, the
“OFF o ON” is displayed at the lower column. change is cancelled and the “Select mainte-
a By default, it is “ON” and the timer function is nance item” screen is returned.
enabled. a By default, the cursor is set to NO (cancel) to
prevent resetting error.
q When you disable “Timer by item”, “OFF” is
displayed at the upper column. q If the default value is executed, all the currently
q When you enable “Timer by item”, “ON” is dis- changed interval times are returned to the
played at the upper column. default values. It is executed on every item
independent of whether or not the function is
q Select YES or NO with the < or > switch. enabled for a specific item.
q The cursor (_) blinks on the selected item. If
“YES” is selected with the t switch, the q Timer remaining time shall be Default value –
change is executed. If “NO” is selected, the Elapsed time since the last replacement.
change is cancelled and the “Select mainte- a The reset frequency is not incremented and
nance item” screen is returned. remains the same as before the resetting.
a By default, the cursor is set to NO (cancel) to a Set enable for enable or disable of individual
prevent resetting error. items.
q Specify disabling the timer or releasing the dis-

abling by maintenance item.
q If you cancel the timer disabled, interval time

before having been disabled is used as the set
value.
q The timer remaining time is reset.

a The reset frequency is not incremented and
remains the same as before the resetting.
WD600-6 10-901 41
4. Selection between timer stop for all items and enable by item
*1 Press the U switch to go to the “ALL ITEMS OFF” screen.

*2 When “ALL ITEMS OFF” is selected
*3 When ALL ITEMS OFF is executed:
The timer function for all items is stopped and the “Select maintenance monitor” screen is restored.
Setting for individual items is also disabled.
When ALL ITEMS OFF is canceled:
The operation is cancelled and the MAINTENANCE MONITOR screen is restored.
*4 When “ALL ITEMS ON” is selected
*5 Select YES or NO with the < or > switch.
The cursor (_) is blinking at the selected item.
a By default, the cursor is set to NO (cancel) to prevent resetting error.
*6 When ALL ITEMS ON is executed:
Interval time being set for all items is disabled independent of whether or not it is enabled or dis-
abled for a specific item.
The timer remaining time is reset.
The reset frequency is not incremented and remains the same as before the resetting.
The “Select maintenance monitor” screen is restored. Setting for individual items is also enabled.
When ALL ITEMS OFF is canceled:
The operation is canceled and the “Select maintenance monitor” screen is restored.
10-901 42 WD600-6
Operating information display function
Outline
q The value of fuel consumption is obtained by adding the target injection amount sent from the engine
controller.
q It is not measured but calculated fuel consumption. Use it as a rough standard.
*1 The upper column displays fuel consumption The lower column displays the travel distance
[L/km or L/mile] per 1 km (or 1 mile) from the [km or mile] from the last resetting.
last resetting. The unit km or mile shall be selected depend-
It is calculated from the fuel consumption and ing on that used on the odometer.
travel distance above. The counting is stopped at 9999999.9, the
The unit km or mile shall be selected depend- upper limit.
ing on that used on the odometer.
The counting is stopped at 99999.9, the upper *3 The upper column displays the cumulative fuel
limit. consumption [L] from the last resetting.
The lower column displays the average fuel The counting is stopped at 9999999.9, the
consumption [L/h] from the last resetting. upper limit.
The counting is stopped at 99999.9, the upper The lower column displays the elapsed time [h]
limit. from the last resetting.
The counting is stopped at 9999999.9, the
*2 The upper column displays the cumulative fuel upper limit.
consumption [L] from the last resetting.
The counting is stopped at 9999999.9, the
upper limit.
WD600-6 10-901 43
*4 Calculation of (*4) is executed when the load 8) If t switch is pressed before finishing
meter is installed. (The screen is not available entering, the cursor moves to the sign
when the load meter is not installed.) position. In this case, the value remains
The upper column displays the loaded volume unchanged. Using the t switch, return to
[ton] from the last resetting. the previous screen.
The counting is stopped at 199999999.9, the 9) If the value confirmed for the lowest-order
upper limit. digit is outside the range from –50.0 to
Short ton or metric ton depends on optional +50.0, the cursor moves to the sign posi-
setting. tion with the value unchanged as with
The lower column displays the loading fre- when the t switch is pressed.
quency from the last resetting.
The counting is stopped at 65000, the upper Processing on the monitor panel:
limit. q Default value: 0.0%
(*1 – *4) q This setting allows correcting the cumulative
Calculation is done only for the duration in fuel consumption (L) in the range of –50.0 to
which the engine is run. +50.0%.
*5 Using the U switch, clear data of (*1), (*2),

(*3), and (*4) to return to the previous screen.
Using the t switch, return to the previous
screen without resetting.
Note: Other than the reset operation above,
you can reset data by initializing the monitor
panel or specifying optional setting to OFF.
Acquisition of fuel consumption (L)

q The monitor panel calculates the cumulative
fuel consumption (L) based on the momentary
fuel consumption (L/h) from the engine control-
ler.
*6 Setting gain correction

1) When the screen appears, the current set
value is displayed and the cursor is placed
on the sign (+/–).
2) When the cursor is placed on the sign,
every pressing the > or < switch displays
“+” io “–” in order.
3) Press the U switch to confirm the sign.
o Cursor moves to the highest-order digit.
4) First, the cursor appears at the highest-
order digit. Each time the > or < switch is
pressed, the value at the digit increases or
decreases between 0 and 9. (The highest-
order digit is between 0 and 2.)
5) Input a desired value and press the U
switch to confirm the entry.
6) The cursor moves to the lowest-order
digit. Select a value in the same manner
as step 4).
7) Input a value at the lowest-order digit and
press the U switch. (The screen returns
to the previous one when the entry is con-
firmed.)
10-901 44 WD600-6
Snap shot function

For this function, see the section of “Testing and adjusting: Manual snapshot function”.
WD600-6 10-901 45
Function of selecting optional device

For setting using this function, see “Testing and
Input of machine serial number (No.)

Model selection function

10-901 46 WD600-6
WD600-6 10-901 47
Rear side of machine monitor
1. Spare rotary switch (SW1)

4. Spare DIP switch (SW5-1)
Do not change settings of spare rotary switches and spare DIP switches.
10-901 48 WD600-6
WD600-6 10-901 49
Signal table by connector
CN1 (070-20-pole) [CN-C01]

Pin No. Specifications I/O Group Form of use Signal name WD600-6 Remarks
1 — — — — —
Power supply of Power supply
2 I — — —
small lamp (+24 V)
Power supply of Power supply
3 I — — —
small lamp (+24 V)
Unswitched power Power supply Unswitched power Unswitched power
4 I —
supply (+24 V) (+24 V) supply (+24 V) supply (+24 V)
Unswitched power Power supply Unswitched power Unswitched power
5 I —
supply (+24 V) (+24 V) supply (+24 V) supply (+24 V)
SW power supply Power supply SW power supply SW power supply
6 I —
(+24 V) (+24 V) (+24 V) (+24 V)
SW power supply Power supply SW power supply SW power supply
7 I —
(+24 V) (+24 V) (+24 V) (+24 V)
8 — — — — — —
9 GND I — GND GND GND
D_OUT_3
11 O A D/O sink (Spare) —
(+24 V, sink 200 mA)
D_OUT_2 (Automatic preheater
12 O A D/O sink —
(+24 V, sink 200 mA) relay)
D_OUT_1 (HST solenoid cutout
13 O A D/O sink —
(+24 V, sink 200 mA) relay)
D_OUT_0
14 O A D/O sink Buzzer (Monitor) Buzzer (Monitor)
(+24 V, sink 200 mA)
Sensor power supply Sensor power Lift pressure sensor
15 O — —
output (+24 V) supply power supply
Lift pressure and
Sensor power supply Sensor power Lift angle sensor
16 O — angle sensor power For load meter
output (+5 V) supply power supply
supply
10-901 50 WD600-6
CN2 (070-18-pole + 12-pole) [CN-C02, CN-C03]

Form of
Pin No. Specifications I/O Group Signal name WD600-6 Remarks
use
CN2A
D_IN_0
1 I B D/I+24V Headlamp Headlamp
(+24 V, 5 mA)
2 D_IN_2 (24 V, 5 mA) I B D/I+24V Starting motor C Starting motor C
Auto grease A
3 D_IN_4 (24 V, 5 mA) I B D/I+24V Auto grease A If equipped
(If equipped)
4 D_IN_6 (24 V, 5 mA) I B D/I+24V (Direction F) —
5 D_IN_8 (24 V, 5 mA) I B D/I+24V (Direction R) —
6 D_IN_10 (24 V, 5 mA) I B D/I+24V (Spare) —
D_IN_12
7 I C D/I+24V Winker right Winker right
(NSW 24 V, 5 mA)
D_IN_14 Monitor mode switch 1 Switch for monitor
8 I C D/I+24V U switch input
(NSW 24 V, 5 mA) U input operation
9 GND O — — SIGNAL GND SIGNAL GND
10 D_IN_1 (24 V, 5 mA) I B D/I+24V Starting motor ACC Starting motor ACC
11 D_IN_3 (24 V, 5 mA) I B D/I+24V Preheat operation —
Auto grease B
12 D_IN_5 (24 V, 5 mA) I B D/I+24V Auto grease B If equipped
(If equipped)
13 D_IN_7 (24 V, 5 mA) I B D/I+24V (Direction N) —
D_IN_13
16 I C D/I+24V Winker left Winker left
(NSW 24 V, 5 mA)
D_IN_15 Monitor mode switch 1 t Switch for monitor
17 I C D/I+24V t switch input
(NSW 24 V, 5 mA) input operation
18 A_IN_0 (0 – 30 V) I H A/I Alternator R Alternator R
CN2B
D_IN_16 Brake oil pressure Brake oil pressure
19 I D D/IGND
(24 V/GND, 5 mA) (Front) (Front)
D_IN_18 Brake oil level
20 I D D/IGND —
(24 V/GND, 5 mA) (Front)
D_IN_20
21 I D D/IGND Air cleaner clogging 1 Clogging of air cleaner
(24 V/GND, 5 mA)
Parking brake
D_IN_22
22 I D D/IGND (Spare) emergency release
(24 V/GND, 5 mA)
switch signal
D_IN_24 Transmission filter Transmission filter
23 I E D/IGND
(24 V/GND, 5 mA) clogging clogging
24 GND O — GND Sensor GND Sensor GND
D_IN_17 Brake oil pressure Brake oil pressure
25 I D D/IGND
(24 V/GND, 5 mA) (Rear) (Rear)
D_IN_19 Brake oil level
26 I D D/IGND —
(24 V/GND, 5 mA) (Rear)
D_IN_21
27 I D D/IGND Air cleaner clogging 2 —
(24 V/GND, 5 mA)
D_IN_23
28 I D D/IGND (Spare) —
(24 V/GND, 5 mA)
D_IN_25 (Seat belt fastening
29 I E D/IGND —
(24 V/GND, 5 mA) warning)
30 A_IN_0 (0 – 30 V) I H A/I Small lamp switch Small lamp switch
WD600-6 10-901 51
CN3 (070-18-pole + 12-pole) [CN-C04, CN-C05]

Form of
use
CN3A
D_IN_26
1 I E D/IGND Parking brake Parking brake
(24 V/GND, 5 mA)
D_IN_28
2 I E D/IGND Engine oil pressure —
(24 V/GND, 5 mA)
D_IN_30 Normal emergency Normal emergency
3 I E D/IGND
(24 V/GND, 5 mA) steering steering
D_IN_32 For load meter
4 I F D/IGND Subtotal switch —
(24 V/GND, 5 mA) (Not used)
D_IN_34
5 I F D/IGND High beam switch High beam switch
(24 V/GND, 5 mA)
D_IN_36
6 I G D/IGND Service function 2 Service function 2
(24 V/GND, 5 mA)
D_IN_38 Monitor mode switch 2 < Switch for monitor
7 I G D/IGND < switch input
(24 V/GND, 5 mA) switch input operation
8 P_IN_0(0.5Vp-p) I M P/I (Spare) —
9 GND O — GND GND GND
D_IN_27
10 I E D/IGND Engine coolant level Engine coolant level
(24 V/GND, 5 mA)
D_IN_29
11 I E D/IGND Engine oil level Engine oil level
(24 V/GND, 5 mA)
12 N.C. I E D/IGND N.C. N.C.
D_IN_33 For load meter
13 I F D/IGND Cancel switch —
(24 V/GND, 5 mA) (Not used)
D_IN_35
14 I F D/IGND (Spare) —
(24 V/GND, 5 mA)
D_IN_37 Monitor mode switch 2 >
15 I G D/IGND > switch input
(24 V/GND, 5 mA) input
D_IN_39
16 I G D/IGND Low steering oil pressure Spare
(24 V/GND, 5 mA)
17 P_IN_1(5Vp-p) I M P/I (Spare) —
18 N.C. — — N.C. N.C.
CN3B
A_IN_2
19 I J A/I Fuel level sensor Fuel level sensor
(High-resistance input)
A_IN_4 Torque converter oil Torque converter oil
20 I J A/I
(High-resistance input) temperature sensor temperature sensor
Engine coolant
A_IN_6 temperature sensor
21 I K A/I —
(High-resistance input) (For automatic
preheater)
Lift pressure sensor For load meter
22 A_IN_8 (0 – 5 V) I L A/I —
(Rod) (Not used)
Battery electrolyte level Battery electrolyte level
23 A_IN_10 (0 – 14 V) — — If equipped
A (If equipped)
24 GND O — GND SIGNAL GND GND
A_IN_3 Hydraulic oil temperature Hydraulic oil temperature
25 I J A/I
(High-resistance input) sensor sensor
A_IN_5 Engine coolant tempera- Brake oil temperature
26 I J A/I
(High-resistance input) ture sensor sensor
Lift pressure sensor For load meter
27 A_IN_7 (0 – 5 V) I L A/I —
(Bottom) (Not used)
For load meter
28 A_IN_9 (0 – 5 V) I L A/I Lift angle sensor —
(Not used)
29 GND O — GND SIGNAL GND GND
Battery electrolyte level
30 A_IN_11 (0 – 14 V) — — —
B
10-901 52 WD600-6
CN4 (070 12-pole) [CN-C06]

Form of
use
Monitor – transmission
1 S_NET(+) I/O N S-NET work equipment —
controller
Monitor – transmission
2 S_NET(+) I/O N S-NET work equipment —
controller
Cummins engine con-
troller, VSM controller Communication
3 CAN+ I/O P
communication (CAN (+))
(CAN (+))
4 S_NET(–) O N S-NET S_NET GND —
5 S_NET(–) O N S-NET S_NET GND —
6 GND O — GND S_NET shield GND
7 GND O — GND CAN shield CAN: twisted only
Cummins engine con-
Communication
8 CAN- I/O P troller communication
(CAN (–))
(CAN (–))
9 (NC)
10 (NC)
11 (NC)
12 (NC)
CN5 (070-14-pole) [CN-C07]

Form of
use
1 (NC) — — —
RS232C serial
2 RS232C_1_RTS I/O Q —
communication
RS232C serial
3 RS232C_1_RD I Q RD —
communication
4 (NC) I R RD N.C. N.C.
5 (NC) I/O R N.C. N.C.
For load meter
BUSY input for load
6 — — — (Spare for medium
meter printer
and large models)
7 (NC) — — —
RS232C serial
8 RS232C_1_CTS I/O Q —
communication
RS232C serial
9 RS232C_1_TX O Q TX —
communication
RS232C serial
10 RS232C_1_SG O Q —
communication
11 (NC) O R N.C. N.C.
12 (NC) O R TX N.C. N.C.
13 (NC) I/O R N.C. N.C.
14 (NC) — — N.C. N.C.
WD600-6 10-901 53
CN6 (040 8-pole)

Form of
use
1 RS232C_0_TXD O S — —
2 (NC) — — N.C. N.C.
3 RS232C_0_TXD O S — —
4 (NC) — — N.C. N.C.
5 RS232C_0_RXD I S — —
6 (NC) — — N.C. N.C.
7 RS232C_0_RXD I S — —
8 GND O — GND —
Setting switches (On circuit board)

Switch Form of
Specifications I/O Group Signal name WD600-6 Remarks
No. use
1 16 Posi rotary switch 1 I — Selection of model (Spare)
Selection of
2 16 Posi rotary switch 2 I — (Spare)
specification
Selection of
3 16 Posi rotary switch 3 I — (Spare)
specification
4 2 Posi DIP switch 1 I — Selection of options (Spare)
10-901 54 WD600-6
WD600-6 10-901 55
SEN04996-02
WD600-6 Wheel dozer

©2019 KOMATSU
All Rights Reserved
10-901 56
SEN04997-00
WHEEL DOZER
WD600-6

WD600-6 55001 and up


Work equipment control system...................................................................................................................... 2
Transmission controller system..................................................................................................................... 28
WD600-6 10-902 1
SEN04997-00 Work equipment control system
Work equipment control system 1
Work equipment controller
10-902 2 WD600-6
Work equipment control system SEN04997-00
WD600-6 10-902 3
1. Work equipment control

1) Work equipment control input and output
10-902 4 WD600-6
2) Work equipment control lever operation
Function
q The work equipment controller operates the work equipment by detecting the operating stroke
of left raise/lower, left-right tilt/forward-reverse pitch from the signals of the work equipment
lever potentiometer, and operating the main spool by operating each EPC valve attached to the
main valve with current control.
WD600-6 10-902 5
q The work equipment control lever is equipped with a lift lower detent notch and adjusted so that
it will operate at the maximum speed just before the detent. The range beyond the lower detent
is the "lift float" operation position, where the lift is operated by external forces.
q The lift is pitched or tilted by operating the work equipment control lever to the right and left,
and pitched forward or backward only while work equipment control lever is operated with the
pitch selector switch on it depressed.
10-902 6 WD600-6
3) Work equipment neutral lock
Function
q When the work equipment lock lever is operated to the lock position, the lock switch becomes
OPEN, and the controller stops the operation of the work equipment by turning ON the work
equipment neutral lock valve, cutting EPC pilot basic pressure.
a While the work equipment is locked, the detent does not operate, and the lever is not held at
the detent position.
q The safety function, in which the work equipment is continued to be locked until the work
equipment control lever is temporarily returned to the neutral position, even if the work equip-
ment is unlocked, is incorporated.
Operation table
Operation by Operation
Input of controller Work equipment control Output of controller
man of machine
Work Work equipment Work equipment lever Work equipment Oil
equipment lever lever switch potentiometer neutral lock valve pressure
Lock OFF ON
— Cut
(LOCK) (OPEN) (24V)
Free to Lock OFF Work equipment control ON
Cut
(unlocking) (OPEN) lever being operated (24V)
After releasing, lever neutral
Lock to Free OFF OFF
of all work equipment Operating
(unlocking) (OPEN) (OPEN)
detected once
Free ON OFF
— Operating
(FREE) (CLOSE) (OPEN)
WD600-6 10-902 7
4) Neutral position and work equipment speed
Function
q The work equipment control lever has neutral play of 5% in the lever stroke, and it is adjusted
so that the work equipment will start working from the position beyond the play.
10-902 8 WD600-6
5) Tilt priority control
Function
q Since this machine is equipped with CLSS, the lift can be tilted or pitched and lifted simulta-
neously. However, this machine is also equipped with the function of preventing the lift from ris-
ing while it is tilted or pitched largely so that the operation feeling of the former models will be
maintained.
q It is realized by limiting the maximum speed of lift raise (table below) for the tilt/pitch speed.
Tilt/pitch speed 0% 20% 40% 60% 70% 100%
Maximum speed of lift raise 100% 80% 30% 0% 0% 0%
6) Lift raise/lower stop modulation
Function
q The work equipment controller operates modulation, when the lift stop operation is performed more
suddenly than a certain speed by the operator, for easing stop shock of lift raise/lower.
q The operation of this stop modulation function can be changed through setting.
a For the method to change and precautions, refer to “Testing and adjusting: changing the lift
raise/lower stop modulation”.
Case A: Modulation rate is 0%

When lever command flow rate > modulation command flow rate
q The output is controlled according to the lever command flow rate.
Case B: Modulation rate is 200%

When lever command flow rate < modulation command flow rate
q The output is controlled according to the modulation command flow rate.
a: Modulation rate is 100% (When machine is delivered)
b: Modulation starting point: 30% of flow rate command.
WD600-6 10-902 9
7) Adjusting range before lever detent position and work equipment starting current
Function
q The work equipment controller has an adjusting function for correction dispersion.
q The range before the detent position is adjusted so that the lever potentiometer voltage at the
detent position will be saved, ensuring control before and after the detent. When it is not
adjusted, such phenomena as “the positioner does not operate normally before and after the
detent,” or “the lever position of lift arm float is not normal” may occur.
q When the work equipment starting current is not adjusted, such phenomena as “the neutral
dead zone is large” or “dashing/stopping shock of the work equipment becomes large” may
occur.
a For the adjusting procedure, refer to “Testing and adjusting: Adjustment of lift raise and EPC
dead zone variations, Adjustment of lift lower (float) lever position before detent and EPC dead
zone variations, and Adjustment of pitch/tilt lever and EPC dead zone variations”.
q Adjusting the starting current means to make the controller recognize the current at which the
work equipment starts moving, or the current at which the work equipment valve spool is
“opened”.
q When the starting current is adjusted, the spool is opened and closed once and the EPC cur-
rent output at this time is used as the starting current to make the effect of the spool operation
hysteresis constant.
10-902 10 WD600-6
q The range before lever detent is a range where the lever operating effort before the notch
changes suddenly.
8) Operation of lift lower detent solenoid

q When the lift lower lever is operated more than a certain point, the lower detent solenoid is
turned ON. When the former exceeds the notch, the latter is maintained.
WD600-6 10-902 11
2. Pump swash plate control
Function
In pump swash plate control, “horsepower loss decrease function in pump relief” and “pickup auxiliary
function when engine speed is low” are included, and based on calculation results of each function, data
with less pump delivery (larger pump EPC current) will be selected.
1) Horsepower loss decrease function in pump relief

q Horsepower loss is decreased by controlling pump delivery in relief, changing the command
value of the pump swash plate, when the work equipment pump is relieved.
q Output to pump EPC is changed with input signal of the loader pump pressure sensor.
10-902 12 WD600-6
q The work equipment controller operates pump EPC in 200 mA until loader pump pressure reaches 21.7
MPa {220 kg/cm2}, and when it becomes 22.5 MPa {230 kg/cm2} or higher, the controller operates pump
EPC in 400 mA.
q In this control, when the delivery is increased (the EPC current is decreased), the EPC current takes 0.4
seconds to be decreased from 700 mA to 200 mA in order to prevent sudden operation due to rapid
increase of the oil flow rate.
Pump pressure Current value (A) Pump flow rate

21.7 MPa
0.2 100%
{220 kg/cm2}
22.5 MPa
0.4 C 60%
{230 kg/cm2}
WD600-6 10-902 13
2) Pickup auxiliary function when engine speed is low

q When the engine speed is low and torque is low, acceleration of the engine in work equipment
operation is aided by limiting the pump delivery.
q The work equipment controller operates pump EPC in 0.9 A until engine speed reaches 500
rpm, and when it becomes 950 rpm or higher, the controller operates pump EPC in 0.2 A.
Engine speed Current value (A) Pump flow rate
500 rpm 0.9 MIN
700 rpm 0.569 C 40%
950 rpm 0.2 100%
10-902 14 WD600-6
3. AJSS control
Function
AJSS is a turn control system with a joystick, which senses articulation angle and faithfully bends the
machine in accordance with the tilting angle of AJSS lever, by adopting pilot oil pressure method with
feedback mechanism.
1) AJSS system
q In AJSS, when the joystick steering lever and the frame are connected with link through the
rotary valve, and deviation occurs between the operating angle of the lever and the machine
frame turning angle, the pilot oil pressure is applied to the steering valve from the rotary valve,
and the machine turns in the direction of lever operation until the operating angle of the lever
and the machine frame turning angle match and the rotary valve closes.
q Even if the EPC valve malfunctions, the operator can steer the machine with the function of the
pressure compensation valve of AJSS. In addition, even if the engine stops, the operator can
steer the machine with the operation of the diverter valve as long as the transmission is rotat-
ing (the machine is traveling).
WD600-6 10-902 15
10-902 16 WD600-6
2) AJSS neutral interlock

q In AJSS, since there is a possibility that the machine operates and turns immediately after the
engine is started, if the joystick steering lever is in a position other than neutral (there is devia-
tion between the operating angle of the lever and the machine frame angle), the engine start
signal is cut, and starting the engine is prohibited by turning the neutral safety relay on.
q If the steering lock lever is locked, and the joystick steering lever is in a position other than neu-
tral while the engine is operating, there is a possibility that the machine turns immediately after
the lever is unlocked, the caution buzzer is sounded in order to call attention of the operator.
q Since the machine does not turn with the steering locked, operation of FR is prohibited with the
transmission controller. Therefore, if the forward-reverse switch of the joystick steering knob is
set to a position other than neutral while the steering is locked, because there is a possibility
that forward-reverse operation occurs immediately after unlocked, the caution buzzer is
sounded in order to call attention of the operator.
Conditions Reference Neutral safety control
Steering pilot Reference
Joystick Steering Engine start
Engine pressure Machine state Transmission
steering lever lock lever neutral safety
NET signal neutral safety
Neutral The key is on,
Without pressure
position Locked the engine is
(switch = OPEN)
deviation stopped
angle less Without pressure
than 6° Unlocked
(switch = OPEN)
Stopped
(below Starting the
500 rpm) Operation engine is not pos-
Without pressure
position Locked sible when the
(switch = OPEN)
deviation joystick steering
angle more lever is operated
than 6° Without pressure
Unlocked
(switch = OPEN)
Transmission
Neutral shift is not possi-
Without pressure
position Locked Lever locked ble when the
(switch = OPEN)
deviation steering is locked
angle less (N maintenance).
Operat- than 6° With pressure Normally
Unlocked
ing (500 (switch = CLOSE) operating
rpm or Transmission
above) Operation The lever is shift is not possi-
Without pressure The caution
position Locked operated while it ble when the
(switch = OPEN) buzzer sounds
deviation is locked steering is locked
angle more (N maintenance)
than 6° With pressure Normally
Unlocked
(switch = CLOSE) operating
WD600-6 10-902 17
3) Speed-sensing steering
q In AJSS, the steering characteristics is changed in accordance with travel speed, by controlling
the pilot basic pressure of the rotary valve with EPC.
q When travel speed is 7 km/h or less, it is controlled to turn speedily when the lever operating
stroke is large, prioritizing V shape work efficiency.
q When travel speed is higher, the turning speed is reduced from the neutral range of lever oper-
ating stroke, limiting sudden turning operation in rapid lever operation.
q It has three changeable tables.
a For the adjustment method and the characteristics of each table, refer to “Testing and adjust-
ing: Modification of AJSS oil pressure command table pattern”.
AJSS characteristics
4) Adjusting neutral position of AJSS

q AJSS recognizes opening of the rotary valve made by lever operation with the frame angle
sensor and lever angel sensor.
q Adjust the neutral position of AJSS to cancel the installation error of the sensors when the
machine travels straight and the rotary valve is set in neutral.
a For adjustment method, see “Testing and adjusting: Adjustment of AJSS neutral position”.
10-902 18 WD600-6
4. AJSS turn signal control

q In AJSS, since the turn signal can not be reset automatically, the turn signal automatic reset opera-
tion is performed using the frame angle input in the controller.
q This control is operated only in AJSS. (In machines with steering, automatic reset is performed with
the mechanism of the conventional turn signal switch installed in the steering.)
1) Machine circuit
2) Operating and stopping turn signal

The operation and stop conditions of the right turn signal are shown below. (Same for the left turn
signal)
Operation: When the right turn signal switch is pressed while the right turn signal is stopped, the
turn signal flashes because the right turn signal relay operates. The flash operation is
performed with the flasher unit.
Stop: Perform the following operation while the right turn signal is operating in order to stop
the right turn signal.
Press the right turn signal switch again.
Press the left turn signal switch. In this case, the left turn signal will start flashing at the
same time.
After the turn signal lights up, when the machine turns right for 10° or more and then the
machine is set in the straight travel position (8° or less), the right turn signal will stop.
(Automatic stop)
After the turn signal lights up, when the machine turns left for 10° or more, the right turn
signal will stop. (Automatic stop)
WD600-6 10-902 19
1) List of display contents of the real-time monitor
In WD600-6, the state of the controller input and output signals can be checked using the real-time
monitor function of the monitor.
The following table shows the display items and display contents in normal operation of the real-
time monitor in relation to the work equipment controller:
Display of item Display contents in
No. Item ID No. Contents of display data Remarks
name normal operation
Software part Part No. of software is Depends on the soft-
1 20202 VERSION
number displayed ware number
Application Application version Depends on application
2 20225 VERSION APP
Version number is displayed version number
VERSION Data version number is Depends on data ver-
3 Data Version 20226
DATA displayed sion number
When work equipment
is in neutral
Converted value pres- : 2.0 ± 2.0 MPa
Loader pump
4 94700 PUMP PRESS sure of loader pump oil {20 ± 20 kg/cm2}
pressure
pressure is displayed Work equipment relief
: 22.5 ± 2.0 MPa
{230 ± 20 kg/cm2}
When work equipment
Input voltage value of is in neutral
Loader pump
5 94701 PUMP PRESS loader pump oil pres- : 0.70 ± 0.2V
pressure
sure is displayed Work equipment relief
: 2.36 ± 0.2V
Li (800 rpm)
: 421 ± 30 mA
Hi (above 950 rpm)
Loader pump
Loader pump EPC : 200 ± 10 mA
EPC current
6 94500 PUMP EPC DIR output command cur- Work equipment relief
value
rent value is displayed (Hi): 400 ± 10 mA
(command)
Engine stop
(below 500 rpm)
: 900 ± 10 mA
Results of pump deliv-
7 Pump delivery 94600 PUMP FLOW ery calculation are dis- — Not used
played
Calculation results of lift
8 Lift angle 06002 BOOM ANG — Not used
angle is displayed
Input voltage value to lift
9 Lift angle 06005 BOOM ANG angle sensor potentiom- — Not used
eter is displayed
When machine is travel-
ing straight
Operation angle con-
: 0.0 ± 1.0 deg
verted value of AJSS
10 Frame angle 94400 FRAME ANGLE When fully turned right
frame potentiometer is
: 39.0 ± 4.0 deg
displayed
When fully turned left
: –39.0 ± 4.0 deg
Number of lift Number of lift lever Display in accordance
11 lever opera- 42100 BOOM LVR operations is displayed with the number of lever
tions in the unit of thousand operations
10-902 20 WD600-6

Neutral
2.50 V ± 0.100 V
Raise (stroke end)
Lever potenti- Input voltage value to lift
4.11 V ± 0.25 V
12 ometer voltage 42000 BOOM POT1 lever potentiometer 1 is
Lower (before detent)
lift 1 displayed
1.11 V ± 0.25 V
Float (detent position)
0.89 V ± 0.25 V
Neutral
2.50 V ± 0.100 V
Raise (stroke end)
Lever potenti- Input voltage value to lift
0.89 V ± 0.25 V
13 ometer voltage 42001 BOOM POT2 lever potentiometer 2 is
Lower (before detent)
lift 2 displayed
3.89 V ± 0.25 V
Float (detent position)
4.11 V ± 0.25 V
Number of Number of pitch/tilt lever Display in accordance
14 pitch/tilt lever 42101 BUCKET LVR operations is displayed with the number of lever
operations in the unit of thousand operations
Neutral
2.50 V ± 0.100 V
Tilt (before detent)
Lever potenti- Input voltage value to
3.89 V ± 0.25 V
15 ometer voltage 42002 BUCKET POT1 pitch/tilt lever potenti-
Tilt (detent position)
pitch/tilt 1 ometer 1 is displayed
4.11 V ± 0.25 V
Full dump
0.89 V ± 0.25 V
Neutral
2.50 V ± 0.100 V
Lever potenti- Input voltage value to Pitch rear/Tilt L.H.
16 ometer voltage 42003 BUCKET POT2 pitch/tilt lever potenti- (stroke end)
pitch/tilt 2 ometer 2 is displayed 0.89 V ± 0.25 V
Pitch front/Tilt R.H.
4.11 V ± 0.25V
Neutral
Lift raise EPC EPC output command
RAISE EPC 0 ± 10 mA
17 current (com- 41900 current value to lift raise
DIR Max.
mand) is displayed
929 ± 10 mA
Neutral
±10 mA
Lift lower EPC EPC output command
LOWER EPC Before detent
18 current (com- 41901 current value to lift
DIR : 640 ± 10 mA
mand) lower is displayed
Float position
: 1,000 ± 10 mA
Neutral
L.H. pitch rear/ EPC output command 0 ± 10 mA
Tilt L.H. EPC current value to Pitch Tilt (Max.)
19 41902 TILT EPC DIR
current (com- rear/Tilt L.H. is dis- 820 ± 10 mA
mand) played Pitch (Max.)
596 ± 70 mA
Neutral
L.H. pitch EPC output command 0 ± 10 mA
front/Tilt R.H. DUMP EPC current value to Pitch Tilt (Max.)
20 41903
EPC current DIR front/Tilt R.H. is dis- 820 ± 10 mA
(command) played Pitch (Max.)
596 ± 70 mA
WD600-6 10-902 21

Lever in neutral
: 384 ± 10 mA
Lever operated fully to
J/S EPC cur- EPC output command Check when
the right
21 rent (com- 41908 AJSS EPC DIR current value to AJSS is AJSS is
595 ± 10 mA
mand) displayed locked
Lever operated fully to
the left
595 ± 10 mA
J/S right EPC EPC output command
J/S EPC DIR In WD600-6, there is no
22 current (com- 41904 current value to J/S
RH corresponding functions
mand) right is displayed
J/S left EPC EPC output command
J/S EPC DIR In WD600-6, there is no
23 current (com- 41905 current value to J/S left
LH corresponding functions
mand) is displayed
In WD600-6, there is no
24 ometer voltage 42004 J/S POTI1 J/S lever potentiometer
corresponding functions
J/S1 1 is displayed
In WD600-6, there is no
25 ometer voltage 42005 J/S POTI2 J/S lever potentiometer
corresponding functions
J/S2 2 is displayed
R.H. Pitch rear Neutral
EPC output command
ECMV current 0 ± 10 mA
26 41906 3RD EPC1 DIR current value to R.H.
value (com- Max.
Pitch rear is displayed
mand) 631 ± 10 mA
R.H. Pitch Neutral
EPC output command
front ECMV 0 ± 10 mA
27 41907 3RD EPC2 DIR current value to R.H.
current value Max.
Pitch front is displayed
(command) 631 ± 10 mA
Number of 3rd Number of 3rd lever
28 lever opera- 42102 3RD LVR operations is displayed — Not used
tions in the unit of thousand
29 ometer voltage 42006 3RD POT1 3rd valve lever potenti- — Not used
3rd valve 1 ometer 1 is displayed
30 ometer voltage 42007 3RD POT2 3rd valve lever potenti- — Not used
3rd valve 2 ometer 2 is displayed
ing straight
Neutral
Check when
Operation angle con- : 0.0 ± 0.5 deg
AJSS lever the engine is
verted value of AJSS Turn the lever fully to
31 operation 94300 AJSS LEVER stopped, or
lever potentiometer is the right
angle AJSS is
displayed : 20.0 ± 3.0 deg
locked
Turn the lever fully to
the left
: –20.0 ± 3.0 deg
ing straight
Neutral
Check when
: 2.5 ± 0.3 V
AJSS lever Input voltage value of the engine is
32 potentiometer 94301 AJSS LEVER AJSS lever potentiome- stopped, or
the right
voltage ter is displayed AJSS is
: 3.33 ± 0.5 V
locked
the left
: 1.67 ± 0.5 V
10-902 22 WD600-6

ing straight
AJSS frame Input voltage value of : 2.5 ± 0.3 V
33 potentiometer 94401 FRAME ANGLE AJSS frame potentiom- When fully turned right
voltage eter is displayed : 0.96 ± 0.5 V
When fully turned left
: 4.04 ± 0.5 V
ing straight
Neutral
AJSS S/T Deviation angle value of Check when
S/T DEFLEC- : 0.0 ± 0.5 deg
34 deviation 94800 AJSS frame and lever is AJSS is
TION Lever fully to the right
angle displayed locked
: 20.0 ± 2.0 deg
Lever fully to the left
: –20.0 ± 2.0 deg
The state of digging
35 Digging flag 94900 WORK FLAG — Not used
judgment is displayed
00000000
(Semi auto SW = OFF)
The state of
Input signal 10000000
36 40910 input signal is Constantly 00000000 Not used
D_IN_0 – 7 (Semi auto SW = ON)
displayed
01000000
(Semi auto SW = ON)
00010000 D-IN-11
Input signal The state of input signal
37 40911 D-IN--8-----15 (Pitch operation switch : Pitch opera-
D_IN_8 – 15 is displayed
= ON) tion switch
D-IN-16
10000000
: Work equip-
(Work position)
ment N lock
Input signal The state of input signal 00000000
38 40912 D-IN-16-----23 SW
D_IN_16 – 23 is displayed (Lock position)
D-IN-17
01000000
: Starter termi-
(Starter operation)
nal C signal
D-IN-30
00000000
: Right winker
00000010
Input signal The state of input signal SW
39 40913 D-IN-24-----31 (Right winker SW = ON)
D_IN_24 – 31 is displayed D-IN-31
00000001
: Left winker
(Left winker SW = ON)
SW
Input signal
D_IN_32 – 39 There is no used items
(Work equip- The state of input signal in this data
40 40961 D-IN-32-----39
ment controller is displayed 00000000 is constantly
does not have displayed
33 – 39)
10000000 D-OUT-0
(Lock position) : Work equip-
ON/OFF output state of
ON/OFF out- 00000000 ment N lock
SOL_OUT0 to 7
41 put 40952 D-OUT--0------7 (Unlock neutral) SOL
'0' is displayed when
D_OUT0--7 00100000 D-OUT-2
setting current output
(Float detent SOL = : Lift float
ON) detent SOL
SOL_OUT8 to 13 and
ON/OFF out- There is no used items
42 put 40953 D-OUT-8-----15 in this data
SIG_OUT0 and 1
D_OUT8--15 Constantly 00000000
'0' is displayed when
setting current output
WD600-6 10-902 23

D-OUT-16
: Operate
10000000
SIG_OUT2 to 3 winker right
(Operate winker right)
ON/OFF out- HSW_OUT0 to 1 D-OUT-17
01000000
43 put 40954 D-OUT-16----23 ON/OFF output state of : Operate
(Operate winker left)
D_OUT16--23 BATT_RY_OUT is dis- winker left
00001000
played D-OUT-20
(Operate safety relay)
: Operate
safety relay
10-902 24 WD600-6
6. Diagnosis
1) Function of troubleshooting
The work equipment controller monitors the input and output signals constantly for troubleshooting
for the system.
If any abnormality is detected by self-diagnosis, the information on it is transmitted through the net-
work to the machine monitor. When abnormality occurs, it can be confirmed on the machine moni-
tor/VHMS.
WD600-6 10-902 25
Work equipment controller
10-902 26 WD600-6
Input and output signals

DEUTSCH-24P [CN-L05]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 Pitch/tilt lever potentio B Input 13 Lift lever potentio B Input
2 Loader pump press. sensor Input 14 NC Input
3 AJSS frame potentio Input 15 NC Input
4 GND_SIG_D 16 NC Output
5 NC Input 17 NC Input
7 Pitch/tilt lever potentio A Input 19 Lift lever potentio A Input
9 AJSS lever potentio Input 21 GND_SIG_A
10 GND_SIG_D 22 PWR_OUT_5V_0 Output
DEUTSCH-40P(1) [CN-L06]
signal signal
1 NC Output 21 NC Input/Output
2 Winker SW. right Input 22 COMM_CAN_L_O Input/Output
3 NC Input 23 NC Input/Output
4 NC Input 24 PWR_CTR_EXT Input
5 NC Input 25 Starter switch(IGN-C) Input
8 Winker relay left Output 28 NC Input
9 NC Output 29 NC
11 NC Output 31 NC
12 NC 32 COMM_CAN_H_O Input/Output
13 NC Input 33 NC Input/Output
14 NC Output 34 NC
15 NC Input 35 Lever prohibiting equipment SW. Input
18 Winker relay right Output 38 Winker SW. left Input
19 NC Output 39 NC
signal signal
1 PWR_IN_BATT Input 21 GND_PWR
2 PWR_IN_BRY Input 22 PWR_IN_BRY Input
3 GND_ACT 23 GND_ACT
4 Safety relay Output 24 PWR_CTR_KEY Input
5 Left Tilt/Left Pitch Back EPC Output 25 Right Pitch Back Output
6 Lifting EPC Output 26 AJSS EPC Output
7 Work neutral lock solenoid Output 27 Magnetic detent of lever float Output
8 NC Output 28 NC Output
12 PWR_IN_BRY Input 32 GND_PWR
13 GND_ACT 33 GND_PWR
14 PWR_CTR_KEY Input 34 NC Output
15 Right Tilt/Left Pitch Forward EPC Output 35 Right Pitch Forward Output
16 Lowering EPC Output 36 Loader pump EPC Output
20 NC Input 40 Pitch SW. Input
WD600-6 10-902 27
SEN04997-00 Transmission controller system
Transmission controller system 1
1. Electrical circuit diagram

Transmission controller electrical circuit diagram (steering wheel specification)
Lockup
10-902 28 WD600-6
Transmission controller system SEN04997-00
WD600-6 10-902 29
Transmission controller electrical circuit diagram (AJSS specification)

Lockup
10-902 30 WD600-6
WD600-6 10-902 31
2. Transmission controller gear shifting control

1) Electronic modulation function
To reduce the shocks made when the gear speed is changed (when the clutch is engaged), the
modulation control is applied. The clutch oil pressure is controlled properly for the condition of the
hydraulic circuit, depending on the engine speed, transmission oil temperature, travel speed, and
gear shifting pattern and according to the transmission modulation data table saved in the transmis-
sion controller memory so that the transmission will be set in any gear speed (including the lockup
clutch) smoothly.
The modulation control is also performed for the clutch on the side to be turned off in order to
reduce lowering of the torque.
If an abnormal time lag is made in gear shifting, the learning function corrects the trigger operation
time automatically.
2) Display of gearshift
The transmission controller displays the state of input signal related to gearshift by sending to the
machine monitor via network.
1] Directional indicators
The directional indicators of the machine monitor display the signal input state of the directional
lever, which is input to the transmission controller. Therefore, when the lever is in neutral posi-
tion, and there is no input signal to the transmission controller, the directional indicators totally
go out, and if two signals are input due to a problem, the two indicators may light up at the
same time.
If the directional lever is in “R” state, the backup lamp relay will be operated, and the back lamp
and back buzzer will be operated.
2] Gear speed indicators

The gear speed indicators of the machine monitor display the signal input state of the gear
speed lever, which is input to the transmission controller. Therefore, when the lever is in neutral
position, and there is no input signal to the transmission controller, the gear speed indicators
totally go out, and if two signals are input due to a problem, an indicator different from the lever
position may light up, because priority is given to higher gear speed.
3] Display of actual gear speed

The actual gear speed display of the machine monitor shows the state of the gear speed and
travel direction, which is output from the transmission controller. When the directional lever is in
“N,” it will be “N” display, and when the directional lever is in “F” or “R,” it will be “F” or “R” +
gear speed display. While the parking brake is operating, this will always be “N” display, but
when the clutch is turned off due to operation of the transmission cut-off brake, there will be no
“N” display.
10-902 32 WD600-6
3) Automatic gear shifting function

In this function, auto shift, in which gear speed is automatically decided depending on travel speed,
and manual shift, in which the speed is decided as the gear speed of the gearshift lever, are
included. In auto shift, the auto shift indicator of the machine monitor lights up, and shifting up/down
and ON/OFF of the lockup clutch are changed with the engine power mode and selected shift
mode.
There are two modes, H/L, in auto shift, whose gearshift points are different depending on the
engine power mode.
In auto shift, shifting up/down are controlled in accordance with the directional lever, gearshift lever,
travel speed, accelerator pedal opening ratio, and data saved in the memory of the transmission
controller according to the engine speed. For the gearshift point of each mode, refer to “3. Auto-shift
points table.”
1] Gearshift lever in the 1st to 4th (when steering option is selected)

The maximum gear speed (gear shifting range) used in the automatic gear shifting operation is
limited.
In the automatic gear shifting operation, the vehicle usually starts in the 2nd gear speed.
Accordingly, if the gearshift lever is in 4th, the gear is shifted up and down between the 2nd
gear speed and 4th gear speeds, and the vehicle starts in the 1st gear speed only when the
kick-down function is used.
2] AJSS
Refer to the section of AJSS.
3] Directional lever in “N” position

The gear speed of transmission gearshift in neutral position is changed in accordance with
travel speed, but display will always be “N”.
4) Shift hold function

q The shift hold function will hold the current gear speed when the hold switch is pressed if the
auto-shift mode is selected, and will not shift up even when the travel speed is increased. Even
if the travel speed is decreased, the gear will not be shifted down.
q While the shift hold function is operating, the shift hold indicator of the machine monitor lights
up. When the shift hold switch is pressed again, the hold will be released, and the indicator will
go out.
q The hold will be released automatically also by the directional lever, gearshift lever, and kick-
down switch operation.
ON/OFF state of lockup will not be held.
5) Kickdown function
1] Kickdown in manual shift operation
q The kickdown switch operates only in the forward 2nd gear speed (F2), and the transmis-
sion is set in the forward 1st gear speed (F1). Operation of the kickdown switch is ignored
in any gear speed other than (F2).
q After the actual gear speed becomes (F1) due to kickdown switch operation, the kickdown
function will be released and the transmission will be set in the gear speed of the lever,
when the directional lever is operated to a position other than forward, or the gearshift
lever is operated to a position other than the 2nd gear speed.
WD600-6 10-902 33
2] Kickdown in auto-shift operation

q The kickdown function will work regardless of the lever position, if the directional lever is in
a position other than N and the gearshift lever is in a position other than the 1st gear
speed.
q The gear speed selected by the operation of the kickdown switch depends on the travel
speed as shown in the following table.
q After the transmission gear is shifted because of the kickdown switch operation, ordinary
gear shift will be performed in accordance with the auto-shift points table, after the time
due to the no-shift time is passed or when the directional lever is operated.
<Reference>
Gear speed before Output shaft speed [rpm] Gear speed No-shift
Travel speed
shifting when kickdown switch = ON after shifting time
conversion
2nd In all range 1st 5 sec
Below 860 12.5 km/h 1st 5 sec
3rd
Above 860 12.5 km/h 2nd 4 sec
Below 860 12.5 km/h 1st 5 sec
4th
Above 860 12.5 km/h 3rd 4 sec
2nd (lockup) In all range 2nd *1
3rd (lockup) In all range 3rd *1
4th (lockup) In all range 4th *1
*1: When lockup is released due to kickdown switch operation, lockup will not be ON again
until the following conditions are satisfied.
q Perform temporary operation to turn the torque converter lockup switch OFFoON.
q The travel speed changes from lockup ON speed or less to lockup ON speed or more
as in the “3. Auto-shift points table.”
6) Torque converter lockup control function

q ON/OFF operation of the lockup is performed automatically due to ON operation of the torque
converter lockup switch.
q When the lockup clutch is ON, the lockup indicator of the machine monitor lights up.
q Even when the manual shift is selected, if the torque converter lockup switch is ON, ON/OFF of
the lockup is performed automatically by the transmission controller.
q The operation gear speed of lockup is shown in the following table.
Lockup operation gear speed (Lockup operates: Q)
Travel mode
F1 F2 F3 F4 R1 R2 R3 R4
MANUAL Q Q Q Q Q Q
Auto H Q Q Q Q Q Q
Auto L Q Q Q Q Q Q
1] Lockup rotation
For ON/OFF of lockup, refer to “3. Auto-shift points table.”
2] Lockup protection function

q Lockup ON only operates when the moving direction of the machine and the position of
the directional lever match.
Determination of moving direction of the machine
q The machine is thought to be stopping when the transmission controller is started (key
on), or the transmission output shaft speed is below 260 rpm.
q While the machine is thought to be stopping and the transmission output shaft speed
becomes 260 rpm or more, if the directional lever is in “F” position, it is thought to be mov-
ing forward, and if it is in “R” position, it is thought to be moving backward.
Q The travel speed is approximately 4 km/h when the transmission output shaft speed is
260 rpm.
10-902 34 WD600-6
7) Hunting prevention function

q The transmission controller prevents hunting by detecting hunting, which occurs between 2nd
and 3rd when auto shift is selected, with the controller.
q If gearshifts of 2nd to 3rd to 2nd to 3rd are performed within 5 seconds from the previous gear-
shift, hunting is thought to have occurred, and the gear speed is selected from 2nd or 3rd,
whose operation time is longer. When hunting prevention function operates, the shift point in
hunting prevention stated in “3. Auto-shift points table” will be selected for the next automatic
gear shifting operation.
q The operation of hunting prevention function ends when the next gear shift operation (including
FR, kickdown operation, etc.) is performed, and the gear will be set to the ordinary shift point of
the auto shift.
q When ON/OFF of 2nd lockup occurs consecutively within 5 seconds, the lock up will be turned
off, and the speed will be changed to lockup ON travel speed when the hunting prevention
function operates.
q The hunting prevention function operates when hunting occurs even in the manual shift.
8) Changing shift points

q The transmission controller has a function to adjust the gearshift points of L mode in auto shift.
q If hunting occurs due to the conditions in a job site, travel speed when shifted up/down can be
changed by adjusting the gearshift points.
a For the changing procedure, refer to “Testing and adjusting: Transmission gearshift point
adjustment.”
9) 4th gear speed derating function

q The transmission controller has a function to limit the operation of the 4th gear speed by
changing the optional setting.
a For the changing procedure, refer to “Optional setting : Prohibition of 4th gear speed.”
10) Transmission initial learning and ECMV current adjustment

q The transmission controller has an adjusting function to correct dispersion between the trans-
mission unit and ECMV solenoid.
q The initial learning function is used to adjust the fill time by changing the trigger operation time.
The ECMV current adjustment function is used to adjust the modulation wave form. Dispersion
of each device is eliminated and the normal condition is obtained by adjusting both of these
items.
q If the adjustment is not performed, a gear shifting shock or a time lag may be made.
a For adjusting procedure, refer to “Testing and adjusting: Setting of transmission initial learning/
Adjustment of transmission ECMV current”.
WD600-6 10-902 35
3. Auto-shift points table

q The relationship among transmission output shaft speed, engine mode, shift switch, and gear shift-
ing operation are shown below.
Engine mode and shift switch
Power mode Economy mode
Shift switch Shift switch Shift switch Shift switch
H L H L
F1oF2 373 373 373 373
F2oF2 (lockup) 516 – 650 516 – 650 500 – 650 500 – 650
F2oF2 (lockup)
616 – 700 616 – 700 600 – 700 600 – 700
when hunting is prevented
F2oF3 435 – 825 435 – 825 387 – 785 387 – 785
F2oF3
485 – 833 485 – 833 437 – 790 437 – 790
F3oF3 (lockup) 987 903 903 903
Gear
shifting F3oF4 784 – 1,431 784 – 1,431 784 – 1,355 784 – 1,355
operation F4oF4 (lockup) 1,743 1,607 1,607 1,607
F4 (lockup) oF4 1,498 1,498 1,498 1,498
F4oF3 688 – 1,375 688 – 1,375 688 – 1,320 688 – 1,320
F3 (lockup) oF3 805 – 849 721 – 849 721 – 849 721 – 849
F3oF2 333 – 791 333 – 791 319 – 738 319 – 738
F3oF2
283 – 691 233 – 691 269 – 638 219 – 638
F2 (lockup) oF2 445 – 477 445 – 477 430 430
a The transmission output shaft speed of 1 rpm corresponds to 0.0145 km/h.

a The shifting down point of F4oF2 and F3oF2 will be 69 rpm, when the accelerator is idle.
10-902 36 WD600-6
4. Transmission protection function

1) Protection function when changing FR
In order to protect the transmission, the controller limits changing F-R operation with the directional
lever during high-speed travel.
1] All range of auto modes (speed position switch at a position other than 1st gear speed) and
manual mode (2nd, 3rd, and 4th)
In auto-shift mode
Range I: F-R is changed and transmission is set in 2nd gear speed. (Ordinary range)
Range II: F-R is changed, transmission is set in 2nd gear speed, and the alarm is turned ON.
Range III: F-R is changed, and the alarm is turned ON. The gear speed of transmission gear-
shift depends on the travel speed.
Then, transmission is shifted down to 2nd gear speed with reduction of the travel
speed.
In manual-shift mode
Range I: Only F-R is changed. (Ordinary range)
Range II: F-R is changed, and the alarm is turned ON.
Range III: F-R is changed, and the alarm is turned ON. The gear speed of transmission gear-
shift depends on the travel speed.
Then, transmission is shifted down to the speed position with reduction of the travel
speed.
a Two seconds immediately after the F-R changing operation, shifting up/down and kick-
down switch operation will not be accepted, and if shifting up/down operation is performed
with the lever operation, gear shift will be performed in two seconds.
In auto-shift, shifting up will not be performed until 2nd gear speed is obtained by speed
reduction.
Transmission output shaft speed

before gear shift (rpm)
A B C
928 963 1,100
Remarks
(Travel speed 13 km/h 14 km/h 16 km/h
conversion)
WD600-6 10-902 37
2) Engine overrun prevention function

1] Shift-down prohibit function (Engine overrun prevention function 1)
q In order to protect the engine and pump, the controller performs shift-down protection, in which
operations are not accepted while shifting down, and the alarm is turned ON while it is operating.
q The operation conditions of the shift-down protection is shown below, and the alarm goes ON until
the gear shift position of the shift lever and the actual output gear shift match. Therefore, even when
the travel speed does not decrease, performing the shift-up operation will stop the alarm.
Protect P condition (A or (B and C)) Condition for resetting protect (D and (E or F))
Condition A Condition B Condition C Condition D Condition E Condition F
Target gear
Transmission Transmission Transmission Transmission
speed to shift Engine output Engine output
output shaft output shaft output shaft output shaft
down speed speed
speed speed speed speed
To 3rd gear Min. Min. Below Below
— —
speed 1,721 rpm 1,721 rpm 1,549 rpm 1,549 rpm
To 2nd gear Min. Min. Below Below Below
Min. 895 rpm
speed 1,102 rpm 1,620 rpm 964 rpm 861 rpm 1,440 rpm
To 1st gear Below Below
Min. 895 rpm Min. 895 rpm — —
speed 861 rpm 861 rpm
q The shift-down protection is valid also in kickdown operation in auto-shift. If the machine is
traveling in travel speed above the protect condition when kickdown operation is performed,
the kickdown operation is not accepted, and the alarm goes ON for three seconds.
2] Lockup reset function (Engine overrun prevention function 2)

q When the transmission output shaft speed becomes equivalent to the engine speed of 2,525 rpm
or above, the lockup is released automatically for preventing engine over run, and the alarm goes
off. For five seconds after it is released temporarily, the lockup stays OFF, but if after five seconds
pass and the transmission output shaft speed becomes equivalent to the engine speed of below
2,375 rpm, lockup will be on again.
Lockup OFF travel speed by function of engine overrun prevention (reference)

Lockup operation OFF value (equivalent to engine speed of 2,525 rpm)
WD600-6
Actual gear speed
Output shaft speed (rpm) Reference travel speed (km/h)
F2 1,094 15.9
F3 1,949 28.3
F4 3,439 50.0
R2 1,200 17.4
R3 2,137 31.1
R4 3,770 54.8
3] Forced shift-up function (Engine overrun prevention function 3)

q When traveling in T/C, if the engine speed becomes 2,525 rpm or more, transmission is shifted
up and the alarm goes ON. After shifting up, it will not be shifted down for three seconds.
q After three seconds pass, when the engine speed becomes below 2,375 rpm, the alarm stops
and the shift control becomes the ordinary control.
q When traveling in 4th gear speed, shift-up is not performed, and only the alarm goes ON.
4] Overrun pre-alarm function

q When the engine speed becomes 2,425 rpm or more, the function to warn operation of overrun
prevention action warning operates.
q The alarm is released when the engine speed becomes below 2,325 rpm.
5] Neutralizer function
q When the parking brake switch is ON (while the parking brake switch is operating), transmis-
sion output is maintained in neutral regardless of the state of the gearshift lever, for parking
brake dragging prevention function.
q Therefore, while the key is on, transmission is always in neutral regardless of the state of the lever.
10-902 38 WD600-6
WD600-6 10-902 39
5. Engine control
1) Engine torque curve switching function

q The transmission controller selects engine power mode from signal input of engine power
mode changing switch, and while it sends torque curve information used in the engine control-
ler, it also sends engine power mode information of power/economy to the monitor panel.
2) Maximum travel speed limit

q For lower fuel consumption in load and carry, the maximum travel speed is limited by setting
the maximum travel speed (select from three levels), and setting the upper limit to throttle
value in F4 lockup state.
Throttle value
Setting information
upper limit
(1) (Default) 90%
(2) 100%
(3) 80%
3) RPM set
q For improving the working efficiency, the engine speed is maintained at an arbitrary speed.
q The engine speed is set with pressing the accelerator pedal, and RMP set idle up/down switch.
q When the right brake is pressed, RPM set is temporarily released.
q For lower fuel consumption, in a setting with auto deceleration function, if the transmission
neutral continues for four seconds or the work equipment neutral state lasts for four seconds or
longer, if the RPM set SET/ACCEL SW and RPM set RESUME/DECEL SW are not operated,
and if the travel speed is 5 km/h or less, the RPM set function is temporarily released, and
transmission follows the signal of the accelerator pedal.
q In the state where the RPM set is temporarily released, if the transmission is set to a position
other than neutral, or the work equipment is in a state other than N, the throttle control state will
be resumed automatically.
Compo- RPM set RPM set SET/ RPM set RESUME/ Right brake pedal RPM set
nent list function switch ACCEL switch DECEL switch operation switch indicator lamp
Switch
Alternate 3-position Momentary proximity
composi- Momentary seesaw switch In-switch LED
switch switch
tion
Brake operated (GND)
Switch ON(24V) ON(GND) Performed through
Brake not operated
theory OFF(OPEN) OFF(OPEN) electrical circuit
(OPEN)
Resume function
When this switch is
While the RPM set
pressed upward, Function to set
function is released
“RPM set auto decel- throttle stroke
with the right brake
eration function is Save the throttle When the right brake
pedal operation Lights up when the
disabled.” stroke when it is ON pedal is pressed, the
(release), press this RPM set function
When this switch is (lock accelerator RPM set function is
switch and the RPM switch is ON
pressed downward, opening ratio) temporarily released.
set function is
“RPM set auto decel- Controls with input
resumed.
eration function is signal edge
Controls with input
Function enabled.” signal edge
Acceleration function Deceleration function
When the switch is When the switch is
pressed and held for pressed and held for
When this switch is
0.5 seconds, the 0.5 seconds, the
pressed in the mid-
throttle stroke set throttle stroke set
dle, the RPM set
value rises in accor- value lowers in
function is OFF.
dance with the time accordance with the
the switch is time the switch is
pressed. pressed.
10-902 40 WD600-6
q For description of the RPM set function, a sample time chart is shown below.
q RPM set ON-OFF switch

Used to turn the RPM set system ON and OFF.
q RPM set idle-up/down selector switch
Used to keep the engine speed at any level.
WD600-6 10-902 41
6. Modulation clutch
1) Modulation clutch control
q The modulation clutch is a function in which drive force from the engine to the tires is continu-
ously limited in accordance with the brake pedal when the left brake pedal is pressed.
1] Modulation clutch system hydraulic circuit diagram
2] Resume control in releasing left brake pedal

q The transmission controller controls so that sudden change of drive force will not occur in
engagement.
10-902 42 WD600-6
3] Modulation clutch invalid control in traveling

q When the left brake is used while traveling, since the engagement of the modulation clutch
is released and the effect of engine brake is not obtained, the following control is added so
that the effect of engine brake is obtained in operation of the left brake.
q Modulation clutch invalid control condition

Torque converter lockup = ON
Or
Throttle opening ratio is 30% or less in gear speed of F2, F3, F4, R2, R3, and R4
q Modulation clutch invalid control finish condition

Torque converter lockup = OFF
And
Throttle opening ratio is 30% or more, or in gear speed of F1, R1, and N
Throttle opening
Gear Speed Torque converter lockup Modulation clutch invalid control state
ratio
— — ON
F2
F3
F4 Start invalid control
Max. 30% —
R2
R3
R4
— Min. 30%
F1
OFF End invalid control
R1 —
N
4] Brake load reduction control

q When the machine is decelerated from high speed travel with the accelerator pedal and
brake pedal pressed (in dump approach operation etc.), the brake load is reduced by low-
ering the modulation clutch oil pressure and reducing the transmissibility of the modulation
clutch.
q Condition for starting brake load reduction control
The throttle opening ratio is 70% or above and the output shaft speed is 1,032 rpm (Refer-
ence travel speed: 15 km/h) or above and the brake signal is turned ON.
q Condition for stopping brake load reduction control
The throttle opening ratio is 50% or below or the output shaft speed is below 688 rpm (Ref-
erence travel speed: 10 km/h) or the brake signal is turned OFF.
Throttle Output shaft Brake load Torque Modulation clutch oil
Brake signal
opening ratio speed reduction control converter lockup pressure command value
70% 1,032 rpm ON o OFF Normal control command
ON Started
or above or above OFF o OFF value o 0.2 MPa
50% Below OFF o 0.2 MPa o Normal control
OFF Stopped
or below 688 rpm Normal control command value
5] Modulation clutch control when transmission gear is shifted

q Transmissibility of the modulation clutch is controlled at the times of starting and changing
directions for improved gear shifting and reducing clutch heat load.
6] Modulation clutch control at the time of starting the engine

q For reduced load of the travel system and improved engine start, the modulation clutch is
completely disengaged when the engine is started.
q When the engine speed is 500 rpm or higher, it will be connected directly with the modula-
tion clutch for performing ordinary control.
WD600-6 10-902 43
7] Setting modulation clutch drive force

q The slippage ratio of the modulation clutch in F1 can be adjusted with a dial.
Settable range (slippage ratio)
80% – 0%
Input: Dial input voltage V 4.00 3.63 3.25 2.88 2.50 2.13 1.75 1.38 1.00
Dial set recognition % 20 30 40 50 60 70 80 90 100
Target transmissibility % 20 30 40 50 60 70 80 90 100
Target modulation
Output: MPa 0.3 0.35 0.45 0.5 0.6 0.8 1 1.5 2.5
clutch oil pressure
Current value mA 212 222 240 248 264 302 333 408 552
q Image of speed, traction power, and transmissibility
8] Modulation clutch emergency operation switch

q Since the modulation clutch is engaged with command, and disengaged without com-
mand, when the transmission controller fails and cannot issue commands, the vehicle
cannot be moved.
q In order to address such trouble, a circuit to directly connect the modulation clutch with
modulation clutch emergency operation switch is equipped.
When the solenoid valve fails, the plate for emergency escape of ECMV is used to
address the problem.
10-902 44 WD600-6
7. Economy lamp
1) Control of economy lamp
q The transmission controller lights up the economy lamp indicator of the machine monitor when
operating in low fuel consumption, in order to prompt low fuel consumption operation to the
operator.
1] Lighting condition of economy lamp

q When the engine power mode is the economy mode, and the accelerator pedal opening
ratio is 80% or less, the economy lamp is lighted.
Accelerator Power Economy
opening ratio mode mode
Min. 80% OFF OFF
Max. 80% OFF Lighting
2] Turning off economy lamp

q The economy lamp can be constantly kept off with the optional setting of the monitor.
a For the setting procedure, refer to “Testing and adjusting: Special functions of machine
monitor (EMMS), Select optional equipment.”
WD600-6 10-902 45
8. Cooling fan control

1) Control of fan
q The cooling fan is driven hydraulically and by controlling the swash plate of the main pressure
pump, the horsepower loss and noise are reduced while the temperature is low.
q The information of the engine speed and engine coolant temperature sensed by the engine
controller, and hydraulic oil temperature, and torque converter oil temperature sensed by the
machine monitor is sent through the network to the transmission controller, and then current
control is performed for the swash plate angle of the fan pump so that the fan speed will be
matched to the temperature and engine speed.
10-902 46 WD600-6
2) Fan speed in accordance with temperature

q As for the fan speed, the target fan speed is determined based on the data with highest tem-
perature among coolant temperature, hydraulic oil temperature, and torque converter oil tem-
perature.
q Basic control of fan speed
a. Target speed when air conditioner operates b. Minimum inclination: 850 mA c. Median value: 677 mA
3) Protection function
q For preventing overrun of the motor of the fan pump, the minimum swash plate is used for the
fan pump when the engine speed is 2,650 rpm or higher.
q When the engine speed or respective temperature data cannot be recognized by the transmis-
sion controller due to such cause as failure of network communication, the fan pump EPC cur-
rent is set to 677 mA, which is equivalent to that of the fixed pump.
4) Control for starting engine

In fan control, a different control from the ordinary control with temperature when starting the
engine.
q When stopping the engine (key switch 1-stage on)
When the engine is stopped, the fan pump EPC current of 677 mA is output, for it is the same
as a state where the engine speed cannot be recognized.
q While cranking
While cranking to start the engine, in order to improve engine start, the minimum swash plate is
used for the fan pump by setting the fan EPC current to 850 mA, reducing the torque neces-
sary for starting the engine.
WD600-6 10-902 47
5) Fan reverse rotation function

q In the hydraulic fan, for cleaning the radiator core, when the fan reverse rotation switch is oper-
ated, the hydraulic fan motor reverse solenoid operates to reverse the fan.
1] Standard specification fan manual reverse rotation function

q It is a function to reverse the fan rotation arbitrarily by the operator. By pressing the fan
manual reverse switch, the turning direction of the fan is changed.
q Changing from forward to reverse, and reverse to forward is performed when the following
conditions are satisfied.
q The fan manual reverse switch is pressed
q The engine speed is 500 rpm or lower.
q The fan reverse indicator flashes when the state of the fan manual reverse switch and the
rotation direction of the fan do not match. While the fan is rotating in reverse direction, the
fan reverse indicator lights up.
Reverse SOL Forward/reverse
Reverse SOL Fan pump Monitor indicator
output before selector switch Engine speed
output EPC output lighting logic
switch operation operation
From OFF to
OFF ON MIN speed From OFF to lighting
ON
From ON to
OFF OFF Ordinary From flashing to OFF
OFF Below 500
From OFF to rpm
ON ON MIN speed From flashing to ON
ON
From ON to
ON OFF Ordinary From flashing to OFF
OFF
From OFF to
OFF OFF Ordinary From OFF to flashing
ON
From ON to
OFF OFF Ordinary From flashing to OFF
OFF
Min. 500 rpm
From OFF to
ON ON As per 3] From flashing to ON
ON
From ON to
ON ON As per 3] From lighting to flashing
OFF
2] Optional specification of fan automatic reverse function

q Not used.
3] Fan speed in reverse

q While it is operating in reverse, cleaning of the radiator core is facilitated by increasing air
flow by turning the fan at the maximum speed without outputting fan pump EPC current
(output 0 mA).
q When the hydraulic oil temperature is below 30°C, however, the fan EPC current is set to
850 mA and the fan speed is minimized to protect the hydraulic circuit.
10-902 48 WD600-6
9. Low temperature bypass control (if equipped)

Low temperature bypass control
q In order to prevent transmission filter peak pressure in extremely low temperature, travel can
optionally prohibited for 30 seconds by bypassing the torque converter charger pump circuit imme-
diately after the engine is started.
1) Operation of low temperature bypass solenoid

The bypass solenoid operates when all the following conditions are satisfied.
(1) Torque converter inlet oil temperature < –20°C
Conditions
(2) Cold district option is enabled
(3) When starting the engine (with C terminal signal and engine speed of 500 rpm or lower)
2) Finishing operation of low temperature bypass solenoid

q Elapsing time after the start of operation is 30 seconds or longer, or cold district option is dis-
abled.
WD600-6 10-902 49
10. AJSS
1) AJSS control
q Equipment allowing turning of the vehicle (steering operation), forward and reverse movement
and shifting up/shifting down, with the AJSS lever located on the left console.
q Since turning of the vehicle is performed by the work equipment controller, refer to the section
of work equipment controller, for turning operation of AJSS.
2) AJSS shifting up/shifting down switch

q The AJSS shifting up/shifting down switch performs shifting up/shifting down in accordance
with the buttons in the manual shift mode.
a However, when shifting down during high-speed travel, the shift-down protection function oper-
ates and shifting down will be performed after the travel speed has decreased.
q When the shift mode is the auto shift mode (both H and L), the maximum gear speed (gear
shifting range) used in the automatic gear shifting operation is limited.
q In the automatic gear shifting operation, the vehicle usually starts in the 2nd gear speed.
Accordingly, if the shift range is 4, the gear is shifted up and down between the 2nd gear speed
and 4th gear speed, and the vehicle starts in the 1st gear speed only when the kick-down func-
tion is used.
1] Function of shifting up/shifting down switch

q When the shifting up/shifting down switches are operated at the same time, shift down is
effective.
q After pressing a switch once, the next shifting up/shifting down switch operation is not
accepted for 0.2 seconds.
3) Neutralizer function
q While the parking brake is operating, or the steering lever is locked, neutral is maintained
regardless of the shift lever position.
q Also, while the parking brake is operating, the AJSS indicator and buzzer operate as shown
below.
Shift
Steering
switch Indicator Buzzer
lock
position
ON Arbitrary Lighting None
Sounding
OFF F or R Flashing
(pip, pip)
OFF N OFF None
10-902 50 WD600-6

1) List of display contents of the real-time monitor
In WA600-6, the state of the controller input and output signals can be checked using the real-time
monitor function of the monitor.
The following table shows the display items and display contents in normal operation of the real-
time monitor in relation to the transmission controller:
Display of item
No. Item ID No. Contents of display data Data unit (and range) Remarks
name
Software part Output mass production Depends on the software
1 20201 VERSION
number software part number part number
Output software version
Software appli- Depends on the software
2 20223 VERSION (APP) (software logic part ver-
cation version version
sion)
Software appli- Output software version
Depends on the software
3 cation data ver- 20224 VERSION (DATA) (software data part ver-
version
sion sion)
Output engine mode for 0: power mode
4 Engine mode 41600 ENGINE MODE
controlling engine output 2: economy mode
X1 [mA]
(0 – 1000[mA])
When engine speed is
below 500 rpm
= 677 mA
ECMV output Output to FAN EPC out-
While cranking (C terminal
5 command value 41400 FAN EPC DIR put command current
operation)
(FAN pump) value
= 850 mA
Switching fan reverse
= 850 mA
Fan operating in reverse
= 0 mA
Fan reverse FAN REVERSE Output fan reverse SW 1:ON(CLOSE)
6 93400
switch input SW input state 0:OFF
Torque converter
Output T/C inlet oil tem- *1 [°C] Option for low tem-
7 inlet oil tempera- 41501 T/C IN OIL TEMP
perature (–30 – 100 [°C]) perature detection
ture
*0.01 [V]
(0.00 – 5.00 [°C])
Torque converter 4.72V = 0°C
Output T/C inlet oil tem-
8 inlet oil tempera- 41502 T/C IN OIL TEMP 4.33V = 30°C
perature
ture 3.55V = 60°C
2.20V = 100°C
1.61V = 120°C
Torque converter
Output T/C input shaft x 1 [min-1]
9 input shaft 93500 T/C SPEED:IN
speed (0 – 32,767 [min-1])
speed
Torque converter Output T/C output shaft
T/C x 1 [Nm]
10 output shaft 93501 torque calculated value
TORQUE:OUT (0 – 400,000)
torque (T2)
Transmission
Not used by this
11 input shaft 31200 T/M SPEED IN — 0
machine
speed
x 1 [min-1]
(0 – 32,767 [min-1])
Transmission
Output output shaft speed 0 km/h = 0 rpm
12 output shaft 31400 T/M SPEED:OUT
[PLS_AC_IN_2] 10 km/h = 788 rpm
speed
20 km/h = 1,376 rpm
30 km/h = 2,063 rpm
40 km/h = 2,751 rpm
x 1 [min-1]
(0 – 32,767 [min-1])
Transmission
T/M Output output shaft speed 0 km/h = 0 rpm
13 output shaft 31404
SPEED:OUT2 [PLS_AC_IN_0] 10 km/h = 788 rpm
speed
20 km/h = 1,376 rpm
30 km/h = 2,063 rpm
40 km/h = 2,751 rpm
WD600-6 10-902 51
Display of item
name
Transmission
Not used by this
14 cut-off operation 41203 T/M CUT SET — 0
machine
setting
Transmission
Not used by this
15 cut-off (left 41201 T/M CUT OFF P — 0
machine
brake) pressure
Transmission
Not used by this
16 cut-off (left 41202 T/M CUT OFF P — 0
machine
brake) pressure
Torque converter TC SPEED Output torque converter x 1 [%]
17 93700
speed ratio RATIO speed ratio (0 – 100 [%])
Transmission oil Output oil temperature
x 1 [°C]
18 temperature 93600 T/M OIL TEMP value of transmission oil
(0 – 150 [°C])
input temperature (A_IN_1)
x 1 [mV]
(0.00 – 5.00 [V])
Input voltage of Output input voltage 4.72 V = 0°C
19 transmission oil 93601 T/M OIL TEMP value of transmission oil 4.33 V = 30°C
temperature temperature (A_IN_1) 3.55 V = 60°C
2.20 V = 100°C
1.61 V = 120°C
Output oil pressure con-
MOD/C oil pres- x 1 [MPa]
20 92400 MOD/C PRESS version value of MOD/C
sure input (0.00 – 5.00 [MPa])
oil pressure input (A_IN7)
MOD/C oil pres- Output voltage value of
x 1 [mV]
21 sure input volt- 92401 MOD/C PRESS MOD/C oil pressure input
(0.00 – 5.00 [V])
age (A_IN7)
Overheat notice ON
when the value is 2.2
or more (lamp on)
Overheat warning
operates and records
when it is 2.9 or more
Output the value of calcu-
MOD/C heat x 1 [100J/cm2] (lamp on, buzzer
22 92500 MOD/C Q lated heat release value
release value (0.0 – 25.5 [100J/cm2]) operates, action
(Q) of MOD/C
code displays, and
error is recorded)
Overheat warning/
notice OFF when it is
1.8 or less (lamp off),
resumed from error
Output the value of calcu-
MOD/C heat x 1 [0.1kW/cm2]
23 92501 MOD/C q lated heat ratio value (q)
ratio (0.00 – 2.55[0.1kW/cm2])
of MOD/C
RPM set switch
Output the state of input 0: RPM set switch OFF
24 (pressed 95500 THROT LOCK A
signal 1: RPM set switch ON
upward)
RPM set switch
0: RPM set auto decelera-
(pressed down-
Output the state of input tion switch OFF
25 ward) (RPM set 95501 THROT LOCK B
signal 1: RPM set auto decelera-
auto decelera-
tion switch ON
tion switch)
Output throttle
Output throttle correction x 1 [%]
26 correction com- 95400 THROTTLE MOD
command output amount (–100 – 100 [%])
mand
Output throttle
Output throttle upper limit x 0.1 [%]
27 stroke upper 44200 THROT LIMIT UP
command output amount (0.0 – 100.0 [%])
limit value
Output throttle
Output throttle lower limit x 0.1 [%]
28 stroke lower limit 44201 THROT LIMIT LO
command output amount (0.0 – 100.0 [%])
value
10-902 52 WD600-6
Display of item
name
Depends on accelerator
pedal operation
Accelerator pedal = 0
Depends on accelerator
Accelerator pedal partial
Acceleration THROTTLE opening ratio; output
29 93801 pressing (opened side) = 1
mode MODE acceleration mode on
Accelerator pedal partial
control
pressing (pressed side) = 2
Accelerator pedal pressing
=3
Traction setting Output set value of trac- x 1 [%]
30 94000 TRACTION DIAL
input value tion dial (0 – 100 [%])
Traction setting Output voltage value of Output voltage value of
31 94001 TRACTION DIAL
input voltage traction dial setting input traction dial setting input
0: Lockup changing switch
Lockup chang-
Output the state of input OFF
32 ing switch input 95000 LOCK UP SW
signal 1: Lockup changing switch
signal
ON
ECMV output ECMV output to 1st clutch
x 1 [mA]
33 command value 31602 ECMV 1 DIR Output command current
(0 – 1000 [mA])
(1st) value
ECMV output to 2nd
ECMV output
clutch x 1 [mA]
34 command value 31603 ECMV 2 DIR
Output command current (0 – 1000 [mA])
(2nd)
value
ECMV output to 3rd
ECMV output
clutch x 1 [mA]
(3rd)
value
ECMV output to 4th
ECMV output
clutch x 1 [mA]
(4th)
value
ECMV output to FWD
ECMV output
clutch x 1 [mA]
37 command value 31608 ECMV F DIR
(FWD)
value
ECMV output to L/U
ECMV output
clutch x 1 [mA]
38 command value 31609 ECMV LU DIR
(L/U)
value
ECMV output to MOD/C
ECMV output
ECMV MOD/C clutch x 1 [mA]
39 command value 31640
DIR Output command current (0 – 1000 [mA])
(MOD/C)
value
ECMV output to REV
ECMV output
clutch x 1 [mA]
40 command value 31606 ECMV R DIR
(REV)
value
ECMV output Output to ECSS valve
x 1 [mA] Not used by this
41 command value 93300 ECSS V DIR Output command current
(0 – 1000 [mA]) machine
(ECSS) value
Output fill time value of
Fill time value x 0.01 [sec]
42 41802 FILL TIME 1 1st clutch
(1st) (0 – 2.55 [sec], without fill: 0)
(state of last gear shift)
43 41803 FILL TIME 2 2nd clutch
(2nd) (0 – 2.55 [sec], without fill: 0)
44 41804 FILL TIME 3 3rd clutch
(3rd) (0 – 2.55 [sec], without fill: 0)
45 41805 FILL TIME 4 4th clutch
(4th) (0 – 2.55 [sec], without fill: 0)
WD600-6 10-902 53
Display of item
name
46 41808 FILL TIME F FWD clutch
(FWD) (0 – 2.55 [sec], without fill: 0)
47 41806 FILL TIME R REV clutch
(REV) (0 – 2.55 [sec], without fill: 0)
000*****
: Changing engine mode
SW OFF
100*****
D-IN0
: Changing engine mode
: Engine mode selec-
SW ON
tion SW
*000****
D-IN3
: Stopping air compressor
: Operating air com-
*001****
pressor
: Operating air compressor
D-IN4
Input signal Output the state of input *00*00**
48 40905 D-IN--0------7 : Shift mode L
D_IN_0 – 7 signal : Manual shift mode
D-IN5
*00*10**
: Shift mode H
: Shift mode L
D-IN6
*00*11**
: MOD/C direct con-
: Shift mode H
nection signal
*00***0*
D-IN7
: MOD/C opened
: C terminal signal
*00***1*
: MOD/C directly connected
*00****1
: Cranking
000*0***
: Kickdown SW = OFF
001*0***
: Kickdown SW = ON
00*00***
: Shift hold SW = OFF
D-IN10
00*10***
: Kickdown SW
: Shift hold SW = ON
D-IN11
00**00**
: Shift hold SW
: RPM set SW = OFF
D-IN13
00**01**
: RPM set SW
Input signal Output the state of input : RPM set SW = ON
49 40906 D-IN--8-----15 D-IN14
D_IN_8 – 15 signal 00**0*0*
: RPM set resume
: RPM set resume SW =
SW
OFF
D-IN15
00**0*1*
: RPM set release
: RPM set resume SW =
right brake pedal
ON
SW
00**0**0
: RPM set release right
brake pedal SW = OFF
00**0**1
: RPM set release right
brake pedal SW = ON
10-902 54 WD600-6
Display of item
name
01******
D-IN16
: AJSS shift-up SW = OFF
: AJSS shift-up (nor-
(AJSS specification)
mally open) (AJSS
10******
specification)
: AJSS shift-up SW = ON
shift range 1st (steer-
ing specification)
**01****
D-IN17
: AJSS shift-down SW =
: AJSS shift-up (nor-
OFF (AJSS specification)
mally closed) (AJSS
**10****
specification)
: AJSS shift-down SW=ON
shift range 2nd
(steering specifica-
1000****
tion)
: shift lever 1st
D-IN18
(steering specification)
: AJSS shift-down
0100****
(normally open)
Input signal Output the state of input : shift lever 2nd
50 40907 D-IN-16-----23 (AJSS specification)
D_IN_16 – 23 signal (steering specification)
shift range 3rd (steer-
0010****
ing specification)
: shift lever 3rd
D-IN19
: AJSS shift-down
0001****
(normally closed)
: shift lever 4th
shift range 4th (steer-
****100*
ing specification)
: direction lever F
D-IN20
****010*
: direction lever F
: direction lever N
D-IN21
****001*
: direction lever N
: direction lever R
D-IN22
*******0
: direction lever R
: parking brake release
D-IN23
*******1
: parking brake signal
: parking brake operation
D-IN25
0101000* : fill SW F
: F1 traveling D-IN26
0010100* : fill SW R
: R2 traveling D-IN27
0000010* : fill SW 1st
: 3rd neutral D-IN28
0100001* : fill SW 2nd
Input signal Output the state of input
51 40908 D-IN-24-----31 : F4 traveling D-IN29
D_IN_24 – 31 signal
0******0 : fill SW 3rd
: Steering lock lever pres- D-IN30
sure SW = OFF or steer- : fill SW 4th
ing specification D-IN31
0******1 : Steering lever lock
: Steering lock lever pres- pressure SW (con-
sure SW = ON stantly 0 in steering
specification)
Input signal 00000000
D_IN_32 – 39 : when foot brake is
(Transmission Output the state of input released D-IN32
52 40942 D-IN-32-----39
controller does signal 10000000 : brake pressure SW
not have 33 – : when foot brake is
39) pressed
WD600-6 10-902 55
Display of item
name
000***00
: modulation clutch invalid
solenoid OFF
100***00
D-OUT0
: modulation clutch invalid
: modulation clutch
solenoid ON
invalid solenoid
ON/OFF output state of *000**00
D-OUT3
Output signal SOL_OUT0 to 7 : fan reverse solenoid OFF
53 40949 D-OUT 0 – 7 : fan reverse solenoid
D_OUT_0 – 7 '0' is displayed when set- *001**00
D-OUT5
ting current output : fan reverse solenoid ON
: low temperature
*00**000
bypass solenoid (if
: low temperature bypass
equipped)
solenoid OFF
*00**100
: low temperature bypass
solenoid ON
SOL_OUT8 to 11B,
Output signal Not used by this
54 40950 D-OUT 8 – 15 SIG_OUT0 to 1 00000000
D_OUT_8 – 15 machine
'0' is displayed when set-
ting current output
SIG_OUT2 to 3,
Output signal HSW_OUT0 to 1, Not used by this
55 40951 D-OUT 16 – 23 00000000
D_OUT_16 – 23 BATT_RY_OUT machine
'0' is displayed when set-
ting current output
16-bit data is dis-
Output initial learning flag 111111
played
Initial learning state of trigger time of (all clutches learned)
56 94100 TRIG FR1234 in the order of F, R, 1,
flag each clutch 000000
2, 3, and 4 on the
[F,R,1,2,3,4] (all clutches to be learned)
monitor
10-902 56 WD600-6
12. Diagnosis
1) Function of troubleshooting
The transmission controller monitors the input and output signals constantly for troubleshooting for
the system.
If any abnormality is detected by self-diagnosis, the information on it is transmitted through the net-
work to the machine monitor.
When abnormality occurs, it can be confirmed on the machine monitor.
WD600-6 10-902 57
Transmission controller
10-902 58 WD600-6
Input and output signals
DEUTSCH-24P [CN-L02]
signal signal
1 T/C lock up SW. Input 13 Throttle with auto decel Input
2 Fan reverse SW. Input 14 T/C inlet oil temp. sensor Input
3 Traction dial Input 15 NC Input
4 GND_SIG_D 16 PWR_OUT_SENS Output
5 A/C compressor signal Input 17 NC Input
6 Starter switch(IGN-C) Input 18 Shift mode signal H Input
7 NC Input 19 Throttle lock without auto decel Input
8 MOD/C oil pressure Input 20 Memory reset Input
9 T/M oil temp. sensor Input 21 GND_SIG_A
10 GND_SIG_D 22 PWR_OUT_5V_0 Output
11 NC Input 23 Engine mode SW. Input
12 MOD/C direct signal Input 24 Shift mode signal L Input
signal signal
1 NC Output 21 NC Input/Output
2 ECMV fill SW.:4th Input 22 COMM_CAN_L_O Input/Output
3 ECMV fill SW.:3rd Input 23 NC Input/Output
4 232C_RxD Input 24 PWR_CTR_EXT Input
5 AJSS shift down(NC)or shift lever:4th Input 25 AJSS shift up(NC)or shift lever:2nd Input
6 Parking brake signal Input 26 Direction lever: N Input
7 ECMV fill SW.:1st Input 27 ECMV fill SW.: F Input
8 NC Output 28 Brake pressure SW. Input
9 NC Output 29 GND_SIG_P
10 NC Input 30 MOD/C speed sensor Input
11 NC Output 31 NC
12 NC 32 COMM_CAN_H_O Input/Output
13 ECMV fill SW.:2nd Input 33 NC Input/Output
14 232_TxD Output 34 232C_GND
15 AJSS shift down(NO)or shift lever:3rd Input 35 AJSS shift up(NO)or shift lever:1st Input
16 Direction lever:R Input 36 Direction lever:F Input
17 ECMV fill SW.:R Input 37 NC Input
18 NC Output 38 S/T lever lock pressure SW. Input
19 NC Output 39 GND_SIG_P
20 Speed sensor(1) Input 40 Speed sensor(2) Input
signal signal
2 PWR_IN_BRY Input 22 PWR_IN_BRY Input
3 GND_ACT 23 GND_ACT
4 TM power hold relay Output 24 KEY switch signal Input
5 ECMV:F. clutch Output 25 ECMV:1st clutch Output
6 ECMV:2nd clutch Output 26 ECMV:4th clutch Output
7 MOD/C cut off SOL. Output 27 Fan pump EPC Output
9 NC Input 29 RESUME/DECEL SW. Input
10 NC Input 30 Kick down SW. Input
12 PWR_IN_BRY Input 32 GND_PWR
13 GND_ACT 33 GND_PWR
14 PWR_CTR_KEY Input 34 NC Output
15 ECMV:R. clutch Output 35 ECMV:lock up clutch Output
16 ECMV:3rd clutch Output 36 ECMV:modulation clutch Output
17 NC Output 37 Fan pump reverse solenoid Output
18 NC Output 38 T/M bypass solenoid Output
19 SET/ACCEL SW. Input 39 Right brake SW. Input
20 NC Input 40 Shift hold SW. Input
WD600-6 10-902 59
SEN04997-00
WD600-6 Wheel dozer

©2009 KOMATSU
All Rights Reserved
10-902 60
SEN04998-02
WHEEL DOZER
WD600-6

WD600-6 55001 and up


Electric transmission control ........................................................................................................................... 2
Engine starting/stopping circuit ....................................................................................................................... 4
Parking brake circuit ....................................................................................................................................... 7
Sensor............................................................................................................................................................11
VHMS controller related................................................................................................................................ 32
Electric lever (Work equipment) .................................................................................................................... 37
WD600-6 10-903 1
SEN04998-02 Electric transmission control
Electric transmission control 1
Combination switch
q The directional lever has 3 positions and the gearshift lever switch has 4 positions.The detent mecha-
nism is not installed to each switch but installed to the body of the combination switch. Each switch is
positioned with 2 pins and fixed to the body with 3 screws. If each lever is set in a desired position, the
switch connected by the shaft operates to supply the current to only the circuit of the desired position.
No. Type Operation
1 Directional lever switch Selects the travel direction and neutral.
2 Gearshift lever switch Selects a gear speed.
3 Gearshift lever stopper Prevents the gearshift lever from moving to the 3rd or 4th position during work.
4 Turn signal Turn signal for L.H. and R.H. turns
Returns the turn signal lever automatically to neutral when the steering wheel is
5 Self-cancel
returned after turning to the right or left.
6 Lamp switch Selects the clearance lamp, headlamp, parking lamp, etc.
7 Dimmer switch Selects main beam and low beam.
8 Hazard switch Flashes turn signals to the left and right simultaneously.
9 Hazard pilot lamp Flashes while the hazard lamp flashes.
10-903 2 WD600-6
Electric transmission control SEN04998-02
q Shaft (2) of directional and gearshift lever (1) of

the combination switch is made one with mag-
net (3). As lever (1) moves, magnet (3) moves,
too.
q Control switch (5) having Hall IC's (4) in it is
installed under magnet (3). Hall IC (4) are
arranged on the board for each position.
q When the directional lever is set in the “F” posi-
tion, magnet (3) comes to directly above Hall
IC (4) of the “F” position of the control switch.
Magnet (3) magnetizes Hall IC (4) through the
clearance and case (6).
q Hall IC (4) is in the magnetism sensor circuit
and it detects the magnetism of magnet (3)
and sends the signal of the “F” position of the
directional lever to the current amplifier circuit.
The current amplifier circuit outputs the signal
to operate the transmission valve.
WD600-6 10-903 3
SEN04998-02 Engine starting/stopping circuit
Engine starting/stopping circuit 1
Function
1. The neutral safety circuit is employed to
secure safety when the engine is started.
q The engine can not be started while the
directional lever is not in N (Neutral).
q When the AJSS lever is in a position other
than neutral, the engine can not be
started.
10-903 4 WD600-6
Engine starting/stopping circuit SEN04998-02
Operation 5. When starting switch is turned to “Start” position

1. When starting switch is turned to “ON” position q If the starting switch is turned to the “Start”
q If the starting switch is turned to the “ON” position, terminals B and C of the starting
position, terminals B and BR of the start- switch are closed and the current flows
ing switch are closed and the current flows from the neutral safety relay through the
from the battery through the starting AJSS neutral safety relay to the starting
switch and battery relay coil to the ground motor, and the engine starts rotating.
and the contacts of the battery relay are When the engine starts rotating, fuel injec-
closed. As a result, the power is supplied tion starts to each cylinder with the rota-
to each circuit of the vehicle. tion signal from the engine rotation sensor
Also, the operation signal is provided from connected to the engine controller, and
the terminal ACC of the starting switch into then the engine starts.
the engine controller, and the engine is 6. Engine stopped
ready to start. q If the starting switch is set in the “OFF”
2. Neutral safety circuit position, the current of terminal ACC of
q When the directional lever is set in the “N” the starting switch is cut out and the ACC
position, current flows from the N contact signal to the engine controller is cut out
of the directional switch to the coil of the accordingly, and the engine controller
neutral safety relay, and by conducting the stops fuel injection.
three terminals of the neutral safety relay q When fuel injection stops, the engine
with the five terminals, the engine slows down the rotation and stops. When
becomes ready to be started. the alternator stops generating electricity,
3. AJSS neutral safety circuit voltage supply from R terminal stops, and
q When the engine is started in a condition the current from BR terminal of the starting
other than steering neutral condition, in switch is cut out, the contact of the battery
which the lever angle of AJSS and the relay opens, and the power supply pro-
machine frame angle are the same, the vided to various parts of the machine is
machine can begin turning immediately cut out.
after it is started, which can be a cause of
danger. Therefore, if the deviation of the
lever angle and the frame angle, sensed
by the work equipment controller, is 6° or
more, starting the engine is prohibited by
energizing the AJSS neutral safety relay
coil by the work equipment controller, and
opening the three and six terminals of the
relay.
4. Neutral maintaining circuit
q The neutral safety relay may not be main-
tained due to voltage decrease of neutral
signal from the directional lever because
of voltage decrease in starting the engine.
In order to prevent this, the “neutral main-
taining relay” is installed to maintain neu-
tral safety relay as long as the signal from
the C terminal of the starting switch, in
case starting the engine is initiated in neu-
tral state.
WD600-6 10-903 5
SEN04998-02 Engine starting/stopping circuit
7. Machine equipped with battery disconnect

switch
q When the battery disconnect switch is
equipped and the switch is OFF (the con-
tact is opened), the starting switch B termi-
nal, respective controllers, and other
constant power supplies are all cut out,
and the state is the same as when the bat-
tery is not connected.
q The battery disconnect switch is usually
used for substitution to take off the minus
terminal of the battery, when the machine
is stored for a long time (a month or lon-
ger), when the electrical system is
repaired, or when electrical welding is per- Position OFF (cut)
formed. Position ON (connected)
When the battery disconnect switch is turned
off, all the electrical system of the machine will
be inoperative.
q The clock of the monitor/radio and recep-
tion preset memory of radio will be lost,
and need to be set again when using
them.
q Such functions as room lamp, step lamp,
and hazard lamp cannot be used either.
q Since VHMS is saving data with battery
power immediately after the starting
switch is turned off, when turning the bat-
tery disconnect switch off, ensure that the
VHMS operation indicators in the rear
frame left component box and at the side
of the battery disconnect switch have
gone out. If it is turned off before the indi-
cator goes out, a cycle of VHMS data,
from the time the starting switch is turned
on to the time when it is turned off, will be
lost. (Information necessary to set the
machine will not be lost)
q Immediately after the fan is operated in
reverse, power is supplied to the fan
reverse solenoid for a while after the start-
ing switch is turned “OFF” in order to pro-
tect the oil pressure motor.
q When turning the battery disconnect 8. Start auxiliary connector
switch off, ensure that the fan rotating in q This machine is optionally equipped with a
reverse has stopped. start auxiliary connector in compliance
with SAE J1283.
k Important q For usage and precautions of the start
Do not turn off the battery disconnect switch auxiliary connector, refer to Operation
while the engine is rotating and immediately Manual.
after the engine has stopped.
If the battery disconnect switch is turned off
while the alternator is generating electricity, the
generated current has nowhere to go, leading
to overvoltage of the electrical system of the
machine, which may cause serious damage to
the electrical system such as electric devices
or controllers.
10-903 6 WD600-6
Parking brake circuit SEN04998-02
Parking brake circuit 1
Operation
1. When starting switch is turned “OFF”
q If the starting switch is turned “OFF,” the con-

tacts of the battery relay open, and no current
flows to the parking brake circuit. While the
starting switch is “OFF,” the current does not
flow into parking brake solenoid valve and the
parking brake is kept applied, regardless of the
position of the parking brake switch, whether it
is “ON (applied)” or “OFF (released).”
WD600-6 10-903 7
SEN04998-02 Parking brake circuit
2. When starting switch is turned “ON”

2-1. When parking brake switch is turned “ON (actuate)” before starting switch is turned “ON”
q Since parking brake selector switch is ON, the

current flows from the battery relay through a
contact of parking brake changing switch,
three contacts, parking brake safety relay coil
and to the chassis ground, thus closing three
terminals and five terminals of parking brake
safety relay. The current from the battery relay
keeps flowing into the coil of parking brake
relay to hold its contacts until the battery relay
contacts open and the current does not flow
into the parking brake circuit any more.
q At this time, the current does not flow into park-
ing brake solenoid and the parking brake is
kept applied.
q This signal is input to transmission controller to
keep the transmission in neutral and prevent
the parking brake from dragging while the
parking brake is applied.
q After that, if the parking brake switch is turned
“OFF (released),” the current flows through
battery relay, parking brake safety relay, three
contacts of parking brake selector switch, two
contacts, emergency brake switch, and parking
brake solenoid, to the chassis ground, and the
parking brake is released.
10-903 8 WD600-6
Parking brake circuit SEN04998-02
2-2. When parking brake switch is turned “OFF (released)” before starting switch is turned “ON”
q While the starting switch is “OFF,” the current

does not flow into parking brake safety relay
and its contacts are open. Even if the starting
switch is turned ON at this time, the current
does not flow into parking brake solenoid.
Accordingly, the parking brake will not be
released automatically.
WD600-6 10-903 9
SEN04998-02 Parking brake circuit
3. When main brake oil pressure lowers (emergency brake is applied)
q If the main brake oil pressure lowers, the con-

tacts of the emergency brake switch installed
to the accumulator open. As a result, the cur-
rent flowing into parking brake solenoid valve
is stopped and the oil in the parking brake cyl-
inder is drained and the parking brake is
applied.
In this case, however, unlike the case where
the park in g brake swit ch is turn ed “ON
(applied)”, the transmission is not set in neutral
since the parking brake release signal is flow-
ing into the transmission controller.
By the above operation, when the emergency
brake is applied, the braking distance can be
reduced by using the engine as a brake. Also,
even if the emergency brake is applied, the
vehicle can be moved.
10-903 10 WD600-6
Sensor SEN04998-02
Sensor 1
Modulation clutch rotation sensor

Output shaft rotation sensor 1
Output shaft rotation sensor 2
1. Magnet 3. Harness
2. Locknut 4. Connector
Function
q Modulation clutch rotation sensor is installed
between torque converter and modulation
clutch. Output shaft rotation sensors 1 and 2
are both installed in the output gear section at
the bottom of the transmission main unit.
Those sensors emit pulse signals according to
the gear rotation signal, which are then trans-
mitted to the transmission controller.
q Signals are converted from pulse to the num-
ber of rotation (rpm) in the transmission con-
troller, transmitted to the machine monitor over
the network. The rpm is then converted into
travel speed in the machine monitor for display.
WD600-6 10-903 11
SEN04998-02 Sensor
Modulation clutch pressure sensor
1. Sensor
2. Lead wire
3. Connector
Function
q Installed to the modulation clutch, this sensor
detects pressure of the clutch to be used for
calculating thermal load to the clutch.
10-903 12 WD600-6
Sensor SEN04998-02
Transmission oil temperature sensor

Torque converter oil temperature sensor
Hydraulic oil temperature sensor
Axle oil temperature sensor
1. Thermistor
2. Plug
3. Harness
4. Connector
Function
q Transmission oil temperature sensor detects
the internal temperature of transmission case.
The temperature data is used by transmission
controller to select the temperature table of
electronic modulation so as to control modula-
tion best matched to the oil temperature.
q Data from torque converter oil temperature
sensor and hydraulic oil temperature sensor is
detected by the machine monitor and indicated
to the gauges. At the same time, the data is
transmitted to the transmission controller via
network and used as the cooling fan control
data.
q Axle oil temperature sensor detects the inter-
nal oil temperature of rear axle with the moni-
tor, and outputs a caution signal when the
temperature rises to a high level.
WD600-6 10-903 13
SEN04998-02 Sensor
Driving force adjust dial
Function
q As the dial is turned, engagement ratio of 1st speed modulation clutch changes.
AJSS steering lock switch
Function
q When AJSS steering lock lever is operated,
steering pilot pressure circuit is cut off, lower-
ing the pilot pressure and opening the switch
accordingly.
q When the steering lock lever is OFF, the pilot
pressure is lowered while the engine is not run-
ning. As the result, AJSS does not operate
same as when the steering lock lever is ON.
10-903 14 WD600-6
Sensor SEN04998-02
AJSS knob
1. Horn switch: horn sounding switch Function

2. Shift down switch: Selects a gear speed.(shift q Directional switch is held at a selected posi-
down) tion. Transmission controller shifts gear
3. Shift up switch: Selects a gear speed.(shift up) according to the signal from the directional
4. Directional switch: Selects the travel direction switch.
and neutral. q Shift-up and -down switches select circuit only
while the switch is being depressed, and the
transmission controller uses this signal for gear
shifting operation accordingly.
q Horn switch operates the relay and sounds the
horn while it is being depressed.
WD600-6 10-903 15
SEN04998-02 Sensor
AJSS lever angle sensor

AJSS frame angle sensor
1. Connector 5. Bearing
2. Case 6. Contact
3. Shaft 7. Mold
4. Element
Function
q Lever angle sensor is installed to AJSS lever in
the L.H. console, and frame angle sensor is to
the follow-up linkage of the machine rear
frame. Data from these sensors are converted
to the lever angle and swing angle respectively
inside the work equipment controller.
10-903 16 WD600-6
Sensor SEN04998-02
Loader pump pressure sensor

Steering pressure sensor (VHMS (if equipped))
Rear brake pressure sensor (VHMS (if equipped))
Front brake pressure sensor (VHMS (if equipped))
1. Sensor
2. Connector
Function Operation
q Installed to the inlet port circuit for the control q When oil pressure led from the pressure input
valve, these sensors convert pump discharge port applies pressure to the diaphragm of oil
pressure to voltage and transmit to the gover- pressure sensor, the diaphragm is deformed
nor pump controller. from deflection.
q Gauge layer is installed to the opposite of the
diaphragm. Deflection of the diaphragm is con-
verted into output voltage by the resistance of
the gauge layer and is sent to the amplifier.
q After amplifying the voltage, the amplifier
transmits the voltage to the governor controller.
q Relational expression of pressure P (MPa {kg/
cm2}) and output voltage (V)
V = 0.08 {0.008} × P + 0.5
WD600-6 10-903 17
SEN04998-02 Sensor
Fuel level sensor
1. Connector 5. Spring
2. Float 6. Contact
3. Arm 7. Spacer
4. Body
Function
q The fuel level sensor is installed to the side of
the fuel tank. The float moves up and down
according to the fuel level.
The float moves the variable resistor through
the arm. The voltage signal is sent to the
machine monitor to indicate the fuel level.
Also, when the machine monitor indicator
reaches a specified position, caution lamp is lit.
10-903 18 WD600-6
Sensor SEN04998-02
Parking brake pressure switch
1. Case 3. Connector
2. Tube
Function
q When the parking brake is released, oil pres-
sure is fed to the brake piston. The oil pressure
operates the pressure switch to turn out the
parking brake pilot lamp on the machine moni-
tor.
WD600-6 10-903 19
SEN04998-02 Sensor
Air cleaner clogging sensor
1. Indicator 3. Adapter
2. Spring
Function
q The air cleaner clogging sensor is installed to
the air cleaner outlet. If the air cleaner is
clogged and the pressure reaches the speci-
fied level (negative pressure), caution lamp on
the machine monitor lights up to output a warn-
ing.
10-903 20 WD600-6
Sensor SEN04998-02
Transmission clogging sensor
1. Body Function
2. Tube q The clogging sensor is installed to the filter
3. Connector section. If the filter is clogged and the pressure
difference between the lower and higher sides
A: Take-out port on low pressure side reaches a specified level, the switch turns
B: Take-out port on high pressure side OFF, and the maintenance caution lamp lights
up. At the same time, a message appears to
the character display to warn on abnormal situ-
ation.
Operating pressure: 275 kPa {2.8 kg/cm2}
Principle of switching: Differential pressure slid-

ing piston type
WD600-6 10-903 21
SEN04998-02 Sensor
Engine oil level sensor
1. Connector 3. Float
2. Bracket 4. Switch
Function
q The engine oil level sensor is installed to the
side of the oil pan. If the oil level lowers below
the specified level, the float lowers and the
switch is turned “OFF”.
10-903 22 WD600-6
Sensor SEN04998-02
Steering oil pressure sensor switch
1. Body 3. Tube
2. Shaft 4. Connector
Function
q The steering oil pressure sensor switch detects
operation of diverter valve spool, which is
tripped to operate when the steering oil pres-
sure drops.
q If the steering oil pressure drops and the spool
operates, the switch piston is turned OFF and
the circuit opens.
WD600-6 10-903 23
SEN04998-02 Sensor
Radiator coolant level sensor
1. Stopper 4. Plug
2. Float 5. Tube
3. Sensor 6. Connector
Function
q The coolant level sensor is installed to the radi-
ator upper tank. If the coolant level lowers
below the specified level, the float lowers and
the switch is turned “OFF”.
10-903 24 WD600-6
Sensor SEN04998-02
Brake accumulator pressure switch (Rear and front)
2. Tube
Function
q If the brake accumulator oil pressure lowers,
the contact becomes OPEN, and the caution
lamp lights up on the machine monitor to warn
of abnormality.
WD600-6 10-903 25
SEN04998-02 Sensor
Battery electrolyte level sensor
1. Body 4. Packing
2. Connector 5. Pin
3. Filter
Function
q The battery electrolyte level sensor is installed
to the battery. If the battery electrolyte level
lowers below the specified level, the sensor tip
is exposed to air and a signal of voltage
change is generated. The signal is sent to the
machine monitor to warn of abnormal situation.
10-903 26 WD600-6
Sensor SEN04998-02
Atmospheric temperature sensor
Specifications
1. Power consumption: Max. 0.5 mW
2. Withstand pressure: 0.98 MPa {10 kg/cm2}
3. Temperature detection range (ambient): –30°C
to 120°C
4. Temperature conservation range: –50°C to
140°C
5. Performance table
Detected
tempera-
–20 –10 0 10 20 50
ture
(°C)
Resis-
tance 30.32 18.58 11.74 7.623 5.077 1.712
(kz)
a: Sensor heat sensitizing portion mount diame-

ter 16 × 1.5
Function
This sensor inputs the atmospheric temperature to
the VHMS controller as a variation of the thermistor
resistance.
WD600-6 10-903 27
SEN04998-02 Sensor
Exhaust temperature sensor and amplifier
Specifications
1. Rated output: DC 24 V
2. Temperature detection range:
100 to 1000°C
300 to 800°C (guaranteed accuracy ±10°C)
3. Output voltage characteristics: as per perfor-
mance table below
4. Range of operating temperature: –40 to 110°C
5. Current consumption: Max. 30 mA
a: Sensor heat sensitizing portion mount diame-

ter R1/8
b: Amplifier
c: Connector (power supply side)
c: Connector (sensor side)
Output voltage characteristics

(ambient temperature: 20°C)…Reference value
Detected
tempera-
50 100 400 700 800
ture
(°C)
Output
voltage 1.191 1.397 2.626 3.899 4.316
(V)
Function
A thermocouple type temperature sensor installed
to the inlet port of turbocharger. It outputs the
exhaust temperature data to the VHMS controller.
10-903 28 WD600-6
Sensor SEN04998-02
Blow-by pressure sensor
Specifications
1. Supply voltage: DC 5 V
2. Output voltage: 0.5 V (when engine stops) and
up
3. Size: Mount (portion “a”) R1/4
Outside diameter of pressure-receiving
seat 37
Cable length 1,110 mm
Function
Converts the internal pressure of engine crankcase
into voltage and inputs the data to the VHMS con-
troller as a blow-by pressure value.
WD600-6 10-903 29
SEN04998-02 Sensor
Communication (ORBCOMM) controller and antenna
Controller
Specifications
1. Operating power supply voltage: DC 12 V to
DC 30 V
2. Size: W306 × D152 × H52 (mm)
Installed position
Installed to under the auxiliary seat.
Connector section
CN1A(ORB-A): AMP070-14
CN1B(ORB-B): SMP070-10
CN2: Communication antenna cable connector
Antenna
Specifications
1. Type: helical whip antenna (1)
2. Impedance: 50 z
3. Input terminal: M-P type
4. Length: 165 ± 20 mm
a: Communication antenna mount
Installed position
Installed on the outside of the cab, at the L.H. front
of the upper part.
Function
Transmits data collected and stored by the VHMS
controller to the computer center via communica-
tions satellites.
10-903 30 WD600-6
Sensor SEN04998-02
Communication (IRIDIUM) controller and antenna
Controller
Specifications
1. Operating power supply voltage: DC 12 V to
DC 24 V
2. Size: W206 × D114 × H50 (mm)
Installed position
Installed to rear of the R.H. console box.
Connector section
&1$ &1% &1 *
CN1A: AMP070-14
CN1B: SMP070-10
CN2: Communication antenna cable connector

Antenna
Specifications
1. Type: Iridium antenna IRD LP/S/BNC-KM/0.15
(1)
2. Impedance: 50 z
3. Connector: BW-P-1.5D
4. Cable length: 150 ± 10 mm
*
a: Communication antenna mount
D
*
Installed position
Installed on the outside of the cab, at the L.H. front
of the upper part.
Function
Transmits data collected and stored by the VHMS
controller to the computer center via communica-
tions satellites.
*
WD600-6 10-903 31
SEN04998-02 VHMS controller related
VHMS controller related 1
a For details of basic precautions, outlines, see

“Testing and adjusting”.
VHMS controller
a For details of basic precautions, outlines,
method of sending and receiving data, and the
procedure for the initial setup, see “Testing and
adjusting”.
Specification
1. Voltage of power supply: DC20V – DC30V
2. Size (mm): W272 × D169 × H72
Function
The VHMS controller collects and stores signals
from each sensor and signals from the machine
controller. It also gives commands for transmitting
the accumulated data through the communications
satellite.
CAN-BUS cable (China mine specification)
1. VHMS harness 6. VHMS controller

2. CAN-BUS cable 7. Receiver side electronic control unit
3. Connector 8. Right console box
4. Terminating resistor (VHMS harness) J1. Branch
5. Terminating resistor (CAN-BUS cable)
10-903 32 WD600-6
VHMS controller related SEN04998-02
Specifications
1. Cable: must conform to standard of ISO11898-2 and SAE J1939/11
Length of cable is regulated.

Parameter Symbol Max Conditions
Bus Length L 39.8 m not including cable stubs
Cable Stub Length S 1m
Node Distance d 39.86 m
Minimum Distance from Resistance d0 - Resistance shall not be within an Electronic Control Unit
2. Terminating Resistor 120 Ohm Total two pieces

a One terminating resistor (4) is installed on VHMS harness (1) on machine side.
Add another terminating resistor (5) to CAN-BUS cable (2) on receiver side.
3. Connector
Part number: DT04-12PC-BE02 (Receptacle)
Provided by: Deutsch
Color: Green
Required wedge P/N: W12P
Number of contacts: 12
Polarizing position: C
Pin assignment table

Pin # Assigned for
1 UNSWITCHED POWER 24 V
2 KEY ACC
3 CAN H
4
5
6 MAIN POWER 24 V
7
8
9
10 CAN L
11 CAN SHIELD
12 POWER GND
Installed position
Connect CAN-BUS cable (2) to connector (3) in the right console box (8)
Function
Data collected and accumulated by VHMS controller (6) is sent to Electronic control unit (7) on receiver side
WD600-6 10-903 33
Accelerator pedal sensor
1. Pedal 2. Connector
Function
Accelerator signal
q Accelerator pedal installed to the floor is pro-
vided with accelerator sensor for the engine
controller. When the accelerator pedal is
stepped on, the potentiometer shaft inside the
accelerator sensor starts rotation and resis-
tance value changes accordingly. Potentiome-
ter is applied with a constant level of voltage
from the engine controller. Voltage signal is
transmitted to the engine controller according
to the depressed angle of accelerator pedal. In
addition, the depressed angle is transmitted to
each controller over the network as the accel-
erator pedal opening data.
Idle validation signal

q The idle validation switch is installed to the
same case with the accelerator pedal sensor.
While the accelerator pedal is released, signal
2 is connected to the ground. When the accel-
erator pedal is pressed, signal 3 is connected
to the ground. The engine controller judges by
these signals whether the accelerator pedal is
released or pressed.
10-903 34 WD600-6
VHMS controller related SEN04998-02
Stop lamp pressure switch
2. Tube
Function
q When the foot brake is stepped on and the brake operating pressure is generated, the pressure switch
contact is closed, the relay is operated and stop lamp lights up.
Emergency brake pressure switch (rear)

Emergency brake pressure switch (front)
2. Tube
Function
q When the brake accumulator pressure lowers, the switch contact opens. Circuit between the parking
brake switch and parking brake solenoid is cut off, and the parking brake is tripped to operate.
WD600-6 10-903 35
Resistor for directly coupling modulation clutch
Function
q Resistor for allowing appropriate current to
flow to the ECMV solenoid for modulation
clutch when the modulation clutch direct-cou-
pling switch is turned ON.
q No current flows when the modulation clutch
direct-coupling switch is turned OFF.
Resistance: 30 z
10-903 36 WD600-6
Electric lever (Work equipment) SEN04998-02
Electric lever (Work equipment) 1

a Do not disassemble.
Otherwise, adjustments will be required for the characteristics of voltage output and operating efforts.
1. Boot
WD600-6 10-903 37
SEN04998-02 Electric lever (Work equipment)
Function
Operating effort characteristics
Operation for RAISE, LOWER and FLOAT
q The control lever is held at position: “FLOAT”. q Free return
10-903 38 WD600-6
Electric lever (Work equipment) SEN04998-02
Operation for LEFT and RIGHT tilt Output voltage characteristics

q Free return q The control unit is installed to the right control
stand and the control lever is installed directly
onto it.
q The operating angle [stroke] of the control
levers sensed with potentiometers and signal
voltages are output to the controller.
q Two potentiometers are installed; one is for
blade RAISE/LOWER operation and the other
is for tilt RIGHT/LEFT operation. Those poten-
tiometers output two opposite signal voltages
shown below.
WD600-6 10-903 39
SEN04998-02
WD600-6 Wheel dozer

©2019 KOMATSU
All Rights Reserved
10-903 40
SEN05044-02
WHEEL DOZER
WD600-6

WD600-6 55001 and up
20 Standard value table 20
100 Standard service value table

Standard service value table for engine .......................................................................................................... 2
Standard service value table for chassis......................................................................................................... 3
WD600-6 20-100 1
SEN05044-02 Standard service value table for engine
Standard service value table for engine 1
Machine model WD600-6

Engine SAA6D170E-5
Standard value for
Item Measurement conditions Unit new machine Service limit value
High idle (E-mode) 1,900 ± 50 1,900 ± 50

High idle (P-mode) 2,000 ± 50 2,000 ± 50
• Engine coolant Low idle (E-mode) 800 ± 25 800 ± 25
Engine speed temperature: Within rpm
operating range Low idle (P-mode) 800 ± 25 800 ± 25
Rated speed (E-mode) 1,700 1,700
Rated speed (P-mode) 1,800 1,800
• All revolution ranges
Exhaust temperature °C Max. 680 700
• Atmospheric temperature: 20°C
Intake air pressure kPa Min. 126.6 Min. 113.3
• At rated output (P-mode)
(Boost pressure) (mmHg) {Min. 950} {Min. 850}
• Engine coolant tem- At sudden acceleration Max. 4.0 5.0
Bosch
Exhaust gas color perature: Within oper-
At high idle (P-mode) index Max. 0.5 2.0
ating range
Intake valve 0.32 —
Valve clearance • Normal temperature mm
Exhaust valve 0.62 —
Compression Engine oil temperature: 40 – 60°C MPa Min. 2.94 2.1
pressure Engine speed: 210 – 250 rpm {kg/cm2} {Min. 30} {21}
• At rated output (P-mode) kPa Max. 3.43 9.41
Blow-by pressure
• Engine coolant temperature: Min. 70°C (mmH2O) {Max. 350} {960}
At rated output Min. 0.39 0.24
• Engine oil tempera- (P-mode) {Min. 4.0} {2.4}
Oil pressure ture: Min. 80°C MPa
{kg/cm2} Min. 0.1 0.08
• SAE30 oil At low idle
{Min. 1.0} {0.8}
• At low idle MPa Min. 1.18 —

EGR valve and {kg/cm2} {Min. 12}
bypass valve drive oil
pressure MPa Min. 1.43
• At high idle —
{kg/cm2} {Min. 14.6}
Oil temperature • All engine speed ranges (Inside oil pan) °C 90 – 110 120
Belt tension for alter-
Deflection made by finger pressure of about
nator and air condi- 98 N {10 kg} mm Auto-tensioner Auto-tensioner
tioner compressor
20-100 2 WD600-6
Standard service value table for chassis SEN05044-02
Standard service value table for chassis 1
*: The value shows the value before the detent.

Category
Standard value for Service limit

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

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

switch (*1)
Operating 5.0 ± 1.0 5.0 ± 2.0

Upshift N {kg}
effort • Engine stopped {0.5 ± 0.1} {0.5 ± 0.2}
• Measure at center of lever knob 5.0 ± 1.0 5.0 ± 2.0
Downshift
{0.5 ± 0.1} {0.5 ± 0.2}
N o FORWARD,
Directional
Operating 5.9 (+4.9/–2.9) Max. 16.7

lever (*2)
N {kg}
effort REVERSE • Engine stopped {0.6 (+0.5/–0.3)} {Max. 1.7}
N o FORWARD, • Measure at center of lever knob
Stroke mm 35 ± 10 35 ± 10
REVERSE
5.9 (+4.9/–2.9) Max. 16.7
1st o 2nd
{0.6 (+0.5/–0.3)} {Max. 1.7}
Gearshift lever (*2)
Operating 5.9 (+4.9/–2.9) Max. 16.7

2nd o 3rd N {kg}
effort {0.6 (+0.5/–0.3)} {Max. 1.7}
• Engine stopped 5.9 (+4.9/–2.9) Max. 16.7
3rd o 4th • Measure at center of lever knob {0.6 (+0.5/–0.3)} {Max. 1.7}
1st o 2nd 35 ± 10 35 ± 20
Stroke 2nd o 3rd mm 35 ± 10 35 ± 20
3rd o 4th 35 ± 10 35 ± 20
10 ± 5 10 ± 8
HOLD o RAISE
{1.0 ± 0.5} {1.0 ± 0.8}
HOLD o LOWER 8±3 8±5
(*3) {0.8 ± 0.3} {0.8 ± 0.6}
Lift
Operating effort
16 ± 5 16 ± 8
LOWER o FLOAT • Engine speed: Low idle
• Hydraulic oil temperature: {1.6 ± 0.5} {1.6 ± 0.8}
45 – 55°C N {kg}
Work equipment control lever
10 ± 5 10 ± 8
FLOAT o HOLD • Measuring position:
{1.0 ± 0.5} {1.0 ± 0.8}
147 mm from the lower part of boot
HOLD o TILT RH 10 ± 5 10 ± 8
(PITCH REAR) {1.0 ± 0.5} {1.0 ± 0.8}
Tilt and
pitch HOLD o TILT LH 10 ± 5 10 ± 8
(PITCH FOR-
{1.0 ± 0.5} {1.0 ± 0.8}
WARD)
HOLD io RAISE 56 ± 6 56 ± 9
HOLD io LOWER
Lift 44 ± 5 44 ± 8
(*3) • Engine speed: Low idle
HOLD io FLOAT • Hydraulic oil temperature: 12 ± 2 12 ± 3
Stroke
HOLD o TILT RH 45 – 55°C mm

56 ± 6 56 ± 9
(PITCH REAR) • Measuring position:
Tilt and 147 mm from the lower part of boot
pitch HOLD o TILT LH
(PITCH FOR- 56 ± 6 56 ± 9
WARD)
(*1): AJSS specification
(*2): Steering wheel specification
(*3): Shows the value before detent
WD600-6 20-100 3
SEN05044-02 Standard service value table for chassis

Category

new machine value
• Engine stopped
Play mm Max. 40 50 – 100
• Machine facing straight to front
• Flat, level, straight, dry, and paved
road 10.0 ± 3 Max. 19.6
Steering wheel
Operating effort N {kg}

• Engine speed: Low idle {1.0 ± 0.3} {Max. 2.0}
(Bucket empty)
• Engine speed: High idle
Turns (Not including play) Turns 3.9 ± 0.3 Max 4.5
• Left lock – right lock
Low idle • Engine started Max. 9.0 Max. 9.8

Operating • Hydraulic oil temperature:
sec.
time High idle 45 – 55°C
Max. 4.8 Max. 5.8
(P-mode) • Left lock – right lock
• Engine started
37.5 ± 7.5 Max. 56.4
Accelerator pedal
Operating effort • Measure at 150 mm from fulcrum N {kg}

{3.83 ± 0.8} {Max. 5.75}
of pedal.
aFor measuring posture, see Fig. A
Neutral (a1) at end of this section 45 ± 2 —
Operating
• Engine speed: Low idle deg.
angle
Max. (a2) • Hydraulic oil temperature: Within 17 ± 2 —
operating range
Left brake pedal Right brake pedal
294 ± 29.4 Max. 421.4

Operating effort aFor measuring posture, see Fig. B N {kg} {30 ± 3} {Max. 43}
Neutral (a1) at end of this section 45 —
Operating
• Engine speed: Low idle
angle Max. (a2) 15(+1/0) —
• Hydraulic oil temperature: Within deg.
operating range
Play 5 ± 0.5 —
274 ± 30 Max. 393

Operating effort aFor measuring posture, see Fig. B N {kg} {27.9 ± 3.1} {Max. 40}
at end of this section
Operating Neutral (a1) • Engine speed: Low idle 55 —
angle Max. (a2) • Hydraulic oil temperature: Within deg. 18.5 ± 0.5 —
operating range
Play 1.5(+0.5/–0.8) —
A aFor measuring posture, see Fig. C Max. 2.5 —
Fitting of wheel lock ring
B at end of this section Max. 4.0 —
Tire
mm
Clearance of wheel lock • Tire inflation pressure: Specified
C pressure 2 – 15 —
ring
• Engine coolant temper- P-mode 1,800 ± 100 1,800 ± 200
Torque converter stall ature: Within operating E-mode 1,730 ± 100 1,730 ± 200
Engine speed
range
• Torque converter oil P-mode 1,940 ± 100 1,940 ± 200
Hydraulic stall
temperature: Within E-mode rpm 1,830 ± 100 1,830 ± 200
operating range P-mode 1,680 ± 100 1,680 ± 300
Torque converter stall + hydrau- • Hydraulic oil tempera-
lic stall ture: Within operating E-mode 1,590 ± 100 1,590 ± 300
range
• Engine stopped
Play deg. Max. 8 Max. 10
• Machine facing straight to front
• Flat, level, straight, dry, and paved 13.7 ± 4.9
Operating effort N {kg} 23.5 {2.4}
AJSS lever
road {1.4 ± 0.5}

Operating angle deg. 86 ± 5 Max. 95
• Left lock – right lock
Low idle • Engine started Max. 9.6 Max. 10.6

Operating • Hydraulic oil temperature: Within
sec.
time High idle operating range
Max. 5 Max. 6
(P-mode) • Left lock – right lock
20-100 4 WD600-6

Category

new machine value
Min. 3.09 Min. 3.09

Low idle • Torque converter oil temperature:
Main relief {Min. 31.5} {Min. 31.5}
Within operating range
pressure 3.65 ± 0.2 3.65 ± 0.2
High idle • Working mode: P-mode
{37.2 ± 2.0} {37.2 ± 2.0}
Torque converter inlet port oil 0.94 ± 0.2 0.94 ± 0.2
pressure {9.6 ± 2.0} {9.6 ± 2.0}
Torque converter outlet port oil • Torque converter oil temperature: 0.57 ± 0.1 0.57 ± 0.1
pressure Within operating range {5.8 ± 1.0} {5.8 ± 1.0}
Transmission, torque converter
• Working mode: P-mode 2.48 ± 0.2 2.48 ± 0.2

Modulation clutch oil pressure • Engine speed: High idle {25.3 ± 2.0} {25.3 ± 2.0}
0.12 ± 0.06 0.12 ± 0.06
Lubrication oil pressure
{1.2 ± 0.6} {1.2 ± 0.6}
MPa 2.68 ± 0.2 2.68 ± 0.2
F clutch
{kg/cm2} {27.3 ± 2} {27.3 ± 2}
3.12 ± 0.2 3.12 ± 0.2
R clutch
{31.8 ± 2.0} {31.8 ± 2.0}
3.07 ± 0.2 3.07 ± 0.2
1st clutch • Torque converter oil temperature: {31.3 ± 2.0} {31.3 ± 2.0}
ECMV output Within operating range
2.09 ± 0.2 2.09 ± 0.2
(clutch) oil 2nd clutch • Working mode: P-mode
{21.3 ± 2.0} {21.3 ± 2.0}
pressure • Engine speed: High idle
• Manual switch: ON 3.07 ± 0.2 3.07 ± 0.2
3rd clutch
{31.3 ± 2.0} {31.3 ± 2.0}
3.07 ± 0.2 3.07 ± 0.2
4th clutch
{31.3 ± 2.0} {31.3 ± 2.0}
1.84 ± 0.2 1.84 ± 0.2
Lockup clutch
{18.8 ± 2.0} {18.8 ± 2.0}
• Hydraulic oil temperature: 45 – 55°C 33.3 ± 0.98 33.3 ± 0.98
Steering relief pressure
• Engine speed: High idle (P-mode) {340 ± 10} {340 (+10/–20)}
• Hydraulic oil temperature: 45 – 55°C
• Engine speed: High idle (P-mode) 2.45 ± 0.1 2.45 ± 0.2
AJSS EPC pressure
Steering
• Operating AJSS fully {25 ± 1} {25 ± 2}

• Frame lock bar: Lock position MPa
{kg/cm2}
Min. 0.49 Min. 0.49
Pilot circuit pressure • Engine speed: High idle (P-mode)
{Min. 5} {Min. 5}
• Steering wheel or AJSS operation
• Hydraulic oil temperature: 45 – 55°C 1.18 – 1.47 0.98 – 1.67
Steering control oil pressure
• Engine speed: High idle (P-mode) {12 – 15} {10 – 17}
• Point where
brake oil pres- 5.88 (+0.49/0) 5.88 (+0.98/–0.49)
Charge cut-in pressure • Engine speed: sure warning {60 (+5/0)} {60 (+10/–5)}
Accumulator
Low idle lamp goes out

• Hydraulic oil MPa
temperature: • Point where oil {kg/cm2}
Within operat- pressure is
9.8 (+0.98/0) 9.8 (+1.47/–0.49)
Charge cut-out pressure ing range going up and
{100 (+10/0)} {100 (+15/–5)}
then starts to go
down
WD600-6 20-100 5

Category

new machine value
1st 6.7 ± 0.3 6.7 ± 0.3
11.7 ± 0.6 11.7 ± 0.6

2nd
P-mode (12.4 ± 0.6) (12.4 ± 0.6)
• ( ): at lockup 20.3 ± 1.0 20.3 ± 1.0
3rd
(21.7 ± 1.1) (21.7 ± 1.1)
33.0 ± 1.7 33.0 ± 1.7
4th
FOR- (37.7 ± 1.9) (37.7 ± 1.9)
WARD
1st 6.3 ± 0.3 6.3 ± 0.3
11.1 ± 0.6 11.1 ± 0.6

2nd
E-mode (12.1 ± 0.6) (12.1 ± 0.6)
• ( ): at lockup 19.2 ± 1.0 19.2 ± 1.0
3rd
(20.9 ± 1.0) (20.9 ± 1.0)
Power train
30.0 ± 1.5 30.0 ± 1.5

4th
(35.5 ± 1.8) (35.5 ± 1.8)
Travel speed km/h
1st 7.3 ± 0.4 7.3 ± 0.4
12.8 ± 0.6 12.8 ± 0.6

2nd
P-mode (13.5 ± 0.7) (13.5 ± 0.7)
• ( ): at lockup 22.0 ± 1.1 22.0 ± 1.1
3rd
(23.7 ± 1.2) (23.7 ± 1.2)
36.0 ± 1.8 36.0 ± 1.8
4th
(41.0 ± 2.1) (41.0 ± 2.1)
REVERSE
1st 6.9 ± 0.3 6.9 ± 0.3
12.1 ± 0.6 12.1 ± 0.6

2nd
E-mode (12.8 ± 0.6) (12.8 ± 0.6)
• ( ): at lockup 20.7 ± 1.0 20.7 ± 1.0
3rd
(22.5 ± 1.1) (22.5 ± 1.1)
30.7 ± 1.5 30.7 ± 1.5
4th
(38.4 ± 1.9) (38.4 ± 1.9)
• Hydraulic oil temperature: Within 4.9 (+0.69/0) 4.9 (+0.88/–0.2)
Brake oil pressure
operating range {50 (+7/0)} {50 (+9/–2)}
• Engine stopped MPa
• Keep brake pedal depressed at 4.9 {kg/cm2} Max. 0.49 Max. 0.49
Drop in brake pressure
MPa {50 kg/cm2} and measure {Max. 5} {Max. 5}
drop in oil pressure after 5 min.
Wheel brake
• Tire inflation pressure: Specified

pressure
• Flat, level, straight, dry, and paved
road
• Speed when applying brake: 20 km/h,
Performance m Max. 5 Max. 5
braking delay: Within 0.1 sec.
• Brake pedal operating effort:
Specified operating effort
29.4 ± 2.94 N {30 ± 3 kg}
• Measure braking distance
Disc wear • Measure with disc wear indicator mm 0 Max. 5.5
20-100 6 WD600-6

Category

new machine value
Min. 2.45 Min. 2.45

Parking brake inlet pressure
{Min. 25.0} {Min. 25.0}
• Torque converter oil temperature:
MPa Min. 3.09 Min. 3.09
Parking brake pilot pressure Within operating range
{kg/cm2} {Min. 31.5} {Min. 31.5}
• Engine speed: Low idle
Parking brake
Parking brake solenoid valve Min. 2.45 Min. 2.45

output pressure {Min. 25.0} {Min. 25.0}
• Tire inflation pressure: Specified
pressure
Performance • Flat paved road with 1/5 (11° 20') — Holds in position Holds in position
grade. Dry, paved road surface
• Machine at operating condition
Disc thickness mm 3.2 ± 0.08 Min. 2.97
Work equipment
EPC valve basic pressure • Hydraulic oil temperature: 45 – 55°C 4.02 (+0.2/–0.2) 4.02 (+0.2/–0.2)
(Orbit-roll input pressure) • Engine speed: High idle (P-mode) {41 (+2/–2)} {41 (+2/–2)}
EPC
• Hydraulic oil temperature: Within MPa

EPC valve Lift RAISE, {kg/cm2} 4.02 (+0.2/–0.2)
operating range 4.02 (+0.2/–0.2)
output pres- FLOAT, Blade TILT,
• Engine speed: High idle (P-mode) {41 (+2/–2)} {41 (+2/–2)}
sure Pitch
• Control lever operated fully
• Hydraulic oil temperature: Within
operating range 24.5 (+0.5/–0.5) 24.5 (+0.5/–0.5)
Work equipment relief pressure
• Engine speed: High idle {250 (+5/–5)} {250 (+5/–5)}
Work equipment
• Blade lever: PITCH REAR

• Hydraulic oil temperature: 45 – 55°C MPa
3.14 ± 0.29 3.14 ± 0.59
Unload pressure • Engine speed: High idle (P-mode) {kg/cm2}
{32 ± 3} {32 ± 6}
• Work equipment control lever: Neutral
1.67 ± 0.2 1.67 ± 0.39
LS differential pressure • Engine speed: High idle (P-mode)
{17 ± 2} {17 ± 4}
• Lift arm lever: at half stroke
WD600-6 20-100 7

Category

new machine value
• Hydraulic oil tempera- P-mode 2.0 ± 0.3 Max. 3

Blade RAISE ture: Within operating
range
E-mode 2.1 ± 0.3 Max. 3.2
• Apply no load
P-mode 1.3 ± 0.3 Max. 2.0
aFor measuring posture,
Blade LOWER see Figs. F and G at end
of this section E-mode 1.3 ± 0.3 Max. 2.0
Work equipment speed
• Hydraulic oil tempera- P-mode 1.1 ± 0.3 Max. 1.7

RH tilt ture: Within operating
range
E-mode 1.2 ± 0.3 Max. 1.8
Blade • Engine speed: High idle
sec.
tilt • Apply no load
P-mode 0.8 ± 0.3 Max. 1.2
Work equipment
LH tilt see Fig. H at end of this

section E-mode 0.8 ± 0.3 Max. 1.2
• Hydraulic oil tempera- P-mode 2.1 ± 0.3 Max. 3.2

Pitch FORWARD ture: Within operating
range
E-mode 2.2 ± 0.3 Max. 3.3
Blade • Engine speed: High idle
pitch • Apply no load
P-mode 1.6 ± 0.3 Max. 2.4
Pitch REAR see Figs. J and K at end
of this section E-mode 1.6 ± 0.3 Max. 2.4
• Hydraulic oil temperature: Within
operating range
Hydraulic drift
• Stop engine and leave for 5 minutes,

then measure for 15 minutes.
Blade teeth mm Max. 100 Max. 100
aApply lift arm and blade in level posi-
tion.
aFor measuring posture, see Fig. L at
end of this section
• Engine speed: High idle (P-mode)
• Engine coolant temperature: Min. 95°C
Max. fan speed • Hydraulic oil temperature: Min. 95°C 980 ± 50 980 ± 100
Min. 105°C
• Engine speed: High idle rpm
• Engine coolant temperature: Max.
Hydraulic drive fan
75°C
Min. fan speed 200 ± 30 200 ± 50
• Hydraulic oil temperature: Max. 75°C
Max. 85°C
• Engine speed: High idle (P-mode)
19.6 ± 2.5 19.6 ± 2.5
Fan drive pressure • Hydraulic oil temperature: Min. 95°C
{200 ± 25} {200 ± 25}
Min. 105°C MPa
• Engine speed: High idle (P-mode) {kg/cm2}
Fan reverse solenoid output 25 ± 2.5 25 ± 2.5
• Hydraulic oil temperature: Min. 95°C
pressure {255 ± 25} {255 ± 25}
Min. 105°C
20-100 8 WD600-6
WD600-6 20-100 9
Machine posture and procedure for performance measurement
a Fig. A a Fig. D
a Fig. B a Fig. E
a Fig. C a Fig. F
20-100 10 WD600-6
a Fig. G a Fig. K
a Fig. H a Fig. L
a Fig. J
WD600-6 20-100 11
SEN05044-02
WD600-6 Wheel dozer

©2018 KOMATSU
All Rights Reserved
20-100 12
SEN05045-03
WHEEL DOZER
WD600-6

WD600-6 55001 and up
30 Testing and adjusting 30
101 Testing and adjusting, Part 1

Tools for testing, adjusting, and troubleshooting............................................................................................. 3
Sketches of special tools ................................................................................................................................ 8
Measuring engine speed................................................................................................................................. 9
Measuring exhaust gas color .........................................................................................................................11
Measuring exhaust temperature ................................................................................................................... 12
Adjusting valve clearance ............................................................................................................................. 14
Testing compression pressures .................................................................................................................... 16
Measuring blow-by pressure......................................................................................................................... 19
Measuring engine oil pressure...................................................................................................................... 20
Testing EGR valve and bypass valve drive oil pressure ............................................................................... 21
Measuring intake air (boost) pressure .......................................................................................................... 23
Handling fuel system equipment................................................................................................................... 24
Releasing residual pressure in fuel system .................................................................................................. 24
Testing fuel pressures ................................................................................................................................... 25
Testing return rate and leakage .................................................................................................................... 26
Bleeding air from fuel circuit.......................................................................................................................... 29
Testing leakage in fuel system ...................................................................................................................... 31
Handling reduced cylinder mode operation .................................................................................................. 32
Handling no-injection cranking operation...................................................................................................... 32
Handling controller voltage circuit ................................................................................................................. 33
Replacing and adjusting alternator and air conditioner compressor belt tension.......................................... 34
Adjusting modulation clutch speed sensor and speed sensor ...................................................................... 35
Measuring directional lever and gear shift lever (Steering wheel specification)............................................ 37
WD600-6 30-101 1
SEN05045-03
Testing and adjusting power train oil pressure .............................................................................................. 38

Flushing procedure for torque converter and transmission hydraulic circuit ................................................. 52
Method of moving machine when transmission valve is broken ................................................................... 54
Moving method of machine disabled by short-to-power failure in work equipment potentiometer................ 56
Adjusting steering stop valve ........................................................................................................................ 58
30-101 2 WD600-6
Tools for testing, adjusting, and troubleshooting SEN05045-03
Tools for testing, adjusting, and troubleshooting 1
Testing and Sym-

Part No. Part Name Q'ty Remarks
adjusting item bol
1 799-201-9001 Handy smoke checker 1 Bosch index: Level 0 – 9
Measuring exhaust gas
A Commercially
color 2 Smoke meter 1
available
Measuring exhaust
B 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
temperature
Adjusting valve Commercially
C Clearance gauge 1
clearance available
1 795-502-1590 Compression gauge 1 0 – 7 MPa {0 – 70 kg/cm2}
795-611-1220 Adapter 1
Measuring compression 2
D 6261-71-6150 Gasket 1
pressures
795-799-5410 Adapter 1
3
795-799-5420 Remover 1
Measuring blow-by
E 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
pressure
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
Measuring engine oil 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
pressure 2 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
799-101-5230 Nipple 1 14 × 1.5 mm
3
6215-81-9720 O-ring 1
F
795T-690-1110 Block 1
4 01435-00835 Bolt 2
Testing drive oil pres-
07000-E2012 O-ring 3
sure of EGR valve and
bypass valve Pressure gauge: 2.5, 6, 40, 60 MPa
5 799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
6 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
Measuring intake air
G 1 799-201-2202 Boost gauge kit 1 –101 – 200 kPa {–760 – 1,500 mmHg}
(boost) pressure
1 {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
Measuring fuel 795-471-1450 Adapter 1
H
pressures 2
07005-00812 Seal washer 1
3 799-101-5160 Nipple 1
4 799-401-2320 Hydraulic tester 1 Pressure gauge: 1 MPa {10 kg/cm2}
1 6167-11-6640 Spacer 1 Inside diameter: 10 mm
2 6206-71-1770 Joint 1 Inside diameter of joint: 10 mm
Commercially
3 Hose 1 Ø 5 mm × 2 – 3 m
available
Testing fuel return rate Commercially
J 4 Hose 1 Ø 15 mm × 2 – 3 m
and leakage available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
WD600-6 30-101 3
SEN05045-03 Tools for testing, adjusting, and troubleshooting
Testing and Sym-

adjusting item bol
Measuring directional
K 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
lever
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
L
power train oil pressure
799-101-5220 Nipple 1 Size: M10 × 1.25
2
07002-11023 O-ring 1 Pressure gauge: 1 MPa {10 kg/cm2}
Method of moving
machine when trans- M 794-423-1190 Plug 1 M20 × 1.5
mission valve is broken
Measuring operating
N 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
effort of AJSS lever
Testing and adjusting
P 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
steering wheel
Gas charging tool assem-
1 792-610-1703 1
bly
2 07000-11009 O-ring 1
3 792-610-2410 Bushing 1
4 792-610-1270 Hose 1
5 792-610-1400 Regulator 1
792-610-1310 Nipple (For Russia) GOST
Testing of accumulator
nitrogen gas pressure 792-610-1320 Nipple (For USA) CGA No. 351
and procedure for P ASA
charging accumulator 792-610-1330 Nipple (For USA)
B-571-1965
with nitrogen gas
6 1 DIN 477-1963
NEN 3268-1966
792-610-1350 Nipple (For Germany)
SIS-SMS
2235/2238
BS341
792-610-1360 Nipple (For UK)
Part 1-1962
Commercially
7 Nitrogen gas cylinder 1
available
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting 799-101-5220 Nipple 1 Size: M10 × 1.25
Q
steering oil pressure 2
07002-11023 O-ring 1
3 799-401-2701 Differential pressure gauge 1
4 799-401-3200 Adapter 1 Size 03
1 799-205-2200 Tachometer kit 1 Digital indication: 6 – 99999.9 rpm
2 {25, 60, 400, 600 kg/cm2}
Testing hydraulic drive 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
R
fan
799-101-5220 Nipple 1 Size: M10 × 1.25
3 07002-11023 O-ring 1
799-401-3500 Adapter 1 Size 06
30-101 4 WD600-6
Testing and Sym-

adjusting item bol
1 {25, 60, 400, 600 kg/cm2}
Bleeding air from 799-101-5220 Nipple 1 Size: M10 × 1.25
S
hydraulic drive fan circuit 2
07002-11023 O-ring 1
3 799-401-3500 Adapter 1 Size 06
4 790-261-1130 Coupling 1
Testing and adjusting Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester
accumulator charge T {25, 60, 400, 600 kg/cm2}
pressure 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
1 793-520-1821 Nipple 1
Testing wheel brake oil 2 793-520-1810 Joint 1
U
pressure 3 385-10178481 Bleeder screw 1
4 793-520-1831 Case assembly 1 M20 × 1.5 (R1/8)
Measuring wear of Commercially
V Slide calipers 1
wheel brake disc available
1 {25, 60, 400, 600 kg/cm2}
Testing parking brake
W
oil pressure 799-101-5220 Nipple 1 Size: M10 × 1.25
2
07002-11023 O-ring
3 799-401-3100 Adapter 1 Size 02
Testing wear of parking Commercially
X Slide calipers 1
brake disc available
Measuring and adjust- 1 79A-264-0021 Push-pull scale 1
ing work equipment Y Commercially
control lever 2 Scale 1
available
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
work equipment oil Z
799-101-5220 Nipple Size: M10 × 1.25
pressure 2
07002-11023 O-ring
3 799-401-2701 Differential pressure gauge 1
1 426-06-32171 Wiring harness 1
Moving machine when
ZA 2 08086-10000 Starting switch 1
removing operator cab
3 421-06-36142 Parking brake switch 1
1 799-608-3101 Service kit 1
2 799-608-3211 • Diskette 1
3 799-608-3220 • Harness 1
VHMS controller initial
ZB Commercially Note type personal com-
setting procedure 4 1 OS: Windows 98/2000/Me/XP/Vista
available puter
Commercially RS232C-USB conversion
5 1
available cable
WD600-6 30-101 5
SEN05045-03 Tools for testing, adjusting, and troubleshooting
Testing and Sym-

adjusting item bol
799-601-4101
or T-adapter assembly 1
799-601-4200
For coolant temperature sensor
795-799-5530 • Socket 1 For fuel temperature sensor
For oil temperature sensor
795-799-5540 • Socket 1 For boost temperature sensor
Troubleshooting for
799-601-4130 • T-adapter 1 For Ne sensor
controllers, sensors,
ZC 799-601-4150 • T-adapter 1 For oil pressure sensor
actuators and wiring
harnesses 799-601-4240 • Socket 1 For ambient pressure sensor
799-601-4250 • Socket 1 For boost pressure sensor
799-601-4330 • Socket 1 For G (Bkup) sensor
For common rail pressure sensor
799-601-9420 • T-adapter 1 (included in 799-601-9000 and
799-601-9200, too)
799-601-9430 • Socket 1 For supply pump PCV
799-601-4100
or
799-601-4200
799-601-9000
or
799-601-9200
For engine controller 60P
799-601-4220 • DRC26 adapter 1
(Only 799-601-4100)
For DTM 2P (Does not included
799-601-9010 • DTM adapter
799-601-4100 and 799-601-4200)
799-601-9020 • DT adapter 1 For DT 2P
For DT 3P (Does not included
799-601-9030 • DT adapter 1
799-601-4100 and 799-601-4200)
799-601-9040 • DT adapter 1 For DT 4P
For DT 6P (Does not included
Troubleshooting for 799-601-9050 • DT adapter 1
799-601-4100 and 799-601-4200)
ZD For DT 8P (Does not included
actuators and wiring 799-601-9070 • DT adapter (Black) 1
harnesses 799-601-4100 and 799-601-4200)
799-601-9110 • DT adapter (Gray) 1
799-601-9120 • DT adapter (Black) 1 For DT 12P (Does not included
799-601-9130 • DT adapter (Green) 1 799-601-4100 and 799-601-4200)
799-601-9140 • DT adapter 1
799-601-4101 T-adapter assembly 1
799-601-4211 • DRC26 adapter 1 For engine controller 50P
799-601-7000
or
799-601-7100
799-601-7400
or
799-601-8000
799-601-7020 • X adapter 1 For X 2P
799-601-7030 • X adapter 1 For X 3P
30-101 6 WD600-6
Testing and Sym-

adjusting item bol
For SWP 6P (Does not included
799-601-7050 • SWP adapter 1
799-601-8000)
For SWP 14P (Does not included
799-601-7070 • SWP adapter 1
799-601-7000 and 799-601-7100)
For M 1P (Does not included
799-601-7080 • M adapter 1
799-601-7000 and 799-601-7100)
799-601-7090 • M adapter 1 For M 2P
799-601-7110 • M adapter 1 For M 3P
799-601-7120 • M adapter 1 For M 4P
799-601-7130 • M adapter 1 For M 6P
799-601-7150 • S adapter 1 For S 10P
For S 12P
799-601-7160 • S adapter (Blue) 1
(Does not included 799-601-8000)
799-601-7170 • S adapter (Blue) 1 For S 16P
799-601-7210 • AMP040 adapter 1 For AMP040 16P
Troubleshooting for
799-601-7220 • AMP040 adapter 1 For AMP040 20P
ZD 799-601-7330 • S adapter (White) 1 For S 16P (Only 799-601-8000)
actuators and wiring
harnesses 799-601-7500 T-adapter assembly 1
799-601-7520 • AMP070 adapter 1 For machine monitor 12P
For machine monitor 14P
799-601-7530 • AMP070 adapter 1
For VHMS controller 14P
799-601-7540 • AMP070 adapter 1
799-601-7550 • AMP070 adapter 1
For HD30 31P
799-601-9290 • HD30 adapter 1
(included in 799-601-9000, too)
For transmission controller 40P
799-601-9350 • DRC26 adapter 1
For work equipment controller 40P
For transmission controller 40P
799-601-9360 • DRC26 adapter 1
For work equipment controller 24P
Measuring coolant and
— 799-101-1502 Digital thermometer 1
oil temperature
Measuring operating 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
effort and pressing —
force 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Measuring stroke and Commercially
— Scale 1
hydraulic drift available
Measuring work Commercially
— Stopwatch 1
equipment speed available
Measuring voltage and Commercially
— Tester 1
resistance available
WD600-6 30-101 7
SEN05045-03 Sketches of special tools
Sketches of special tools 1
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
F4 Block
30-101 8 WD600-6
Measuring engine speed SEN05045-03
Measuring engine speed 1 2. Measuring torque converter stall speed
k
1) Referring to “Special function of machine
Put chocks under the tires.
k
monitor”, select the real time monitoring
When measuring, check that there are no function of the service mode.
persons around the machine. 2) Select the two-item simultaneous monitor-
ing (2 ITEMS) and then enter the following
a Measure the engine speed under the following code numbers directly.
condition. a Monitoring items
q Engine coolant temperature: [1] Code No.01002: ENG SPEED
Within operating range (Engine speed)
q Hydraulic oil temperature: [2] Code No.40100: TC OIL TEMP
Within operating range (Torque converter oil temperature)
q Torque converter oil temperature:
1. Measuring engine speed (low idle and high

idle)
1) Referring to “Special function of machine
monitor”, select the real time monitoring
function of the service mode.
2) Select and display “ENG SPEED” from the
engine controller monitoring items.
a Monitoring item: ENG SPEED
Code No. 01002: ENG SPEED
(Engine speed)
3) Start the engine.

4) Press the left brake pedal securely.
5) Set the transmission auto shift and man-
ual shift selector switch in the MANUAL
position.
6) While keeping the directional lever or for-
ward-reverse switch at the N (Neutral)
position, set the gearshift lever or gear
shift switch to the 4th position.
7) Release the parking brake.
8) While pressing the brake pedal, set the
directional lever or switch to the F (for-
ward) or R (reverse) position.
k Keep pressing the brake pedal
3) Start the engine, set it in the measuring
condition, and measure the engine speed. securely.
9) While running the engine at high idle,
press the accelerator pedal gradually.
When the torque converter stalls, mea-
sure the engine speed.
a Measure the stall speed 2 – 3 times.
a Do not keep stalling the torque con-
verter for more than 20 seconds. Take
care that the torque converter oil tem-
perature will not exceed 120°C.
a Measure the torque converter stall
speed when the power mode and
economy mode are turned on.
WD600-6 30-101 9
SEN05045-03 Measuring engine speed
3. Measuring hydraulic stall speed 4. Measuring torque converter stall and

1) Referring to “Special function of machine hydraulic stall (full stall) speed
monitor”, select the real time monitoring 1) Set the machine monitor as in “2. Measur-
function of the service mode. ing torque converter stall speed”.
2) Select the two-item simultaneous monitor- 2) Start the engine.
ing (2 ITEMS) and then enter the following 3) Press the left brake pedal securely.
code numbers directly. 4) Set the transmission auto shift and man-
a Monitoring items ual shift selector switch in the MANUAL
[1] Code No.01001: ENG SPEED position.
(Engine speed) 5) While keeping the directional lever at N
[2] Code No. 04401: HYD TEMP (Neutral) position, set the gearshift lever in
(hydraulic oil temperature) the 4th position.
directional lever to the F (forward) or R
(reverse) position.
securely.
8) While running the engine at high idle, stall
the torque converter and relieve the lift
cylinder or tilt & pitch cylinder on the
extraction side simultaneously and mea-
sure the engine speed at this time.
3) Run the engine at high idle. a Measure the full stall speed when the
4) Relieve the lift cylinder or tilt & pitch cylin- power mode and economy mode are
der on the extraction side and measure turned on.
the engine speed.
a Measure the hydraulic stall speed
when the power mode and economy
mode are turned on.
30-101 10 WD600-6
Measuring exhaust gas color SEN05045-03
Measuring exhaust gas color 1
a Measuring instruments for exhaust gas color

Symbol Part No. Part Name
1 799-201-9001 Handy smoke checker
A Commercially
2 Smoke meter
available
k When installing and removing the measuring

instruments, take care not to touch a hot part.
a If an air source and an electric power source
are not available in the field, use handy smoke
checker A1. When recording official data, use
smoke meter A2.
a Measure the exhaust gas color under the fol- 2) Connect the probe hose, receptacle of the
lowing condition. accelerator switch, and air hose to smoke
q Engine coolant temperature: Within oper- meter A2.
ating range a Keep the pressure of the supplied
compressed air at 1.5 MPa {15 kg/
1. Measuring with handy smoke checker A1 cm2} or below.
1) Stick a sheet of filter paper to smoke 3) Connect the power cable to a 100 V AC
checker A1. receptacle.
2) Insert the exhaust gas intake pipe in the a Confirm that the smoke meter power
muffler (exhaust pipe). switch is in the OFF position, before con-
3) Start the engine and heighten the engine necting the power cable to an outlet.
coolant temperature to the operating range. 4) Loosen the cap nut of the suction pump
4) Accelerate the engine suddenly or run it at and fit the filter paper.
high idle and operate the handle of smoke a Fit the filter paper securely so that the
checker A1 so that the filter paper will exhaust gas will not leak.
absorb the exhaust gas. 5) Turn on the power switch of smoke meter A2.
6) Start the engine and keep it running until

5) Take out the filtering paper and compare it the engine coolant temperature rises to
with the attached scale for judgement. the operating range.
6) Remove the measurement tool after the 7) Accelerate the engine suddenly or run it at
measurement, and make sure that the high idle and press the accelerator pedal
machine is back to normal condition. of smoke meter A2 and collect the
exhaust gas into the filter paper.
2. Measuring with smoke meter A2 8) Put the polluted filtering paper on non-pol-
1) Insert the probe of smoke meter A2 in the luted filtering paper (more than 10 sheets)
outlet of the muffler (exhaust pipe) and fix in the filtering paper holder, and read the
it to the exhaust pipe with a clip. indicated value.
9) Remove the measurement tool after the
measurement, and make sure that the
machine is back to normal condition.
WD600-6 30-101 11
SEN05045-03 Measuring exhaust temperature
Measuring exhaust temperature 1
a Measuring instrument for exhaust temperature

B 799-101-1502 Digital thermometer
k Install and remove the measuring instru-

ment after the exhaust manifold is cooled.
a Measure the exhaust temperature under the
following condition.
q Engine coolant temperature:
q Hydraulic oil temperature:
4. Procedure for periodic measurement done in
preventive maintenance
1. Open the left side cover.
a To prevent the torque converter from over-
heating, increase the exhaust temperature
2. Remove exhaust temperature pickup plug (1)
once through full-stall operation (torque
(R1/8) at the bottom of exhaust manifold.
converter stall + hydraulic stall), and then
a You may measure at either front or rear
measure the exhaust temperature while
plug.
only the torque converter is stalled.
1) Start the engine and heighten the coolant
temperature to the operating range.
2) Press the left brake pedal securely.
position.
4) While keeping the directional lever at N
(Neutral) position, set the gearshift lever to
the 4th position.
directional lever or switch to the F (for-
securely.
3. Install sensor [1] of digital thermometer B and
7) Press the accelerator pedal gradually to
connect them to meter [2].
the high idle. While running the engine at
a Take care that the wiring harness of the
high idle, stall the torque converter and
digital thermometer will not touch a hot
relieve the lift cylinder or tilt & pitch cylin-
part during measurement.
der on the extraction side simultaneously.
(full stall)
a Increase the exhaust temperature to
about 650°C (the state of (a) in the
figure).
30-101 12 WD600-6
Measuring exhaust temperature SEN05045-03
8) As the exhaust temperature reached

about 650°C, release the hydraulic relief
and then decrease the exhaust tempera-
ture by stalling torque converter alone.
(the state of (b) in the figure)
a The exhaust temperature starts low-
ering from the level of the full-stall
operation. Measure the exhaust tem-
perature as it stabilized. (the state of
(c) in the figure)
a If the exhaust temperature rises in
stead of going down, set a higher full
stall temperature than the current one
(650°C).
5. Procedure for measuring the maximum exhaust

temperature
Operate the machine actually and measure the
maximum exhaust temperature.
a Use the PEAK mode of the thermometer
(in which the maximum value can be
saved).
a The exhaust temperature largely depends
on the outside air temperature (intake air
temperature of the engine). Accordingly, if
any abnormal value is obtained, correct it
by the following calculation.
a Corrected value [°C] = Measured value +
2 × (20 – Outside air temperature)
6. Remove the measurement tool after the mea-

surement, and make sure that the machine is
back to normal condition.
3 Exhaust temperature pickup plug:
2.9 – 5.9 Nm {0.3 – 0.6 kgm}
WD600-6 30-101 13
SEN05045-03 Adjusting valve clearance
Adjusting valve clearance 1
a Adjusting tool for valve clearance

Symbol Part No. Part name
Commercially
C Clearance gauge
available
1. Remove covers (1) and (2) and bracket (3) and

then remove 6 cylinder covers (4). For details,
see Disassembly and assembly, “Removal and
installation of cylinder head assembly”.
2. Remove inspection hole plug (a) from the left

side of the timing gear case.
4. When the No. 1 cylinder is at the compression
3. Rotate crankshaft forward to align cut (b) of top dead center, adjust the valve clearances
supply pump drive gear to the center of the marked with q in the valve arrangement draw-
inspection hole. ing.
a Crank the crankshaft using the cranking a When adjusting the position, loosen lock-
device provided in the rear left side of the nut (8) of adjustment screw (7) and then
engine. adjust the clearance by inserting clear-
a The left side in above figure indicates the ance gauge C between crosshead (6) and
compression to dead center of No. 1 cylin- rocker arm (5) until the cylinder becomes
der and right side is the compression to slightly movable.
dead center position of No. 6 cylinder.
a The compression top dead center allows
moving the rocker arm manually by the
valve clearance. When the locker arm is
not movable, the current position is not the
compression top dead center. In this case,
rotate the crankshaft one more turn.
30-101 14 WD600-6
Adjusting valve clearance SEN05045-03
5. Rotate the crankshaft forward by a single turn

to adjust the valve clearance indicated with Q
in the valve arrangement drawing.
a Adjustment procedure is the same as
above.
a Valve clearance
q Intake valve: 0.32 mm
q Exhaust valve: 0.62 mm
6. While fixing adjustment screw (7), tighten lock-

nut (8).
3 Locknut: 57.8 – 77.4 Nm {5.9 – 7.9 kgm}
a After tightening the locknut, check the
valve clearance again.
7. After finishing adjustment, return the removed

parts.
3 Cylinder head cover mounting bolt:
{No.1, 3, 4, 5 and 6 cylinders}
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
{No.2 cylinder}
58.8 – 73.5 Nm {6 – 7.5 kgm}
3 Inspection hole plug:
58.8 – 78.4 Nm {6.0 – 8.0 kgm}
WD600-6 30-101 15
SEN05045-03 Testing compression pressures
Testing compression pressures 1
a Testing tools for compression pressure

1 795-502-1590 Compression gauge
795-611-1220 Adapter
2
D 6261-71-6150 Gasket
795-799-5410 Adapter
3
795-799-5420 Remover
k When measuring the compression pres-

sure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
a Pull out the injector by driving the weight
caught in a rotating part.
of tool D3 up and down while the pin (indi-
a Measure the compression pressure after the
cated with the arrow) at the tip of tool D3 is
engine is warmed up (Engine oil temperature:
being inserted to hole (a) of adapter (9).
40 – 60°C).
1. Remove covers (1) and (2) and bracket (3) and

then remove cylinder head cover (4) to be
check compression pressures. For details, see
Disassembly and assembly, “Removal and
installation of cylinder head assembly”.
2. Adjust the valve clearance of the cylinder to be

check. For details, see “Adjusting valve clear-
ance”.
3. Disconnect fuel high-pressure tube (5) and

injector harness (6).
a When removing the injector harness,
remove the injector side terminal and
rocker housing side mounting bolt first.
a Loosen two terminal nuts alternately.
4. Remove bolt (7) and then remove injector (8)

along with adapter (9).
30-101 16 WD600-6
Testing compression pressures SEN05045-03
5. Install adapter D2 to the mounting hole on the 8. After finishing testing, remove the testing tools
injector and compression gauge D1. and return the removed parts.
a Fit the gasket to the injector end without a Install the injector and fuel high-pressure
fail tube according to the following procedure.
a Fix the adapter using the holder for injec- 1) Install gasket (10) and O-rings (11) and
tor and adapter. (12).
3 Holder mounting bolt: a Take care not to install O-ring (11) to
58.8 – 73.5 Nm {6.0 – 7.5 kgm} slot (b).
a Apply a little amount of engine oil to the 2) Set adapter (9) to injector (8) and then
connecting parts of the adapter and gauge push them into the cylinder head with
so that air will not leak easily. hands.
2 O-ring: Engine oil
6. Set the mode to the no injection cranking oper-

ation. For details, see “Special functions of 3) Install holder (7) and then tighten bolt (13)
machine monitor”. and washer (14) temporarily.
k If the engine is not set in the no-injec- 2 Spherical part of washer: Engine oil
tion cranking mode, it will start and will 4) Install the fuel high-pressure tube and
be dangerous. Accordingly, be sure to then tighten sleeve nut (5).
set the engine in this mode. 5) Tighten bolt (13) permanently.
3 Bolt: 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
7. Rotate the engine with the starting motor and 6) Tighten sleeve nut (5) permanently.
measure the compression pressure. 3 Sleeve nut: 39.2 – 44.1 Nm {4 – 4.5 kgm}
a Read the pressure gauge pointer when it
is stabilized.
WD600-6 30-101 17
SEN05045-03 Testing compression pressures
a Install the injector wiring harness accord-

ing to the following procedure.
1) Assemble injector harness (6) through
inside of the rocker arm housing, and then
fix the connector side with plate (15).
2)Set spacer (16) and fix with bolt (17).

3)Tighten nut (18) on the injector side alter-
nately.
3 Nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}

{No.1, 3, 4, 5 and 6 cylinders}
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
{No.2 cylinder}
58.8 – 73.5 Nm {6 – 7.5 kgm}
30-101 18 WD600-6
Measuring blow-by pressure SEN05045-03
Measuring blow-by pressure 1 8. Press the accelerator pedal gradually to the

high idle. While running the engine at high idle,
a Blow-by pressure measurement tools stall the torque converter and measure the
Symbol Part No. Part Name blow-by pressure.
a Do not keep stalling the torque converter
E 799-201-1504 Blow-by checker
for more than 20 seconds. Take care that
a Measure the blow-by pressure under the fol- the torque converter oil temperature will
lowing condition. not exceed 120°C.
q Engine coolant temperature: a Normally, the blow-by pressure should be
Within operating range measured while the engine is operated at
q Hydraulic oil temperature: the rated output. In the field, however, an
Within operating range approximate value can be obtained by
q Torque converter oil temperature: stalling the torque converter.
Within operating range a If it is impossible to run the engine at the
rated output or stall the torque converter,
1. Stop the engine. Install nozzle [1] and hose [2] measure while the engine is running at
of blow-by checker E to blow-by hose (1) and high idle. The value obtained in this case
connect them to gauge [3]. is about 80% of the blow-by pressure at
the rated output.
a Precaution for measuring blow-by pressure
The blow-by pressure may vary largely
with the engine condition. If the measured
value is judged abnormal, check for
increase of oil consumption, bad exhaust
gas color, deterioration of oil, high deterio-
ration speed of oil, etc. which are related
to the abnormal blow-by pressure.
2. Start the engine and increase the engine cool-

ant temperature to the operating range.
3. Press the left brake pedal securely.
4. Set the transmission auto shift and manual

shift selector switch in the MANUAL position.
5. While keeping the directional lever or forward-

reverse switch at the N (Neutral) position, set 9. Remove the measurement tool after the mea-
the gearshift lever or gear shift switch to the surement, and make sure that the machine is
4th position. back to normal condition.
6. Release the parking brake.
7. While pressing the brake pedal, set the direc-

tional lever or switch to the F (forward) or R
(reverse) position.
k Keep pressing the brake pedal securely.
WD600-6 30-101 19
SEN05045-03 Measuring engine oil pressure
Measuring engine oil pressure 1 4. Start the engine and heighten the coolant tem-
perature to the operating range.
a Engine oil pressure measurement tools
Symbol Part No. Part Name 5. While running the engine at low idle and high
idle, measure the oil pressure.
1
790-261-1204 Digital hydraulic tester
F 2 799-401-2320 Gauge
799-101-5230 Nipple (14 × 1.5 mm)
3
6215-81-9720 O-ring
a Measure the engine oil pressure under the fol-

lowing condition.
1. Open the right side cover.
2. Remove engine oil pressure pickup plug (1)

(14 × 1.5 mm) on the engine oil filter bracket.
3 Oil pressure pickup plug:
45 – 49 Nm {4.6 – 5 kgm}
3. Install nipple F3 (14 × 1.5 mm) and then con-

nect gauge F2 (1 MPa {10 kg/cm2}).
30-101 20 WD600-6
Testing EGR valve and bypass valve drive oil pressure SEN05045-03
Testing EGR valve and bypass 4. Install EGR valve drive oil supply tube (1) to
valve drive oil pressure 1
the top of tool F4 and tighten flange mounting
bolts (2) on the EGR valve side.
a Testing instruments for EGR valve and bypass 3 Flange mounting bolt (2):
valve drive oil pressure 27 – 34 Nm {2.8 – 3.5 kgm}

795T-690-1110 Block
4 01435-00835 Bolt
F 07000-E2012 O-ring
5 799-101-5002 Hydraulic tester
6 790-261-1204 Digital hydraulic tester
2. Remove flange mounting bolts (2) of EGR

valve drive oil supply tube (1) on the EGR
valve side and clamp mounting bolts (3).
5. Install the nipple (component part of F5) to
measuring hole (a) (size: PT 1/8) of took F4
and connect hydraulic tester F5.
Reference: Since the maximum oil pressure to
be measured will be about 3 MPa {30 kg/cm2},
select a proper pressure gauge in the kit.
3. Install tool F4 to the EGR valve oil supply area.

3 Mounting bolt (4) (component part of
F4): 27 – 34 Nm {2.8 – 3.5 kgm}
WD600-6 30-101 21
SEN05045-03 Testing EGR valve and bypass valve drive oil pressure
6. Run the engine and measure the oil pressure

at low idle and high idle.
7. After finishing measurement, remove the mea-

suring instruments and return the removed
parts.
a Replace the flange O-ring on the EGR
valve side with new one.
3 Flange mounting bolt (2):

27 – 34 Nm {2.8 – 3.5 kgm}
3 Clamp mounting bolt (3):
58.8 – 73.5 Nm {6 – 7.5 kgm}
30-101 22 WD600-6
Measuring intake air (boost) pressure SEN05045-03
Measuring intake air (boost) 4. Start the engine.

pressure 1
5. Press the left brake pedal securely.
a Measuring instruments for intake air (boost)
pressure 6. Set the transmission auto shift and manual
Symbol Part No. Part Name shift selector switch in the MANUAL position.
G 799-201-2202 Boost gauge kit
7. While keeping the directional lever or forward-
k
reverse switch at the N (Neutral) position, set
When installing and removing the measur-
the gearshift lever or gear shift switch to the
ing instruments, take care not to touch a
4th position.
hot part of the engine.
a Measure the intake air pressure (boost pres-
8. Release the parking brake.
sure) under the following condition.
9. While pressing the brake pedal, set the direc-
tional lever to the F (forward) or R (reverse)
position.
k Keep pressing the brake pedal securely.
10. Press the accelerator pedal gradually to the
high idle. While running the engine at high idle,
stall the torque converter and measure the
intake air pressure (boost pressure).
2. Remove exhaust temperature pickup plug (1)
a Do not keep stalling the torque converter
(R1/8) in the rear side of the air intake mani-
for more than 20 seconds. Take care that
fold.
the torque converter oil temperature will
not exceed 120°C.
3. Install nipple [1] in boost gauge kit G and con-

nect pressure gauge [2].
WD600-6 30-101 23
SEN05045-03 Handling fuel system equipment
Handling fuel system equipment 1 Releasing residual pressure in

a Precautions for testing and maintaining fuel fuel system 1
system a Pressure is generated in the low-pressure cir-

The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump – Fuel filter – Supply pump
trouble. High-pressure circuit:
When testing and maintaining the fuel system, Supply pump – Common rail – Injector
take care more than the past. If dust, etc. sticks a The pressure in both low-pressure circuit and
to any part, wash that part thoroughly with high-pressure circuit lowers to a safety level
clean fuel. automatically 30 seconds after the engine is
a Precautions for replacement of fuel filter car- stopped.
tridge a Before the fuel circuit is tested and its parts are
The fuel filter cartridge used must be a genuine removed, the residual pressure in the fuel cir-
Komatsu part. cuit must be released completely. Accordingly,
The fuel injection pump and nozzle of the com- observe the following.
mon rail type fuel injection system (CRI) are k Before testing the fuel system or removing
consisted of more precision parts than those its parts, wait at least 30 seconds after stop-
used for the current pumps and nozzles. This ping the engine until the residual pressure
system, therefore, employs a special filter with in the fuel circuit is released. (Do not start
highly efficient filtering performance to prevent the work just after stopping the engine
mixing of foreign substances. Thus, substitut- since there is residual pressure.)
ing it with a non-genuine filter could cause
troubles in the fuel system. It is strictly prohib-
ited to use such part.
30-101 24 WD600-6
Testing fuel pressures SEN05045-03
Testing fuel pressures 1 5. Run the engine at high idle and measure the
fuel pressure.
a Testing tools for fuel pressure a If the fuel pressure is in the following
Symbol Part No. Part name range, it is normal.
1 Engine speed Fuel pressure
Min. 0.15 MPa
795-471-1450 Adapter High idle
H 2 {Min. 1.5 kg/cm2}
07005-00812 Seal washer
3 799-101-5160 Nipple
4 799-401-2320 Hydraulic tester
a Test only the fuel pressure in the low-pressure

circuit from the feed pump through the engine
controller cooler and fuel filter to the supply
pump.
k Since the pressure in the high-pressure cir-
cuit from the supply pump through the
common rail to the injector is very high, it
cannot be measured.
2. Remove plug (1).

6. After finishing testing, remove the testing tools
and return the removed parts.
3 Plug (1): 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
3. Install adapter H2.
4. Install nipple H3 to adapter H2 and connect

them to hydraulic tester H4.
WD600-6 30-101 25
SEN05045-03 Testing return rate and leakage
Testing return rate and leakage 1
a Testing tools for leakage from pressure limiter 1. Preparation work

and return rate from injector 1) Remove tube (3) between common rail (1)
and block (2).
Symbol Part No. Part name 2) Insert spacer J1 to block (2) side and
1 6167-11-6640 Spacer tighten the currently removed joint bolt
again.
2 6206-71-1770 Joint
a Connect the return pipe to the fuel
Commercially tank again, too.
3 Hose (ø5 mm × (2 to 3 m))
available a Be sure to provide a gasket to both
J Commercially ends of the spacer.
4 Hose (ø15 mm × (2 to 3 m))
available
Commercially
5 Measuring cylinder
available
Commercially
6 Stopwatch
available
a Prepare an oil pan of about 20 l to receive the

fuel flowing out during the test.
30-101 26 WD600-6
Testing return rate and leakage SEN05045-03
2. Testing leakage of fuel

1) Route inspection hose J3 in such that it
may be free from slack and then insert its
end to the oil pan (saucer).
2) Set the mode that allows confirming the
engine speed with the real time monitoring
function. For details, see “Special func-
tions of machine monitor”.
3) Start the engine and keep its speed to
1,600 rpm with no load.
4) After making sure the engine speed is sta-
bilized, measure leakage volume per min-
ute using measuring cylinder J5.
a You may test for 20 seconds and
3) Insert joint J2 to common rail (1) side and
judge by multiplying the result by 3.
tighten the currently removed joint bolt
a If the leakage of fuel is in the following
again.
range, it is normal.
a Be sure to fit the gaskets to both ends
of the joint.
4) Connect inspection hose J3 to the tip of Measurement Leakage volume
joint J2. condition (cc/min)
a Bind the connecting part of the test At stall or relief Max. 10
hose with a wire, etc. to prevent it
from coming off.
a The above is the preparation work for
testing the leakage of fuel.
5) After finishing testing, stop the engine.
WD600-6 30-101 27
SEN05045-03 Testing return rate and leakage
3. Testing return rate of fuel
5) After finishing testing, stop the engine.

1) Remove the hose at spill outlet (4) and
connect inspection hose J4 in stead. Then 4. Work after finishing testing
insert the hose end to the oil pan (saucer). After finishing all testing, remove the testing
2) Set the mode that allows confirming the tools and return the removed parts.
engine speed with the real time monitoring
function. For details, see “Special func-
tions of machine monitor”.
3) Run the engine at the rated output.
4) After making sure the engine speed is sta-
bilized, measure leakage volume per min-
ute using measuring cylinder J5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) of fuel is in the
following range, it is normal.
Rated output speed Limit of return rate (spill)

(rpm) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
30-101 28 WD600-6
Bleeding air from fuel circuit SEN05045-03
Bleeding air from fuel circuit 1 4. Shift switch (3) for the electric priming pump in
the engine room to ON position.
a Bleed air according to this procedure in the fol- a Lamp (4) will start flashing and operation
lowing cases. of the electric priming pump will be
q When the fuel filter was replaced started.
q When fuel ran out
q When starting the engine for the first time
after replacing the fuel piping or supply
pump
a When the fuel filter is replaced, don't feed fuel to
the filters, including both the main and pre-filter.
k Pressure is constantly applied to the fuel
circuit as long as operation of the electric
priming pump is continued. Loosening the
air bleeding plug from this state might
allow fuel to burst out. Thus, don't try to
loosen the plug while the pump is in opera-
tion.
1. Set the starting switch to OFF position.
3. Open air bleeding valve (1).
WD600-6 30-101 29
SEN05045-03 Bleeding air from fuel circuit
a The built-in timer of this switch automati- 9. Start the engine with the starting motor.
cally starts or stops operation of the elec- a The air in the high-pressure circuit is bled
tric priming pump. (See the figure below) automatically if the engine is cranked.
a Operation of the electric priming pump is a If the engine does not start, inappropriate
stopped as long as flashing of the lamp is bleeding air in the low-pressure circuit
continued. It is not an error. may be suspected. In this case, perform
a Shifting the switch to “OFF” while the lamp the followings:
is flashing turns off the lamp and stops the 1) Shift the electric priming pump switch to
electric priming pump. ON position.
2) Start the engine while the electric priming
pump is operating.
a If the engine does not start, repeat
this.
3) After the engine starts, let the engine run
for more than 5 minutes to bleed air com-
pletely from the fuel circuit.
5. As the specified duration (about 6.5 minutes) is

expired, lamp (4) automatically goes off, stop-
ping the electric priming pump.
a When the fuel filter alone was replaced,
above completes bleeding air.
6. When fuel is not provided in the fuel circuit

such as when run out of fuel occurred or when
replacement of the fuel pipe or supply pump
was done, set switch (3) to “ON” again after
the electric priming pump is automatically
stopped.
7. Bleeding air, in this case, completes as lamp

(4) went off.
8. Close air bleeding valve (1).
30-101 30 WD600-6
Testing leakage in fuel system SEN05045-03
Testing leakage in fuel system 1 9. Inspect the fuel piping and devices for fuel
k
leakage.
Very high pressure is generated in the high- a Check mainly around the high-pressure
pressure circuit of the fuel system. If fuel circuit parts coated with the color checker
leaks while the engine is running, it is dan- for fuel leakage.
gerous since it can catch fire. a If fuel leakage is recognized, repeat the
After testing the fuel system or removing procedure from step 1 after repairing the
its parts, test it for fuel leakage according leakage.
to the following procedure. a If no fuel leakage is detected, check is
a Clean and degrease the engine and the parts completed.
around it in advance so that you can test it eas-
ily for fuel leakage.
1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at speed below 1,000 rpm and

stop it after its speed is stabilized.
3. Inspect the fuel piping and devices for fuel

leakage.
a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If fuel leakage is recognized, repeat the
procedure from step 1 after repairing the
leakage.
4. Run the engine at low idle.

leakage.
for fuel leakage.
leakage.
6. Run the engine at high idle.

leakage.
for fuel leakage.
leakage.
8. Run the engine at high idle and load it.

a When checking while the components to
be checked are mounted on the machine,
stall the torque converter or relieve the
hydraulic pump.
WD600-6 30-101 31
SEN05045-03 Handling reduced cylinder mode operation
Handling reduced cylinder mode Handling no-injection cranking

operation 1 operation 1
a Reduced cylinder mode operation means to a No-injection cranking means to crank the
run the engine with the fuel injectors of 1 or engine with the starting motor while all the
more cylinders disabled electrically to reduce injections are stopped electrically. The purpose
the number of effective cylinders. The pur- and effect of this operation are as follows.
poses and effects of this operation are as fol- q When a machine or engine has been stored for
lows. a long time, implementing the no-injection
cranking before starting the engine lubricates
1. This operation is used to find out a cylinder the engine parts and thus prevents its seizure.
which does not output power normally (or, a The no-injection cranking operation is set from
combustion in it is abnormal). the service mode of the machine monitor. For
details, see “Special functions of machine
2. When a cylinder is selected for the reduced monitor”.
cylinder mode operation, if the engine speed
and output do not change from the normal
operation (all-cylinder operation), that cylinder
has 1 or more defects. The possible defects
are as follows.
q Leakage through cylinder head gasket
q Defective injection
q Defective piston, piston ring, or cylinder
liner
q Defective valve mechanism (Moving valve
system)
q Defect in electrical system
3. Since the common rail fuel injection system

controls the injector of each cylinder electroni-
cally, the operator can perform the reduced cyl-
inder mode operation easily with switches to
find out a defective cylinder.
a The reduced cylinder mode operation is
set from the service mode of the machine
monitor.
For details, see “Special functions of
machine monitor”.
30-101 32 WD600-6
Handling controller voltage circuit SEN05045-03
Handling controller voltage circuit1

1. Disconnection or connection of the connector
between the engine controller and engine must
be done after turning off the starting switch.
2. It is prohibited to start the engine when T-

adapter is inserted or connected, for trouble-
shooting purpose, to the connector between
the engine controller and engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
WD600-6 30-101 33
SEN05045-03 Replacing and adjusting alternator and air conditioner compressor belt tension
Replacing and adjusting

alternator and air conditioner
compressor belt tension 1
a The auto-tensioner is provided for the alterna-

tor and air conditioner compressor belt. Thus,
testing and adjustment of the belt is usually not
necessary.
a Following describes the auto-tensioner adjust-
ment procedure to be employed for the belt
replacement.
2. Remove cover (1).

6. Tighten locknut (2).
7. Install cover (1).
3. Loosen locknut (2), tighten push bolt (3) fully

and then push in tension pulley (4).
4. Replace belt (5).
5. After replacing the belt, loosen push bolt (3)

until its threaded portion protrudes 90 mm.
30-101 34 WD600-6
Adjusting modulation clutch speed sensor and speed sensor SEN05045-03
Adjusting modulation clutch speed sensor and speed sensor 1
1. Modulation clutch output shaft speed sensor

1) Loosen locknut (2) of modulation clutch
output shaft speed sensor (1).
2) Screw in speed sensor (1) until its tip
lightly contacts against the plate (3).
a Before installing the sensor, check
that its tip is free from steel chips and
flaws.
2 Threaded portion:
Gasket sealant (LG-5)
3) Return speed sensor (1) by 3/4 – 1 turn.
4) Fix speed sensor (1) with locknut (2).

3 Locknut:
49.6 – 68.6 Nm {5 – 7 kgm}
WD600-6 30-101 35
SEN05045-03 Adjusting modulation clutch speed sensor and speed sensor
2. Speed sensor
1) Loosen locknut (6) of speed sensors (4)
and (5).
2) Screw in speed sensors (4) and (5) until
their tip lightly contacts against the gear
tooth (7).
a Before installing the sensor, check
that its tip is free from steel chips and
flaws.
2 Threaded portion:
3) Return speed sensors (4) and (5) by 1/2 – 1

turn.
4) Fix speed sensors (4) and (5) with locknut

(6).
3 Locknut: 49.6 – 68.6 Nm {5 – 7 kgm}
30-101 36 WD600-6
Measuring directional lever and gear shift lever (Steering wheel specification) SEN05045-03
Measuring directional Stroke of directional lever (1) and gear shift

lever and gear shift lever lever (2)
(Steering wheel specification) 1 1. Stop the engine.
Measuring instrument 2. Make mark (a) at the center of the control lever
Symbol Part No. Part Name knob. Move the knob in the operating direction
K 79A-264-0021 Push-pull scale and measure its stroke.
a Figure shows the work of directional lever.
k Put chocks under the tires securely.
Operating effort of directional lever (1) and gear

shift lever (2)
1. Stop the engine.
2. Install tool K or a spring balance to a point 10

mm from the control lever end and pull it in the
operating direction to measure the operating
effort at that time.
a Measure the operating effort at each gear
speed.
a Figure shows the work of directional lever.
WD600-6 30-101 37
SEN05045-03 Testing and adjusting power train oil pressure
Testing and adjusting power train oil pressure 1
(*1): For transmission Serial No. up to 100090

(*2): For transmission Serial No. 100091 and up
30-101 38 WD600-6
Testing and adjusting power train oil pressure SEN05045-03
Oil pressure measuring point and measuring 1. Remove rear frame left and right side covers
gauge (13).
a Applicable only to the machine equipped
Measuring with the rear frame side covers
No. Measured oil pressure gauge
MPa {kg/cm2}
1 Main relief pressure 6 {60}
2 Torque converter inlet pressure 2.5 {25}
3 Torque converter outlet pressure 1 {10}
4 Modulation clutch oil pressure 6 {60}
5 Lockup clutch pressure 6 {60}
6 Transmission F clutch pressure 6 {60}
7 Transmission R clutch pressure 6 {60}
8 Transmission 1st clutch pressure 6 {60}
9 Transmission 2nd clutch pressure 6 {60}
10 Transmission 3rd clutch pressure 6 {60}
11 Transmission 4th clutch pressure 6 {60}
12 Lubrication pressure 1 {10}
a Testing and adjusting instruments for power

train oil pressure

1
L
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
k Put chocks under the tires.

a Measure the power train oil pressure under the
WD600-6 30-101 39
Measurement 5) After finishing measurement, remove the

1. Measuring transmission main relief pressure measuring instruments and return the
1) Remove transmission main relief pressure removed parts.
pickup plug (1) (10 × 1.25 mm).
2) Connect nipple L2 (10 × 1.25 mm) and oil

pressure gauge [1] in hydraulic tester L1.
a Use the oil pressure gauge of 6 MPa
{60 kg/cm2}.
3) Start the engine and keep the directional

lever or switch at the N (Neutral) position.
4) While running the engine at low idle and
high idle, measure the transmission main
relief pressure.
30-101 40 WD600-6
2. Measuring torque converter inlet pressure 5) After finishing measurement, remove the
1) Remove torque converter inlet pressure measuring instruments and return the
pickup plug (2) (10 × 1.25 mm). removed parts.
(*1): For transmission Serial No. up to 100090

(*2): For transmission Serial No. 100091 and up
2) Connect nipple L2 (10 × 1.25 mm) and oil

pressure gauge [1] in hydraulic tester L1.
a Use the oil pressure gauge of 2.5 MPa
{25 kg/cm2}.

measure torque converter relief pressure
(inlet pressure).
WD600-6 30-101 41
3. Measuring torque converter outlet pressure 5) Remove the measurement tool after the
1) Remove torque converter outlet pressure measurement, and make sure that the
pickup plug (3). machine is back to normal condition.
2) Connect nipple L2 and oil pressure gauge

[1] in hydraulic tester L1.
{10 kg/cm2}.

measure torque converter outlet pressure.
30-101 42 WD600-6
4. Measuring modulation clutch pressure

1) Remove modulation clutch pickup plug (4).

{60 kg/cm2}.

position.
4) Press the right brake pedal.
5) Start the engine and turn the parking
brake switch OFF.
6) While keeping the directional lever at N
(Neutral) position, set the gearshift lever in
the 4th position.
7) While pressing the right brake pedal, set
the directional lever or switch to the F (for-
k Keep pressing the right brake
pedal securely.
measure the modulation clutch pressure.
WD600-6 30-101 43
5. Measuring lockup clutch pressure

k This measurement is done in the travel-
ing condition. Reasonable care, there-
fo re , mu st b e pai d to s af ety of
surrounding area.
1) Remove lockup clutch pressure pickup
plug (5).


{60 kg/cm2}.
3) Turn the torque converter lockup switch

ON.
ual shift selector switch in the AUTO posi-
tion.
brake switch OFF.
6) Set the gear shift lever or gear shift switch
to 2nd position.
7) Start traveling while setting the directional
lever or switch to the F (forward) or R
(reverse) position.
8) Measure the lockup clutch oil pressure as
the lockup pilot lamp came on while travel-
ing is continued with the engine at high
idle.
30-101 44 WD600-6
6. Measuring F (forward) clutch pressure

1) Remove F (forward) clutch oil pressure
pickup plug (6).

{60 kg/cm2}.

position.
brake switch OFF.
6) While keeping the directional lever or
switch at N (Neutral) position, set the
gearshift lever to the 4th position.
the directional lever or switch to F (for-
ward).
pedal securely.
measure the F clutch oil pressure.
WD600-6 30-101 45
7. Measuring R (reverse) clutch pressure

1) Remove R (reverse) clutch oil pressure
pickup plug (7).

{60 kg/cm2}.

position.
brake switch OFF.
gearshift lever in the 4th position.
the directional lever or switch to R
(reverse).
pedal securely.
measure the R clutch oil pressure.
30-101 46 WD600-6
8. Measuring 1st clutch pressure

1) Remove 1st clutch oil pressure pickup
plug (8).

{60 kg/cm2}.

position.
brake switch OFF.
gearshift lever in the 1st position.
pedal securely.
measure the 1st clutch oil pressure.
WD600-6 30-101 47
9. Measuring 2nd clutch pressure

1) Remove 2nd clutch oil pressure pickup
plug (9).

a Use the oil pressure gauge with
capacity 6 MPa {60 kg/cm2}.

position.
brake switch OFF.
gearshift lever in the 2nd position.
pedal securely.
measure the 2nd clutch oil pressure.
30-101 48 WD600-6
10. Measuring 3rd clutch pressure

1) Remove 3rd clutch oil pressure pickup
plug (10).

{60 kg/cm2}.

position.
brake switch OFF.
gearshift lever in the 3rd position.
pedal securely.
measure the 3rd clutch oil pressure.
WD600-6 30-101 49
11. Measuring 4th clutch pressure

1) Remove 4th clutch oil pressure pickup
plug (11).

{60 kg/cm2}.

position.
brake switch OFF.
gearshift lever in the 4th position.
pedal securely.
measure the 4th clutch oil pressure.
30-101 50 WD600-6
12. Measuring lubrication pressure Adjustment

1) Remove lubrication pressure pickup plug Adjusting transmission main relief valve
k Stop the engine before starting adjustment
(12).
of the transmission main relief valve.
a If the transmission main relief pressure is out
of the specified range, adjust it according to
the following procedure.
1. Remove plug (14) from transmission and
torque converter relief valve plug (13).

{10 kg/cm2}.
2. Remove inner spring (16) and outer spring

(15).
3. Adjust the torque converter relief pressure by

changing the number of shims (17).
a Standard shim thickness:
3.5 mm (0.5 × 7 pieces)
a Quantity of adjustment per shim:
0.039 MPa {0.39 kg/cm2}

measure the lubrication pressure.
WD600-6 30-101 51
SEN05045-03 Flushing procedure for torque converter and transmission hydraulic circuit
Flushing procedure for torque 3) Loosen hexagonal portion (a) of 3 trans-

converter and transmission mission oil filter cases (3) to remove trans-
mission oil filter cases (3).
hydraulic circuit 1
a After removing the transmission oil fil-
a Metal chips and dirt in the torque converter and ter case, clean inside of the case as
transmission hydraulic circuit shorten the lives well as removed parts other than the
of the torque converter and transmission and filter.
can cause internal breakage. Accordingly, 4) Remove 3 filter elements (4) and replace
flush the hydraulic circuit to remove the metal them with 3 flushing elements (561-15-
chips and dirt. 55670).
5) Install 3 transmission oil filter cases (3).
1. Flush the hydraulic circuit in the following
cases. 3 Hexagonal portion (a) of transmis-
1) When metal chips are circulated in the sion oil filter case:
hydraulic circuit because of damage of the 58.8 – 78.5 Nm {6 – 8 kgm}
torque converter, transmission, or another 3 Drain plug:
hydraulic device. 49 – 58.8 Nm {5 – 6 kgm}
2) When the torque converter or transmis-
sion is overhauled or repaired.
2. Install the element for flushing.

1) Open bottom cover (2) provided in accu-
mulator installation position (1) on the left
side of the machine body.
3. Fill the transmission case with oil.

a Add oil through oil filler (5) to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil
level again.
5 Transmission case: 83 l (Refill capacity)
2) Remove 3 transmission oil filter cases (3)
and drain plug (4) to drain oil.
a Before draining oil, prepare an oil
pan.
30-101 52 WD600-6
Flushing procedure for torque converter and transmission hydraulic circuit SEN05045-03
4. Flush the hydraulic circuit according to the fol- 6. Replace the transmission last chance filter.
lowing procedure. 1) Remove cover on the right side of the rear
1) Start the engine and run it at low idle with- frame.
out operating the gearshift lever or direc- a Applicable only to the machine
tional lever for about 20 minutes. equipped with the rear frame side
a Increase the engine speed to about covers.
1,500 rpm sometimes. 2) Loosen hexagonal portion (a) of the trans-
a If the engine coolant temperature mission last chance filter case (7) to
gauge does not rise to the operating remove the cases.
range because of low atmospheric a After removing the transmission oil fil-
temperature, continue the warm-up ter case, clean inside of the case as
operation further. well as removed parts other than the
2) Operate or drive the machine for at least filter.
20 minutes. 3) Remove filter element (8) and replace it
a Use all the gear speeds (Forward, with a new element (569-15-51731).
reverse, and 1st – 4th, including mod- 4) Install transmission last chance filter case
ulation clutch and lockup clutch). (7).
3) Run the engine at low idle for about 20 a Replace the current O-ring with a new
minute, similarly to 4-1). one, coat it with a small amount of oil
and then install it.
5. Replace the filter element. 3 Hexagonal portion (b) of transmis-
1) Replace filter element (4) used for flushing sion last chance filter case:
with new element (714-07-28712) in the 34.3 – 44.1 Nm {3.5 – 4.5 kgm}
same procedure as 2.
k If the element used for flushing is
used for long hours, it is clogged
quickly. Accordingly, be sure to
replace it with new one.
a Replace the current O-ring with a new
one, coat it with a small amount of oil
and then install it.
2) Add oil and check the oil level again.
WD600-6 30-101 53
SEN05045-03 Method of moving machine when transmission valve is broken
Method of moving machine when transmission valve is broken 1
a Locations of ECMV assemblies and connector Nos.
a Device for moving machine when transmission k When working while the oil temperature is
valve is broken still high, take care not to burn your body.
1. Remove cover (1) on the left side of the rear
M 794-423-1190 Plug
frame.
a Applicable only to the machine equipped
a Even if you cannot move the machine because
with the rear frame side covers.
of breakage of a transmission valve part (elec-
a Remove mud and dirt from around the
trical system, solenoid valve, spool, etc.), you
ECMV.
can move it by installing plugs M.
k Installation of plugs M to the ECMV is a
means to move the machine from a danger-
ous job site to a safe place where you can
repair it when you cannot move it at any
gear speed because of breakage of the
transmission control valve. Accordingly,
use this method only when the transmis-
sion control valve is broken. Install plugs M
only in an emergency where the broken
machine cannot be towed and there is no
means to move it.
k When moving the machine by this method,
observe the procedure and take care of
safety.
k Lower the work equipment to the ground 2. Disconnect all the connectors from each
fully, apply the parking brake, and put ECMV. (14 places)
chocks under the tires to prevent the
machine from moving.
k When working, stop the engine.
30-101 54 WD600-6
Method of moving machine when transmission valve is broken SEN05045-03
3. Remove 3 solenoids (2) from the modulated k After moving the machine, stop the
clutch ECMV, 2nd ECMV, and F or R ECMV engine, apply the parking brake, and
and install plugs M. put chocks under the tires.
q For forward travel:
F solenoid and 2nd solenoid 6. After moving the machine, remove the devices
q For reverse travel: and return the removed parts.
R solenoid and 2nd solenoid
a If a wrong solenoid is removed, the trans-
mission may be broken. Take care.
a Install each plug with its projection side
toward the ECMV. Check that the O-ring is
fitted to the mating face.
a Take care that mud or dirt will not enter the
removed solenoids and valves.
4. Press the right brake pedal securely.
5. Start the engine, release the parking brake,

and then release the right brake pedal gradu-
ally to start and move the machine.
a If the parking brake cannot be released
because of a trouble in the electrical sys-
tem, see “Method of releasing parking
brake manually”.
k Remove the chocks.
k If the engine is started, the transmis-
sion is engaged and the machine starts
immediately. Accordingly, when start-
ing the engine, check the moving direc-
tion of the machine and secure safety
around the machine thoroughly and
keep pressing the brake pedal.
WD600-6 30-101 55
SEN05045-03 Moving method of machine disabled by short-to-power failure in work equipment potentiometer
Moving method of machine disabled by short-to-power failure in work

equipment potentiometer 1
a Electric circuit diagram
a Moving method of machine disabled by short- 1. Remove cover (1).

to-power failure in work equipment potentiom-
eter
a When the machine is disabled due to short-to-
power failure in work equipment potentiometer,
removing and interchanging the pins of the
connectors allow the disabled machine to
move temporarily.
k For using this method, the machine must
be able to move if the lift arm is raised.
k Use this method only when moving the dis-
abled machine to a safe place for repair.
Never use this method for other purposes.
k Follow the specified procedure and work
safely to move the disabled machine. 2. Disconnect connector CNS02 (2).
k Apply the parking brake and set the tire
stoppers to prevent the machine from mov-
ing.
k Stop the engine when performing this work.
k Take care not to get scaled when the oil is
at high temperatures.
30-101 56 WD600-6
Moving method of machine disabled by short-to-power failure in work equipment potentiometer SEN05045-03
q When short-to-power to tilt sensor power

line
3. Remove No. 8 pin (3) of connector CNS02.
a Cover the removed pin with vinyl tape to
prevent short.
4. Start the engine and operate the lift lever to

check that the work equipment can be raised.
q When short-to-power to lift sensor power

line
5. Remove No. 4 pin (4) of connector CNS02.
a Cover the removed pin with vinyl tape to
prevent short.
6. Remove No. 8 pin (3) and install No. 4 pin (4)

to interchange them.
7. Start the engine and operate the lift lever to

check that the work equipment can be raised.
8. Start the engine, release the parking brake,

and take your foot from the right brake pedal
gradually to move the machine.
k Remove tire stoppers.
WD600-6 30-101 57
SEN05045-03 Adjusting steering stop valve
Adjusting steering stop valve 1 4. Run the engine at low idle and return the steer-
ing wheel slowly until the clearance between
Preparation the tip of steering stop valve (3) and head (b)
Before adjusting the stopper bolt, operate the steer- of stopper bolt (1) becomes about 20 to 30
ing and check that the frame stoppers contact at mm.
each steering end.
a If the frame stoppers are damaged or lost,
repair them so that the frames will contact
against them on each side.
Adjusting
1. Loosen locknut (2) and then tighten stopper
bolt (1) to minimum length (d) so that it may not
contact against steering stop valve (3) during
the steering operation.
5. Tighten locknut (2) by rotating stopper bolt (1)

in the loosening direction 8 – 8.5 turns (c
dimension: 14.0 – 14.9 mm).
a Adjust both the right and left side accord-
ing to above 1 – 5 methods.
2. Run the engine at low idle and then bring front

frame (4) and rear frame (5) into contact each
other by turning the steering wheel slowly.
k Use care in this operation so that your
body or arm may not be caught
between the front and rear frames.
3. Stop the engine and then loosen stop bolt (1)

until it touches the contact surface of steering
stop valve (3).
30-101 58 WD600-6
Adjusting steering stop valve SEN05045-03
WD600-6 30-101 59
SEN05045-03
WD600-6 Wheel dozer

©2019 KOMATSU
All Rights Reserved
30-101 60
SEN05046-01
WHEEL DOZER
WD600-6

WD600-6 55001 and up

Measuring operating effort of AJSS lever (AJSS specification) ...................................................................... 3
Testing and adjusting AJSS lever angle sensor and frame angle sensor (AJSS specification) ...................... 4
Testing and adjusting steering stopper bolt (AJSS specification) ................................................................... 6
Testing and adjusting steering wheel (Steering wheel specification) .............................................................. 8
Testing steering oil pressure ......................................................................................................................... 10
Bleeding air from steering cylinder circuit ..................................................................................................... 14
Testing hydraulic drive fan ............................................................................................................................ 15
Bleeding air from hydraulic drive fan circuit .................................................................................................. 18
Measuring brake pedal ................................................................................................................................. 20
Measuring brake performance ...................................................................................................................... 21
Testing and adjusting accumulator charge pressure..................................................................................... 22
Testing of accumulator nitrogen gas pressure and procedure for charging brake accumulator with nitrogen
gas ......................................................................................................................................................... 24
Testing wheel brake oil pressure................................................................................................................... 32
Measuring wear of wheel brake disc............................................................................................................. 34
Bleeding air from wheel brake circuit ............................................................................................................ 35
Releasing residual pressure in brake accumulator circuit............................................................................. 36
Testing parking brake performance............................................................................................................... 37
Measuring parking brake oil pressure ........................................................................................................... 38
Testing wear of parking brake disc................................................................................................................ 41
Method of releasing parking brake manually ................................................................................................ 42
Measuring and adjusting work equipment control lever................................................................................ 43
Measuring work equipment oil pressure ....................................................................................................... 44
WD600-6 30-102 1
SEN05046-01
Bleeding air from work equipment circuit ...................................................................................................... 49

Moving machine for removing operator cab.................................................................................................. 50
Preparations for work on troubleshooting of electric system......................................................................... 52
Procedure for testing diodes ......................................................................................................................... 56
30-102 2 WD600-6
Measuring operating effort of AJSS lever (AJSS specification) SEN05046-01
Measuring operating effort of AJSS lever (AJSS specification) 1
a Measuring instruments for AJSS lever operat-

ing effort

N 79A-264-0021 Push-pull scale
a Measure the operating effort of AJSS lever

under the following condition.
q Hydraulic oil temperature: Within operating range
q Engine speed: Low idle
1. Install and fix push-pull scale N at operating

point (a) of AJSS lever (1).
2. Measure operating effort of AJSS lever (1) by

pulling the lever in the right and left using
push-pull scale N.
a Operate the work equipment control lever
at the ordinary operating speed and mea-
sure the minimum necessary effort to
operate the AJSS lever.
WD600-6 30-102 3
SEN05046-01 Testing and adjusting AJSS lever angle sensor and frame angle sensor (AJSS specification)
Testing and adjusting AJSS lever angle sensor and frame angle sensor
(AJSS specification) 1
30-102 4 WD600-6
Testing and adjusting AJSS lever angle sensor and frame angle sensor (AJSS specification) SEN05046-01
Adjusting
Adjust according to Special functions of machine
monitor (EMMS), 7-11 Adjustment of AJSS neutral
position.
WD600-6 30-102 5
SEN05046-01 Testing and adjusting steering stopper bolt (AJSS specification)
Testing and adjusting steering stopper bolt (AJSS specification) 1
30-102 6 WD600-6
Testing and adjusting steering stopper bolt (AJSS specification) SEN05046-01
Testing Adjusting
1. Start the engine and set steering lock lever (1) a If clearance (a) is not normal, adjust it accord-
to Free position. ing to the following procedure.
2. Move AJSS lever (2) to the right or left stroke 1. Set steering lock lever to free position and
end with the engine running at low idle. Main- return the steering to the center position.
tain the steering at that position.
k Operate the steering slowly. Use care 2. Set steering lock lever (1) to lock position.
in this operation so that your body or
arm may not be caught between the 3. Adjust protrusion dimension (b) nonconforming
front and rear frames. side adjustment bolt (5).
a Protrusion dimension (b):
3. Set steering lock lever (1) to lock position. Increasing its length increases clearance (a)
Decreasing it decreases clearance (a)
4. Make sure that clearance (a) between front a Standard protrusion dimension (b) (Refer-
frame (3) and rear frame (4) is normal. ence): 15 mm
a Clearance (a): 20 – 30 mm 3 Locknut: 8.8 – 10.8 Nm {0.9 – 1.1 kgm}
a Check the left steering and right steering
separately. a After the adjustment, check clearance (a)
again using the above testing procedure.
WD600-6 30-102 7
SEN05046-01 Testing and adjusting steering wheel (Steering wheel specification)
Testing and adjusting steering

wheel (Steering wheel
specification) 1
a Testing and adjusting device for steering wheel

P 79A-264-0021 Push-pull scale
Measuring play of steering wheel
a Measure the play of the steering wheel under

the following condition.
q Engine: Stopped
q Position of machine: Straight travel condition
Measuring method
1. Move the steering wheel to the right and left 2 – 3
times and check that the steering mechanism is
in neutral, and then make mark (A) on the
machine monitor frame.
2. Turn the steering wheel to the right and make

mark (B) at a position where the operating
effort becomes heavy.
3. Turn the steering wheel to the left and make

mark (C) at a position where the operating
effort becomes heavy. Then, measure the
straight distance between marks (B) and (C).
30-102 8 WD600-6
Testing and adjusting steering wheel (Steering wheel specification) SEN05046-01
Measuring operating effort of steering wheel Measuring operating time of steering wheel
a Measure the operating effort of the steering a Measure the operating time of the steering
wheel under the following condition. wheel under the following condition.
q Road: Flat, level, paved, and dry road q Road: Flat, level, paved, and dry road
q Engine coolant temperature: q Engine coolant temperature:
Within operating range Within operating range
q Hydraulic oil temperature: q Hydraulic oil temperature:
Within operating range Within operating range
q Tire inflation pressure: Specified pressure q Tire inflation pressure: Specified pressure
q Engine: Low idle (No load on blade) q Engine speed: Low idle and high idle
Measuring method Measuring method

1. Install push-pull scale P to the steering wheel 1. Start the engine.
knob. a After starting the engine, raise the blade
a Install push-pull scale P to the center. about 400 mm and release the frame lock
lever.
2. Start the engine.
a After starting the engine, raise the bucket 2. Turn the steering wheel to the right or left
about 400 mm and release the frame lock stroke end.
lever.
3. Turn the steering wheel to the right or left
3. Pull push-pull scale P in the tangential direc- stroke end and measure the full-stroke time.
tion and read it while the steering wheel is a Do not turn the steering wheel forcibly but
moving smoothly. turn it at the speed of 60 revolutions per
a The operating effort is not the value indi- minute.
cated when the steering wheel starts mov- a While running the engine at low idle and
ing. high idle, measure the time to turn the
steering wheel to the right and left respec-
tively.
WD600-6 30-102 9
SEN05046-01 Testing steering oil pressure
Testing steering oil pressure 1 1. Steering relief pressure

1) Connect oil pressure gauge [1] of hydrau-
a Measuring instruments for steering oil pressure lic tester Q1 to steering circuit oil pressure
Symbol Part No. Part Name pickup nipple (2) on the right steering cyl-
inder head side.
1 a Use the oil pressure gauge of 40 MPa
790-261-1203 Digital hydraulic tester {400 kg/cm2}.
799-101-5220 Nipple (10 × 1.25)
Q 2
07002-11023 O-ring
3 799-401-2701 Differential pressure gauge
4 799-401-3200 Adapter (Size 03)
a Measure the steering oil pressure under the

Measuring
k Loosen the oil filler cap of the hydraulic 2) Run the engine at high idle and turn the
tank to release the internal pressure of the steering wheel to the right. When the
hydraulic tank, then operate the steering steering relief valve operates, measure
wheel 2 – 3 times to release the residual the oil pressure.
pressure from the piping. a When the gauge was connected to
k Apply frame lock lever (1). steering circuit pickup plug (3) at the
bottom of the right side steering cylin-
der, measure the pressure by turning
the steering wheel to the left.
3) After finishing measurement, remove the

measuring instruments and return the
removed parts.
30-102 10 WD600-6
Testing steering oil pressure SEN05046-01
2. Steering pilot circuit pressure 3) Connect nipple Q2 (10 × 1.25 mm) and oil
1) Remove cover (4) at the accumulator pressure gauge [1] of hydraulic tester Q1.
installation position situated on the left a Use the oil pressure gauge of 6 MPa
side of the machine. {60 kg/cm2}.
2) Remove the steering control circuit pres-

sure pickup plug (10 × 1.25 mm) (6) or (7)
measure the oil pressure as the steering
of steering valve assembly (5).
wheel is turned.
q (6) Plug: Turn the steering wheel right
(or shift AJSS lever to right)
q (7) Plug: Turn the steering wheel left
(or shift AJSS lever to left)

removed parts.
WD600-6 30-102 11
SEN05046-01 Testing steering oil pressure
3. Measuring AJSS EPC solenoid valve output 5) Lock the steering lock lever.
pressure (only for AJSS specification) 6) Start the engine and then measure AJSS
1) Lift and remove step (16). EPC solenoid valve output pressure when
4 Step assembly: 130 kg the engine is set to high idle with AJSS
lever being set at neutral.
2) Disconnect solenoid output pressure hose

(18) from AJSS EPC solenoid valve (17). 7) Remove the measurement tool after the
3) Connect adapter Q4 and solenoid output

pressure hose (18).
4) Connect nipple [2] and oil pressure gauge
[1] in hydraulic tester Q1.
{60 kg/cm2}.
30-102 12 WD600-6
Testing steering oil pressure SEN05046-01
Adjusting 2. Steering LS differential pressure

k When adjusting the oil pressure, be sure to 1) If the steering LS differential pressure is
stop the engine. abnormal, adjust LS valve (14) of steering
1. Steering relief pressure pump assembly (13) according to the fol-
1) If the steering relief pressure is abnormal, lowing procedure.
adjust steering relief valve (10) of steering
valve assembly (5) according to the fol-
lowing procedure.
2) Loosen locknut (14) and turn adjustment

screw (15) to adjust the pressure.
a Adjustment screw:
q Turned to the right, the LS differ-
2) Loosen locknut (11) and turn adjustment ential pressure lowers.
screw (12) to adjust the pressure. q Turned to the left, the LS differ-
a Adjustment screw: ential pressure rises.
q Turned to the right, the pressure a Quantity of adjustment per turn of
rises. adjustment screw:
q Turned to the left, the pressure Per turn: 1.3 MPa {13.3 kg/cm2}
3 Locknut: 49 – 68.6 Nm {5 – 7 kgm}
lowers.
a Quantity of adjustment per turn of
adjustment screw:
Per turn: 17.9 MPa {183 kg/cm2}
3 Locknut:
27 – 31 Nm {2.8 – 3.2 kgm}
3. AJSS EPC solenoid valve output pressure

Adjustment of AJSS EPC solenoid valve out-
put pressure is done by adjusting AJSS EPC
output current. For details, see “Special func-
tions of machine monitor”, 7-12 AJSS EPC
output current adjustment (AJSS specifica-
tion).
WD600-6 30-102 13
SEN05046-01 Bleeding air from steering cylinder circuit
Bleeding air from steering

cylinder circuit 1
a Before starting the operation, make sure the

specified level of hydraulic oil is provided.
a If the steering valve or the steering cylinder
was removed and installed, bleed air from the
steering circuit according to the following pro-
cedure.
1. Run the engine at idle for about 5 minutes.
2. While running the engine at low idle, steer the

machine to the right and left 4 – 5 times.
a Stop the piston rod about 100 mm before
each stroke end and take care not to
relieve the circuit.
3. While running the engine at high idle, perform

the operation of 2.
4. While running the engine at low idle, move the

piston rod to the stroke end and relieve the cir-
cuit.
30-102 14 WD600-6
Testing hydraulic drive fan SEN05046-01
Testing hydraulic drive fan 1 Tachometer kit R1
a Testing tools for hydraulic drive fan

1 799-205-1100 Tachometer kit
2
R
799-101-5220 Nipple (M10 × 1.25)
3
07002-11023 O-ring
4 799-401-3500 Adapter (Size 06)
k Set the bucket bottom horizontally and

lower it to the ground, and then put chocks
under the tires.
k When removing the oil pressure pickup 2) While running the engine at high idle and
plug and disconnecting the hose, loosen low idle, measure the fan speed.
the oil filler cap of the hydraulic tank to 3) After finishing measurement, remove the
release the internal pressure of the tank. measuring instruments and return the
a Measurement condition removed parts.
q Engine coolant temperature: Min. 95°C
q Hydraulic oil temperature: Min. 95°C
q Torque converter oil temperature: Min. 105°C
1. Measuring fan speed

1) Set probe [2] to stand [1] of tachometer kit
R1 and stick reflection tape [3] to the fan.
WD600-6 30-102 15
SEN05046-01 Testing hydraulic drive fan
2. Measuring fan drive oil pressure 6) While running the engine at high idle,
1) Open radiator grille (1). measure the fan drive oil pressure.
2) Remove fan net (2) at the center.

3) Disconnect P port hose (4) of fan motor measuring instruments and return the
(3). removed parts.
4) Connect adapter R4 and hose (4).

5) Connect nipple R3 (10 × 1.25 mm) and oil
pressure gauge [1] in hydraulic tester R2.
{400 kg/cm2}.
30-102 16 WD600-6
Testing hydraulic drive fan SEN05046-01
3. Measuring fan reverse solenoid output 5) Turn the cooling fan reverse switch ON.
pressure 6) While running the engine at high idle,
1) Open radiator grille (1). measure the fan reverse solenoid drive oil
2) Remove fan net (2) at the center. pressure.
a Measure the fan forward and reverse
drive oil pressures. When the fan is
reversed, check that the solenoid
operates and the specified oil pres-
sure is applied.
3) Remove fan reverse solenoid output pres-

sure pickup plug (10 × 1.25 mm) (5) from
fan motor (3).

removed parts.
4) Connect nipple R3 (10 × 1.25 mm) and oil

pressure gauge [1] in hydraulic tester R2.
{400 kg/cm2}.
WD600-6 30-102 17
SEN05046-01 Bleeding air from hydraulic drive fan circuit
Bleeding air from hydraulic drive 3) As oil free from air started to flow out of air
fan circuit bleeder (3), tighten air bleeder (3).
3 Air bleeder:
1
a Testing tools for bleeding air from hydraulic drive 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
fan circuit 4) Start the engine and run it at low idle for 5
Symbol Part No. Part Name minutes minimum.
1 2. Bleeding air from fan motor circuit
790-261-1204 Digital hydraulic tester 1) Open radiator grille (4).
799-101-5220 Nipple (10 × 1.25) 2) Remove fan net (5) at the center.
S 2
07002-11023 O-ring
3 799-401-3500 Adapter (Size 06)
4 790-261-1130 Coupling
a Before starting the operation, make sure the

specified level of hydraulic oil is provided.
1. Bleeding air from fan pump

1) Open pump top cover (1).
3) Disconnect P port hose (7) of fan motor

(6).
2) Stop the engine and then loosen air

bleeder (3) of fan pump (2) to connect air
bleeding hose [1].
30-102 18 WD600-6
Bleeding air from hydraulic drive fan circuit SEN05046-01
4) Connect adapter S3 and hose (7).

5) Connect nipple S2 (10 × 1.25 mm) and
hose [1] in hydraulic tester S1 and also
connect air bleeder coupling S4 to the out-
let end of hose.
a Put the outlet end of the hose in an oil
receiver.
6) Run the engine. When the oil flows out of

the outlet end of the hose, stop the
engine.
7) After finishing bleeding air, remove the
tools and return the removed parts.
WD600-6 30-102 19
SEN05046-01 Measuring brake pedal
Measuring brake pedal 1
a Measurement condition
Measuring pressing angle of pedal

1. Install push gauge [1] to the foot of the mea-
surer.
a Set the push gauge in a position 150 mm
from the fulcrum of the pedal.
2. While running the engine at low idle, measure

pedal pressing angle (a1).
3. Apply angle gauge [2] to the brake pedal and

measure pressing angle (a2) from pressing
angle a1 to pressing angle (a3) (a2 = a1 – a3).
q (a2): Pressing angle at pressing effort of
321 ± 32.1 N {32.8 ± 3.3 kg}
30-102 20 WD600-6
Measuring brake performance SEN05046-01
Measuring brake performance 1
a Measure the brake performance under the fol- Measuring method

lowing condition. 1. Start the engine and drive the machine.
q Road: Flat, level, paved, and dry road
q Braking initial speed: 20 km/h 2. Set the gear shift lever or gear shift switch to
q Tire inflation pressure: Specified pressure 4th position for run up.
q Tire size: 35/65-33-24PR
q Brake pedal pressing force: Specified press- 3. When the travel speed becomes the braking
ing force initial speed of 20 km/h, press the left brake
294 ± 29.4 N {30 ± 3 kg} pedal with the specified force.
q Pressing time lag: 0.1 second a Decide the approach course and braking
point in advance and apply the brake at
that braking point.
4. Measure the distance from the braking point to

the stop point.
a Perform the above measurement 3 times
and obtain the average.
WD600-6 30-102 21
SEN05046-01 Testing and adjusting accumulator charge pressure
Testing and adjusting

accumulator charge pressure 1
a Testing and adjusting instruments for accumu-

lator charge pressure
T
a Measure the accumulator charge pressure

under the following condition.
k Put chocks under the tires securely.
k While the engine is stopped, press the
brake pedal at least 100 times to release the
pressure from the accumulator circuit.
Measuring
1. Remove cover (1) at the accumulator installa-
tion position situated on the left side of the
machine.
2. After removing cover (1), insert your hand

through the opening and connect oil pressure
gauge [1] of hydraulic tester T to accumulator
charge valve measuring nipple [2].
a Use the oil pressure gauge of 40 MPa {400
kg/cm2}.
3. Measure the accumulator charge cut-in pres-
sure.
While running the engine at low idle, when the
brake oil pressure caution lamp on the monitor
panel goes off, measure the oil pressure.
a Cut-in pressure:5.88 (+0.49/0) MPa
{60 (+5/0) kg/cm2}
4. Measure the accumulator charge cut-out pres-

sure.
After the accumulator charge cut-in operation,
the rising oil pressure gauge lowers suddenly.
Measure the oil pressure at this time.
30-102 22 WD600-6
Testing and adjusting accumulator charge pressure SEN05046-01
a Cut-out pressure:9.8 (+0.98/0) MPa

{100 (+10/0) kg/cm2}
a Adjustment screw:
q Turned to the right, the pressure rises.
q Turned to the left, the pressure lowers.
a Quantity of adjustment per turn of adjust-
ment screw: 5.59 MPa {57 kg/cm2}
3 Locknut: 9.8 – 11.8 Nm {1.0 – 1.2 kgm}
a After finishing measurement, check the
Adjusting
accumulator charge cut-in and cut-out
a If the accumulator charge cut-out pressure is pressures again according to the above
adjusted, the cut-in pressure changes accord- measurement procedure.
ing to the valve area ratio.
1. Loosen locknut (4) of unload relief valve (accu-

mulator charge cut-out valve) (3) and turn
adjustment screw (5) to adjust the pressure.
WD600-6 30-102 23
Testing of accumulator nitrogen gas pressure and procedure for charging brake accumulator with
SEN05046-01 nitrogen gas
Testing of accumulator nitrogen an accessory of gas charging tool P1, to gas

gas pressure and procedure for valve (4), and check for leakage.
a In some cases, threaded portion height (B) of
charging brake accumulator with gas valve (4) is short for depth (A) from the end
nitrogen gas 1
face of adapter (5) of gas charging tool P1 to
packing (6). In this case, nitrogen gas may leak
a Testing and adjusting tools through the threaded portion of gas valve (4).
Symbol Part No. Part name To prevent this, securely install gas charging
1 792-610-1703 Gas charging tool assembly
tool P1.
2 07000-11009 O-ring
3 792-610-2410 Bushing
4 792-610-1270 Hose
5 792-610-1400 Regulator
P 792-610-1310 Nipple (For Russia)
792-610-1320 Nipple (For USA)
6 792-610-1330 Nipple (For USA)
792-610-1350 Nipple (For Germany)
792-610-1360 Nipple (For UK)
Commercially
7 Nitrogen gas cylinder
available
k Put on the appropriate protective equip-
ment (goggles, leather gloves, protective
clothes) so that the leaked nitrogen gas is Testing of accumulator nitrogen gas pressure
not applied to your skin or clothes. Perform
a The accumulators for the front brake, rear
the work on the windward side as much as
brake, and parking brake have the same shape.
possible.
a The accumulator can be tested similarly in an
k When using the nitrogen gas indoors or on
uninstalled state as well.
an ill-ventilated location, ventilate the
a Both old accumulator and new one are listed.
room, etc. and observe the Industrial Safety
Confirm shape of accumulator and test.
and Health Law, Ordinance on Prevention
1. Stop the engine, depress the brake pedal
of Anoxia, etc.
k
repeatedly until its reaction force disappears in
The accumulator is charged with high-pres-
order to completely release the oil pressure
sure nitrogen gas, and improper operation
from the brake circuit.
may cause an explosion which will lead to
a As a guide, by depressing the brake pedal
serious injury or death. When handling,
approximately 30 times, the reaction force
always observe the following.
of the brake pedal disappears and the oil
q Do not bring open flame close to it or do
pressure is released.
not dispose of it in fire.
q Do not perform drilling, welding or flame- 2. Remove cap (3) from accumulator (1). (Old
cutting. type accumulator)
q Do not hit or roll it, or subject it to any
impact.
q When discarding it, gradually discharge
the filled nitrogen gas into the atmosphere
outside by using gas charging tool P1.
k Be sure to charge the accumulator with
nitrogen gas.
Precautions for connecting gas charging tool P1

a The threaded portion of adapter (5) of gas
charging tool P1 is coated with sealant. If the
adapter is removed without reason, it can
cause gas leakage. Never remove it.
a When connecting gas charging tool P1 to
accumulator (1), always fit O-ring P2, which is
30-102 24 WD600-6
nitrogen gas SEN05046-01
3. Remove plug (9) from accumulator (1). 3) Fully turn handle (a) of gas charging tool
(New type accumulator) P1 counterclockwise until it stops (to close
piping between accumulator (1) and gas
charging tool P1), and fully turn handle (b)
clockwise to close, then connect them.
a Since valve (7) on the hose connec-
tion side of gas charging tool P1 is a
check valve (one-way valve), gas
does not leak from the hose connec-
tion port into the atmosphere.
4) Connect gas charging tool P1 to gas valve
(4) of accumulator (1) or extension (8).
5) Cover valve (7) to prevent entry of rain,
snow, sand, or dust.
4. Connect gas charging tool P1 to gas valve (4)

of accumulator (1) according to the following
procedure.
1) Install attached O-ring P2 to gas valve (4).
(Old type accumulator)
Reference
q Handle (a): Turn counterclockwise to close the
valve, and clockwise to open the valve (to con-
nect the charge valve and accumulator)
a This valve is opened when tightened
q Handle (b): Turn counterclockwise to open the
valve (to open to the atmosphere), and clock-
2) Install extension (8) attached to gas charge wise to close the valve (to disconnect from the
tool P1, to gas valve (4). atmosphere)
(New type accumulator) a This valve is closed when tightened
a Do not attach O-ring P2. 5. Slowly turn handle (a) of gas charging tool P1
clockwise, and read the gauge value.
a Check the gas pressure by referring to the
following table, since the display varies
depending on the temperature at mea-
surement.
(The unit of values in the formula is °C)
Specified gas pressure =
Standard gas pressure x ((273 + t)/(273 + 20))
t: Gas temperature at measurement (°C)
Reference: "t" can be assumed to be the
ambient temperature.
WD600-6 30-102 25
Table 1 Accumulator gas pressure table 6. When reducing the nitrogen gas pressure in
Ambient Gas pressure the accumulator after testing it
tempera-
MPa kg/cm2
Remarks a Initial state: Open handle (a)
ture °C 1) Slowly turn handle (b) clockwise, and
15 3.06 31.2
gradually release the nitrogen gas through
16 3.07 31.3
17 3.08 31.4 the threaded portion of handle (b). Imme-
18 3.09 31.5 diately after the gauge of gas charging
19 3.10 31.6 tool P1 reaches the standard pressure in
20 3.11 31.8 Table 1, turn handle (b) clockwise to close
21 3.12 31.9 the valve, and adjust the nitrogen gas
22 3.14 32.0 pressure in accumulator (1).
23 3.15 32.1
24 3.16 32.2 2) Go to step 8.
25 3.17 32.3
26 3.18 32.4 7. When charging the accumulator with nitrogen
27 3.19 32.5 gas after testing the nitrogen gas pressure in it
28 3.20 32.6
1) Close the valve by turning handle (a)
29 3.21 32.7
30 3.22 32.8 counterclockwise until it stops.
31 3.23 32.9 2) Gradually turn handle (b) counterclock-
32 3.24 33.1 wise, and discharge the nitrogen gas
33 3.25 33.2 remaining in charging tool P1 through the
34 3.26 33.3 threaded portion of handle (b), then keep
35 3.27 33.4
the valve open.
36 3.28 33.5
37 3.29 33.6 (To bleed air in the hose, open the piping
38 3.31 33.7 between handle (b) and atmosphere)
39 3.32 33.8 3) Go to "Procedure for charging accumula-
40 3.33 33.9 tor with nitrogen gas", step 4.6), and
41 3.34 34.0 charge the accumulator with nitrogen gas
42 3.35 34.1 and adjust the gas pressure.
43 3.36 34.2
44 3.37 34.4
45 3.38 34.5 8. After testing, close the valve by turning handle
46 3.39 34.6 (a) counterclockwise until it stops.
47 3.40 34.7
48 3.41 34.8 9. Remove gas charging tool P1 from accumula-
49 3.42 34.9
Standard temperature
tor (1), and restore the machine.
50 3.43 35.0 1) Turn handle (b) counterclockwise to open
Standard gas pressure
the valve, and discharge the nitrogen gas
remaining in gas charging tool P1 through
a Compare the gauge gas pressure with the the threaded portion of handle (b).
specified gas pressure in Table 1. When
2) Remove gas charging tool P1.
the gas pressure is too high, go to step 6,
and adjust the gas pressure. 3) Remove extension (8). (New type accu-
a Compare the gauge gas pressure with the mulator)
specified gas pressure in Table 1. If the
gas pressure is insufficient, go to step 7,
then perform adjustment according to
"Procedure for charging accumulator with
nitrogen gas".
a When the gas pressure is normal, go to
step 8.
30-102 26 WD600-6
4) Remove O-ring P2 from gas valve (4) of Procedure for charging accumulator with nitro-
accumulator (1). (Old type accumulator) gen gas
a The accumulator can be charged in uninstalled
state as well.
1. Stop the engine, depress the brake pedal
repeatedly until its reaction force disappears in
order to completely release the oil pressure
from the brake circuit.
a As a guide, by depressing the brake pedal
approximately 30 times, the reaction force
of the brake pedal disappears and the oil
pressure is released.
2. Remove cap (3) from accumulator (1). (Old

type accumulator)
10. Apply soapy water to gas valve (4) (previous

mentioned) of the accumulator, and check that
no nitrogen gas is leaking.
11. Install cap (3) to accumulator (1). (Old type

accumulator)
3 Cap:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
3. Remove plug (9) from accumulator (1).

(New type accumulator)
12. Install plug (9) to accumulator (1).

3 Plug:
73.5 to 98.0 Nm {7.5 to 10.0 kgm}
WD600-6 30-102 27
4. Connect gas charging tool P1 and nitrogen cyl-

inder P7 to gas valve (4) of accumulator (1)
according to the following procedure.
1) Turn handle (a) of gas charging tool P1
counterclockwise until it stops. (Close the
piping between accumulator (1) and gas
charging tool P1)
2) Turn handle (b) counterclockwise for
opening. (To bleed air in the hose, open
the piping between handle (b) and atmo-
sphere)
3) Install attached O-ring P2 to gas valve (4).
Reference
q Handle (a): Turn counterclockwise to close the
valve, and clockwise to open the valve (to con-
nect the charge valve and accumulator)
4) Install extension (8) attached to gas charge a This valve is opened when tightened
tool P1, to gas valve (4).
(New type accumulator) q Handle (b): Turn counterclockwise to open the
a Do not attach O-ring P2. valve (to open to the atmosphere), and clock-
wise to close the valve (to disconnect from the
atmosphere)
a This valve is closed when tightened
q Handle (c): Turn counterclockwise to close the

regulator (to stop discharge of gas), and clock-
wise to open the regulator (to discharge gas).
a This regulator is opened when tightened
5. Bleed air in the hoses according to the follow-

ing procedure.
1) Open valve (d) of nitrogen gas cylinder P7
until the pressure on the gas cylinder side
of regulator P5 becomes approximately 7
5) Connect gas charging tool P1 to gas valve MPa {70 kg/cm2}.
(4) of accumulator (1) or extension (8). 2) Slightly turn handle (c) clockwise to open,
6) Connect bushing P3 to gas charging tool and set the pressure on the hose side of
P1. regulator P5 to 0.19 to 0.29 MPa {2 to 3
7) Turn handle (c) of regulator P5 until it kg/cm2}. When nitrogen gas starts leaking
stops (closes), and connect regulator P5 through the threaded portion of handle (b),
to nitrogen gas cylinder P7. turn handle (b) clockwise and close the
a Use nipple P6 to connect the regula- valve.
tor, depending on the specification of 3) Turn handle (c) counterclockwise to close
the nitrogen gas cylinder. the valve of regulator P5.
8) Connect hose P4 to bushing P3 and regu-
lator P5.
30-102 28 WD600-6
6. Charge the accumulator with nitrogen gas Table 1 Accumulator charge gas pressure table
according to the following procedure. Ambient Gas pressure
a Keep valve (d) open as in the state of 5.1). tempera-
MPa kg/cm2
Remarks
1) Slowly turn handle (a) clockwise, and stop ture °C
15 3.06 31.2
when you feel a light reaction force.
16 3.07 31.3
a Do not turn handle (a) excessively, 17 3.08 31.4
otherwise it damages the accumula- 18 3.09 31.5
tor valve core and gas may leak. 19 3.10 31.6
Operate handle (a) carefully. 20 3.11 31.8
2) Slowly turn handle (c) clockwise to open 21 3.12 31.9
22 3.14 32.0
the valve of regulator P5, and add nitro-
23 3.15 32.1
gen gas to the accumulator until the pres- 24 3.16 32.2
sure gauge of gas charging tool P1 25 3.17 32.3
indicates the specified pressure. 26 3.18 32.4
a During the work, turn handle (c) 27 3.19 32.5
sometimes to close the valve of regu- 28 3.20 32.6
lator P5 and stabilize the pressure, 29 3.21 32.7
30 3.22 32.8
then check the nitrogen gas pressure
31 3.23 32.9
in accumulator (1) with the gauge of 32 3.24 33.1
gas charging tool P1. 33 3.25 33.2
a Check the gas pressure by referring 34 3.26 33.3
to Table 1, since the gas pressure dis- 35 3.27 33.4
play varies depending on the temper- 36 3.28 33.5
ature at measurement. 37 3.29 33.6
38 3.31 33.7
(The unit of values in the formula is
39 3.32 33.8
°C) 40 3.33 33.9
Specified gas pressure = Standard 41 3.34 34.0
gas pressure x ((273 + t)/(273 + 20)) 42 3.35 34.1
t: Gas temperature at charge (°C) 43 3.36 34.2
Reference: "t" can be assumed to be 44 3.37 34.4
the ambient temperature. 45 3.38 34.5
46 3.39 34.6
3) When the gauge of gas charging tool P1 47 3.40 34.7
exceeds the specified gas pressure in 48 3.41 34.8
Table 1 49 3.42 34.9
1] Turn handle (c) counterclockwise to Standard temperature
50 3.43 35.0
close the valve of regulator P5. Standard gas pressure
2] Slowly turn handle (b) counterclock-
wise, and gradually release the nitro-
gen gas through the threaded portion
of handle (b). Immediately after the
gauge of gas charging tool P1
reaches the specified gas pressure in
Table 1, turn handle (b) clockwise to
close the valve, and adjust the nitro-
gen gas pressure in accumulator (1).
WD600-6 30-102 29
7. When the nitrogen gas pressure in the accu- 8. Apply soapy water to gas valve (4) (previous
mulator reaches the pressure in the table, mention) of the accumulator, and check that
remove each tool according to the following the nitrogen gas is not leaked.
procedure.
1) Turn handles (a) and (c) counterclockwise 9. Install cap (3) to accumulator (1).
to close the accumulator and valve of reg- 3 Cap:
ulator P5. 9.8 to 12.7 Nm {1.0 to 1.3 kgm}
2) Close valve (d) of nitrogen gas cylinder P7.
3) Turn handle (b) counterclockwise to open
the valve, and discharge the nitrogen gas
remaining in gas charging tool P1 and
hose P4 through the threaded portion of
handle (b).
4) Remove hose P4, regulator P5, bushing
P3, and nipple P6.
10. Install plug (9) to accumulator (1).

3 Plug:
73.5 to 98.0 Nm {7.5 to 10.0 kgm}
5) Remove gas charging tool P1 from gas

valve (4) of accumulator (1). 11. Check that there is no reduction of the nitrogen
6) Remove extension (8). gas pressure within 1 week after the nitrogen
(New type accumulator) gas is charged.
7) Remove O-ring P2 from gas valve (4). a Check the functions within 5 minutes after
(Old type accumulator) stopping the engine. (After 5 minutes or
longer of engine stop, the oil pressure of
the brake circuit is lowered and the correct
test cannot be performed.)
1) Stop the machine on a level ground, and set
the parking brake switch to "Park" position.
2) Start the engine, run it at medium speed
for a minute, and stop the engine.
3) Turn the starting switch to ON position.
Depress the brake pedal several times,
and count the number of times the brake
is depressed when the brake oil pressure
caution lamp lights up.
30-102 30 WD600-6
q When number of presses is 4 or less:

The accumulator gas pressure may
be low
q When number of presses is 5 or
more: The accumulator gas pressure
is normal
Reference: How to discharge nitrogen gas when

discarding accumulator
a When discarding an uninstalled accumulator,
you need to discharge the nitrogen gas.
1. Connect gas charging tool P1 to gas valve (4)
of accumulator (1) or extension (8). For details,
see "Testing of accumulator nitrogen gas pres-
sure", 1 to 4.
2. Slowly turn handle (a) clockwise, and stop

when you feel a light reaction force.
a Do not turn handle (a) excessively, other-
wise it damages the accumulator valve
core and gas may leak. Operate handle (a)
carefully.
3. Gradually tun handle (b) counterclockwise.

When nitrogen gas starts leaking through the
threaded portion of handle (b), leave the han-
dle as it is, and discharge the nitrogen gas.
4. When nitrogen gas stops leaking, leave handle

(a) as it is, and remove gas charging tool P1
from accumulator (1).
5. Remove extension (8).

6. Remove O-ring P2 from gas valve (4).

7. Discard the accumulator.

a According to step 4, gas valve (4) of accu-
mulator (1) remains open.
WD600-6 30-102 31
SEN05046-01 Testing wheel brake oil pressure
Testing wheel brake oil pressure 1
a Measuring tools for wheel brake oil pressure

1 793-520-1821 Nipple
2 793-520-1810 Joint
U
3 385-10178481 Bleeder screw
4 793-520-1831 Gauge assembly
k Even when the brake pedal is not usable

due to troubles on brake-related equip-
ment, highly pressurized oil in the accumu-
lator can burst out. Thus, it is required to
release pressure in the accumulator circuit 2. Drop in wheel brake oil pressure
by pressing the brake pedal 100 times mini- 1) Remove cover (1) and bleeder screw (2).
mum while maintaining the engine at
stopped state.
k Apply the parking brake and put chocks
under the tires securely.
a Measure the oil pressure of the front brakes
(right and left) and rear brakes (right and left)
similarly.
a Measure the wheel brake oil pressure under
the following condition.
Measuring
1. Wheel brake oil pressure
1) Remove cover (1) and bleeder screw (2). 2) Install nipple U1, joint U2, bleeder screw
U3 and gauge assembly U4.
3) Connect hose [1] to bleeder screw U3 and
then bleed air from the brake circuit. For
details, see “Bleeding air from wheel brake
circuit”.
2) Install nipple U1, joint U2, bleeder screw

U3 and gauge assembly U4.
3) Connect hose [1] to bleeder screw U3 and
then bleed air from the brake circuit. For
details, see “Bleeding air from wheel brake
circuit”.
4) Start the engine and measure the wheel
brake oil pressure as the left brake pedal
is pressed.
30-102 32 WD600-6
Testing wheel brake oil pressure SEN05046-01
4) Start the engine and accumulate pressure

in the accumulator.
5) Stop the engine and press the left brake to
set the oil pressure to 4.9 MPa {50 kg/cm2}.
Maintain this state for 5 minutes and then
measure the pressure drop.
a Use care so that the brake pedal may
not be moved for 5 minutes.
a Remove the measuring instruments
after the measurement and return the
currently removed parts to their origi-
nal position. Then bleed air from the
wheel brake circuit. For details, see
Bleeding air from wheel brake circuit.
WD600-6 30-102 33
SEN05046-01 Measuring wear of wheel brake disc
Measuring wear of wheel brake

disc 1

Commercially
V Slide calipers
available
k Stop the machine in a level place and put

chocks under the tires.
1. Remove cap (1).
2. Lightly press the brake pedal to the stroke end.
4. After testing, return cap (1).

3 Cap (1): 29.4 – 39.2 Nm {3.0 – 4.0 kgm}
3. While shaft (2) is pushed in, measure projec-
tion (x) (wear volume) from guide (3) using a
slide caliper V.
a Keep pressing the brake pedal during
measurement.
a If the protrusion (x) in the figure is below 0,
replace the disc.
q Wear (y): 5.5 – (x): Max. 5.5 mm
30-102 34 WD600-6
Bleeding air from wheel brake circuit SEN05046-01
Bleeding air from wheel brake

circuit 1
k Stop the machine in a level place and put

a If a brake circuit part is removed and installed,
bleed air from the brake circuit according to the
a Bleed air from the front brake circuit and rear
brake circuit similarly (2 places each).
1. Start the engine to accumulate pressure in the

accumulator and then stop the engine.
2. Connect hose [1] to bleeder screw (1) and

place hose [1] in the oil pan.
3. Press the brake pedal and then loosen bleeder

screw (1) to bleed air.
a Return the brake pedal slowly after tight-
ening bleeder screw (1).
a Use the left brake pedal.
4. Repeat this operation until the oil flowing

through hose [1] becomes free from bubbles.
Then press the pedal fully and tighten bleeder
screw (1) while the oil is flowing.
5. Bleed air from other brake cylinders, too, using

the same procedure.
a When a complete bleeding is required, it is
advisable to start the operation from the
brake cylinder situated farthest from the
brake pedal.
a As accumulated pressure in the accumu-
lator is decreased, start the engine to
accumulate pressure in the accumulator.
Then bleed air using the same procedure
as described above.
a After finishing bleeding air, run the engine
at low idle and check the oil level in the
hydraulic tank. If the level is low, add oil up
to the specified level.
WD600-6 30-102 35
SEN05046-01 Releasing residual pressure in brake accumulator circuit
Releasing residual pressure in

brake accumulator circuit 1
k Before disconnecting any of the following

brake accumulator circuits, release resid-
ual pressure in that brake circuits.
q Piping between accumulator charge valve and

brake accumulator
q Piping between accumulator charge valve and
parking brake emergency release valve
q Piping between brake accumulator and brake
valve on both sides
1. Stop the engine.
2. Press the brake pedal at least 100 times to

release the pressure from the brake accumula-
tor circuit.
30-102 36 WD600-6
Testing parking brake performance SEN05046-01
Testing parking brake performance1

a Measurement condition
q Tire inflation pressure: Specified pressure
q Road: 1/5 gradient (11° 20'), flat, and dry road
q Machine: Ready for operation
Measuring method
1. Start the engine and set the machine in the
straight travel position, and then drive up a
slope of 1/5 gradient.
2. Press the brake to stop the machine, set the

directional lever in the N position, and stop the
engine.
3. Turn the parking brake switch ON (to park),

and then release the brake gradually. At this
time, the machine must not move.
a When the engine is stopped, the parking
brake is turned ON (to park) automatically.
a Measure the parking brake performance
on an uphill and a downhill.
WD600-6 30-102 37
SEN05046-01 Measuring parking brake oil pressure
Measuring parking brake oil 2) Remove parking brake inlet pressure

pressure 1
pickup plug (10 × 1.25 mm) (2).
a Measuring instruments for parking brake oil

pressure
1
W 799-101-5220 Nipple (10 × 1.25)
2
07002-11023 O-ring
3 799-401-3100 Adapter (Size 02)
k Put chocks under the tires.

k Install and remove the measuring instru-
ments after the oil temperature lowers fully.
3) Connect nipple W2 and oil pressure
a Measure the parking brake oil pressure under gauge [1] of hydraulic tester W1.
the following condition. a Use the oil pressure gauge with
q Engine coolant temperature: capacity 6 MPa {60 kg/cm2}.
q Power train oil temperature:
1. Parking brake inlet pressure

1) Remove rear frame left side cover (1).
a Applicable only to the machine
equipped with the rear frame side
covers.
30-102 38 WD600-6
Measuring parking brake oil pressure SEN05046-01
4) While running the engine at low idle, mea- 3) Install adapter W3 and connect parking
sure the parking brake inlet pressure. brake pilot pressure hose (3).
k Keep pressing the brake pedal for 4) Connect nipple [2] and oil pressure gauge
safety. [1] in hydraulic tester W1.
a Measure the oil pressure at turning a Use the oil pressure gauge with
OFF of the parking brake. capacity 6 MPa {60 kg/cm2}.
a If the parking brake solenoid valve
output pressure is normal and parking
brake inlet pressure is abnormal, fail-
ure on the parking brake emergency
release valve can be suspected.
5) While running the engine at low idle, mea-

sure the parking brake pilot pressure.
k Keep pressing the brake pedal for
safety.
a Measure the oil pressure at turning
5) Remove the measurement tool after the OFF of the parking brake.
2. Parking brake pilot pressure (Transmis-

sion valve seat pressure)
1) Start the engine and then right-articulate
the steering to be maximum.
2) Disconnect parking brake pilot pressure
hose (3).

WD600-6 30-102 39
SEN05046-01 Measuring parking brake oil pressure
3. Parking brake solenoid valve output pres- 5) While running the engine at low idle, mea-
sure sure the parking brake solenoid valve out-
1) Remove rear frame right side cover. put pressure.
a Applicable only to the machine k Keep pressing the brake pedal for
equipped with the rear frame side safety.
covers. a Measure the oil pressure at turning
2) Disconnect parking brake solenoid valve OFF of the parking brake.
output pressure hose (5). a If the parking brake pilot pressure is
normal and parking brake solenoid
valve output pressure is abnormal,
failure on the check valve on the
parking brake solenoid inlet side or
failure on the parking brake solenoid
can be suspected.
3) Install adapter W3 and connect parking

brake solenoid valve output pressure hose
(5).
4) Connect nipple [2] and oil pressure gauge
[1] in hydraulic tester W1.
a Use the oil pressure gauge with
capacity 6 MPa {60 kg/cm2}. 6) Remove the measurement tool after the
30-102 40 WD600-6
Testing wear of parking brake disc SEN05046-01
Testing wear of parking brake disc 1 4. If allowable depth (a) is above the limit, remove
parking brake disc (4) and measure its thick-
Measuring instruments ness (W), referring to Disassembly and assem-
Symbol Part No. Part Name bly, “Removal and installation of parking brake
Commercially disc assembly”.
X Slide calipers q Service limit thickness (W): Min. 2.97 mm
available
a If the parking brake disc thickness is
below the service limit, replace the disc.
a If the parking brake does not work effectively,
check the parking brake disc for wear accord-
ing to the following procedure.
k Lower the work equipment fully and put
k When checking, stop the engine.
1. Drain the oil from the transmission case.

6 Transmission case: 83 l
2. Remove either of 2 plugs (1).
q Refilling with oil (Transmission case)

Add oil through the oil filler to the specified
through the system. Then, check the oil level
again.
3. Measure depth (a) from the end of cage (2) to

piston (3) with slide calipers X.
q Limit depth (a): Max. 30.5 mm
WD600-6 30-102 41
SEN05046-01 Method of releasing parking brake manually
Method of releasing parking brake 4. After moving to a safe place, restore the
manually machine to the original condition.
2 Mounting bolt (2): Adhesive (LT-2)
1
a The parking brake is controlled hydraulically. If 3 Mounting bolt (2):

you cannot release the parking brake because of 98 – 123 Nm {10 – 12.5 kgm}
a trouble in the transmission, emergency release 2 Plug (1): Gasket sealant (LG-5)
solenoid valve, etc., you can move the machine
by releasing the parking brake manually. q Refilling with oil (Transmission case)
k Releasing the parking brake manually is a After releasing the parking brake manually, add
means to move the machine from a danger- oil through the oil filler to the specified level.
ous job site to a safe place. Apply this Run the engine to circulate the oil through the
means only in an emergency. system. Then, check the oil level again.
k Lower the work equipment to the ground
and put chocks under the tires to prevent
the machine from moving.
k When applying this means, stop the engine.
1. Drain the oil from the transmission case.

2. Remove 2 plugs (1). (Right and left)
3. Prepare 2 cage mounting bolts (2) and tighten

them alternately in plug (1) installation position.
a Remove 2 bolts (2) on the diagonal positions.
a Tighten 2 bolts (2) to pull piston (3) and
release the parking brake.
a Tighten the 2 bolts gradually and evenly.
(After they reached the seats, give about
3 +1/4 turns further to them.)
30-102 42 WD600-6
Measuring and adjusting work equipment control lever SEN05046-01
Measuring and adjusting work 2. Stroke of work equipment control lever

equipment control lever 1
1) Operate the work equipment control lever
and measure its stroke at each position.
(Steering wheel specification) a Apply a mark to the lever knob and
a Measuring and adjusting tools for work equip- measure the stroke with scale Y2.
ment control lever a If the stroke is out of the standard
range, check for play of the linkage
and wear of the bushing.
1 79A-264-0021 Push-pull scale
Y Commercially
2 Scale
available
a Measure and test the work equipment control

lever under the following condition.
k Apply the lock bar to the frame.
Measuring
1. Operating effort of work equipment control
lever
1) Install and fix push-pull scale Y1 to the
work equipment control lever.
a Install push-pull scale Y1 to the center
of the knob.
a Operate the work equipment control
lever at the ordinary operating speed
and measure the minimum necessary
effort to operate the knob.
WD600-6 30-102 43
SEN05046-01 Measuring work equipment oil pressure
Measuring work equipment oil 2) Connect nipple Z2 and oil pressure gauge
pressure 1
[1] of hydraulic tester Z1.
a Measuring instruments for work equipment oil {400 kg/cm2}.
pressure
1
Z 799-101-5220 Nipple (10 × 1.25)
2
07002-11023 O-ring
3 799-401-2701 Differential pressure gauge
Measuring
1. Preparation work
1) Stop the machine on level ground, lower
the work equipment to the ground, stop
the engine, and set the parking brake
lever in the lock position. 3) Start the engine and set the work equip-
2) Lower the work equipment to the ground, ment lock lever in the FREE position.
stop the engine, and then operate the 4) Run the engine at a high idle speed, move
work equipment control lever two or three the blade control lever to PITCH REAR
times to release the residual pressure in position to set the cylinder in relief condi-
the piping. tion at its stroke end, and measure the oil
pressure.
2. Measurement of work equipment relief
pressure
1) Remove work equipment relief pressure
pickup plug (10 x 1.25 mm) (1).

k After measuring the oil pressure,
release pressure in the circuit and
then remove the oil pressure
gauge and nipple using the same
procedure as 1. Preparations for
work.
30-102 44 WD600-6
Measuring work equipment oil pressure SEN05046-01
3. Measuring unload oil pressure 4) Measure the oil pressure when the engine
1) Open pump top cover (2). is run at high idle and all levers are set to
neutral.
2) Remove pump pressure pickup plugs

(M10 × 1.25 mm) (3) and (4) from the work
equipment pump.
q Pump pressure pickup plug (3): F pump
k After measuring the oil pressure,
q Pump pressure pickup plug (4): R pump
release pressure in the circuit and
then remove the oil pressure
gauge and nipple using the same
procedure as 1. Preparations for
work.
4. Measuring LS differential pressure

a Before measuring oil pressure of the LS
control circuit, make sure that the work
equipment relief oil pressure and work
equipment PPC oil pressure are normal.
a LS differential pressure is calculated from
the pump discharge pressure and LS
pressure (actuator negative pressure)
3) Install nipple Z2 and then connect oil pres- being measured at the same time.
sure gauge [1] of hydraulic tester Z1. 1) Open pump top cover (2).
{60 kg/cm2}.
WD600-6 30-102 45
2) Remove pump pressure pickup plugs a Use the oil pressure gauge of 40 MPa
(M10 × 1.25) (3) and (4), and LS pressure {400 kg/cm2}.
pickup plugs (M10 × 1.25) (5) and (6) from Since the differential pressure is 2.4
the work equipment pump. MPa {25 kg/cm 2 } at maximum, the
q Pump pressure pickup plug (3): For F same gauge can be used throughout
pump the measurement.
q Pump pressure pickup plug (4): For R
pump
q LS pressure pickup plug (5): For F
pump
q LS pressure pickup plug (6): For R
pump
a Measurement shall be conducted
using the combination of pump pres-
sure pickup plug (3) and LS pressure
pickup plug (5) as well as pump pres-
sure pickup plug (4) and LS pressure
pickup plug (6).
4) Move the blade control lever and measure

the pump discharge pressure and LS
pressure (actuator load pressure) at the
same time while the cylinder is in between
its stroke ends.
a Prevent the cylinder from turning to
full stroke as long as measurement is
continued.
a Calculation of LS differential pressure:
LS differential pressure = Pump dis-
charge pressure – LS pressure
3) Install nipple Z2 and then connect oil pres- 5) Remove the measurement tool after the
sure gauge [1] of hydraulic tester Z1 or dif- measurement, and make sure that the
ferential pressure gauge Z3. machine is back to normal condition.
a When using the differential pressure k After measuring the oil pressure,
gauge, connect its high-pressure side release pressure in the circuit and
to the pump pressure side and low- then remove the oil pressure
pressure-side to LS pressure side. gauge and nipple using the same
The differential pressure gauge procedure as 1. Preparations for
requires 12 V power supply. Thus, work.
connect a battery.
30-102 46 WD600-6
Measuring work equipment oil pressure SEN05046-01
Adjusting
a Adjustment of the unload valve is not available.
1. Adjusting work equipment relief pressure
1) Remove inspection cover (7) on the front
frame.
a After the adjustment, measure the

work equipment relief pressure again
using the procedure for measure-
ment.
2) Loosen locknut (9) of main relief valve (8)

of the work equipment control valve and
turn adjustment screw (10) to adjust the
pressure.
a Adjustment screw:
q Turned to the right, the pressure
rises.
q Turned to the left, the pressure
lowers.
adjustment screw:
12.55 MPa {128 kg/cm2}
3 Locknut: 29.4 – 39.2 Nm {3 – 4 kgm}
WD600-6 30-102 47
2. Adjusting LS differential pressure

1) Loosen locknut (13) of LS valves (11) and
(12) of the work equipment pump and then
turn adjustment screw (14) to adjust the
pressure.
q LS valve (11): For F pump
q LS valve (12): For R pump
a Adjustment screw:
q Turned to the right, the LS differ-
ential pressure lowers.
q Turned to the left, the LS differ-
ential pressure rises.
adjustment screw:
1.3 MPa {13.3 kg/cm2}
3 Locknut: 49 – 68.6 Nm {5 – 7 kgm}
a After the adjustment, measure LS dif-

ferential pressure again using the
procedure for measurement.
30-102 48 WD600-6
Bleeding air from work equipment circuit SEN05046-01
Bleeding air from work equipment 2. Air bleeding from hydraulic cylinder
circuit 1
1) Run the engine at low idle for about 5 min-
utes.
1. Bleeding air from work equipment pump 2) While running the engine at low idle, extend
(piston pump) and retract the cylinder to be bled 4 or 5
1) Remove pump top cover (1). times.
a Move the piston rod to about 100 mm
before the stroke end and never
relieve the oil.
3) While running the engine at low idle, move
the cylinder to the stroke end to relieve the
oil.
2) Stop the engine and then loosen air

bleeder (3) of work equipment pump (2) to
connect air bleeding hose [1].
3) As oil free from air started to flow out of air

bleeding hose [1] of work equipment pump
(2), tighten air bleeder.
3 Air bleeder:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
4) Start the engine and run it at low idle for 5
minutes minimum.
WD600-6 30-102 49
SEN05046-01 Moving machine for removing operator cab
Moving machine for removing operator cab 1
a Wiring harness ZA1
a Machine moving device for removing oper- 1. Remove the operator cab assembly (2). For
ator cab details, see Disassembly and assembly,
“Removal and installation of operator cab
assembly”.
1 426-06-32171 Wiring harness
ZA 2 08086-10000 Starting switch
3 421-06-36142 Parking brake switch
a When it is impossible to move a machine into

the maintenance shop without removing the
operator cab or when moving a machine to a
safe place with the operator cab being
removed, using wiring harness ZA1 allows
moving the machine.
a In this case, starting switch ZA2 and parking
brake ZA3 are used in place of the starting
switch and parking brake switch used on the
machine body.
k The harness is prepared only for moving
the machine in to a maintenance shop or
moving it from a work site to a safer place.
It should not be used for any purpose other
than above.
fully, apply the parking brake, and put
chocks under the tires so that the machine
will not move.
30-102 50 WD600-6
Moving machine for removing operator cab SEN05046-01
2. Connect B, BR, C and ACC of wiring harness 5. Disconnect axle pedal connector L17.
ZA1 to B, BR, C and ACC terminals of starting
switch ZA2. 6. Connect AXL of wiring harness ZA1 to axle
a Use care so that an improper connection pedal connector L17 (male side).
may not occur.
a Figure shows starting switch ZA2.
7. Connect CL16 of wiring harness ZA1 to con-

nector CL16 (female side) that has been dis-
3. Connect P/B of wiring harness ZA1 to connec- connected as the operator cab has been
tor P/B of parking brake switch ZA3. removed.
a Figure shows parking brake switch ZA3. a Only for steering wheel specification
4. Connect CL12 of wiring harness ZA1 to con- 8. Start the engine and move the machine to a
nector CL12 (male side) that has been discon- maintenance shop or a safe place.
nected as the operator cab has been removed. k Remove the chocks.
9. After removing the machine, restore it to the

original condition.
WD600-6 30-102 51
SEN05046-01 Preparations for work on troubleshooting of electric system
Preparations for work on

troubleshooting of electric system 1
a When carrying out troubleshooting of an elec-

tric circuit related to the machine monitor,
transmission controller, work equipment con-
troller, engine controller or VHMS controller,
expose the related connectors according to the
1. Machine monitor
1) Pull out switches from the cover (1) and
then disconnect the connectors.
q C08 connector: Parking brake switch
q C09 connector: Character display 2) Remove cover (1).
mode selector switch
q C10 connector: Character display
item selector switch
q C11 connector
q C12 connector
a Don't try to forcibly disconnect the
connectors inserting your hand
through the bottom of the cover. Such
action can damage the connectors or
switches.
3) Remove 4 bracket mounting bolts (3) of

machine monitor (2) and turn over the
machine.
a Use care in this operation so that the
wiring harness may not be forcibly
pulled.
q C08 connector: Parking brake switch
mode selector switch
item selector switch
q C11 connector
q C12 connector
q C13 connector: Front wiper switch
q C14 connector: Hazard switch
q C15 connector: Lamp switch
q C16 connector: Dimmer switch
30-102 52 WD600-6
Preparations for work on troubleshooting of electric system SEN05046-01
4) Connect T-adapter used for troubleshoot-

ing to connectors C01, C02, C03, C04,
C05 and C06 of machine monitor (2).
2. Transmission controller
1) Remove tray (4) from the right rear side of
the operator seat.
3. Work equipment controller

1) Remove tray (4) from the right rear side of
the operator seat.
2) Remove rear covers (5) and (6) of the

operator seat.
ing to connectors L02, L03 and L04 of
transmission controller (7).
a When it is difficult to remove or install
the connectors, do it after removing
the transmission controller first.
a The connectors are fixed in place with
the screw. Loosen the screw before
disconnecting the connector.
a When the connectors were returned
to the original position, tighten the
screw to the specified torque.
3 Screw: 2.82 Nm {0.288 kgm}
WD600-6 30-102 53
SEN05046-01 Preparations for work on troubleshooting of electric system
2) Remove rear covers (5) and (6) of the 4. Engine controller

operator seat. 1) Open the right side cover.
3) Connect T-adapter used for troubleshoot- 2) Connect T-adapter used for troubleshoot-
ing to connectors L05, L06 and L07 of ing to connectors E18, E19 and ENG of
work equipment controller (8). engine controller (9).
a When it is difficult to remove or install a When it is difficult to remove or install
the connectors, do it after removing the connectors, do it after removing
the work equipment controller first. the work equipment controller first.
a The connectors are fixed in place with a The connectors are fixed in place with
the screw. Loosen the screw before the screw. Loosen the screw before
disconnecting the connector. disconnecting the connector.
a When the connectors were returned a When the connectors were returned
to the original position, tighten the to the original position, tighten the
screw to the specified torque. screw to the specified torque.
3 Screw: 2.82 Nm {0.288 kgm} 3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
5. VHMS controller
1) Remove front console cover (10) situated
in the right side of the operator seat.
2) Pull out the VHMS controller fixed to the
back side of cover (10).
30-102 54 WD600-6
Preparations for work on troubleshooting of electric system SEN05046-01

ing to connectors V01, V02, V04, V06 and
V07 of VHMS controller (11).
a When it is difficult to remove or install
the connectors, do it after removing
VHMS controller first.
WD600-6 30-102 55
SEN05046-01 Procedure for testing diodes
Procedure for testing diodes 1 3) Determine acceptability of the diode from

the indicated value.
a Check an assembled-type diode (8 pins) and q Indicated value remains unchanged:
independent diode (2 pins) in the following Conduction is absent (Failure)
manner. q The indicated value changes: The
a The conductive directions of the assembled- diode has conductivity (Normal) (See
type diode are indicated on the surface of the a below.)
diode as shown in the following figure. a A value between 460 to 600 is indi-
cated for silicon diodes.
a The conductive directions of the single diode is

indicated on the surface of the diode as shown 2. When using analog type circuit tester
in the following figure. 1) Switch the testing mode to resistance
range.
2) Apply the leads of the tester as explained
below and check the movement of the
pointer.
1] Put the red probe (+) of the test lead
to the anode (P) and the black probe
(–) to the cathode (N) of diode.
2] Apply the red (+) lead of the tester to
the cathode (N) side of the diode and
apply the black (–) lead to the anode
(P) side.
3) Determine if a specific diode is good or no
good by the way the pointer swings.
q With the connection 1] above, the
1. When using digital type circuit tester pointer is not moved. It swings, how-
1) Switch the testing mode to diode range ever, wh en the conn ectio n 2] is
and confirm the indicated value. employed. Normal (However, magni-
a Voltage of the battery inside is dis- tude of the pointer's move (indicating
played with conventional circuit testers. the resistance value) varies depend-
2) Put the red probe (+) of the test lead to the ing on the given tester model and the
anode (P) of and the black probe (-) to the measurement range selected).
cathode (N) of diode, and confirm the indi- q The pointer swings with both the con-
cated value. nections of 1] and 2]: Defective (Inter-
30-102 56 WD600-6
Procedure for testing diodes SEN05046-01
WD600-6 30-102 57
SEN05046-01
WD600-6 Wheel dozer

©2019 KOMATSU
All Rights Reserved
30-102 58
SEN05047-02
WHEEL DOZER
WD600-6

WD600-6 55001 and up

Machine monitor-based adjustment at replacement, disassembly and assembly, and additional
installation for each sensor and controller .................................................................................................. 2
Special functions of machine monitor (EMMS) ............................................................................................... 5
WD600-6 30-103 1
SEN05047-02 installation for each sensor and controller
Machine monitor-based adjustment at replacement, disassembly and

assembly, and additional installation for each sensor and controller 1
1) Setting items that are necessary for replacement and disassembly and assembly as well as addi-
tional installation of sensors and controllers.
a When any of the following devices or parts was replaced, disassembled or assembled, the
machine monitor-based initialization of the sensors and solenoids is required.
a The machine monitor-based adjustment shall be implemented in the ascending order of the
item numbers (starting from (A)).
a Refer to the next page for adjustment items (A – K).
Correspondence chart of device, parts and adjustment item

Devices or optional parts being replaced, disassembled, assembled or added Adjustment item
Machine monitor A, B, C
Transmission main body D, E, F
Transmission controller A, B, D. E, F
Transmission ECMV solenoid D, E, F
Work equipment control valve G, I
Work equipment neutral lock EPC solenoid I
Work equipment electric lever H
Work equipment controller A, B, G, H, I, J
AJSS follow up link J
AJSS frame angle sensor J
AJSS lever angle sensor J
AJSS rotary valve J
Work equipment G
VHMS K
Adding and removing an optional device B
30-103 2 WD600-6
installation for each sensor and controller SEN05047-02
Adjustment item chart

Adjustment item Contents of adjustment
A Selection of model
B Selection of an optional device
C Input of serial number
D Adjustment of transmission ECMV current
E Reset of transmission initial learning
F Transmission initial learning
G Adjustment of right and left pitch speed
H Adjustment of work equipment EPC lever position before detent
I Adjustment of work equipment EPC starting current
J Adjustment of AJSS neutral position
K Initial setting of VHMS
L Setting of "service meter reading" and "odometer"
2) User needs-based adjustment

When user pointed out a trouble or requested solution for a trouble, the following setting change
shall be conducted by the machine monitor.
a Refer to the next page for adjustment items (M – X).

Correspondence chart of remarks or request and adjustment item
Contents of user's remarks or request Adjustment item
Want to change the display unit of the speedometer. M
Want to turn off display of the economy lamp. O
Want to limit the machine maximum speed. P, Q
Want to suppress hunting. R
Want to change the gearshift travel speed in the auto shift. R
Large shocks result at stopping the lift raise/lower or a substantial overrun occurs at stop-
S
ping.
Large shocks result from changeover of AJSS or follow to the lever is slow. T, U
Travel speed indication is too fast/slow. V
Want to turn off the character display-based travel speed/engine speed indication. W
Want the power mode to turn on as the starting switch is turned on. (Power mode priority) X
Want to decrease fuel consumption during high-speed travel (F4 lockup). Q
WD600-6 30-103 3
SEN05047-02 installation for each sensor and controller
Adjustment item chart

Adjustment item Contents of adjustment Description No. (*)
M Optional device selecting: Selection of speed unit 11
N Optional device selecting: Selection of weight unit 11
O Optional device selecting: Selection economy lamp display 11
P Optional device selecting: Selection of no 4th position 11
Q Adjustment of sensor: Adjustment of maximum travel speed 7-16
R Adjustment of sensor: Adjustment of L mode shift point 7-3
S Adjustment of sensor: Adjustment of lift lower stop modulation 7-14
T Adjustment of sensor: Change of AJSS lever pattern 7-10
U Adjustment of sensor: Change of AJSS EPC current 7-11
V Optional device selecting: Correction of travel peed (change of tire size) 11
W Optional device selecting: Change of travel peed/engine speed display 11
X Optional setting and change of power mode priority 11
*: Description No. of “Service mode” in “Special functions of machine monitor (EMMS)”

a Change of the display unit of the speed meter as well as the weight is not available when the specifica-
tion is prepared for a country where SI unit is employed.
30-103 4 WD600-6
Special functions of machine monitor (EMMS) SEN05047-02
Special functions of machine monitor (EMMS) 1
Normal functions and special functions of machine monitor

The machine monitor is equipped with the normal functions and special functions. Various items of data are
displayed on the character display in the middle of the machine monitor.
Depending on the internal setting of the machine monitor, the display items are divided into automatic dis-
play items and items displayed when the machine monitor switches are operated.
3) Normal functions: Operator mode
Functions for which the content is normally displayed or which can be displayed and operated by the
operator operating the switches.
a See the Operation and maintenance manual for details of the operator mode.
4) Special functions: Service mode
Functions which the serviceman can display and operate with the special switches to carry out inspec-
tion, maintenance, and troubleshooting.
Operator mode Service mode

Procedure for switching to service mode and
1 Service meter/clock display function (*2) 1
screen display
2 Load meter function (*1) 2 Electrical system fault history display function
3 Odometer display function 3 Mechanical system fault history display function
4 Maintenance monitoring function 4 Real-time monitoring function
5 Telephone number input function 5 Engine reduced-cylinder function
6 Language selection function 6 No injection cranking function
7 Monitor brightness adjustment function 7 Adjustment function
⇔
8 Time adjustment function (*2) 8 Maintenance monitoring function
Travel speed/engine speed display selecting
9 9 Operating information display function
function
Travel speed/engine speed display/non-display
10 10 Manual snapshot function
selecting function (*2)
11 Action code display function 11 Optional device selecting function
12 Failure code display function 12 Machine serial number input function
13 Model selection function
14 Initialize function
*1: This display is not available when the load meter function is turned off through option selection of service mode.
WD600-6: Load meter is not equipped.
*2: This display is not available when the travel speed/engine speed display selecting function is turned off through
option selection of service mode.
WD600-6 30-103 5
SEN05047-02 Special functions of machine monitor (EMMS)
Functions and flow of the service mode
30-103 6 WD600-6
WD600-6 30-103 7
30-103 8 WD600-6
Operator mode 3. Odometer display function

a Following overviews the operator mode. Press [U] switch from the ordinary service
a See the section "Structure, function and main- meter and clock display screen to display the
tenance standard" or the Operation and main- odometer.
tenance manual for details of the operator The load meter specifications displays the
mode. odometer as [<] switch is pressed succeeding
to display of the load meter function.
1. Service meter/clock display function a For details, see the "Other functions of
Turning on the starting switch displays the ser- machine monitor" of the "Operation" sec-
vice meter in the upper space and the clock in tion in the Operation and maintenance
the lower space. manual.
4. Maintenance monitoring function

1) Filter, oil replacement time display (auto-
2. Load meter function
matic display)
Since WD600-6 is equipped with the machine
As the filter or oil replacement time draws
monitor designed for WA600-6, the load meter
close, the machine monitor automatically
function screen can be displayed but the func-
displays its information to alert operator's
tion is not available for the WD600-6.
attention.
2) Resetting replacement time (selection
menu)
As maintenance operation for a filter or oil
is completed, the machine monitor allows
resetting the time interval through the
switch operation.
WD600-6 30-103 9
5. Telephone number input function 7. Monitor brightness adjustment function

Telephone numbers are entered through the Brightness of the machine monitor is adjust-
switch operation. And modification or cancella- able in seven levels through the switch opera-
tion of the phone numbers in the machine tion.
monitor is also available through the switch a Adjustment of brightness is available in
operation. two approaches – adjustment of the moni-
a When action code [E03] is displayed, a tor alone and separate adjustment of the
phone number is displayed along with monitor and liquid crystal.
[CALL]. a For details, see the "Other functions of
a For details, see the "Other functions of machine monitor" of the Operation section
machine monitor" of the Operation section in the Operation and maintenance man-
in the Operation and maintenance manual.
ual.
6. Language selection function

Switch operation allows selecting a display lan-
guage of the machine monitor.
a Functions of the service mode are con-
stantly displayed in English since they are
exempted from the display selection func-
tion.
a A desired language is selectable from
English, Japanese, German, French, Ital-
ian, Spanish and Swedish.
a For details, see the "Other functions of
machine monitor" of the Operation section
in the Operation and maintenance man- 8. Time adjustment function
ual. The time indicated by the clock of the machine
monitor is adjustable.
in the Operation and maintenance man-
ual.
30-103 10 WD600-6
9. Travel speed/engine speed display select- 11. Action code display function
ing function If a trouble occurs, the machine monitor dis-
A unit to be used for the machine monitor plays an action code corresponding to the seri-
speed display is selectable from km/h and ousness of the trouble to alert the operator for
MPH. It is also possible to turn on or off the dis- appropriate actions.
play of the travel speed and engine speed. a The figure below shows an example of the
a For details, see the "Other functions of screen on which action code [E03] and
machine monitor" of the Operation section [CALL + Telephone number] are alter-
in the Operation and maintenance man- nately displayed.
ual. a When action code [E01] or [E02] is dis-
played, [CALL + Telephone number] is not
displayed.
10. Travel speed/engine speed display/non-dis-

play selecting function
A unit for the machine monitor speed display is
selectable from km/h and MPH. It is also possi-
ble to turn on or off display of the travel speed
and engine speed.
in the Operation and maintenance man-
ual.
WD600-6 30-103 11
a Action codes and actions alerted to operator

CALL + Tele-
Action code Actions recommended to operator
phone number
• Do necessary testing and/or servicing as the current work is over or at
E01 Not displayed
shift of the operator.
• When an overrun-related item is displayed
Slow down the engine or machine speed.
E02 Not displayed
• When an overheat-related item is displayed
Stop the machine and run the engine at mid speed with no load.
E03 Displayed • Stop the engine and machine immediately and contact a serviceman.
12. Failure code display function a The service code display function displays
Pressing [>] switch once while an action is dis- the following information.
played on the machine monitor displays the A: Failure code (location code + problem
failure code corresponding to the failure cur- code)
rently warned. B: Controller code
a The failure codes detected in the past are MON: Machine monitor
divided into failures of the electrical sys- TM: Transmission controller
tem and the mechanical system and are WRK: Work equipment controller
recorded as fault history. (For details, see ENG: Engine controller
"Service mode".) VHMS: VHMS controller
a When two or more failures are involved, C: The system where failure occurred
pressing [>] switch displays further codes.
a If [>] switch is pressed again after it was
pressed to display every involved failure
code, the service meter display screen will
be restored.
Pressing [>] switch one more time dis-
plays the failure codes from the first.
If [>] switch is not touched for 3 seconds,
the action code display screen is automat-
ically displayed.
a For details of a displayed failure code, see

"Failure code list".
a If any switch operation is not done for 30
seconds or more on the failure code dis-
play screen, the action code display
screen is automatically turned on.
30-103 12 WD600-6
Service mode (*1): When the cursor is located at the left-

1. Procedure for switching to Service mode most position, pressing the switch
and screen display restores the normal screen (Operator
When using Service mode, carry out the fol- mode).
lowing special operation to switch the screen When the cursor is at a location other
display. than the leftmost position, pressing
1-1. Checking screen display the switch returns the cursor to the
Make sure that the machine monitor is set to leftmost position.
the operator mode and any of "Service meter", If any switch operation is not done for
"Action code" or "Failure code" is displayed on 60 seconds or more from ID input
the screen. screen, the normal screen is automat-
1-2. Displaying ID input initial screen ically turned on.
Hold down [t] switch and [<] switch simulta-
neously for 5 seconds minimum to open ID
input initial screen.
a Holding down the two switches for 5 sec-
onds or more makes the entire screen
blank. As this state is recognized, release
the buttons.
1-4. Displaying menu initial screen

a After settling 4-digit ID, turn on the menu
initial screen of Service mode.
a Once entered and settled, an ID remains
effective until the starting switch is turned
off.
1-3. Inputting and confirming ID

Operate the buttons to input the ID.
q ID: 6491
1) Cursor (C) is positioned at the highest-
order digit. Pressing [<] and [>] switches
changes the value of this digit in the range
of 0 – 9.
2) Press [U] switch when the intended value
appeared to specify it.
a The cursor moves to the 2nd digit.
3) Set the value in the same order and then
press [U] switch.
a When you have entered a wrong value to
a position except the highest-order digit,
1-5. Selecting service mode menu
move to the highest-order digit using [t]
a Pressing [<] and [>] switches from the
switch to repeat the procedure from the
menu screen displays Service mode
first. In this case, values that had been
menus endlessly in the following order.
entered remain as they are until modified.
a The menus are displayed in the field indi-
When the cursor is at the highest-order
cated with [*] mark.
digit, it can move to the higher layer using
[1] ELECTRIC FAULT: Electrical system
[t] switch.(*1).
fault history display function
[2] MACHINE FAULT: Mechanical sys-
tem fault history display function
WD600-6 30-103 13
[3] REAL-TIME MONITOR: Real-time 2. Electrical system fault history display func-
monitoring function tion (ELECTRIC FAULT)
[4] CYLINDER CUT-OUT: Engine The machine monitor records the past failures
reduced-cylinder function in the electrical system as the failure codes.
[5] NO INJECTION: No injection crank- The failure codes are displayed from the fol-
ing function lowing operations.
[6] TUNING: Adjustment function 2-1. Selecting the menu
[7] MAINTENANCE MONITOR: Mainte- Select the ELECTRIC FAULT from the menu
nance monitoring function screen of Service mode.
[8] OPERATION INFO: Operating infor- a [**] field displays total number of the fault
mation display function history currently recorded (up to 20
[9] SNAPSHOT: Manual snapshot cases).
[10] OPTIONAL SELECT: Optional device
selecting function
[11] MACHINE No. SET: Machine serial
number input function
[12] MACHINE WA6**: Model selection
function
[13] INITIALIZE: Initialize function (Func-
tion specialized for plant)
1-6. Completion of mode and function
Either of the following procedures ends a
mode or function independent of the function
being selected and the layer in which it is used.
1) When the operation is to be continued
using another mode or function: Press [t]
switch to return to the menu screen.
2-2. Displaying fault history
a Note, however, that [t] switch functions
Press [U] button while the menu is selected to
as an execution key on [YES/NO] screen.
display the recorded fault history.
a When the normal screen (Operator mode)
was inadvertently turned on, repeat above
steps from 1) (input of the ID is not neces-
sary).
2) When ending an operation completely:
Turn the starting switch off from the cur-
rent state.
2-3. Displayed fault history

The electric system fault history display func-
tion displays the following information.
A: Record number
B: Failure code (Location code in four digits +
Problem code in two digits)
C: Number of occurrences (number of occur-
rences of same code in past)
D: Elapsed time 1 (Elapsed time on service
meter from the first occurrence)
E: Elapsed time 2 (Elapsed time on service
meter from the last occurrence)
a The code of a failure currently occurring is
indicated in flashing.
30-103 14 WD600-6
a For details of a displayed failure code, see 2-6. Deleting all fault history
"Failure code list" of the failure code dis- 1) Press [<] or [>] switch while the fault his-
play function. tory is on the screen to display the ALL
a Note that part of the information displayed CLEAR menu screen.
from the electrical system fault history dis-
play function and the failure code display
function is not identical.
a When the requested fault history is not
recorded, [-] is indicated in the display
space.
2) Press [U] switch to display the ALL

CLEAR screen.
3) Select "YES" or "NO" using [<] or [>]
switch.
a The selected cursor will start flashing. If
"YES" is selected and [ t ] swit ch is
2-4. Switching fault history display pressed, the information will be deleted. If
Pressing [<] or [>] switch while a set of fault "NO" is selected and t switch is pressed,
history is on the screen displays another set of deletion is cancelled and the "Mainte-
recorded fault history. nance interval change item" screen is
2-5. Deleting individual fault history restored.
1) Press [U] switch while the target fault his- a By default, the cursor is set to NO (cancel)
tory of deletion is on the screen to turn on to prevent resetting error.
CLEAR screen. a Information of the currently occurring fail-
2) Select "YES" or "NO" using [<] or [>] ure is not deletable.
switch.
"YES" is selected and [ t ] switch is
pressed, the information will be deleted. If
"NO" is selected and [t] switch is
pressed, deletion is cancelled and the
"Maintenance interval change item"
screen is restored.
a By default, the cursor is set to NO (cancel)
to prevent resetting error.
a Information of the currently occurring fail-
ure is not deletable.
WD600-6 30-103 15
3. Mechanical system fault history display 3-3. Displayed fault history

function (MACHINE FAULT) The mechanical system fault history display
The machine monitor records the past failures function displays the following information.
in the mechanical system as the failure codes.
The failure codes are displayed from the fol- A: Record number
lowing operations. B: Failure code (Location code in four digits +
3-1. Selecting the menu Problem code in two digits)
a Select MACHINE FAULT from the menu C: Number of occurrences (number of occur-
screen of Service mode. rences of same code in past)
a [**] field displays total number of the fault D: Elapsed time 1 (Service meter at first
history currently recorded. occurrence)
E: Elapsed time 2 (Service meter at last
occurrence)
a The code of a failure currently occurring is
indicated in flashing.
a For details of a displayed failure code, see
"Failure code list" of the failure code dis-
play function.
a Note that part of the information displayed
from the mechanical system fault history
display function and the failure code dis-
play function is not identical.
a When the requested fault history is not
recorded, [-] is indicated in the display
space.
3-2. Displaying fault history
Press [U] switch while the menu is selected to
display the recorded fault history.
3-4. Switching fault history display

Pressing [<] or [>] switch while a set of fault
history is on the screen displays another set of
recorded fault history.
3-5. Deleting fault history (Not available)
The fault history of the mechanical system is
not deletable.
30-103 16 WD600-6
4. Real-time monitoring function 4-3. Selecting sub menu

(REAL-TIME MONITOR) a Press [<] or [>] switch from the sub menu
The machine monitor checks state of the screen to display the sub menus endlessly
machine on real-time basis referencing signals in the following order.
of the sensors being installed in various parts a The sub menus are displayed in the field
of the machine. indicated with [*] mark.
The real-time monitoring functions displays fol- [1] MONITOR PANEL: Machine monitor
lowing two types of information. system
q 1 item independent display [2] TRANSMISSION: Transmission con-
(for each controller) troller system
q 2 items simultaneous display [3] BOOM: Work equipment controller
(code input) system
4-1. Selecting the menu [4] ENGINE: Engine controller system
Select REAL-TIME MONITORING from the [5] VHMS: VHMS controller system
menu screen of Service mode. [6] 2 ITEMS: 2 items display
4-2. Displaying sub menu 4-4. Setting the 1 item individual monitoring
Press [U] switch while the menu is selected to 1) Select the target controller system of mon-
display the sub menu initial screen. itoring from the sub menu screen.
2) Press [U] switch while the sub menu is

selected to display the MONITOR PANEL
screen.
WD600-6 30-103 17
3) Press [<] or [>] switch to select a monitor- 4-5. Setting 2 items simultaneous monitoring
ing item. 1) Select 2 ITEMS from the sub menu
a The monitoring items are scrolled accord- screen.
ing to the internally set order. 2) Press [U] switch while the sub menu is
a Holding down [U] switch turns on high- selected to display the monitoring code
speed scrolling. input screen.
a Holding and cancelling the monitoring
data: Pressing [U] switch while the moni-
toring is in progress holds the monitoring
data and [U] mark starts flashing.Press-
ing [U] switch again restores the active
state.
1] This cursor (C) is located at the high-

est-order digit. Pressing [<] or [>]
switch changes the value of this digit
in the range of 0 – 9.
2] Press [U] switch when the intended
value appeared to specify it as the set
value.
4) Display data for 1 item individual monitor- a The cursor moves to the 2nd position.
ing 3] Set the value in the same order and
The 1 item individual monitoring screen then press [U] switch.
displays the following information. a When you have entered a wrong
A: Item display value to a position except the highest-
B: Monitoring codes (5 digits) order digit, the cursor can move to the
1: Monitoring data highest-order digit using [ t ] switch
(including the unit used) and repeat the procedure from the
a See the "Monitoring code list" for first. In this case, values that had
details. been entered remain as they are until
modified. When the cursor is at the
highest-order digit, it can move to the
higher layer using [t] switch.
30-103 18 WD600-6
3) As both monitoring codes are settled, the

2 ITEMS screen will be turned on.
a Holding and cancelling the monitoring
data:
Pressing [U] switch while the monitoring
is in progress holds the monitoring data
and [U] mark starts flashing.Pressing [U]
switch again restores the active state.
4) Display data for 2 items simultaneous

monitoring
a The 2 items simultaneous monitoring
screen displays the following information.
A: Monitoring code 1
1: Monitoring data 1 (including the unit
used)
B: Monitoring code 2
2: Monitoring data 2 (including the unit
used)
a See the "Monitoring code list" for details.
WD600-6 30-103 19
Monitoring code list

MON [Mechanical monitor system]
Monitoring Monitoring items Displayed items Data display range Unit
No.
codes (*1) (*2) (*3) (*4)
1 20200 Monitor ROM part number VERSION Arabic numerals Status display
2 20221 Application version VERSION (APP) Arabic numerals Status display
3 20222 Data version VERSION (DATA) Arabic numerals Status display
4 01001 Engine speed ENG SPEED 0 – 3000 rpm
5 40000 Travel speed SPEED 0 – 50 km/h
6 04202 Fuel level FUEL SENSOR 0 – 100 %
7 04207 Fuel level sensor voltage FUEL SENSOR 0.00 – 5.00 V
8 04103 Engine coolant temperature COOLANT TEMP –40 – 210 °C
9 40100 Torque converter oil temperature TC OIL TEMP 24 – 131 °C
Torque converter oil temperature
10 40101 TC OIL TEMP 0.00 – 5.00 V
sensor voltage
11 04401 Hydraulic oil temperature HYD TEMP 24 – 131 °C
Hydraulic oil temperature sensor
12 04404 HYD TEMP 0.00 – 5.00 V
voltage
13 30202 Rear brake oil temperature R BRAKE OIL 24 – 131 °C
Rear brake oil temperature sensor
14 30205 R BRAKE OIL 0.00 – 5.00 V
voltage
15 04302 Charge level ALTERNATOR R 0.00 – 30.00 V
16 40200 Small lamp voltage SMALL LAMP 0.00 – 30.00 V
Battery electrolyte level A sensor
17 40300 BATTERY A 0.00 – 30.00 V
voltage
Battery electrolyte level B sensor
18 40301 BATTERY B 0.00 – 30.00 V
voltage (*5)
19 06001 Lift arm angle (*5) BOOM ANG –90 – 90 Degree (°)
20 06003 Lift arm angle sensor voltage (*5) BOOM ANG 0.00 – 5.00 V
21 40400 Lift arm bottom pressure (*5) BOOM BTM PRESS 0.00 – 50.00 MPa
Lift arm bottom pressure sensor volt-
22 40402 BOOM BTM PRESS 0.00 – 5.00 V
age (*5)
23 40500 Lift arm head pressure (*5) BOOM HED PRESS 0.00 – 50.00 MPa
Lift arm head pressure sensor volt-
24 40501 BOOM HED PRESS 0.00 – 5.00 V
age (*5)
25 40600 Calibration pressure (*5) CAL PRESS 0.00 – 50.00 MPa
26 40800 Load meter calculated weight (*5) MES LOAD 0.00 – 50.00 ton
27 30802 Rotary switch setting state SW1, SW2, SW3 F, F, F Status display
28 30904 DIP switch setting state SW5-1, SW5-2 ON/OFF, ON/OFF Status display
32 40900 Input signal D_IN_0-7 D-IN--0------7 See attached table Status display
37 40952 Output signal D_OUT_0-3 D-OUT--0--3 See attached table Status display
30-103 20 WD600-6
*1: All items are displayed including those for which sensors are not provided depending on the given
model or option.
*2: Abbreviated expression is employed because of number of characters usable is restricted.
*3: If a value is below (or above) the display range, it will be displayed as the lowest (highest) value in the
range.
*4: SI units alone are employed whenever a unit is needed.
*5: WD600-6: Not used
a Note that the following monitoring items display information involving two to three systems at a time.
No.27: Rotary switch setting state (displays threes switches at a time)
No.28: DIP switch setting state (displays two switches at a time)
WD600-6 30-103 21

Monitoring Input/Out-
No. Displayed items Description of ON/OFF switch
codes put signal
D-IN-0 Head lamp high beam Lighting of head lamp = ON (24 V)/OFF (OPEN)
D-IN-1 Starting motor BR Starting switch = ON (24 V)/OFF (OPEN)
D-IN-2 Starting switch C Starting switch = ON (24 V)/OFF (OPEN)
D-IN-3 — —
Auto grease A
1 40900 D-IN-4 (Applicable to a machine equipped Tank empty or failed = ON (24 V)/OFF (OPEN)
with optional auto grease)
Auto grease B
D-IN-5 (Applicable to a machine equipped In operation or failed = ON (24 V)/OFF (OPEN)
with optional auto grease)
D-IN-6 — —
D-IN-7 — —
D-IN-8 — —
D-IN-9 — —
D-IN-10 WD600-6: Not used Pressing of switch = ON (24 V)/OFF (OPEN)
2 40901 Lighting of turn signal right lamp = ON (GND)/

D-IN-12 Turn signal right
OFF (OPEN)
Lighting of turn signal left lamp = ON (GND)/
D-IN-13 Turn signal left
OFF (OPEN)
D-IN-14 U switch Pressing of switch = ON (24 V)/OFF (OPEN)
D-IN-15 t switch Pressing of switch = ON (24 V)/OFF (OPEN)
D-IN-16 Brake oil pressure (front) Normal oil pressure = ON (GND)/OFF (OPEN)
D-IN-17 Brake oil pressure (rear) Normal oil pressure = ON (GND)/OFF (OPEN)
D-IN-18 — —
D-IN-19 — —
3 40902 D-IN-20 Clogged air cleaner No clogging = ON (GND)/OFF (OPEN)
D-IN-21 — —
Parking brake emergency release
D-IN-22 Pressing of switch = ON (24 V)/OFF (OPEN)
switch
D-IN-24 Transmission filter clogging No clogging = ON (GND)/OFF (OPEN)
D-IN-25 — —
D-IN-26 Parking brake Parking brake operation = ON (GND)/OFF (OPEN)
D-IN-27 Engine coolant level Normal coolant level = ON (GND)/OFF (OPEN)
4 40903 D-IN-28 — —
D-IN-29 Engine oil level Low oil level = ON (GND)/OFF (OPEN)
Operation of emergency steering
Operation of emergency steering = ON (GND)/
D-IN-30 (Applicable to a machine equipped
OFF (OPEN)
with the optional emergency steering)
D-IN-31 — —
30-103 22 WD600-6

codes put signal
D-IN-32 WD600-6: Not used Pressing of switch = ON (GND)/OFF (OPEN)
D-IN-33 WD600-6: Not used Pressing of switch = ON (GND)/OFF (OPEN)
D-IN-34 High beam (dimmer switch) High beam = ON (GND)/OFF (OPEN)
Working fuel consumption display
D-IN-35 Pressing of switch = ON (GND)/OFF (OPEN)
5 40904 switch
D-IN-36 Service 2 mode ON = ON(GND)/OFF(OPEN)
D-IN-37 [>] switch Pressing of switch = ON (GND)/OFF (OPEN)
D-IN-38 [<] switch Pressing of switch = ON (GND)/OFF (OPEN)
D-IN-39 — —
D-OUT-0 Alarm buzzer Output ON = (24 V)/OFF (OPEN)
D-OUT-1 — —
6 40952
D-OUT-2 — —
D-OUT-3 — —
WD600-6 30-103 23
TM [Transmission controller system]

Monitoring Monitoring items Displayed items Data display range Unit Remarks
No.
code (*1) (*2) (*3) (*4) (*5)
Transmission controller ROM part num- Status
1 20201 VERSION Arabic numerals
ber display
Status
2 20223 Application version VERSION APP 20223
display
Status
3 20224 Data version VERSION DATA 20224
display
0: Power mode Status
4 41600 Selection of engine mode ENGINE MODE
2: Economy mode display
Fan pump EPC current value (Com-
5 41400 FAN EPC DIR 0 – 1000 mA
mand)
FAN REVERSE 0: OFF Status
6 93400 Fan reverse switch input
SW 1: ON (CLOSE) display
7 41501 Torque converter inlet oil temperature T/C IN OIL TEMP –30 – 100°C °C
Torque converter inlet oil temperature
8 41502 T/C IN OIL TEMP 0.00 – 5.00 V
sensor voltage
9 93500 Torque converter input shaft speed T/C SPEED:IN 0 – 32767 rpm
T/C
10 93501 Torque converter output shaft torque 0 – 400000 Nm
TORQUE:OUT
11 31200 Transmission output shaft speed T/M SPEED IN — rpm Not used
12 31400 Transmission output shaft speed T/M SPEED:OUT 0 – 32767 rpm
T/M
13 31404 Transmission output shaft speed 2 0 – 32767 rpm
SPEED:OUT2
TC SPEED
14 41203 Torque converter speed ratio 0 – 200 %
RATIO
15 41201 Transmission cut-off operation setting T/M CUT SET 0.00 – 50.00 MPa
Transmission cut-off (left brake) pres-
16 41202 T/M CUT OFF P 0.00 – 50.00 MPa
sure
Transmission cut-off (left brake) pres-
17 93700 T/M CUT OFF P 0.00 – 5.00 V
sure sensor voltage
18 93600 Transmission oil temperature T/M OIL TEMP 0 – 150 °C
Transmission oil temperature sensor
19 93601 T/M OIL TEMP 0.00 – 5.00 V
input voltage
20 92400 Modulation clutch oil pressure MOD/C PRESS 0.00 – 50.00 MPa
Modulation clutch oil pressure input volt-
21 92401 MOD/C PRESS 0.00 – 5.00 V
age
22 92500 Modulation clutch calorific value MOD/C Q 0 – 25.5 100J/cm2
0.1
23 92501 Modulation clutch calorific rate MOD/C q 0 – 2.55
kW/cm2
THROTTLE
24 95500 Throttle correction command output –100 – 100 %
MOD
THROT LIMIT
25 95501 Throttle opening upper limit output 0 – 100.0 %
UP
26 95400 Throttle opening lower limit output THROT LIMIT LO 0 – 100.0 %
RPM idle-up/down selector switch 0: OFF Status
27 44200 THROT LOCK A
(idle-up) 1: ON display
RPM idle-up/down selector switch 0: OFF Status
28 44201 THROT LOCK B
(idle-down) 1: ON display
30-103 24 WD600-6

No.
code (*1) (*2) (*3) (*4) (*5)
0: Accelerator
pedal open
1: Accelerator
pedal partial
pressing (open
side)
THROTTLE Status
29 93801 Accelerator mode 2: Accelerator
MODE display
pedal partial
pressing (press-
ing side)
3: Accelerator
pedal full press-
ing
30 94000 Traction setting input value TRACTION DIAL 0 – 100 %
31 94001 Traction setting input voltage TRACTION DIAL 0.00 – 5.00 V
0: OFF Status
32 95000 Lockup selector switch input signal LOCK UP SW
1: ON display
33 31602 1st ECMV current value (Command) ECMV 1 DIR 0 – 1000 mA
34 31603 2nd ECMV current value (Command) ECMV 2 DIR 0 – 1000 mA
35 31604 3rd ECMV current value (Command) ECMV 3 DIR 0 – 1000 mA
36 31605 4th ECMV current value (Command) ECMV 4 DIR 0 – 1000 mA
F (forward) ECMV current value
37 31608 ECMV F DIR 0 – 1000 mA
(Command)
Lockup clutch ECMV current value
38 31609 ECMV LU DIR 0 – 10000 mA
(Command)
Modulation clutch ECMV current value ECMV MOD/C
39 31640 0 – 1000 mA
(Command) DIR
R (reverse) ECMV current value
40 31606 ECMV R DIR 0 – 1000 mA
(Command)
ECSS (travel damper) solenoid valve WD600-6:
41 93300 ECSS V DIR 0 – 1000 mA
current value (Command) Not used
0 – 2.55
42 41802 1st fill time FILL TIME 1 (When fill is not sec
provided: 0)
0 – 2.55
43 41803 2nd fill time FILL TIME 2 (When fill is not sec
provided: 0)
0 – 2.55
44 41804 3rd fill time FILL TIME 3 (When fill is not sec
provided: 0)
0 – 2.55
45 41805 4th fill time FILL TIME 4 (When fill is not sec
provided: 0)
0 – 2.55
46 41808 F (forward) fill time FILL TIME F (When fill is not sec
provided: 0)
0 – 2.55
47 41806 R (reverse) fill time FILL TIME R (When fill is not sec
provided: 0)
Status
48 40905 Input signal D_IN_0-7 D-IN--0------7 See attached table
display
WD600-6 30-103 25

No.
code (*1) (*2) (*3) (*4) (*5)
Status
49 40906 Input signal D_IN_8-15 D-IN--8-----15 See attached table
display
Status
50 40907 Input signal D_IN_16-23 D-IN-16-----23 See attached table
display
Status
display
Status
display
Status
53 40949 Output signal D_OUT_0-7 D-OUT-0------7 See attached table
display
Status
54 40950 Output signal D_OUT_8-15 D-OUT-8-----15 See attached table Not used
display
Status
55 40951 Output signal D_OUT_16-23 D-OUT-16----23 See attached table Not used
display
Status
56 94100 Clutch trigger initial learning flag TRIG FR1234 0/1(ON/OFF)
display
model or option.
range.
*5: An item that does not allow monitoring is indicated as "Not used" though its code and item name may be
displayed on the machine monitor.
30-103 26 WD600-6

Input/
Monitoring
No. Output Displayed items Description of ON/OFF switch
code
signal
Engine mode selector switch (Power
D-IN-0 Engine mode selector switch
mode) = ON (GND)/OFF (OPEN)
D-IN-1 — —
D-IN-2 — —
Air conditioner compressor operation =
D-IN-3 Air conditioner compressor operation
1 40905 ON (GND)/OFF (OPEN)
D-IN-4 Shift mode L Shift mode L = ON (GND)/OFF (OPEN)
D-IN-5 Shift mode H Shift mode H = ON (GND)/OFF (OPEN)
Modulation clutch direct connection sig-
D-IN-6 Modulation clutch direct connection signal
nal present = ON (24 V)/OFF (OPEN)
D-IN-7 C terminal signal Starting switch = ON (24 V)/OFF (OPEN)
D-IN-8 — —
D-IN-9 — —
Pressing of switch = ON (GND)/OFF
D-IN-10 Kick-down switch
(OPEN)
D-IN-11 Shift hold switch
(OPEN)
2 40906 D-IN-12 — —
Pressing of switch = ON (24 V)/OFF
D-IN-13 RPM set ON/OFF switch
(OPEN)
D-IN-14 RPM set idle-up/down switch selector switch
(OPEN)
Pressing right brake pedal = ON (GND)/
D-IN-15 Throttle lock release right brake pedal switch
OFF (OPEN)
WD600-6 30-103 27

Input/
Monitoring
code
signal
• Shift-up switch
• Joystick steering shift-up
= ON (24 V)/OFF (OPEN)
(Normally open)
(Joystick steering specification)
D-IN-16 (Joystick steering specification)
• Shift lever 1st
• Shift range 1st
• Shift-up switch
• Joy stick steering shift-up
= ON (OPEN)/OFF (24 V)
(Normally closed)
• Shift lever 2nd
• Shift range 2nd
=ON (24 V)/OFF (OPEN)
• Shift-up switch
(Normally open)
• Shift lever 3rd
• Shift range 3rd
3 40907 (Steering wheel specification)
• Shift-up switch
(Normally closed)
• Shift lever 4th
• Shift range 4th
Directional lever F (forward) or directional
Directional lever F (forward) or directional
D-IN-20 selector switch F (forward) = ON (24 V)/
selector switch F (forward)
OFF (OPEN)
Directional lever N (neutral) or directional
Directional lever N (neutral) or directional
D-IN-21 selector switch N (neutral)
selector switch N (Neutral).
Directional lever R (reverse) or directional
Directional lever R (reverse) or directional
D-IN-22 selector switch R (reverse) = ON (24 V)/
selector switch R (reverse)
OFF (OPEN)
D-IN-23 Parking brake signal Parking brake = ON (24 V)/OFF (OPEN)
D-IN-24 — —
ECMV fill switch F (forward) = ON (GND)/
D-IN-25 F ECMV fill switch F (forward)
OFF (OPEN)
ECMV fill switch R (reverse)
D-IN-26 F ECMV fill switch R (reverse)
= ON (GND)/OFF (OPEN)
ECMV fill switch 1st
D-IN-27 ECMV fill switch 1st
4 40908 ECMV fill switch 2nd
D-IN-28 ECMV fill switch 2nd
ECMV fill switch 3rd
D-IN-29 ECMV fill switch 3rd
ECMV fill switch 4th
D-IN-30 ECMV fill switch 4th
Steering lever lock detection pressure switch Steering lever lock pressure switch
D-IN-31
(Joystick steering specification) = ON (GND)/OFF (OPEN)
30-103 28 WD600-6

Input/
Monitoring
code
signal
Brake pressure switch
D-IN-32 Brake pressure switch
= ON (5V)/OFF (OPEN)
D-IN-33 — —
D-IN-34 — —
5 40942 D-IN-35 — —
D-IN-36 — —
D-IN-37 — —
D-IN-38 — —
D-IN-39 — —
D-OUT-0 Modulation clutch cut-off release solenoid Output ON = (24 V)/OFF (OPEN)
D-OUT-1 — —
D-OUT-2 — —
D-OUT-3 Fan reverse solenoid Output ON = (24 V)/OFF (OPEN)
6 40949
D-OUT-4 — —
D-OUT-5 Low temperature bypass solenoid Output ON = (24 V)/OFF (OPEN)
D-OUT-6 — —
D-OUT-7 — —
WD600-6 30-103 29
WRK [Work equipment controller system]

No.
code (*1) (*2) (*3) (*4) (*5)
XXXXRYYY [3rd –
10th digits of part
number are dis-
Work equipment controller software ver- played]
1 20202 VERSION —
sion Example: When the
number is 7831-46-
R110 o
"3146R110"
Status
2 20225 Application version VERSION APP Arabic numerals
display
Status
3 20226 Data version VERSION DATA Arabic numerals
display
4 94700 Loader pump pressure PUMP PRESS 0.00 – 50.00 MPa
5 94701 Loader pump pressure sensor voltage PUMP PRESS 0.00 – 5.00 V
6 94500 Loader pump EPC current (Command) PUMP EPC DIR 0 – 1000 mA
7 94600 Pump delivery flow rate PUMP FLOW 0 – 264 cc/r
Degree WD600-6:
8 06002 Lift arm angle BOOM ANG –180.0 – +180.0
(°) Not used
WD600-6:
9 06005 Lift arm angle sensor voltage BOOM ANG 0.00 – 5.00 V
Not used
Degree
10 94400 Frame angle FRAME ANGLE –180.0 – +180.0
(°)
0 – 256000
11 42100 Lift lever operation frequency BOOM LVR (*6) (On thousand-time —
basis)
12 42000 Lever potentiometer voltage lift 1 BOOM POT1 (*6) 0.00 – 5.00 V
13 42001 Lever potentiometer voltage lift 2 BOOM POT2 (*6) 0.00 – 5.00 V
0 – 256000
BUCKET LVR
14 42101 Pitch/tilt lever operation frequency (In a thousand of —
(*6)
times)
BUCKET LVR
15 42002 Lever potentiometer voltage pitch/tilt 1 0.00 – 5.00 V
(*6)
BUCKET POT2
16 42003 Lever potentiometer voltage pitch/tilt 2 0.00 – 5.00 V
(*6)
17 41900 Lift raise EPC current (Command) RAISE EPC DIR 0 – 1000 mA
LOWER EPC
18 41901 Lift lower EPC current (Command) 0 – 1000 mA
DIR
Tilt LH, LH pitch REAR EPC current TILT EPC DIR
19 41902 0 – 1000 mA
(Command) (*6)
Tilt RH, RH pitch FORWARD EPC cur- DUMP EPC DIR
20 41903 0 – 1000 mA
rent (Command) (*6)
21 41908 AJSS EPC current (Command) AJSS EPC DIR 0 – 1000 mA
WD600-6:
22 41904 J/S right EPC current (Command) J/S EPC DIR RH 0 – 1000 1mA
Not used
WD600-6:
23 41905 J/S left EPC current (Command) J/S EPC DIR LH 0 – 1000 1mA
Not used
WD600-6:
24 42004 Lever potentiometer voltage J/S 1 J/S POT1 0.00 – 5.00 V
Not used
30-103 30 WD600-6

No.
code (*1) (*2) (*3) (*4) (*5)
WD600-6:
25 42005 Lever potentiometer voltage J/S 2 J/S POT2 0.00 – 5.00 V
Not used
RH pitch REAR EPC current value 3RD EPC1 DIR WD600-6:
26 41906 0 – 1000 1mA
(Command) (*6) Not used
RH pitch FORWARD EPC current value 3RD EPC2 DIR WD600-6:
27 41907 0 – 1000 1mA
(Command) (*6) Not used
0 – 256000
WD600-6:
28 42102 3rd lever operation frequency 3RD LVR (In a thousand of —
Not used
times)
Lever potentiometer voltage 3-spool WD600-6:
29 42006 3RD POT1 0.00 – 5.00 0.01V
valve 1 Not used
Lever potentiometer voltage 3-spool WD600-6:
30 42007 3RD POT2 0.00 – 5.00 0.01V
valve 2 Not used
Degree
31 94300 AJSS lever operation angle AJSS LEVER –180.0 – +180.0
(°)
32 94301 AJSS lever potentiometer voltage AJSS LEVER 0.00 – 5.00 V
33 94401 AJSS frame potentiometer voltage FRAME ANGLE 0.00 – 5.00 V
S/T DEFLEC- Degree
34 94800 AJSS steering deviation angle –180.0 – +180.0
TION (°)
Status WD600-6:
35 94900 Digging-in-progress flag WORK FLAG ON/OFF
display Not used
Status
display
Status
37 40911 Input signal D_IN_8-15 D-IN--8-----15 See attached table
display
Status
display
Status
display
Status
40 40961 Input signal D_IN_32-39 D-IN-32-----39 See attached table Not used
display
Status
41 40952 Output signal D_OUT_0-7 D-OUT-0------7 See attached table
display
Status
42 40953 Output signal D_OUT_8-15 D-OUT-8-----15 See attached table Not used
display
Status
43 40954 Output signal D_OUT_16-23 D-OUT-16----23 See attached table
display
model or option.
range.
*6: Since WD600-6 is equipped with the machine monitor designed for WA600-6, monitoring items dis-
played on the screen may differ from actual testing items.
WD600-6 30-103 31

codes put signal
D-IN-0 — —
D-IN-1 — —
D-IN-2 — —
1 40910 D-IN-3 — —
D-IN-4 — —
D-IN-5 — —
D-IN-6 — —
D-IN-8 — —
D-IN-9 — —
D-IN-10 — —
Pitch control switch: ON (GND)/OFF
D-IN-11 Pitch control switch
2 40911 (OPEN)
D-IN-12 — —
D-IN-13 — —
D-IN-14 — —
D-IN-15 — —
Work equipment neutral lock switch
D-IN-16 Work equipment neutral lock switch (Working position) ON = (24 V)/OFF
(OPEN)
Starting switch START = ON (24 V)/OFF
D-IN-17 Starting motor C terminal signal
(OPEN)
D-IN-18 — —
3 40912
D-IN-19 — —
D-IN-20 — —
D-IN-21 — —
D-IN-22 — —
D-IN-23 — —
D-IN-24 — —
D-IN-25 — —
D-IN-26 — —
D-IN-27 — —
4 40913 D-IN-28 — —
D-IN-29 — —
Turn signal right switch = ON (GND)/OFF
D-IN-30 Turn signal right switch
(OPEN)
Turn signal left switch = ON (GND)/OFF
D-IN-31 Turn signal left switch
(OPEN)
D-OUT-0 Work equipment neutral lock solenoid Output ON = ON (24 V)/OFF (OPEN)
D-OUT-1 — —
D-OUT-2 Lift float detent solenoid Output ON = ON (24 V)/OFF (OPEN)
D-OUT-3 — —
5 40952
D-OUT-4 — —
D-OUT-5 — —
D-OUT-6 — —
D-OUT-7 — —
30-103 32 WD600-6

codes put signal
D-OUT-16 Operation of turn signal right Output ON = ON (24 V)/OFF (OPEN)
D-OUT-17 Operation of turn signal left Output ON = ON (24 V)/OFF (OPEN)
D-OUT-18 — —
D-OUT-19 — —
6 40954
D-OUT-20 Safety relay operation Output ON = ON (24 V)/OFF (OPEN)
D-OUT-21 — —
D-OUT-22 — —
D-OUT-23 — —
WD600-6 30-103 33
ENG [Engine controller system]

No.
code (*1) (*2) (*3) (*4) (*5)
Status
1 20400 Hardware serial No. ECM S/N Arabic numerals
display
POWER SUP-
2 03200 Battery voltage 0.0 – 480.0 V
PLY
3 01002 Engine speed ENG SPEED 0 – 4000 rpm
COOLANT
4 04104 Engine coolant temperature –40 – 210 °C
TEMP
Engine coolant temperature sensor COOLANT
5 04105 0.00 – 5.00 V
voltage TEMP
6 37200 Oil pressure sensor ENG OIL PRESS –99.9 – 999.9 kPa
7 37201 Oil pressure sensor voltage ENG OIL PRESS 0.00 – 5.00 V
8 42700 Engine oil temperature ENG OIL TEMP –40 – 210 °C
9 42702 Engine oil temperature sensor voltage ENG OIL TEMP 0.00 – 5.00 V
10 36400 Common rail pressure RAIL PRESS 0 – 400 MPa
11 36402 Common rail pressure sensor voltage RAIL PRESS 0.00 – 5.00 V
AMBIENT
12 37400 Atmospheric pressure –99.9 – 999.9 kPa
PRESS
AMBIENT
13 37402 Atmospheric pressure sensor voltage 0.00 – 5.00 V
PRESS
14 18400 Air intake temperature INTAKE TEMP –50 – 200 °C
15 18401 Air intake temperature sensor voltage INTAKE TEMP 0.00 – 5.00 V
16 04204 Fuel temperature FUEL TEMP –40 – 210 °C
17 14201 Fuel temperature sensor voltage FUEL TEMP 0.00 – 5.00 V
18 18500 Boost temperature CHG TEMP –50 – 200 °C
19 18501 Boost temperature sensor voltage CHG TEMP 0.00 – 5.00 V
20 36500 Boost pressure CHG PRESS-A –99.9 – 999.9 kPa
21 36502 Boost pressure sensor voltage CHG PRESS-A 0.00 – 5.00 V
22 17900 EGR valve differential pressure EGR DIF PRESS –99.9 – 999.9 kPa
EGR valve differential pressure sen-
23 17901 EGR DIF PRESS 0.00 – 5.00 V
sor voltage
EGR IN PRESS-
24 18000 EGR valve inlet pressure –99.9 – 999.9 kPa
A
EGR valve inlet pressure sensor volt- EGR IN PRESS-
25 18002 0.00 – 5.00 V
age A
EGR VALVE
26 18100 EGR valve position 0.00 – 99.99 mm
POS
EGR VALVE
27 18101 EGR valve position sensor voltage 0.00 – 5.00 V
POS
OUTPUT
28 18700 Engine output torque –24000 – 24000 Nm
TORQUE
29 36700 Equivalent torque TORQUE RATIO 0 – 100 %
FINAL THROT-
30 31706 Final accelerator position 0 – 100 %
TLE
31 37300 Momentary fuel consumption FUEL RATE 0.0 – 999.9 l/h
Final injection volume command (in INJECT COM-
32 18600 0 – 1000 mg
weight) MAND
33 36300 Final injection timing command TFIN INJECT TIMING –180.0 – 180.0 CA
30-103 34 WD600-6
ENG [Engine controller system]

No.
code (*1) (*2) (*3) (*4) (*5)
34 31701 Accelerator pedal position THROTTLE POS 0 – 100 %
35 31707 Accelerator pedal sensor voltage THROTTLE POS 0.00 – 5.00 V
36 18200 Bypass valve position BPS VALVE POS 0.00 – 99.99 mm
37 18202 Bypass valve position sensor voltage BPS VALVE POS 0.00 – 5.00 V
Status
38 18300 Idle validation signal IVS 1 ON/OFF
display
Status
39 18301 Idle validation signal IVS 2 ON/OFF
display
40 18900 Engine controller internal temperature ECM IN TEMP –40 – 210 °C
Final common rail pressure command PRESS COM-
41 36200 0 – 400 MPa
PFIN MAND
PCV valve close timing (BTDC stan-
42 17201 PCV TIMING –180.0 – 180.0 CA
dard)
Status
43 17500 Selection of engine mode POWER MODE 0–4
display
Incoming value is dis-
Name of selected model (upper 8 dig- played as is Status
44 00400 MACHINE ID (H)
its) (Upper 8 digits of 16 display
characters)
Name of selected model (lower 8 dig- played as is Status
45 00401 MACHINE ID (L)
its) (Lower 8 digits of 16 display
characters)
Status
46 20216 Build version BUILD VER played as is (8 char-
display
acters)
Status
47 20217 Calibration data version CAL VER played as is (8 char-
display
acters)
model or option.
range.
WD600-6 30-103 35
VHMS [VHMS controller system]

Monitoring Monitoring items Displayed items Data display range Unit
No. Remarks
code (*1) (*2) (*3) (*4)
1 37501 Atmospheric temperature ATR TEMP –30 + 100 °C
BLOWBY
2 42801 Blow-by pressure 0.0 – 20.0 kPa
PRESS
3 42703 Engine oil temperature ENG OIL TEMP 0 – 180 °C
EXHAUST TEMP
4 42610 Exhaust gas temperature (F) 200 – 950 °C
F
EXHAUST TEMP
5 42611 Exhaust gas temperature (R) 200 – 950 °C
R
BRAKE PRESS
6 92800 Brake oil pressure (F) 0.00 – 50.00 MPa
F
BRAKE PRESS
7 92801 Brake oil pressure (R) 0.00 – 50.00 MPa
R
Status
8 92900 Brake signal BRAKE SIG ON/OFF
display
9 93000 Steering oil pressure S/T OIL PRESS 0.00 – 50.00 MPa
Status
10 93100 Start signal START SIG ON/OFF
display
Status
display
Status
12 40948 Output signal D_OUT_0-3 D-OUT--0--3 See attached table
display
Status
13 90947 SEL signal D_SEL_0-3 D-SEL--0--3 See attached table
display
model or option.
range.
30-103 36 WD600-6
VHMS [VHMS controller system]

codes put signal
D-IN-0
D-IN-1
D-IN-2
D-IN-3
1 40944
D-IN-4
D-IN-5
D-IN-6
D-IN-7
D-SEL-0
D-SEL-1
5 40947
D-SEL-2
D-SEL-3
D-OUT-0
D-OUT-1
6 40958
D-OUT-2
D-OUT-3
WD600-6 30-103 37
5. Engine reduced-cylinder function 3) Selecting a cylinder to be reduced

The engine reduced-cylinder function denotes Using [<] or [>] switch, select a cylinder to
setting the injector of a single cylinder or two or be reduced from No. 1 – No. 6 cylinders
more cylinders to electrically no injection state and then settle the selected cylinder using
and turns on the operation on reduced-cylinder [U] switch.
condition. When any cylinders of the engine a The cylinder to be reduced is selectable
were suspected for abnormal output (combus- while the engine is run.
tion), this approach is used to single out the a Any number of cylinders can be reduced –
failed cylinder. a single unit or two or more units.
1) Selecting the menu q [>] switch: Advances the cursor right-
Display the CYLINDER CUT-OUT screen ward
from the menu screen of Service mode. q [<] switch: Advances the cursor left-
ward
q [U] switch: Settles the cylinder to be
reduced (the cursor starts flashing
after the settlement)
q [t] switch: Restores the CYLINDER
CUT-OUT screen
2) Displaying sub menu

Press [U] switch while the menu is
selected to display the sub menu.
a As the reduced-cylinder command is

issued from the engine controller to the
cylinder to be reduced, the bottom of the
stopped cylinder number turns to black.
a The cylinder No. and engine speed are

displayed on the upper line and the final
injection rate command is displayed on
the lower line simultaneously.
30-103 38 WD600-6
4) Cancelling a reduced cylinder 2) Pressing [U] switch sets up the no injec-

Using [<] or [>] switch, select the currently tion cranking.
stopped cylinder and then press [U] a If this screen does not appear as [U]
switch to cancel the reduced-cylinder switch is hit, a communication error should
command from the engine controller. The be suspected.
black display will disappear.
a If the no injection cranking is selected as

6. No injection cranking function the engine is running, the engine stop
The machine monitor is equipped with the func- instruction screen will appear.
tion capable of lubricating the engine through a In such case, stop the engine once and
no injection cranking. When a machine has then do the set up again.
been stored for a long time, this function is
used to lubricate the engine prior to its restart in
order to prevent its wear or damages out of oil.
The no injection cranking must be set up while
the engine is stopped.
1) Selecting menu
Display the NO INJECTION screen from
menu screen of Service mode.
WD600-6 30-103 39
7. Adjustment function 7-1. Adjustment of transmission ECMV current

The machine monitor implements initial setting 7-1-1. Preparations for transmission ECMV current
after disassembly or replacement of the trans- adjustment
mission, or after replacement or addition of 1) Display the REAL-TIME MONITOR from
sensor and EPC valve or controller. Through the menu screen of Service mode.
the initial setting, the machine monitor corrects
and adjusts the installation error or manufac-
turing variations of individual parts.
a Adjustment function
No. Adjustment item
7-1 Adjustment of transmission ECMV current
7-2 Setting of transmission initial learning
7-3 Adjustment of transmission shift point
7-4 Adjusting lift raise EPC starting current
Adjustment of lift lower (float) lever and
7-5
variations in the dead zone of EPC
Adjusting variation correcting calibration of
7-5-1 2) Press [U] switch to display the sub menu
lift lower (float) EPC lever
and then select TRANSMISSION using [<]
7-5-2 Adjusting lift lower EPC starting current
or [>] switch. (TRANSMISSION screen)
Adjustment of LH pitch REAR/tilt LH EPC
7-6
starting current
Adjustment of LH pitch FORWARD/tilt RH
7-7
EPC starting current
Adjustment of RH pitch REAR variations in
7-8
the dead zone of EPC
Adjustment of RH pitch FORWARD
7-9
Adjustment of AJSS neutral position (AJSS
7-10
specification)
Adjustment of AJSS EPC output current
7-11
Adjustment of difference of speed between
7-12
RH and LH cylinders of pitch FORWARD
3) Press [U] switch to settle the real-time
Adjustment of difference of speed between
7-13
RH and LH cylinders of pitch REAR
monitoring of the transmission controller.
a As the selection is settled, the application
Adjustment of lift raise/lower stop program version of the transmission con-
7-14
modulation
troller will be displayed.
Modification of AJSS oil pressure command q [20223]: ID number of display item
7-15
table pattern q [******]: Display of data
7-16 Adjustment of maximum speed limit (Program version)
30-103 40 WD600-6
4) Using [<] or [>] switch, move the cursor to

Operating
the T/M OIL TEMP screen. order
1 2 3 4
q [93600]: ID number of transmission
control oil temperature Gear
N2 F2 F1 F2
speed
q [******]: Display of transmission con-
trol oil temperature Holding Min. 2 Min. 2 Min. 2 Min. 2
time sec. sec. sec. sec.
Operating
5 6 7 8
order
Gear
F3 F4 F3 F2
speed
Holding Min. 2 Min. 2 Min. 2 Min. 2
time sec. sec. sec. sec.
Operating
9 10 11
order
Gear
N2 R2 N2
speed
Holding Min. 2 Min. 2 Min. 2
time sec. sec. sec.
7-1-2. Conformation of transmission oil tempera-
ture control
1) Start the engine, press the brake pedal 7-1-3. Adjustment of transmission ECMV current
fully and then release the parking brake. a Targets of correction are 6 types – F (forward),
2) Set the transmission shift mode to the R (reverse), 1st, 2nd, 3rd and 4th. As the
Manual, directional lever or directional engine is started, correction of all of above
selector switch to F (forward) and shift clutches is started automatically.
lever or switch to 4th. a Since the learning operation requires the spec-
3) Make sure from "7-1-1 Preparations for ified oil temperature, the oil temperature must
transmission ECMV current adjustment" be adjusted to 70 – 80°C range.
that the transmission controlled oil tem- 1) Turn on the starting switch (engine is not
perature is 70 – 80°C.If it is out of the started) and then display T/M OIL TEMP
range, stall the torque converter and referencing "7-2-1 Preparations for trans-
adjust the temperature to 70 – 80°C. mission ECMV current adjustment".
4) Return the directional lever or directional 2) Make sure the transmission controlled oil
selector switch to N (neutral) and maintain temperature is in the 70 – 80°C range
it in that position. After 3 minutes, make when the engine is set to low idle, acceler-
sure the oil temperature is still in the 70 – ator pedal to OFF, directional lever or
80°C range. directional selector switch to neutral and
5) Let the oil pervade in the transmission by parking brake to ON.
operating the reverse lever or directional
selector switch, or the gearshift lever or
switch in the following manner.
a When executing the operation, the
engine shall be set to low idle, man-
ual switch to ON and lockup switch to
OFF.
a Make sure the machine is normal
(failure is not detected).
a When stalling the torque converter,
use care it may not be overheated.
WD600-6 30-103 41
3) Display the TUNING screen from the 7) Using [U] switch, select AUTO from the
menu screen of Service mode. automatic correction (AUTO) and manual
correction (MANUAL) selection screen to
settle the automatic correction.
4) Hold down [U] switch for 5 seconds mini-

mum to display 01: TM TRIGGER screen.
a Selecting ECMV TUNING AUTO displays
IP in the character display, automatically
starting transmission ECMV current
adjustment.
5) Using [<] or [>] switch from the sub menu,

select 02: ECMV TUNING.
Operating
1 2 3 4
order
IP [IP F-1] [IP F-2] [IP F-3] [IP F-4]
ECMV/ F/1st F/2nd F/3rd F/4th
frequency time time time time
Operating
5 6 7 8
order
IP [IP R-1] [IP R-2] [IP R-3] [IP R-4]
ECMV/ R/1st R/2nd R/3rd R/4th
Operating
9 10 11 12
6) Press [U] switch to settle the adjustment order
item. IP [IP 1-1] [IP 1-2] [IP 1-3] [IP 1-4]
ECMV/ 1st/1st 1st/2nd 1st/3rd 1st/4th
30-103 42 WD600-6
Operating a Codes for abnormal end

13 14 15 16
order Reason CODE
IP [IP 2-1] [IP 2-2] [IP 2-3] [IP 2-4]
Deviation from correc-
1
ECMV/ 2nd/1st 2nd/2nd 2nd/3rd 2nd/4th tion condition
Absence of fill signal 2
Operating In excess of correc-
17 18 19 20 3
order tion value
IP [IP 3-1] [IP 3-2] [IP 3-3] [IP 3-4]
a If abnormal end code "1" (NG1: Deviation
ECMV/ 3rd/1st 3rd/2nd 3rd/3rd 3rd/4th from correction condition) was displayed,
set the condition again referencing "7-1-1
Operating Preparations for transmission ECMV cur-
21 22 23 24 rent adjustment" and repeat the correc-
order
tion.
IP [IP 4-1] [IP 4-2] [IP 4-3] [IP 4-4]
a If abnormal end code "2" (NG2: Absence
ECMV/ 4th/1st 4th/2nd 4th/3rd 4th/4th of fill) was displayed, implement trouble-
shooting of the failure codes 15STLH and
DXHTKA. If the state is normal, repeat the
operation starting from "7-1-1 Prepara-
8) As the correction is normally completed,
tions for transmission ECMV current
OK is displayed in the character display.
adjustment" and repeat the correction.
(The value of T depends on the applica-
ble gear speed.)
a If the abnormal end code "3" (NG3: In
excess of correction value) was displayed,
execute the troubleshooting of failure
code 15STL1. Then after making sure the
condition is normal, implement "7-1-1
Preparations for transmission ECMV cur-
rent adjustment" again. (The value of T
depends on the applicable gear speed.)
9) As the operation ended normally, turn the
starting switch off and the corrected value
will be stored on the transmission control-
a If the correction is not normally ended, the ler after 3 seconds.
code for abnormal end will be indicated. a When it is required to turn on the starting
(Following shows an example of the oper- switch immediately after the adjustment,
ation in which the 1st time correction of maintain the starting switch, just in case,
the 3rd position has ended abnormally). at off position for 10 seconds minimum
and then turn it on.
WD600-6 30-103 43
7-2. Setting of transmission initial learning 5) Press [U] switch to settle the adjustment
When initializing all the past initial trigger learn- item. As the item is settled, the initial
ing data stored on the transmission controller, learning reset screen appears.
employ the following procedure. a If the initial learning is not done, INITIAL
7-2-1. Reset of initial learning STATUS will be displayed.
1) Turn on the starting switch. (Engine does
not start)
2) Set the directional lever (directional selec-
tor switch for AJSS specification) to the
neutral.
3) Display the TUNING screen from the
a When the initial learning is completed,

TUNED will be displayed.

1] When TUNED is displayed, press [U]

switch to display the initial learning
reset screen.
2] Press [<] or [>] switch from the initial
learning reset screen to move the cur-
sor to YES position and then press
[t] switch to reset the initial learning.
3] When suspending the reset opera-
tion, select NO from above 2] or press
[t] switch on TUNED screen.
30-103 44 WD600-6
7-2-2. Preparations for transmission initial learning 4) Using [U] switch, settle 2 items display of
1) Display the REAL-TIME MONITOR from the transmission control oil temperature
the menu screen of Service mode. and the trigger learning display.
a Content of the trigger learning is displayed
for each of F, R, 1st, 2nd, 3rd and 4th
clutch in the figure.
q 0: Learning not done yet
q 1: Learning completed
2) Press [U] switch to display the sub menu,

select 2 ITEMS using [<] or [>] switch and
then settle the selection using [U] switch.
(SEL ITEMS 1,2 screen)
7-2-3. Implementation of transmission initial learn-

ing
a Before starting the transmission initial learning,
be sure to implement "7-1 Adjustment of trans-
mission ECMV current" and "7-2-1 Reset of ini-
tial learning". Then start the initial learning
a Implement the gearshift operation using actual
travel, bench travel or while pressing the wheel
brake.
k When actual travel is employed for the
operation, be sure to choose a spacious
field while paying reasonable care to the
environment.
3) From the SEL ITEMS 1,2 screen, enter ID
a When executing the operation, the engine shall
number 93600 of the transmission control
be set to low idle, manual switch to ON and
oil temperature and ID number 94100 for
lockup switch to OFF.
displaying the trigger learning.
1) Start the engine, press the brake pedal
a Referring to "4-5. Setting 2 items
fully and then release the parking brake.
simultaneous monitoring".
2) Set the transmission shift mode to the
Manual, directional lever or directional
selector switch to F (forward) and shift
lever or switch to 4th.
3) Make sure from "7-2-2 Preparations for
transmission initial learning" that the trans-
mission control oil temperature is 70 –
80°C. If it is out of the range, stall the
torque converter and adjust the tempera-
ture to 70 – 80°C. (If the initial learning is
performed while the oil temperature is out
of the specified range, time lags and gear-
shift shocks can result).
WD600-6 30-103 45
4) Execute the initial learning by operating 7-3. Adjustment of transmission shift point
the directional lever or directional selector a This function is used for modifying the shift
switch, or the gearshift lever or switch in point when the shift mode switch is at L posi-
the following manner. tion by adding a correction amount.
a The factory default setting of the correction
Operating
order
1 2 3 4 amount shall be 0.
a The shift point depends on the engine mode.
Gear When this function is used, however, the same
N2 F2 F1 F2
speed
correction value is applied independent of the
Holding Min. 6 Min. 6 Min. 6 Min. 4 engine mode.
time sec. sec. sec. sec. a Some of the shift points being adjusted with
the shift point adjustment function may not
Operating
order
5 6 7 8 include the following shift patterns.
q The shift point that is used when the hunt-
Gear ing prevention function is turned on.
F3 F4 F3 F2
speed
q The shift down point that is used when the
Holding Min. 4 Min. 4 Min. 4 Min. 4 accelerator is set to idle.
time sec. sec. sec. sec. a After a shift point adjustment is done, confirma-
tion on the machine must be done.
Operating
9 10 11
order
7-3-1. Clearing an adjusted shift point
Gear 1) Display the TUNING screen from the
N2 R2 N2
speed
Holding Min. 4 Min. 4 Min. 4
time sec. sec. sec.
a Hold the gearshift lever in each gear

speed for more than the specified time.
a If the gearshift lever is operated before the
specified time is reached, the initial learn-
ing is not completed (TUNED is not dis-
played).
7-2-4. Conformation of completion of transmission

initial learning
1) Referencing "7-2-2 Preparations for trans-
mission initial learning", make sure 111111
is marked on ID number 94100, indicating
that the initial learning is completed. 2) Hold down [U] switch for 5 seconds mini-
2) Press [t] switch to end confirmation of the mum to display 01: TM TRIGGER screen.
initial learning.
30-103 46 WD600-6
3) Using [<] or [>] switch, select 04: SHIFT <Gear shift pattern change procedure>
rpm screen from the sub menu. a As an example of a gear shift pattern
change, following describes the procedure
for changing the gear shift travel speed
pattern from F2T/C to F3T/C. (The same
applies to other gear shift patterns, too.)
1) Select 04: SHIFT rpm screen using [U]
switch and then select 01:F2T/C o F3T/C
using [<] or [>] switch.
4) Press [U] switch to settle the selection.

a As the selection is settled, 0: ALL CLEAR
will be displayed in the lower space.
5) Press [U] switch to settle ALL CLEAR.
a As all the stored values are cleared,
the set value is returned to the default
and the screen returns to the shift
point adjustment item. 2) Press [U] switch to settle the selection.
a If [t] switch is pressed in place of [U] a As the selection is settled, the Shift
switch, the stored value is not cleared point adjusting value input screen will
and the screen returns to the adjust- appear.
ment items. a This screen displays the currently
entered shift point adjusting value.
7-3-2. Adjusting a shift point a Adjusting value input screen when
a This operation allows changing a gear Adjusting value = 0
shift travel speed when L auto-shift mode
is selected.
a Gear shift patterns are changed as shown
below.
No. Gear shift pattern to be changed
0 ALL CLEAR
1 F2 T/C o F3 T/C
2 F2 L/U o F3 L/U
3 F3 T/C o F4 T/C
4 F3 L/U o F4 L/U
5 F4 L/U o F3 L/U
6 F4 T/C o F3 T/C
7 F3 T/C o F2 T/C
8 F3 L/U ON
9 F3 L/U OFF
10 F4 L/U ON
11 F4 L/U OFF
• T/C: Torque converter travel
• L/U: Lockup travel
WD600-6 30-103 47
3) Press [<] or [>] switch to select a desired 7-4. Adjusting lift raise EPC starting current
adjusting value. a Start the engine prior to the setup opera-
a When adjusting a shift point, 50 rpm tion.
of the transmission output shaft 1) Display the TUNING screen from the
speed is used as a unit. menu screen of Service mode.
a Adjusting the transmission output
shaft speed by 50 rpm changes the
travel speed by approximately 0.727
km/h.
q Selecting +50 rpm increases the
speed by approximately 0.7 km/h.
q Selecting –50 rpm decreases the
speed by approximately 0.7 km/h.
4) After selecting a desired setting data,
press [t] switch to end the setup proce-
dure.


item of 06: RAISE EPC.
4) Set the lift cylinder in medium position.

(Do not extend the cylinder to the stroke
end.)
30-103 48 WD600-6
5) Start raising the lift gradually while setting 2) Hold down [U] switch for 5 seconds mini-
the engine to high idle. mum to display 01: TM TRIGGER screen.
6) Return the lever through fine operation. As
the lift is stopped, maintain the lever at
that position.
7) Pressing [U] switch turns on reading of
the commanded value of EPC and then
stores the difference between it and the
standard value as the offset value.

item of 07: LOWER EPC.
8) The setting is complete as 06: RAISE

EPC screen was restored succeeding to 2
times of buzzer beep.
a If [U] switch is pressed when the lever is
at neutral, the adjusted value is cleared. In
this case, 06: RAISE EPC screen will be
restored succeeding to 2 times of buzzer
beep.
7-5. Adjustment of lift lower (float) lever and

4) Stop the lift EPC lever in a position just
before the float detent position and main-
7-5-1. Adjusting variation correcting calibration of
tain the lever at this position.
lift lower (float) EPC lever
a Take care so that float detent operation
a This adjustment is needed when the electric
may not turn on.
(EPC) work equipment lever or the work equip-
ment controller is disassembled or replaced.
a Before starting the adjustment, lower the blade
lever voltage and then stores the read
to the ground and stop the engine.
voltage replacing the currently stored
standard value.
WD600-6 30-103 49
a The setting is complete as 07: LOWER 3) Using [<] or [>] switch, move the cursor to
EPC screen was restored after 2 times of item of 07: LOWER EPC.
buzzer beep.
a If the lever output voltage at this point is
below the standard value (off the design
range), pressing [U] switch sounds the
buzzer for 1 second and the screen
remains unchanged as U = SET like
shown in the above figure. In this case,
the adjustment is cancelled and 07:
LOWER EPC screen will be restored.
a If [u] switch is pressed at this point, cor-
rection of variations in the work equipment
EPC lever detent position is stopped even
if it is not completed.
7-5-2. Adjusting lift lower EPC starting current

4) Set the cylinder in medium position.
a Start the engine prior to the setup opera-
(Do not extend the cylinder to the stroke
tion.
end.)
5) Start lowering the lift gradually while main-
taining the engine at high idle.
6) Return the lever through fine operation. As
the lift is stopped, maintain the lever at
that position.

8) The setting is complete as 07: LOWER

EPC screen was restored after 2 times of
buzzer beep.
this case, 07: LOWER EPC screen will be
restored after 2 times of buzzer beep.
30-103 50 WD600-6
7-6. Adjusting LH pitch rear/tilt LH EPC start- 4) Set the tilt cylinder in the medium position
ing current (Do not extend the cylinder to the stroke
a Start the engine prior to the setup opera- ends.)
tion. 5) Operate LH tilt while maintaining the
1) Display the TUNING screen from the engine at high idle.
menu screen of Service mode. 6) Return the lever through fine operation. As
the tilt is stopped, maintain the lever at
that position.

8) The setting is complete as 10: Adjusting

LH pitch rear/tilt LH EPC starting current
screen was restored after 2 times of
buzzer beep.
this case, 10: Adjusting LH pitch rear/tilt
LH EPC starting current screen will be

item of 10: Adjusting LH pitch rear/tilt LH
EPC starting current.
a Since WD600-6 is equipped with the
machine monitor designed for WA600-6,
monitoring items displayed on the screen
may differ from actual testing items.
WD600-6 30-103 51
7-7. Adjustment of LH pitch FORWARD/tilt LH 4) Set the bucket roughly horizontal without
EPC starting current applying any load.
a Start the engine prior to the setup opera- 5) Start dumping the bucket gradually while
tion. maintaining the engine at high idle.
1) Display the TUNING screen from the 6) Return the lever through fine operation. As
menu screen of Service Mode. the bucket is stopped, maintain the lever
at that position.

8) The setting is complete as 11: Adjustment

of LH pitch FORWARD/tilt LH EPC start-
ing current screen was restored after 2
times of buzzer beep.
this case, 11: Adjustment of LH pitch FOR-
WARD/tilt LH EPC starting current screen
will be restored after 2 times of buzzer
beep.

item of 11: Adjustment of LH pitch FOR-
WARD/tilt LH EPC starting current.
30-103 52 WD600-6
7-8. Adjusting RH pitch REAR EPC starting 4) Set the tilt cylinder in the medium position
current (Do not extend the cylinder to the stroke
a Start the engine prior to the setup opera- ends.)
tion. 5) Tilt the blade gradually while maintaining
1) Display the TUNING screen from the the engine at high idle.
menu screen of Service mode. 6) Return the lever through fine operation. As
that position.

8) The setting is complete as 10: Adjusting

RH pitch REAR EPC starting current
buzzer beep.
this case, 10: Adjusting RH pitch REAR
EPC starting current screen will be

item of 10: Adjusting RH pitch REAR EPC
starting current.
Since WD600-6 is equipped with the
WD600-6 30-103 53
7-9. Adjustment of RH pitch FORWARD EPC 4) Set the RH pitch cylinder in the medium
starting current position. (Do not extend the cylinder to the
a Start the engine prior to the setup opera- stroke ends.)
tion. 5) Start tilting the blade gradually while main-
1) Display the TUNING screen from the taining the engine at high idle.
menu screen of Service Mode. 6) Return the lever through fine operation. As
that position.

8) The setting is complete as Adjustment of

RH pitch FORWARD EPC starting current
buzzer beep.
this case, Adjustment of RH pitch FOR-
WARD EPC starting current screen will be

item of Adjustment of RH pitch FOR-
WARD EPC starting current.
30-103 54 WD600-6
7-10. Adjustment of AJSS neutral position 4) Set the machine to the straight travel posi-
(AJSS specification) tion and also set AJSS lever to neutral.
1) Display the TUNING screen from the 5) Press [U] switch from this state.
menu screen of Service mode. a If AJSS lever is not movable from the cur-
rent neutral position to the straight travel
position, adjust AJSS follow-up link.

6) 2 times of buzzer beep notify completion
of the setting.
a 1 second-long beep indicates that the set
frame and lever angle voltage is not con-
forming to the specified value. In this
case, adjustment does not start.
7) Press [t] switch to end the adjustment
mode.
a If [t] switch is pressed while the calibra-
tion is continued, the calibration currently
underway will be stopped even if it is not
completed.
8) When the adjustment was not success-
fully executed, check the frame and lever
angle sensor voltages from the real time
monitoring.
item of 12: J/S NEUTRAL.
a Adjust the frame and lever angle sensor
mounting position so that the voltage dis-
played on the real-time monitoring may fall
in within the following range and then
implement the sensor adjustment again.
Voltage
Angle sensor Lift arm position
range
Straight travel
Frame angle sensor 2.50 ± 0.3 V
position
Lever angle sensor Neutral state 2.50 ± 0.3 V
7-11. Adjustment of AJSS EPC output current

a If this adjustment is necessary, consult the
factory before performing it.
WD600-6 30-103 55
7-12. Adjustment of difference of speed 4) Press [U] switch to settle the selection.
between RH and LH cylinder of pitch a As the selection is settled, the BOOM
FORWARD TABLE screen will be displayed.
5) When the left cylinder moves too fast in

forward pitch operation, use [<] or [>]
2) Hold down [U] switch for 5 seconds mini- switch to reduce the set value in the order
mum to display 01: TM TRIGGER screen. of 7 o 6 o 5 o 4 o 3 o 2 o 1, and check
the speed difference between both cylin-
ders in forward pitch operation.
When the left cylinder move too slow, use
[<] or [>] switch to increase the set value
in the order of 1 o 2 o 3 o 4 o 5 o 6 o
7 , a n d c h e c k t h e s p e e d d i ff e r e n c e
between both cylinders in forward pitch
operation.
a Default setting is "4".
6) Press [t] switch to settle the adjustment.

item of 14: BOOM TABLE.
30-103 56 WD600-6
7-13. Adjustment of difference of speed 4) Press [U] switch to settle the selection.
between RH and LH cylinder of pitch a As the selection is settled, the tilt & pitch
REAR lever adjustment screen will be displayed.
5) When the left cylinder moves too fast in

2) Hold down [U] switch for 5 seconds mini- rear pitch operation, use [<] or [>] switch
mum to display 01: TM TRIGGER screen. to reduce the set value in the order of 7 o
6 o 5 o 4 o 3 o 2 o 1, and check the
speed difference between both cylinders
in rear pitch operation.
When the left cylinder moves too slow,
use [<] or [>] switch to increase the set
value in the order of 1 o 2 o 3 o 4 o 5 o
6 o 7, and check the speed difference
between both cylinders in rear pitch oper-
ation.
a Default setting is "4".

item of 15: BUCKET TBL.
WD600-6 30-103 57
7-14. Adjustment of lift raise/lower stop modu- 2) Hold down [U] switch for 5 seconds mini-
lation mum to display 01: TM TRIGGER screen.
a When the lift lever is operated for sudden stop,
this function modifies the speed reduction rate
of the stop modulation, which is prepared for
alleviating shocks resulting from stopping, by
applying the stop modulation to EPC output
current.
a The stop modulation function acts the same
way in both the raise and lower directions.
a The data at delivery is set to 100% of the stan-
dard.
Modulation
State Remarks
quantity
The stop modulation
Stopping shocks can
is not activated. The 3) Using [<] or [>] switch, move the cursor to
result if the operator
0% blade is stopped with- item of 16: LOWER STOP.
does not pay reason-
out delaying to the
able care.
lever stroke.
It allows compatibility
between delay in
100% —
response at stop and
stopping shocks
The blade overruns
It alleviates stopping the target stop posi-
shocks that can result tion because its stop-
200%
from operator's sud- ping is delayed even
den stop operation. when the lever is set
at neutral.

menu screen of Service mode. 4) Press [U] switch to settle the selection.
a As the selection is settled, the LIFT
LOWER STOP screen will appear.
5) Select a desired table from 0, 100 and 200
by use of [<] or [>] switch.
30-103 58 WD600-6
7-15. Modification of AJSS oil pressure com- 1) Display the TUNING screen from the
mand table pattern menu screen of Service mode.
a This function modifies stopping shock and
response of AJSS by changing the data on
EPC output current to the AJSS lever stroke.
a The table at delivery is Table No. 2.
a Following summarizes characteristics of
respective tables.
<Table No. 1>
q It offers the fine control priority level. In order to
support the operators who have switched from
CAT J/S specification machine, this mode sets
the maximum swing speed lower than the
default value and alleviates shocks resulting
from sudden steering lever operation without
sacrificing operability of AJSS.
q In this table, difference between the high-
speed travel range and low-speed working
range is reduced.
q With the traveling speed at 25 km/h or below
and the lever angle at 17° or above, it assures
the maximum swing speed of approximately
90% of the default (Table No. 2).
<Table No. 2>

q This table offers the default level. It strikes a
balance between the machine performance
and steering performance.
q It is the table when delivered.
q It assures the maximum swing speed when the
traveling speed is set to 7 km/h or below and
the lever angle to 17° or above.
<Table No. 3> 3) Using [<] or [>] switch, move the cursor to
q This table offers the response priority level. It item of 21: AJSS TBL.
decreases the sense of catch-up by turning on
the maximum swing speed, in the low-speed
working range, before the steering lever
reaches the stroke end.
q It, however, allows greater shocks to result
from sudden steering lever operation – a con-
tradictory phenomenon.
q V shape workload priority mode
q It assures the maximum swing speed when the
traveling speed is set to 15 km/h or below and
the lever angle to 15° or above. This table sets
a swing angle faster than the default (Table No.
2) in the lever angle range of 10 – 17° in order
to alleviate the sense of catch-up.
a The maximum swing speed is not available
from the data of Table No. 1. Thus, Table No. 2
or 3 shall be used for measuring the swing
speed.
WD600-6 30-103 59
4) Press [U] switch to settle the selection. 2) Hold down [U] switch for 5 seconds mini-
a As the selection is settled, the AJSS TBL mum to display 01: TM TRIGGER screen.
screen will be displayed.

5) Select a desired table from 1, 2 and 3 by item of 22: SPEED LIMIT.
use of [<] or [>] switch.
7-16. Adjustment of maximum speed limit

a This maximum speed limit adjusting function is
used to enhance fuel consumption in the for-
ward 4th lockup travel.
a First select the maximum travel speed
(selected from three levels). Then set the
upper limit of the throttle opening for F (for-
ward), 4th and L/U (lockup) to limit the maxi-
mum travel speed.
a The throttle opening is limited to 90%, when
delivered.
a Select a restricted throttle opening from 80%,
4) Press [U] switch to settle the selection.
90% and 100% (no restriction).
a As the selection is settled, the maximum
a The state in which F (forward), 4th and L/U
speed limit adjustment screen will be dis-
(lockup) are selected is, in other words, the
played.
state in which F4 gear shift is completed and
5) Select “throttle position (80%, 90%, or
L/U is at the holding pressure.
100%)” using [<] or [>] switch and then
a When gear shift to a speed other than F4 is
press [U] switch to settle the setting
started or when L/U is cancelled, the upper
change.
limit value of this control becomes 100% (no
restriction).
a Setting at delivery is 90%.
30-103 60 WD600-6
8. Maintenance monitoring function

The maintenance function offers the following
capabilities in the maintenance of filters and
oils.
q Change of maintenance interval time
q Selection between enabling or disabling
timer by item
q Setting of a default value
q Selection between enabling or disabling
timer for items
8-1. Changing maintenance interval time
1) Display the MAINTENANCE MONITOR
screen from the menu screen of Service
mode.
2) Press [U] switch to display 01: ENG OIL

screen.
a The lower left side space indicates the
time remained up to the replacement.
a The lower right side space indicates the
cumulative replacement frequencies.
3) Using [<] or [>] switch, select the item for
which the maintenance interval is to be
changed from the following.
WD600-6 30-103 61
List of maintenance items
Indication of items on the Replacement

Item ID No.
character display interval time (H)
Engine oil 01 ENG OIL 500
Engine oil filter 02 ENG OIL FILTER 500
Fuel pre-filter 41 FUEL P FILT 500
Transmission oil filter 13 TRANSM FILTER 500
Fuel filter 03 FUEL FILT 500
Transmission oil 12 TRANSM OIL 1000
Corrosion resistor 06 CORR-RESISTER 1000
Hydraulic tank breather element 05 HYD BREATHER 2000
Hydraulic oil filter 04 HYD FILT 2000
Hydraulic oil 10 HYD OIL 2000
Axle oil 15 AXLE OIL 2000
4) Settle the target items of interval change a When you have entered a wrong value to
by use of [U] switch. a position except the highest-order digit,
move to the highest-order digit using [t]
switch and repeat the procedure from the
first. In this case, the value that had been
entered remains as it is until modified.
When the cursor is at the highest-order
digit, move to the higher layer using [t]
switch.
5) Maintenance interval time change proce-

dure
1] This cursor (C) is located at the high-
est-order digit. Pressing [<] or [>]
switch changes the value of this digit
in the range of 0 – 9.
value.
3] Set the values up to the lowest-order
digit in the same order and then press
[U] switch.
q When the input interval time is within
the setting range: The screen
changes to the check screen.
q When the entered interval time is out
of the setting range: The entered
interval time does not replace the cur-
rent value and the input screen will be
restored.
a The shortest interval time value is 50 h.
30-103 62 WD600-6
6) Select "YES" or "NO" using [<] or [>] a When "Timer by item" is disabled, the
switch. order of display becomes OFF o ON.
a The selected cursor will start flashing. If a The default display is ON.
"YES" is selected and [ t] switch is
maintenance interval change item screen
is restored.
a When an interval time is changed, the
timer remaining time is changed as shown
below.
q Timer remaining time = Interval time being
set – Elapsed time from the last replace-
ment
2) Press [U] switch from this state.
a If "Timer by item" is disabled, OFF will be
displayed in the upper column.
8-2. Selection between enabling or disabling timer

by item
1) Pressing [<] or [>] switch from 8-1-3)
maintenance Interval time change screen
a If "Timer by item" is enabled, ON will be
displays the "Selection between enabling
displayed in the upper column.
or disabling timer by item" screen.
a When "Timer by item" is enabled, the
order of display is ON o OFF.
WD600-6 30-103 63
3) Select "YES" or "NO" using [<] or [>] 3) Press [U] switch from this state.
switch. 4) Select "YES" or "NO" using [<] or [>] switch.
a The selected cursor will start flashing. If a The selected cursor will start flashing. If
"YES" is selected and [t] switch is "YES" is selected and [t] switch is
pressed, the information will be deleted. If pressed, the change will be enabled If
"NO" is selected and [t] switch is "NO" is selected and [t] switch is
pressed, deletion is cancelled and the pressed, the change will not be imple-
maintenance interval change item screen mented and the maintenance monitoring
is restored. screen will be restored.
a By default, the cursor is set to NO (cancel) a By default, the cursor is set to NO (cancel)
to prevent resetting error. to prevent resetting error.
a An interval time is changed, the timer
remaining time is changed as shown
below.
q Timer remaining time = Interval time being
set – Elapsed time from the last replace-
ment
8-3. Changing set default value.

1) Press [U] switch from the MAINTE-
NANCE MONITOR screen of Service
mode to display 01: ENG OIL screen.
a If the default value setting is executed, all

the currently changed interval times are
returned to the default values. It is executed
on every item independent of whether or not
the function is enabled for a specific item.
a Timer remaining time shall be Default
value – Elapsed tim e since the last
replacement.
a Executing the default value setting does
not affect the reset frequency. Namely, it
remains the same as before this operation
2) Using [<] or [>] switch, select the INITIALIZE was executed.
screen. a Set enable for enable or disable of individ-
ual items.
8-4. Selection between timer stop for all items and

enable all items
1) Press [U] switch from the MAINTE-
NANCE MONITOR screen of Service
mode to display 01: ENG OIL screen.
30-103 64 WD600-6
2) Using [<] or [>] switch, select the ALL 5) Press [U] switch from the ALL ITEMS o
ITEMS OFF OR ON screen from the fol- OFF screen or the ALL ITEMS o ON
lowing table. screen.
a When [U] switch is pressed from the ALL
ITEMS o OFF screen, OFF will be is dis-
played in the upper space.
3) Press [U] switch to display the ALL

ITEMS o OFF screen.
a When [U] switch is pressed from the ALL

ITEMS o ON screen, ON will be is dis-
played in the upper space.
6) Select "YES" or "NO" using [<] or [>]
switch.
"YES" is selected a nd [t] switch is
maintenance interval change item screen
is restored.
4) Press [<] or [>] switch when selecting the
ALL ITEMS o ON.
WD600-6 30-103 65
7) As the timer stop for all items is executed: 9. Operating information display function
a The timer function for all items is stopped It is a fuel consumption-related function and
a n d t h e M A I N T E N A N C E M O N I TO R displays the following information.
screen is restored. q Fuel consumption ratio and average fuel
a Setting for individual items is also disabled. consumption
a If cancelled: The operation is cancelled q Cumulative fuel consumption and travel
a n d t h e M A I N T E N A N C E M O N I TO R distance
screen is restored. q Cumulative fuel consumption and elapsed
8) When timer enable for all items is executed: time
a Interval time being set for all items is exe- 1) Selecting menu
cuted to the set value before disabled Display the OPERATION INFO screen
independent of whether or not it is from the menu screen of Service mode.
enabled or disabled for a specific item.
a The timer remaining time is reset. (The
reset frequency remains the same as
before the resetting.)
a The MAINTENANCE MONITOR screen is
restored.
a Setting for individual items is also enabled.
a If cancelled: The operation is cancelled
a n d t h e M A I N T E N A N C E M O N I TO R
screen is restored.
2) Press [U] switch to display the fuel con-

sumption ratio and average fuel consump-
tion screen.
3) Using [<] or [>] switch, select the item to
be displayed from 1] – 4] on the fuel con-
sumption ratio and average fuel consump-
tion screen.
1] Fuel consumption ratio and average
fuel consumption screen
a The upper column displays fuel con-
sumption [L/km or L/mile] per 1 km (or
1 mile) from the last resetting.
q Above value is computed from the
fuel consumption ratio and travel dis-
tance (odometer distance).
q The counting is stopped at 99999.9,
the upper limit.
a The lower column displays the aver-
age fuel consumption [L/h] from the
last resetting.
the upper limit.
a Calculation is done only for the dura-
tion in which the engine is run.
30-103 66 WD600-6
a The lower column displays the

elapsed time [h] from the last reset-
ting.
the upper limit.
2] Cumulative fuel consumption and travel

distance
a The upper column displays the cumu-
lative fuel consumption [L] from the
last resetting.
the upper limit.
a The lower column displays the travel 4) Deleting display data
distance [km or mile] from the last a Data on screens 5) – 8) allow deletion.
resetting. a Select a desired item and then delete it
q The unit km or mile shall be selected using [U] switch.
depending on that used on the odom- a Use [t] switch when canceling deletion of
eter. data.
the upper limit.
3] Cumulative fuel consumption and

elapsed time
a The upper column displays the cumu-
lative fuel consumption [L] from the
last resetting.
the upper limit.
WD600-6 30-103 67
5) Setting gain correction

a Gain correction denotes the function of
correcting cumulative fuel consumption.
a Gain correction is available only from the
fuel consumption ratio and average fuel
consumption screen.
1] After deleting data (RESET screen),
press [<] or [>] switch to display the
current set value.
2] Pressing [U] switch displays the cor-

rection screen.
a Default value: 0.0%
a This setting allows correcting the
cumulative fuel consumption in the
range of –50.0 to +50.0.
3] Move the cursor to [+] or [–].
4] Pressing [<] or [>] switch alternately
displays [+] and [–].
5] Press [U] switch to settle [+] or [–].
a The cursor moves to the highest-
order digit of the set value.
6] Pressing [<] or [>] switch changes the
value of this digit in the range of 0 – 9.
value.
8] Set the values up to the lowest digit in
the same order as above and then
press [U] switch to settle.
a As the selection is settled, the pre-
ceding screen is restored.
a If [t] switch is pressed before finish-
ing entering, the cursor moves to the
[+] and [–] position. In this case, the
value remains unchanged. Pressing
[t] switch again restores the preced-
ing screen.
a If the value is not in the –50 – +50
range, pressing [U] switch at the low-
est digit just moves the cursor the [+]
and [–] position and the value
remains as it is.
30-103 68 WD600-6
10. Manual snapshot function 3) Press [U] switch to start the snapshot.
a The manual snapshot function stores 7 min- a The upper column displays the
utes and 30 seconds worth data to be used for elapsed time.
Pm clinic or testing/adjustment to VHMS con- a [–] sign in the leftmost position of the
troller. lower column is replaced with [*] and
a When collecting data at a regular interval for it starts flashing.
Pm clinic, it is required to observe the machine a For every 30 seconds, [–] is replaced
operating procedure specified for the quick with [*] starting with the leftmost one.
Pm. As for the data collection for the testing or When two or more [*] signs are dis-
adjustment purpose, however, no specified played, the rightmost one flashes.
machine operating procedure is stipulated". a Pressing [t] switch while the snap-
a When using the data being stored with the shot is taking place stops the snap-
manual snapshot function, a PC must be con- shot.
nected. For the connecting as well as operat-
ing procedure, refer to VHMS controller initial
setting procedure. (Connection of a PC may be
done before or after the snapshot.)
a For detail of operation of the snapshot function,
see the VHMS controller initial setting proce-
dure, "7 Quick Pm implementation procedure".
1) Display the SNAPSHOT screen from the
4) Refer to the VHMS controller initial setting

procedure, "7 Pm clinic implementation
procedure for the machine operation".
a After 10th [*] is displayed (5 minutes
elapsed from the start), [#] will be dis-
played for 11th through 15th posi-
tions.
q *: Indicates the data sampling interval
is once every 10 seconds.
2) Pressing [U] switch to turn on the ready q #: Data sampling interval is once
(READY) screen. every 1 second.
a The lower column displays 15 pieces of
[–] sign. 5) As 7 minutes and 30 seconds elapsed
from start of the snapshot, following
screen appears and then the initial screen
is restored in 5 seconds later.
(End of snapshot)
WD600-6 30-103 69
11. Optional device selecting function

a When enabling optional setting, turn the starting switch off once after changing the current setting and
then turn on the starting switch again after respective in-vehicle controller power supplies have been
completely turned off (it takes approximately 15 seconds).
a List of installed optional devices and their setting

Display in Item
Item Default Description of selection
English No.
This item does not function (WD600-6).
Lift arm model LIFT BOOM 1 STD
No change allowed
AUTO
Auto grease 2 None When an option is provided, select ADD.
GREASE
Low battery electrolyte sensor BAT LIQUID 3 None When an option is provided, select ADD.
TRANSM
Transmission clogging sensor 4 None When an option is provided, select ADD.
CLOG
Printer PRINTER 5 None When an option is provided, select ADD.
Normally, 0% shall be maintained without modify-
Tire size TIRE SIZE 6 0
ing current setting.
SHORT Factory-setting is done through special operation.
Selecting weight unit 7 None
TON Thus, setting change not available.
SPEED Factory-setting is done through special operation.
Travel speed unit 8 MPH
(UNIT) Thus, setting change not available.
Engine speed or travel speed
RPM/ Normally, ADD shall be maintained without modify-
display on character display and 10 Provided
SPEED ing current setting.
normal screen
LOAD This item does not function (WD600-6).
Load meter 11 None
METER No change allowed
Emergency steering EMERG S/T 13 Provided When an option is not provided, select NO ADD.
Joystick steering or right FNR This item does not function (WD600-6).
J/S-FNR SW 14 NON
switch or both are absent No change allowed
Normally, ADD shall be maintained without modify-
Selecting ECO lamp display ECO LAMP Provided
ing current setting.
This item does not function (WD600-6).
ECSS E.C.S.S. 20 None
No change allowed
AUTO RE This item does not function (WD600-6).
Automatic reversing fan 21 None
FAN No change allowed
Torque converter lockup LOCK UP 22 None Select ADD.
FORBID Normally, ADD shall be maintained without modify-
No 4th 23 None
4TH ing current setting.
THROT
Setting RPM 24 None When an option is provided, select ADD.
LOCK
When an option is provided, select ADD.
P-MODE
Power mode priority 25 None (Setting available: Power mode is introduced as
PRI
starting switch is turned on)
COLD This item does not function.
Very cold region specification 26 None
SPEC No change allowed
AJSS AJSS STG 30 None
No change allowed
EPC 3-lever EPC 3RD 31 None When an option is provided, select ADD.
VHMS controller VHMS 40 Provided
No change allowed
30-103 70 WD600-6
1) Display the OPTIONAL SELECT screen 11-2. Option setting/not setting selection
from the menu screen of Service mode. a Among the items included in the list of
installed optional devices and their setting,
the option setting/not setting selection
applies to the following items.
a If the options are not selected, the option
non-selection screen is displayed.
2) Hold down [U] switch for 5 seconds or

longer.
3) The 1: LIFT BOOM screen will appear.
a If the options are selected, the option

elected screen is displayed.
4) Using [<] or [>] switch, select a desired

optional device from the list of installed
options and their setting.
5) Modify contents of the option setting using
[U] switch. a [U] switch allows alternately displaying
6) Press [t] switch to return to the OPTIONAL the option non-selection screen and the
SELECT screen. option-selected screen.
11-1. Changing lift arm model option selection

a This item does not function.
No change is allowed.
WD600-6 30-103 71
11-3. Setting tire deflection option 12. Machine serial number input function
a Select the tire deflection option from the list of 1) Display the MACHINE No. SET screen
installed optional devices and their setting. from the menu screen of Service mode.
a Pressing [U] switch sequentially displays
[@@]% in the following order.
a The display progresses from +00 through –10.
Pressing [U] switch at this point returns the
display to +00.
Order No.1 No.2 No.3 No.4 No.5 No.6 No.7

@@ +00 +02 +04 +06 +08 +10 +12
Order No.8 No.9 No.10 No.11 No.12 No.13 No.14

@@ –02 –4 –6 –8 –10 –12 +00
a As the display is switched, the sound (beep)

indicating acceptance of the operation will be
generated.
2) Press [U] switch to display the MACHINE
No. screen.
3) Enter the serial number according to the
a The cursor is positioned at the high-
est-order digit.
1] Pressing [<] or [>] switch increases or
decreases the value at the cursor
position. Select a desired value using
these switches.
2] Press [U] switch to settle the selec-
tion.
a The cursor moves to the digit situated
immediately on the right hand.
3] Set the values up to the lowest digit in
11-4. Storing option selection the same order as above and then
1) When the option selection was changed, press [U] switch to settle.
turn off the starting switch once to stop the a As the selection is settled, the imme-
controller operation completely.(After turn- diately preceding screen is restored.
ing off the starting switch, wait for 5 sec- a Pressing [t] switch while entry is tak-
onds without doing any switch operation.) ing place will move the cursor the
2) The specified option selection is enabled highest-order digit. In this case,
as the starting switch is turned on. repeat entry from the highest-order
a Whenever an option selection is made, turn digit.
off the starting switch once and then turn it a If [t] switch is pressed while the cur-
on again in approximately 15 seconds. sor is at the highest-order digit, the
immediately preceding screen will be
restored.
30-103 72 WD600-6
13. Model selection function

When the Service mode is turned on, check 3) Using [<] or [>], replace WA5** with
the models registered to the machine monitor. WA6**.
If the selected model was found in the a Press [t] switch when stopping the model
machines installed to the machine monitor, selection.
there is no need of changing the model even a As the operation is stopped, the sound
though the model changing function is avail- (beep) indicating acceptance of the opera-
able. tion will be generated, restoring the
MACHINE screen.
13-1. Implementing the model change 4) Settle the selected model by use of [U]
1) Display the MACHINE screen from the switch.
menu screen of Service mode. a As the selection is settled, the sound
a If WD600-6 or WA600-6 is selected, (beep) indicating acceptance of the opera-
WA6** will be displayed on the screen. tion will be generated, restoring the
a In the case of WA500-6, the display will be MACHINE screen.
WA5**. a Make sure the model on the MACHINE
screen is the target model.
13-2. Storing model change

1) When the model change was done, turn off
the starting switch once to stop the controller
operation completely. (After turning off the
starting switch, wait for 5 seconds without
doing any switch operation.)
2) The model being selected as the starting
switch is turned on is validated.
a Whenever a model change was done, turn
off the starting switch once and then turn it
on again in approximately 15 seconds.
14. Initialize function

2) Hold down [U] switch for 5 seconds to
This function is used only in the factory. It is,
display the model selection screen.
therefore, not used for a service purpose.
WD600-6 30-103 73
SEN05047-02
WD600-6 Wheel dozer

©2011 KOMATSU
All Rights Reserved
30-103 74
SEN05048-05
WHEEL DOZER
WD600-6

WD600-6 55001 and up

VHMS controller initial setting procedure (ORBCOMM installation specification)........................................... 2
VHMS controller initial setting procedure (IRIDIUM installation specification) .............................................. 24
Precautions for replacing VHMS controller ................................................................................................... 46
Pm-clinic inspection table ............................................................................................................................. 52
WD600-6 30-104 1
SEN05048-05 VHMS controller initial setting procedure (ORBCOMM installation specification)
VHMS controller initial setting 1. Confirmation of machine information,

procedure (ORBCOMM installation engine information, transmission controller
information and controller information
specification) 1
a This confirmation procedure is targeted at
a Equipment used for VHMS controller initial set- the entire machine.
ting Confirm and record the machine informa-
tion, engine information, VHMS controller
Symbol Part No. Part name information and ORBCOMM terminal
information.
1 799-608-3101 Service kit
2 799-608-3211 • Diskette
No. Information to be confirmed
3 799-608-3220 • Harness
1 Model name
ZB Note type PC
Commercially 2 Machine serial No.
4 (Windows 98/2000/Me/XP/
available
Vista) 3 Current service meter hour
Commercially 4 Engine serial No.
5 RS232C-USB conversion cable
available 5 Transmission serial No.
6 VHMS controller serial No.
a Initial setting of VHMS controller shall be done
according to the following procedure. This ORBCOMM terminal serial No.
7
operation is needed prior to a full-scale opera- [Only for machines equipped with ORBCOMM]
tion of a machine being delivered and assem-
bled in the field, or prior to resumption of its a VHMS controller (1) and ORBCOMM ter-
operation after a long time of storage. minal (2) are installed in the right side
a Machine data collected with VHMS controller stand of the operator seat.
are stored and managed on WebCARE data-
base. In order to endure smooth data process-
ing on WebCARE, consistency must be
provided among the settings done on VHMS
controller. Inconsistencies in the settings
obstruct loading of data to WebCARE, ham-
pering appropriate use of VHMS data. The ini-
tial setting, therefore, is a must.
a For the installation procedure of the VHMS ini-
tial setting program to a PC, refer to the opera-
tion and maintenance manual being bundled
with the service kit ZB1.
a In the procedure, service menus of the
machine monitor are used. Thus, it is advis-
able to reference the information contained in
the "Special functions of machine monitor" to
understand their procedure beforehand.
a The initial setting procedure is described in the
ORBCOMM installation specification and the
ORBCOMM-less specification. When using the
ORBCOMM installation specification, imple-
ment the procedures needed for VHMS alone,
bypassing those prepared only for ORBCOMM
installation specification.
a Check each step of the setting work referenc-
ing the VHMS initial setting work check sheet.
a Information such as models shown in the fig-
ures may not be identical with actual ones.
30-104 2 WD600-6
VHMS controller initial setting procedure (ORBCOMM installation specification) SEN05048-05
2. Connecting a PC 3. Confirming VHMS controller operation and

a This work is done inside the cab. confirming satellite capturing state
1) Make sure the starting switch is at OFF a This work is done inside the cab.
position. a Confirmation of capturing of the satellite is
k Before connecting or disconnect- done for [ORBCOMM installation specifi-
ing a PC, be sure to turn off the cation].
starting switch. 1) Turn the starting switch ON.
2) With personal computer ZB4 switched 2) Check the controller for normal operation
ON, connect it to download connector referencing 7-segment LED of VHMS con-
DPC7 by wiring harness ZB3. troller.
a Connect RS232C terminal of the PC. a VHMS controller is fed with switch
a If the personal computer does not power supply. Thus, its operation is
have the connection port for RS232C judged normal if its 7-segment LED
terminal, connect by using RS232C- starts flashing while rotating as the
USB conversion cable ZB5. starting switch is turned on and then if
(To use the USB conversion cable, its the controller starts counting in the
driver must be installed to the per- ascending order.
sonal computer.)
3) Among the 7-segment LED situated in the

right side of VHMS controller, refer to the
a Download connector DLF is installed one that represents the decimal point to
in the front side of the right stand of check whether or not ORBCOMM control-
operator seat. ler has captured the communication satel-
lite. [ORBCOMM installation specification]
a Check whether or not ORBCOMM
controller is capturing the communi-
cation satellite from VHMS controller.
a It is successfully capturing the satel-
lite when the LED representing the
decimal point in the right side 7-seg-
ment LED is flashing.
WD600-6 30-104 3
4. Starting the VHMS initial setting tool 5. Initial setting of VHMS controller (Ver. 3. 5. 2. 1
a This work is done inside the cab (from PC). or older version)
1) Operating [VHMS initial setting tool] icon on a This work is done inside the cab (from
the PC, start up the VHMS initial setting tool. PC).
a It is prohibited in the initial setting to mod-
Important ify the data of service meter [SMR].
a Appearance of the setup screen of [Machine Information]
the VHMS setting tool depends its 1) Open [Machine Information] tab.
tool. a [Data clear and Set up] menu displays
a When using Ver.3.5.2.1 or older ver- [Machine Information] tab first.
sion (CD-ROM), the setting proce- 2) Check every data for correctness.
dure shall conform to that described
in Section 5.
a When using an update version
(Ver.3.5.2.1 or after), the procedure in
Section 6 shall be used.
a It is recommended to download the
latest VHMS version from WebCARE
to update the currently used version.
(Related material: PARTS & SER-
VICE OPERAT ION TIPS SEK N-
5052)
2) Enter the 10-digit service ID to [Service ID].
a Service ID: 7826119000
3) Select [Data clear and Set up] from
[Select Function] item.
4) Click [OK] button to proceed to the setup
screen.
3) When [Date/Time] information is not appro-
priate, correct it in the following manner.
1] Press [Edit] button in the lower right
side of [Date/Time] box to display the
correction screen.
2] After correcting it to the correct infor-
mation, press [OK] button.
30-104 4 WD600-6
4) When [Machine Information] information is [Communication Setting] [ORBCOMM installation

not appropriate, correct it in the following specification only]
manner. a This setting shall be implemented after the
1] Press [Edit] button in the lower right request for station opening has been made
side of [Machine Information] dialog and station of ORBCOMM has been opened.
box to display the correction screen. 6) Open [Communication Setting] tab.
2] After correcting it to the correct infor- 7) Check every data for correctness.
5) As every data in [Machine Information]

has been checked and corrected, press
[Apply] button to settle the setting.
a As [Apply] button is pressed, a mes-
sage confirming above setting will
appear on the screen. Check the set- 8) When modifying the setting of [SHORT
ting again and, if the setting is correct, FAULT HISTORY], employ the following
press [OK] button. procedure.
a ORBCOMM installation specification 1] Select [SHORT FAULT HISTORY] from
requires the settlement operation after the screen and then press [Edit] button
[Communication Setting] is completed. in the lower left side of [File Transfer
Setting] block to display the setup
screen.
2] Correct the setting and, as it is com-
pleted, press [OK] button.
a In the initial setting, select [Occur-
rence] from [Timing] item and then
set the function to ON.
WD600-6 30-104 5
9) When modifying the setting of [SHORT 11) As every data in [Communication Setting]
TREND ANALYSIS], employ the following has been checked and corrected, press
procedure. [Apply] button to settle the setting.
1] Select [SHORT TREND ANALYSIS] a As [Apply] button is pressed, a mes-
from the screen and then press [Edit] sage confirming above setting will
button in the lower left side of [File appear on the screen. Check the set-
Transfer Setting] block to display the ting again and, if the setting is correct,
setup screen. press [OK] button.
a In the initial setting, enter [20h] to
[SMR] and then set the function to
ON.
10) When modifying the setting of [Satellite 12) As every data in [Machine Information]
Setting], employ the following procedure. and [Communication Setting] has been
1] Press [Edit] button in the [Satellite checked and corrected, press [Exit] button
Setting] block to display the correc- to end [VHMS initial setting tool].
tion screen.
2] Set the GCC code to the region
applied and, as setting is completed,
press [OK] button.
GCC codes and applicable regions

Code Applicable region Code Applicable region
1 America 122 Korea
120 Italy 123 Brazil
121 Malaysia 130 Japan
30-104 6 WD600-6
6. Initial setting of VHMS controller (Ver. 3. 5. 2. 1 3) Confirm the machine information and, if
or later version) they are correct, press [Next] button.
a This work is done inside the cab (from PC).
ify the data of service meter [SMR].
1) Select [VHMS Setting] and then press
[Next] button.
a When VHMS has been installed later,

it is required to enter the information
such as [Serial No.].
2) Select [Set up & All clear] and press [Next]

button.
WD600-6 30-104 7
4) Select the time zone. 8) If there is no problem in the setting dis-

5) Enter the local time. played last, press [Apply] button.
6) When DST (Daylight Saving Time) (or
summer time) is currently used, press
[Next] button.
a Selecting DST advances the clock by
an hour. Thus, correction of the time
is needed again.
9) A screen message will confirm whether or

not the data before the setting is to be
saved. If the data is not necessary, select
[NO].
7) Set the GCC code to the target region of

application and, as setting is completed,
press [Next] button.

1 America 122 Korea
10) As correction of the first setting is com-

pleted, press [OK] button to end the pro-
gram.
30-104 8 WD600-6
11) Turn the starting switch OFF.

Check that the 7-segment LED of the
VHMS controller keeps displaying for sev-
eral seconds and then goes off securely.
12) Opening station request of ORBCOMM

terminal
Fill in the necessary matters in the paper of
“VHMS request of ORBCOMM terminal”
and send KOMTRAX Support, Komatsu
Ltd. by mail.
WD600-6 30-104 9
a To activate ORBCOMM terminal, please fill in the below form and send by e-mail to KOMTRAX Support,
Komatsu Ltd.
To: KOMTRAX Support, Komatsu Ltd.

Address 2-3-6, Akasaka Minato-ku Tokyo, Japan Important
E-mail JP00MB_cs_kom@global.komatsu
For VHMS equipped machine;

DO NOT connect ORBCOMM antenna and turn the
machine key switch ON prior to terminal activation.
If ORBCOMM antenna is connected and the

machine key switch is turned on prior to terminal
activation,
ORBCOMM Inc (USA) send command signal
automatically to disable the ORBCOMM terminal.
After 24 hours from disable, Orbcomm terminal

(part number 7826-12-2302 or up) will be
reactivated automatically.
Older ORBCOMM terminal is not re-activated
automatically.
VHMS Request for ORBCOMM Terminal

To activate ORBCOMM terminal, please fill in the below form and send by e-mail to KOMTRAX Support, Komatsu Ltd.
Terminal Info.
Terminal Part Number P/N (Please fill in terminal P/N & S/N or put on enclosed sticker
here)
Terminal S/N S/N
Terminal Activation Date (YY/MM/DD) / /

Country to use
Machine Info. Model-Type-#S/N – #
With GPS Antenna Yes / No
DB Info.
DB’s Contact Address
DB’s Name
Phone Number (Country-Area-Local-Local) – – –
Fax Number (Country-Area-Local-Local) – – –
E-mail Address
Name (Please print) First Middle Family
Subsidiary Info.
Subsidiary’s Contact Address
Subsidiary’s Name
E-mail Address
Signature
Notes)
It will take one or two weeks to activate after being received this sheet.
ORBCOMM terminal is unable to communicate before activation being completed.
30-104 10 WD600-6
7. Quick Pm clinic implementation procedure 6) Press the buzzer cancel switch [U] to
a Quick Pm denotes the Pm click done by start the snapshot.
use of the manual snapshot function of the a As the snapshot is started, the upper
machine monitor. column starts displaying the elapsed
a It stores 7 minutes and 30 seconds worth time.
of data to VHMS controller. a [–] in the leftmost position of the lower
k Park the machine in a flat place. column is replaced with [*] for every
30 seconds. When 2 or more [*] signs
1) Start the engine. are displayed, the rightmost one
2) Switch the machine monitor to Service flashes.
menu. a When stopping the snapshot currently
a For the procedure of opening Service taking place, press the buzzer cancel
menu, see "Special functions of switch [t].
machine monitor (EMMS)".
3) Display the manual snapshot function
mode.
7) After the snapshot is started, operate the

machine according to the following table.
a Make sure the engine coolant tem-
perature and torque converter oil tem-
4) Press the buzzer cancel switch [U]. perature are within the operating
5) [READY] will be displayed on the screen, range.
turning on the standby mode. a After 10th [*] is displayed (5 minutes
a The lower column displays 15 pieces elapsed from the start), [#] will be dis-
of [–] sign. played for 11th through 15th posi-
tions.
q #: Indicates the data sampling interval
is once every 1 second.
WD600-6 30-104 11
a Machine operation for snapshot
Machine operation
No. Start End
Machine status Power mode Work equipment
1 0:00 1:00 Low idle OFF —
2 1:00 1:30 Hi idle OFF —
3 1:30 2:00 Hi idle ON —
4 2:00 2:30 Low idle ON Right steering
5 2:30 3:00 Hi idle ON Right steering
6 3:00 3:30 Low idle ON Left steering
7 3:30 4:00 Hi idle ON Left steering
8 4:00 4:30 Low idle ON Blade relief
9 4:30 5:00 Hi idle ON Blade relief
10 5:00 5:30 T/C stall (Note 1) ON —
11 5:30 6:00 Hi idle ON —
12 6:00 6:30 T/C stall (Note 1) ON Blade relief
13 6:30 7:00 Hi idle ON Foot brake operation (Note 2)
14 7:00 7:30 Low idle ON Foot brake operation (Note 2)
(Note 1): 1) Set the auto-shift and manual selector switch to the manual.
2) Press the brake pedal fully, set the lever to F4 (forward at 4th) and set the engine to high idle.
(Note 2): Repeat pumping of the foot brake 20 times.
30-104 12 WD600-6
8) As 7 minutes and 30 seconds elapsed

is restored in 5 seconds. (End of snap-
shot)
WD600-6 30-104 13
Important 10) Open the quick Pm data to draw a graph.

Data of quick Pm are recorded only once. a Select time for X-axis and select the
Thus, if another quick PM is repeated, the cur- following for Y-axis.
rent data will be overwritten with the last one. q Engine speed
In order to avoid above trouble, be sure to q Fuel Inject (fuel injection)
download data of every completed quick Pm q Blowby Press (Blow-by pressure)
shall to PC. For the procedure, see 8. Down- q F Exhaust Temp (Exhaust temperature
load of setting data. 1, 2 and 3 cylinders)
q R Exhaust Temp (Exhaust tempera-
9) Read the quick PM data by use of the ture 4, 5 and 6 cylinders)
analysis tool. q Engine Oil Temp (Engine oil tempera-
a For detailed usage of the analysis ture)
tool, see the operation and mainte- q Engine Oil Press (Engine oil pres-
nance manual. sure)
q Coolant Temp (Engine coolant tem-
perature)
q Boost Press (Boost pressure)
q Accelerator Pos (Accelerator angle)
q Ambient Temp (Ambient temperature)
q Loader Pump P (Work equipment oil
pressure)
q ST Pump Press (Steering oil pressure)
q Hyd Oil Temp (Hydraulic oil tempera-
ture)
q Boom Angle (Lift arm angle)
q Frame Angle (Frame angle)
q T/M Out Speed (Transmission output
speed)
q Shift Indicator (Shift position)
q Lock Up Signal (Lockup signal)
q T/C Oil Temp (Torque converter oil
temperature)
30-104 14 WD600-6
11) Apply a check mark to the Display graph

value at clicked position.
WD600-6 30-104 15
12) Clicking the graph shows, below the

graph, the X-axis value of respective mea-
surement items. (An example of a graph
displayed – Not an actual one)
30-104 16 WD600-6
13) Record above values in the Pm clinic inspection sheet.

a Following shows the relation between the data needed for Pm clinic and the measuring condi-
tions.
Transmission modulation pressure

Measurement items
Exhaust gas temperature
Steering pump pressure
Rear brake temperature

Loader pump pressure
Front brake pressure

Engine oil pressure
Blow-by pressure
Boost pressure
Engine speed
E/P
Machine operation
mode
Low idle E-mode Q Q Q
Hi idle E-mode Q Q
Hi idle P-mode Q Q
Right steering + low idle P-mode Q
Right steering + high idle P-mode Q
Left steering + low idle P-mode Q
Left steering + high idle P-mode Q
Torque converter stall (Note 1) P-mode Q Q Q Q
Hi idle P-mode
Torque converter stall + blade relief P-mode Q Q Q Q
Foot brake operation (Note 2) + high idle P-mode Q Q
Foot brake operation (Note 2) + low idle P-mode Q Q
WD600-6 30-104 17
8. Download of setting data

1) Using harness [1] of service kit ZB1, con-
nect PC ZB4 to download connector DLF
in the cab or download connector VDL on
the ground.
2) When using download connector DLF in

the cab, set the starting switch to ON posi-
tion.
3) When using download connector VDL on
the ground, set switch (4) to ON position.
a Download connector DLF in the cab a The green LED will come on.
is installed in the front side of the right
stand of operator seat.
4) Operating [VHMS analysis tool] on PC,

start up the VHMS analysis tool.
a Download connector VDL on the
ground is provided under cover (3) in
the accumulator installation position,
which is located on the left side of the
machine body.
30-104 18 WD600-6
a Enter [User Name] and [Password]. 9. Confirmation of download data

a For the operating procedure, see the 1) Check the setting data using [View] function.
VHMS analysis tool operation and a For the operating procedure, see the
maintenance manual. VHMS analysis tool operation and
maintenance manual.
a Make sure that [MFA0] code, which
was used in the quick snapshot, is
indicated in [Fault History].
a Make sure the snap shot data are
recorded.
5) Using [Download] function, download the

data currently recorded on VHMS to PC.
a For the operating procedure, see the
VHMS analysis tool operation and
maintenance manual. 2) As check of the setting data is finished,
a After making sure the download is end [VHMS analysis tool].
complete, proceed to the next step.
WD600-6 30-104 19
10. Disconnecting the PC

1) Make sure the starting switch is at OFF
position.
k Before connecting or disconnect-
ing a PC, be sure to turn off the
starting switch.
2) End the OS of PC ZB4 and then turn off
the PC power.
11. Report to Komatsu

As steps 1 – 9 are completed, send VHMS/
WebCARE setting report to VHMS/WebCARE
Support in Komatsu Headquarters.
a This report is a must since setting on the
receiving end in the satellite communica-
tion must be done by Komatsu.
a In this case, send VHMS data via Notes
3) When the data was download into the cab, (LAN) or E-mail (WAN).
disconnect harness [1] of service kit ZB1 Komatsu VHMS/WebCARE Support
from download connector DLF.
2-3-6, Akasaka Minato-Ku Tokyo, Japan
FAX: 81-3-5561-4738 (from outside of Japan)

FAX: 03-5561-4738 (Domestic user)
E-mail: JP00MB_webcare@global.komatsu
4) When the data was download to the

ground, disconnect harness [1] of service
kit ZB1 from download connector VDL
30-104 20 WD600-6
[For storage] Date of setting:

DB/branch
VHMS Initial Setting Work Check Sheet office name
Data entered by:
Setup step Check item Result
Model name
Serial No.
Confirmation of machine body and
1 Engine serial No.
component nameplates
Transmission controller serial No.
VHMS controller serial No.
Connection between PC and VHMS

2 Is the connection secure? yes no
controller
Is it operating normally?
VHMS controller check for normal
3 (Displays counting in ascending-order succeeding to yes no
operation
rotation)
Is "Data Clear and Set up" selected for the setting tool
4 Starting of VHMS initial setting tool yes no
mode?
Initial setting of VHMS controller Is model name identical with machine body? yes no
Is machine body serial No. correctly entered? yes no
(Setting of machine body informa- Is engine serial No. correctly entered? yes no
5 tion)
In this step, basic machine body Is today's date entered? yes no
information are set on VHMS con- Is current time entered? yes no
troller
Is SMR correctly entered? yes no
6 Saving of settings Is LED (7-segment) turned off? yes no
7 Confirmation of VHMS function Is LED operation normal? yes no
Is service mode "SNAPSHOT" turned on and is the

8 Execution of quick Pm yes no
switch hit?
9 Data storing operation on VHMS Is LED (7-segment) turned off? yes no
10 Download Is LED operation normal? yes no
Are all files downloaded? yes no

Hour, min-
The time downloaded (Reference wrist watch)
ute:
[Confirmation of data]
11 Confirmation of download data
Is [MFA0] error present in Fault History? yes no
Are SMR and time in Fault History consistent with set-
yes no
tings?
Is any data missing in Snap Shot0? yes no
WD600-6 30-104 21

DB/branch
ORBCOMM Station Opening Work office name
Check Sheet Data entered by:
Model name
Serial No.
Confirmation of machine body and Engine serial No.
1
component nameplates Transmission serial No.
ORBCOMM terminal serial No.

controller
operation
rotation)
4 Starting of VHMS initial setting tool Is "Set up" selected for the setting tool mode? yes no
Entry of setting to S.Fault History

Initial setting of VHMS controller Presence/absence of communication On Off
1. Setting of communication
(Setting of machine body infor- Number of cases (Default is 8 cases)
mation and PLM are completed) Entry of setting of S.Trend Analysis setting
Presence/absence of communication On Off
Interval (Default is 20H)
5
Entry of setting of S.Payload data
Tabulation start time
Interval of tabulation (in days) day
2. Setting for start of communica-
Is GCC code set? (130 for Japan) yes no
tion
6 Saving of settings Is LED (7-segment) turned off after data was stored? yes no
How is decimal point display in VHMS monitor

ORBCOMM controller performance
7 (7-segment)? yes no
check
(OFF, ON, long/short flashing)
30-104 22 WD600-6
WD600-6 30-104 23
SEN05048-05 VHMS controller initial setting procedure (IRIDIUM installation specification)
VHMS controller initial setting 1. Confirmation of machine information,

procedure (IRIDIUM installation engine information, transmission controller
information and controller information
specification) 1
a This confirmation procedure is targeted at
a Equipment used for VHMS controller initial set- the entire machine.
ting Confirm and record the machine informa-
tion, engine information, VHMS controller
Symbol Part No. Part name information and IRIDIUM terminal informa-
tion.
1 799-608-3101 Service kit
2 799-608-3211 • Diskette
No. Information to be confirmed
3 799-608-3220 • Harness
1 Model name
ZB Note type PC
Commercially 2 Machine serial No.
4 (Windows 98/2000/Me/XP/
available
Vista) 3 Current service meter hour
Commercially 4 Engine serial No.
5 RS232C-USB conversion cable
available 5 Transmission serial No.
6 VHMS controller serial No.
a Initial setting of VHMS controller shall be done
according to the following procedure. This IRIDIUM terminal serial No.
7
operation is needed prior to a full-scale opera- [Only for machines equipped with IRIDIUM]
tion of a machine being delivered and assem-
bled in the field, or prior to resumption of its a VHMS controller (1) and IRIDIUM terminal
operation after a long time of storage. (2) are installed in the right side stand of
a Machine data collected with VHMS controller the operator seat.
pering appropriate use of VHMS data. The ini-
tial setting, therefore, is a must.
a For the installation procedure of the VHMS ini-
tial setting program to a PC, refer to the opera-
tion and maintenance manual being bundled
with the service kit ZB1.
a In the procedure, service menus of the
machine monitor are used. Thus, it is advis-
able to reference the information contained in
the "Special functions of machine monitor" to
understand their procedure beforehand.
a The initial setting procedure is described in the
IRIDIUM installation specification and the IRID-
IUM-less specification. When using the IRID-
IUM installation specification, implement the
procedures needed for VHMS alone, bypass-
ing those prepared only for IRIDIUM installa-
tion specification.
ing the VHMS initial setting work check sheet.
30-104 24 WD600-6
VHMS controller initial setting procedure (IRIDIUM installation specification) SEN05048-05
2. Connecting a PC 3. Confirming VHMS controller operation and

a This work is done inside the cab. confirming satellite capturing state
1) Make sure the starting switch is at OFF a This work is done inside the cab.
position. a Confirmation of capturing of the satellite is
k Before connecting or disconnect- done for [IRIDIUM installation specifica-
ing a PC, be sure to turn off the tion].
starting switch. 1) Turn the starting switch ON.
2) With personal computer ZB4 switched 2) Check the controller for normal operation
ON, connect it to download connector referencing 7-segment LED of VHMS con-
DPC7 by wiring harness ZB3. troller.
a Connect RS232C terminal of the PC. a VHMS controller is fed with switch
a If the personal computer does not power supply. Thus, its operation is
have the connection port for RS232C judged normal if its 7-segment LED
terminal, connect by using RS232C- starts flashing while rotating as the
USB conversion cable ZB5. starting switch is turned on and then if
(To use the USB conversion cable, its the controller starts counting in the
driver must be installed to the per- ascending order.
sonal computer.)
3) Among the 7-segment LED situated in the

right side of VHMS controller, refer to the
a Download connector DLF is installed one that represents the decimal point to
in the front side of the right stand of check whether or not IRIDIUM controller
operator seat. has captured the communication satellite.
[IRIDIUM installation specification]
a Check whether or not IRIDIUM con-
troller is capturing the communica-
tion satellite from VHMS controller.
a It is successfully capturing the satel-
lite when the LED representing the
decimal point in the right side 7-seg-
ment LED is flashing.
WD600-6 30-104 25
4. Starting the VHMS initial setting tool 5. Initial setting of VHMS controller (Ver. 3. 5. 2. 1
a This work is done inside the cab (from PC). or older version)
1) Operating [VHMS initial setting tool] icon on a This work is done inside the cab (from
the PC, start up the VHMS initial setting tool. PC).
Important ify the data of service meter [SMR].
a Appearance of the setup screen of [Machine Information]
the VHMS setting tool depends its 1) Open [Machine Information] tab.
tool. a [Data clear and Set up] menu displays
a When using Ver.3.5.2.1 or older ver- [Machine Information] tab first.
sion (CD-ROM), the setting proce- 2) Check every data for correctness.
dure shall conform to that described
in Section 5.
a When using an update version
(Ver.3.5.2.1 or after), the procedure in
Section 6 shall be used.
a It is recommended to download the
latest VHMS version from WebCARE
to update the currently used version.
(Related material: PARTS & SER-
VICE OPERAT ION TIPS SEK N-
5052)
2) Enter the 10-digit service ID to [Service ID].
a Service ID: 7826119000
3) Select [Data clear and Set up] from
[Select Function] item.
4) Click [OK] button to proceed to the setup
screen.
3) When [Date/Time] information is not appro-
priate, correct it in the following manner.
1] Press [Edit] button in the lower right
side of [Date/Time] box to display the
correction screen.
2] After correcting it to the correct infor-
30-104 26 WD600-6
4) When [Machine Information] information is [Communication Setting] [IRIDIUM installation

not appropriate, correct it in the following specification only]
manner. a This setting shall be implemented after the
1] Press [Edit] button in the lower right request for station opening has been made
side of [Machine Information] dialog and station of IRIDIUM has been opened.
box to display the correction screen. 6) Open [Communication Setting] tab.
2] After correcting it to the correct infor- 7) Check every data for correctness.
5) As every data in [Machine Information]

has been checked and corrected, press
[Apply] button to settle the setting.
a As [Apply] button is pressed, a mes-
sage confirming above setting will
appear on the screen. Check the set- 8) When modifying the setting of [SHORT
ting again and, if the setting is correct, FAULT HISTORY], employ the following
press [OK] button. procedure.
a IRIDIUM installation specification 1] Select [SHORT FAULT HISTORY] from
requires the settlement operation after the screen and then press [Edit] button
[Communication Setting] is completed. in the lower left side of [File Transfer
Setting] block to display the setup
screen.
a In the initial setting, select [Occur-
rence] from [Timing] item and then
set the function to ON.
WD600-6 30-104 27
9) When modifying the setting of [SHORT 11) As every data in [Communication Setting]
TREND ANALYSIS], employ the following has been checked and corrected, press
procedure. [Apply] button to settle the setting.
1] Select [SHORT TREND ANALYSIS] a As [Apply] button is pressed, a mes-
from the screen and then press [Edit] sage confirming above setting will
button in the lower left side of [File appear on the screen. Check the set-
Transfer Setting] block to display the ting again and, if the setting is correct,
setup screen. press [OK] button.
a In the initial setting, enter [20h] to
[SMR] and then set the function to
ON.
10) When modifying the setting of [Satellite 12) As every data in [Machine Information]
Setting], employ the following procedure. and [Communication Setting] has been
1] Press [Edit] button in the [Satellite checked and corrected, press [Exit] button
Setting] block to display the correc- to end [VHMS initial setting tool].
tion screen.
2] Set the GCC code to the region
applied and, as setting is completed,
press [OK] button.

1 America 122 Korea
30-104 28 WD600-6
6. Initial setting of VHMS controller (Ver. 3. 5. 2. 1 3) Confirm the machine information and, if
or later version) they are correct, press [Next] button.
ify the data of service meter [SMR].
1) Select [VHMS Setting] and then press
[Next] button.
a When VHMS has been installed later,

it is required to enter the information
such as [Serial No.].
2) Select [Set up & All clear] and press [Next]

button.
WD600-6 30-104 29
4) Select the time zone. 8) If there is no problem in the setting dis-

5) Enter the local time. played last, press [Apply] button.
6) When DST (Daylight Saving Time) (or
summer time) is currently used, press
[Next] button.
a Selecting DST advances the clock by
an hour. Thus, correction of the time
is needed again.
9) A screen message will confirm whether or

not the data before the setting is to be
saved. If the data is not necessary, select
[NO].
7) Set the GCC code to the target region of

application and, as setting is completed,

1 America 122 Korea
10) As correction of the first setting is com-

pleted, press [OK] button to end the pro-
gram.
30-104 30 WD600-6

Check that the 7-segment LED of the
VHMS controller keeps displaying for sev-
eral seconds and then goes off securely.
12) Opening station request of IRIDIUM termi-

nal
Fill in the necessary matters in the paper of
“VHMS request of IRIDIUM terminal” and
send KOMTRAX Support, Komatsu Ltd. by
mail.
WD600-6 30-104 31
a To activate IRIDIUM terminal, please fill in the below form and send by e-mail to KOMTRAX Support,
Komatsu Ltd.
To: KOMTRAX Support, Komatsu Ltd.

Address 2-3-6, Akasaka Minato-ku Tokyo, Japan Important
E-mail JP00MB_cs_kom@global.komatsu
VHMS Request for IRIDIUM Terminal

To activate IRIDIUM terminal, please fill in the below form and send by e-mail to KOMTRAX Support, Komatsu Ltd.
Terminal Info.
Terminal Part Number P/N (Please fill in terminal P/N & S/N or put on enclosed sticker
here)
Terminal S/N S/N
Terminal Activation Date (YY/MM/DD) / /

Country to use
Machine Info. Model-Type-#S/N – #
With GPS Antenna Yes / No
DB Info.
DB’s Contact Address
DB’s Name
E-mail Address
Subsidiary Info.
Subsidiary’s Contact Address
Subsidiary’s Name
E-mail Address
Signature
Notes)
It will take one or two weeks to activate after being received this sheet.
IRIDIUM terminal is unable to communicate before activation being completed.
30-104 32 WD600-6
7. Quick Pm clinic implementation procedure 6) Press the buzzer cancel switch [U] to
a Quick Pm denotes the Pm click done by start the snapshot.
use of the manual snapshot function of the a As the snapshot is started, the upper
machine monitor. column starts displaying the elapsed
a It stores 7 minutes and 30 seconds worth time.
of data to VHMS controller. a [–] in the leftmost position of the lower
k Park the machine in a flat place. column is replaced with [*] for every
30 seconds. When 2 or more [*] signs
1) Start the engine. are displayed, the rightmost one
2) Switch the machine monitor to Service flashes.
menu. a When stopping the snapshot currently
a For the procedure of opening Service taking place, press the buzzer cancel
menu, see "Special functions of switch [t].
machine monitor (EMMS)".
3) Display the manual snapshot function
mode.
7) After the snapshot is started, operate the

machine according to the following table.
a Make sure the engine coolant tem-
perature and torque converter oil tem-
4) Press the buzzer cancel switch [U]. perature are within the operating
5) [READY] will be displayed on the screen, range.
turning on the standby mode. a After 10th [*] is displayed (5 minutes
a The lower column displays 15 pieces elapsed from the start), [#] will be dis-
of [–] sign. played for 11th through 15th posi-
tions.
q #: Indicates the data sampling interval
is once every 1 second.
WD600-6 30-104 33
a Machine operation for snapshot
Machine operation
No. Start End
Machine status Power mode Work equipment
1 0:00 1:00 Low idle OFF —
2 1:00 1:30 Hi idle OFF —
3 1:30 2:00 Hi idle ON —
4 2:00 2:30 Low idle ON Right steering
5 2:30 3:00 Hi idle ON Right steering
6 3:00 3:30 Low idle ON Left steering
7 3:30 4:00 Hi idle ON Left steering
8 4:00 4:30 Low idle ON Blade relief
9 4:30 5:00 Hi idle ON Blade relief
10 5:00 5:30 T/C stall (Note 1) ON —
11 5:30 6:00 Hi idle ON —
12 6:00 6:30 T/C stall (Note 1) ON Blade relief
13 6:30 7:00 Hi idle ON Foot brake operation (Note 2)
14 7:00 7:30 Low idle ON Foot brake operation (Note 2)
(Note 1): 1) Set the auto-shift and manual selector switch to the manual.
2) Press the brake pedal fully, set the lever to F4 (forward at 4th) and set the engine to high idle.
(Note 2): Repeat pumping of the foot brake 20 times.
30-104 34 WD600-6
8) As 7 minutes and 30 seconds elapsed

is restored in 5 seconds. (End of snap-
shot)
WD600-6 30-104 35
Important 10) Open the quick Pm data to draw a graph.

Data of quick Pm are recorded only once. a Select time for X-axis and select the
Thus, if another quick PM is repeated, the cur- following for Y-axis.
rent data will be overwritten with the last one. q Engine speed
In order to avoid above trouble, be sure to q Fuel Inject (fuel injection)
download data of every completed quick Pm q Blowby Press (Blow-by pressure)
shall to PC. For the procedure, see 8. Down- q F Exhaust Temp (Exhaust temperature
load of setting data. 1, 2 and 3 cylinders)
q R Exhaust Temp (Exhaust tempera-
9) Read the quick PM data by use of the ture 4, 5 and 6 cylinders)
analysis tool. q Engine Oil Temp (Engine oil tempera-
a For detailed usage of the analysis ture)
tool, see the operation and mainte- q Engine Oil Press (Engine oil pres-
nance manual. sure)
q Coolant Temp (Engine coolant tem-
perature)
q Boost Press (Boost pressure)
q Accelerator Pos (Accelerator angle)
q Ambient Temp (Ambient temperature)
q Loader Pump P (Work equipment oil
pressure)
q ST Pump Press (Steering oil pressure)
q Hyd Oil Temp (Hydraulic oil tempera-
ture)
q Boom Angle (Lift arm angle)
q Frame Angle (Frame angle)
q T/M Out Speed (Transmission output
speed)
q Shift Indicator (Shift position)
q Lock Up Signal (Lockup signal)
q T/C Oil Temp (Torque converter oil
temperature)
30-104 36 WD600-6
11) Apply a check mark to the Display graph

value at clicked position.
WD600-6 30-104 37
12) Clicking the graph shows, below the

graph, the X-axis value of respective mea-
surement items. (An example of a graph
displayed – Not an actual one)
30-104 38 WD600-6
13) Record above values in the Pm clinic inspection sheet.

a Following shows the relation between the data needed for Pm clinic and the measuring condi-
tions.
Transmission modulation pressure

Measurement items
Exhaust gas temperature
Steering pump pressure
Rear brake temperature

Loader pump pressure
Front brake pressure

Engine oil pressure
Blow-by pressure
Boost pressure
Engine speed
E/P
Machine operation
mode
Low idle E-mode Q Q Q
Hi idle E-mode Q Q
Hi idle P-mode Q Q
Right steering + low idle P-mode Q
Right steering + high idle P-mode Q
Left steering + low idle P-mode Q
Left steering + high idle P-mode Q
Torque converter stall (Note 1) P-mode Q Q Q Q
Hi idle P-mode
Torque converter stall + blade relief P-mode Q Q Q Q
Foot brake operation (Note 2) + high idle P-mode Q Q
Foot brake operation (Note 2) + low idle P-mode Q Q
WD600-6 30-104 39
8. Download of setting data

1) Using harness [1] of service kit ZB1, con-
nect PC ZB4 to download connector DLF
in the cab or download connector VDL on
the ground.
2) When using download connector DLF in

the cab, set the starting switch to ON posi-
tion.
3) When using download connector VDL on
the ground, set switch (4) to ON position.
a Download connector DLF in the cab a The green LED will come on.
is installed in the front side of the right
stand of operator seat.
4) Operating [VHMS analysis tool] on PC,

start up the VHMS analysis tool.
a Download connector VDL on the
ground is provided under cover (3) in
the accumulator installation position,
which is located on the left side of the
machine body.
30-104 40 WD600-6
a Enter [User Name] and [Password]. 9. Confirmation of download data

a For the operating procedure, see the 1) Check the setting data using [View] function.
VHMS analysis tool operation and a For the operating procedure, see the
maintenance manual. VHMS analysis tool operation and
maintenance manual.
a Make sure that [MFA0] code, which
was used in the quick snapshot, is
indicated in [Fault History].
a Make sure the snap shot data are
recorded.
5) Using [Download] function, download the

data currently recorded on VHMS to PC.
a For the operating procedure, see the
VHMS analysis tool operation and
maintenance manual. 2) As check of the setting data is finished,
a After making sure the download is end [VHMS analysis tool].
complete, proceed to the next step.
WD600-6 30-104 41
10. Disconnecting the PC

1) Make sure the starting switch is at OFF
position.
k Before connecting or disconnect-
ing a PC, be sure to turn off the
starting switch.
2) End the OS of PC ZB4 and then turn off
the PC power.
11. Report to Komatsu

As steps 1 – 9 are completed, send VHMS/
WebCARE setting report to VHMS/WebCARE
Support in Komatsu Headquarters.
a This report is a must since setting on the
receiving end in the satellite communica-
tion must be done by Komatsu.
a In this case, send VHMS data via Notes
3) When the data was download into the cab, (LAN) or E-mail (WAN).
disconnect harness [1] of service kit ZB1 Komatsu VHMS/WebCARE Support
from download connector DLF.

4) When the data was download to the

ground, disconnect harness [1] of service
kit ZB1 from download connector VDL
30-104 42 WD600-6

DB/branch
VHMS Initial Setting Work Check Sheet office name
Data entered by:
Model name
Serial No.
Confirmation of machine body and
1 Engine serial No.
component nameplates
Transmission controller serial No.

controller
operation
rotation)
Is "Data Clear and Set up" selected for the setting tool
4 Starting of VHMS initial setting tool yes no
mode?
Initial setting of VHMS controller Is model name identical with machine body? yes no
Is machine body serial No. correctly entered? yes no
(Setting of machine body informa- Is engine serial No. correctly entered? yes no
5 tion)
In this step, basic machine body Is today's date entered? yes no
information are set on VHMS con- Is current time entered? yes no
troller
Is SMR correctly entered? yes no
6 Saving of settings Is LED (7-segment) turned off? yes no
7 Confirmation of VHMS function Is LED operation normal? yes no
Is service mode "SNAPSHOT" turned on and is the

8 Execution of quick Pm yes no
switch hit?
10 Download Is LED operation normal? yes no
Are all files downloaded? yes no

Hour, min-
The time downloaded (Reference wrist watch)
ute:
[Confirmation of data]
11 Confirmation of download data
Is [MFA0] error present in Fault History? yes no
Are SMR and time in Fault History consistent with set-
yes no
tings?
Is any data missing in Snap Shot0? yes no
WD600-6 30-104 43

DB/branch
IRIDIUM Station Opening Work office name
Check Sheet Data entered by:
Model name
Serial No.
Confirmation of machine body and Engine serial No.
1
component nameplates Transmission serial No.
IRIDIUM terminal serial No.

controller
operation
rotation)
4 Starting of VHMS initial setting tool Is "Set up" selected for the setting tool mode? yes no
Entry of setting to S.Fault History

Initial setting of VHMS controller Presence/absence of communication On Off
1. Setting of communication
(Setting of machine body infor- Number of cases (Default is 8 cases)
mation and PLM are completed) Entry of setting of S.Trend Analysis setting
Interval (Default is 20H)
5
Entry of setting of S.Payload data
Tabulation start time
Interval of tabulation (in days) day
2. Setting for start of communica-
Is GCC code set? (130 for Japan) yes no
tion
6 Saving of settings Is LED (7-segment) turned off after data was stored? yes no
How is decimal point display in VHMS monitor

IRIDIUM controller performance
7 (7-segment)? yes no
check
(OFF, ON, long/short flashing)
30-104 44 WD600-6
WD600-6 30-104 45
SEN05048-05 Precautions for replacing VHMS controller
Precautions for replacing VHMS 2. Confirmation, saving and loading of VHMS

controller 1
controller setting information (Ver. 3. 5. 2. 1 or
older version)
a Care should be paid to the following equipment a This work is done inside the cab (from PC).
when replacing VHMS controller a Setting information is saved from the
VHMS controller to be replaced to the PC
Symbol Part No. Part name and the saved information is loaded to the
1 799-608-3101 Service kit new VHMS controller after the replace-
ment.
2 799-608-3210 • Diskette
2-1. Confirmation and saving of VHMS controller
ZB 3 799-608-3220 • Wiring harness setting information prior to replacement
Commercially Note type PC 1) Connect the PC and start the VHMS initial
4
available (Windows 98/2000/Me/XP) setting tool.
a See the "VHMS controller initial set-
a When it is required to replace a VHMS control- ting procedure" for this operation.
ler, setup of the replacing VHMS controller 2) Select [Save/Load] and press [OK] button.
shall be conducted before and after the
replacement according to the following proce-
dure.
a Machine data collected with VHMS controller
pering appropriate use of VHMS data. Setting
work after replacement, therefore, is a must.
ing the "VHMS initial setting work check
sheet".
[Operations needed prior to replacement of

VHMS controller]
1. Download of the remaining data
a Using [Download] function, download the 3) Confirm every information before the
currently recorded and remained data on replacement.
VHMS to PC. 4) Select [Save] from [File] of the menu.
a For the operating procedure, refer to "8.
Download of setting data" in "VHMS con-
troller initial setting procedure".
30-104 46 WD600-6
Precautions for replacing VHMS controller SEN05048-05
2-2. Loading the setting information to the replacing

VHMS controller
1) Connect the PC again and start the VHMS
initial setting tool.
ting procedure" for this operation.
2) Select [Save/Load] and press [OK] button.
5) Reconfirm the information and then press

[OK] button to save the information.
3) Select [Load] from [File] of the menu.
6) Select [Exit] from [File] of the menu to end

the VHMS setting tool.
7) Disconnect the PC.
a Refer to "10. Disconnecting the PC"
in "VHMS controller initial setting pro-
cedure".
8) Turns the PC power off.
9) Proceed to replacement of VHMS control-
lers.
WD600-6 30-104 47
4) Currently saved information will be dis- 7) After adjusting time, press [OK] button.
played. Press [OK] button.
8) Press [Apply] button to display contents of

the setting. Check the setting again and, if
it is acceptable, press [OK] button.
5) Display the saved information on another

screen.
6) Press [Edit] button and adjust the time.
30-104 48 WD600-6
9) The confirmation screen will ask whether 3. Confirmation, saving and loading of VHMS
or not the data before the above setup is controller setting information (Ver. 3. 5. 2. 1
to be saved. Press [NO] button. or later version)
a It is not necessary to save the data before a This work is done inside the cab (from PC).
the setting. a Setting information is saved from the VHMS
controller to be replaced to the PC and the
saved information is loaded to the new
VHMS controller after the replacement.
3-1. Confirmation of VHMS controller setting infor-
mation prior to replacement
1) Connect the PC and start the VHMS initial
setting tool.
2) Select [When VHMS needs to be replaced]
and then press [Next] button.
10) The setup result is displayed. Confirm the

contents and press [Close] button.
3) Select [Save current setting before

replacement of VHMS controller] and
11) Select [Exit] from [File] of the menu to end

the VHMS initial setting tool.
WD600-6 30-104 49
4) Confirm every information before the 3) Select [Use previous setting after replace-
replacement and then press [Save] but- ment of VHMS controller] and press [Next]
ton. button.
5) Select [Exit] from [File] of the menu to end 4) Currently saved information will be dis-
the VHMS initial setting tool. played. Press [Next] button.
6) Disconnect the PC.
a Refer to "10. Disconnecting the PC"
in "VHMS controller initial setting pro-
cedure".
7) Turns the PC power off.
8) Proceed to replacement of VHMS control-
lers.
3-2. Loading the setting information to the replacing

VHMS controller
1) Connect the PC again and start the VHMS
initial setting tool.
2) Select [When VHMS needs to be
replaced] and then press [Next] button.
5) Adjust the time and press [Apply] button.
30-104 50 WD600-6
6) The confirmation screen will ask whether [Operations needed after replacement of VHMS
or not the data before the above setup is controller]
to be saved. Press [NO] button. a Execute the quick Pm referring "7. Executing
a It is not necessary to save the data quick Pm" in "VHMS controller initial setting
before the setting. procedure".
a Download the data referring "8. Download of
setting data" in "VHMS controller initial setting
procedure".
a After the replacement, send VHMS/WebCARE
setting report sheet to VHMS/WebCARE Sup-
port in Komatsu Headquarters.
a Also send two sets of data, the downloaded
before and after the VHMS replacement, via
Notes (LAN) or E-mail (WAN).
Komatsu VHMS/WebCARE Support

7) The above completes modification of the

setting. Press [OK] button to end the
VHMS initial setting tool.
WD600-6 30-104 51
SEN05048-05 Pm-clinic inspection table
Pm-clinic inspection table 1
WD600-6 Serial No. 55001 and up

Machine serial No. #
Engine serial No.

hour inspection SAA6D170E-5 #
Work instruction No. Date of execution Service meter Inspector
Year: Month: Day: hours
Interview with operator and walk-around check

Is there abnormality before starting inspection? Outside temperature
Max. °C
Min. °C
Altitude m
Maximum coolant temperature (overheated)? Maximum torque converter oil temperature

(During operation) (overheated)? (During operation)
a If machine is cold, warm it up.
a Working mode: P-mode
Standard
Service limit Measurement
Item Condition Unit value for new Good Bad
value result
machine
Engine at low idle 775 – 825 775 – 825
Engine at high idle 1,950 – 2,050 1,950 – 2,050
Engine at high idle and torque converter
1,700 – 1,900 1,600 – 2,000
stalled
Engine speed rpm
Engine at high idle and work equipment
1,840 – 2,040 1,740 – 2,140
relieved
Torque converter stalled + Work equipment
1,580 – 1,780 1,380 – 1,980
relieved
Engine
Engine at high idle and torque converter kPa Max. 3.43 9.4
Blow-by pressure
stalled {mmH2O} {Max. 350} {960}
Min. 0.34 0.21
Engine at high idle
Lubricating oil MPa {Min. 3.5} {2.1}
SAE15W-40
pressure {kg/cm2} Min. 0.1 0.08
Engine at low idle
{Min. 1.0} {0.8}
kPa Min. 126.6 Min. 113.3
Boost pressure Engine at rated output (P-mode)
{mmHg} {Min. 950} {Min. 850}
Exhaust Engine at high idle and toque converter stalled
°C Max. 650 700
temperature Outside temperature: 20°C
a When shifting transmission gear to forward/reverse position, apply brake securely. Good Bad
• Torque converter oil Min. 3.09 Min. 3.09
Low idle
Main relief temperature: Within {Min. 31.5} {Min. 31.5}
pressure operating range 3.65 ± 0.2 3.65 ± 0.2
High idle • Working mode: P-mode {37.2 ± 2.0} {37.2 ± 2.0}
Torque converter inlet port oil 0.94 ± 0.2 0.94 ± 0.2
pressure {9.6 ± 2.0} {9.6 ± 2.0}
• Torque converter oil
Torque converter outlet port oil temperature: Within 0.57 ± 0.1 0.57 ± 0.1
pressure operating range {5.8 ± 1.0} {5.8 ± 1.0}
• Working mode: P-mode 2.48 ± 0.2 2.48 ± 0.2
Modulation clutch oil pressure • Engine speed: {25.3 ± 2.0} {25.3 ± 2.0}
Transmission valve
High idle
0.12 ± 0.06 0.12 ± 0.06
Lubrication oil pressure
{1.2 ± 0.6} {1.2 ± 0.6}
MPa 2.68 ± 0.2 2.68 ± 0.2
F clutch
{kg/cm2} {27.3 ± 2} {27.3 ± 2}
3.12 ± 0.2 3.12 ± 0.2
R clutch
{31.8 ± 2.0} {31.8 ± 2.0}
• Torque converter oil 3.07 ± 0.2 3.07 ± 0.2
1st clutch temperature: {31.3 ± 2.0} {31.3 ± 2.0}
ECMV output Within operating range
2.09 ± 0.2 2.09 ± 0.2
(clutch) oil 2nd clutch • Working mode: P-mode
{31.3 ± 2.0} {31.3 ± 2.0}
pressure • Engine speed:
High idle 3.07 ± 0.2 3.07 ± 0.2
3rd clutch
• Manual switch: ON {31.3 ± 2.0} {31.3 ± 2.0}
3.07 ± 0.2 3.07 ± 0.2
4th clutch
{31.3 ± 2.0} {31.3 ± 2.0}
1.84 ± 0.2 1.84 ± 0.2
Lockup clutch
{18.8 ± 2.0} {18.8 ± 2.0}
30-104 52 WD600-6
Pm-clinic inspection table SEN05048-05
Pm-clinic inspection table

WD600-6 Serial No. 55001 and up
Standard
Service limit Measurement
Item Condition Unit value for new Good Bad
value result
machine
Secure frame with frame lock bar.
Steering relief Hydraulic oil temperature: 45 – 55°C 32.32 – 34.28 31.32 – 34.28
Steering
pressure Engine speed at high idle {330 – 350} {320 – 350}

MPa
Hydraulic oil temperature: 45 – 55°C {kg/cm2}
AJSS EPC 2.35 – 2.55 2.25 – 2.65
Engine speed at high idle
pressure {24 – 26} {23 – 27}
Operating AJSS fully
Parking brake inlet Min. 2.45 Min. 2.45
pressure {Min. 25.0} {Min. 25.0}
Parking brake pilot Torque converter oil temperature: Min. 3.09 Min. 3.09
MPa
pressure Within operating range {Min. 31.5} {Min. 31.5}
{kg/cm2}
Engine speed: Low idle
Parking brake sole-
Min. 2.45 Min. 2.45
noid valve output
{Min. 25.0} {Min. 25.0}
pressure
Tire inflation pressure: Specified pressure
Parking brake Test on flat and dry paved slope of 1/5
— Stopped Stopped
performance (11° 20').
Set machine in operating state.
Disc thickness mm 3.2 ± 0.08 Min. 2.97
Measure when
Charge cut-in brake oil pres- 5.88 – 6.37 5.39 – 6.86
pressure Hydraulic oil tempera- sure warning {60 – 65} {55 – 70}
ture: Within operating lamp goes off.
range Measure when
Brake
Engine at low idle MPa

Charge cut-out brake oil pres- 9.8 – 10.78 9.31 – 11.27
{kg/cm2}
pressure sure starts low- {100 – 110} {95 – 115}
ering after rising.
Hydraulic oil temperature: Within operating
4.9 – 5.59 4.7 – 5.78
Brake oil pressure range
{50 – 57} {48 – 59}
Engine at low idle
Engine: Stopped
Lowering of brake kPa Max. 0.49 Max. 0.49
Measure lowering of oil pressure from 4.9
oil pressure {kg/cm2} {Max. 5} {Max. 5}
MPa {50 kg/cm2} in 5 minutes.
Tire inflation pressure: Specified pressure
Test on flat, level, straight, and dry paved
road.
Wheel brake Braking initial speed: 20km/h,
m Max. 5 Max. 5
performance Delay in pressing pedal: Max 0.1 sec
Brake pedal pressing force:
Specified force, 294 ± 29.4 Nm {30 ± 3 kg}
Measure braking distance.
Wear of wheel
Measure with disc wear indicator. mm 0 Max. 5.5
brake disc
24.5 (+0.5/ 24.5 (+0.5/
Work equipment Blade circuit
–0.5) –0.5)
valve relief pressure relieved
MPa {250 (+5/–5)} {250 (+5/–5)}
Work equipment {kg/cm2}
Blade lift lever at 1.47 – 1.87 1.28 – 2.06
valve LS differential
half stroke {15 – 19} {13 – 21}
pressure
Hydraulic oil tem-
Work equipment
perature: 45 – 55°C Rising time 1.7 – 2.3 Max. 3

Blade lift speed Engine at high idle Lowering time 1.0 – 1.6 Max. 2.0
RH tilt 0.8 – 1.4 1.7
Blade tilt speed sec
LH tilt 0.5 – 1.1 1.2
Pitch forward time 1.8 – 2.4 Max. 3.2
Blade pitch speed
Pitch rear time 1.3 – 1.9 Max. 2.4
Hydraulic oil tem-
Hydraulic drift of perature: Within mm/
Tip of blade Max. 65 Max. 100
work equipment operating range 15 min.
Engine: Stopped
Visual check of Front axle There must not be
Axle
—
differential drain plug Rear axle excessive metal powder.
WD600-6 30-104 53
SEN05048-05
WD600-6 Wheel dozer

©2019 KOMATSU
All Rights Reserved
30-104 54
SEN05049-01
WHEEL DOZER
WD600-6

WD600-6 55001 and up
40 Troubleshooting 40
100 Failure code table and fuse locations

Failure codes list ............................................................................................................................................. 2
Fuse locations............................................................................................................................................... 14
WD600-6 40-100 1
SEN05049-01 Failure codes list
Failure codes list 1
Failure Action Category of

Troubled part Trouble Controller
code code record
Electrical
1500L0 TORQFLOW transmission Double meshing TM E03
system
Mechanical
15B0NX Transmission filter Clogging MON E01
system
When command current is Electrical
15SAL1 ECMV F clutch TM E03
OFF, fill signal is ON system
15SALH ECMV F clutch TM E01
ON, fill signal is OFF system
15SBL1 ECMV R clutch TM E03
15SBLH ECMV R clutch TM E01
15SEL1 ECMV 1st clutch TM E03
15SELH ECMV 1st clutch TM E01
15SFL1 ECMV 2nd clutch TM E03
15SFLH ECMV 2nd clutch TM E01
15SGL1 ECMV 3rd clutch TM E03
15SGLH ECMV 3rd clutch TM E01
15SHL1 ECMV 4th clutch TM E03
15SHLH ECMV 4th clutch TM E01
Mechanical
15W0NT Transmission modulation clutch Overheat TM E02
system
Electrical
2F00MA Parking brake Malfunction MON E03
system
Mechanical
2G42ZG Front accumulator Low oil pressure MON E03
system
Mechanical
2G43ZG Rear accumulator Low oil pressure MON E03
system
VHMS system
A000N1 Engine Overrun VHMS —
(n201)
Mechanical
AA1ANX Air cleaner Clogging MON E01
system
Signal disagrees with Electrical
AB00L6 Alternator MON E03
operating state of engine system
Mechanical
AB00MA Alternator Malfunction MON E03
system
Mechanical
B@BAZG Engine oil Low oil pressure ENG E03
system
Mechanical
B@BAZK Engine oil Low level MON E01
system
40-100 2 WD600-6
Failure codes list SEN05049-01

code code record
Mechanical
B@BCNS Coolant Overheating ENG E02
system
Mechanical
B@BCZK Coolant Low level MON E01
system
Mechanical
B@C7NS Brake oil Overheating MON E02
system
Mechanical
b@CENS Torque converter oil Overheating MON E02
system
Mechanical
B@CENS Torque converter oil Overheating MON E02
system
Mechanical
B@GAZK Battery electrolyte Low level MON E01
system
Mechanical
B@HANS Hydraulic oil Overheating MON E02
system
Electrical
CA111 Abnormality in engine controller — ENG E03
system
Electrical
CA115 Engine Ne or Bkup speed sensor error — ENG E03
system
Charge (boost) pressure sensor high Electrical
CA122 — ENG E03
error system
Electrical
CA123 Charge (boost) pressure sensor low error — ENG E03
system
Electrical
CA131 Throttle sensor high error — ENG E03
system
Electrical
CA132 Throttle sensor low error — ENG E03
system
Electrical
CA135 Oil pressure sensor high error — ENG E01
system
Electrical
CA141 Oil pressure sensor low error — ENG E01
system
Electrical
CA144 Coolant temperature sensor high error — ENG E01
system
Electrical
CA145 Coolant temperature sensor low error — ENG E01
system
Charge (boost) temperature sensor high Electrical
CA153 — ENG E01
error system
Charge (boost) temperature sensor low Electrical
CA154 — ENG E01
error system
Electrical
CA187 Sensor power supply 2 low error — ENG E03
system
Engine oil pressure sensor high error Electrical
CA212 — ENG E01
(VHMS) system
Engine oil pressure sensor low error Electrical
CA213 — ENG E01
(VHMS) system
Electrical
CA221 Ambient pressure sensor high error — ENG E01
system
Electrical
CA222 Ambient pressure sensor low error — ENG E01
system
Electrical
CA227 Sensor power supply 2 voltage high error — ENG E03
system
WD600-6 40-100 3

code code record
Electrical
CA234 Engine overspeed — ENG E02
system
Ne speed sensor supply power voltage Electrical
CA238 — ENG E03
error system
Electrical
CA263 Fuel temperature sensor high error — ENG E01
system
Electrical
CA265 Fuel temperature sensor low error — ENG E01
system
Electrical
CA271 PCV1 short circuit — ENG E03
system
Electrical
CA272 PCV1 disconnection — ENG E03
system
Electrical
CA273 PCV2 short circuit — ENG E03
system
Electrical
CA274 PCV2 disconnection — ENG E03
system
Electrical
CA322 Injector #1 open/short error — ENG E03
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
CA342 Calibration code incompatibility — ENG E03
system
Electrical
CA351 Injectors drive circuit error — ENG E03
system
Electrical
CA352 Sensor power supply 1 voltage low error — ENG E03
system
Electrical
CA386 Sensor power supply 1 voltage high error — ENG E03
system
Electrical
CA431 Idle validation switch error — ENG E01
system
Electrical
CA432 Idle validation action error — ENG E03
system
Electrical
CA441 Battery voltage low error — ENG E03
system
Electrical
CA442 Battery voltage high error — ENG E03
system
Electrical
CA449 Common rail pressure high error 2 — ENG E03
system
Electrical
CA451 Common rail pressure sensor high error — ENG E03
system
Electrical
CA452 Common rail pressure sensor low error — ENG E03
system
40-100 4 WD600-6

code code record
Electrical
CA553 Common rail pressure high error 1 — ENG E03
system
Common rail pressure sensor in range Electrical
CA554 — ENG E03
error system
Electrical
CA559 Supply pump pressure very low error 1 — ENG E03
system
Electrical
CA689 Engine Ne speed sensor error — ENG E03
system
Electrical
CA731 Engine Bkup speed sensor phase error — ENG E03
system
Electrical
CA757 All continuous data lost error — ENG E03
system
Electrical
CA778 Engine Bkup speed sensor error — ENG E03
system
Electrical
CA1228 EGR valve servo error 1 — ENG E03
system
Electrical
CA1625 EGR valve servo error 2 — ENG E03
system
Electrical
CA1626 Bypass valve solenoid current high error — ENG E03
system
Electrical
CA1627 Bypass valve solenoid current low error — ENG E03
system
Electrical
CA1628 Bypass valve servo error 1 — ENG E03
system
Electrical
CA1629 Bypass valve servo error 2 — ENG E03
system
Electrical
CA1631 Bypass valve lift sensor high error — ENG E03
system
Electrical
CA1632 Bypass valve lift sensor low error — ENG E03
system
Electrical
CA1633 KOMNET datalink timeout error — ENG E03
system
Electrical
CA2185 Throttle sensor supply voltage high error — ENG E03
system
Electrical
CA2186 Throttle sensor supply voltage low error — ENG E03
system
Electrical
CA2249 Supply pump pressure very low error 2 — ENG E03
system
Electrical
CA2271 EGR valve position sensor high error — ENG E03
system
Electrical
CA2272 EGR valve position sensor low error — ENG E03
system
EGR valve solenoid operation short Electrical
CA2351 — ENG E03
circuit system
EGR valve solenoid operation Electrical
CA2352 — ENG E03
disconnection system
Electrical
CA2555 Intake air heater relay open circuit — ENG E01
system
Electrical
CA2556 Intake air heater relay short circuit — ENG E01
system
WD600-6 40-100 5

code code record
Electrical
D191KA AJSS neutral safety relay Disconnection WRK E01
system
Electrical
D191KB AJSS neutral safety relay Short-circuit WRK E01
system
Transmission oil pressure bypass Electrical
D198KA Disconnection TM E01
solenoid system
Transmission oil pressure bypass Electrical
D198KB Short circuit TM E01
solenoid system
Transmission oil pressure bypass Short circuit with power Electrical
D198KY TM E01
solenoid supply line system
Electrical
D5ZHKA Terminal C signal Disconnection TM E01
system
Electrical
D5ZHKB Terminal C signal Short circuit TM E01
system
Disconnection or short Electrical
D5ZHKZ Terminal C signal WRK E01
circuit system
Signal disagrees with
Electrical
D5ZHL6 Terminal C signal engine running or stopped MON E01
system
state
Electrical
DA80L4 Auto grease controller ON/OFF signals disagree MON —
system
Electrical
DAF3KK Machine monitor Low source voltage (input) MON E03
system
Electrical
DAF5KP 5V power source Low output voltage MON E01
system
Defective communication
Electrical
DAFRKR Machine monitor CAN communication (Abnormality in target MON E03
system
component system)
Electrical
DAQ0KK Transmission controller Low source voltage TM E03
system
Electrical
DAQ0KT Transmission controller Abnormality in controller TM E01
system
Transmission controller load power Electrical
DAQ2KK Low source voltage (input) TM E03
supply line system
Transmission controller model selection Disagreement of model
DAQ9KQ MON E03 —
wiring harness selection signals
Transmission controller CAN Electrical
DAQRKR (Abnormality in target TM E03
communication system
component system)
DAQRMA Transmission controller Malfunction TM E03 —
Electrical
DB2RKR Engine controller CAN communication (Abnormality in target TM E03
system
component system)
Electrical
DB90KK Work equipment controller Low source voltage (input) WRK E03
system
Electrical
DB90KT Work equipment controller Abnormality in controller WRK E01
system
Work equipment controller load power Electrical
DB92KK Low source voltage (input) WRK E03
supply line system
Work equipment controller power supply Electrical
DB95KX Out of input signal range WRK E03
output system
40-100 6 WD600-6

code code record
Work equipment controller model Disagreement of model
DB99KQ MON E03 —
selection wiring harness selection signals
Work equipment controller CAN Electrical
DB9RKR (Abnormality in target TM E03
component system)
Work equipment controller CAN
DB9RMA Malfunction MON E03 —
communication
Transmission controller CAN Electrical
DB9RMC Defective operation WRK E03
VHMS system
DBB0KK VHMS controller Low source voltage (input) VHMS —
(n901)
Disagreement of model VHMS system
DBB0KQ VHMS controller VHMS —
selection signals (nF11)
VHMS system
DBB3KK VHMS controller battery power supply Low source voltage (input) VHMS —
(n905)
VHMS system
DBB5KP VHMS controller 5 V power supply output Low output voltage VHMS —
(n904)
VHMS controller 24 V power supply VHMS system
DBB6KP Low output voltage VHMS —
output (n902)
VHMS controller 12 V power supply VHMS system
DBB7KP Low output voltage VHMS —
output (n903)
VHMS system
DBBQKR VHMS controller KOMNET (Abnormality in target VHMS —
(n802)
component system)
Switch is kept pressed for Electrical
DD15LD t switch (Panel switch 1) MON E01
long time system
DD16LD U switch (Panel switch 2) MON E01
long time system
DD17LD < switch (Panel switch 3) MON E01
long time system
DD18LD > switch (Panel switch 4) MON E01
long time system
Electrical
DDA7L4 RPM set ON/OFF switch ON/OFF signals disagree TM E01
system
Electrical
DDA8KB RPM set idle-up/down switch (idle-up) Short circuit TM E01
system
Electrical
DDA9KB RPM set idle-up/down switch (idle-down) Short circuit TM E01
system
Electrical
DDB6L4 Parking brake switch (Neutralizer) ON/OFF signals disagree TM E03
system
DDD1LD Pitch operation switch WRK E01
long time system
Electrical
DDDBKA Traction adjustment dial Disconnection TM E01
system
Electrical
DDDBKB Traction adjustment dial Short circuit TM E01
system
Electrical
DDE5MA Emergency steering drive switch Malfunction MON E01
system
Electrical
DDK4KA AJSS FNR switch Disconnection TM E03
system
WD600-6 40-100 7

code code record
Electrical
DDK4KB AJSS FNR switch Short circuit TM E03
system
Electrical
DDK5L4 AJSS shift-up/down switch ON/OFF signals disagree TM E01
system
Electrical
DDK6KA FNR lever switch Disconnection TM E03
system
Electrical
DDK6KB FNR lever switch Short circuit TM E03
system
Lock detection pressure switch of Electrical
DDP5KA Disconnection TM E01
steering lock lever system
Electrical
DDT0L4 Shift mode selector switch ON/OFF signals disagree TM E01
system
DDW9LD Kick-down switch TM E01
long time system
DDWLLD Hold switch TM E01
long time system
Electrical
DF10KA Transmission shift lever switch Disconnection TM E01
system
Electrical
DF10KB Transmission shift lever switch Short circuit TM E01
system
VHMS system
DGE5KX Atmospheric temperature sensor Out of input signal range VHMS —
(n401)
Electrical
DGF1KA Transmission oil temperature sensor Disconnection TM E01
system
Electrical
DGF1KB Transmission oil temperature sensor Short circuit TM E01
system
Electrical
DGH2KX Hydraulic oil temperature sensor Out of input signal range MON E01
system
Electrical
DGR2KA Rear brake oil temperature sensor Disconnection MON E01
system
Electrical
DGR2KX Rear brake oil temperature sensor Out of input signal range MON E01
system
Electrical
DGT1KA Torque converter oil temperature sensor Disconnection MON E01
system
Electrical
DGT1KB Torque converter oil temperature sensor Short circuit MON E01
system
Electrical
DGT1KX Torque converter oil temperature sensor Out of input signal range MON E01
system
VHMS system
DGT4KA Exhaust gas temperature sensor (F) Disconnection VHMS —
(n312)
VHMS system
DGT4KB Exhaust gas temperature sensor (F) Short circuit VHMS —
(n311)
VHMS system
DGT5KA Exhaust gas temperature sensor (R) Disconnection VHMS —
(n322)
VHMS system
DGT5KB Exhaust gas temperature sensor (R) Short circuit VHMS —
(n321)
Oil pressure sensor of work equipment Electrical
DH21KA Disconnection WRK E01
pump system
Oil pressure sensor of work equipment Electrical
DH21KB Short circuit WRK E01
pump system
40-100 8 WD600-6

code code record
VHMS system
DHE5KB Blow-by pressure sensor Short circuit VHMS —
(n332)
Short circuit with power VHMS system
DHE5KY Blow-by pressure sensor VHMS —
supply line (n331)
Signal disagrees with Electrical
DHT2L6 Transmission filter clogging sensor MON E01
operating state of engine system
VHMS system
DHT8KX Steering oil pressure sensor Out of input signal range VHMS —
(n533)
Electrical
DHTBKA Modulation clutch pressure sensor Disconnection TM E03
system
Electrical
DHTBKB Modulation clutch pressure sensor Short circuit TM E03
system
VHMS system
DHU2KX Front brake oil pressure sensor (F) Out of input signal range VHMS —
(n711)
VHMS system
DHU3KX Rear brake oil pressure sensor (R) Out of input signal range VHMS —
(n712)
Electrical
DK30KA AJSS lever angle sensor Disconnection WRK E01
system
Short circuit with power Electrical
DK30KY AJSS lever angle sensor WRK E01
supply line system
Electrical
DK59KA Lift EPC lever potentiometer (Main) Disconnection WRK E03
system
Lift EPC lever potentiometer Short circuit with power Electrical
DK59KY WRK E03
(Main & Sub) supply line system
Electrical
DK59L8 Lift EPC lever potentiometer (Main) Analog signals disagree WRK E03
system
Electrical
DK5AKA Lift EPC lever potentiometer (Sub) Disconnection WRK E03
system
DK5AKY Lift EPC lever potentiometer (Sub) WRK E03
supply line system
Tilt & pitch EPC lever potentiometer Electrical
DK5BKA Disconnection WRK E03
(Main) system
Tilt & pitch EPC lever potentiometer Short circuit with power Electrical
DK5BKY WRK E03
(Main) supply line system
DK5BL8 Analog signals disagree WRK E03
(Main & Sub) system
DK5CKA Disconnection WRK E03
(Sub) system
Tilt & pitch EPC lever potentiometer Short circuit with power Electrical
DK5CKY WRK E03
(Sub) supply line system
Electrical
DKD0KA Frame angle sensor Disconnection WRK E01
system
DKD0KY Frame angle sensor WRK E01
supply line system
Disconnection or short Electrical
DKD0KZ AJSS lever and frame angle sensor WRK E01
circuit system
Modulation clutch output shaft speed Electrical
DLFAKA Disconnection TM E03
sensor system
Modulation clutch output shaft speed Electrical
DLFALC Speed signals disagree TM E03
sensor system
WD600-6 40-100 9

code code record
Transmission output shaft speed sensor Electrical
DLT3KA Disconnection TM E03
(2) system
DLT3LC Speed signals disagree TM E03
(2) system
DLT4KB Short circuit TM E03
(1) system
DLT4KX Out of input signal range TM E03
(1) system
Electrical
DV00KB Alarm buzzer Short circuit MON E01
system
Electrical
DW4PKA Blade raise EPC solenoid Disconnection WRK E03
system
Electrical
DW4PKB Blade raise EPC solenoid Short circuit WRK E03
system
DW4PKY Blade raise EPC solenoid WRK E03
supply line system
Electrical
DW4QKA Blade lower EPC solenoid Disconnection WRK E03
system
Electrical
DW4QKB Blade lower EPC solenoid Short circuit WRK E03
system
DW4QKY Blade lower EPC solenoid WRK E03
supply line system
Electrical
DW4RKA Tilt LH and pitch REAR EPC solenoid Disconnection WRK E03
system
Electrical
DW4RKB Tilt LH and pitch REAR EPC solenoid Short circuit WRK E03
system
DW4RKY Tilt LH and pitch REAR EPC solenoid WRK E03
supply line system
Tilt RH and pitch FORWARD EPC Electrical
DW4SKA Disconnection WRK E03
solenoid system
Tilt RH and pitch FORWARD EPC Electrical
DW4SKB Short circuit WRK E03
solenoid system
Tilt RH and pitch FORWARD EPC Short circuit with power Electrical
DW4SKY WRK E03
Electrical
DW7BKA Fan reverse solenoid Disconnection TM E01
system
Electrical
DW7BKB Fan reverse solenoid Short circuit TM E01
system
DW7BKY Fan reverse solenoid TM E01
supply line system
Work equipment neutral lock EPC Electrical
DWM1KA Disconnection WRK E01
solenoid system
Work equipment neutral lock EPC Electrical
DWM1KB Short circuit WRK E01
solenoid system
Work equipment neutral lock EPC Short circuit with power Electrical
DWM1KY WRK E01
Electrical
DWN7KA Blade float magnet detent solenoid Disconnection WRK E01
system
Electrical
DWN7KB Blade float magnet detent solenoid Short circuit WRK E01
system
40-100 10 WD600-6

code code record
DWN7KY Blade float magnet detent solenoid WRK E01
supply line system
Modulation clutch cut-off release Electrical
DWNFKA Disconnection TM E01
solenoid system
Modulation clutch cut-off release Electrical
DWNFKB Short circuit TM E01
solenoid system
Modulation clutch cut-off release Short circuit with power Electrical
DWNFKY TM E03
Electrical
DX16KA Fan pump EPC solenoid Disconnection TM E01
system
Electrical
DX16KB Fan pump EPC solenoid Short circuit TM E01
system
DX16KY Fan pump EPC solenoid TM E01
supply line system
Electrical
DXA1KA Pump PC-EPC solenoid Disconnection WRK E01
system
Electrical
DXA1KB Pump PC-EPC solenoid Short circuit WRK E01
system
Electrical
DXF0KA AJSS EPC solenoid Disconnection WRK E01
system
Electrical
DXF0KB AJSS EPC solenoid Short circuit WRK E01
system
Electrical
DXH1KA Lockup ECMV solenoid Disconnection TM E01
system
Electrical
DXH1KB Lockup ECMV solenoid Short circuit TM E01
system
DXH1KY Lockup ECMV solenoid TM E03
supply line system
Electrical
DXH4KA 1st clutch ECMV solenoid Disconnection TM E03
system
Electrical
DXH4KB 1st clutch ECMV solenoid Short circuit TM E03
system
DXH4KY 1st clutch ECMV solenoid TM E03
supply line system
Electrical
DXH5KA 2nd clutch ECMV solenoid Disconnection TM E03
system
Electrical
DXH5KB 2nd clutch ECMV solenoid Short circuit TM E03
system
DXH5KY 2nd clutch ECMV solenoid TM E03
supply line system
Electrical
DXH6KA 3rd clutch ECMV solenoid Disconnection TM E03
system
Electrical
DXH6KB 3rd clutch ECMV solenoid Short circuit TM E03
system
DXH6KY 3rd clutch ECMV solenoid TM E03
supply line system
Electrical
DXH7KA R clutch ECMV solenoid Disconnection TM E03
system
Electrical
DXH7KB R clutch ECMV solenoid Short circuit TM E03
system
WD600-6 40-100 11

code code record
DXH7KY R clutch ECMV solenoid TM E03
supply line system
Electrical
DXH8KA F clutch ECMV solenoid Disconnection TM E03
system
Electrical
DXH8KB F clutch ECMV solenoid Short circuit TM E03
system
DXH8KY F clutch ECMV solenoid TM E03
supply line system
Electrical
DXHHKA 4th clutch ECMV solenoid Disconnection TM E03
system
Electrical
DXHHKB 4th clutch ECMV solenoid Short circuit TM E03
system
DXHHKY 4th clutch ECMV solenoid TM E03
supply line system
Electrical
DXHJKA RH pitch REAR EPC solenoid Disconnection WRK E03
system
Electrical
DXHJKB RH pitch REAR EPC solenoid Short circuit WRK E03
system
DXHJKY RH pitch REAR EPC solenoid WRK E03
supply line system
Electrical
DXHKKA RH pitch FORWARD EPC solenoid Disconnection WRK E03
system
Electrical
DXHKKB RH pitch FORWARD EPC solenoid Short circuit WRK E03
system
DXHKKY RH pitch FORWARD EPC solenoid WRK E03
supply line system
Electrical
DXHPKA Modulation clutch solenoid Disconnection TM E03
system
Electrical
DXHPKB Modulation clutch solenoid Short circuit TM E03
system
DXHPKY Modulation clutch solenoid TM E03
supply line system
Electrical
DXHPMA Modulation clutch solenoid Malfunction TM E01
system
VHMS system
F@BBZL Blow-by pressure High error VHMS —
(n338)
VHMS system
F@BYNR Exhaust gas temperature (F) Abnormal heat VHMS —
(n362)
VHMS system
F@BYNS Exhaust gas temperature (F) Overheating VHMS —
(n361)
VHMS system
F@BZNR Exhaust gas temperature (R) Abnormal heat VHMS —
(n372)
VHMS system
F@BZNS Exhaust gas temperature (R) Overheating VHMS —
(n371)
40-100 12 WD600-6
a Those failure codes to which the corresponding number is not indicated in the action code space are not
displayed on the ordinary screen if a failure is found. They are just recorded in the abnormality record
(electrical system and mechanical system) of the service menu.
a The category of record is used for indicating to which of the electrical and mechanical system of the ser-
vice menu's abnormality record a given failure is classified. VHMS failure codes, which are available
only in VHMS specifications, are stored only in VHMS controller; therefore, they are not recorded in the
abnormality record.
(The VHMS abnormality record can be downloaded by connecting your PC to the VHMS controller.) The
4-digit VHMS failure code enclosed in ( ) indicates an error code that is displayed with two digits on each
7-segment LED of the VHMS controller.
WD600-6 40-100 13
SEN05049-01 Fuse locations
Fuse locations 1
Connection table of fuse box and circuit breaker

a This connection table indicates the devices to which the power of the fuse box and circuit breaker is
supplied. (A switch power supply is a device which supplies power while the starting switch is in the ON
position and a constant power supply is a device which supplies power while the starting switch is in the
OFF and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuse box and
circuit breaker to see if the power is supplied normally.
Fuse box 1
Type of power supply Fuse No. Capacity of fuse Destination of power

1 10 A Starting switch terminal B circuit
2 10 A Hazard lamp circuit
Constant power supply 3 10 A Stair lamp circuit
Circuit breaker CBF1
(30A) 4 10 A Transmission controller (B) circuit
5 10 A Work equipment controller (B) circuit
6 10 A Machine monitor (B), VHMS controller (B) circuit
Switch power supply
7 5A Engine controller circuit
starting switch ACC
8 10 A Horn circuit
9 20 A Air conditioner circuit
10 10 A Auto grease circuit
Switch power supply 11 20 A Rear glass heater circuit
circuit breaker CBF2
(105A) 12 10 A Radio circuit
13 20 A Air suspension seat, DC-DC converter circuit
14 10 A VHMS controller (A) circuit
15 10 A Spare
Fuse box 2

1 10 A Turn signal lamp circuit
2 10 A Back-up lamp and blinking lamp circuit
3 20 A Front working lamp circuit
4 20 A Rear working lamp circuit
Switch power supply 5 10 A Transmission controller (A) circuit

circuit breaker CBF3 6 10 A Parking brake circuit
(105A) 7 10 A Work equipment controller (A) circuit
8 10 A Machine monitor (A) circuit
9 20 A Wiper and washer circuit
10 10 A Spare
11 20 A Main lamp circuit
Relay circuit power 12 10 A Right clearance lamp circuit
supply of small lamp 13 10 A Left clearance lamp circuit
Relay circuit power 14 10 A Right headlamp circuit
supply of small lamp 15 10 A Left headlamp circuit
40-100 14 WD600-6
Fuse locations SEN05049-01
Circuit breaker
Circuit breaker
Type of power supply Breaker capacity Destination of power
No.
Starting switch circuit, work equipment controller circuit,
Constant power supply CBF1 30 A
machine monitor circuit, VHMS controller circuit
Switch power supply CBF2 105 A Fuse box (A): Circuits 8 – 15
Switch power supply CBF3 105 A Fuse box (B): Circuits 1 – 11
Constant power supply CBF4 20 A Engine controller circuit
Locations and numbers of fuse boxes and circuit breakers
WD600-6 40-100 15
SEN05049-01
WD600-6 Wheel dozer

©2016 KOMATSU
All Rights Reserved
40-100 16
SEN05050-01
WHEEL DOZER
WD600-6

WD600-6 55001 and up
200 General information on troubleshooting

Points to remember when performing troubleshooting ................................................................................... 2
How to proceed in troubleshooting ................................................................................................................. 4
Checks before troubleshooting ....................................................................................................................... 6
Classification and procedures of troubleshooting ........................................................................................... 7
Information in troubleshooting table...............................................................................................................11
Troubleshooting method for disconnecting wiring harness of pressure sensor system................................ 13
Phenomena looking like troubles and troubleshooting Nos. ......................................................................... 16
Connection table for connector pin numbers ................................................................................................ 18
T- branch box and T- branch adapter table ................................................................................................... 54
WD600-6 40-200 1
SEN05050-01 Points to remember when performing troubleshooting
Points to remember when performing troubleshooting 1
(Rev. 2014/11)
k Stop the machine on a level place and make sure that the frame lock pin, chocks, parking brake,
etc. are applied normally.
k When performing the operation with 2 or more service technicians, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns,
so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k Before disconnecting wiring, etc., be sure to remove the starting switch key and disconnect the
battery ground cable.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
k Before starting inspection or replacement of the coolant temperature sensor, be sure to drain
about 10 l of coolant because the coolant can spout out through the temperature sensor mount-
ing port even if the radiator cap has been removed.
k When inspecting or replacing the engine oil pressure sensor (switch), open the engine oil filler
port and make sure the engine oil temperature has dropped enough to avoid burning.
k When checking or replacing an oil temperature sensor or oil pressure sensor, loosen the oil filler
cap of hydraulic tank to release the pressure inside the hydraulic tank and release the remaining
pressure in the hydraulic circuit. For details, see "Releasing remaining pressure in hydraulic cir-
cuit" in Testing and adjusting. Use the monitoring function to display the hydraulic oil tempera-
ture on the machine monitor and check that it is 40°C or below to prevent burn injury.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to perform repairs swiftly, and to
prevent reoccurrence of the failure.
Despite the importance of understanding the structure and operation of the target system in troubleshooting,
you should be aware how identifying rough causes of the given undesirable symptom through the interview
with the operator concerned can facilitate the troubleshooting.
1. When performing troubleshooting, do not hurry to disassemble the machine.
If the machine is disassembled immediately after any failure occurs,
q Parts that have no connection with the failure or other unnecessary parts are disassembled.
q It will become impossible to find the cause of the failure.
It will also cause a waste of staff-hours, parts, or oil or grease, and at the same time, will also lose the
confidence of the user or operator.
For this reason, when performing troubleshooting, it is necessary to perform thorough prior investigation
and to perform troubleshooting corresponding to the fixed procedure.
2. Points to ask the user or operator
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything unusual about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before this?
4) Under what conditions did the failure occur?
5) Had any repairs been performed before the failure? When were these repairs performed?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1) Does the machine have abnormal symptoms?
2) Check "Check before starting" items.
3) Check other check items.
4) Check other maintenance matters which can be checked externally and are considered to be necessary.
4. Checking failure
Check the extent of the failure yourself, and judge whether it is a real failure or a problem of the method
of operation, etc.
a When operating the machine to reproduce the failure symptom, do not perform any investigation or
measurement that may make the problem worse.
40-200 2 WD600-6
Points to remember when performing troubleshooting SEN05050-01
5. Troubleshooting
Use the results of the investigation and inspection in Items 2 to 4 to narrow down the causes of failure,
then use the troubleshooting flowchart or troubleshooting flow (matrix) to locate the position of the failure
exactly.
a The basic procedure for troubleshooting is as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or information.
6. Measures to remove root cause of failure
Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur
again. To prevent this, you must locate and eliminate the primary cause behind the given failure.
WD600-6 40-200 3
SEN05050-01 How to proceed in troubleshooting
How to proceed in troubleshooting 1
(Rev. 2011/09)
40-200 4 WD600-6
How to proceed in troubleshooting SEN05050-01
WD600-6 40-200 5
SEN05050-01 Checks before troubleshooting
Checks before troubleshooting 1
Item Criteria Remedy

1. Check of level and type of fuel — Add fuel
2. Check for foreign matter in fuel — Clean or drain
3. Check of level and type of oil in engine oil pan Between H and L Add oil
Between FULL and
4. Check of coolant level Add coolant
LOW
Lubricating oil 5. Check of air cleaner for clogging No red Clean or replace
and coolant 6. Check of level and type of hydraulic oil Between H and L Add oil
In upper range of site
7. Check of level and type of transmission oil Add oil
gauge
8. Check of engine oil filter for clogging — Replace
9. Check of hydraulic oil filter for clogging — Replace
10. Check of transmission oil filter for clogging — Replace
11. Check of battery terminal cables for looseness
— Retighten or replace
and corrosion
12. Check of alternator terminal cables for
Electrical — Retighten or replace
looseness and corrosion
parts
13. Check of starting motor terminal cables for
— Retighten or replace
looseness and corrosion
14. Check of operation of instruments — Repair or replace
15. Check for abnormal noise and smell — Repair
Hydraulic and 16. Check for oil leakage — Repair
mechanical
equipment 17. Bleeding air — Bleed air
18. Check of effect of brake — Repair or adjust
19. Check of battery voltage (with engine stopped) 20 – 30 V Charge or replace
20. Check of battery electrolyte level Between U.L and L.L Add or replace
21. Check wires for discoloration, burn, and removal
— Replace
of cover
22. Check for removed wire clamp and drooping
— Repair
wire
Electrical 23. Check wiring for wetting with water

Disconnect and dry
equipment (Check connectors and terminals for wetting —
connectors
with water, in particular)
24. Check of slow-blow fuses and fuses for
— Replace
disconnection and corrosion
25. Check of alternator voltage After several-minute
Repair or replace
(with engine at medium speed or higher) operation: 27.5 – 29.5 V
26. Check of operating sound of battery relay
— Replace
(Starting switch OFF  ON)
40-200 6 WD600-6
Classification and procedures of troubleshooting SEN05050-01
Classification and procedures of troubleshooting 1
Classification of troubleshooting
Mode Content
Code display Troubleshooting by failure code (code display)
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical systems
S-mode Troubleshooting of the engine unit
Troubleshooting procedure
If a failure symptom appears on the machine, select an appropriate troubleshooting No. according to the
following procedure, and go to the corresponding troubleshooting section.
1. Procedure for troubleshooting to be taken when an action level is displayed on machine monitor:
If an action level appears on the machine monitor, display the failure code by using the abnormality record
display function (for electrical and mechanical systems) of the machine monitor (EMMS). (See [*1].)
Perform the corresponding troubleshooting classified in [Code display] mode according to the displayed
failure code.
a Each failure code appears "flashing" when the problem corresponding to it is detected. Even if a failure
code appears "lighting up" with the starting switch in ON, the problem corresponding to that failure code
has not necessarily been repaired (some problems can be detected by simply turning the starting
switch to ON position).
a If any failure code is recorded, be sure to perform the operation for reproducing it to see whether the
problem corresponding to it still remains as a problem or has been repaired (for the method of
reproducing the failure code, see the troubleshooting in [Code display]).
2. Procedure for troubleshooting to be taken when failure code is recorded:

If no action level appears on the machine monitor, display the failure code by using the abnormality record
display function (for electrical and mechanical systems) of the machine monitor (EMMS). (See [*2].)
1) If a failure code is recorded, perform the corresponding troubleshooting classified in [Code display]
mode according to that failure code.
a Each failure code appears "flashing" when the problem corresponding to it is detected. Even if a
failure code appears "lighting up" with the starting switch in ON, the problem corresponding to that
failure code has not necessarily been repaired (some problems can be detected by simply turning
the starting switch to ON position).
a If any failure code is recorded, be sure to perform the operation for reproducing it to see whether
the problem corresponding to it still remains as a problem or has been repaired (for the method of
reproducing the failure code, see the troubleshooting in [Code display]). (See [*1].)
a A failure code of the mechanical system cannot be deleted.
2) If a failure code is not recorded in the machine monitor (EMMS), a problem that the machine cannot
find out by itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the failure symptom again to select the same symptom from the table of "Failure
symptom and troubleshooting No.", and then perform the troubleshooting related to that symptom in
the "E mode", "H mode", or "S mode".
3. Action to take after failure is eliminated

Clear all the failure codes in the electrical system abnormality record, referring to [*2].
WD600-6 40-200 7
SEN05050-01 Classification and procedures of troubleshooting
[*1] a Holding down the two switches for 5

Failure code display function seconds or more makes the entire screen
While an action level appears on the machine blank. As this state is recognized, release
monitor, press [>] switch once to display the the buttons.
failure code of currently unsolved failure.
a The failure codes detected in the past are
classified into failures of the electrical sys-
tem and the mechanical system and are
recorded as abnormality records. (For
details, see "Service mode".)
a When two or more failures are involved,
pressing [>] switch displays further codes.
a After [>] switch is pressed to display all fail-
ure codes of currently unsolved failures, if
[>] switch is pressed again, the service
meter display screen will be restored.
Pressing [>] switch one more time displays
the failure codes from the first.
If no switch is touched for 30 seconds, the
action level display screen is automatically
3) Inputting and accepting ID
displayed.
Operate the buttons to input the ID.
q ID: "6491"
1] With cursor (C) located at the highest-order
digit, press "<" or ">" switch to change the
value of this digit in the range of "0" to "9".
2] If a desired numerical number is displayed,
press "U" switch to accept it.
a The cursor moves to the 2nd digit
position.
3] Similarly set remaining 3 digits and press
"U" switch.
a If you have entered a wrong value, you
can move to the highest-order digit by
using t switch except when the cursor is
located at a position other than the
[*2] highest-order digit allowing to repeat the
1. Procedure for switching to service mode and procedure from the first. In this case, the
operation on screen value that had been entered remains as
When using the service mode, perform following they are until modified. When the cursor
special operation to switch the screen display. is at the highest-order digit, you can move
Reference: The language displayed in the to the higher layer by using t switch.
service mode is English When the cursor is located at the leftmost
irrespective of the language position, pressing the switch restores the
selected in the operator mode. standard screen (operator mode).
1) Checking screen display When the cursor is located at a position
Check that the machine monitor is in the other than the leftmost position, pressing
operator mode and any of the "Service the switch returns the cursor to the
meter", "Action level", or "Failure code" is leftmost position.
displayed on the screen. If no switch operation is performed for 60
2) Displaying ID input initial screen seconds or longer in the ID input screen,
Hold down "t" switch and "<" switch the screen automatically changes to the
simultaneously for 5 seconds minimum to standard screen.
open the ID input initial screen.
40-200 8 WD600-6
Classification and procedures of troubleshooting SEN05050-01
2. Electrical system abnormality record display

function (ELECTRIC FAULT)
For the failure code list, see Troubleshooting,
The machine monitor records the past failures in
the electrical system as the failure codes. The
failure codes are displayed from the following
operations.
1) Selecting a menu
Select the ELECTRIC FAULT (Electrical
system abnormality record display function)
from the service mode menu screen.
a [**] field displays total number of
abnormality records currently stored (up
to 20 records).
4) Displaying menu initial screen
a After accepting 4-digit ID, display the
menu initial screen in the service mode.
a Once you enter and accept an ID, it is
effective until the starting switch is turned
to OFF position.
2) Displaying abnormality record

With the menu item being selected, press
[U] button to display stored abnormality
record information.
5) Selecting menu in service mode

a Pressing [<] or [>] switch displays each
service mode menu item in the following
order.
[1] ELECTRIC FAULT: Electrical system
abnormality
record display
function
[2] MACHINE FAULT: Mechanical system
abnormality record
display function
While menu items [3] to [12] are provided,
they are not described in this section.
3) Clearing abnormality record information
With abnormality record information being
displayed, Press [<] or [>] switch to display
the ALL CLEAR menu screen.
WD600-6 40-200 9
SEN05050-01 Classification and procedures of troubleshooting
3. Mechanical system abnormality record

display function (MACHINE FAULT)
For the failure code list, see Troubleshooting,
The machine monitor records the past failures in
the mechanical as the failure codes. The failure
codes are displayed from the following
operations.
1) Selecting a menu
a Select "MACHINE FAULT" (mechanical
system abnormality record display
function) from the service mode menu
screen.
a "**" displays the number of abnormality
records currently recorded.
Press [U] switch to display the ALL CLEAR
screen.
Select "YES" or "NO" by using [<] or [>]
switch.
"YES" is selected and [t] switch is
"NO" is selected, deletion is cancelled
and "Abnormality record information"
screen is restored.
a By default, the cursor is set to "NO"
(cancel) to prevent resetting error.
a The currently unsolved failure information
(blinking) cannot be cleared.
2) Displaying abnormality record

With the menu item being selected, press
[U] switch to display stored abnormality
record information.
3) Clearing abnormality record (not allowed)

Abnormality record information of the
mechanical system cannot be deleted.
40-200 10 WD600-6
Information in troubleshooting table SEN05050-01
Information in troubleshooting table 1
(Rev. 2010/03)
a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before performing troubleshooting, understand that information fully.
User code Failure code
Display on Failure name displayed on the Abnormality Record screen of the
Display on machine Failure
machine moni- machine monitor
monitor
tor
Detail of failure Description of the failure detected by the machine monitor or controller
Action of
Action to be taken to protect the system and equipment when the machine monitor or controller detects
machine moni-
a trouble
tor or controller
Problem on
Problem that appears on machine as result of action (above) taken by machine monitor or controller
machine
Related infor-
Information related to detected failure or troubleshooting
mation
Cause Procedure, measuring location, criteria and remarks
<Details of description>
q Procedure
1 Defective component
q Measuring location
a "Between A and B" means the measurement of voltage, resistance or oth-
ers between terminals A and B.
q Criteria to judge probable causes (normal value)
q Remarks for judgment
Open or short circuit in wiring <How to use troubleshooting sheet>
2 q Perform troubleshooting procedures in numerical order.
harness
q If the check result does not meet the criteria, the probable cause described
on the left column is the actual cause of the failure.
q If the check result shows no abnormality, and unless otherwise specified, pro-
ceed to the next step (next cause item).
Open circuit in wiring harness q Check that the failure is fixed after a failure was found and repaired.
3 (wire breakage or defective con- <Failures in wiring harness>
tact of connector) q Open circuit in wiring
The connector connection is defective or the wire is broken.
q Ground fault
A harness not connected to ground circuit contacts the ground wiring or ma-
chine.
Ground fault in wiring harness
4 q Hot short circuit
(contact with ground circuit)
A harness not connected to the power circuit (24 V) contacts with the power
circuit.
q Short circuit
An independent wire in the harness contacts with other wire.
(poor insulation at connector and others)
Hot short circuit <Precautions for troubleshooting>
5
(contact with 24 V circuit) (1) Connector number indication method and handling of T-adapter
For troubleshooting, insert or connect T-adapter as follows unless otherwise
specified.
q When "male" or "female" is not indicated with a connector number, dis-
connect the connector, and insert T-adapter between the male and fe-
6 Short circuit in wiring harness male connectors.
q When "male" or "female" is indicated with a connector number, discon-
nect the connector, and connect T-adapter only to either male or femae
connector.
(2) Description sequence of pin number and handling of tester lead
For troubleshooting, connect the positive (+) and negative (-) leads as shown
below unless otherwise specified.
7 Defective controller
q Connect the positive (+) lead to pin or wire indicated first.
q Connect the negative (-) lead to a pin or wire indicated second.
WD600-6 40-200 11
SEN05050-01 Information in troubleshooting table
Related circuit diagram
This is the excerpted circuit diagram related to troubleshoot-

ing
q The circuit diagram contains the connector Nos., pin
Nos., and connector colors related to the failure.
q The circuit diagram contains the destination or source of
the branch line in a wiring harness.
q Arrow (io): Roughly shows the location on the ma-
chine.
q NO: Normally Open
q NC: Normally Closed
40-200 12 WD600-6
Troubleshooting method for disconnecting wiring harness of pressure sensor system SEN05050-01
Troubleshooting method for disconnecting wiring harness of pressure

sensor system 1
a Since pressure sensor consists not only of resistors but also electronic circuits such as amplifiers, it may
have the differences among the resistances measured and its own polarities. So troubleshooting must be
performed carefully.
Failure codes applicable to this diagnosis

q CA123: Charge air pressure sensor low error
q CA222: Ambient pressure sensor low error
Procedure
1. Measure and record resistance of pressure sensor unit.
1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor.
2) Measure resistances R1 and R2 between pins.
a If tester probes polarities to apply are reversed, measured values may change. Therefore, when
measuring resistances, apply the same tester probe polarities to the pressure sensor in steps 1 and
2.
a If measured value is infinite, take measurements with tester probes polarities exchanged each oth-
er and record the finite value obtained as a measured value.
a Since measured values may be different from each other, take several measurements. Cause of
the differences appears to be that the sensor may be charged by the tester. Take several measure-
ment in both steps 1 and 2. Take the fact into consideration this differences when determining
whether the wiring harness is disconnected in step 3.
2. Measure and record resistance with wiring harness between pressure sensor and engine controller
connected
1) Since 5 V power supply to pressure sensor is supplied to other sensors, disconnect the other sensor
connectors first.(*)
2) Connect the pressure sensor to be measured, disconnect connector (3) on engine controller side, and
connect T-adapter (4) to wiring harness side.
3) Connect T-box (5) to T-adapter (4) and measure respective pins for resistances R1' and R2'.
3. Judging open circuit

If there is an "apparent difference" between resistances R1 and R2 measured in step 1 and resistances
R1' and R2' measured in step 2, "wiring harness is disconnected".
a "Apparent difference" means a difference of 10 or more times.
WD600-6 40-200 13
SEN05050-01 Troubleshooting method for disconnecting wiring harness of pressure sensor system
List of pressure sensor measuring locations and reference values

Internal resistance of measured
Measuring location at
Sensor sensor Remarks
sensor pin
(Reference value)
Charge pressure R2: Between (1) and (3) Approx. 2.9kz Sensor is common to engine mod-
sensor R1: Between (2) and (3) Approx. 4.3kz els 125, 170 and 12V140
Sensor is common to engine mod-
R2: Between (1) and (3) Approx. 3.2kz
els 95, 125, 170 and 12V140
Ambient pressure R1: Between (2) (+) and
Approx. 4.6kz
sensor (1) (-) If polarities are reversed, resis-
R1: Between (1) (+) and tance value changes.
Approx. 2.9kz
(2) (-)
*: When measuring R2', disconnect the following connectors.(See circuit diagram related to each code)
q When measuring R2' of charge pressure sensor (CA123)
Connectors of resistance RES, engine oil pressure sensor, ambient pressure sensor, and G sensor
q When measuring R2' of ambient pressure sensor (CA222)
Connectors of charge pressure sensor, resistance RES, engine oil pressure sensor, and G sensor
40-200 14 WD600-6
Troubleshooting method for disconnecting wiring harness of pressure sensor system SEN05050-01
Measurement record (For measuring locations, see circuit diagram related to each code)
Sensor + Wiring harness
Sensor unit (Measuring
(Measuring location on
Sensor location on sensor pin Measured value Measured value
wiring harness side of
side)
engine controller)
R1: Between (1) (+) and
R2: Between (1) and (3)
Charge pressure (2) (-)
sensor R1': Between (44) and
(47)
R2': Between (37) and
(38) (*)
Ambient pressure R1: Between (2) (+) and R1': Between (3) (+)
sensor (1) (-) and (38) (-)
R1: Between (1) (+) and R1': Between (38) (+)
(2) (-) and (3) (-)
WD600-6 40-200 15
SEN05050-01 Phenomena looking like troubles and troubleshooting Nos.
Phenomena looking like troubles and troubleshooting Nos. 1
Troubleshooting
No. Phenomena looking like trouble Code
E-mode H-mode S-mode
display
Phenomena related to action codes and failure codes
1 Action codes are displayed on machine monitor Check failure code
2 If failure code display function is checked, failure codes are displayed q
Phenomena related to engine
3 Engine does not start easily. E-1 S-1
4 Engine does not crank E-1 S-2 a)
Engine cranks but exhaust smoke does not comes
5 Engine does S-2 b)
out
not start.
Exhaust smoke comes out but engine does not start
6 S-2 c)
(Fuel is injected)
7 Engine does not pick up smoothly. S-3
8 Engine stops during operation H-2 S-4
9 Engine rotation is abnormal (Engine hunts) S-5
10 Output is insufficient (Power is low) S-6
11 Exhaust gas color is bad (Incomplete combustion) S-7
12 Oil consumption is excessive (or exhaust smoke is blue) S-8
13 Engine oil becomes contaminated quickly S-9
14 Fuel is consumed much S-10
15 Coolant contains oil (blows back or reduces) S-11
16 Engine oil pressure drops S-12
17 Oil level rises (Water or fuel is mixed in oil) S-13
18 Coolant temperature too high (Overheating) S-14
19 Abnormal sound comes out S-15
20 Vibration is excessive S-16
21 Air cannot be bled from fuel circuit S-17
Phenomena related to power train
22 Machine does not start H-1
23 Torque converter lockup is not switched (engine stalls) H-2
24 Torque converter lockup is not turned on H-3
Travel speed is low, rush force is low, grade-ability is low, and gear
25 H-4
speed does not change
26 Large shocks are made when machine starts and gear is shifted H-5
27 Large time lag is made when machine starts and gear is shifted H-6
28 Torque converter oil temperature is high H-7
Phenomena related to steering
29 Machine cannot be steered [machine with steering wheel] H-8
30 Machine cannot be steered [machine with AJSS] H-9
31 Steering response is low [machine with steering wheel] H-10
32 Steering response is low [machine with AJSS] H-11
33 Steering is heavy [machine with steering wheel] H-12
Steering wheel shakes or makes large shocks
34 H-13
[machine with steering wheel]
40-200 16 WD600-6
Phenomena looking like troubles and troubleshooting Nos. SEN05050-01
Troubleshooting
No. Phenomena looking like trouble Code
E-mode H-mode S-mode
display
35 Steering wheel shakes or makes large shocks [machine with AJSS] H-14
Phenomena related to brake
36 Wheel brake does not work or braking force is low H-15
37 Wheel brake is not reset or it drags H-16
38 Parking brake does not work or braking force is low H-17
Parking brake cannot be reset or it drags
39 H-18
(including emergency release system)
Phenomena related to work equipment
40 Blade does not rise H-19
41 Blade speed is low or rising force of lift is insufficient H-20
42 When blade rises, its speed lowers at specific height H-21
43 Blade cannot be held with lift cylinder (Blade floats) H-22
44 Hydraulic drift of blade is large H-23
45 Blade shakes during operation H-24
46 Blade does not tilt and pitch H-25
47 Blade speed is low or tilt and pitch force is insufficient H-26
48 Blade spool lowers during tilt and pitch operation H-27
49 Blade cannot be held with tilt and pitch cylinder H-28
50 Hydraulic drift of blade is large H-29
Blade shakes while machine is traveling with load
51 H-30
(Work equipment valve is in HOLD)
Engine speed lowers remarkably or engine stalls during work
52 H-31
equipment control
53 Large shock is made when work equipment starts and stops H-32
When work equipment circuit is relieved singly, other work equipment
54 H-33
moves
Fan speed is abnormal (Fan sound and vibration are abnormally
55 H-34
large or engine overheats)
Others
56 Wiper does not operate E-2
57 Windshield washer does not operate E-3
Headlamp, clearance lamp, tail lamp, and license plate lamp do not
58 E-4
light up or go off
59 Working lamp does not light up or go off E-5
60 Step lamp does not light up or go off E-6
61 Turn signal lamp and hazard lamp do not light up or go off E-7
62 Brake lamp does not light or it keeps lighting up E-8
63 Backup lamp does not light or it keeps lighting up E-9
64 Backup buzzer does not sound or it keeps sounding E-10
65 Horn does not sound or it keeps sounding E-11
66 Warning buzzer does not sound or it keeps sounding E-12
67 Air conditioner does not operate or stop E-13
Electric priming pump does not operate or does not stop
68 E-14
automatically
When starting switch is turned to ON position, machine monitor
69 E-15
displays nothing
WD600-6 40-200 17
SEN05050-01 Connection table for connector pin numbers
Connection table for connector pin numbers (Rev. 2009.04)
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
40-200 18 WD600-6
Connection table for connector pin numbers SEN05050-01
WD600-6 40-200 19
40-200 20 WD600-6
WD600-6 40-200 21
40-200 22 WD600-6
WD600-6 40-200 23
40-200 24 WD600-6
WD600-6 40-200 25
40-200 26 WD600-6
WD600-6 40-200 27
40-200 28 WD600-6
WD600-6 40-200 29
40-200 30 WD600-6
WD600-6 40-200 31
40-200 32 WD600-6
WD600-6 40-200 33
40-200 34 WD600-6
WD600-6 40-200 35
40-200 36 WD600-6
WD600-6 40-200 37
40-200 38 WD600-6
WD600-6 40-200 39
40-200 40 WD600-6
WD600-6 40-200 41
40-200 42 WD600-6
WD600-6 40-200 43
40-200 44 WD600-6
WD600-6 40-200 45
40-200 46 WD600-6
WD600-6 40-200 47
40-200 48 WD600-6
WD600-6 40-200 49
SEN05050-01
40-200 50
WD600-6 40-200 51
40-200 52 WD600-6
WD600-6 40-200 53
SEN05050-01 T- branch box and T- branch adapter table
T- branch box and T- branch adapter table (Rev. 2009.03)1
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
40-200 54 WD600-6
T- branch box and T- branch adapter table SEN05050-01
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 — q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 — q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
WD600-6 40-200 55
SEN05050-01 T- branch box and T- branch adapter table
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190* 3 1,2,3L q q
Commonrail pressure
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280* Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
“*” Shows not T-adapter but socket.
40-200 56 WD600-6
T- branch box and T- branch adapter table SEN05050-01
WD600-6 40-200 57
SEN05050-01
WD600-6 Wheel dozer

©2016 KOMATSU
All Rights Reserved
40-200 58
SEN05051-01
WHEEL DOZER
WD600-6

WD600-6 55001 and up
301 Troubleshooting by failure code

(Display of code), Part 1
Failure code [1500L0] TORQFLOW transmission: Double meshing .............................................................. 3
Failure code [15B0NX] Transmission Oil Filter Clogging ................................................................................ 4
Failure code [15SAL1] ECMV F clutch: When command current is OFF, fill signal is ON.............................. 6
Failure code [15SALH] ECMV F clutch: When command current is ON, fill signal is OFF............................. 8
Failure code [15SBL1] ECMV R clutch: When command current is OFF, fill signal is ON ........................... 10
Failure code [15SBLH] ECMV R clutch: When command current is ON, fill signal is OFF .......................... 12
Failure code [15SEL1] ECMV (1): When command current is OFF, fill signal is ON .................................... 14
Failure code [15SELH] ECMV (1): When command current is ON, fill signal is OFF ................................... 16
Failure code [15SFL1] ECMV (2): When command current is OFF, fill signal is ON .................................... 18
Failure code [15SFLH] ECMV (2): When command current is ON, fill signal is OFF ................................... 20
Failure code [15SFLH] ECMV (2): When command current is ON, fill signal is OFF ................................... 20
Failure code [15SGL1] ECMV (3): When command current is OFF, fill signal is ON.................................... 22
Failure code [15SGLH] ECMV (3): When command current is ON, fill signal is OFF................................... 24
Failure code [15SHL1] ECMV (4): When command current is OFF, fill signal is ON .................................... 26
Failure code [15SHLH] ECMV (4): When command current is ON, fill signal is OFF ................................... 28
Failure code [15W0NT] Transmission modulation clutch: Overheating ........................................................ 30
Failure code [2F00MA] Parking brake: Malfunction ...................................................................................... 31
Failure code [2G42ZG] Front Accumulator Oil Pressure Low....................................................................... 34
WD600-6 40-301 1
301 Troubleshooting by failure code (Display of code), Part 1
SEN05051-01
40-301 2 WD600-6
Failure code [1500L0] TORQFLOW transmission: Double meshing SEN05051-01
Failure code [1500L0] TORQFLOW transmission: Double meshing 1
Action code Failure code TORQFLOW transmission: Double meshing

Trouble
E03 1500L0 (Transmission controller system)
Contents of
• A combination for double meshing is input as a fill signal.
trouble
Action of • Turns the centralized warning lamp and warning buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The transmission may be broken.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal 1 See failure codes [15SAL1], [15SBL1], [15SEL1], [15SFL1], [15SGL1] and [15SHL1].
state
WD600-6 40-301 3
SEN05051-01 Failure code [15B0NX] Transmission Oil Filter Clogging
Failure code [15B0NX] Transmission Oil Filter Clogging 1
Action code Failure code Transmission oil filter: Clogging

Failure
E01 15B0NX (Machine monitor system)
• Transmission filter clogging sensor circuit is OPEN. (When torque converter oil temperature is
Detail of failure
above 50°C)
Action of • Turns on transmission oil filter clogging caution lamp.
controller • If failure disappears, machine becomes normal by itself.
Problem on • Transmission oil filter clogging caution lamp lights up.
machine • Transmission may be damaged.
• Input (ON/OFF) from transmission oil filter clogging sensor can be checked by using monitoring
Related infor-
function. (Code: 40903 D-IN-24)
mation
• Method of reproducing failure code: Start engine.
Cause Standard value in normal condition, remarks for troubleshooting

Clogged transmission oil
1 Transmission oil filter may be clogged. Check it.
filter
1. Turn starting switch to OFF position.
2. Disconnect connector B09, and connect T-adapter to male
Defective transmission oil side.
filter clogging sensor
2 Resis-
(Internal open or short Filter is normal Max. 1z
Between B09 tance
circuit)
(male) (1) and (2) Resis-
Filter is clogged Min. 1 Mz
tance
Probable 1. Turn starting switch to OFF position.
causes and cri- 2. Disconnect connectors C03 and B09, and connect T-adapter to
teria Open circuit in wiring female side.
harness
3 Between C03 (female) (5) and B09 Resis-
(Wire breakage or defective Max. 1z
(female) (1) tance
contact of connector)
Resis-
Between B09 (female) (2) and ground Max. 1z
tance
1. Turn the starting switch to OFF position.
2. Insert T-adapter into connector C03.
3. Turn starting switch to ON position.
4 Defective machine monitor
Between C03 (5) Filter is normal Voltage Max. 1 V
and ground Filter is clogged Voltage Min. 7 V
40-301 4 WD600-6
Failure code [15B0NX] Transmission Oil Filter Clogging SEN05051-01
Circuit diagram related to transmission clogging sensor
WD600-6 40-301 5
SEN05051-01 Failure code [15SAL1] ECMV F clutch: When command current is OFF, fill signal is ON
Failure code [15SAL1] ECMV F clutch: When command current is OFF,

fill signal is ON 1
Action code Failure code ECMV F clutch: When command current is OFF, fill signal is ON
Trouble
E03 15SAL1 (Transmission controller system)
Contents of • When F ECMV solenoid output is turned OFF, F ECMV fill switch signal ON is input, and clutch is
trouble not released.
• Judges that the F ECMV fill switch signal is turned ON.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until directional lever or directional
selector switch is set to N (Neutral).
Problem that
appears on • F travel is enabled, but R travel is disabled.
machine
• The output state (current) to the F clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31608, ECMV F DIR).
Related
• The input state (ON/OFF) from the F fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-25).
Cause Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
Defective F ECMV fill switch Directional lever or
1 Resis-
(Internal short circuit) directional switch: Max. 1 z
Between F.SW tance
F (Forward)
(male) (1) and
chassis ground Directional lever or
Resis-
directional switch: Min. 1 Mz
tance
Other than above
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring without turning starting switch ON.
value in normal 2 harness
state (Contact with ground circuit) Between L03 (female) (27) or F.SW (female) Resis-
Min. 1 Mz
(1) and chassis ground tance
troubleshooting.
Defective transmission Directional lever or
3
controller directional switch: Voltage Max. 1 V
Between L03 (27) F (Forward)
and chassis ground Directional lever or
directional switch: Voltage 8 – 10 V
Other than above
40-301 6 WD600-6
Failure code [15SAL1] ECMV F clutch: When command current is OFF, fill signal is ON SEN05051-01
Circuit diagram related to transmission F clutch
WD600-6 40-301 7
SEN05051-01 Failure code [15SALH] ECMV F clutch: When command current is ON, fill signal is OFF
Failure code [15SALH] ECMV F clutch: When command current is ON,

fill signal is OFF 1
Action code Failure code ECMV F clutch: When command current is ON, fill signal is OFF
Trouble
E01 15SALH (Transmission controller system)
Contents of
• When F ECMV solenoid output is turned ON, F ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the F ECMV fill switch signal is turned OFF.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • When the travel direction is changed, a shock or a time lag may be made.
machine
tion (Code: 31608, ECMV F DIR).
Related • The input state (ON/OFF) from the F fill switch can be checked with the monitoring function (Code:
information 40908, D-IN-25).
• Method of reproducing failure code: Start engine, and set directional lever or switch to F.
• This error code may be displayed just after the transmission oil is replaced.

troubleshooting.
Defective F ECMV fill switch Directional lever or
1 Resis-
(Internal disconnection) directional switch: Max. 1 z
Between F.SW tance
F (Forward)
(male) (1) and
Resis-
tance
Other than above
Possible causes
Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
and standard
harness without turning starting switch ON.
value in normal 2
state (Disconnection or defective Between L03 (female) (27) and F.SW Resis-
contact of connector) Max. 1 z
(female) (1) tance
troubleshooting.
3
Between L03 (27) F (Forward)
Other than above
40-301 8 WD600-6
Failure code [15SALH] ECMV F clutch: When command current is ON, fill signal is OFF SEN05051-01
Circuit diagram related to transmission F clutch
WD600-6 40-301 9
SEN05051-01 Failure code [15SBL1] ECMV R clutch: When command current is OFF, fill signal is ON
Failure code [15SBL1] ECMV R clutch: When command current is OFF,

fill signal is ON 1
Action code Failure code ECMV R clutch: When command current is OFF, fill signal is ON
Trouble
E03 15SBL1 (Transmission controller system)
Contents of • When R ECMV solenoid output is turned OFF, R ECMV fill switch signal ON is input, and clutch is
trouble not released.
• Judges that the R ECMV fill switch signal is turned ON.
controller • Even if cause of failure disappears, system does not reset itself until directional selector switch is
set to N (Neutral).
Problem that
appears on • The machine can travel in the R position, but cannot travel in the F position.
machine
• The output state (current) to the R clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31606, ECMV R DIR).
Related
• The input state (ON/OFF) from the R fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-26).

troubleshooting.
Defective R ECMV fill switch Directional lever or
1 Resis-
Between R.SW tance
R (Reverse)
(male) (1) and
Resis-
tance
Other than above
Possible causes
and standard Grounding fault in wiring without turning starting switch ON.
value in normal 2 harness
state (Contact with ground circuit) Between L03 (female) (17) or R.SW Resis-
Min. 1 Mz
(female) (1) and chassis ground tance
troubleshooting.
3
Between L03 (17) R (Reverse)
Other than above
40-301 10 WD600-6
Failure code [15SBL1] ECMV R clutch: When command current is OFF, fill signal is ON SEN05051-01
Circuit diagram related to transmission R clutch
WD600-6 40-301 11
SEN05051-01 Failure code [15SBLH] ECMV R clutch: When command current is ON, fill signal is OFF
Failure code [15SBLH] ECMV R clutch: When command current is ON,

fill signal is OFF 1
Action code Failure code ECMV R clutch: When command current is ON, fill signal is OFF
Trouble
E01 15SBLH (Transmission controller system)
Contents of
• When R ECMV solenoid output is turned ON, R ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the R ECMV fill switch signal is turned OFF.
Problem that
appears on • When the travel direction is changed, a shock or a time lag may be made.
machine
tion (Code: 31606, ECMV R DIR).
Related • The input state (ON/OFF) from the R fill switch can be checked with the monitoring function (Code:
information 40908, D-IN-26).
• Method of reproducing failure code: Start engine, and set directional lever or switch to R.

troubleshooting.
Defective R ECMV fill switch Directional lever or
1 Resis-
Between R.SW tance
R (Reverse)
(male) (1) and
Resis-
tance
Other than above
Possible causes
and standard
value in normal 2
state (Disconnection or defective Between L03 (female) (17) and R.SW Resis-
(female) (1) tance
troubleshooting.
3
Between L03 (17) R (Reverse)
Other than above
40-301 12 WD600-6
Failure code [15SBLH] ECMV R clutch: When command current is ON, fill signal is OFF SEN05051-01
Circuit diagram related to transmission R clutch
WD600-6 40-301 13
SEN05051-01 Failure code [15SEL1] ECMV (1): When command current is OFF, fill signal is ON
Failure code [15SEL1] ECMV (1): When command current is OFF, fill
signal is ON 1
Action code Failure code ECMV (1): When command current is OFF, fill signal is ON
Trouble
E03 15SEL1 (Transmission controller system)
Contents of • When 1st ECMV solenoid output is turned OFF, 1st ECMV fill switch signal ON is input, and clutch
trouble is not released.
• Judges that the 1st ECMV fill switch signal is turned ON.
• Holds 2nd, 3rd, and 4th proportional solenoid outputs OFF.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until directional lever or directional
Problem that
appears on • The machine can travel at 1st, but not at 2nd, 3rd, and 4th.
machine
• The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31602, ECMV 1 DIR).
Related
• The input state (ON/OFF) from the 1st fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-27).

troubleshooting.
Defective 1st ECMV fill • Keep pressing brake pedal to prevent machine from traveling.
1
switch (Internal short circuit) Shift lever: Resis-
Between 1.SW Max. 1 z
1st (1st speed) tance
(male) (1) and
chassis ground Shift lever: Resis-
Min. 1 Mz
Other than above tance
Grounding fault in wiring without turning starting switch ON.
Possible causes 2 harness
and standard (Contact with ground circuit) Between L03 (female) (7) or 1.SW (female) Resis-
Min. 1 Mz
value in normal (1) and chassis ground tance
state a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Set the auto shift and manual shift selector switch in the MANU-
Defective transmission AL position.
3 • Set the directional lever or directional selector switch to the F
controller
(forward) or R (reverse) position.
Shift lever:
Voltage Max. 1 V
Between L03 (7) and 1st (1st speed)
chassis ground Shift lever:
Voltage 8 – 10 V
Other than above
40-301 14 WD600-6
Failure code [15SEL1] ECMV (1): When command current is OFF, fill signal is ON SEN05051-01
Circuit diagram related to transmission 1st clutch
WD600-6 40-301 15
SEN05051-01 Failure code [15SELH] ECMV (1): When command current is ON, fill signal is OFF
Failure code [15SELH] ECMV (1): When command current is ON, fill
signal is OFF 1
Action code Failure code ECMV (1): When command current is ON, fill signal is OFF
Trouble
E01 15SELH (Transmission controller system)
Contents of
• When 1st ECMV solenoid output is turned ON, 1st ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the 1st ECMV fill switch signal is turned OFF.
Problem that
• The machine does not travel at 1st.
appears on
• When the 1st gear speed is changed, a shock or a time lag may be made.
machine
• The input state (ON/OFF) from the 1st fill switch can be checked with the monitoring function (Code:
Related 40908, D-IN-27).
information • Method of reproducing failure code: Start engine, and set the manual/auto shift selector switch in
the MANUAL position, then set the directional lever or directional selector switch to the F (forward)
or R (reverse), and 1st shift lever position.

troubleshooting.
Defective 1st ECMV fill • Keep pressing brake pedal to prevent machine from traveling.
1 switch (Internal
Shift lever: Resis-
disconnection) Between 1.SW Max. 1 z
1st (1st speed) tance
(male) (1) and
Min. 1 Mz
Possible causes 2
and standard (Disconnection or defective Between L03 (female) (7) and 1.SW Resis-
value in normal (female) (1) tance
troubleshooting.
controller
Shift lever:
Voltage Max. 1 V
Between L03 (7) and 1st (1st speed)
Voltage 8 – 10 V
Other than above
40-301 16 WD600-6
Failure code [15SELH] ECMV (1): When command current is ON, fill signal is OFF SEN05051-01
Circuit diagram related to transmission 1st clutch
WD600-6 40-301 17
SEN05051-01 Failure code [15SFL1] ECMV (2): When command current is OFF, fill signal is ON
Failure code [15SFL1] ECMV (2): When command current is OFF, fill
signal is ON 1
Trouble
E03 15SFL1 (Transmission controller system)
Contents of • When 2nd ECMV solenoid output is turned OFF, 2nd ECMV fill switch signal ON is input, and clutch
• Judges that the 2nd ECMV fill switch signal is turned ON.
Action of
• Holds 1st, 3rd, and 4th proportional solenoid outputs OFF.
controller
Problem that
appears on • The machine can travel at 2nd, but not at 1st, 3rd, and 4th.
machine
• The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring
function (Code: 31603, ECMV 2 DIR).
Related
• The input state (ON/OFF) from the 2nd fill switch can be checked with the monitoring function
information
(Code: 40908, D-IN-28).

troubleshooting.
Defective 2nd ECMV fill • Keep pressing brake pedal to prevent machine from traveling.
1
2nd (2nd speed) tance
(male) (1) and
Min. 1 Mz
Min. 1 Mz
troubleshooting.
controller
Shift lever:
Voltage Max. 1 V
Between L03 (13) 2nd (2nd speed)
and chassis ground Shift lever:
Voltage 8 – 10 V
Other than above
40-301 18 WD600-6
Failure code [15SFL1] ECMV (2): When command current is OFF, fill signal is ON SEN05051-01
Circuit diagram related to transmission 2nd clutch
WD600-6 40-301 19
SEN05051-01 Failure code [15SFLH] ECMV (2): When command current is ON, fill signal is OFF
Failure code [15SFLH] ECMV (2): When command current is ON, fill
signal is OFF 1
Trouble
E01 15SFLH (Transmission controller system)
Contents of
• When 2nd ECMV solenoid output is turned ON, 2nd ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the 2nd ECMV fill switch signal is turned OFF.
Problem that
• The machine does not travel at 2nd.
appears on
• When the 2nd gear speed is changed, a shock or a time lag may be made.
machine
• The input state (ON/OFF) from the 2nd fill switch can be checked with the monitoring function
Related (Code: 40908, D-IN-28).
information • Method of reproducing failure code: Start engine, and set the manual/auto shift selector switch in
the MANUAL position, then set the directional lever or directional selector switch to the F (forward)
or R (reverse), and 2nd shift lever position.

troubleshooting.
Defective 2nd ECMV fill • Keep pressing brake pedal to prevent machine from traveling.
1 switch (Internal
Shift lever: Resis-
2nd (2nd speed) tance
(male) (1) and
Min. 1 Mz
Possible causes 2
troubleshooting.
controller
Shift lever:
Voltage Max. 1 V
Between L03 (13) 2nd (2nd speed)
and chassis ground Shift lever:
Voltage 8 – 10 V
Other than above
40-301 20 WD600-6
Failure code [15SFLH] ECMV (2): When command current is ON, fill signal is OFF SEN05051-01
Circuit diagram related to transmission 2nd clutch
WD600-6 40-301 21
SEN05051-01 Failure code [15SGL1] ECMV (3): When command current is OFF, fill signal is ON
Failure code [15SGL1] ECMV (3): When command current is OFF, fill
signal is ON 1
Trouble
E03 15SGL1 (Transmission controller system)
Contents of • When 3rd ECMV solenoid output is turned OFF, 3rd ECMV fill switch signal ON is input, and clutch
• Judges that the 3rd ECMV fill switch signal is turned ON.
• Holds 1st, 2nd, and 4th proportional solenoid outputs OFF.
Action of
controller
• Even if cause of failure disappears, system does not reset itself until directional selector switch is
set to N (Neutral).
Problem that
appears on • The machine can travel at 3rd, but not at 1st, 2nd, and 4th.
machine
• The output state (current) to the 3rd clutch ECMV solenoid can be checked with the monitoring func-
Related
• The input state (ON/OFF) from the 3rd fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-29).

troubleshooting.
Defective 3rd ECMV fill • Keep pressing brake pedal to prevent machine from traveling.
1
3rd (3rd speed) tance
(male) (1) and
Min. 1 Mz
Min. 1 Mz
troubleshooting.
controller
Shift lever:
Voltage Max. 1 V
Between L03 (3) and 3rd (3rd speed)
Voltage 8 – 10 V
Other than above
40-301 22 WD600-6
Failure code [15SGL1] ECMV (3): When command current is OFF, fill signal is ON SEN05051-01
Circuit diagram related to transmission 3rd clutch
WD600-6 40-301 23
SEN05051-01 Failure code [15SGLH] ECMV (3): When command current is ON, fill signal is OFF
Failure code [15SGLH] ECMV (3): When command current is ON, fill
signal is OFF 1
Trouble
E01 15SGLH (Transmission controller system)
Contents of
• When 3rd ECMV solenoid output is turned ON, 3rd ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the 3rd ECMV fill switch signal is turned OFF.
Problem that
• The machine does not travel at 3rd.
appears on
• When the 3rd gear speed is changed, a shock or a time lag may be made.
machine
• The input state (ON/OFF) from the 3rd fill switch can be checked with the monitoring function (Code:
information • Method of reproducing failure code: Turn starting switch ON, and set the manual/auto shift selector
switch in the MANUAL position, then set the directional lever or directional selector switch to the F
(forward) or R (reverse), and 3rd shift lever position.

troubleshooting.
Defective 3rd ECMV fill • Keep pressing brake pedal to prevent machine from traveling.
1 switch (Internal
Shift lever: Resis-
3rd (3rd speed) tance
(male) (1) and
Min. 1 Mz
Possible causes 2
troubleshooting.
controller
Shift lever:
Voltage Max. 1 V
Between L03 (3) and 3rd (3rd speed)
Voltage 8 – 10 V
Other than above
40-301 24 WD600-6
Failure code [15SGLH] ECMV (3): When command current is ON, fill signal is OFF SEN05051-01
Circuit diagram related to transmission 3rd clutch
WD600-6 40-301 25
SEN05051-01 Failure code [15SHL1] ECMV (4): When command current is OFF, fill signal is ON
Failure code [15SHL1] ECMV (4): When command current is OFF, fill
signal is ON 1
Trouble
E03 15SHL1 (Transmission controller system)
Contents of • When 4th ECMV solenoid output is turned OFF, 4th ECMV fill switch signal ON is input, and clutch
• Judges that the 4th ECMV fill switch signal is turned ON.
• Holds 1st, 2nd, and 3rd proportional solenoid outputs OFF.
Action of
controller
set to N (Neutral).
Problem that
appears on • The machine can travel at 4th, but not at 1st, 2nd, and 3rd.
machine
• The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring func-
Related
• The input state (ON/OFF) from the 4th fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-30).

troubleshooting.
Defective 4th ECMV fill • Keep pressing brake pedal to prevent machine from traveling.
1
4th (4th speed) tance
(male) (1) and
Min. 1 Mz
Min. 1 Mz
troubleshooting.
controller
Shift lever:
Voltage Max. 1 V
Between L03 (2) and 4th (4th speed)
Voltage 8 – 10 V
Other than above
40-301 26 WD600-6
Failure code [15SHL1] ECMV (4): When command current is OFF, fill signal is ON SEN05051-01
Circuit diagram related to transmission 4th clutch
WD600-6 40-301 27
SEN05051-01 Failure code [15SHLH] ECMV (4): When command current is ON, fill signal is OFF
Failure code [15SHLH] ECMV (4): When command current is ON, fill
signal is OFF 1
Trouble
E01 15SHLH (Transmission controller system)
Contents of
• When 4th ECMV solenoid output is turned ON, 4th ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the 4th ECMV fill switch signal is turned OFF.
Problem that
• The machine may not travel at 4th.
appears on
• When the 4th gear speed is changed, a shock or a time lag may be made.
machine
tion (Code: 31605, ECMV 4).
• The input state (ON/OFF) from the 4th fill switch can be checked with the monitoring function (Code:
information • Method of reproducing failure code: Turn starting switch ON, and set the manual/auto shift selector
switch in the MANUAL position, then set the directional lever or directional selector switch to the F
(forward) or R (reverse), and 4th shift lever position.

troubleshooting.
Defective 4th ECMV fill • Keep pressing brake pedal to prevent machine from traveling.
1 switch (Internal
Shift lever: Resis-
4th (4th speed) tance
(male) (1) and
Min. 1 Mz
Possible causes 2
troubleshooting.
controller
Shift lever:
Voltage Max. 1 V
Between L03 (2) and 4th (4th speed)
Voltage 8 – 10 V
Other than above
40-301 28 WD600-6
Failure code [15SHLH] ECMV (4): When command current is ON, fill signal is OFF SEN05051-01
Circuit diagram related to transmission 4th clutch
WD600-6 40-301 29
SEN05051-01 Failure code [15W0NT] Transmission modulation clutch: Overheating
Failure code [15W0NT] Transmission modulation clutch: Overheating 1
Action code Failure code Transmission modulation clutch: Overheating

Trouble
E02 15W0NT (Transmission controller system)
Contents of
• The calorific value of the modulation clutch is higher than the set value. (Overheating)
trouble
Problem that
appears on —
machine
• The state (calorific value) of the modulation clutch can be checked with the monitoring function
(Code: 92500, MOD/C Q).
Related
• The state (heat rate) of the modulation clutch can be checked with the monitoring function (Code:
information
92501, MOD/C q).
• Method of reproducing failure code: Engine started + Travel

Possible causes Transmission controller may be defective
1 Transmission controller
and standard (Since trouble is in system, troubleshooting cannot be carried out.)
value in normal Cause may be wrong operation such as continuous use of
state 2 Overload modulation clutch.
Explain correct operating method to operator.
40-301 30 WD600-6
Failure code [2F00MA] Parking brake: Malfunction SEN05051-01
Failure code [2F00MA] Parking brake: Malfunction 1
Action code Failure code Parking brake: Malfunction

Trouble
E03 2F00MA (Machine monitor system)
Contents of • While the F or R clutch is operated, the parking brake operation sensor circuit is OPEN.
trouble (The neutralizer does not work.)
Problem that
appears on • The parking brake drags (is kept operated).
machine
• The input state (ON/OFF) from the parking indicator switch can be checked with the monitoring func-
tion (Code: 40903, D-IN-26).
Related
information
• This error may be displayed because of engine stall operation or the emergency brake is applied
during travel.

without turning starting switch ON.
Defective parking brake
Parking brake: Resis-
1 indicator switch Max. 1 z
Between PB.SW Released tance
(Internal disconnection)
(male) (1) and (2) Parking brake: Resis-
Min. 1 Mz
Operates tance
Parking brake switch: Resis-
Min. 1 Mz
Between C08 (male) ON tance
(3) and (4) Parking brake switch: Resis-
Defective parking brake Max. 1 z
OFF tance
2 switch (Internal
Parking brake switch: Resis-
disconnection) Max. 1 z
Between C08 (5) and ON tance
(6) Parking brake switch: Resis-
Possible causes Min. 1 Mz
OFF tance
and standard
Between C08 (3) and Resis-
value in normal Always Min. 1 Mz
(6) tance
state
Defective parking brake
Resis-
3 solenoid (Internal Between PB.PS (male) (1) and (2) 10 – 40 z
tance
disconnection)
Between PB.PS (male) (1), (2) and chassis Resis-
Min. 1 Mz
ground tance
Parking brake:
Normal brake
Resis-
Defective emergency brake pressure Max. 1 z
tance
4 pressure switch (Internal Between B06 (male), Min. 4.9 MPa
disconnection) B07 (male) (1) and {50 kg/cm2}
(2) Parking brake:
Low brake pressure Resis-
Min. 1 Mz
Min. 3.14 MPa tance
{32 kg/cm2}
WD600-6 40-301 31
SEN05051-01 Failure code [2F00MA] Parking brake: Malfunction

Between C04 (female) (1) and PB.SW Resis-
Max. 1 z
(female) (1) tance
Between C08 (female) (3) and B06 (female) Resis-
Max. 1 z
Disconnection in wiring (1) tance
harness Between B06 (female) (2) and B07 (female) Resis-
5 Max. 1 z
(Disconnection or defective (1) tance
contact) Between B07 (female) (2) and PB.PS Resis-
Possible causes Max. 1 z
(female) (1) tance
and standard
value in normal Between C08 (female) (3) and L03 (female) Resis-
Max. 1 z
state (6) tance
Between PB.SW (female) (2) and chassis Resis-
Max. 1 z
ground tance
troubleshooting.
Parking brake oil
pressure: Voltage Max. 1 V
Between C04 (1) and Released
chassis ground Parking brake oil
pressure: Voltage 20 – 30 V
Operates
40-301 32 WD600-6
Failure code [2F00MA] Parking brake: Malfunction SEN05051-01
Circuit diagram related to parking brake
WD600-6 40-301 33
SEN05051-01 Failure code [2G42ZG] Front Accumulator Oil Pressure Low
Failure code [2G42ZG] Front Accumulator Oil Pressure Low 1
Action code Failure code Front accumulator: Low oil pressure

Failure
E03 2G42ZG (Machine monitor system)
Detail of failure • After 45 seconds from engine startup, front brake accumulator pressure sensor circuit opened.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
• Front brake accumulator oil pressure lowers.
Problem on
• Brake may not work.
machine
• Parking brake may keep working.
• Input (ON/OFF) from front brake oil pressure sensor can be checked with monitoring function
Related infor-
(Code: 40902, D-IN-16).
mation
• Method of reproducing failure code: Turn starting switch to ON position.

Front brake accumulator oil Check front brake accumulator oil pressure.
1
pressure lowers. (See Testing and adjusting)
side.
3. Depress brake pedal 10 times, then perform troubleshooting.
4. Start engine.
Defective front brake oil Front brake

accumulator oil pres-
2 pressure sensor (internal sure: Normal pres- Resis-
open circuit) Max. 1z
sure tance
Min. 5.88 MPa
Probable Between B05 {Min. 60kg/cm2}
causes and cri- (male) (1) and (2)
teria Front brake
Resis-
sure: Low pressure Min. 1 Mz
tance
Max. 3.92 MPa
{Max. 40kg/cm2}
2. Disconnect connectors C03 and B05 and connect T-adapters
Open circuit in wiring to each female side.
harness
(female) (1) tance
Resis-
Between B05 (female) (2) and ground Max. 1z
tance
If no failure is found by above checks, machine monitor is
4 Defective machine monitor defective. (Since this is an internal defect, troubleshooting cannot
be performed.)
40-301 34 WD600-6
Failure code [2G42ZG] Front Accumulator Oil Pressure Low SEN05051-01
Circuit diagram related to front brake accumulator
WD600-6 40-301 35
SEN05051-01
WD600-6 Wheel dozer

©2016 KOMATSU
All Rights Reserved
40-301 36
SEN05052-02
WHEEL DOZER
WD600-6

WD600-6 55001 and up

Failure code [2G43ZG] Rear Accumulator Oil Pressure Low ......................................................................... 4
Failure code [A000N1] (or VHMS_LED display: “n2” → “01”) Engine: Overrun ............................................. 7
Failure code [AA1ANX] Air Cleaner Clogging................................................................................................. 8
Failure code [AB00L6] Alternator: Signal disagrees with run and stop of engine ......................................... 10
Failure code [AB00MA] Alternator: Malfunction ............................................................................................ 12
Failure code [B@BAZG] Engine oil pressure: Low error .............................................................................. 14
Failure code [B@BAZK] Eng Oil Level Low.................................................................................................. 15
Failure code [B@BCNS] Engine coolant temperature: Overheating ............................................................ 16
Failure code [B@BCZK] Engine coolant level low ........................................................................................ 18
Failure code [B@C7NS] Brake oil overheating............................................................................................. 20
Failure code [b@CENS] Torque converter oil overheating ........................................................................... 21
Failure code [B@CENS] Torque converter oil overheating........................................................................... 22
Failure code [B@GAZK] Low Battery Fluid Level ......................................................................................... 23
Failure code [B@HANS] Hyd Oil Overheat................................................................................................... 24
Failure code [CA111] Abnormality in engine controller ................................................................................. 26
Failure code [CA115] Engine Ne or Bkup speed sensor error ...................................................................... 29
Failure code [CA122] Charge (boost) pressure sensor high error ................................................................ 30
Failure code [CA123] Charge (boost) pressure sensor low error ................................................................. 32
Failure code [CA131] Throttle sensor high error........................................................................................... 34
Failure code [CA132] Throttle sensor low error ............................................................................................ 37
Failure code [CA135] Engine oil pressure sensor high error ........................................................................ 40
WD600-6 40-302 1
SEN05052-02
Failure code [CA141] Engine oil pressure sensor low error.......................................................................... 42

Failure code [CA144] Coolant temperature sensor high error ...................................................................... 44
Failure code [CA145] Coolant temperature sensor low error........................................................................ 46
Failure code [CA153] Charge (boost) temperature sensor high error........................................................... 48
Failure code [CA154] Charge (boost) temperature sensor low error ............................................................ 50
Failure code [CA187] Sensor power supply 2 low error................................................................................ 52
Failure code [CA212] Engine oil temperature sensor high error ................................................................... 54
Failure code [CA213] Engine oil temperature sensor low error .................................................................... 56
Failure code [CA221] Atmospheric pressure sensor high error .................................................................... 58
Failure code [CA222] Atmospheric pressure sensor low error...................................................................... 60
40-302 2 WD600-6
SEN05052-02
WD600-6 40-302 3
SEN05052-02 Failure code [2G43ZG] Rear Accumulator Oil Pressure Low
Failure code [2G43ZG] Rear Accumulator Oil Pressure Low 1
Action code Failure code Rear accumulator: Low oil pressure

Failure
E03 2G43ZG (Machine monitor system)
Detail of failure • After 45 seconds from engine startup, rear brake accumulator pressure sensor circuit opened.
• Rear brake accumulator oil pressure lowers.
Problem on
• Brake may not work.
machine
• Parking brake may keep working.
• Input (ON/OFF) from rear brake oil pressure sensor can be checked with monitoring function (Code:
Related infor-
40902, D-IN-17).
mation

Rear brake accumulator oil Check rear brake accumulator oil pressure.
1
pressure lowers. (See Testing and adjusting)
side.
3. Depress brake pedal 10 times, then perform troubleshooting.
4. Start engine.
Defective rear brake oil Rear brake

2 pressure sensor (internal sure: Normal pres- Resis-
open circuit) Max. 1 Ω
sure tance
Min. 5.88 MPa
Probable Between B04 {Min. 60kg/cm2}
causes and cri- (male) (1) and (2)
teria Rear brake
Resis-
sure: Low pressure Min. 1 MΩ
tance
Max. 3.92 MPa
{Max. 40kg/cm2}
2. Disconnect connectors C03 and B04 and connect T-adapters
harness
(Wire breakage or defective Max. 1 Ω
(female) (1) tance
Resis-
Between B04 (female) (2) and ground Max. 1 Ω
tance
If no failure is found by above checks, machine monitor is
be performed.)
40-302 4 WD600-6
Failure code [2G43ZG] Rear Accumulator Oil Pressure Low SEN05052-02
Circuit diagram related to rear brake accumulator
WD600-6 40-302 5
SEN05052-02 Failure code [2G43ZG] Rear Accumulator Oil Pressure Low
40-302 6 WD600-6
Failure code [A000N1] (or VHMS_LED display: “n2” → “01”) Engine: Overrun SEN05052-02
Failure code [A000N1] (or VHMS_LED display: “n2” → “01”) Engine:

Overrun 1
Action code Failure code Engine: Overrun

Trouble
— A000N1 (VHMS controller system)
Contents of
• Engine speed exceeded 2,624 rpm.
trouble
Action of • None in particular.
Problem that
appears on —
machine
• The monitor panel does not display any failure code (the relevant failure code can be checked by
downloading data stored in the VHMS controller).
• The LED of the VHMS controller displays “n2” o “01”.
Related
• VHMS controller inputs engine speed signal with CAN communication from engine controller.
information
• If failure code [CA212] (engine speed sensor high error (VHMS)) is displayed, carry out trouble-
shooting for it first.
• Method of reproducing failure code: Start engine and travel.

Possible causes
Engine speed increased due to shift-down during travel.
and standard 1 Defective operating travel
• Instruct the operator on how to travel the machine properly.
value in normal
state If the above is normal, VHMS controller may be defective.
2 Defective VHMS controller
(Since trouble is in system, troubleshooting cannot be carried out.)
WD600-6 40-302 7
SEN05052-02 Failure code [AA1ANX] Air Cleaner Clogging
Failure code [AA1ANX] Air Cleaner Clogging 1
Action code Failure code Air cleaner: Clogged

Failure
E01 AA1ANX (Machine monitor system)
Detail of failure • Air cleaner clogging sensor circuit is open.

Action of • Turns on air cleaner clogging caution lamp.
Problem on • Engine does not start easily, does not pick up smoothly, lacks output power, and exhaust smoke is
machine black.
• Input (ON/OFF) from air cleaner clogging sensor can be checked with monitoring function (Code:
Related infor-
40902 D-IN-20).
mation

1 Air cleaner clogging Air cleaner may be clogged. Check it.
2. Disconnect connector E15.
Defective dust indicator 3. Start engine.
2
(Internal open circuit)
If failure code [AA1ANX] is not displayed, dust indicator is
defective.
a Be ready with starting switch at OFF, then perform trouble-
shooting without turning starting switch to ON position.
Resis- 200 to
Between L107 (male) (1) and (2)
Defective dust indicator tance 400 Ω
relay(L107) 1. Turn starting switch to OFF position.
3
(Internal open or short 2. Disconnect connector L107, and replace dust indicator relay
circuit) with another relay of same model.
3. Start engine.
Probable If failure code [AA1ANX] is not displayed, original dust indicator

causes and cri- relay is defective.
teria 1. Turn starting switch to OFF position.
2. Disconnect connectors L107, C03, and E15 and connect T-
adapters to female side.
3. Remove fuse No. 8 in fuse box B.
Open circuit in wiring Between C03 (female) (3) and L107 Resis-
Max. 1 Ω
harness (female) (3) tance
4
(Wire breakage or defective Resis-
Between L107 (female) (6) and ground Max. 1 Ω
contact of connector) tance
Between L107 (female) (2) and E15 Resis-
Max. 1 Ω
(female) (1) tance
Resis-
Between E15 (female) (2) and ground Max. 1 Ω
tance
Ground fault in wiring 2. Disconnect connectors L107 and E15, and connect T-adapter
5 harness to either female side.
(Contact with ground circuit) Between ground and L107 (female) (2) or Resis-
Min. 1 MΩ
E15 (female) (1) tance
40-302 8 WD600-6
Failure code [AA1ANX] Air Cleaner Clogging SEN05052-02

Probable
causes and cri- Dust indicator: Nor-
teria 6 Defective machine monitor mal (Air cleaner is Voltage 7 to 30V
Between C03 (3) normal)
and ground Dust indicator: Defec-
tive (Air cleaner is Voltage Max. 1 V
clogged)
Circuit diagram related to dust indicator
WD600-6 40-302 9
SEN05052-02 Failure code [AB00L6] Alternator: Signal disagrees with run and stop of engine
Failure code [AB00L6] Alternator: Signal disagrees with run and stop of
engine 1
Action code Failure code Alternator: Signal disagrees with run and stop of engine
Failure
E03 AB00L6 (Machine monitor system)
Detail of failure • While engine is stopped, alternator terminal R input voltage is 12 V or above.
Problem on • Engine does not start.
machine • Service meter advances only with starting switch turned to ON position.
• Input (voltage) from alternator can be checked with monitoring function (Code: 04302 ALTERNA-
Related infor-
TOR R).
mation

2. Disconnect alternator terminal R.
3. Start engine.
Defective alternator
1 Between alternator Engine running
(Internal defect) 27.5 to
terminal R (alterna- (Throttle at 1/2 or Voltage
29.5V
tor side) (E03) and higher)
ground Engine stopped Voltage Max. 1 V
Probable
Hot short circuit in wiring 2. Disconnect alternator terminal R.
causes and cri-
teria 2 harness (contact with 24 V 3. Turn starting switch to ON position.
circuit) Between alternator terminal R (harness
Voltage Max. 1 V
side) (E03) and ground
3. Start engine.
3 Defective machine monitor Engine running
27.5 to
Between C02 (18) (Throttle at 1/2 or Voltage
29.5V
and ground higher)
Engine stopped Voltage Max. 1 V
40-302 10 WD600-6
Failure code [AB00L6] Alternator: Signal disagrees with run and stop of engine SEN05052-02
Circuit diagram related to alternator
WD600-6 40-302 11
SEN05052-02 Failure code [AB00MA] Alternator: Malfunction
Failure code [AB00MA] Alternator: Malfunction 1
Action code Failure code Alternator: Malfunction

Failure
E03 AB00MA (Machine monitor system)
Detail of failure • While engine is running, alternator terminal R input voltage is 5V or less.
• Battery deteriorates.
Problem on
• Engine does not start.
machine
• Service meter does not advance.
• Input (voltage) from alternator can be checked with monitoring function (Code: 04302 ALTERNA-
Related infor-
TOR R).
mation

1 Deterioration of battery Battery may have deteriorated. Check it.
3. Start engine.
29.5V
Open circuit in wiring 2. Disconnect alternator terminal R.
harness 3. Disconnect connector C02, and connect T-adapter to female
3 side.
(Wire breakage or defective
Probable
causes and cri- contact of connector) Between alternator terminal R (E03) and Resis-
Max. 1 Ω
teria C02 (female) (18) tance
Ground fault in wiring 3. Disconnect connectors C02, R21, E01, and E02, and connect
4 harness T-adapter to female side of C02.
(Contact with ground circuit)
Between ground and alternator R terminal Resis-
Min. 1 MΩ
(E03) or C02 (female) (18) tance
3. Start engine.
5 Defective machine monitor Engine running
27.5 to
Between C02 (18) (Throttle at 1/2 or Voltage
29.5V
and ground higher)
Engine stopped Voltage Max. 1 V
40-302 12 WD600-6
Failure code [AB00MA] Alternator: Malfunction SEN05052-02
WD600-6 40-302 13
SEN05052-02 Failure code [B@BAZG] Engine oil pressure: Low error
Failure code [B@BAZG] Engine oil pressure: Low error 1
Action code Failure code

Trouble Engine oil pressure: Low error
E03 B@BAZG
Contents of
• When engine was running, engine oil pressure became lower than operating range.
trouble
Action of
• Limits output for travel (Limits injection rate and engine speed)
controller
Problem that
• Engine output drops.
appears on
• If the engine is operated continuously, it may become out of order.
machine
Related
information

Possible causes Since engine oil pressure may become excessively low, check it
1 Low engine oil pressure
and standard and repair the trouble.
value in normal If cause 1 is not a cause of the trouble, engine oil pressure sensor
state Defective engine oil pressure
2 system may be defective.
sensor system
Carry out troubleshooting for failure codes [CA135] and [CA141].
40-302 14 WD600-6
Failure code [B@BAZK] Eng Oil Level Low SEN05052-02
Failure code [B@BAZK] Eng Oil Level Low 1
Action code Failure code Engine oil: Low level

Failure
E01 B@BAZK (Machine monitor system)
Detail of failure • Engine oil level sensor circuit is open.

Action of • Turns on engine oil level caution lamp.
Problem on
• Engine oil level is low (Engine may be broken).
machine
• Input (ON or OFF) from the engine oil level sensor can be checked with monitoring function (Code:
Related infor-
40903 D-IN-29).
mation

1 Low engine oil level Engine oil level may be low. Check it.
2. Disconnect connector E14, and connect T-adapter to male
Defective engine oil level side.
2 sensor Resis-
Between E14 Engine oil is normal Max. 1 z
(Internal open circuit) tance
(male) (1) and
ground Resis-
Engine oil is low Min. 1 Mz
tance
Probable
causes and cri- 1. Turn starting switch to OFF position.
teria Open circuit in wiring 2. Disconnect connectors C04 and E14, and connect T-adapters
harness to each female side.
3
Between C04 (female) (11) and E14 Resis-
(female) (1) tance
Between C04 (11) Engine oil is normal Voltage Max. 1 V
and ground Engine oil is low Voltage Min. 7 V
Circuit diagram related to engine oil level sensor
WD600-6 40-302 15
SEN05052-02 Failure code [B@BCNS] Engine coolant temperature: Overheating
Failure code [B@BCNS] Engine coolant temperature: Overheating 1
Action code Failure code

Trouble Engine coolant temperature: Overheating
E02 B@BCNS
Contents of
• When engine was running, coolant temperature exceeded operating range.
trouble
Action of
• Limits output and continues operation.
controller
Problem that
appears on
• If the engine is operated continuously, it may become out of order.
machine
Related
information

Possible causes Overheating of engine Since engine coolant temperature may become overheat, check it
1
and standard coolant temperature and repair the trouble.
value in normal If cause 1 is not a cause of the trouble, engine coolant temperature
state Defective engine coolant
2 sensor system may be defective.
temperature sensor system
Carry out troubleshooting for failure codes [CA144] and [CA145].
40-302 16 WD600-6
Failure code [B@BCNS] Engine coolant temperature: Overheating SEN05052-02
WD600-6 40-302 17
SEN05052-02 Failure code [B@BCZK] Engine coolant level low
Failure code [B@BCZK] Engine coolant level low 1
Action code Failure code Coolant: Low level

Failure
E01 B@BCZK (Machine monitor system)
Detail of failure • Coolant level sensor circuit is open.

Action of • Turns on coolant level caution lamp.
Problem on
• Coolant level decreases. Engine overheats (Engine may be broken).
machine
• Input (ON/OFF) from coolant level sensor can be checked with monitoring function (Code: 40903
Related infor-
D-IN-27).
mation

1 Low coolant level Coolant level may be low. Check it.
2. Disconnect connector G05, and connect T-adapter to male
Defective coolant level side.
2 sensor Radiator coolant level Resis-
Max. 1 z
(internal open circuit) Between G05 is normal tance
(male) (1) and (2) Lowered radiator Resis-
Min. 1 Mz
coolant level tance
Probable 2. Disconnect connectors C04 and G05 and connect T-adapters
causes and cri- Open circuit in wiring to each female side.
teria harness
3 Between C04 (female) (10) and G05 Resis-
(Wire breakage or defective Max. 1 z
(female) (1) tance
Resis-
Between G05 (female) (2) and ground Max. 1 z
tance
4 Defective machine monitor Radiator coolant
Voltage Max. 1 V
Between C04 (10) level is normal
and ground Lowered radiator
Voltage Min. 7 V
coolant level
40-302 18 WD600-6
Failure code [B@BCZK] Engine coolant level low SEN05052-02
Circuit diagram related to coolant level sensor
WD600-6 40-302 19
SEN05052-02 Failure code [B@C7NS] Brake oil overheating
Failure code [B@C7NS] Brake oil overheating 1
Action code Failure code Brake oil tank: Overheating

Failure
E02 B@C7NS (Machine monitor system)
• Brake oil temperature was above 130 °C for 5 seconds.

Detail of failure
• When travel speed was above 35 km/h, brake oil temperature was above 125 °C for 5 seconds.
Problem on • Brake oil temperature caution lamp lights up.
machine • Brake may be damaged.
• Input (oil temperature) from rear brake oil temperature sensor can be checked with monitoring func-
tion (Code: 30202 R BRAKE OIL).
Related infor-
• Input (voltage) from rear brake oil temperature sensor can be checked with monitoring function
mation
(Code: 30205 R BRAKE OIL).

Brake may overheat due to improper brake operation during travel.
Probable 1 Improper brake operation
• Teach operator proper brake operation.
causes and cri-
teria Defective rear brake oil
2 temperature sensor system Perform troubleshooting for failure code [DGR2KX].
(internal defect)
40-302 20 WD600-6
Failure code [b@CENS] Torque converter oil overheating SEN05052-02
Failure code [b@CENS] Torque converter oil overheating 1
Action code Failure code Torque converter oil: Overheating

Failure
E02 b@CENS (Machine monitor system)
Detail of failure • Torque converter oil temperature is above 120 °C.

Action of • If failure disappears (oil temperature keeps below 120 °C for 1 second), machine becomes normal
controller by itself.
Problem on • Torque converter oil temperature caution lamp lights up (if machine is used as it is, torque converter
machine may be damaged).
• Input (oil temperature) from torque converter oil temperature sensor can be checked with monitoring
function (Code: 40100 TC OIL TEMP).
Related infor-
• Input (voltage) from torque converter oil temperature sensor can be checked with monitoring func-
mation
tion (Code: 40101 TC OIL TEMP).

Torque converter oil may overheat due to stall of torque converter,
Overheating of torque
Probable 1 etc. (see Troubleshooting of hydraulic and mechanical system (H-
converter oil
causes and cri- mode)).
teria
Defective torque converter
2 oil temperature sensor Perform troubleshooting for failure code [DGT1KX].
system
WD600-6 40-302 21
SEN05052-02 Failure code [B@CENS] Torque converter oil overheating
Failure code [B@CENS] Torque converter oil overheating 1
Action code Failure code Torque converter oil: Overheating

Failure
E02 B@CENS (Machine monitor system)
Detail of failure • Torque converter oil temperature is above 130 °C.

• Lights up centralized warning lamp and sounds alarm buzzer.
Action of
controller • If failure disappears (oil temperature keeps below 130 °C for 1 second), machine becomes normal
by itself.
Problem on • Torque converter oil temperature caution lamp lights up (if machine is used as it is, torque converter
machine may be damaged).
• Input (oil temperature) from torque converter oil temperature sensor can be checked with monitoring
function (Code: 40100 TC OIL TEMP).
Related infor-
• Input (voltage) from torque converter oil temperature sensor can be checked with monitoring func-
mation
tion (Code: 40101 TC OIL TEMP).

Torque converter oil may overheat due to stall of torque converter,
Overheating of torque
Probable 1 etc. (see Troubleshooting of hydraulic and mechanical system (H-
converter oil
causes and cri- mode)).
teria
Defective torque converter
2 oil temperature sensor Perform troubleshooting for failure code [DGT1KX].
system
40-302 22 WD600-6
Failure code [B@GAZK] Low Battery Fluid Level SEN05052-02
Failure code [B@GAZK] Low Battery Fluid Level 1
Action code Failure code Battery fluid: Low level

Failure
E01 B@GAZK (Machine monitor system)
Detail of failure • The electrolyte level sensor (if equipped) voltage is below 2 V (for continuous 10 seconds).
Action of • Turns on electrolyte level caution lamp.
• Electrolyte level caution lamp lights up.
Problem on
• Electrolyte level becomes low.
machine
• Engine startability may become poor.
• Input (voltage) from electrolyte level sensor can be checked with monitoring function (Code: 40300
Related infor-
BATTERY A).
mation

Electrolyte level becomes
1 Electrolyte level may be low. Check it.
low.
2. Disconnect connector D05, and connect T-adapter to male
side.
Defective electrolyte level
2 sensor Battery electrolyte
Voltage Min. 2 V
level: Normal
(Internal open circuit) Between D05 (1)
and chassis ground Battery electrolyte
level: Insufficient level Voltage Max. 2 V
(Low level)
Probable
Open circuit in wiring 2. Disconnect connectors C05 and D05 and connect T-adapters
teria
harness to each female side.
3
Between C05 (female) (5) and D05 Resis-
(female) (1) tance
4 Defective machine monitor Battery electrolyte

Voltage Min. 2 V
level: Normal
Between C05 (5)
and chassis ground Battery electrolyte
level: Insufficient level Voltage Max. 2 V
(Low level)
Circuit diagram related to electrolyte level sensor
WD600-6 40-302 23
SEN05052-02 Failure code [B@HANS] Hyd Oil Overheat
Failure code [B@HANS] Hyd Oil Overheat 1
Action code Failure code Hydraulic oil: Overheating

Failure
E02 B@HANS (Machine monitor system)
Detail of failure • Hydraulic oil temperature is above 100 °C.

Problem on • Hydraulic oil overheat warning is displayed. (If machine is used as it is, pump and cylinder seals
machine may be broken).
• Input (oil temperature) from hydraulic oil temperature sensor can be checked with monitoring func-
tion (Code: 04401 HYD TEMP).
Related infor-
• Input (voltage) from hydraulic oil temperature sensor can be checked with monitoring function
mation
(Code: 04404 HYD TEMP).

Probable
1 Overheating of hydraulic oil Hydraulic oil may be overheating. Check it.
causes and cri-
teria Defective hydraulic oil
2 Perform troubleshooting for failure code [DGH2KX].
temperature sensor
40-302 24 WD600-6
Failure code [B@HANS] Hyd Oil Overheat SEN05052-02
WD600-6 40-302 25
SEN05052-02 Failure code [CA111] Abnormality in engine controller
Failure code [CA111] Abnormality in engine controller 1
Action code Failure code Abnormality in engine controller

Failure
E03 CA111 (Engine controller system)
Detail of failure q Trouble occurred in engine controller.

Action of con-
q Turns the centralized warning lamp and alarm buzzer ON.
troller
Problem on
q Engine continues running, but it may stop during operations or may not restart once it is in stopped.
machine
q Power supply voltage of engine controller can be checked with monitoring function.
Related infor-
(Code: 03200 Battery voltage)
mation
q Method of reproducing failure code: Turn starting switch to ON position

1 Loose or corroded battery terminal Battery cable terminal may be loose or corroded. Check it.
Loosened terminal or partial dis- 1. Turn starting switch to OFF position.

2
connection at terminal Check terminals of alternator, battery relay, ground (E22) etc. for looseness.
See descriptions of wiring harness and connectors in "Electrical equipment" in
Defective wiring harness connec-
3 "Checks before troubleshooting" of "General information on troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position, then carry out troubleshooting.
2. Perform troubleshooting when engine is cranked.
4 Improper battery voltage
Between battery terminal (+) and (-). Voltage 20 – 30 V

2. Insert T-adapter between male and female side of connector ER1.
5 Defective alternator 3. Start engine (Engine speed: Middle or faster).
Between ER1 (4) and ground Voltage 26 – 30.5 V
2. Disconnect connector E19, and connect T-adapter to female side.
6 Defective input power supply 3. Turn starting switch to ON position.
Between E19 (female) (4) and (1) Voltage 20 – 30 V
If no abnormality is found by above checks, engine controller is defective.
(Since failure is in it, troubleshooting cannot be performed.)
q Reference: The followings are standard values in normal condition.
1. Turn starting switch to OFF position and disconnect ground strap.
7 Defective engine controller 2. Insert T-adapter between male and female sides of E19.
3. Connect the ground cable.
4. Measure voltage with starting switch at OFF position and when starting
engine.
Between E19 (4) and (1) Voltage 20 – 30 V
40-302 26 WD600-6
Failure code [CA111] Abnormality in engine controller SEN05052-02
WD600-6 40-302 27
SEN05052-02 Failure code [CA111] Abnormality in engine controller
Circuit diagram related to engine controller power supply
40-302 28 WD600-6
Failure code [CA115] Engine Ne or Bkup speed sensor error SEN05052-02
Failure code [CA115] Engine Ne or Bkup speed sensor error 1
Action code Failure code Abnormality in engine Ne/Bkup speed sensor

Failure
Detail of failure • Abnormality occurred in the signal of Ne and Bkup speed sensor circuits at the same time.
Action of con- • Stops the engine.
troller • Turns the centralized warning lamp and alarm buzzer ON.
Problem on • The engine does not start. (if engine has been stopped.)
machine • Engine stops. (if engine has been running.)
Related infor-
mation

1 Defective Ne speed sensor system Carry out troubleshooting for failure code [CA689].
2 Defective Bkup speed sensor system Carry out troubleshooting for failure code [CA778].
If cause is not found by above checks,, engine controller may be
3 Defective engine controller defective. (Since failure is in it, troubleshooting cannot be per-
formed.)
WD600-6 40-302 29
SEN05052-02 Failure code [CA122] Charge (boost) pressure sensor high error
Failure code [CA122] Charge (boost) pressure sensor high error 1
Action code Failure code Charge pressure sensor too high

Failure
Detail of failure • High voltage occurred in charge pressure sensor (boost pressure sensor) signal circuit.
Action of con- • Takes it that boost pressure is at fixed value (400 kPa {4.1 kg/cm2}), and allows engine to run.
Problem on
machine
• The signal (voltage) from the charge pressure sensor (boost pressure sensor) can be checked with
the monitoring function (Code: 36502 (V)).
• Pressure (Boost pressure) sensed by charge pressure sensor (boost pressure sensor) can be
Related infor-
checked with monitoring function (Code: 36500 (kPa)).
mation
• If sensor connector is disconnected, code [CA123] for "Low Error" is displayed, even in normal con-
dition.

tor
and check them.
Defective sensor power supply If failure code [CA187] or [CA227] is displayed at the same time, carry out trou-
2
system bleshooting for that first.
2. Disconnect connector PIM.
Defective charge pressure (boost 3. Turn starting switch to ON position.
3
pressure) sensor
If failure code changes from [CA122] to [CA123], charge pressure (boost pres-
sure) sensor is defective.
2. Disconnect connectors ENG and PIM, and connect T-adapter to female side
4 Short circuit in wiring harness of ENG.
Between ENG (female) (37) - (44) Resistance Min. 1 Mz

Hot short circuit in wiring harness 2. Disconnect connector PIM, and insert T-adapter into connector ENG.
5 3. Turn starting switch to ON position (with connector PIM disconnected).
(Short circuit with 24 V circuit)
Between ENG (44) and (47) Voltage Max. 1V
6 Defective engine controller
40-302 30 WD600-6
Failure code [CA122] Charge (boost) pressure sensor high error SEN05052-02
Circuit diagram related to charge pressure sensor
WD600-6 40-302 31
SEN05052-02 Failure code [CA123] Charge (boost) pressure sensor low error
Failure code [CA123] Charge (boost) pressure sensor low error 1
Action code Failure code Charge pressure sensor too low

Failure
Detail of failure • Low voltage occurred in charge pressure sensor (boost pressure sensor) signal circuit.
Action of con- • Takes it that boost pressure is at fixed value (400 kPa {4.1 kg/cm2}), and allows engine to run.
Problem on
machine
• The signal (voltage) from the charge pressure sensor (boost pressure sensor) can be checked with
the monitoring function (Code: 36502 (V)).
• Pressure (Boost pressure) sensed by charge pressure sensor (boost pressure sensor) can be
checked with monitoring function (Code: 36500 (kPa)).
Related infor-
mation
• Because troubleshooting "socket" for this sensor features female connector alone, it is not usable
for checking open circuit in wiring harness and voltage at sensor connector (not designed as a T-
adapter).
• If sensor connector is disconnected, this code is displayed.

tor
and check them.
If failure code [CA187] or [CA227] is also displayed, perform troubleshooting for
it first.
Defective power supply system of 1. Turn starting switch to OFF position.
2 charge pressure sensor (boost 2. Insert T-adapter into connector ENG.
pressure sensor) 3. Turn starting switch to ON position.
4.75 – 5.25
Between ENG (37) and (47) Power input Voltage
V
2. Disconnect connectors ENG and PIM.
3 Short circuit in wiring harness 3. Connect T-adapter to female side of ENG.
Between ENG (female) (44) and (47) Resistance Min. 1 Mz

2. Disconnect connectors ENG and PIM, and connect T-adapter to female side
Ground fault in wiring harness of ENG.
4
Between ENG (female) (44) and ground Resistance Min. 1 Mz
If cause is not found by the above checks, there may be open circuit in wiring
5 Open circuit in wiring harness
harness. (*)
a If causes 1 - 5 are not the cause for the trouble and check result of cause 6
is abnormal, sensor is defective.
Defective charge pressure (boost 1. Turn starting switch to OFF position.
pressure) sensor 2. Insert T-adapter into connector ENG.
6
(Improper input voltage to engine 3. Turn starting switch to ON position.
controller)
Sensor out-
Between ENG (44) and (47) Voltage 0.3 – 4.7 V
put
*: See "Troubleshooting method for disconnected wiring harness of pressure sensor system" of "Related trou-
bleshooting information".
40-302 32 WD600-6
Failure code [CA123] Charge (boost) pressure sensor low error SEN05052-02
Circuit diagram related to charge pressure sensor
WD600-6 40-302 33
SEN05052-02 Failure code [CA131] Throttle sensor high error
Failure code [CA131] Throttle sensor high error 1
Action code Failure code Throttle sensor too high

Failure
Detail of failure • High voltage occurred in accelerator pedal signal circuit.

Action of con- • Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 50% when it is ON.
Problem on
• The engine does not reach full throttle.
machine
• The input state (position of accelerator pedal) from the throttle sensor can be checked with the mon-
itoring function (Code: 31701).
Related infor-
• The input voltage from the throttle sensor can be checked with the monitoring function (Code:
mation
31707).

tor
and check them.
If failure code [CA2185] is displayed, troubleshoot it first.
Defective throttle sensor power 2. Disconnect connectors C17 and connect T-adapter to female side.
2
supply system 3. Turn starting switch to ON position.
4.75 – 5.25
Between C17 (female) (1) and (3) Power input Voltage
V
Depress accelerator Approx. 3.7
Voltage
Defective accelerator pedal (throt- pedal. V
3 Between C17 (2) and (3)
tle sensor) Release accelerator Approx. 0.4
Voltage
pedal. V
Sensor voltage is measured with wiring harness connected. Accordingly, if volt-
age is abnormal, check wiring harness and controller, too, for another cause of
trouble, and then judge.
a If no abnormality is found in checks on cause 4, this check is not required.
2. Disconnect connectors E18 and C17, and connect T-adapter to female side
4 Short circuit in wiring harness of either of them.
Between E18 (female) (9) and (22), or between C17
Resistance Min. 1 Mz
(female) (1) and (2)
Hot short circuit in wiring harness 2. Disconnect connector C17 and connect T-adapter to female side.
5 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between C17 (female) (2) and (3) Voltage Max. 1 V
40-302 34 WD600-6
Failure code [CA131] Throttle sensor high error SEN05052-02

If no abnormality is found by the above checks, the engine controller is defec-
tive. (Since the failure is in it, troubleshooting cannot be performed.)
• Reference; the followings are standard values in normal condition.
2. Insert T-adapter between male and female sides of E18.
4. Operate accelerator pedal, and troubleshoot.
4.75 – 5.25
Between E18 (22) and (23) Power supply Voltage
V
Voltage
pedal. V
Between E18 (9) and (23)
Release accelerator Approx. 0.4
Voltage
pedal. V
WD600-6 40-302 35
SEN05052-02 Failure code [CA131] Throttle sensor high error
Circuit diagram related to throttle sensor
40-302 36 WD600-6
Failure code [CA132] Throttle sensor low error SEN05052-02
Failure code [CA132] Throttle sensor low error 1
Action code Failure code Throttle sensor too low

Failure
Detail of failure • Accelerator pedal signal circuit of throttle sensor detected abnormally low voltage.
Action of con- • Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 50% when it is ON.
Problem on
• The engine does not reach full speed.
machine
• The input state (position of accelerator pedal) from the throttle sensor can be checked with the mon-
itoring function (Code: 31701).
Related infor-
• The input voltage from the throttle sensor can be checked with the monitoring function (Code:
mation
31707).

tor
and check them.
If failure code [CA2186] is also indicated, perform troubleshooting for it first.
Defective throttle sensor power 2. Disconnect connectors C17 and connect T-adapter to female side.
2
4.75 – 5.25
Between C17 (female) (1) and (3) Power input Voltage
V
2. Insert T-adapter info connector C17
Voltage
Defective accelerator pedal (throt- pedal. V
3 Between C17 (2) and (3)
tle sensor) Release accelerator Approx. 0.4
Voltage
pedal. V
Sensor voltage is measured with wiring harness connected. Accordingly, if volt-
age is abnormal, check wiring harness and controller, too, for another cause of
trouble, and then judge.
2. Disconnect connector E18 and C17 and connect T-adapter to each female side.
a If no abnormality is found in checks on cause 2,
Open circuit in wiring harness this check is not required. Resistance Max. 1 z
4 (Open circuit in wiring or defective Between E18 (female) (22) and C17 (female) (1)
contact in connector) Between E18 (female) (9) and C17 (female) (2) Resistance Max. 1 z
a If no abnormality is found in checks on cause 2,
this check is not required. Resistance Max. 1 z
Between E18 (female) (23) and C17 (female) (3)
2. Disconnect connectors E18 and C17, and connect T-adapter to female side
5 Short circuit in wiring harness of either of them.
Between E18 (female) (9) and (23), or between C17
WD600-6 40-302 37
SEN05052-02 Failure code [CA132] Throttle sensor low error

Ground fault in wiring har- 2. Disconnect connectors E18 and C17, and connect T-adapter to female side of
ness either of them.
6
(Contact with ground cir-
Between E18 (female) (9) or C17 (female) (2) and
cuit) Resistance Min. 1 Mz
ground
If no abnormality is found by above checks, engine controller is defective. (Since fail-
ure is in it, troubleshooting cannot be performed.)
• Reference: the followings are standard values in normal condition.
2. Insert T-adapter between male and female sides of E18.
7 Defective engine controller 4. Operate accelerator pedal, and troubleshoot.
Between E18 (22) and (23) Power supply Voltage 4.75 – 5.25 V
Depress accelerator
Voltage Approx. 3.7 V
pedal.
Between E18 (9) and (23)
Release accelerator
Voltage Approx. 0.4 V
pedal.
40-302 38 WD600-6
Failure code [CA132] Throttle sensor low error SEN05052-02
WD600-6 40-302 39
SEN05052-02 Failure code [CA135] Engine oil pressure sensor high error
Failure code [CA135] Engine oil pressure sensor high error 1
Action code Failure code Eng Oil Press Sensor High Error
Failure
Detail of failure • High voltage was detected in engine oil pressure sensor signal circuit.
Action of con-
• Takes it that engine oil pressure is default (250 kPa {2.5 kg/cm2}), and allows engine to run.
troller
Problem on
machine
• Signal voltage from the engine oil pressure sensor can be checked with the monitoring function
(Code: 37201 (V)).
Related infor-
• Oil pressure sensed by engine oil pressure sensor can be checked with monitoring function (Code:
mation
37200 (kPa)).

tor
and check them.
Defective power supply system of
2 If failure code [CA187] or [CA227] indicated, carry out troubleshooting for it first.
engine oil pressure sensor
Defective engine oil pressure sen- 2. Disconnect connector POIL.
sor
If failure code changes from [CA135] to [CA141], sensor is defective.
Open circuit in wiring harness 2. Disconnect connectors ENG and POIL, and connect T-adapter to each
4 (Open circuit in wiring or defective female side.
contact in connector)
Between ENG (female) (47) and POIL (female) (2) Resistance Max. 1 z
2. Disconnect connectors ENG and POIL, and connect T-adapter to female
5 Short circuit in wiring harness side of either one of them.
Between ENG (female) (13) and (37), or between
POIL (female) (1) and (3)
2. Disconnect connector POIL.
3. Connect T-adapter to female side of connector POIL or connect T-adapter to
Hot short circuit in wiring harness connector ENG.
6
(Short circuit with 24 V circuit) 4. Turn starting switch to ON position (with connector POIL disconnected).
Voltage Max. 1 V
40-302 40 WD600-6
Failure code [CA135] Engine oil pressure sensor high error SEN05052-02
Circuit diagram related to engine oil pressure sensor
WD600-6 40-302 41
SEN05052-02 Failure code [CA141] Engine oil pressure sensor low error
Failure code [CA141] Engine oil pressure sensor low error 1
Action code Failure code Eng Oil Press Sensor Low Error
Failure
Detail of failure • Low voltage was detected in engine oil pressure sensor signal circuit.
Action of con-
• Takes it that engine oil pressure is default (250 kPa {2.5 kg/cm2}), and allows engine to run.
troller
Problem on
machine
• Signal voltage from the engine oil pressure sensor can be checked with the monitoring function
(Code: 37201 (V)).
Related infor-
• Oil pressure sensed by engine oil pressure sensor can be checked with monitoring function (Code:
mation
37200 (kPa)).

tor
and check them.
it first.
Defective power supply system of 2. Disconnect connector POIL and connect T-adapter to each female side of
2
engine oil pressure sensor them.
Power sup- 4.75 – 5.25
Between POIL (female) (1) and (2) Voltage
ply input V
2. Disconnect connectors ENG and POIL and connect T-adapter to female side.
a If power supply input in checks on cause 2 is nor-
mal, this check is not required. Resistance Max. 1 z
Open circuit in wiring harness Between ENG (female) (37) and POIL (female) (1)
3 (Open circuit in wiring or defective
contact in connector) a If power supply input in checks on cause 2 is nor-
Between ENG (female) (47) and POIL (female) (2)
Between ENG (female) (13) and POIL (female) (3)
Resistance Max. 1 z
(Sensor output)
Ground fault in wiring harness side of either one of them.
4
Between ENG (female) (13) or POIL (female) (3) and
ground
5 Short circuit in wiring harness side of either one of them.
40-302 42 WD600-6
Failure code [CA141] Engine oil pressure sensor low error SEN05052-02

a If cause items 1 - 5 are not the cause for the trouble and check result of cause
6 is abnormal, sensor is defective.
Defective engine oil pressure sen- 1. Turn starting switch to OFF position.
6 sor (Improper input voltage to 2. Insert T-adapter into connector ENG.
engine controller) 3. Turn starting switch to ON position.
Sensor out-
put
Circuit diagram related to engine oil pressure sensor
WD600-6 40-302 43
SEN05052-02 Failure code [CA144] Coolant temperature sensor high error
Failure code [CA144] Coolant temperature sensor high error 1
Action code Failure code Coolant Temp Sens High Error

Failure
Detail of failure • High voltage was detected in engine coolant temperature sensor signal circuit.
Action of con-
• Sets coolant temperature to fixed temperature (90 °C), and allows for operation.
troller
Problem on • Engine does not start easily at low temperature.
machine • Overheat prevention function does not work.
• Signal voltage from engine coolant temperature sensor can be checked with monitoring function
(Code: 04105 (V)).
• Temperature sensed by engine coolant temperature sensor can be checked by using monitoring
function. (Code: 04104 (°C))
Related infor-
mation
• This failure code is displayed if temperature sensor connector is disconnected.
• Because troubleshooting "socket" for this sensor features female connector alone, it is not connect-
able to female connector of sensor wiring harness, and thus not usable for checking open circuit (not
designed as a T-adapter).

tor
and check them.
2. Disconnect connector TWTR and connect socket to male side of connector.
a If coolant temperature sensor has resistance of 700 z - 37 kz with coolant
temperature above 0 °C, regard coolant temperature sensor as normal.
Defective coolant temperature 0 °C Resistance 30 – 37 kz

2 Between TWTR (male)
sensor 25 °C Resistance 9.3 – 10.7 kz
(A) and (B)
a Coolant temperature - 50 °C Resistance 3.2 – 3.8 kz
Resistance character-
80 °C Resistance 1.0 – 1.3 kz
istics
95 °C Resistance 700 – 800 z
2. Disconnect connector ENG and connect T-adapter to female side.
Open or short circuit in wiring har- Between ENG (female) (15) and (38) (Coolant tem-
3
ness perature: Min. 0 °C) 700 z –
Resistance
a Use "coolant temperature -Resistance character- 37 kz
istics" table shown above as resistance criteria.
40-302 44 WD600-6
Failure code [CA144] Coolant temperature sensor high error SEN05052-02
Circuit diagram related to coolant temperature sensor
WD600-6 40-302 45
SEN05052-02 Failure code [CA145] Coolant temperature sensor low error
Failure code [CA145] Coolant temperature sensor low error 1
Action code Failure code Coolant Temp Sens Low Error

Failure
Detail of failure • Low voltage was detected in engine coolant temperature sensor signal circuit.
Action of con-
• Sets coolant temperature to fixed temperature (90 °C), and allows for operation.
troller
machine • Overheat prevention function does not work.
• Signal voltage from engine coolant temperature sensor can be checked with monitoring function
(Code: 04104 (V)).
Related infor-
function. (Code: 04104 ( °C))
mation
• If temperature sensor connector is disconnected, this failure code is not displayed but failure code
[CA144] for "High Error" is displayed.

tor
and check them.
2. Disconnect connector TWTR and connect socket to male side of connector.
a If coolant temperature sensor has resistance of 700 z - 37 kz with coolant
temperature above 0 °C, regard coolant temperature sensor as normal.
0 °C Resistance 30 –37 kz
Between TWTR (male)
Defective coolant temperature (A) and (B)
2
sensor a Coolant temperature - 50 °C Resistance 3.2 – 3.8 kz
Resistance character-
istics
All coolant
Between (B) and ground tempera- Resistance Min. 1 Mz
ture range
3 Short circuit in wiring harness Between ENG (female) (15) and (38) (Coolant tem-
perature: Min. 0 °C) 700 z –
Resistance
a Use "coolant temperature -Resistance character- 37 kz
Ground fault in wiring harness 2. Disconnect connectors ENG and TWTR, and connect T-adapter to female
4 side of ENG.
If no abnormality is found by above checks, engine controller is defective. (Since
failure is in it, troubleshooting cannot be performed.)
40-302 46 WD600-6
Failure code [CA145] Coolant temperature sensor low error SEN05052-02
Circuit diagram related to coolant temperature sensor
WD600-6 40-302 47
SEN05052-02 Failure code [CA153] Charge (boost) temperature sensor high error
Failure code [CA153] Charge (boost) temperature sensor high error 1
Action code Failure code Charge (Boost) temperature sensor signal voltage is too high.
Failure
Detail of failure • High voltage was detected in charge (boost) temperature sensor signal circuit.
Action of con- • Set charge temperature to fixed temperature (70 °C), and allow for operation.
troller • Limits engine output and allows engine to run.
machine • Engine output drops.
• Signal voltage from charge temperature sensor (boost temperature sensor) can be checked with
monitoring function (Code: 18501 (V)).
• Temperature sensed by charge temperature sensor (boost temperature sensor) can be checked by
using monitoring function. (Code: 18500 ( °C))
Related infor-
mation

tor
and check them.
2. Disconnect connector TIM and connect socket to male side of connector.
a If temperature sensor has resistance of 280 z – 382 kz, regard charge tem-
perature sensor as normal.
-40 °C Resistance 291 – 382 kz
Defective charge temperature -20 °C Resistance 85 – 109 kz

2 Between TIM (male) (A)
sensor 0 °C Resistance 29 – 36 kz
and (B)
a Charge temperature - 30 °C Resistance 7.3 – 8.8 kz
Resistance chariacter-
istic
Open or short circuit in wiring har-
3 Between ENG (female) (23) and (47)
ness 280 z –
a Use "charge temperature-Resistance character- Resistance
382 kz
40-302 48 WD600-6
Failure code [CA153] Charge (boost) temperature sensor high error SEN05052-02
Circuit diagram related to charge temperature sensor
WD600-6 40-302 49
SEN05052-02 Failure code [CA154] Charge (boost) temperature sensor low error
Failure code [CA154] Charge (boost) temperature sensor low error 1
Action code Failure code Charge (Boost) temperature sensor signal volatge too low
Failure
Detail of failure • Low voltage was detected in charge (boost) temperature sensor signal circuit.
Action of con- • Set charge temperature to fixed temperature (70 °C), and allow for operation.
troller • Limits engine output and allows engine to run.
machine • Engine output drops.
• Signal voltage from charge temperature sensor (boost temperature sensor) can be checked with
monitoring function (Code: 18501 (V)).
• Temperature sensed by charge temperature sensor (boost temperature sensor) can be checked by
Related infor-
using monitoring function. (Code: 18500 ( °C))
mation

tor
and check them.
2. Disconnect connector TIM and connect socket to male side of connector.
a If temperature sensor has resistance of 280 z - 382 kz, regard charge tem-
perature sensor as normal.
-40 °C Resistance 291 – 382 kz
Defective charge temperature -20 °C Resistance 85 –109 kz

2 Between TIM (male) (A)
sensor 0 °C Resistance 29 –36 kz
and (B)
a Charge temperature - 30 °C Resistance 7.3 – 8.8 kz
Resistance chariacter-
60 °C Resistance 2.3 –2.7 kz
istic
3 Short circuit in wiring harness Between ENG (female) (23) and (47)
280 z –
a Use "charge temperature-Resistance character- Resistance
382 kz
Ground fault in wiring harness 2. Disconnect connectors ENG and TIM and connect T-adapter to female side
4 of ENG.
40-302 50 WD600-6
Failure code [CA154] Charge (boost) temperature sensor low error SEN05052-02
Circuit diagram related to charge temperature sensor
WD600-6 40-302 51
SEN05052-02 Failure code [CA187] Sensor power supply 2 low error
Failure code [CA187] Sensor power supply 2 low error 1
Action code Failure code Sens Supply 2 Volt Low Error

Failure
Detail of failure • Low voltage appears in sensor power supply 2 (5 V) circuit.

• Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor signals.
• Ignores signals from engine oil pressure sensor, takes it that engine oil pressure is default value (250
kPa {2.5 kg/cm2}), and allows engine to run.
• Ignores signals from ambient pressure sensor, takes it that ambient pressure is default value (52.44
Action of con- kPa {0.53 kg/cm2}), and allows engine to run.
troller • Ignores signals from boost pressure sensor, takes it that boost pressure is at fixed value (400 kPa
{4.1 kg/cm2}), and allows engine to run.
• Ignores signals from EGR valve lift sensor and bypass valve lift sensor, limits engine output and clos-
es EGR valve and bypass valve.
Problem on
machine
Related infor-
mation

tor
and check them.
Defective input power supply sys- If failure code [CA441] or [CA442] is displayed, perform troubleshooting for fail-
2
tem ure code [CA441] first.
2. Disconnect following connectors sequentially one by one and turn starting
switch to ON position each time.
3. After troubleshooting, return to 1.
If this failure code is not displayed when a connector is disconnected, that sen-
sor or engine wiring harness is defective.
a Other failure codes are displayed, too. This is because the connector is dis-
connected. Ignore failure codes other than [CA187].
Sensor, harness Connector
3 Defective sensor or wiring harness
Bkup speed sensor G connector
Oil pressure sensor POIL connector
Charge (boost) pressure sensor PIM connector
Ambient pressure sensor PAMB connector
EGR valve lift sensor SEGR connector
Bypass valve lift sensor SBP connector
Engine harness ENG
2. Disconnect connector ENG and connect T-adapter to male side.
4 Defective engine controller 3. Turn starting switch to ON position with engine wiring harness disconnected.
4.75 – 5.25
Between ENG (male) (37) and (47) Voltage
V
40-302 52 WD600-6
Failure code [CA187] Sensor power supply 2 low error SEN05052-02
Circuit diagram related to sensor power supply 2
WD600-6 40-302 53
SEN05052-02 Failure code [CA212] Engine oil temperature sensor high error
Failure code [CA212] Engine oil temperature sensor high error 1
Action code Failure code Eng Oil Temp Sensor Low Error
Failure
Detail of failure • High voltage was detected engine oil temperature sensor signal circuit
Action of con-
• Sets engine oil temperature to fixed value (100 °C), and allows engine to run.l
troller
Problem on
machine
• Signal voltage from engine oil temperature sensor can be checked with monitoring function (Code:
42702 (V)).
• Temperature sensed by engine oil temperature sensor can be checked with monitoring function
(Code: 42700 (°C)).
Related infor-
mation

tor
and check them.
2. Disconnect connectors TOIL and connect socket to male side of connector.
a If oil temperature sensor resistance is 700 z - 37 kz with oil temperature is
above0 °C, regard oil temperature sensor as normal.
0 °C Resistance 30 – 37 kz
2 Defective oil temperature sensor Between TOIL (male) (A)
and (B)
a Oil temperature -Re- 50 °C Resistance 3.2 – 3.8 kz
sistance characteris-
tics
Open or short circuit in wiring har- Between ENG (female) (17) and (47) (Oil tempera-
3
ness ture: Min. 0 °C) 700 z –
Resistance
a Use "Oil temperature -Resistance characteristics" 37 kz
table shown above as resistance criteria.
40-302 54 WD600-6
Failure code [CA212] Engine oil temperature sensor high error SEN05052-02
Circuit diagram related to engine oil temperature sensor
WD600-6 40-302 55
SEN05052-02 Failure code [CA213] Engine oil temperature sensor low error
Failure code [CA213] Engine oil temperature sensor low error 1
Action code Failure code Eng Oil Temp Sensor Low Error
Failure
Detail of failure • Low voltage was detected in engine oil temperature sensor signal circuit.
Action of con-
• Sets engine oil temperature to fixed value (100 °C), and allows engine to run.
troller
Problem on
machine
• Signal voltage from engine oil temperature sensor can be checked with monitoring function (Code:
42702 (V)).
• Temperature sensed by engine oil temperature sensor can be checked with monitoring function
Related infor-
(Code: 42700 (°C)).
mation

tor
and check them.
2. Disconnect connectors TOIL and connect socket to male side of connector.
a If oil temperature sensor resistance is 700 z – 37 kz with oil temperature is
above 0 °C, regard oil temperature sensor as normal.
0 °C Resistance 30 – 37 kz
Between TOIL (male) (A)
and (B)
2 Defective oil temperature sensor
a Oil temperature -Re- 50 °C Resistance 3.2 – 3.8 kz
sistance characteris-
tics
All oil tem-
Between (B) and ground perature Resistance Min. 1 Mz
range
3 Short circuit in wiring harness Between ENG (female) (17) and (47) (Oil tempera-
ture: Min. 0 °C) 700 z –
Resistance
a Use "Oil temperature -Resistance characteristics" 37 kz
Ground fault in wiring harness 1. Turn starting switch to OFF position.
4
(Contact with ground circuit) 2. Disconnect connectors ENG and TOIL, and connect T-adapter to female side
of ENG.
40-302 56 WD600-6
Failure code [CA213] Engine oil temperature sensor low error SEN05052-02
Circuit diagram related to engine oil temperature sensor
WD600-6 40-302 57
SEN05052-02 Failure code [CA221] Atmospheric pressure sensor high error
Failure code [CA221] Atmospheric pressure sensor high error 1
Action code Failure code Ambient Press Sens High Error

Failure
Detail of failure • High voltage was detected in ambient pressure sensor signal circuit.
Action of con- • Takes it that ambient pressure value is default value (52.44 kPa {0.53 kg/cm2}), and allows engine
troller to run.
Problem on
machine
• Signal voltage from ambient pressure sensor can be checked with monitoring function (Code: 37402
(V)).
Related infor-
• Ambient pressure sensed by the ambient pressure sensor can be checked with monitoring function
mation
(Code: 37400 (kPa)).

tor
and check them.
Defective power supply line of If failure code [CA187] or [CA227] is also displayed, perform troubleshooting for
2
ambient pressure sensor it first.
Defective ambient pressure sen- 2. Disconnect connector PAMB.
sor
2. Disconnect connector ENG and PAMB, and connect T-adapter to female
4 Short circuit in wiring harness side of ENG.
2. Disconnect connector PAMB.
Hot short circuit in wiring harness 3. Insert T-adapter into connector ENG.
5
(Contact with 24 V circuit) 4. Turn starting switch to ON position (with connector PAMB disconnected).
Between ENG (3) and (38) Voltage Max. 1 V
40-302 58 WD600-6
Failure code [CA221] Atmospheric pressure sensor high error SEN05052-02
Circuit diagram related to ambient pressure sensor
WD600-6 40-302 59
SEN05052-02 Failure code [CA222] Atmospheric pressure sensor low error
Failure code [CA222] Atmospheric pressure sensor low error 1
Action code Failure code Ambient Press Sens Low Error

Failure
Detail of failure • Low voltage was detected ambient pressure sensor signal circuit.
Action of con- • Takes it that ambient pressure value is default value(52.44 kPa {0.53 kg/cm2}), and allows engine to
troller run.
Problem on
machine
• Signal voltage from ambient pressure sensor can be checked with monitoring function (Code: 37402
(V)).
• Ambient pressure sensed by the ambient pressure sensor can be checked with monitoring function
(Code: 37400 (kPa)).
Related infor-
mation
• Because troubleshooting "socket" for this sensor features female connector alone, it is not usable
for checking open circuit in wiring harness and voltage at sensor connector (not designed as a T-
adapter).
• If sensor connector is disconnected, this code is displayed.

tor
and check them.
it first.
Defective power supply line of
2 2. Insert T-adapter into connector ENG.
ambient pressure sensor
4.75 – 5.25
Between ENG (37) and (38) Power input Voltage
V
2. Disconnect connectors PAMB and ENG.
3 Short circuit in wiring harness 3. Connect T-adapter to female side of ENG.
Ground fault in wiring harness 2. Disconnect connectors PAMB and ENG and connect T-adapter to female
4 side of ENG.
If cause is not found by the above checks, there may be open circuit in wiring
5 Open circuit in wiring harness
harness. (*)
a If causes 1 - 5 are not the cause for the trouble and check result of cause 6
is abnormal, sensor is defective.
Defective ambient pressure sen- 1. Turn starting switch to OFF position.
sor 2. Insert T-adapter into connector ENG.
6
(Improper input voltage to engine 3. Turn starting switch to ON position.
controller)
Sensor out-
Between ENG (3) and (38) Voltage 0.3 - 4.7 V
put
If no abnormality is found by above checks, the engine controller is defective.
*: See "Troubleshooting method for disconnected wiring harness of pressure sensor system" of "Related trou-
bleshooting information".
40-302 60 WD600-6
Failure code [CA222] Atmospheric pressure sensor low error SEN05052-02
Circuit diagram related to ambient pressure sensor
WD600-6 40-302 61
SEN05052-02 Failure code [CA227] Sensor power supply 2 high error
Failure code [CA227] Sensor power supply 2 high error 1
Action code Failure code Sensor power supply circuit voltage is too high
Failure
Detail of failure • High voltage appears in sensor power supply 2 (5 V) circuit.

• Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor signals.
• Ignores signals from engine oil pressure sensor, takes it that engine oil pressure is default value (250
kPa {2.5 kg/cm2}), and allows engine to run.
• Ignores signals from ambient pressure sensor, takes it that ambient pressure is default value (52.44
Action of con- kPa {0.53 kg/cm2}), and allows engine to run.
troller • Ignores signals from boost pressure sensor, takes it that boost pressure is at fixed value (400 kPa
{4.1 kg/cm2}), and allows engine to run.
• Ignores signals from EGR valve lift sensor and bypass valve lift sensor, limits engine output and
closes EGR valve and bypass valve.
Problem on
machine
Related infor-
mation

Perform troubleshooting for failure code [CA187].
40-302 62 WD600-6
Failure code [CA227] Sensor power supply 2 high error SEN05052-02
WD600-6 40-302 63
SEN05052-02
WD600-6 Wheel dozer

©2017 KOMATSU
All Rights Reserved
40-302 64
SEN05053-02
WHEEL DOZER
WD600-6

WD600-6 55001 and up

Failure code [CA234] Engine overspeed ........................................................................................................ 3
Failure code [CA238] Ne speed sensor power supply error ........................................................................... 4
Failure code [CA263] Fuel Temp Sensor High Error....................................................................................... 6
Failure code [CA265] Fuel Temp Sensor Low Error ....................................................................................... 8
Failure code [CA271] PCV1 Short circuit...................................................................................................... 10
Failure code [CA272] PCV1 Disconnection ...................................................................................................11
Failure code [CA273] PCV2 Short circuit...................................................................................................... 12
Failure code [CA322] Injector #1 open/short error........................................................................................ 14
Failure code [CA342] Calibration code inconsistency................................................................................... 26
Failure code [CA351] Injectors drive circuit error.......................................................................................... 27
Failure code [CA352] Sens Supply 1 Volt Low Error .................................................................................... 28
Failure code [CA431] Idle validation switch error.......................................................................................... 31
Failure code [CA432] Idle validation action error .......................................................................................... 34
Failure code [CA441] Battery voltage low error ............................................................................................ 37
WD600-6 40-303 1
SEN05053-02
Failure code [CA442] Battery voltage high error ........................................................................................... 38

Failure code [CA451] Rail Press Sensor High Error ..................................................................................... 40
Failure code [CA452] Rail Press Sensor Low Error ...................................................................................... 42
Failure code [CA554] Common rail pressure sensor in range error.............................................................. 45
Failure code [CA559] Supply pump pressure very low error 1...................................................................... 46
Failure code [CA689] Engine Ne speed sensor error ................................................................................... 50
Failure code [CA731] Engine Bkup speed sensor phase error ..................................................................... 52
Failure code [CA757] All continuous data lost error ...................................................................................... 53
Failure code [CA778] Engine Bkup speed sensor error................................................................................ 54
Failure code [CA1228] EGR valve servo error 1........................................................................................... 56
Failure code [CA1625] EGR valve servo error 2........................................................................................... 57
Failure code [CA1626] (Bypass valve solenoid current high error)............................................................... 58
Failure code [CA1627] (Bypass valve solenoid current low error) ................................................................ 60
Failure code [CA1628] Bypass Valve Servo Error 1...................................................................................... 62
Failure code [CA1629] Bypass Valve Servo Error 2...................................................................................... 63
Failure code [CA1631] (Bypass valve lift sensor high error) ......................................................................... 64
Failure code [CA1632] (Bypass valve lift sensor low error)........................................................................... 66
Failure code [CA1633] KOMNET datalink timeout error ............................................................................... 68
40-303 2 WD600-6
Failure code [CA234] Engine overspeed SEN05053-02
Failure code [CA234] Engine overspeed 1
Action code Failure code Engine overspeed

Failure
– CA234 (Engine controller defective)
Detail of failure • Engine speed exceeded operating range.

Action of con- • Reduce fuel injection rate until engine speed lowers in operating range.
Problem on
• Engine speed fluctuates.
machine
Related infor- • Engine speed can be checked by using monitoring function. (Code: 01002 (rpm))
mation • Method of reproducing failure code: Start engine and keep it running at high idle.

1 Use of improper fuel Improper fuel may be used. Check it.
2 Defect in related system If another failure code is displayed, perform troubleshooting for it.
The method of using machine may be improper, so instruct the operator on how
3 Usage is improper
to use machine properly.
If causes 1 and 2 are not cause of failure, engine controller may be defective.
WD600-6 40-303 3
SEN05053-02 Failure code [CA238] Ne speed sensor power supply error
Failure code [CA238] Ne speed sensor power supply error 1
Action code Failure code Ne Speed Sens Supply Volt Error

Failure
Detail of failure • Abnormality occurred in Ne speed sensor power supply (5 V) circuit.

Action of con- • Controls engine by using signals from Bkup speed sensor.
troller • Limits engine output and continues operation.
Problem on
• Engine stops during operation (When engine Bkup speed sensor is also defective).
machine
• Engine cannot be started if it is stopped. (When engine Bkup speed sensor is also defective)
Related infor-
• Method of reproducing failure code: Turn the starting switch to ON position.
mation

tor
and check them.
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. After troubleshooting, return to 1.
If this failure code is not displayed when a connector is disconnected, that sen-
sor or engine wiring harness is defective.
2 Defective sensor or wiring harness a Other failure codes are displayed, too. This is because the connector is dis-
connected. Ignore failure codes other than [CA238].
Ne speed sensor NE
Engine harness ENG
4.75 to 5.25
Between ENG (male) (16) and (48) Voltage
V
Circuit diagram related to Ne speed sensor
40-303 4 WD600-6
Failure code [CA238] Ne speed sensor power supply error SEN05053-02
WD600-6 40-303 5
SEN05053-02 Failure code [CA263] Fuel Temp Sensor High Error
Failure code [CA263] Fuel Temp Sensor High Error 1
Action code Failure code Fuel temperature sensor signal voltage is too high
Failure
(Engine controller system)
E01 CA263
Detail of failure q High voltage was detected in fuel temperature sensor signal circuit.
q Uses signals from coolant temperature sensor to perform fuel injection rate correction based on fuel
Action of con- temperature.
troller q If coolant temperature sensor is also defective, sets fuel temperature value to fixed value (95 °C)
and allows engine to run.
Problem on
machine
q Signal voltage from the fuel temperature sensor can be checked with the monitoring function (Code:
14201 (V)).
q Temperature sensed by fuel temperature sensor can be checked with the monitoring function (Code:
Related infor- 14204 (°C)).
mation q Method of reproducing failure code: Turn the starting switch to ON position.
q This failure code is displayed if temperature sensor connector is disconnected.
q Because that T-adapter for sensor connector is “socket” type, it cannot be connected to wiring har-
ness.

Defective wiring harness
1 "Checks before troubleshooting" of "General information on troubleshooting", and
connector
check them.
2. Disconnect connector TFUEL and connect socket to male side of connector.
a If coolant temperature sensor resistance is 700 z – 37 kz with coolant temperature
is above 0 °C, regard coolant temperature sensor as normal.
0 °C Resistance 30 - 37 kz
Defective fuel temperature
2
sensor TFUEL(male) between 25 °C Resistance 9.3 - 10.7 kz
(A) and (B)
50 °C Resistance 3.2 - 3.8 kz
a Fuel temperature -Re-
sistance characteristic 80 °C Resistance 1.0 - 1.3 kz
95 °C Resistance 700 - 800 z
Open or short circuit in wir- Between ENG (female) (30) and (47) (Fuel temperature :
3
ing harness above 0 °C) 700 z -
Resistance
a Use “Fuel temperature - Resistance characteristics” 37 kz
table shown above as resistance critaeria.
If no abnormality is found by above checks, engine controller is defective. (Since this
is an internal failure, troubleshooting cannot be performed.)
40-303 6 WD600-6
Failure code [CA263] Fuel Temp Sensor High Error SEN05053-02
Circuit diagram related to fuel temperature sensor
WD600-6 40-303 7
SEN05053-02 Failure code [CA265] Fuel Temp Sensor Low Error
Failure code [CA265] Fuel Temp Sensor Low Error 1
Action code Failure code Fuel temperature sensor signal voltage is to low
Failure
E01 CA265
Detail of failure q Low voltage was detected in fuel temperature sensor signal circuit.
q Uses signals from coolant temperature sensor to perform fuel injection rate correction based on fuel
Action of con- temperature.
troller q If coolant temperature sensor is also defective, sets fuel temperature value to fixed value (95 °C)
and allows engine to run.
Problem on
machine
q Signal voltage from fuel temperature sensor can be checked with monitoring function (Code: 14201
(V)).
q Temperature sensed by fuel temperature sensor can be checked with monitoring function (Code:
Related infor-
04204 (°C)).
mation
q Method of reproducing failure code: Turn the starting switch to ON position.
q This code is not displayed but failure code for “High Error” is displayed, if sensor connector is dis-
connected.

Defective wiring harness Check wire harness and connectors by referring to "Electrical equipment" described in
1
connector "Check before troubleshooting" of "General information on troubleshooting".
2. Disconnect connector TFUEL and connect socket to male side.
a If coolant temperature sensor resistance is 700 z – 37 kz with coolant temperature
is above0 °C, regard coolant temperature sensor as normal.
0 °C Resistance 30 - 37 kz
TFUEL(male) between 25 °C Resistance 9.3 - 10.7 kz
Defective fuel temperature
2 (A) and (B)
sensor 50 °C Resistance 3.2 - 3.8 kz
a Fuel temperature - Re-
sistance characteristic 80 °C Resistance 1.0 - 1.3 kz
95 °C Resistance 700 - 800 z
All fuel tem-
Between (B) and ground perature Resistance Min. 1 Mz
range
Short circuit in wiring har- Between ENG (female) (30) and (47) (Fuel temperature :
3
ness above 0 °C) 700 z -
Resistance
a Use ”Fuel temperature - Resistance characteristics” 37 kz
Ground fault in wiring har- 1. Turn starting switch to OFF position.
4 ness 2. Disconnect connector TFUEL, and connect T-adapter to female side of ENG.
(Contact with ground circuit) Between ENG (female) (30) and ground Resistance Min. 1 Mz
If no abnormality is found by the above checks, engine controller is defective. (Since
this is an internal failure, troubleshooting cannot be performed.)
40-303 8 WD600-6
Failure code [CA265] Fuel Temp Sensor Low Error SEN05053-02
Circuit diagram related to fuel temperature sensor
WD600-6 40-303 9
SEN05053-02 Failure code [CA271] PCV1 Short circuit
Failure code [CA271] PCV1 Short circuit 1
Action code Failure code IMV/PCV1 Short Error

Failure
Detail of failure • Short circuit was detected in supply pump PCV1 circuit.
Action of con-
troller
Problem on
machine
Related infor- • Under normal conditions, pulse voltage of approx. 24 V is applied to PCV1 (1) while engine is run-
mation ning. However, it cannot be measured with multimeter since it is pulse voltage.

tor
and check them.
2. Disconnect connector PCV1.
Defective supply pump PCV1 3. Turn starting switch to ON position.
2
(internal short circuit)
If failure code changes from [CA271] to [CA272], supply pump PCV1 is defec-
tive.
3 Short circuit in wiring harness
Between ENG (female) (4) and (5) (PCV1 resis-
Resistance 2.3 – 5.3 z
tance)
2. Disconnect connector ENG and PCV1, and connect T-adapter to female side
4
5
(Contact with 24 V circuit) 4. Turn starting switch to ON position (with connector PCV1 disconnected).
(Since failure is in it troubleshooting cannot be performed.)
Circuit diagram related to PCV1
40-303 10 WD600-6
Failure code [CA272] PCV1 Disconnection SEN05053-02
Failure code [CA272] PCV1 Disconnection 1
Action code Failure code IMV/PCV1 Open Error

Failure
Detail of failure • Disconnection was detected in supply pump PCV1 circuit.

Action of con-
troller
Problem on
machine
• Under normal conditions, pulse voltage of approx. 24 V is applied to PCV (1) while engine is running.
Related infor- However it cannot be measured with multimeter since it is pulse voltage.
mation • Because troubleshooting "socket" for PCV1 features female connector alone, it is not connectable
to female connector of sensor wiring harness, and thus not usable for checking open circuit (not de-
signed as a T-adapter).

tor
and check them.
Defective supply pump PCV1 2. Disconnect connectors PCV1 and connect socket to male side.
2
(Internal disconnection) Resis- 2.3 –
Between PCV1 (male) (1) and (2)
tance 5.3 z
Open or short circuit in wiring har- 2. Disconnect connector ENG and connect T-adapter to female side.
3
ness Resis- 2.3 –
Between ENG (female) (4) and (5) (PCV1 resistance)
tance 5.3 z
2. Disconnect connectors ENG and PCV1.
3. Connect T-adapter to female side of connector ENG.
4 Resis-
(Contact with ground circuit) Between ENG (female) (4) and ground Min. 1 Mz
tance
Resis-
Between ENG (female) (5) and ground Min. 1 Mz
tance
WD600-6 40-303 11
SEN05053-02 Failure code [CA273] PCV2 Short circuit
Failure code [CA273] PCV2 Short circuit 1
Action code Failure code PCV2 short circuit error

Failure
Detail of failure • Short circuit was detected in supply pump PCV2 circuit.
Action of con-
troller
Problem on
machine
Related infor-
• While engine is running normally, approximately 24 V of pulse voltage is applied to PCV2 (1). But it
mation
is pulse voltage and cannot be measured by using multimeter.

tor
and check them.
Defective supply pump PCV2 2. Disconnect connector PCV2.
(Internal short)
If failure code changes from [CA273] to [CA274], supply pump PCV2 is defective.
Between ENG (female) (9) and (10) (PCV2 resis-
tance)
2. Disconnect connector ENG and PCV2, and connect T-adapter to female side
4
5
(Contact with 24 V circuit) 4. Turn starting switch to ON position (with connector PCV2 disconnected).
40-303 12 WD600-6
Failure code [CA274] PCV2 Disconnection SEN05053-02
Failure code [CA274] PCV2 Disconnection 1
Action code Failure code PCV2 disconnection

Failure
Detail of failure • Disconnection was detected in supply pump PCV2 circuit.

Action of con-
troller
Problem on
machine
Related infor-
• While engine is running normally, approximately 24 V of pulse voltage is applied to PCV2 (1). But it
mation
is pulse voltage and cannot be measured by using multimeter.

tor
and check them.
Defective supply pump PCV2 2. Disconnect connector PCV2 and connect socket to male side.
2
(internal open circuit)
Between PCV2 (male) (1) and (2) Resistance 2.3 – 5.3 z
Open or short circuit in wiring har- 2. Disconnect connector ENG and connect T-adapter to female side.
3
ness Between ENG (female) (9) and (10) (PCV2 resis-
tance)
2. Disconnect connector ENG and PCV2.
Ground fault in wiring harness 3. Connect T-adapter to female side of connector ENG.
4
(Since the failure is in it, troubleshooting cannot be performed.)
WD600-6 40-303 13
SEN05053-02 Failure code [CA322] Injector #1 open/short error
Failure code [CA322] Injector #1 open/short error 1
Action code Failure code Injector #1(L#1) open/short circuit error

Failure
Detail of failure • Disconnection or short circuit was detected in injector #1 circuit.

Action of con-
troller
Problem on • Engine output drops.
machine • Engine speed does not stabilize
Related infor-
• While engine is running normally, approximately 65 V of pulse voltage is applied to injector (positive)
mation
side. But it is pulse voltage and cannot be measured by using multimeter.

tor
and check them.
2. Disconnect connector CN1 and connect T-adapter to male side.
2 Defective injector #1
Between CN1 (male) (1) and (2) Resistance 0.4 – 1.1 z
Between CN1 (male) (1) and ground Resistance Min. 1 Mz
Open circuit or ground fault of wir-
3
ing harness Between ENG (female) (45) and (53) Resistance 0.4 – 1.1 z
Open circuit in wiring harness 2. Disconnect connectors ENG and CN1, and connect T-adapters to each
Between ENG (female) (45) and CN1 (female) (1) Resistance Max. 1 z
Ground fault in wiring harness 2. Disconnect connectors ENG and CN1, and connect T-adapter to female side
5 of either one of them.
Between ENG (female) (45) or CN1 (female) (1) and
ground
2. Disconnect connectors ENG and CN1, and connect T-adapter to female side
of ENG.
a Check with circuit tester in continuity mode.
Between ENG (female) (45) and each pin other than No continuity
(45) (No sound is heard)
Defective other cylinder injectors If the failure codes for other injectors are displayed, perform troubleshooting of
7
or wiring harness them, too.
40-303 14 WD600-6
Failure code [CA322] Injector #1 open/short error SEN05053-02
Circuit diagram related to injector #1
WD600-6 40-303 15
Action code Failure code Injector #5(L#5) open/short circuit error

Failure

Action of con-
troller
machine • Engine speed does not stabilize.
Related infor-
mation

tor
and check them.
3
ing harness Between ENG (female) (46) and (60) Resistance 0.4 - 1.1 z
ground
of ENG.
Defective other cylinder injectors If failure codes for other injectors are displayed, perform troubleshooting for
7
40-303 16 WD600-6
WD600-6 40-303 17
Action code Failure code Injector #3(L#3) open /short circuit error
Failure

Action of con-
troller
Related infor-
mation

tor
and check them.
3
ground
of ENG.
7
40-303 18 WD600-6
WD600-6 40-303 19
Action code Failure code Injector #6 (L#6) open / short circuit error
Failure
Detail of failure • Opening or short circuit was detected in drive circuit of No. 6 injector.
Action of con-
troller
Related infor-
mation

tor
and check them.
3
ground
of ENG.
Between ENG1 (female) (57) and each pin other No continuity
than (57) (No sound is heard)
Between ENG1 (female) (59) and each pin other No continuity
than (59) (No sound is heard)
Defective injector or wiring har- If the failure codes for other injectors are displayed, perform troubleshooting for
7
ness of another cylinder them, too.
40-303 20 WD600-6
WD600-6 40-303 21
Action code Failure code Injector #2 Open/Short circuit error

Failure

Action of con-
troller
Related infor-
mation

tor
and check them.
3
ground
2. Disconnect connectors ENG and CN, and connect T-adapter to female side
of ENG.
7
40-303 22 WD600-6
WD600-6 40-303 23
Action code Failure code Injector #4 (L#4) open / short circuit error
Failure

Action of con-
troller
Related infor-
mation

tor
and check them.
3
ground
of ENG.
7
40-303 24 WD600-6
WD600-6 40-303 25
SEN05053-02 Failure code [CA342] Calibration code inconsistency
Failure code [CA342] Calibration code inconsistency 1
Action code Failure code Engine controller data inconsistency

Failure
Detail of failure • Data inconsistency occurred in engine controller.

Action of con-
troller
Problem on • Engine continues running ordinarily, but it may stop during operation or may not restart once it is
machine stopped.
Related infor-
mation

Preform troubleshooting for failure code [CA111].
40-303 26 WD600-6
Failure code [CA351] Injectors drive circuit error SEN05053-02
Failure code [CA351] Injectors drive circuit error 1
Action code Failure code Injectors drive circuit error

Failure
Detail of failure • Abnormality has occurred in injector drive circuit.

Action of con- • Limits engine output for travel (Limits common rail pressure) and allows engine to run
Problem on
machine
Related infor-
mation

Check whether other failure code (failure code related to injector system ) are
1 Defect in related system
displayed together. If another code is displayed, perform troubleshooting for it.
Perform troubleshooting for failure code [ CA111]
WD600-6 40-303 27
SEN05053-02 Failure code [CA352] Sens Supply 1 Volt Low Error
Failure code [CA352] Sens Supply 1 Volt Low Error 1
Action code Failure code Sensor power supply 1voltage is too low
Failure
E03 CA352
Detail of failure q Low voltage was detected in sensor power supply 1 (5 V) circuit.
Action of con-
q Limits engine output (limits common rail pressure) and allows engine to run.
troller
Problem on
q Engine output drops.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Defective wiring harness Check wire harness and connectors by referring to "Electrical equipment" described
1
connector in "Check before troubleshooting" of "General information on troubleshooting".
2. Disconnect following connectors one by one and turn starting switch to ON posi-
tion each time.
3. After each troubleshooting, turn starting swith to OFF position.
If this failure code is not displayed when sensor is disconnected, the sensor or
Defective sensor or wiring engine wiring harness is defective.
2 harness a Other failure code(s) is(are) displayed at the same time. This is because the sen-
sor connector is disconnected. Therefore, ignore failure codes other than [CA352].
Common rail pressure sensor PFUEL
Engine harness ENG
Between ENG (male) (33) and (47) Voltage 4.75 – 5.25 V
40-303 28 WD600-6
Failure code [CA352] Sens Supply 1 Volt Low Error SEN05053-02
Circuit diagram related to sensor power supply 1 40-235
WD600-6 40-303 29
SEN05053-02 Failure code [CA386] Sensor power supply 1 high error
Failure code [CA386] Sensor power supply 1 high error 1
Action code Failure code Sensor power supply 1 voltage is too high
Failure
Detail of failure • High voltage is detected in sensor power supply 1 (5 V) circuit.

Action of con- • Limits engine output (limits common rail pressure) and allows engine to run
Problem on
machine
Related infor-
mation

Perform troubleshooting for failure code [CA352]
40-303 30 WD600-6
Failure code [CA431] Idle validation switch error SEN05053-02
Failure code [CA431] Idle validation switch error 1
Action code Failure code Idle validation switch : error

Failure
Detail of failure • Signals 1 and 2 (IVS1 and IVS2) from idle validation switch are unusual.
Action of
• Runs engine at the throttle opening based on signal from throttle sensor.
controller
Problem on
machine
• Input (ON/OFF) from the idle validation switch 1 can be checked by using monitoring function.
(Code: ENGINE, 18300, IVS 1)
Related
information
No. Cause Procedure, measuring location, criteria, and remarks

See the descriptions of wiring harness and connectors in "Electrical equipment" of
1 "Check before troubleshooting" in "General information on troubleshooting", and
connector
check them.
Defective power supply 3. Turn starting switch to ON position.
2
system a If normal, go to cause 6.
Between C30 (1) and (2) Voltage 4.75 to 5.25 V
Open circuit in wiring harness 2. Disconnect connector L04 and C30 and connect T-adapters to each female side.
3 (Wire breakage or defective Between L04 (female) (34) and C30 (female) (1) Resistance Max. 1 z
Between L02 (female) (4) and C30 (female) (2) Resistance Max. 1 z
Ground fault in wiring har- 2. Disconnect connectors L04 and C30 and connect T-adapter to female side of
4 ness 1 either of them.
(Contact with ground circuit) Between L04 (female) (34) or C30 (female) (1) and
ground
Defective transmission con- If cause is found by cause 2, and if cause is not found by the check of cause 3 or 4,
5
troller transmission controller is defective.
4. Operate accelerator pedal and troubleshoot.
Defective accelerator pedal
6 a If abnormal, check wiring harness for causes 7 and 8. When wiring harness is
(internal failure)
not abnormal, accelerator pedal is defective.
Between C17 (5) and (4) See Signal 1 in the figure 1.
Between C17 (6) and (4) See Signal 2 in the figure 1.
1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Disconnect connectors C17, C30 and E18, and connect T-adapters to female
Open circuit 2 in wiring side of them.
harness
7
(Wire breakage or defective Between E18 (female) (32) and C17 (female) (4) Resistance Max. 1 z
contact of connector) Between E18 (female) (11) and C17 (female) (5) Resistance Max. 1 z
Between E18 (female) (1) and C17 (female) (6) Resistance Max. 1 z
WD600-6 40-303 31
SEN05053-02 Failure code [CA431] Idle validation switch error

1. Turn starting switch to OFF position and disconnect battery ground cable.
2. Disconnect connectors C17, E18 and L04, and connect T-adapters to female
side of connectors E18 and L04.
Between E18 (female) (11) and each pin other than (11) Resistance Min. 1 Mz
If no failure is found by above checks, engine controller is defective. (Since this is
an internal failure, troubleshooting cannot be performed.)
• Reference
Defective engine controller
9 2. Insert T-adapter into connector E18.
(internal failure)
Between E18 (11) and (32) See Signal 1 in the figure 1 below.
Between E18 (1) and (32) See Signal 2 in the figure 1 below.
Fig. 1
Throttle: Signal voltage of throttle sensor
Idle validation: Signal voltage of idle validation
switch
Signal 1: Signal voltage of idle validation switch 1
...Dash line
...Bold line
Operating range: Operating range of accelerator

pedal (Pin 2 of connector C17)
40-303 32 WD600-6
Failure code [CA431] Idle validation switch error SEN05053-02
Circuit diagram related to idle validation
WD600-6 40-303 33
SEN05053-02 Failure code [CA432] Idle validation action error
Failure code [CA432] Idle validation action error 1
Action code Failure code Idle validation switch : action error

Failure
Detail of failure • Idle validation switch signal and throttle sensor signal are inconsistent.
Action of • Operates at position of throttle of accelerator pedal (throttle sensor).
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem on • Engine speed does not rise from low idle.
machine • Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related
• Input voltage from the throttle sensor can be checked by using monitoring function.
information
(Code: ENGINE, 31707, THROTTLE POS)
• Accelerator pedal position sensed by the throttle sensor can be checked by using monitoring func-
tion. (Code: ENGINE, 31701, THROTTLE POS)

As for idle validation switch, perform troubleshooting for failure code [CA431].
1
(For throttle sensor, perform troubleshooting for causes 2 and after.)
Defective power supply 3. Turn starting switch to ON position.
2
system a If abnormal, go to cause 4.
Between C17 (1) and (3) Voltage 4.75 to 5.25 V
4. Operate accelerator pedal and troubleshoot.
Defective accelerator pedal a If abnormal, check wiring harness for causes 4 and 5. When wiring harness is
3 not abnormal, accelerator pedal is defective.
(internal failure)
Approx. 3.7
Between C17 (2) and (3) Depress accelerator pedal. Voltage
V
a See output voltage in
the figure 1. Approx. 0.4
Release accelerator pedal. Voltage
V
2. Disconnect connectors C17 and E18, and connect T-adapters to female side of
Open circuit in wiring harness them.
4 (Wire breakage or defective Between E18 (female) (22) and C17 (female) (1) Resistance Max. 1 z
2. Disconnect connectors C17 and E18, and connect T-adapter to female side of
5 Short circuit in wiring harness connector E18.
40-303 34 WD600-6
Failure code [CA432] Idle validation action error SEN05053-02

If no abnormality is found in the above checks, engine controller is defective.
• Reference
2. Insert T-adapter into connector E18.
Defective engine controller 3. Turn starting switch to ON position.
6 4. Operate accelerator pedal and troubleshoot.
(internal failure)
Approx. 3.7
Between E18 (9) and (23) Depress accelerator pedal. Voltage
V
a See output voltage in
the figure 1. Approx. 0.4
Release accelerator pedal. Voltage
V
Fig. 1
Throttle: Signal voltage of throttle sensor
Idle validation: Signal voltage of idle validation
switch
...Dash line
...Bold line
Operating range: Operating range of accelerator

pedal (Pin 2 of connector C17)
Circuit diagram related to idle validation
WD600-6 40-303 35
SEN05053-02 Failure code [CA432] Idle validation action error
40-303 36 WD600-6
Failure code [CA441] Battery voltage low error SEN05053-02
Failure code [CA441] Battery voltage low error 1
Action code Failure code Battery power circuit voltage is to low

Failure
Detail of failure • Low voltage (5.7 V or below) is detected in power supply circuit.
Action of con-
troller
Problem on • Engine continues running ordinarily, but it may stop during operation or may not restart once it is
machine stopped.
Related infor-
mation

WD600-6 40-303 37
SEN05053-02 Failure code [CA442] Battery voltage high error
Failure code [CA442] Battery voltage high error 1
Action code Failure code Battery Voltage High Error

Failure
Detail of failure • High voltage (36 V or higher) appears in power supply circuit.
Action of con-
troller
Problem on
• Engine continues running, but it may stop during operations or may not restart once it is in stopped.
machine
Related infor-
• Power supply voltage of engine controller can be checked by using monitoring function. (Code: 03200
mation
(V))

Preform troubleshooting for failure code [CA111].
40-303 38 WD600-6
Failure code [CA449] Common rail pressure high error 2 SEN05053-02
Failure code [CA449] Common rail pressure high error 2 1
Action code Failure code Rail Press Very High Error

Failure
• Common rail pressure sensor circuit detects abnormally high pressure (pressure exceeding set
Detail of failure
maximum level).
Action of con-
• Limits engine output (limits common rail pressure) and allows engine to run.
troller
machine • Turns the centralized warning lamp and alarm buzzer ON.
• Signal voltage from common rail pressure sensor can be checked with monitoring function (Code:
36402 (V)).
Related infor-
• Common rail pressure sensed by common rail pressure sensor can be checked with monitoring
mation
function (Code: 36400 (MPa)).

WD600-6 40-303 39
SEN05053-02 Failure code [CA451] Rail Press Sensor High Error
Failure code [CA451] Rail Press Sensor High Error 1
Action code Failure code Common rail pressure sensor signal voltage is too high.
Failure
E03 CA451
Detail of failure q High voltage was detected in signal circuit of common rail pressure sensor.
Action of con-
q Limits engine output (limits common rail pressure) and allows engine to run.
troller
Problem on
machine
q Signal voltage from common rail pressure sensor can be checked with monitoring function (Code:
36402 (V)).
Related infor- q Common rail pressure sensed by common rail pressure sensor can be checked with monitoring
mation function (Code: 36400 (MPa)).
q This failure code is displayed if common rail pressure sensor connector is disconnected.

1
a If failure code [CA352] (Ground fault in sensor power supply line) or [CA386] is dis-
played, perform troubleshooting for it first.
Defective common rail pres- 1. Turn starting switch to OFF position.
2 sure sensor power supply 2. Disconnect connector PFUEL and connect T-adapter to female side.
line 3. Turn starting switch to ON position.
Power supply
Between PFUEL (female) (1) and (3) Voltage 4.75 – 5.25V
input
2. Disconnect connectors PFUEL and ENG and connect T-adapters to each female
side.
a If power supply input in checks on cause 2 is normal,
Open circuit in wiring har-
ness
3 Between ENG(female) (33) and PFUEL (female) (1)
(wire breakage or defective
a If power supply input in checks on cause 2 is normal,
Between ENG (female) (47) and PFUEL (female) (3)
Between ENG (female) (25) and PFUEL (female) (2)
Resistance Max. 1 z
(Sensor output)
Short circuit in wiring har- 2. Disconnect connectors PFUEL and ENG
4 3. Connect T-adapter to female side of ECM.
ness
2. Disconnect connectors PFUEL and insert T-adapter into connector ECM.
Hot short in wiring harness 3. Turn starting switch to ON position (with connector PFUEL disconnected).
5
(Contact with 24 V circuit) a ENG (25) pin is connected to 5V source through resistor in engine controller.
Between ENG (25) and (47) Voltage Approx. 5V
a If causes 1 – 5 are not cause of failure and check result of cause 6 is abnormal,
Defective common rail pres- sensor is defective.
sure sensor 1. Turn starting switch to OFF position.
6 2. Insert T-adapter into connector ENG.
(Improper input voltage to
engine controller) 3. Turn starting switch to ON position.
Between ENG (25) and (47) Sensor output Voltage 0.2 – 4.6V
If no abnormality is found by the above checks, the engine controller is defective.
(Since this is an internal failure, troubleshooting cannot be performed.)
40-303 40 WD600-6
Failure code [CA451] Rail Press Sensor High Error SEN05053-02
Circuit diagram related to common rail pressure
WD600-6 40-303 41
SEN05053-02 Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA452] Rail Press Sensor Low Error 1
Action code Failure code Common rail pressure sensor signal voltage is to low
Failure
E03 CA452
Detail of failure q Low voltage was detected in signal circuit of common rail pressure sensor.
Action of con-
q Limits engine output (limits common rail pressure), and allows engine to run.
troller
Problem on
machine
q Signal voltage from the common rail pressure sensor can be checked with monitoring function
(Code: 36402 (V)).
q Common rail pressure sensed by common rail pressure sensor can be checked with monitoring
Related infor-
mation
q Method of reproducing failure code: Turn starting switch to ON position.
q This failure code is not displayed but failure code, [CA451] for “High Error” is displayed when sen-
sor connector is disconnected even if it is normal.

1
a If failure code [CA352] or [CA386] is displayed, perform troubleshooting for it first.
Defective common rail pres- 1. Turn starting switch to OFF position.
2 sure sensor power supply 2. Disconnect connector PFUEL and connect T-adapter to female side.
line 3. Turn starting switch to ON position.
Power supply
Between PFUEL (female) (1) and (3) Voltage 4.75 – 5.25V
input
Defective common rail pres- 2. Disconnect connector PFUEL
sure sensor
Ground fault in wiring har- 2. Disconnect connectors ENG and PFUEL, and connect T-adapter to female side of
4 ness ENG.
Short circuit in wiring har- 2. Disconnect connectors ENG and PFUEL, and connect T-adapter to female side of
5 ENG.
ness
Between ENG (25) and (47) Resistance Min. 1 Mz
If no abnormality is found by above checks, engine controller is defective. (Since this
40-303 42 WD600-6
Failure code [CA452] Rail Press Sensor Low Error SEN05053-02
Circuit diagram related to common rail pressure
WD600-6 40-303 43
SEN05053-02 Failure code [CA553] Common rail pressure high error 1
Failure code [CA553] Common rail pressure high error 1 1
Action code Failure code Common rail pressure is high

Failure
• Abnormal high pressure (higher than set pressure) was detected more than 10 seconds in the signal
Detail of failure
circuit of common rail pressure sensor.
Action of con-
troller
Problem on
machine
36402 (V)).
Related infor-
mation

2 Use of improper fuel Check fuel used (for high viscosity).
Defective electrical system of Electrical system of common rail pressure sensor may be defective. Perform
3
common rail pressure sensor troubleshooting for failure codes [CA451] and [CA452].
Defective mechanical system of
4 Check mechanical system of common rail pressure sensor.
common rail pressure sensor
5 Defective overflow valve Check overflow valve for broken spring, worn seat, and stuck ball.
6 Clogging of overflow piping Check overflow piping for clogging.
7 Defective pressure limiter A mechanical defect of the pressure limiter may exist, check the limiter.
40-303 44 WD600-6
Failure code [CA554] Common rail pressure sensor in range error SEN05053-02
Failure code [CA554] Common rail pressure sensor in range error 1
Action code Failure code Common rail pressure sensor signal voltage is beyond input range
Failure
Detail of failure • Signal voltage of common rail pressure sensor is beyond input range.
Action of con- • Limits engine output (limits common rail pressure) and allows engine to run.
Problem on
machine
36402 (V)).
Related infor-
• Common rail pressure sensed by common rail pressure sensor can be checked with monitoring func-
mation
tion (Code: 36400 (MPa)).

Perform troubleshooting for failure code [CA451], [CA452]
WD600-6 40-303 45
SEN05053-02 Failure code [CA559] Supply pump pressure very low error 1
Failure code [CA559] Supply pump pressure very low error 1 1
Action code Failure code Rail Press Low Error

Failure
Detail of failure • Supply pump does not pressure feed fuel (level1).
Action of con- • Limits common rail pressure.
Problem on
machine
Related infor-
mation

1 Defect in related system If another failure code is displayed, perform troubleshooting for it first.
2 Use of improper fuel Fuel used may be improper. Check it.
a For more information on troubleshooting, see Note 1. For check of fuel pres-
sure in fuel low-pressure circuit, see Testing and adjusting, "Testing fuel
pressure".
3 Defect in low pressure circuit parts
Fuel pressure in low-pressure circuit
0.15 – 0.3 MPa
(At high idle or under load equivalent to
{1.5–3.0 kg/cm2}
rated output operation)
4 Clogged fuel filter, or strainer a For more information on troubleshooting, see Note 2.
Defective electrical system of sup- Electrical system of supply pump PCV may be defective. Perform troubleshoot-
5
ply pump PCV ing for failure code [CA271], [CA272], [CA273], or [CA274].
Defective common rail pressure Common rail pressure sensor may be defective. Check wiring harness for dam-
6
sensor age.
a For check of leakage from pressure limiter, see Testing and adjusting,
"Checking fuel return rate and leakage".
7 Defective pressure limiter Leakage from pressure limiter
(Rated output operation or equivalent Max. 10 cc/min
(load at stalling))
a For check of limit return rate (spill) from injector, see Testing and adjusting,
"Checking fuel return rate and leakage".
Engine speed during rated output oper-
Injector return
ation or equivalent
(spill) limit
(load at stalling)
8 Defective injector 1,600 rpm 960 cc/min
1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
9 Defective supply pump If causes 1 – 8 are not detected, supply pump may be defective.
<How to use check sheet>

Perform the above troubleshooting and use the attached "Check sheet for no-pressure feed", to note the
check resuets.
40-303 46 WD600-6
Failure code [CA559] Supply pump pressure very low error 1 SEN05053-02
Note 1: To determine if low-pressure circuit parts is defective, check following items.

1) Fuel level
2) Clogging of fuel tank breather
3) Seizure and wear of feed pump and clogging of filter
4) Leakage or clogging of low-pressure fuel piping
5) Defective operation of bypass valve and installation of wrong part (See Fig. 1)
6) Clogged fuel filter
7) Fuel in oil pan (Fuel leakage inside head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1):Spring is visible through both holes.
q Bypass valve (2): Spring is visible through nut side hole.
q Fuel inlet joint (3): Gauze filter is visible through both holes
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
q Fuel filter: Replace (Replace both prefilter and main filter.)
q Water separator: Disassemble and check. If screen (4) is clogged, clean it.
q Gauze filter: Disassemble and check. Clean, if clogged.
q Upstream strainer of gauze filter: Disassemble and check. Clean, if clogged.
WD600-6 40-303 47
Check sheet for no-pressure feed

Machine model Working No.
Model serial No. # Checked on / /
Engine Service meter h
Engine serial No. # Worker name
A. Visual check Good Bad

1 Fuel leakage to outside
2 Clogged fuel tank breather
B. Check with machine monitor (Abnormality record, monitoring, cylinder cutout operation) Good Bad
3 Checking error and failure codes / / / /
Checking monitoring information
Standard value Measured
Code Display item Check conditions Unit Good Bad
(Reference value) value
Low idle rpm 800 ± 25
01002 Engine speed High idle rpm 2,000 ± 50
Full stall (P-mode) rpm 1,680 ± 100
Position of accelerator Low idle % 0
31701
pedal High idle % 100
Common rail pressure
4 36200 Rating or equivalent MPa
command
36400 Common rail fuel pressure Rating or equivalent MPa
Low idle CA — — —
36300 Injection timing command High idle CA — — —
Rating or equivalent CA — — —
kPa Min. 126.6
36500 Boost pressure Rating or equivalent — —
{mmHg} {Min. 950}
04104 Engine coolant temperature Low idle °C — — —
04204 Fuel temperature Low idle °C — — —
Checking cylinder cut-out operation (Engine speed)
Function Cutout cylinder Check conditions Unit Good Bad
Cylinder 1 Low idle rpm — — —
5 Cylinder 2 Low idle rpm — — —
Cylinder
cut-out
function

C. Checking fuel circuit pressure Check conditions Unit Good Bad
MPa Min. 0.15
6 Pressure in fuel low-pressure circuit High idle
{kg/cm2} {Min. 1.5}
D. Checking strainer, filter Good Bad

7 Visual check of strainer
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve

E. Checking leakage and fuel return rate Check conditions Unit Good Bad
11 Leakage through pressure limiter No load, full stall, or relief cc/min Max. 10
Rating or equivalent Speed:
cc/min 960
1,600 rpm
Rating or equivalent
cc/min 1,020
1,700 rpm
12 Return rate from injector cc/min 1,080 Return rate:
1,800 rpm
cc/min 1,140
1,900 rpm
cc/min 1,200
2,000 rpm
40-303 48 WD600-6
WD600-6 40-303 49
SEN05053-02 Failure code [CA689] Engine Ne speed sensor error
Failure code [CA689] Engine Ne speed sensor error 1
Action code Failure code Eng Ne Speed Sensor Error

Failure
Detail of failure • Abnormal signal appear in engine Ne speed sensor circuit.

Action of con-
• Controls engine by using signals from engine Bkup speed sensor.
troller
• Engine stops during operation (When engine Bkup speed sensor is also defective).
Problem on
• Engine cannot be started if it is stopped. (When engine Bkup speed sensor is also defective)
machine
• Since inside of speed sensor is not composed of coil but Hall sensor and electronic circuit, speed
Related infor- sensor cannot be determined to be normal by measuring its resistance with circuit tester.
mation • Since speed sensor outputs 5 V pulse voltage during normal operation, it cannot be measured with
multimeter.
• Speed sensor calculates engine speed by detecting holes made in the flywheel.

tor
and check them.
Defective Ne speed sensor power
2 If failure code [CA238] is also displayed, perform troubleshooting for it first.
supply line
Breakage or improper installation
Engine Ne speed sensor may be damaged or improperly installed (loose).
3 (looseness) of engine Ne speed
Check sensor.
sensor
2. Disconnect connector NE and connect T-adapter to female side.
Defective Ne speed sensor power 3. Turn starting switch to ON position.
4
supply input
Power sup-
Between NE (female) (1) and (2) Voltage 4.75 – 5.25 V
ply input
2. Disconnect connectors ENG and NE.
If no abnormality is found in checks on cause 4, this
Open circuit in wiring harness check is not required. Resistance Max. 1 z
5 (Open circuit in wiring or defective Between ENG (female) (16) and NE (female) (1)
contact in connector) If no abnormality is found in checks on cause 4, this
check is not required. Resistance Max. 1 z
Between ENG (female) (48) and NE (female) (2)
Between ENG (female) (27) and NE (female) (3) Resistance Max. 1 z
2. Disconnect connectors ENG and NE.
6 Short circuit in wiring harness Resistance Min. 1 Mz
NE (female) (1) and (3)
NE (female) (2) and (3)
Ground fault in wiring harness 2. Disconnect connectors ENG and NE.
7
(Contact with ground circuit) Between ENG (female) (27) or NE (female) (3) and
ground
40-303 50 WD600-6
Failure code [CA689] Engine Ne speed sensor error SEN05053-02

Hot short circuit in wiring harness 2. Disconnect connector NE.
Between NE (female) (3) and ground Voltage Max. 1 V
If failure is not found by above checks, engine Ne speed sensor may be defec-
9 Defective engine Ne speed sensor
tive. (Since failure is in it, troubleshooting cannot be performed.)
If cause is not found by above checks,, engine controller may be defective.
Circuit diagrams related to engine Ne speed sensor
q Ne speed sensor detects part (A) of flywheel (1), where hole (H) is not made to recognize one turn of fly-
wheal, and the engine controller calculates the engine speed and phase.
WD600-6 40-303 51
SEN05053-02 Failure code [CA731] Engine Bkup speed sensor phase error
Failure code [CA731] Engine Bkup speed sensor phase error 1
Action code Failure code Engine Bkup speed sensor phase error
Failure
• Engine Bkup speed sensor circuit detects phase error.

Detail of failure
• (Bkup speed sensor signal is out of phase with Ne speed sensor signal.)
Action of con- • Controls the engine by using signals from engine Ne speed sensor.
• Engine stops during operation (when Ne speed sensor is also defective at the same time).
Problem on
• Engine cannot be started once it is stopped (when Ne speed sensor is also defective at the same
machine
time).
Related infor-
a To replace Bkup speed sensor, fuel supply pump must be replaced as a unit. (See Disassembly and
mation
assembly, "Removal and installation of fuel supply pump".)

Defective engine Ne speed sensor Engine Ne speed sensor may be defective. Perform troubleshooting for failure
1
system code [CA689]
Defective engine Bkup speed sen- Engine Bkup speed sensor may be defective. Perform troubleshooting for fail-
2
sor system ure code [CA778]
40-303 52 WD600-6
Failure code [CA757] All continuous data lost error SEN05053-02
Failure code [CA757] All continuous data lost error 1
Action code Failure code All engine controller data lost error
Failure
Detail of failure • All data in engine controller are lost.

Action of con-
troller
Problem on
• Engine continues running, but it may stop during operations or may not restart once it is in stopped.
machine
Related infor-
mation

WD600-6 40-303 53
SEN05053-02 Failure code [CA778] Engine Bkup speed sensor error
Failure code [CA778] Engine Bkup speed sensor error 1
Action code Failure code Eng Bkup Speed Sensor Error

Failure
E03 CA778
Detail of failure q Abnormality has occurred in engine Bkup speed sensor circuit.
q Controls engine by using Ne speed sensor signal.
Action of con-
q Limits engine output and allows engine to run.
troller
q Engine stops during operation (when Ne speed sensor is also defective at the same time).
Problem on
q Engine cannot be started once it is stopped (when Ne speed sensor is also defective at the same
machine
time).
q Method of reproducing failure code: Start engine.
a If engine Bkup speed sensor is replaced, fuel supply pump must be replaced.
Related infor- (See "Disassembly and assembly", "Removal and installation of fuel supply pump assembly".)
mation q Since inside of speed sensor is not composed of coil but electronic circuit, speed sensor cannot be
determined to be normal by measuring its resistance with circuit tester.
q Since output of normal speed sensor is 5 V pulse voltage, it cannot be measured with circuit tester.

1
Defective sensor power sup-
2 If failure code [CA187] or [CA227] is also displayed, troubleshoot it first.
ply line
Damage or improper instal-
Engine Bkup speed (G) sensor may be damaged or improperly installed (loose).
3 lation (loose) of engine Bkup
Check sensor.
speed (G) sensor
4 Defective resistor (RES) 2. Disconnect connector RES and connect T-adapter to male side.
Between RES (male) (1) and (2) Resistance 620 z
Defective engine Bkup 2. Disconnect connector G and connect T-adapter to female side.
5 speed sensor power supply 3. Turn starting switch to ON position.
input Power supply
Between G (female) (A) and (B) Voltage 4.75 – 5.25 V
input
Open or short circuit in wir- 1. Turn starting switch to OFF position.
6 ing harness 2. Disconnect connectors ENG and G, and connect T-adapter to female side of ENG.
(Resistor RES line) Between ENG (female) (37) and (26) Resistance 620 z
2. Disconnect connectors ENG, G and RES, and connect T-adapters to each female
side.
Open circuit in wiring har- a If power supply voltage in checks on cause 5 is nor-
ness mal, this check is not required. Resistance Max. 1 z
7 Between ENG (female) (37) and G (female) (A)
(wire breakage or defective
contact of connector) a If power supply voltage in checks on cause 5 is nor-
Between ENG (female) (47) and G (female) (B)
Between ENG (female) (26) and G (female) (C) Resistance Max. 1 z
40-303 54 WD600-6
Failure code [CA778] Engine Bkup speed sensor error SEN05053-02

2. Disconnect connectors ENG, G and RES, and connect T-adapter to female side
of ENG or G.
Short circuit in wiring har- Between ENG (female) (26) and (37), or between G
8 Resistance Min. 1 Mz
ness (female) (A) and (C)
Between ENG (female) (26) and (47), or between G
(female) (B) and (C)
Ground fault in wiring har- 2. Disconnect connectors ENG and G and connect T-adapters to either female side.
9 ness (contact with ground
circuit) Between ENG (female) (26) or G (female) (C) and
ground
Hot short circuit in wiring 2. Disconnect connectors G and RES, and connect T-adapter to female side.
10 harness (Contact with 24 V 3. Turn starting switch to ON position.
circuit)
Between G (female) (C) and ground Voltage Max. 1 V
Defective engine Ne speed If engine failure is not found by above checks, engine Bkup speed sensor may be
11
sensor defective. (Since this is an internal failure, troubleshooting cannot be performed.)
If failure is not found by above checks, engine controller may be defective. (Since
failure is in it, troubleshooting cannot be performed.)
Circuit diagram related to engine Bkup speed sensor
WD600-6 40-303 55
SEN05053-02 Failure code [CA1228] EGR valve servo error 1
Failure code [CA1228] EGR valve servo error 1 1
Action code Failure code Abnormal EGR valve servo 1

Failure
E03 CA1228
q An abnormality has occurred in EGR valve servo (level 1).
Detail of failure
(Response from EGR lift sensor differs for EGR valve opening command value.)
Action of con- q Stops current to EGR valve (closes EGR valve and bypass valve).
troller q Turns the centralized warning lamp and alarm buzzer ON.
Problem on
machine
Related infor- q EGR valve position can be checked with monitoring function (Code: 18100 (mm)).
mation q Method of reproducing failure code: Turn starting switch to ON position.

1 Defect in related system If another failure code is indicated, carry out troubleshooting for it.
a For measurement of EGR valve drive pressure, see Testing and adjusting, “ Mea-
suring EGR valve and bypass valve drive pressure” .
Engine speed EGR valve drive pressure
Improper EGR valve drive
2 Low idle Min. 1.18 MPa {12 kg/cm2}
pressure
High idle Min. 1.43 MPa {14.6 kg/cm2}
If EGR valve drive pressure is not normal, check items 3 and 4.
a For check of engine oil pressure, see Testing and adjusting, "Testing engine oil
pressure".
Engine Engine oil pressure
Defective engine hydraulic
3 Low idle Min. 0.08 MPa {0.8 kg/cm2}
system (main circuit)
High idle Min. 0.21 MPa {2.1 kg/cm2}
If engine oil pressure is not normal, perform troubleshooting (S mode) for engine.
(S-12 Oil pressure lowers.)
Defective oil pump relief
4 Oil pump relief valve for the EGR valve circuit may be defective, check it.
valve for EGR valve
Defective oil pipe for EGR
5 Oil pipe for the EGR valve circuit may be defective, check it.
valve
Defective oil return pipe for
6 Oil return pipe for the EGR valve circuit may be defective, check it.
EGR valve
7 Defective EGR valve EGR valve may be defective, check it.
Defective EGR valve lift
8 Perform troubleshooting for failure code [CA2271].
sensor
If causes 1 – 8 are not cause of faillure, engine controller may be defective. (Since
40-303 56 WD600-6
Failure code [CA1625] EGR valve servo error 2 SEN05053-02
Failure code [CA1625] EGR valve servo error 2 1
Action code Failure code Abnormal EGR valve servo 2

Failure
E03 CA1625
q An abnormality has occurred in EGR valve servo (level 2).
Detail of failure
(Response from EGR lift sensor differs for EGR valve opening command value.)
q Limits engine output and allows engine to run.
Action of con-
q Stops current to EGR valve (closes EGR valve and bypass valve).
troller
Problem on
machine
Related infor- q EGR valve position can be checked with the monitoring function (Code: 18100 (mm)).
mation q Method of reproducing failure code: Turn starting switch to ON position.

WD600-6 40-303 57
SEN05053-02 Failure code [CA1626] (Bypass valve solenoid current high error)
Failure code [CA1626] (Bypass valve solenoid current high error) 1
Action code Failure code Bypass valve solenoid current high error
Failure
Detail of failure • High current was detected in drive circuit of bypass valve solenoid.
Action of
• Close EGR and bypass valves.
controller
Problem on
• Engine output lowers.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

1
2. Disconnect connector BP and connect T-adapter to male side.
Defective bypass valve sole-
2
noid (internal disconnection) Between BP (male) (1) and (2) Resistance 10 - 21 z
Between BP (male) (1) and ground Resistance Min. 1 Mz
Open or short circuit in wir- a If resistance is above 1 Mz, wiring harness is broken. If resistance is below 1 z,
3
ing harness wiring harness has short circuit.
Between ENG (female) (31) and (11) Resistance 10 - 21 z

2. Disconnect connectors ENG and BP, and connect T-adapters to either female
Short circuit in wiring har-
4 side.
ness
Between ENG (female) (31) and (11), or
between BP (female) (1) and (2)
Hot short circuit in wiring 2. Disconnect connector BP and connect T-adapter to female side.
5 harness (Contact with 24 V 3. Turn starting switch to ON position (with connector BP disconnected).
circuit)
Between BP (female) (1) and (2) Voltage Max. 1 V
If cause is not found by the above checks, engine controller may be defective. (Since
40-303 58 WD600-6
Failure code [CA1626] (Bypass valve solenoid current high error) SEN05053-02
Circuit diagram related to bypass valve solenoid & lift sensor
WD600-6 40-303 59
SEN05053-02 Failure code [CA1627] (Bypass valve solenoid current low error)
Failure code [CA1627] (Bypass valve solenoid current low error) 1
Action code Failure code Bypass valve solenoid drive circuit disconnection error
Failure
Detail of failure • Disconnection error was detected in drive circuit of bypass valve solenoid.
Action of
controller
Problem on
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

1
Defective bypass valve sole- 2. Disconnect connector BP and connect T-adapter to male side.
2
noid (Internal disconnection)
Between BP (male) (1) and (2) Resistance 10 - 21 z
3
a If cause 3 is not the cause for the trouble, this check is not required.
Open circuit in wiring har- 1. Turn starting switch to OFF position.
ness (Wire breakage or 2. Disconnect connectors ENG and BP, and connect T-adapters to each female side.
4
defective contact of connec- Between ENG (female) (31) and BP (female) (1) Resistance Max. 1 z
tor)
Between ENG (female) (11) and BP (female) (2) Resistance Max. 1 z
If no abnormality is found by the above checks, engine controller may be defective.
40-303 60 WD600-6
Failure code [CA1627] (Bypass valve solenoid current low error) SEN05053-02
WD600-6 40-303 61
SEN05053-02 Failure code [CA1628] Bypass Valve Servo Error 1
Failure code [CA1628] Bypass Valve Servo Error 1 1
Action code Failure code Bypass Valve servo error 1

Failure
• Bypass valve has servo error (level 1).
Detail of failure
(Response from bypass valve lift sensor differs from bypass valve opening command value.)
• Limits engine output and allows engine to run.
Action of controller • Stops outputting current to bypass valve (closes EGR valve and bypass valve).
Problem on
machine
• Bypass valve position can be checked by using monitoring function. (Code: 18200 (mm))
Related information

Defect in bypass valve and
1 bypass valve lift sensor sys- If another failure code is displayed, perform troubleshooting for it.
tem
a For measurement of bypass valve drive pressure, see Testing and adjusting,
“ Measuring bypass valve and bypass valve drive pressure” .
Min. 1.18
Low speed MPa
Improper bypass valve drive {12 kg/cm2}
2 Bypass valve drive pres-
pressure Engine speed
sure Min. 1.43
Full speed MPa
{14.6 kg/cm2}
If bypass valve drive pressure is not normal, perform checks on causes 3 and 4.
a For check of engine oil pressure, see Testing and adjusting, "Testing engine oil
pressure".
Min. 0.08
Low speed MPa
Defective engine oil system {0.8 kg/cm2}
3 Engine speed Engine oil pressure
(main circuit) Min. 0.21
Full speed MPa
{2.1 kg/cm2}
If engine oil pressure is not normal, preform troubleshooting (S mode) for engine. (S-
12 Oil pressure lowers.)
Defective oil pump for
4 Oil pump or relief valve for bypass valve circuit may be defective. Check them.
bypass valve
Defective oil pipe for bypass
5 Oil pipe for bypass valve circuit may be defective. Check it.
valve
Defective oil return pipe for
6 Oil return pipe for bypass valve circuit may be defective. Check it.
bypass valve
7 Defective bypass valve Bypass valve may be defective. Check it.
Defective bypass valve lift
8 Perform troubleshooting for failure code [CA1631].
sensor
If no failure is found by checks on causes 1 to 8, engine controller may be
defective. (Since this is an internal failure, troubleshooting cannot be performed.)
40-303 62 WD600-6
Failure code [CA1629] Bypass Valve Servo Error 2 SEN05053-02
Failure code [CA1629] Bypass Valve Servo Error 2 1
Action code Failure code Bypass Valve servo error 2

Failure
• Bypass valve has servo error (level 2).
Detail of failure
(Response from bypass valve lift sensor differs from bypass valve opening command value.)
• Limits engine output and allows engine to run.
Action of
• Stops outputting current to bypass valve (closes EGR valve and bypass valve).
controller
Problem on
machine
Related • Bypass valve position can be checked by using monitoring function. (Code: 18200 (mm))
information • Method of reproducing failure code: Turn starting switch to ON position.

WD600-6 40-303 63
SEN05053-02 Failure code [CA1631] (Bypass valve lift sensor high error)
Failure code [CA1631] (Bypass valve lift sensor high error) 1
Action code Failure code Bypass valve lift sensor high error
Failure
Detail of failure • Bypass valve lift sensor circuit is abnormally high.
Action of
controller
Problem on
machine
• The input state (position: mm) from the bypass valve lift sensor can be checked with the monitoring
function (Code: 18200).
Related
• The input state (voltage) from the bypass valve lift sensor can be checked with the monitoring func-
information
tion (Code: 18202).
• Method of reproducing failure code: Start engine

Defective wiring Check wire harness and connectors by referring to "Electrical equipment" described in
1
harness connector "Check before troubleshooting" of "General information on troubleshooting".
Defective sensor
2 power supply sys- If failure code [CA187] or [CA227] is also displayed, troubleshoot it first.
tem

Defective bypass 2. Disconnect connector SBP.
3 valve lift sensor 3. Turn starting switch to ON position (with connector SBP disconnected).
(internal defect)
Short circuit in wir- 2. Disconnect connectors ENG and SBP, and connect T-adapters to either female side.
4
ing harness Between ENG (female) (37) and (29), between SBP (female) (1)
and (3), or between SBP (female) (1) and (4)
Hot short in wiring 2. Disconnect connector SBP and connect T-adapter to female side.
5 harness (contact 3. Turn starting switch to ON position (with connector SBP disconnected).
with 24 V circuit)
Between SBP (female) (3) or (4) and (2) Voltage Max. 1 V
If cause is not found by the above checks, engine controller may be defective. (Since this is
Defective engine q Reference; the following is standard value in normal condition.

6 1. Turn starting switch to OFF position.
controller
2. Insert T-adapter into connector ENG.
40-303 64 WD600-6
Failure code [CA1631] (Bypass valve lift sensor high error) SEN05053-02
WD600-6 40-303 65
SEN05053-02 Failure code [CA1632] (Bypass valve lift sensor low error)
Failure code [CA1632] (Bypass valve lift sensor low error) 1
Action code Failure code Bypass valve lift sensor low error
Failure
Detail of failure • Bypass valve lift sensor circuit is abnormally low.
Action of
controller
Problem on
machine
• The input state (position: mm) from the bypass valve lift sensor can be checked with the monitoring
function (Code: 18200).
Related
• The input state (voltage) from the bypass valve lift sensor can be checked with the monitoring func-
information
tion (Code: 18202).

1
If failure code [CA187] (Ground fault in sensor power supply line) or [CA227] is displayed,
perform troubleshooting for it first.
Defective sensor
2 power supply sys- 1. Turn starting switch to OFF position.
tem 2. Disconnect connector SBP and connect T-adapter to female side.
Between SBP (female) (1) and (2) Power supply Voltage 4.75 – 5.25 V
2. Disconnect connectors SBP and ENG, and connect T-adapters to each female side.
a If power supply voltage in check on cause 2 is normal, this
Open circuit in wir-
ing harness
Between ENG (female) (37) and SBP (female) (1)
3 (wire breakage or
defective contact of
connector)
Between ENG (female) (47) and SBP (female) (2)
Between ENG (female) (29) and SBP (female) (3) and, between
Resistance Max. 1 z
ENG (female) (29) and SBP (female) (4), (Sensor output)
Ground fault in wir- 1. Turn starting switch to OFF position.
ing harness 2. Disconnect connectors ENG and SBP, and connect T-adapters to either female side.
4
(Contact with Between ENG (female) (29) and ground, or between SBP
ground circuit) (female) (3) and ground
Short circuit in wir- 2. Disconnect connectors ENG and SBP, and connect T-adapters to either female side.
5
ing harness Between ENG (female) (29) and (47), or between SBP (female)
(2) and (3)
a If cause items 1 - 5 are not the cause for the trouble and check result of cause 6 is abnor-
mal, sensor is defective.
Defective bypass 1. Turn starting switch to OFF position.
6 2. Insert T-adapter into connector ENG or SBP.
valve lift sensor
Between ENG (29) and (47), or between SBP (3) and (2) Voltage 0.5 – 4.5 V
Defective engine If no abnormality is found by the above checks, the engine controller is defective. (Since this
7
controller is an internal failure, troubleshooting cannot be performed.)
40-303 66 WD600-6
Failure code [CA1632] (Bypass valve lift sensor low error) SEN05053-02
WD600-6 40-303 67
SEN05053-02 Failure code [CA1633] KOMNET datalink timeout error
Failure code [CA1633] KOMNET datalink timeout error 1
Action code Failure code CAN (KOMNET) communication disconnection

Failure
• Engine controller detected communication error in CAN (KOMNET) communication circuit between
Detail of failure
engine controller and power train controller, work equipment controller or machine monitor.
Action of con- • Controls engine in default mode, and holds state at the time of abnormally.
troller • If cause of failure disappears, machine becomes normal by itself.
• Information may not be transmitted normally through CAN (KOMNET) communication and machine
Problem on
may not operate normally.
machine
(Trouble phenomenon depends on failed section.)
Related infor-
mation

Perform troubleshooting for failure code [DB2RKR].
40-303 68 WD600-6
Failure code [CA1633] KOMNET datalink timeout error SEN05053-02
WD600-6 40-303 69
SEN05053-02
WD600-6 Wheel dozer

©2017 KOMATSU
All Rights Reserved
40-303 70
SEN05054-02
WHEEL DOZER
WD600-6

WD600-6 55001 and up

Failure code [CA2185] Throttle sensor supply voltage high error ................................................................... 4
Failure code [CA2186] Throttle sensor power supply low error ...................................................................... 6
Failure code [CA2249] Supply pump pressure very low error 2 ..................................................................... 8
Failure code [CA2271] EGR valve lift sensor high error ............................................................................... 10
Failure code [CA2272] EGR valve lift sensor low error................................................................................. 12
Failure code [CA2351] EGR valve solenoid operation short circuit .............................................................. 14
Failure code [CA2352] EGR valve solenoid operation disconnect ............................................................... 16
Failure code [CA2555] Intake air heater relay open circuit error .................................................................. 18
Failure code [CA2556] Intake air heater relay short circuit error .................................................................. 20
Failure code [D191KA] AJSS neutral safety relay open circuit ..................................................................... 22
Failure code [D191KB] AJSS neutral safety relay short circuit ..................................................................... 24
Failure code [D198KA] Transmission oil pressure bypass solenoid: Disconnection..................................... 26
Failure code [D198KB] Transmission oil pressure bypass solenoid: Short circuit ........................................ 27
Failure code [D198KY] Transmission oil pressure bypass solenoid: Short circuit with power supply line .... 28
Failure code [D5ZHKA] Terminal C signal open circuit ................................................................................. 30
Failure code [D5ZHKB] Terminal C signal short circuit ................................................................................. 32
Failure code [D5ZHKZ] Terminal C signal open or short circuit .................................................................... 34
Failure code [D5ZHL6] Terminal C signal disagrees with run and stop of engine ........................................ 36
Failure code [DA80L4] Auto-greasing controller disagrees with ON/OFF signal .......................................... 38
Failure code [DAF3KK] Machine monitor: Source voltage low (input) .......................................................... 40
Failure code [DAF5KP] Machine monitor: Output voltage low...................................................................... 42
WD600-6 40-304 1
SEN05054-02
Failure code [DAFRKR] CAN communication with machine monitor: Communication error (Abnormality in
target component system) ........................................................................................................................ 44
Failure code [DAQ0KK] Transmission controller: Source voltage low .......................................................... 45
Failure code [DAQ0KT] Transmission controller: Defect in controller ........................................................... 48
Failure code [DAQ2KK] Transmission controller load power supply line: Source voltage low (Input) .......... 50
Failure code [DAQ9KQ] Transmission controller model selection: Model selection signal disagreement .... 53
Failure code [DAQRKR] CAN communication with transmission controller: Communication error
(Abnormality in target component system) ............................................................................................... 54
Failure code [DAQRMA] Transmission controller (Option setting): Malfunction............................................ 59
40-304 2 WD600-6
SEN05054-02
WD600-6 40-304 3
SEN05054-02 Failure code [CA2185] Throttle sensor supply voltage high error
Failure code [CA2185] Throttle sensor supply voltage high error 1
Action code Failure code Throttle sensor power supply voltage is high
Failure
Detail of failure • High voltage (5.25 V or higher) is detected in throttle sensor power supply circuit.
Action of • Sets throttle opening to 0% when accelerator pedal is not depressed and to 50% of full throttle when
controller pedal is depressed, and allows engine to run.
Problem on • Engine does not run at full throttle.
Related
information

See descriptions of wiring harness and connectors in "Electrical equipment" of
1 "Check before troubleshooting" of "General information on troubleshooting", and
connector
check them.
2. Disconnect connector C17 and turn starting switch to ON position.
Defective throttle sensor
2 If this failure code is not displayed, throttle sensor is defective.
(accelerator pedal)
a Other failure codes are displayed, too. This is because connector is disconnect-
ed. Ignore failure codes other than [CA2185].
2. Disconnect connectors E18 and C17, and connect T-adapters to female sides of
3 Short circuit in wiring harness E18.
Between E18 (female) (22) and each pin other than
E18 (22)
2. Disconnect connector E18 and connect T-adapter to male side.
4 Defective engine controller 3. Turn starting switch to ON position.
Between E18 (male) (22) and (23) Voltage 4.75 to 5.25 V
Hot short circuit in wiring 2. Disconnect connector C17 and connect T-adapter to female side.
5 harness 3. Turn starting switch to ON position.
(Contact with 24 V)
Between C17 (female) (1) and ground Voltage 4.75 to 5.25 V
40-304 4 WD600-6
Failure code [CA2185] Throttle sensor supply voltage high error SEN05054-02
WD600-6 40-304 5
SEN05054-02 Failure code [CA2186] Throttle sensor power supply low error
Failure code [CA2186] Throttle sensor power supply low error 1
Action code Failure code Throttle sensor power supply voltage is low
Failure
Detail of failure • Low voltage is detected in throttle sensor power supply circuit.
Action of • Sets throttle opening to 0% when accelerator pedal is not depressed and to 50% of full throttle when
controller accelerator pedal is depressed, and allows engine to run.
Problem on • Engine does not run at full throttle.
Related
information

See descriptions of wiring harness and connectors in "Electrical equipment" of
1 "Check before troubleshooting" of "General information on troubleshooting", and
connector
check them.
2. Disconnect connector C17 and turn starting switch to ON position.
Defective throttle sensor
2 If this failure code is not displayed, throttle sensor is defective.
(accelerator pedal)
a Other failure codes are displayed too. This is because that connector is discon-
nected. Ignore failure codes other than [CA2186].
Ground fault in wiring 2. Disconnect connectors E18 and C17, and connect T-adapter to female side of
3 harness one of them.
(Contact with ground circuit) Between E18 (female) (22) or C17 (female) (1) and
ground
2. Disconnect connectors E18 and C17, and connect T-adapter to female side of
4 Short circuit in wiring harness E18.
Between E18 (female) (22) and each pin other than
E18 (22)
2. Disconnect connector E18 and connect T-adapter to male side.
5 Defective engine controller 3. Turn starting switch to ON position with wiring harness disconnected.
Between E18 (male) (22) and (23) Voltage 4.75 to 5.25 V
40-304 6 WD600-6
Failure code [CA2186] Throttle sensor power supply low error SEN05054-02
WD600-6 40-304 7
Failure code [CA2249] Supply pump pressure very low error 2 1
Action code Failure code Supply pump no-pressure feed error 2

Failure
Detail of failure • No-pressure feed error (level 2) in supply pump was detected.
Action of con- • Limits common rail pressure.
Problem on
machine
• The signal voltage from the common rail pressure sensor can be checked with the monitoring func-
tion (Code: 36402 (V)).
Related infor-
mation

40-304 8 WD600-6
WD600-6 40-304 9
SEN05054-02 Failure code [CA2271] EGR valve lift sensor high error
Failure code [CA2271] EGR valve lift sensor high error 1
Action code Failure code EGR valve lift sensor signal voltage is too high.
Failure
E03 CA2271
Detail of failure q High voltage was detected in EGR valve lift sensor signal circuit.
q Limits engine output and continues operation.
Action of con-
q Closes the EGR valve and bypass valve.
troller
Problem on
machine
q Signal voltage from EGR valve lift sensor can be checked with monitoring function (Code: 18101
(V)).
Related infor-
q Position (mm) sensed by EGR valve lift sensor can be checked with monitoring function (Code:
mation
18100 (mm).

1
Defective sensor
2 power supply sys- If failure code [CA187] or [CA227] is also displayed, troubleshoot it first.
tem

Defective EGR 2. Disconnect connector SEGR.
3 valve lift sensor 3. Turn starting switch to ON position (with connector SEGR disconnected).
(internal defect)
Short circuit in wir- 2. Disconnect connectors ENG and SEGR, and connect T-adapters to either female side.
4
ing harness Between ENG (female) (37) and (19), between SEGR (female)
(1) and (3), or between SEGR (female) (1) and (4)
Hot short in wiring 2. Disconnect connector SEGR and connect T-adapter to female side.
5 harness (contact 3. Turn starting switch to ON position (with connector SEGR disconnected).
with 24 V circuit)
Between SEGR (female) (3) or (4) and (2) Voltage Max. 1 V
If cause is not found by the above checks, engine controller may be defective. (Since this is
Defective engine q Reference; the following is standard value in normal condition.

6 1. Turn starting switch to OFF position.
controller
2. Insert T-adapter into connector ENG.
Between ENG(19) and (47) Voltage 1.0 – 4.0 V
40-304 10 WD600-6
Failure code [CA2271] EGR valve lift sensor high error SEN05054-02
Circuit diagram related to EGR valve
WD600-6 40-304 11
SEN05054-02 Failure code [CA2272] EGR valve lift sensor low error
Failure code [CA2272] EGR valve lift sensor low error 1
Action code Failure code EGR valve lift sensor signal voltage is too low.
Failure
E03 CA2272
Detail of failure q The signal of EGR valve lift sensor circuit is abnormally low.
Action of con-
troller
Problem on
machine
q The signal (voltage) from the EGR valve lift sensor can be checked with the monitoring function
(Code: 18101 (V)).
Related infor-
q Position (mm) sensed by EGR valve lift sensor can be checked with monitoring function (Code:
mation
18100 (mm)).

1
If failure code [CA187] (Ground fault in sensor power supply line) or [CA227] is displayed,
perform troubleshooting for it first.
Defective sensor
2 power supply sys- 1. Turn starting switch to OFF position.
tem 2. Disconnect connector SEGR and connect T-adapter to female side.
Between SEGR (female) (1) and (2) Power supply Voltage 4.75 – 5.25 V
2. Disconnect connectors SEGR and ENG, and connect T-adapters to each female side.
Open circuit in wir- check is not required. Resistance Max. 1 z
ing harness Between ENG (female) (37) and SEGR (female) (1)
3 (wire breakage or a If power supply voltage in check on cause 2 is normal, this
defective contact of check is not required. Resistance Max. 1 z
connector) Between ENG (female) (47) and SEGR (female) (2)
Between ENG (female) (19) and SEGR (female) (3) and,
between ENG (female) (19) and SEGR (female) (4), (Sensor Resistance Max. 1 z
output)
Ground fault in wir- 1. Turn starting switch to OFF position.
ing harness 2. Disconnect connectors ENG and SEGR, and connect T-adapters to either female side.
4
(Contact with Between ENG (female) (19) and ground, or between SEGR
ground circuit) (female) (3) and ground
Short circuit in wir- 2. Disconnect connectors ENG and SEGR, and connect T-adapters to either female side.
5
ing harness Between ENG (female) (19) and (47), or between SEGR
a If cause items 1 - 5 are not the cause for the trouble and check result of cause 6 is abnor-
mal, sensor is defective.
Defective EGR 1. Turn starting switch to OFF position.
6 2. Insert T-adapter into connector ENG or SEGR.
valve lift sensor
Between ENG (19) and (47), or between SEGR (3) and (2) Voltage 0.5 – 4.5 V
Defective engine If no abnormality is found by the above checks, the engine controller is defective. (Since this
7
controller is an internal failure, troubleshooting cannot be performed.)
40-304 12 WD600-6
Failure code [CA2272] EGR valve lift sensor low error SEN05054-02
WD600-6 40-304 13
SEN05054-02 Failure code [CA2351] EGR valve solenoid operation short circuit
Failure code [CA2351] EGR valve solenoid operation short circuit 1
Action code Failure code Short circuit in power supply line to EGR valve solenoid
Failure
E03 CA2351
Detail of failure q Short circuit was detected in the power supply line to EGR valve solenoid.
Action of con-
troller
Problem on
machine
Related infor-
mation

1
2. Disconnect connector EGR and connect T-adapter to male side.
Defective EGR valve sole-
2
noid (internal disconnection) Between EGR (male) (1) and (2) Resistance 10 - 21 z
Between EGR (male) (1) and ground Resistance Min. 1 Mz
3
Between ENG (male) (22) and (11) Resistance 10 - 21 z

2. Disconnect connectors ENG and EGR, and connect T-adapters to either female
Short circuit in wiring har-
4 side.
ness
Between ENG (female) (22) and (11), or
between EGR (female) (1) and (2)
Hot short circuit in wiring 2. Disconnect connector EGR and connect T-adapter to EGR side.
5 harness (Contact with 24 V 3. Turn starting switch to ON position (with connector EGR disconnected).
circuit)
Between BP (female) (1) and (2) Voltage Max. 1 V
If cause is not found by the above checks, engine controller may be defective. (Since
40-304 14 WD600-6
Failure code [CA2351] EGR valve solenoid operation short circuit SEN05054-02
WD600-6 40-304 15
SEN05054-02 Failure code [CA2352] EGR valve solenoid operation disconnect
Failure code [CA2352] EGR valve solenoid operation disconnect 1
Action code Failure code Disconnection in power supply line to EGR valve solenoid drive system
Failure
E03 CA2352
Detail of failure q Disconnection error was detected in power supply line to EGR valve solenoid.
Action of con-
troller
Problem on
machine
Related infor-
mation

1
Defective EGR valve sole- 2. Disconnect connector EGR and connect T-adapter to male side.
2
noid (Internal disconnection)
Between EGR (male) (1) and (2) Resistance 10 - 21 z
3
a If cause 3 is not the cause for the trouble, this check is not required.
Open circuit in wiring har-
2. Disconnect connectors ENG and EGR, and connect T-adapters to each female
ness (Wire breakage or
4 side.
defective contact of connec-
tor) Between ENG (female) (22) and EGR (female) (1) Resistance Max. 1 z
Between ENG (female) (11) and EGR (female) (2) Resistance Max. 1 z
If no abnormality is found by the above checks, engine controller may be defective.
40-304 16 WD600-6
Failure code [CA2352] EGR valve solenoid operation disconnect SEN05054-02
WD600-6 40-304 17
SEN05054-02 Failure code [CA2555] Intake air heater relay open circuit error
Failure code [CA2555] Intake air heater relay open circuit error 1
Action code Failure code Intake air heater relay open circuit
Failure
Detail of failure • Open circuit is detected in drive circuit (primary circuit) of preheat relay.
Action of con-
• None in particular
troller
Problem on • Intake air heater does not work (degraded starting performance at low temperature and emission
machine of white smokes)
Related infor- • Method of reproducing failure code: Turn starting switch to ON position (Coolant temperature: Max.
mation -5 °C)
• Troubleshooting for this failure code covers circuit starting from engine controller to primary (coil)
side of preheat relay L106.

See the descriptions of harness and connectors in "Electrical equipment" of
1 Defective harness connector "Checks before troubleshooting" in "General information on troubleshooting",
and check them.
2. Disconnect relay L106, and connect T-adapter to male side.
Between L106 (male) (1) and (2) Resistance 200 – 400 z
2 Defective preheat relay 1. Turn starting switch to OFF position.
2. Replace relay L106 with another one.
If this failure code disappears, original preheat relay L106 is defective.
2. Disconnect connector E18, and connect T-adapter to female side.
3 Open or short circuit in harness
Between E18 (female) (40) and (42)
Resistance 200 – 400 z
a Relay L106 coil resistance
2. Disconnect connector E18 and relay L106, and connect T-adapter to female
4 Open circuit in harness side.
Between E18 (female) (40) and L106 (female) (1) Resistance Max. 1 z
Between E18 (female) (42) and L106 (female) (2) Resistance Max. 1 z
40-304 18 WD600-6
Failure code [CA2555] Intake air heater relay open circuit error SEN05054-02
Circuit diagram related to intake air heater
WD600-6 40-304 19
SEN05054-02 Failure code [CA2556] Intake air heater relay short circuit error
Failure code [CA2556] Intake air heater relay short circuit error 1
Action code Failure code Intake air heater relay short circuit
Failure
Detail of failure • Short circuit is detected in drive circuit (primary circuit) of preheat relay.
Action of con-
troller
Problem on • Intake air heater does not work (degraded starting performance at low temperature and emission of
machine white smokes)
Related infor- • Method of reproducing failure code: Turn starting switch to ON position (Coolant temperature: Max.
mation -5 °C)
• Troubleshooting for this failure code covers circuit starting from engine controller to primary (coil)
side of preheat relay L106.

See the descriptions of harness and connectors in "Electrical equipment" of
1 Defective harness connector "Checks before troubleshooting" in "General information on troubleshooting",
and check them.
Between L106 (male) (1) and (2) Resistance 200 – 400 z
2 Defective preheat relay 1. Turn starting switch to OFF position.
2. Replace relay L106 with another one.
If this failure code disappears, original preheat relay L106 is defective.
2. Disconnect connector E18 and relay L106, and connect T-adapters to either
3 Ground fault in harness female side.
Between E18 (female) (40) or L106 (female) (1) and
ground
2. Disconnect connector E18 and relay L106, and connect T-adapter to female
side of E18.
4 Short circuit in harness a Check by using multimeter in continuity mode.
Between E18 (female) (40) and each pin other than No continuity
40-304 20 WD600-6
Failure code [CA2556] Intake air heater relay short circuit error SEN05054-02
Circuit diagram related to intake air heater
WD600-6 40-304 21
SEN05054-02 Failure code [D191KA] AJSS neutral safety relay open circuit
Failure code [D191KA] AJSS neutral safety relay open circuit 1
Action code Failure code AJSS Neutral safety relay: Open circuit
Failure
E01 D191KA (Work equipment controller system)
• Signal is not output to neutral safety relay due to open circuit in AJSS neutral safety relay output
Detail of failure
system.
Action of
• If failure disappears, machine becomes normal by itself.
controller
Problem on • While AJSS lever is operated, engine can be started (Steering moves immediately after engine
machine starts).
• Only AJSS specification (if equipped).
Related infor- • Neutral safety relay does not function if AJSS neutral position adjustment (initial setting) is not per-
mation formed.
• Method of reproducing failure code: Operate AJSS lever while engine is stopped.

Defective AJSS neutral 2. Disconnect relay L104, and connect T-adapter to male side.
1 safety relay (L104)
(Internal open circuit) Resis- 200 to
tance 400 z
2. Disconnect connectors L07 and L104 and connect T-adapters
Probable Open circuit in wiring to each female side.
causes and cri- harness
teria 2 Between L07 (female) (4) and L104 Resis-
(female) (1) tance
Resis-
Between L104 (female) (2) and ground Max. 1z
tance
Defective work equipment 2. Insert T-adapter into connector L07.
3 3. Operate AJSS lever with starting switch in ON position.
controller
Between L07 (4) and ground Voltage 20 to 30V
40-304 22 WD600-6
Failure code [D191KA] AJSS neutral safety relay open circuit SEN05054-02
Circuit diagram related to AJSS neutral safety relay
WD600-6 40-304 23
SEN05054-02 Failure code [D191KB] AJSS neutral safety relay short circuit
Failure code [D191KB] AJSS neutral safety relay short circuit 1
Action code Failure code AJSS Neutral safety relay: Short circuit
Failure
E01 D191KB (Work equipment controller system)
Detail of failure • Abnormal current flows due to ground fault in AJSS neutral safety relay output system.
• Turns off output to AJSS neutral safety relay.
Action of
• Even if failure disappears, machine does not become normal until starting switch is turned to OFF
controller
position.
Problem on • While AJSS lever is operated, engine can be started (Steering moves immediately after engine
machine starts).
• Only AJSS specification (if equipped).
• Neutral safety relay does not function if AJSS neutral position adjustment (initial setting) is not per-
Related infor-
formed.
mation
• While error is occurring, controller does not output voltage.
• Method of reproducing failure code: Operate AJSS lever while engine is stopped.

Defective AJSS neutral
1 safety relay (L104) Resis- 200 to
tance 400 z
(Internal short circuit)
Resis-
Between L104 (male) (1) or (2) and ground Min. 1 MΩ
tance
Probable
causes and cri-
teria Ground fault in wiring 2. Disconnect connectors L07 and L104, and connect T-adapter
2 harness to either female side.
Min. 1 MΩ
L104 (female) (1) tance
Defective work equipment 2. Insert T-adapter into connector L07.
3 3. Operate AJSS lever with starting switch in ON position.
controller
Between L07 (4) and ground Voltage 20 to 30V
40-304 24 WD600-6
Failure code [D191KB] AJSS neutral safety relay short circuit SEN05054-02
Circuit diagram related to AJSS neutral safety relay
WD600-6 40-304 25
SEN05054-02 Failure code [D198KA] Transmission oil pressure bypass solenoid: Disconnection
Failure code [D198KA] Transmission oil pressure bypass solenoid:

Disconnection 1
Action code Failure code Transmission oil pressure bypass solenoid: Disconnection
Trouble
E01 D198KA (Transmission controller system)
Contents of
• Transmission oil pressure bypass solenoid trouble is detected.
trouble
Action of
• None in particular.
controller
Problem that
appears on
machine
Related
• Transmission oil pressure bypass solenoid is not set in WD600-6.
information

Possible causes
and standard Option may be set defectively.
value in normal Referring to Testing and adjusting, “Special functions of machine monitor (EMMS)”, “11. Optional
1
state device selecting function”, check that the very cold region specification (COLD SPEC) is set to “NO
ADD”.
40-304 26 WD600-6
Failure code [D198KB] Transmission oil pressure bypass solenoid: Short circuit SEN05054-02
Failure code [D198KB] Transmission oil pressure bypass solenoid:

Short circuit 1
Action code Failure code Transmission oil pressure bypass solenoid: Short circuit
Trouble
E01 D198KB (Transmission controller system)
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Possible causes
1
ADD”.
WD600-6 40-304 27
Failure code [D198KY] Transmission oil pressure bypass solenoid: Short circuit with power supply
SEN05054-02 line
Failure code [D198KY] Transmission oil pressure bypass solenoid:

Short circuit with power supply line 1
Action code Failure code Transmission oil pressure bypass solenoid: Short circuit with power
Trouble
E01 D198KY line (Transmission controller system)
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Possible causes
1
ADD”.
40-304 28 WD600-6
Failure code [D198KY] Transmission oil pressure bypass solenoid: Short circuit with power supply
line SEN05054-02
WD600-6 40-304 29
SEN05054-02 Failure code [D5ZHKA] Terminal C signal open circuit
Failure code [D5ZHKA] Terminal C signal open circuit 1
Action code Failure code Terminal C signal: Open circuit

Failure
E01 D5ZHKA (Transmission controller system)
• Terminal C system has open circuit or ground fault (While engine speed is 500 rpm or higher, start-
Detail of failure
ing switch terminal C signal has not been input).
Action of • None in particular
Problem on
machine
• Input (ON/OFF) from starting switch terminal C to transmission controller can be checked with mon-
Related infor-
itoring function. (Code: 40905 D-IN-7) (Transmission controller system).
mation
• Method of reproducing failure code: Turn starting switch to START position.

Defective fuse No. 1
1 If fuse is blown, circuit probably has ground fault (See cause 4).
in fuse box 1
2. Disconnect connector CL12, and connect T-adapter to male
side.
3. Perform troubleshooting with starting switch in ON/OFF and
Defective starting switch START position.
2
Resis-
START Max. 1 z
Between CL12 (1) tance
and (3) Resis-
OFF/ON Min. 1 Mz
tance
2. Disconnect connectors CL12, L02, L103, L104, and connect T-
adapters to each female side.
Open circuit in wiring Between CL12 (female) (3) and L103 Resis-
harness Max. 1 z
3 (female) (5) tance
Between L103 (female) (3) and L104 Resis-
Probable
(female) (6) tance
causes and cri-
teria Between L104 (female) (3) and L02 Resis-
Max. 1 z
(female) (6) tance
2. Disconnect connectors CL12, C02, L02, L112, L103, L104, and
R23 to R26, and connect T-adapter to either female side.
Ground fault in wiring Between ground and CL12 (female) (3) or Resis-
Min. 1 Mz
4 harness L103 (female) (5) tance
Min. 1 Mz
Between ground and L104 (female) (3) or Resis-
Min. 1 Mz
2. Insert T-adapter into connector L02.
Defective transmission START position.
5
controller Starting switch:
Voltage 20 to 30 V
Between L02 (6) START
and ground Starting switch:
Voltage Max. 1 V
OFF/ON
40-304 30 WD600-6
Failure code [D5ZHKA] Terminal C signal open circuit SEN05054-02
Circuit diagram related to engine starting system
WD600-6 40-304 31
SEN05054-02 Failure code [D5ZHKB] Terminal C signal short circuit
Failure code [D5ZHKB] Terminal C signal short circuit 1
Action code Failure code Terminal C signal: Short circuit

Failure
E01 D5ZHKB (Transmission controller system)
• Hot short in terminal C system (While engine speed is 500 rpm or higher, starting switch terminal C
Detail of failure
signal is input).
Action of • Stops engine starting aid function.
Problem on
machine
• Input (ON/OFF) from starting switch terminal C to transmission controller can be checked with mon-
Related infor-
itoring function. (Code: 40905 D-IN-7) (Transmission controller system).
mation

side.
1
Resis-
START Max. 1 z
and (3) Resis-
OFF/ON Min. 1 Mz
tance
2. Disconnect connectors L103 and L104, and connect T-
Probable adapters to each female side.
causes and cri- Hot short circuit in wiring 3. Turn starting switch to ON position.
teria 2 harness Between L103 (female) (5) and ground Voltage Max. 1 V
(Contact with 24V circuit)
Between ground and L103 (female) (3) or
Voltage Max. 1 V
L104 (female) (6)
Between L104 (female) (3) and ground Voltage Max. 1 V
Defective transmission START position.
3
Voltage 20 to 30 V
Voltage Max. 1 V
OFF/ON
40-304 32 WD600-6
Failure code [D5ZHKB] Terminal C signal short circuit SEN05054-02
WD600-6 40-304 33
SEN05054-02 Failure code [D5ZHKZ] Terminal C signal open or short circuit
Failure code [D5ZHKZ] Terminal C signal open or short circuit 1
Action code Failure code Terminal C signal: Open or short circuit

Failure
E01 D5ZHKZ (Work equipment controller system)
• Terminal C system has open circuit (While engine speed is 500 rpm or higher, starting switch ter-
Detail of failure
minal C signal has not been input).
Problem on
• Engine starts while work equipment control lever is not in neutral.
machine
• Input (ON/OFF) from starting switch terminal C to work equipment controller can be checked with
Related infor-
monitoring function. (Code: 40912 D-IN-17) (Work equipment controller system).
mation

Defective fuse No. 1
1 If fuse is blown, circuit probably has ground fault (See cause 4).
in fuse box 1
side.
2
Resis-
START Max. 1 z
and (3) Resis-
OFF/ON Min. 1 Mz
tance
2. Disconnect connectors CL12, L103, and L06, and connect T-
Open circuit in wiring adapters to each female side.
harness
3 Between CL12 (female) (3) and L103 Resis-
Probable (Wire breakage or defective Max. 1 z
(female) (5) tance
causes and cri- contact of connector)
teria Between L103 (female) (3) and L06 Resis-
Max. 1 z
(female) (25) tance
2. Disconnect connectors CL12, L103, and L06, and connect T-
Ground fault in wiring adapter to either female side.
4 harness Between ground and CL12 (female) (3) or Resis-
Min. 1 Mz
(Contact with ground circuit) L103 (female) (5) tance
Min. 1 Mz
Defective work equipment START position.
5
Voltage 20 to 30V
Voltage Max. 1 V
OFF/ON
40-304 34 WD600-6
Failure code [D5ZHKZ] Terminal C signal open or short circuit SEN05054-02
WD600-6 40-304 35
SEN05054-02 Failure code [D5ZHL6] Terminal C signal disagrees with run and stop of engine
Failure code [D5ZHL6] Terminal C signal disagrees with run and stop of
engine 1
Action code Failure code Terminal C signal: Signal disagrees with run and stop of engine
Failure
E01 D5ZHL6 (Machine monitor system)
• Terminal C system has open circuit or ground fault (While engine speed is 500 rpm or higher, start-
Detail of failure
ing switch terminal C signal has not been input).
Problem on
machine
• Input (ON/OFF) from starting switch terminal C to machine monitor can be checked with monitoring
Related infor-
function. (Code: 40900 D-IN-2) (Machine monitor system).
mation

Defective fuse No. 1 in fuse If fuse is burnt out, circuit probably has ground fault (See check on
1
box 1 Cause 4).
2. Disconnect connector CL12, and connect T-adapter to male side.
2
(Internal open circuit) Resis-
START Max. 1 z
and (3) Resis-
OFF/ON Min. 1 Mz
tance
2. Disconnect connectors CL12, L103, L104, C02, and L02, and
connect T-adapters to each female side.
Open circuit in wiring Between CL12 (female) (3) and L103 Resis-
harness Max. 1 z
Between L103 (female) (3) and L104 Resis-
Probable (female) (6) tance
causes and cri- Between L104 (female) (3) and C02 Resis-
teria Max. 1 z
(female) (2) tance
2. Disconnect connectors CL12, L103, L104, C02, L02, and R23
to R26, and connect T-adapter to either female side.
Ground fault in wiring Between ground and CL12 (female) (3) or Resis-
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
C02 (female) (2) tance
START position.
Starting switch:
Voltage 20 to 30V
Between C02 (2) START
Voltage Max. 1 V
OFF/ON
40-304 36 WD600-6
Failure code [D5ZHL6] Terminal C signal disagrees with run and stop of engine SEN05054-02
WD600-6 40-304 37
SEN05054-02 Failure code [DA80L4] Auto-greasing controller disagrees with ON/OFF signal
Failure code [DA80L4] Auto-greasing controller disagrees with ON/OFF

signal 1
Action code Failure code Auto-greasing controller: Disagrees with ON/OFF signal
Failure
- DA80L4 (Machine monitor system)
Detail of failure • Both circuits of auto-greasing sensor inputs A and B are open or their voltage is 24V simultaneously.
Problem on
• Auto-greasing system does not operate.
machine
• Input (ON/OFF) from auto-greasing controller can be checked with monitoring function (Code:
40900 D-IN-4 and D-IN-5).
Related infor-
• Only machines with auto-greasing system (if equipped)
mation
• Method of reproducing failure code: Turn starting switch to ON position + Press auto-greasing start
button.

Defective auto grease con-
1 troller (Internal disconnec- a Refer to and troubleshoot for auto grease system.
tion or short circuit)
2. Disconnect connectors C02 and R38, and connect T-adapters
harness
2 Between C02 (female) (3) and R38 Resis-
(Wire breakage or defective Max. 1 Ω
(female) (2) tance
Between C02 (female) (12) and R38 Resis-
Max. 1 Ω
(female) (3) tance
Probable 1. Turn starting switch to OFF position.
causes and cri-
2. Disconnect connectors C02 and R38, and connect T-adapter to
teria
Ground fault in wiring either female side.
3 harness Between ground and C02 (female) (3) or Resis-
Min. 1 MΩ
(Contact with ground circuit) R38 (female) (2) tance
Between ground and C02 (female) (12) or Resis-
Min. 1 MΩ
R38 (female) (3) tance
2. Disconnect connector R38, and connect T-adapter to female
Hot short circuit in wiring side.
4 harness 3. Turn starting switch to ON position.
(Contact with 24V circuit)
Between R38 (female) (2) and ground Voltage Max. 1 V
Between R38 (female) (3) and ground Voltage Max. 1 V
40-304 38 WD600-6
Failure code [DA80L4] Auto-greasing controller disagrees with ON/OFF signal SEN05054-02

3. Turn starting switch to ON position and press auto-greasing
start button.
Real-time monitor
Between C02 (3) –
Auto (Code: 40900):
ground (0 V) Auto
grease: D-IN-4 0
grease
Operat- Real-time monitor
Between C02 (12) – lamp:ON
ing (Code: 40900):
ground (24 V)
D-IN-5 1
Real-time monitor
Between C02 (3) –
Auto (Code: 40900): Auto
ground (0 V)
Defective auto-greasing grease: D-IN-4 0 grease
controller Abnor- Real-time monitor lamp:Blink
Probable 5 mal Between C02 (12) – (2 Hz)
(Internal open or short (Code: 40900):
causes and cri- ground (0 V)
teria circuit) D-IN-5 0
Real-time monitor
Between C02 (3) –
Auto (Code: 40900): Auto
ground (24 V)
grease: D-IN-4 1 grease
Tank Real-time monitor lamp:Blink
empty Between C02 (12) – (Code: 40900): (1 Hz)
ground (0 V)
D-IN-5 0
Real-time monitor
Between C02 (3) –
Auto (Code: 40900):
ground (24 V) Auto
grease: D-IN-4 1
grease
Abnor- Real-time monitor
Between C02 (12) – lamp:OFF
mal (Code: 40900):
ground (24 V)
D-IN-5 1
If no failure is found by checks on causes 1 to 5, machine monitor
6 Defective machine monitor may be defective. (Since this is an internal defect, troubleshooting
cannot be performed.)
Circuit diagram related to auto-greasing
WD600-6 40-304 39
SEN05054-02 Failure code [DAF3KK] Machine monitor: Source voltage low (input)
Failure code [DAF3KK] Machine monitor: Source voltage low (input) 1
Action code Failure code Machine monitor: Source voltage low (input)
Failure
E03 DAF3KK (Machine monitor system)
• When voltage of SW power supply (power supply for operation) is above 17 V, voltage of UNSW
Detail of failure
power supply (power supply for memory) is below 17 V.
Action of con- • Lights up centralized warning lamp and sounds alarm buzzer.
troller • If failure disappears, machine becomes normal by itself.
Problem on • Service meter reading is incorrect, odometer does not advance, and abnormality record data is not
machine saved.
Related infor-
mation

Trip of circuit breaker If circuit breaker has tripped, circuit probably has ground fault (See
1
(CBF1) cause 5).
2
box 1 Cause 5).
1. Turn starting switch to OFF position and disconnect battery
ground cable.
2. Disconnect connector C01, and connect T-adapter to female
side.
3. Install the battery ground cable, and turn starting switch to ON
3 Defective wiring harness
position (connect ACC).
a Leave machine monitor disconnected.
Between C01 (female)(4) and (9) Voltage 20 to 30 V
Between C01 (female)(5) and (10) Voltage 20 to 30 V
ground cable.
2. Disconnect connector C01, and connect T-adapter to female side.
Probable Resis-
Between C01 (female) (9) and ground Max. 1 z
causes and cri- tance
teria Resis-
tance
Resis-
tance
Resis-
Open circuit in wiring tance
harness Resis-
4 Between C01 (female) (19) and ground Max. 1 z
(Wire breakage or defective tance
contact of connector) Resis-
tance
If no failure is found by check on cause 3, this check is not required.
ground cable.
2. Remove fuse No. 6 in fuse box 1.
3. Disconnect connector C01, and connect T-adapter to female side.
Between battery (+) and fuse No. 6 in fuse Resis-
Max. 1 z
box 1 tance
Between fuse No. 6 in fuse box 1 and C01 Resis-
Max. 1 z
(female) (4), (5) tance
40-304 40 WD600-6
Failure code [DAF3KK] Machine monitor: Source voltage low (input) SEN05054-02

ground cable.
Ground fault in wiring 3. Disconnect connector C01, and connect T-adapter to female
5 harness side.
Between ground and battery (+) or fuse No. Resis-
Min. 1 Mz
Probable 6 in fuse box 1 tance
causes and cri-
teria Between ground and fuse No. 6 in fuse box 1 Resis-
Min. 1 Mz
or C01 (female) (4), (5) tance
ground cable.
position.
Between C01 (4) and (9) Voltage 20 to 30V
Between C01 (5) and (10) Voltage 20 to 30V
Circuit diagram related to machine monitor power supply
WD600-6 40-304 41
SEN05054-02 Failure code [DAF5KP] Machine monitor: Output voltage low
Failure code [DAF5KP] Machine monitor: Output voltage low 1
Action code Failure code Machine monitor: Output voltage is low

Failure
E01 DAF5KP (Machine monitor system)
• When voltage of SW power supply (power supply for operation) is above 17 V, sensor voltage is
Detail of failure
below 5 V.
Action of con- • None in particular
troller • Even if failure disappears, machine does not become normal until engine is started again.
Problem on
• Load is not displayed.
machine
Related infor- • Only load meter specification (if equipped)
mation • Method of reproducing failure code: Turn starting switch to ON position.

2. Disconnect connectors of following sensors one by one, and turn
starting switch to ON position each time.
a If this failure code lights off, disconnected sensor is defec-
tive.
a Since connector is disconnected, other failure codes appear.
Defective angle sensor or
Ignore all the other failure codes except this one.
1 pressure sensor (internal
3. Each time troubleshooting is finished, return to step 1.
defect)
Sensor Connector
Lift arm angle sensor F13
Probable Lift arm bottom pressure sensor F14

causes and cri-
teria Lift arm rod pressure sensor F15
Ground fault in wiring 2. Disconnect connectors C01, F13, F14, and F15.
2 harness 3. Connect T-adapter to female side of connector C01.
(Contact with ground circuit) Resis-
Between C01 (female) (16) and ground Min. 1 Mz
tance
2. Disconnect connectors F13, F14, and F15, and connect T-
adapter to either female side.
3 Defective machine monitor 3. Turn starting switch to ON position (with connectors F13, F14,
and F15 disconnected).
Between ground and F13 (female) (A), F14 4.85 to
Voltage
(female) (A) or F15 (female) (A) 5.15 V
40-304 42 WD600-6
Failure code [DAF5KP] Machine monitor: Output voltage low SEN05054-02
Circuit diagram related to machine monitor sensor power supply
WD600-6 40-304 43
Failure code [DAFRKR] CAN communication with machine monitor: Communication error
SEN05054-02 (Abnormality in target component system)
Failure code [DAFRKR] CAN communication with machine monitor:

Communication error (Abnormality in target component system) 1
Action code Failure code CAN communication with machine monitor: Communication error
Failure (Abnormality in target component system)
E03 DAFRKR (Transmission controller system)
• Transmission controller cannot receive information from machine monitor through CAN communi-
Detail of failure
cation.
Action of con-
• Uses CAN information obtained from machine monitor just before failure occurs.
troller
Problem on
• Machine monitor does not display normally.
machine
• Check that power supply circuit of machine monitor is normal.
• Start of CAN communication is recognized by each controller when ACC signal of starting switch is
received.
• Failure code is transmitted to and displayed on machine monitor by CAN communication. Accord-
ingly, if CAN communication with machine monitor fails, failure code [DAFRKR] is not displayed on
machine monitor and it can be observed only through KOMTRAX system.
Related infor-
• When failure code [D**RKR], [DB9RMC], or [DBBQKR] is also displayed, write down all of dis-
mation
played codes.
• Failure code [DAFRKR] is displayed. That is, there cannot be short circuit, ground fault, or hot short
circuit in CAN communication line.
• Since each controller and machine monitor are connected directly to the battery, they are supplied
with power even when starting switch is in OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by using mul-
timeter.

Probable Defective power supply to
1 Perform troubleshooting for failure code [DAF3KK].
causes and cri- machine monitor
teria
Defective CAN Perform checks on causes 2 to 5 in troubleshooting for failure code
2
communication [DAQRKR].
40-304 44 WD600-6
Failure code [DAQ0KK] Transmission controller: Source voltage low SEN05054-02
Failure code [DAQ0KK] Transmission controller: Source voltage low 1
Action code Failure code Transmission controller: Source voltage low

Failure
E03 DAQ0KK (Transmission controller system)
• UNSW power supply voltage (power supply directly from battery) of the transmission controller is
low.
Detail of failure
• UNSW power supply voltage (battery direct power supply) is below 18 V and engine speed is above
500 rpm.
• Cannot detect input signals correctly.
Action of con-
• Even if failure disappears, machine does not become normal until directional lever or directional se-
troller
lector switch is set to N (NEUTRAL).
Problem on
• Machine does not operate normally.
machine
Related infor-
mation

1
(CBF1) cause 5).
2
box 1 Cause 5).
ground cable.
2. Disconnect connector L04, and connect T-adapter to female side.
3 Defective wiring harness position (connect ACC).
a Leave transmission controller disconnected.
Between L04 (female) (1) and (21) Voltage 20 to 30 V
ground cable.
Probable 2. Disconnect connector L04, and connect T-adapter to female side.
causes and cri- Resis-
teria Between L04 (female) (21) and ground Max. 1 z
tance
Resis-
Between L04 (female) (31) and ground Max. 1 z
tance
Resis-
tance
Open circuit in wiring
Resis-
harness Between L04 (female) (33) and ground Max. 1 z
4 tance
contact of connector) If no failure is found by check on cause 3, this check is not required.
ground cable.
3. Disconnect connector L04, and connect T-adapter to female
side.
Between battery (+) and fuse No. 4 in fuse Resis-
Max. 1 z
box 1 tance
Between fuse No. 4 in fuse box 1 and L04 Resis-
Max. 1 z
WD600-6 40-304 45
SEN05054-02 Failure code [DAQ0KK] Transmission controller: Source voltage low

ground cable.
Ground fault in wiring 3. Disconnect connector L04, and connect T-adapter to female
5 harness side.
Between ground and battery (+) or fuse No. Resis- Min.
Probable 4 in fuse box 1 tance 1Mz
causes and cri-
Between ground and fuse No. 4 in fuse box 1 Resis- Min.
teria
or L04 (female) (1), (11) tance 1Mz
ground cable.
Defective transmission 3. Install the battery ground cable, and turn starting switch to ON
6
controller position.
Between L04 (1) and (21) Voltage 20 to 30 V
40-304 46 WD600-6
Failure code [DAQ0KK] Transmission controller: Source voltage low SEN05054-02
Circuit diagram related to transmission controller power supply
WD600-6 40-304 47
SEN05054-02 Failure code [DAQ0KT] Transmission controller: Defect in controller
Failure code [DAQ0KT] Transmission controller: Defect in controller 1
Action code Failure code Transmission controller: Defect in controller

Failure
E01 DAQ0KT (Transmission controller system)
Detail of failure • Information in ROM (non-volatile memory) in transmission controller is abnormal.

• Reset internal adjustment values to default values.
troller • Even if failure disappears, machine does not become normal until starting switch is turned to OFF
position.
Problem on
• Transmission shifting feel may become bad.
machine
Related infor-
mation
Probable Cause Standard value in normal condition, remarks for troubleshooting

causes and cri- Defective transmission Since this is internal failure, troubleshooting cannot be performed
teria 1
controller (Replace controller).
40-304 48 WD600-6
Failure code [DAQ0KT] Transmission controller: Defect in controller SEN05054-02
WD600-6 40-304 49
SEN05054-02 Failure code [DAQ2KK] Transmission controller load power supply line: Source voltage low (Input)
Failure code [DAQ2KK] Transmission controller load power supply line:

Source voltage low (Input) 1
Action code Failure code Transmission controller load power supply line: Source voltage low
Failure (Input)
E03 DAQ2KK (Transmission controller system)
• Voltage of 24 V solenoid power supply system is low.
Detail of failure • Detection conditions: Terminal C input is turned OFF, UNSW power supply (battery direct power
supply) is above 20 V, and solenoid power supply is below 18 V.
• Does not display failure codes that may be detected wrongly due to low 24 V solenoid source volt-
Action of con-
age.
troller
• Even if failure disappears, machine does not become normal until directional lever or directional se-
lector switch is set to N (NEUTRAL).
Problem on
• Transmission is kept in neutral.
machine
Related infor-
mation

a Be ready with starting switch at OFF, then perform troubleshoot-
ing without turning starting switch to ON position.
Resis- 200 to
tance 400 z
Defective fan motor relay
1 (L117) (internal open or
2. Disconnect connector L117, and replace fan motor relay with
short circuit)
another relay of same model.
Probable When failure code [DA2QKK] is not displayed, original fan motor
causes and cri- relay is defective.
teria
ground cable.
2 Defective wiring harness a Leave transmission controller disconnected.
40-304 50 WD600-6
Failure code [DAQ2KK] Transmission controller load power supply line: Source voltage low (Input) SEN05054-02

ground cable.
side.
Resis-
tance
Resis-
tance
Resis-
tance
Resis-
Open circuit in wiring Between L04 (female) (33) and ground Max. 1 z
tance
harness
3 If no failure is found by check on cause 2, this check is not required.
ground cable.
2. Disconnect connectors L117 and L04, and connect T-adapters to
each female side.
Resis-
tance
Probable Between L04 (female) (4) and L117 (female) Resis-
causes and cri- Max. 1 z
(1) tance
teria
Between L117 (female) (5) and each of L04 Resis-
Max. 1 z
(female) (2), (12), and (22) tance
Between L117 (female) (3) and L04 (female) Resis-
Max. 1 z
(1) tance
Ground fault in wiring ground cable.
4 harness 2. Disconnect connectors L117 and L04, and connect T-adapter to
(Contact with ground circuit) either female side.
Between ground and L04 (female) (2), (12), Resis- Min.
(22), or L117 (female) (5) tance 1 Mz
ground cable.
Defective transmission position.
5
controller
WD600-6 40-304 51
SEN05054-02 Failure code [DAQ2KK] Transmission controller load power supply line: Source voltage low (Input)
Circuit diagram related to transmission controller power supply
40-304 52 WD600-6
Failure code [DAQ9KQ] Transmission controller model selection: Model selection signal
disagreement SEN05054-02
Failure code [DAQ9KQ] Transmission controller model selection: Model

selection signal disagreement 1
Action code Failure code Transmission controller model selection: Model selection signal
Failure disagreement
E03 DAQ9KQ (Machine monitor system)
Detail of failure • Transmission controller model is mistaken for another model.
• Continues to operate by regarding machine model is same as the one before this failure code is gen-
erated.
Action of con-
troller
• Does not display failure codes that may be detected wrongly.
Problem on
• Gear shifting shocks may occur.
machine
Related infor-
mation

causes and cri- Abnormal model selection Set model with machine monitor.
teria 1
by machine monitor (See Testing and adjusting)
WD600-6 40-304 53
Failure code [DAQRKR] CAN communication with transmission

controller: Communication error (Abnormality in target component
system) 1
Action code Failure code CAN communication with transmission controller: Communication
Failure error (Abnormality in target component system)
E03 DAQRKR (Machine monitor system)
• Machine monitor cannot receive information from transmission controller through CAN communica-
Detail of failure
tion circuit.
• Uses CAN information obtained from transmission controller just before failure occurs.
Action of con-
troller
Problem on
• Machine monitor does not display normally.
machine
received.
• When failure code [D**RKR], [DB9RMC], or [DBBQKR] is also displayed, at least CAN communi-
cation between another controller and machine monitor is established. That is, there cannot be short
circuit, ground fault, or hot short circuit in CAN communication line.
• When [DAQRKR] is displayed, but none of failure codes [D**RKR], [DB9RMC], and [DBBQKR] is
Related infor-
displayed, CAN communication may not be established between any controllers. That is, there may
mation
be short circuit, ground fault, or hot short circuit in CAN communication line.
• Machine monitor detects only this code in CAN communication errors. Accordingly, when this code
is displayed, it does not always indicate that transmission controller has failure.
• Another controller may have failure and disable whole CAN communication.
• Since active signal is pulse voltage, it cannot be measured by using multimeter.

Defective power supply to
1 Perform troubleshooting for failure code [DAQ0KK].
transmission controller
Probable 2. Disconnect connectors CAN1 and E21, and connect T-adapters
causes and cri- to each male side.
teria Defective CAN terminating
3. Perform troubleshooting with starting switch in OFF position.
resistor
2
(Internal open or short Resis- 120 ±
Between CAN1 (male) (A) and (B)
circuit) tance 12 z
Resis- 120 ±
Between E21 (male) (A) and (B)
tance 12 z
40-304 54 WD600-6
(Abnormality in target component system) SEN05054-02

• CAN communication line
a Since 2 CAN terminating resistors of 120 z are connected in
parallel, when circuit resistance is measured at any connector, if
it is 60 z of combined resistance, there is no open circuit.
ground cable.
2. Disconnect following connectors L03, E18, C06, L06, and V06
one by one, and connect T-adapter to female side of discon-
nected one.
a If open circuit is found (resistance between 2 terminals is 1 z or
below), disconnect all CAN communication connectors of every
Open or short circuit in controller and check whether short circuit occurs in wiring har-
3
wiring harness ness or inside controller.
Resis- Approx.
Between L03 (female) (32) and (22)
tance 60 z
Resis- Approx.
Between E18 (female) (46) and (47)
tance 60 z
Resis- Approx.
Between C06 (female) (3) and (8)
tance 60 z
Probable
causes and cri- Resis- Approx.
teria tance 60 z
Resis- Approx.
Between V06 (female) (4) and (12)
tance 60 z
ground cable.
2. Insert T-adapters into connectors L04, E18, E19, C01, L07, and
V01.
3. Connect battery ground cable and turn starting switch to ON
position.
Defective starting switch Between L04 (14) and (21) Voltage 20 to 30 V
ACC signal Between L04 (24) and (31) Voltage 20 to 30 V
4 (Start of CAN
communication is not Between E18 (39) and E19 (1) Voltage 20 to 30 V
recognized)
Between C01 (6) and (9) Voltage 20 to 30 V
Between C01 (7) and (10) Voltage 20 to 30 V
Between V01 (17) and (19) Voltage 20 to 30 V
WD600-6 40-304 55

a If no failure is found by check on cause 3, this check is not re-
quired.
ground cable.
2. Disconnect connectors L03, E18, C06, L06, V06, CAN1, and
E21, and connect T-adapters to their female side.
Between L03 (female) (32) and E21 (female) Resis-
Max. 1 z
(A) tance
Max. 1 z
(B) tance
Max. 1 z
(32) tance
Max. 1 z
(22) tance
Between L03 (female) (32) and C06 (female) Resis-
Max. 1 z
(3) tance
Between L03 (female) (22) and C06 (female) Resis-
Max. 1 z
(8) tance
Max. 1 z
(46) tance
Max. 1 z
(47) tance
Probable Open circuit in wiring
causes and cri- harness Between L03 (female) (32) and CAN1 Resis-
teria 5 Max. 1 z
(Wire breakage or defective (female) (A) tance
contact of connector) Between L03 (female) (22) and CAN1 Resis-
Max. 1 z
(female) (B) tance
Between L03 (female) (32) and V06 (female) Resis-
Max. 1 z
(4) tance
Between L03 (female) (22) and V06 (female) Resis-
Max. 1 z
(12) tance
a If no failure is found by check on cause 4, this check is not re-
quired.
ground cable.
2. Disconnect connectors L04, E18, C01, L07, and V01, and
connect T-adapters to their female side.
Between starting switch (ACC) and L04 Resis-
Max. 1 z
Between starting switch (ACC) and C01 Resis-
Max. 1 z
Between starting switch (ACC) and E18 Resis-
Max. 1 z
(female) (39) tance
Between starting switch (ACC) and L07 Resis-
Max. 1 z
Between starting switch (ACC) and V01 Resis-
Max. 1 z
(female) (17) tance
40-304 56 WD600-6

a If no failure (no open circuit) is found by check on cause 5, mea-
sure resistance at any 1 place in each case.
ground cable.
Ground fault in wiring connect T-adapters to their female side.
6 harness
Between ground and any of E18 (female)
(46), L03 (female) (32), C06 (female) (3), Min. 1 Mz
tance
L06 (female) (32), or V06 (female) (4)
Resis-
(47), L03 (female) (22), C06 (female) (8), Min. 1 Mz
tance
a If no failure (no open circuit) is found by check on cause 5, mea-
sure resistance at any 1 place in each case.
ground cable.
connect T-adapters to their female side.
Short circuit or hot short 3. Connect battery ground cable.
7 circuit in wiring harness 4. Turn starting switch to ON position.
(contact with 24 V circuit)
(46), L03 (female) (32), C06 (female) (3), Voltage 1 to 4 V
Probable L06 (female) (32), or V06 (female) (4)
causes and cri- Between ground and any of E18 (female)
teria (47), L03 (female) (22), C06 (female) (8), Voltage 1 to 4 V
• When no failure is found by above checks and failure code
[DBBQKR] is displayed, transmission controller may be defec-
tive.
• When no failure is found by above checks and failure code
[DBBQKR] is not displayed;
a Identify which controller is defective by disconnecting them one
by one from CAN communication line by repeating the following
steps 1 to 3.
Defective engine controller, 1. Turn starting switch to OFF position and disconnect battery
transmission controller, work ground cable.
8
equipment controller, or 2. Disconnect CAN communication connectors of engine controller,
VHMS & PLM controller transmission controller, work equipment controller, and VHMS &
PLM controller one by one (See related circuit diagrams).
3. Connect battery ground cable, turn starting switch to ON position,
and perform troubleshooting.
4. Return to step 1 and check next controller.
Did failure code change to [D**RKR] other
than [DAQRKR] or to [DBBQKR]? If YES, the discon-
nected controller is
Did number of CAN communication failure defective.
codes decrease?
a If no failure is found by above checks, machine monitor may be
be performed.)
WD600-6 40-304 57
Circuit diagram related to CAN communication line
40-304 58 WD600-6
Failure code [DAQRMA] Transmission controller (Option setting): Malfunction SEN05054-02
Failure code [DAQRMA] Transmission controller (Option setting):

Malfunction 1
Action code Failure code Transmission controller (Option setting): Malfunction

Failure
E03 DAQRMA (Transmission controller system)
Detail of failure • Option setting of machine monitor disagrees with option recognition in transmission controller.
Action of con- • Transmission controller operates according to its own option setting recognition.
troller • Lights up centralized warning lamp and sounds alarm buzzer.
Problem on
machine -
Related infor-
mation

causes and cri-
teria 1 Defective option setting Perform setting again.
WD600-6 40-304 59
SEN05054-02
WD600-6 Wheel dozer

©2017 KOMATSU
All Rights Reserved
40-304 60
SEN05055-02
WHEEL DOZER
WD600-6

WD600-6 55001 and up

Failure code [DB2RKR] CAN communication from engine controller: Communication error (Abnormality in
target component system) .......................................................................................................................... 4
Failure code [DB90KK] Work equipment controller: Source voltage low (input) ............................................. 7
Failure code [DB90KT] Work equipment controller: Defect in controller....................................................... 10
Failure code [DB92KK] Work equipment controller load power supply line: Source voltage low (input) .......11
Failure code [DB95KX] Work equipment controller power supply output: Out of range ............................... 14
Failure code [DB99KQ] Work equipment controller model selection: Model selection signal disagreement 16
Failure code [DB9RKR] CAN communication with work equipment controller: Communication error
(Abnormality in target component system) ............................................................................................... 17
Failure code [DB9RMA] Work equipment controller (Option setting): Malfunction ....................................... 18
Failure code [DB9RMC] CAN communication with transmission controller: Malfunction ............................. 19
Failure code [DBB0KK] or change of VHMS_LED display from "n9" to "01" (VHMS controller: Source voltage
low (input)) ................................................................................................................................................ 20
Failure code [DBB0KQ] or change of VHMS_LED display from "nF" to "11" (VHMS controller: Disagreement
of model selection signals) ....................................................................................................................... 22
Failure code [DBB3KK] or change of VHMS_LED display from "n9" to "05" (VHMS controller battery power
supply: Source voltage low (input))........................................................................................................... 24
Failure code [DBB5KP] or change of VHMS_LED display from "n9" to "04" (VHMS controller 5 V power
supply output: Output voltage low) ........................................................................................................... 26
Failure code [DBB6KP] or change of VHMS_LED display from "n9" to "02" (VHMS controller 24V power
supply output: Output voltage low) ........................................................................................................... 28
WD600-6 40-305 1
SEN05055-02
Failure code [DBB7KP] or change of VHMS_LED display from "n9" to "03" (VHMS controller 12V power
supply output: Output voltage low)............................................................................................................ 30
Failure code [DBBQKR] or change of VHMS_LED display from "n8" to "02" (CAN communication of VHMS
controller: Communication error (Abnormality in target component system))........................................... 32
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time ............................. 34
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time............................. 36
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time .............................. 38
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time .............................. 40
40-305 2 WD600-6
SEN05055-02
WD600-6 40-305 3
Failure code [DB2RKR] CAN communication from engine controller: Communication error
Failure code [DB2RKR] CAN communication from engine controller:

Communication error (Abnormality in target component system) 1
Action code Failure code CAN communication from engine controller: Communication error
E03 DB2RKR (Transmission controller system)
Detail of failure • Transmission controller cannot recognize engine controller through CAN communication.
• Does not update CAN communication information from engine controller.
• Fixes engine speed to 2,100 rpm.
Action of con- • Fixes throttle position recognition to 80%.
troller • Does not detect slip of modulation clutch.
Problem on • Information to be obtained from engine controller is not displayed and special functions that need
machine information do not work. In another case, received data are not updated.
received.
• When failure code [D**RKR], [DB9RMC], or [DBBQKR] is also displayed, write down all of dis-
Related infor- played codes.
mation • Failure code [DB2RKR] is displayed. That is, there cannot be short circuit, ground fault, or hot short

Defective circuit breaker If circuit breaker has tripped, circuit probably has ground fault (See
1
(CBF4) cause 6).
a If circuit breaker CBF4 has not tripped, this check is not required.
2. Disconnect connector E19, and connect T-adapter to male side.
Defective engine controller a Measured value: Approx. 9 to 20 kz
2 a When 10 z or below, engine controller is defective (has internal
short circuit).
Resis-
Between E19 (male) (4) and (1) Min. 10 z
tance
Probable
causes and cri-
teria ground cable.
Defective power supply to 2. Insert T-adapter into connector E19.
3
engine controller 3. Connect battery ground cable, and perform troubleshooting.
Between E19 (4) and (1) Voltage 20 to 30 V
ground cable.
Open circuit in wiring 2. Disconnect connector E19, and connect T-adapter to female
harness side.
4
Between battery (+) and E19 (female) (4) Max. 1 z
Resis-
Between E19 (female) (1) and ground Max. 1 z
tance
40-305 4 WD600-6

ground cable.
Ground fault in wiring 2. Disconnect connector E19, and connect T-adapter to female
5 harness side.
Probable Resis-
Between E19 (female) (4) and ground Max. 1 z
causes and cri- tance
teria
Defective CAN
6 Perform checks on causes 2 to 5 in failure code [DAQRKR].
a If no failure is found by above checks, engine controller may be
defective.
(Since this is an internal defect, troubleshooting cannot be per-
formed.)
Circuit diagram related to engine controller power supply
WD600-6 40-305 5
Circuit diagram related to CAN communication
40-305 6 WD600-6
Failure code [DB90KK] Work equipment controller: Source voltage low (input) SEN05055-02
Failure code [DB90KK] Work equipment controller: Source voltage low

(input) 1
Action code Failure code Work equipment controller: Source voltage low (input)
Failure
E03 DB90KK (Work equipment controller system)
• UNSW power supply voltage (power supply directly from battery) of the work equipment controller
Detail of failure is low.
• UNSW power supply voltage (battery direct power supply) is below 18 V.
• Does not display failure codes other than this code if voltage of UNSW power supply (battery direct
power supply) remains under 18 V for more than 2 seconds.
Action of con- • Even if failure disappears, machine does not become normal until AJSS lever and work equipment
troller control lever are set to N (NEUTRAL).
• Cannot detect input signals normally, thus cannot perform normal operation.
Problem on
• Machine does not operate normally.
machine
Related infor-
mation

1
(CBF1) cause 5).
2
box 1 Cause 5).
ground cable.
side.
3 Defective wiring harness
a Leave work equipment controller disconnected.
ground cable.
Probable 2. Disconnect connector L07, and connect T-adapter to female side.
causes and cri-
teria Resis-
tance
Resis-
tance
Resis-
tance
Resis-
harness Between L07 (female) (33) and ground Max. 1 z
4 tance
ground cable.
side.
Between battery (+) and fuse No. 5 terminal Resis-
Max. 1 z
in fuse box 1 tance
Between fuse No. 5 in fuse box 1 and L07 Resis-
Max. 1 z
WD600-6 40-305 7
SEN05055-02 Failure code [DB90KK] Work equipment controller: Source voltage low (input)

ground cable.
5 harness side.
Between ground and battery (+) or terminal Resis- Min.
Probable of fuse No. 5 in fuse box 1 tance 1 Mz
causes and cri-
Between ground and terminal of fuse No. 5 Resis- Min.
teria
in fuse box 1 or L07 (female) (1), (11) tance 1 Mz
ground cable.
Defective work equipment 3. Install the battery ground cable, and turn starting switch to ON
6
controller position.
40-305 8 WD600-6
Failure code [DB90KK] Work equipment controller: Source voltage low (input) SEN05055-02
Circuit diagram related to work equipment controller power supply
WD600-6 40-305 9
SEN05055-02 Failure code [DB90KT] Work equipment controller: Defect in controller
Failure code [DB90KT] Work equipment controller: Defect in controller 1
Action code Failure code Work equipment controller: Defect in controller

Failure
E01 DB90KT (Work equipment controller system)
Detail of failure • Information in ROM (non-volatile memory) in work equipment controller is abnormal.
• Reset internal adjustment values to default values.
troller • Even if failure disappears, machine does not become normal until starting switch is turned to OFF
position.
Problem on • Machine may wrongly detect failure.
machine • Performance decreases because work equipment is controlled by abnormal data.
Related infor-
mation

causes and cri- Defective work equipment Since this is internal defect, troubleshooting cannot be performed.
teria 1
controller (Replace controller.)
40-305 10 WD600-6
Failure code [DB92KK] Work equipment controller load power supply line: Source voltage low (input) SEN05055-02
Failure code [DB92KK] Work equipment controller load power supply

line: Source voltage low (input) 1
Action code Failure code Work equipment controller load power supply line: Source voltage
Failure low (input)
E03 DB92KK (Work equipment controller system)
• Voltage of 24 V solenoid power supply system is low.
Detail of failure • Detection conditions: Terminal C input is turned OFF, continuous power supply (battery direct power
supply) is above 20 V, and solenoid power supply is below 18 V.
• Cannot output to solenoid. (If voltage is below 18 V, all outputs are stopped.)
troller • Even if failure disappears, machine does not become normal until AJSS lever and work equipment
control lever are set to N (NEUTRAL).
Problem on
• Work equipment does not operate.
machine
Related infor-
mation

1
(CBF3) cause 5).
2
box 2 Cause 5).
ground cable.
side.
a Leave work equipment controller disconnected.
Probable ground cable.
causes and cri-
teria 2. Disconnect connector L07, and connect T-adapter to female side.
Resis-
tance
Resis-
tance
Resis-
Open circuit in wiring tance
harness Resis-
4 Between L07 (female) (33) and ground Max. 1 z
(Wire breakage or defective tance
ground cable.
Between battery (+) and terminal of fuse No. Resis-
Max. 1 z
7 in fuse box 2 tance
Between terminal of fuse No. 7 in fuse box 2 Resis-
Max. 1 z
and L07 (female) (2), (12), (22) tance
WD600-6 40-305 11
SEN05055-02 Failure code [DB92KK] Work equipment controller load power supply line: Source voltage low (input)

ground cable.
5 harness side.
Between ground and battery (+) or terminal Resis- Min.
of fuse No. 7 in fuse box 2 tance 1 Mz
Probable
causes and cri- Between ground and terminal of fuse No. 7 Resis- Min.
teria in fuse box 2 or L07 (female) (2), (12), (22) tance 1 Mz
ground cable.
Defective work equipment position.
6
controller
40-305 12 WD600-6
Failure code [DB92KK] Work equipment controller load power supply line: Source voltage low (input) SEN05055-02
Circuit diagram related to work equipment controller 24 V power supply
WD600-6 40-305 13
SEN05055-02 Failure code [DB95KX] Work equipment controller power supply output: Out of range
Failure code [DB95KX] Work equipment controller power supply output:

Out of range 1
Action code Failure code Work equipment controller power supply output: Out of range
Failure
E03 DB95KX (Work equipment controller system)
Detail of failure • Output voltage of 5 V sensor power supply system is out of normal range (Outside 4.7 to 5.3 V).
• Cannot detect input signals correctly due to abnormal potentiometer signal.
Action of con-
troller
Problem on • Work equipment cannot be operated (stops totally).
machine • Following potentiometer errors occur.
Related infor-
mation

2. Disconnect one of connectors of following potentiometers and
pressure sensor one by one, and turn starting switch to ON posi-
tion each time.
a If this failure code is not displayed, disconnected potentiom-
eter or pressure sensor is defective.
a Since connector is disconnected, other failure codes are
Defective potentiometer
1 displayed. Ignore all the other failure codes except this one.
Frame angle potentiometer Connector L12
AJSS lever potentiometer Connector S30
Blade EPC lever potentiometer Connector S02
Loader pump pressure sensor Connector F16
Probable
teria Ground fault in wiring 2. Disconnect connectors L05, L12, S30, S02, and F16.
2 harness 3. Connect T-adapter to female side of connector L05.
(Contact with ground circuit) Resis- Min.
Between L05 (female) (22) and ground
tance 1 Mz
2. Disconnect connector L05, and connect T-adapter to male side.
Defective work equipment 3. Turn starting switch to ON position.
3
controller
4.7 to 5.3
Between L05 (22) and (21) Voltage
V
2. Disconnect connectors L12, S02, S30, and F16, and connect T-
Hot short circuit in wiring adapter to female side of L12.
4 harness 3. Turn starting switch to ON position (with connectors L12, S03,
(Contact with 24 V circuit) S02, S16, S30, and F16 disconnected).
4.7 to 5.3
Between L12 (female) (C) and ground Voltage
V
40-305 14 WD600-6
Failure code [DB95KX] Work equipment controller power supply output: Out of range SEN05055-02
Circuit diagram related to work equipment controller 5 V power supply
WD600-6 40-305 15
Failure code [DB99KQ] Work equipment controller model selection: Model selection signal
SEN05055-02 disagreement
Failure code [DB99KQ] Work equipment controller model selection:

Model selection signal disagreement 1
Action code Failure code Work equipment controller model selection: Model selection signal
Failure disagreement
E03 DB99KQ (Machine monitor system)
Detail of failure • Work equipment controller model is mistaken for another model.
• Continues to operate by regarding machine model is same as the one before this failure code is gen-
erated.
Action of con-
• Does not display failure codes that may be detected wrongly.
troller
Problem on
• Gear shifting shocks may occur.
machine
Related infor-
mation

causes and cri- Abnormal model selection Set model with machine monitor.
teria 1
by machine monitor (See Testing and adjusting)
40-305 16 WD600-6
Failure code [DB9RKR] CAN communication with work equipment controller: Communication error
Failure code [DB9RKR] CAN communication with work equipment

controller: Communication error (Abnormality in target component
system) 1
Action code Failure code CAN communication with work equipment controller:
Failure Communication error (Abnormality in target component system)
E03 DB9RKR (Transmission controller system)
• Transmission controller cannot receive CAN communication information from work equipment con-
Detail of failure
troller.
Action of con-
• Uses CAN information obtained from work equipment controller just before failure occurs.
troller
Problem on
machine -

received.
• When failure code [D**RKR], [DB9RMC] or [DBBQKR] is also displayed, write down all of displayed
Related infor- codes.
mation • Failure code [DB9RKR] is displayed. That is, there cannot be short circuit, ground fault, or hot short

1 Perform troubleshooting for failure code [DB90KK].
work equipment controller
Probable Defective CAN Perform checks on causes 2 to 5 in troubleshooting for failure code
causes and cri- 2
communication system [DAQRKR].
teria
a If no failure is found by above checks, work equipment controller
Defective work equipment may be defective.
3
controller (Since this is an internal defect, troubleshooting cannot be per-
formed.)
WD600-6 40-305 17
SEN05055-02 Failure code [DB9RMA] Work equipment controller (Option setting): Malfunction
Failure code [DB9RMA] Work equipment controller (Option setting):

Malfunction 1
Action code Failure code Work equipment controller (Option setting): Malfunction
Failure
E03 DB9RMA (Machine monitor system)
• Option setting of machine monitor disagrees with option setting recognition in work equipment con-
Detail of failure
troller.
troller • Work equipment controller operates according to its own option setting recognition.
Problem on
-
machine
Related infor-
mation

causes and cri-
teria 1 Defective option setting Set options again.
40-305 18 WD600-6
Failure code [DB9RMC] CAN communication with transmission controller: Malfunction SEN05055-02
Failure code [DB9RMC] CAN communication with transmission

controller: Malfunction 1
Action code Failure code CAN communication with transmission controller: Malfunction
Failure
E03 DB9RMC (Work equipment controller system)
• Work equipment controller cannot receive CAN communication information from transmission con-
troller.
Detail of failure • Travel speed signal cannot be received from transmission controller.
• Engine start prohibition signal cannot be received from transmission controller.
Action of con-
• Judges travel speed to be 0 km/h.
troller
• Uses CAN information obtained from transmission controller just before failure occurs.
• Semi auto-digging may be occasionally or always disabled.
Problem on
• Engine can start when AJSS is not in neutral.
machine
• Turning speed increases since AJSS cannot sense travel speed properly.
received.
• When failure code [D**RKR] or [DBBQKR] is also displayed, write down all of displayed codes.
Related infor-
• Failure code [DB9RMC] is displayed. That is, there cannot be short circuit, ground fault, or hot short
mation

1 Perform troubleshooting for failure code [DAQ0KK].
transmission controller
Probable
causes and cri- Defective CAN
2 Perform checks on causes 2 to 6 in failure code [DAQRKR].
teria communication system
a If no failure is found by above checks, transmission controller
Defective transmission
3 may be defective. (Since this is an internal defect, troubleshoot-
controller
ing cannot be performed.)
WD600-6 40-305 19
Failure code [DBB0KK] or change of VHMS_LED display from "n9" to "01" (VHMS controller: Source
SEN05055-02 voltage low (input))
Failure code [DBB0KK] or change of VHMS_LED display from "n9" to

"01"
(VHMS controller: Source voltage low (input)) 1
Action code Failure code VHMS controller: Source voltage low (input)
Failure
- DBB0KK (VHMS controller system)
Detail of failure • When engine speed is 500 rpm or above, VHMS controller switch voltage is below 19.5 V.
Problem on
-
machine
• Machine monitor does not display any failure code (However, relevant failure codes can be checked
by downloading data stored in VHMS controller to personal computer).
Related infor- • LED display on VHMS controller changes from "n9"o "01".
mation • When failure code DAF3KK (Machine monitor: Source voltage low (input)) is displayed, perform
troubleshooting for it first.
• Method of reproducing failure code: Start engine + Increase engine speed to 500 rpm or above.

1
box 1 Cause 4).
ground cable.
2. Disconnect connector V01, and connect T-adapter to female side.
a Leave machine monitor disconnected.
Between V01 (female) (8) and (11) Voltage 20 to 30 V
ground cable.
2. Disconnect connector V01.
Resis-
Probable Between V01 (female) (11) and ground Max. 1 z
tance
causes and cri-
teria Resis-
Between V01 (female) (12) and ground Max. 1 z
tance
Resis-
tance
Open circuit in wiring Resis-
harness tance
3
contact of connector) Between V02 (female) (12) and ground Max. 1 z
tance
Resis-
tance
ground cable.
3. Disconnect connector V01, and connect T-adapter to female
side.
Between terminal of fuse No. 14 in fuse box Resis-
Max. 1 z
1 and V01 (female) (8), (9) tance
40-305 20 WD600-6
Failure code [DBB0KK] or change of VHMS_LED display from "n9" to "01" (VHMS controller: Source
voltage low (input)) SEN05055-02

ground cable.
Ground fault in wiring 3. Disconnect connector V01, and connect T-adapter to female
4 harness side.
Between ground and terminal of fuse No. 14
Resis- Min.
Probable in fuse box 1, V01 (female) (8), or V01
tance 1 Mz
causes and cri- (female) (9)
teria
2. Insert T-adapter into connector V01.
position.
4. Start engine + Increase engine speed to 500 rpm or above.
Circuit diagram related to VHMS controller power supply
WD600-6 40-305 21
Failure code [DBB0KQ] or change of VHMS_LED display from "nF" to "11" (VHMS controller:
SEN05055-02 Disagreement of model selection signals)
Failure code [DBB0KQ] or change of VHMS_LED display from "nF" to

"11"
(VHMS controller: Disagreement of model selection signals) 1
Action code Failure code VHMS controller: Disagreement of model selection signals
Failure
- DBB0KQ (VHMS controller system)
Detail of failure • Abnormal connector connection is detected.

Problem on
• System may not operate normally.
machine
Related infor- by downloading data stored in VHMS controller to personal computer).
mation • LED display on VHMS controller changes from "nF"o "11".

Wrong connection of VHMS
Check connectors V02 and V04, and connectors V03 and V05 for
1 controller connector (when
Probable wrong connection.
system works properly)
causes and cri-
teria If result of above check is normal, VHMS controller may be
defective.
(Since this is an internal defect, troubleshooting cannot be
performed.)
40-305 22 WD600-6
Failure code [DBB0KQ] or change of VHMS_LED display from "nF" to "11" (VHMS controller:
Disagreement of model selection signals) SEN05055-02
WD600-6 40-305 23
Failure code [DBB3KK] or change of VHMS_LED display from "n9" to "05" (VHMS controller battery
SEN05055-02 power supply: Source voltage low (input))
Failure code [DBB3KK] or change of VHMS_LED display from "n9" to

"05"
(VHMS controller battery power supply: Source voltage low (input)) 1
Action code Failure code VHMS controller: Source voltage low (input)
Failure
- DBB3KK (VHMS controller system)
Detail of failure • Continuous power supply voltage of VHMS controller is below 10 V.

Problem on
-
machine
mation • LED display on VHMS controller changes from "n9"o "05".
• Method of reproducing failure code: Keep starting switch in OFF position.

ground cable.
a Leave VHMS controller disconnected.
ground cable.
side.
Resis-
tance
Probable
causes and cri- Resis-
teria tance
Resis-
tance
Resis-
harness Between V01 (female) (20) and ground Max. 1 z
2 tance
Resis-
contact of connector) Between V02 (female) (12) and ground Max. 1 z
tance
Resis-
tance
ground cable.
side.
Between terminal of fuse No. 6 in fuse box 1 Resis-
Max. 1 z
and V01 (female) (6), (7) tance
40-305 24 WD600-6
Failure code [DBB3KK] or change of VHMS_LED display from "n9" to "05" (VHMS controller battery
power supply: Source voltage low (input)) SEN05055-02

ground cable.
Probable 2. Insert T-adapter into connector V01.
causes and cri- 3. Install the battery ground cable, and turn starting switch to ON
teria 3 Defective VHMS controller
position.
Circuit diagram related to VHMS controller power supply
WD600-6 40-305 25
Failure code [DBB5KP] or change of VHMS_LED display from "n9" to "04" (VHMS controller 5 V
SEN05055-02 power supply output: Output voltage low)
Failure code [DBB5KP] or change of VHMS_LED display from "n9" to

"04"
(VHMS controller 5 V power supply output: Output voltage low) 1
Action code Failure code VHMS controller 5 V power supply output: Output voltage low
Failure
- DBB5KP (VHMS controller system)
Detail of failure • Ground fault in VHMS controller 5 V sensor power supply

Action of con-
troller
position.
Problem on
machine -

2. Disconnect connectors of following sensors one by one, and turn
starting switch to ON position each time.
tive.
Defective pressure sensor 3. Each time troubleshooting is finished, return to step 1.
1
Sensor Connector
Blowby pressure sensor V25
Steering pressure sensor V23
Rear brake pressure sensor V13
Probable
causes and cri- Front brake pressure sensor V14
teria
ground cable.
Ground fault in wiring 2. Disconnect connectors V01, V25, V23, V13, V14, and connect T-
2 harness adapter to either female side.
(Contact with ground circuit) Between ground and V01 (female) (5), V13
Resis- Min.
(female) (B), V14 (female) (B), V23 (female)
tance 1 Mz
(B) or V25 (female) (B)
ground cable.
3 Defective VHMS controller 3. Install the battery ground cable, and turn starting switch to ON
position.
4.5 to 5.5
Between V01 (5) and (11), (12), (19), or (20) Voltage
V
40-305 26 WD600-6
Failure code [DBB5KP] or change of VHMS_LED display from "n9" to "04" (VHMS controller 5 V
power supply output: Output voltage low) SEN05055-02
Circuit diagram related to VHMS controller 5 V sensor power supply
WD600-6 40-305 27
Failure code [DBB6KP] or change of VHMS_LED display from "n9" to "02" (VHMS controller 24V

"02"
(VHMS controller 24V power supply output: Output voltage low) 1
Failure
Detail of failure • Ground fault in VHMS controller 24 V sensor or indicator lamp power supply
Action of con-
troller
position.
Problem on
machine -

2. Disconnect connectors of following sensors and indicator lamp
one by one, and turn starting switch to ON position each time.
tive.
Defective temperature
1 sensor or indicator lamp
Sensor, indicator lamp Connector
Indicator lamp V21
Exhaust gas temperature sensor (R.H.) V29
Probable Exhaust gas temperature sensor (L.H.) V30
causes and cri-
teria 1. Turn starting switch to OFF position and disconnect battery
ground cable.
2. Disconnect connectors V01, V21, V29, and V30.
Ground fault in wiring 3. Connect T-adapter to female side of one of connectors V01, V29,
2 harness and V30.
Between ground and V01 (female) (2), V21
Resis- Min.
(female) (1), V29 (female) (1), or V30
tance 1 Mz
(female) (1)
ground cable.
position.
Between V01 (2) and (11), (12), (19), or (20) Voltage 20 to 30 V
40-305 28 WD600-6
WD600-6 40-305 29

"03"
(VHMS controller 12V power supply output: Output voltage low) 1
Failure
Detail of failure • Ground fault in VHMS controller 12 V indicator lamp power supply
Action of con-
troller
position.
Problem on
-
machine

2. Disconnect connector V15, and turn starting switch to ON posi-
Defective VHMS 12 V
tion.
1 indicator lamp
a If this failure code goes out, 12 V indicator lamp is defective.
ground cable.
Probable Ground fault in wiring 2. Disconnect connectors V01 and V15, and connect T-adapter to
causes and cri- 2 harness either female side.
teria (Contact with ground circuit)
Between ground and V01 (female) (3) or V15 Resis- Min.
(female) (1) tance 1 Mz
ground cable.
position.
11.5 to
Between V01 (3) and (11), (12), (19), or (20) Voltage
12.5 V
40-305 30 WD600-6
WD600-6 40-305 31
Failure code [DBBQKR] or change of VHMS_LED display from "n8" to "02" (CAN communication of
SEN05055-02 VHMS controller: Communication error (Abnormality in target component system))
Failure code [DBBQKR] or change of VHMS_LED display from "n8" to

"02"
(CAN communication of VHMS controller: Communication error
(Abnormality in target component system)) 1
Action code Failure code CAN communication of VHMS controller: Communication error
- DBBQKR (VHMS controller system)
Detail of failure • VHMS controller cannot receive CAN communication information from each controller.
Action of con-
troller
Problem on
• System may not operate normally.
machine

causes and cri- If any of failure codes CA1633, DAFRKR, DAQRMA, DB2RKR, DB9RKR, DB9RMA, and
teria 1
DB9RMC is displayed, perform troubleshooting for it first.
40-305 32 WD600-6
Failure code [DBBQKR] or change of VHMS_LED display from "n8" to "02" (CAN communication of
VHMS controller: Communication error (Abnormality in target component system)) SEN05055-02
WD600-6 40-305 33
SEN05055-02 Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept

pressed for long time 1
Action code Failure code t switch (Panel switch 1): Switch is kept pressed for long time
Trouble
E01 DD15LD (Machine monitor system)
Contents of • The input circuit of the machine monitor mode selector switch 1 “t” (Panel switch 1) is kept
trouble CLOSED for more than continuous 1 minute.
Problem that
appears on • The operator cannot operate the monitor (cannot enter the service mode).
machine
• The input state (ON/OFF) from the machine monitor mode selector switch 1 “t” (Panel switch 1)
Related can be checked with the monitoring function (Code: 40901 D-IN-15).
information • The operator may not be able to use the monitoring function because of the t switch trouble.

2. Disconnect connector C09, and connect T-adapter to male side.
Defective t switch (Panel t switch Resis-
Max. 1 z
1 switch 1) (Internal short cir- (Panel switch 1): ON tance
cuit) Between C09 (male)
(4) and (5) t switch
Resis-
(Panel switch 1): Min. 1 Mz
tance
Other than above
Possible causes 2. Disconnect connector C09, and connect T-adapter to female
and standard Hot short in wiring harness side.
value in normal 2 3. Turn starting switch to ON position.
state Between C09 (female) (4) and chassis
Voltage Max. 1 V
ground
t switch
3 Defective machine monitor Voltage 20 – 30 V
(Panel switch 1): ON
Between C02 (17)
and chassis ground t switch
(Panel switch 1): Voltage Max. 1 V
Other than above
40-305 34 WD600-6
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time SEN05055-02
Circuit diagram related to t switch and U switch
WD600-6 40-305 35
SEN05055-02 Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept

pressed for long time 1
Action code Failure code U switch (Panel switch 2): Switch is kept pressed for long time
Trouble
Contents of • The input circuit of the machine monitor mode selector switch 2 “U” (Panel switch 2) is kept
trouble CLOSED for more than continuous 1 minute.
Problem that
appears on • The operator cannot operate the monitor.
machine
• The input state (ON/OFF) from the machine monitor mode selector switch 2 “U” (Panel switch 2)
information • The operator may not be able to use the monitoring function because of the U switch trouble.

U switch
Defective U switch (Panel Resis-
(Panel switch 2): Max. 1 z
1 switch 2) (Internal short cir- tance
Between C09 (male) ON
cuit)
(5) and (6) U switch
Resis-
tance
Other than above
Possible causes 2. Disconnect connector C09, and connect T-adapter to female
and standard Hot short in wiring harness side.
value in normal 2 3. Turn starting switch to ON position.
state Between C09 (female) (6) and chassis
Voltage Max. 1 V
ground
U switch
3 Defective machine monitor (Panel switch 2): Voltage 20 – 30 V
Between C02 (8) and ON
chassis ground U switch
(Panel switch 2): Voltage Max. 1 V
Other than above
40-305 36 WD600-6
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time SEN05055-02
Circuit diagram related to t switch and U switch
WD600-6 40-305 37
SEN05055-02 Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed
for long time 1
Action code Failure code < switch (Panel switch 3): Switch is kept pressed for long time
Trouble
Contents of • The input circuit of the machine monitor mode selector switch 3 “<” (Panel switch 3) is kept
trouble “CLOSED” for more than continuous 1 minute.
Problem that
machine
• The input state (ON/OFF) from the machine monitor mode selector switch 3 “<” (Panel switch 3) can
Related be checked with the monitoring function (Code: 40904 D-IN-38).
information • The operator may not be able to use the monitoring function because of the < switch trouble.

< switch
Defective < switch (Panel Resis-
Between C10 ON
cuit)
(female) (4) and (5) < switch
Resis-
tance
Other than above
Possible causes
and standard Grounding fault in wiring har- 2. Disconnect connectors C10 and C04, and connect T-adapter to
2 ness either female side.
value in normal
state (Contact with ground circuit) Between C10 (female) (4) or C04 (female) Resis-
Min. 1 Mz
< switch
3 Defective monitor panel (Panel switch 3): Voltage Max. 1 V
Between C04 ON
(female) (7) and
chassis ground < switch
(Panel switch 3): Voltage 7 – 30 V
Other than above
40-305 38 WD600-6
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time SEN05055-02
Circuit diagram related to > switch and < switch
WD600-6 40-305 39
SEN05055-02 Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed
for long time 1
Action code Failure code > switch (Panel switch 4): Switch is kept pressed for long time
Trouble
Contents of • The input circuit of the machine monitor mode selector switch 4 “>” (Panel switch 4) is kept
trouble “CLOSED” for more than continuous 1 minute.
Problem that
machine
• The input state (ON/OFF) from the machine monitor mode selector switch 4 “>” (Panel switch 4)
information • The operator may not be able to use the monitoring function because of the > switch trouble.

> switch
Defective > switch (Panel Resis-
Between C10 ON
cuit)
(female) (5) and (6) > switch
Resis-
tance
Other than above
Possible causes
and standard Grounding fault in wiring har- 2. Disconnect connectors C10 and C04, and connect T-adapter to
value in normal
state (Contact with ground circuit) Between C10 (female) (6) or C04 (female) Resis-
Min. 1 Mz
> switch
3 Defective monitor panel (Panel switch 3): Voltage Max. 1 V
Between C04 ON
(female) (15) and
chassis ground > switch
(Panel switch 3): Voltage 7 – 30 V
Other than above
40-305 40 WD600-6
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time SEN05055-02
Circuit diagram related to > switch and < switch
WD600-6 40-305 41
SEN05055-02
WD600-6 Wheel dozer

©2017 KOMATSU
All Rights Reserved
40-305 42
SEN05056-03
WHEEL DOZER
WD600-6

WD600-6 55001 and up

Failure code [DDA7L4] RPM set ON/OFF switch: ON-OFF signals disagree ................................................ 4
Failure code [DDA8KB] RPM set idle-up/down selector switch (idle-up): Short circuit ................................... 6
Failure code [DDA9KB] RPM set idle-up/down selector switch (idle-down): Short circuit .............................. 9
Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF signals disagree ................................ 12
Failure code [DDD1LD] Pitch operation switch: Switch is kept pressed for long time .................................. 16
Failure code [DDDBKA] Traction adjustment dial: Disconnection................................................................. 18
Failure code [DDDBKB] Traction adjustment dial: Short circuit .................................................................... 20
Failure code [DDE5MA] Emergency steering drive switch: Malfunction ....................................................... 22
Failure code [DDK4KA] AJSS FNR switch: Disconnection........................................................................... 24
Failure code [DDK4KB] AJSS FNR switch: Short circuit .............................................................................. 26
Failure code [DDK5L4] AJSS shift-up/down switch: ON/OFF signals disagree............................................ 28
Failure code [DDK6KA] FNR lever switch: Disconnection ............................................................................ 31
Failure code [DDK6KB] FNR lever switch: Short circuit................................................................................ 34
Failure code [DDP5KA] Lock detection pressure switch of steering lock lever: Disconnection .................... 36
Failure code [DDT0L4] Shift mode selector switch: ON/OFF signals disagree............................................. 38
Failure code [DDW9LD] Kick-down switch: Switch is kept pressed for long time ......................................... 40
Failure code [DDWLLD] Hold switch: Switch is kept pressed for long time .................................................. 42
Failure code [DF10KA] Transmission shift lever switch: Disconnection ....................................................... 44
Failure code [DF10KB] Transmission shift lever switch: Short circuit ........................................................... 48
Failure code [DGE5KX] (or VHMS_LED display: “n4” → “01”) Atmospheric temperature sensor:
Out of input signal range .......................................................................................................................... 50
WD600-6 40-306 1
SEN05056-03
Failure code [DGF1KA] Transmission oil temperature sensor: Disconnection ............................................. 52

Failure code [DGF1KB] Transmission oil temperature sensor: Short circuit ................................................. 54
40-306 2 WD600-6
SEN05056-03
WD600-6 40-306 3
SEN05056-03 Failure code [DDA7L4] RPM set ON/OFF switch: ON-OFF signals disagree
Failure code [DDA7L4] RPM set ON/OFF switch: ON-OFF signals disagree 1
Action code Failure code RPM set ON/OFF switch: ON/OFF signals disagree
Trouble
E01 DDA7L4 (Transmission controller system)
Contents of
• RPM set does not function because of a hot short circuit in RPM set ON-OFF switch system.
trouble
Action of • Turns RPM set function OFF
Problem that
appears on • RPM setting is disabled
machine
• The input state (ON/OFF) from the RPM set ON-OFF switch (push up) can be checked with the
monitoring function (Code: 44200 THROT LOCK A).
Related
• The input state (ON/OFF) from the RPM set ON-OFF switch (pressed downward) can be checked
information
with the monitoring function (Code: 44201 THROT LOCK B).
• Method of reproducing failure code: Turn the starting switch and RPM set ON/OFF switch ON

2. Disconnect connector S12, and connect T-adapter to male side.
RPM set ON/OFF Resis-
Min. 1 Mz
Between S12 (male) switch: ON tance
(4) and (5) RPM set ON/OFF Resis-
Max. 1 z
switch: OFF tance
Defective RPM set ON/OFF
1 RPM set ON/OFF Resis-
switch (Internal short circuit) Max. 1 z
Between S12 (male) switch: ON tance
(5) and (6) RPM set ON/OFF Resis-
Min. 1 Mz
switch: OFF tance
Between S12 (male)
Resis-
(4), (5), (6) and chas- Normal Min. 1 Mz
tance
sis ground
Possible causes
2. Disconnect connector S12, and connect T-adapter to female
and standard
side.
value in normal
Hot short in wiring harness 3. Turn starting switch to ON position.
state 2
(Contact with 24 V circuit) Between S12 (female) (4) and chassis
Voltage Max. 1 V
ground
Between S12 (female) (6) and chassis
Voltage Max. 1 V
ground
RPM set ON/OFF
Voltage Max. 1 V
Between L02 (13) switch: ON
Defective transmission and chassis ground
3 RPM set ON/OFF
controller Voltage 20 – 30 V
switch: OFF
RPM set ON/OFF
Voltage 20 – 30 V
and chassis ground RPM set ON/OFF
Voltage Max. 1 V
switch: OFF
40-306 4 WD600-6
Failure code [DDA7L4] RPM set ON/OFF switch: ON-OFF signals disagree SEN05056-03
Circuit diagram related to RPM set ON/OFF switch
WD600-6 40-306 5
SEN05056-03 Failure code [DDA8KB] RPM set idle-up/down selector switch (idle-up): Short circuit
Failure code [DDA8KB] RPM set idle-up/down selector switch (idle-up):

Short circuit 1
Action code Failure code RPM set idle-up/down selector switch (idle-up): Short circuit
Trouble
E01 DDA8KB (Transmission controller system)
Contents of • Idle-up does not function due to ground fault in RPM set idle-up/down selector switch (idle-up) sys-
trouble tem.
Problem that
machine
• The input state (ON/OFF) from the RPM set idle-up/down selector switch can be checked with the
Related monitoring function (Code: 40906 D-IN-13, D-IN-14).
information • Method of reproducing failure code: Turn the starting switch and RPM set ON-OFF switch ON and
operate the RPM set idle-up/down selector switch (idle-up)

RPM set idle-up/
Resis-
down selector switch: Min. 1 Mz
tance
Between S13 (male) Idle-up position
(4) and (5) RPM set idle-up/
Resis-
down selector switch: Max. 1 z
tance
Defective RPM set idle-up/ Idle-down position
1 down selector switch (Inter- RPM set idle-up/
Possible causes Resis-
nal short circuit) down selector switch: Max. 1 z
and standard tance
value in normal
state (5) and (6) RPM set idle-up/
Resis-
tance
Idle-down position
Between S13 (male)
Resis-
tance
sis ground
Grounding fault in wiring har- 2. Disconnect connectors S13 and L04, and connect T-adapter to
(Contact with ground circuit) Between L04 (female) (19) or S13 (female) Resis-
Min. 1 Mz
40-306 6 WD600-6
Failure code [DDA8KB] RPM set idle-up/down selector switch (idle-up): Short circuit SEN05056-03

RPM set idle-up/
down selector switch:
Voltage 7 – 10 V
Idle-up position or
Between L04 (29) neutral
Possible causes
and chassis ground
and standard RPM set idle-up/
value in normal Defective transmission
3 down selector switch: Voltage Max. 1 V
state controller
Idle-down position
RPM set idle-up/
down selector switch: Voltage Max. 1 V
Idle-up position
Between L04 (19)
and chassis ground RPM set idle-up/
Voltage 7 – 10 V
Idle-down position or
neutral
WD600-6 40-306 7
SEN05056-03 Failure code [DDA8KB] RPM set idle-up/down selector switch (idle-up): Short circuit
Circuit diagram related to RPM set idle-up/down selector switch
40-306 8 WD600-6
Failure code [DDA9KB] RPM set idle-up/down selector switch (idle-down): Short circuit SEN05056-03
Failure code [DDA9KB] RPM set idle-up/down selector switch (idle-down):

Short circuit 1
Action code Failure code RPM set idle-up/down selector switch (idle-down): Short circuit
Trouble
E01 DDA9KB (Transmission controller system)
Contents of • Engine speed cannot be set to optional speed due to ground fault in the RPM set idle-up/down se-
trouble lector switch system.
Problem that
machine
• The input state (ON/OFF) from the RPM set idle-up/down selector switch can be checked with the
Related monitoring function (Code: 40906 D-IN-13, D-IN-14).
information • Method of reproducing failure code: Turn the starting switch and RPM set ON-OFF switch ON and
operate the RPM set idle-up/down selector switch (idle-down)

RPM set idle-up/
Resis-
tance
(4) and (5) RPM set idle-up/
Resis-
down selector switch: Max. 1 z
tance
Defective RPM set idle-up/ Idle-down position
1 down selector switch (Inter- RPM set idle-up/
nal short circuit) down selector switch: Max. 1 z
and standard tance
value in normal
state (5) and (6) RPM set idle-up/
Resis-
tance
Idle-down position
Between S13 (male)
Resis-
tance
sis ground
Grounding fault in wiring har- 2. Disconnect connectors S13 and L04, and connect T-adapter to
Min. 1 Mz
WD600-6 40-306 9
SEN05056-03 Failure code [DDA9KB] RPM set idle-up/down selector switch (idle-down): Short circuit

RPM set idle-up/
Voltage 7 – 10 V
Idle-up position or
Between L04 (29) neutral
Possible causes
and chassis ground
and standard RPM set idle-up/
3 down selector switch: Voltage Max. 1 V
state controller
Idle-down position
RPM set idle-up/
down selector switch: Voltage Max. 1 V
Idle-up position
Between L04 (19)
and chassis ground RPM set idle-up/
Voltage 7 – 10 V
Idle-down position or
neutral
40-306 10 WD600-6
Failure code [DDA9KB] RPM set idle-up/down selector switch (idle-down): Short circuit SEN05056-03
Circuit diagram related to RPM set idle-up/down selector switch
WD600-6 40-306 11
SEN05056-03 Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF signals disagree
Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF

signals disagree 1
Action code Failure code Parking brake switch (Neutralizer): ON/OFF signals disagree)
Trouble
E03 DDB6L4 (Transmission controller system)
(This failure code may be displayed when parking brake emergency release switch is turned ON.)
• Controller outputs a failure signal when all conditions are satisfied.
Contents of
1) Parking brake switch signal ON (neutralizer signal OPEN)
trouble
2) Parking brake released (by CAN communication from the machine monitor)
3) Hydraulic oil temperature under 25°C
Problem that
appears on • The machine cannot travel or parking brake indicator is kept OFF.
machine
• The input state (ON/OFF) from the parking switch can be checked with the monitoring function
(Code: 40903 D-IN-26).
• The input state (ON/OFF) from the parking brake indicator switch can be checked with the monitor-
ing function (Code: 40907 D-IN-23).
Related
• If failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range) is displayed,
information
carry out troubleshooting for it first.
• If failure code [DAFRKR] (Machine monitor CAN communication: Defective communication (Abnor-
mality in target component system) is displayed, carry out troubleshooting for it first.
• Method of reproducing failure code: Turn the starting switch and parking brake switch ON

1 Deterioration of battery Battery may have deteriorated. Check it.
3. Start engine.
29.5V
Possible causes 1. Turn starting switch to OFF position.
and standard 2. Disconnect connector PB.SW, and connect T-adapter to male
value in normal side.
state 3. Start engine.
Parking brake oil
pressure:
Defective parking brake indi- Resis-
When parking brake Max. 1 z
3 cator switch tance
is released, Min. 0.61
Between PB.SW MPa {Min. 6.2 kg/cm2}
(male) (1) and (2) Parking brake oil
pressure: When park-
Resis- Min. 1
ing brake applied,
tance Mz
Max. 0.34 MPa {Max.
3.5 kg/cm2}
40-306 12 WD600-6
Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF signals disagree SEN05056-03

2. Disconnect connector C08, and connect T-adapter to female
side.
Parking brake switch: Resis- Min. 1
Between C08 (male) ON tance Mz
Defective parking brake (3) and (4) Parking brake switch: Resis-
Max. 1 z
4 switch (Internal disconnec- OFF tance
tion) Parking brake switch: Resis-
Max. 1 z
Between C08 (male) ON tance
(5) and (6) Parking brake switch: Resis- Min. 1
OFF tance Mz
Between C08 (male) Resis- Min. 1
Normal
(3) and (6) tance Mz
and standard 2. Disconnect connectors PB.SW, C04, C08 and L03, and connect
value in normal T-adapters to each female side.
state Disconnection in wiring har- Between C04 (female) (1) and PB.SW Resis-
ness Max. 1 z
(Disconnection or defective
Between PB.SW (female) (2) and chassis Resis-
contact) Max. 1 z
ground tance
Between C08 (female) (3) and L03 (female) Resis-
Max. 1 z
(6) tance
Parking brake switch:
Defective transmission con- Voltage Max. 1 V
6 ON
troller
Between L03 (6) and After starting switch
chassis ground ON, turn parking
Voltage 20 – 30 V
brake switch ON and
OFF.
WD600-6 40-306 13
SEN05056-03 Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF signals disagree
40-306 14 WD600-6
Failure code [DDB6L4] Parking brake switch (Neutralizer): ON/OFF signals disagree SEN05056-03
Circuit diagram related to parking brake switch
WD600-6 40-306 15
SEN05056-03 Failure code [DDD1LD] Pitch operation switch: Switch is kept pressed for long time
Failure code [DDD1LD] Pitch operation switch: Switch is kept pressed

for long time 1
Action code Failure code Pitch operation switch: Switch is kept pressed for long time
Trouble
E01 DDD1LD (Work equipment controller system)
Contents of
• Detected continuous operation for 30 seconds and longer.
trouble
Action of • Judged that pitch operation switch is turned ON
Problem that
appears on • Blade tilt operation speed decreases.
machine
• The input state (ON/OFF) from the pitch operation switch can be checked with the monitoring func-
Related
tion (Code: 40911 D-IN-11).
information
• Method of reproducing failure code: Turn the starting switch and pitch operation switch ON

Pitch operation Resis-
Max. 1 z
Defective pitch operation Between S07 (male) switch: ON tance
1 switch (4) and (8) Pitch operation Resis-
(Internal short circuit) Min. 1 Mz
switch: OFF tance
Between S07 (male)
Resis-
(5) and chassis Normal Min. 1 Mz
tance
Possible causes ground
and standard 1. Turn starting switch to OFF position.
value in normal Grounding fault in wiring har- 2. Disconnect connectors S07 and L07, and connect T-adapter to
state 2 ness either female side.
Min. 1 Mz
Defective work equipment
3 Pitch operation
controller Voltage Max. 1 V
and chassis ground Pitch operation
Voltage 7 – 10 V
switch: OFF
40-306 16 WD600-6
Failure code [DDD1LD] Pitch operation switch: Switch is kept pressed for long time SEN05056-03
Circuit diagram related to pitch operation switch
WD600-6 40-306 17
SEN05056-03 Failure code [DDDBKA] Traction adjustment dial: Disconnection
Failure code [DDDBKA] Traction adjustment dial: Disconnection 1
Action code Failure code Traction adjustment dial: Disconnection

Trouble
E01 DDDBKA (Transmission controller system)
Contents of • Traction adjustment disabled because of disconnection in the traction adjustment dial system
trouble (Traction adjustment dial signal voltage: Max. 0.3 V)
• For the traction adjustment dial value, use the value immediately before abnormality occurs.
Action of
controller
Problem that
appears on • Traction adjustment is disabled
machine
• The input state (%) from the traction adjustment dial can be checked with the monitoring function
(Code: 94000 TRACTION DIAL).
Related
• The input state (Voltage) from the traction adjustment dial can be checked with the monitoring func-
information
tion (Code: 94001 TRACTION DIAL).
• Method of reproducing failure code: Turn the starting switch ON

side.
Defective 5V sensor power 3. Turn starting switch to ON position.
1
supply system a If power supply voltage is abnormal, proceed to troubleshooting
for cause 4.
Between S09 (female) (3) and Power 4.25 –
Voltage
(1) supply 5.25 V
and standard 2. Insert T-adapter into connector S09.
value in normal 3. Turn starting switch to ON position.
state
0.5 – 4.5
Dial position: Always Voltage
V
Defective traction adjustment Between S09 (male) Dial position: MAX Voltage
0.5 – 1.0
2 (2) and (3) V
dial (Internal disconnection)
4.0 – 4.5
Dial position: MIN Voltage
V
a If power supply voltage is normal and sensor output voltage is
abnormal, it is difficult to judge whether cause is ground fault or
hot short circuit of harness. Judge after troubleshooting for wir-
ing harness.
40-306 18 WD600-6
Failure code [DDDBKA] Traction adjustment dial: Disconnection SEN05056-03

2. Disconnect connectors L02 and S09, and connect T-adapters to
each female side.
Between L02 (female) (3) and S09 (female) Resis-
Max. 1 z
(2) tance
a If power supply voltage measured in
Disconnection in wiring har- check on cause 1 is normal, this check is
3 ness Resis-
not required. Max. 1 z
(Internal disconnection) tance
Between L02 (female) (21) and S09 (female)
(3)
check on cause 1 is normal, this check is
Resis-
Possible causes not required. Max. 1 z
tance
and standard Between L02 (female) (22) and S09 (female)
value in normal (1)
state 1. Turn starting switch to OFF position.
Ground fault in wiring har- 2. Disconnect connectors L02 and S09, and connect T-adapter to
(contact with ground circuit) Between L02 (female) (3) or S09 (female) Resis- Min.
(2) and ground tance 1 Mz
Defective transmission con- Between L02 (3) and 4.75 –
5 Dial position: Always Voltage
troller chassis ground 5.25 V
Dial position: Always Voltage 0.5 – 4.5 V
Between L02 (22)
Dial position: MAX Voltage 0.5 – 1.0 V
and chassis ground
Dial position: MIN Voltage 4.0 – 4.5 V
Circuit diagram related to traction adjustment dial
WD600-6 40-306 19
SEN05056-03 Failure code [DDDBKB] Traction adjustment dial: Short circuit
Failure code [DDDBKB] Traction adjustment dial: Short circuit 1
Action code Failure code Traction adjustment dial: Short circuit

Trouble
E01 DDDBKB (Transmission controller system)
Contents of • Traction adjustment disabled because of hot short circuit in the traction adjustment dial system
trouble (Traction adjustment dial signal voltage: Min 4.7 V)
• For the traction adjustment dial value, use the value immediately before abnormality occurs.
Action of
controller
Problem that
appears on • Traction adjustment is disabled
machine
• The input state (%) from the traction adjustment dial can be checked with the monitoring function
(Code: 94000 TRACTION DIAL).
Related
• The input state (Voltage) from the traction adjustment dial can be checked with the monitoring func-
information
tion (Code: 94001 TRACTION DIAL).

2. Insert T-adapter into connector S09.
0.5 – 4.5
Dial position: Always Voltage
V
Defective traction adjustment Between S09 (male) Dial position: MAX Voltage
0.5 – 1.0
1 (2) and (3) V
dial (Internal disconnection)
4.0 – 4.5
Dial position: MIN Voltage
V
ing harness.
Possible causes
value in normal 2. Disconnect connector C09, and connect T-adapter to female
state side.
2
(Contact with 24 V circuit) Between S09 (female) (2) and chassis
Voltage Max. 1 V
ground
Between S09 (female) (1) and chassis
Voltage Max. 1 V
ground
Defective transmission con- Between L02 (3) and 4.75 –
3 Dial position: Always Voltage
troller chassis ground 5.25 V
Dial position: Always Voltage 0.5 – 4.5 V
Between L02 (22)
Dial position: MAX Voltage 0.5 – 1.0 V
and chassis ground
Dial position: MIN Voltage 4.0 – 4.5 V
40-306 20 WD600-6
Failure code [DDDBKB] Traction adjustment dial: Short circuit SEN05056-03
Circuit diagram related to traction adjustment dial
WD600-6 40-306 21
SEN05056-03 Failure code [DDE5MA] Emergency steering drive switch: Malfunction
Failure code [DDE5MA] Emergency steering drive switch: Malfunction 1
Action code Failure code Emergency steering drive switch: Malfunction

Trouble
E01 DDE5MA (Machine monitor system)
Contents of • When engine stopped, steering pump pressure detected because of ground fault in the emergency
trouble steering drive switch system.
Problem that
appears on • The emergency steering operates.
machine
• The input state (ON/OFF) from the emergency steering motor can be checked with the monitoring
Related
function (Code: 40903 D-IN-30).
information

2. Disconnect connector T04, and connect T-adapter to male side.
3. Start engine, and relieve the steering circuit.
Steering relief oil Resis-
Defective emergency steer- Min. 1 Mz
Between T04 (male) pressure: Low tance
1 ing drive switch
(1) and (2) Steering relief oil Resis-
(Internal defect) Max. 1 z
pressure: Always tance
Between T04 (male)
Resis-
(1), (2) and chassis Always Min. 1 Mz
tance
Possible causes ground
value in normal Grounding fault in wiring har- 2. Disconnect connectors T04 and C04, and connect T-adapter to
state 2 ness either female side.
(Contact with ground circuit) Between C04 (female) (3) or T04 (female) Resis-
Min. 1 Mz
4. Start engine, and relieve the steering circuit
Steering relief oil
Voltage 20 – 30 V
Between C04 (3) and pressure: Low
chassis ground Steering relief oil
Voltage Max. 1 V
pressure: Always
40-306 22 WD600-6
Failure code [DDE5MA] Emergency steering drive switch: Malfunction SEN05056-03
Circuit diagram related to emergency steering drive switch
WD600-6 40-306 23
SEN05056-03 Failure code [DDK4KA] AJSS FNR switch: Disconnection
Failure code [DDK4KA] AJSS FNR switch: Disconnection 1
Action code Failure code AJSS FNR switch: Disconnection

Trouble
E03 DDK4KA (Transmission controller system)
Contents of
• AJSS FNR signal input is disabled because of disconnection in the AJSS FNR input signal system.
trouble
• Sets to neutral
controller • Even if cause of failure disappears, system does not reset itself until AJSS FNR switch is set to N
(Neutral).
Problem that
appears on • The machine does not travel.
machine
• The input signal (ON/OFF) from the AJSS FNR switch can be checked with the monitoring function
Related (Code: 40907 D-IN-20, D-IN-21 or D-IN-22).
information • Only for AJSS specification (if equipped)
• Method of reproducing failure code: Turn the starting switch and AJSS FNR switch ON

Defective fuse No.5 of fuse If the fuse is burnt, the circuit probably has a grounding fault, etc.
1
box 2 (See cause 4.)
AJSS FNR switch: Resis-
Max. 1 z
Between S31 (male) F (Forward) tance
(1) and (2) AJSS FNR switch: Resis-
Min. 1 Mz
Max. 1 z
Defective AJSS FNR switch Between S31 (male) N (Neutral) tance
2 (Internal disconnection or (1) and (3) AJSS FNR switch: Resis-
short circuit) Min. 1 Mz
Max. 1 z
Possible causes Between S31 (male) R (Reverse) tance
and standard (S31 (male)1) and (4) AJSS FNR switch: Resis-
value in normal Min. 1 Mz
state
Between S31 (male)
Resis-
(1), (2), (3), (4) and Always Min. 1 Mz
tance
chassis ground
2. Disconnect connectors S31 and L03, and connect T-adapters to
each female side.
3. Remove fuse No. 5 of fuse box 2.
Disconnection in wiring har- Max. 1 z
ness (4) tance
3
(Disconnection or defective Between L03 (female) (26) and S31 (female) Resis-
Max. 1 z
contact of connector) (3) tance
Max. 1 z
(2) tance
Between fuse No. 5 of fuse box 2 and S31 Resis-
Max. 1 z
(female) (1) tance
40-306 24 WD600-6
Failure code [DDK4KA] AJSS FNR switch: Disconnection SEN05056-03

2. Disconnect connectors S31 and L03, and connect T-adapter to
either female side.
3. Remove fuse No. 5 of fuse box 2.
Between L03(female) (16) or S31 (female) Resis-
Grounding fault in wiring har- (4) and chassis ground Min. 1 Mz
tance
4 ness
(Contact with ground circuit) Min. 1 Mz
Min. 1 Mz
Possible causes Between fuse No. 5 of fuse box 2 and S31 Resis-
and standard Min. 1 Mz
(female) (1) tance
value in normal
state
AJSS FNR switch:
Between L03 (36) Voltage 20 – 30 V
F (Forward)
and chassis ground
Defective transmission con- Other than above Voltage Max. 1 V
5
troller AJSS FNR switch:
N (Neutral)
and chassis ground
Other than above Voltage Max. 1 V
AJSS FNR switch:
R (Reverse)
and chassis ground
Circuit diagram related to AJSS FNR switch
WD600-6 40-306 25
SEN05056-03 Failure code [DDK4KB] AJSS FNR switch: Short circuit
Failure code [DDK4KB] AJSS FNR switch: Short circuit 1
Action code Failure code AJSS FNR switch: Short circuit

Trouble
E03 DDK4KB (Transmission controller system)
Contents of
• Multiple signal input because of hot short circuit in the AJSS FNR input signal system.
trouble
• Sets to neutral
controller • Even if cause of failure disappears, system does not reset itself until AJSS steering FNR switch is
set to N (Neutral).
Problem that
machine
• The input signal (ON/OFF) from the AJSS steering FNR switch can be checked with the monitoring
Related function (Code: 40907 D-IN-20, D-IN-21 or D-IN-22).
information • Only for AJSS specification (if equipped)
• Method of reproducing failure code: Turn the starting switch and AJSS steering FNR switch ON

Max. 1 z
Between S31 (male) F (Forward) tance
(1) and (2) AJSS FNR switch: Resis-
Min. 1 Mz
Max. 1 z
Defective AJSS FNR switch Between S31 (male) N (Neutral) tance
1 (Internal disconnection or (1) and (3) AJSS FNR switch: Resis-
Possible causes
and standard Max. 1 z
Between S31 (male) R (Reverse) tance
value in normal
state (S31 (male)1) and (4) AJSS FNR switch: Resis-
Min. 1 Mz
Between S31 (male)
Resis-
(1), (2), (3), (4) and Always Min. 1 Mz
tance
chassis ground
2. Disconnect connector S31.
2
(Contact with 24 V circuit) Between L03 (16) and chassis ground Voltage Max. 1 V
Between L03 (26) and chassis ground Voltage Max. 1 V
40-306 26 WD600-6
Failure code [DDK4KB] AJSS FNR switch: Short circuit SEN05056-03

AJSS FNR switch:
Possible causes F (Forward)
and standard and chassis ground
value in normal 3
state troller AJSS FNR switch:
N (Neutral)
and chassis ground
AJSS FNR switch:
R (Reverse)
and chassis ground
Circuit diagram related to AJSS FNR switch
WD600-6 40-306 27
SEN05056-03 Failure code [DDK5L4] AJSS shift-up/down switch: ON/OFF signals disagree
Failure code [DDK5L4] AJSS shift-up/down switch: ON/OFF signals

disagree 1
Action code Failure code AJSS shift-up/down switch: ON/OFF signals disagree
Trouble
E01 DDK5L4 (Transmission controller system)
Contents of
• AJSS shift-up/down switch system has disconnection, ground fault or hot short.
trouble
Action of • Turns the shift-up/down function of AJSS OFF.
Problem that
appears on • Gear cannot be shift up and down with AJSS.
machine
• The input signal (OFF input) from the AJSS shift-up switch can be checked with the monitoring func-
• The input signal (ON input) from the AJSS shift-up switch can be checked with the monitoring func-
Related
• The input signal (OFF input) from the AJSS shift-down switch can be checked with the monitoring
information
• The input signal (ON input) from the AJSS shift-down switch can be checked with the monitoring
• Method of reproducing failure code: Turn starting switch and AJSS shift-up/down switch ON.

Defective fuse No. 5 in fuse If the fuse is burnt, the circuit probably has a grounding fault, etc.
1
box 2 (See cause 4).
AJSS shift-up/down Resis-
Min. 1 Mz
Between S31 (male) switch: Shift-up ON tance
(1) and (5) AJSS shift-up/down Resis-
Max. 1 z
switch: Shift-up OFF tance
Max. 1 z
Possible causes Between S31 (male) switch: Shift-up ON tance
and standard (1) and(6)AJSS shift-up/down Resis-
Defective AJSS shift-up/down switch: Shift-up OFF tance
state 2 switch AJSS shift-up/down Resis-
Max. 1 z
Max. 1 z
Min. 1 Mz
Between S31 (male)
Resis-
(5), (6), (7), (8) and Always Min. 1 Mz
tance
chassis ground
40-306 28 WD600-6
Failure code [DDK5L4] AJSS shift-up/down switch: ON/OFF signals disagree SEN05056-03

each female side.
Between fuse No. 5 in fuse box 2 and S31 Resis-
Max. 1 z
(female) (1) tance
Disconnection in wiring
harness Between L03 (female) (5) and S31 (female) Resis-
Max. 1 z
3 (Disconnection in wiring or (5) tance
defective contact in Between L03 (female) (15) and S31 (female) Resis-
connector) Max. 1 z
(15) tance
Max. 1 z
(25) tance
Max. 1 z
(35) tance
Possible causes either female side.
and standard Between fuse No. 5 in fuse box 2 or S31 Resis-
state
Between L03 (female) (5) or S31 (female) Resis-
Ground fault in wiring harness (5) and chassis ground Min. 1 Mz
4 tance
(Contact with GND circuit)
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
Hot short 4. Turn starting switch to ON position.
5 (Contact with 24V circuit) in Between L03 (5) and chassis ground Voltage Max. 1 V
wiring harness
WD600-6 40-306 29
SEN05056-03 Failure code [DDK5L4] AJSS shift-up/down switch: ON/OFF signals disagree

AJSS shift-up/down
switch: Voltage Max. 1 V
Between L03 (5) and Shift-down ON
chassis ground AJSS shift-up/down
switch: Voltage 20 – 30 V
Shift-down OFF
AJSS shift-up/down
Possible causes Between L03 (15) Shift-down ON
and standard and chassis ground AJSS shift-up/down
6 switch: Voltage Max. 1 V
state controller
Shift-down OFF
AJSS shift-up/down
Between L03 (25) Shift-up ON
and chassis ground AJSS shift-up/down
Shift-up OFF
AJSS shift-up/down
Between L03 (35) Shift-up ON
and chassis ground AJSS shift-up/down
Shift-up OFF
Circuit diagram related to AJSS shift-up/down switch
40-306 30 WD600-6
Failure code [DDK6KA] FNR lever switch: Disconnection SEN05056-03
Failure code [DDK6KA] FNR lever switch: Disconnection 1
Action code Failure code FNR lever switch: Disconnection

Trouble
E03 DDK6KA (Transmission controller system)
Contents of • Since the FNR (directional) lever switch signal system is disconnected or in ground fault, all the
trouble lever signals are not input
• Sets to neutral
controller • Even if cause of failure disappears, system does not reset itself until FNR (directional) lever is set to
N (Neutral).
Problem that
• The machine does not travel.
appears on
• Shift indicator turns out.
machine
• The input state (ON/OFF) from the FNR (directional) lever switch can be checked with the monitor-
Related ing function (Code: 40907 D-IN-20, D-IN-21 or D-IN-22).
information • Only for steering wheel specification (STD)
• Method of reproducing failure code: Turn the starting switch and FNR (directional) switch ON

1
side.
2
for cause 4.
Between L04 (female) (1) and Power
Voltage 20 – 30 V
(10) supply
Possible causes 2. Insert T-adapter into connector L04.
and standard 3. Turn starting switch to ON position.
value in normal
state FNR (directional)
Between L04 (2) and Voltage 20 – 30 V
lever: N (Neutral)
(10)
FNR (directional)
Defective FNR (directional) Between L04 (3) and Voltage 20 – 30 V
lever: F (Forward)
3 lever switch (Internal discon- (10)
nection or short circuit) Other than above Voltage Max. 1 V
FNR (directional)
lever: R (Reverse)
(10)
ing harness.
WD600-6 40-306 31
SEN05056-03 Failure code [DDK6KA] FNR lever switch: Disconnection

each female side.
Between fuse No. 5 of fuse box 2 and L04 Resis-
Max. 1 z
(female) (1) tance
Disconnection in wiring har-
ness Max. 1 z
4 (4) tance
contact of connector) Between L03 (female) (26) and L04 (female) Resis-
Max. 1 z
(3) tance
Max. 1 z
(2) tance
Between chassis ground and L04 (female) Resis-
Max. 1 z
(10) tance
2. Disconnect connectors L03 and L04, and connect T-adapter to
either female side.
3. Remove fuse No.5 of fuse box 2.
Possible causes
and standard Between fuse No. 5 of fuse box 2 or L04 Resis-
Grounding fault in wiring har- (female) (1) and chassis ground Max. 1 z
value in normal tance
5 ness
state
(Contact with ground circuit) Between L03 (female) (16) or L04 (female) Resis-
Min. 1 Mz
Between L03 (female) (26) or L04 (female) Resis-
Min. 1 Mz
Min. 1 Mz
FNR (directional)
lever: Neutral
and chassis ground
6
troller FNR (directional)
lever: F (Forward)
and chassis ground
FNR (directional)
lever: R (Reverse)
and chassis ground
40-306 32 WD600-6
Failure code [DDK6KA] FNR lever switch: Disconnection SEN05056-03
Circuit diagram related to FNR (directional) lever switch
WD600-6 40-306 33
SEN05056-03 Failure code [DDK6KB] FNR lever switch: Short circuit
Failure code [DDK6KB] FNR lever switch: Short circuit 1
Action code Failure code FNR lever switch: Short circuit

Trouble
E03 DDK6KB (Transmission controller system)
Contents of • Since the FNR (directional) lever switch signal system is hot short, all the FNR (directional) lever
trouble signals are not input.
• Sets to neutral
controller • Even if cause of failure disappears, system does not reset itself until FNR (directional) lever is set to
N (Neutral).
Problem that • The machine does not travel.
appears on • Multiple shift indicator turns on.
machine • Travel is enabled by using joystick FNR switch after setting the shift to neutral.
• The input state (ON/OFF) from the FNR (directional) lever switch can be checked with the monitor-
Related ing function (Code: 40907 D-IN-20, D-IN-21 or D-IN-22).
• Method of reproducing failure code: Turn the starting switch ON and operate FNR (directional) lever

FNR (directional)
lever: N (Neutral)
(10)
FNR (directional)
Defective FNR (directional) Between L04 (3) and Voltage 20 – 30 V
lever: F (Forward)
1 lever switch (Internal short (10)
circuit) Other than above Voltage Max. 1 V
FNR (directional)
Possible causes lever: R (Reverse)
(10)
and standard Other than above Voltage Max. 1 V
value in normal a If power supply voltage is normal and sensor output voltage is
state abnormal, it is difficult to judge whether cause is ground fault or
ing harness.
side.
Hot short in wiring harness Between L04 (female) (4) and shassis
2 Voltage Max. 1 V
(Contact with 24 V circuit) ground
Between L04 (female) (3) and shassis
Voltage Max. 1 V
ground
Between L04 (female) (2) and shassis
Voltage Max. 1 V
ground
40-306 34 WD600-6
Failure code [DDK6KB] FNR lever switch: Short circuit SEN05056-03

FNR (directional)
Possible causes Between L03 (36) Voltage 20 – 30 V
lever: Neutral
and standard and chassis ground
value in normal 3
state troller FNR (directional)
lever: F (Forward)
and chassis ground
FNR (directional)
lever: R (Reverse)
and chassis ground
Circuit diagram related to FNR (directional) lever switch
WD600-6 40-306 35
SEN05056-03 Failure code [DDP5KA] Lock detection pressure switch of steering lock lever: Disconnection
Failure code [DDP5KA] Lock detection pressure switch of steering lock

lever: Disconnection 1
Action code Failure code Lock detection pressure switch of steering lock lever: Disconnec-
Trouble tion
E01 DDP5KA (Transmission controller system)
Contents of • Steering lock lever lock signal cannot be detected because of disconnection of lock detection pres-
trouble sure switch of steering lock lever.
Problem that
appears on • If steering lock lever is locked, steering can be operated.
machine
• The input state (ON/OFF) from the lock detection pressure switch of the steering lock lever can be
Related
checked with the monitoring function (Code: 40908 D-IN-31).
information
• Method of reproducing failure code: Turn the starting switch ON and lock the steering lock lever

Defective lock detection 2. Disconnect connector L13, and connect T-adapter to male side.
pressure switch of steering Steering lock lever: Resis-
1 Min. 1 Mz
lock lever Between L13 (male) Lock tance
(Internal disconnection) (1) and (2) Steering lock lever: Resis-
Max. 1 z
Release tance
Possible causes Disconnection in wiring har- 2. Disconnect connectors L13 and L03, and connect T-adapters to
and standard ness
2 each female side.
value in normal (Disconnection or defective
state Between L03 (female) (38) and L13 (female) Resis-
(1) tance
Defective transmission con-
3 Steering lock lever:
troller Voltage 7 – 10 V
Between L03 (38) Lock
and chassis ground Steering lock lever:
Voltage Max. 1 V
Release
40-306 36 WD600-6
Failure code [DDP5KA] Lock detection pressure switch of steering lock lever: Disconnection SEN05056-03
Circuit diagram related to lock detection pressure switch of steering lock lever
WD600-6 40-306 37
SEN05056-03 Failure code [DDT0L4] Shift mode selector switch: ON/OFF signals disagree
Failure code [DDT0L4] Shift mode selector switch: ON/OFF signals

disagree 1
Action code Failure code Shift mode selector switch: ON/OFF signals disagree
Trouble
E01 DDT0L4 (Transmission controller system)
Contents of • The signals input from the transmission manual/auto shift selector switch are combined in an impos-
trouble sible manner.
Action of • Selects the manual shift mode.
Problem that
• The position of the transmission manual/auto shift selector switch does not match the shift mode
appears on
during auto shift.
machine
• The input state (H/L) from the transmission manual/auto shift selector switch can be checked with
Related the monitoring function (Code: 40905 D-IN-4, D-IN-5).
information • The operator can check the current shift mode with the automatic shift pilot lamp.

3. Operate shift mode, and carry out troubleshooting
Resis-
Manual shift Min. 1 Mz
tance
Between S10 (male)
Resis-
(3) and Auto shift (L) Min. 1 Mz
tance
(1), (2), (4)
Resis-
Auto shift (H) Min. 1 Mz
tance
Resis-
tance
Between S10 (male) Resis-
Auto shift (L) Min. 1 Mz
Defective transmission man- (2) and (4) tance
1 ual/auto-shift selector switch Resis-
Auto shift (H) Max. 1 z
(Internal defect). tance
Possible causes
Resis-
and standard Manual shift Min. 1 Mz
tance
value in normal
state Between S10 (male) Resis-
Auto shift (L) Max. 1 z
(1) and (2) tance
Resis-
tance
Resis-
tance
Between S10 (male) Resis-
Auto shift (L) Min. 1 Mz
(1) and (4) tance
Resis-
tance
Disconnection in wiring har- each female side.
ness
2 Between L02 (female) (18) and S10 (female) Resis-
(Disconnection or defective Max. 1 z
(4) tance
Max. 1 z
(2) tance
40-306 38 WD600-6
Failure code [DDT0L4] Shift mode selector switch: ON/OFF signals disagree SEN05056-03

Grounding fault in wiring har- either female side.
3 ness Between L02 (female) (18) or S10 (female) Resis- Min.
(Contact with ground circuit) (4) and chassis ground tance 1 Mz
Between L02 (female) (24) or S10 (female) Resis- Min.
(2) and chassis ground tance 1 Mz
side.
Possible causes 4
and standard (Contact with 24 V circuit) Between S10 (female) (4) and chassis
Voltage Max. 1 V
value in normal ground
state Between S10 (female) (2) and chassis
Voltage Max. 1 V
ground
4. Operate shift mode, and carry out troubleshooting.
Manual shift Voltage Max. 1 V
Defective transmission con- Between L02 (18)
5 Auto shift (L) Voltage Max. 1 V
troller and chassis ground
Auto shift (H) Voltage 20 – 30 V
Manual shift Voltage Max. 1 V
Between L02 (24)
Auto shift (L) Voltage 20 – 30 V
and chassis ground
Auto shift (H) Voltage 20 – 30 V
Circuit diagram related to transmission manual/auto shift selector switch
WD600-6 40-306 39
SEN05056-03 Failure code [DDW9LD] Kick-down switch: Switch is kept pressed for long time
Failure code [DDW9LD] Kick-down switch: Switch is kept pressed for

long time 1
Action code Failure code Kick-down switch: Switch is kept pressed for long time
Trouble
E01 DDW9LD (Transmission controller system)
Contents of
• Since the kick-down switch system is in ground fault, the kick-down is not turned OFF.
trouble
Action of • Turns the kick-down ON when a grounding fault is detected, then do not control the kick-down.
Problem that
appears on • When ground fault occurs, turn the kick-down ON once.
machine
• The input state (ON/OFF) from the kick-down switch can be checked with the monitoring function
Related
(Code: 40906 D-IN-10).
information

Kick-down switch: Resis-
Max. 1 z
Between S07 (male) ON tance
Defective kick-down switch
1 (3) and (7) Kick-down switch: Resis-
OFF tance
Between S07 (male)
Resis-
tance
ground
Possible causes
value in normal 2. Disconnect connectors S07 and L04, and connect T-adapter to
state 2 ness 3. Turn starting switch to ON position.
Min. 1 Mz
3 Kick-down switch:
troller Voltage Max. 1 V
Between L04 (30) ON
and chassis ground Kick-down switch:
Voltage 7 – 10 V
OFF
40-306 40 WD600-6
Failure code [DDW9LD] Kick-down switch: Switch is kept pressed for long time SEN05056-03
Circuit diagram related to kick-down switch and hold switch
WD600-6 40-306 41
SEN05056-03 Failure code [DDWLLD] Hold switch: Switch is kept pressed for long time
Failure code [DDWLLD] Hold switch: Switch is kept pressed for long time 1
Action code Failure code Hold switch: Switch is kept pressed for long time
Trouble
E01 DDWLLD (Transmission controller system)
Contents of
• Since the hold switch system is in ground fault, the hold switch cannot be selected.
trouble
Action of • Holds once when a grounding fault occurs, then do not control holding.
Problem that
appears on • When ground fault occurs, turn the hold switch once.
machine
• The input state (ON/OFF) from the hold switch can be checked with the monitoring function
Related
(Code: 40906 D-IN-11).
information

Resis-
Hold switch: ON Max. 1 z
Between S07 (male) tance
Defective hold switch
1 (3) and (4) Resis-
(Internal short circuit) Hold switch: OFF Min. 1 Mz
tance
Between S07 (male)
Resis-
Possible causes tance
ground
and standard
value in normal 1. Turn starting switch to OFF position.
state 2. Disconnect connectors S07 and L04, and connect T-adapters to
2 ness 3. Turn starting switch to ON position.
Min. 1 Mz
Defective transmission con- 3. Turn starting switch to ON position.
3
troller
Between L04 (40) Hold switch: ON Voltage Max. 1 V
and chassis ground Hold switch: OFF Voltage 7 – 10 V
40-306 42 WD600-6
Failure code [DDWLLD] Hold switch: Switch is kept pressed for long time SEN05056-03
Circuit diagram related to kick-down switch and hold switch
WD600-6 40-306 43
SEN05056-03 Failure code [DF10KA] Transmission shift lever switch: Disconnection
Failure code [DF10KA] Transmission shift lever switch: Disconnection 1
Action code Failure code Transmission shift lever switch: Disconnection

Trouble
E01 DF10KA (Transmission controller system)
Contents of • Since the transmission shift lever switch input signal system is disconnected or in ground fault, the
trouble signal is not input.
Action of • Fixed to the shift range before the abnormality occurred
Problem that
• The transmission is not set to the selected gear speed.
appears on
• Shift indicator displays the shift range before the abnormality occurred
machine
• The input state (ON/OFF) from each shift switch can be checked with the monitoring function
Related (Code: 40907 D-IN-16, D-IN-17, D-IN-18 or D-IN-19).
• Method of reproducing failure code: Turn the starting switch ON and operate shift lever

1
side.
2
for cause 4.
Between L04 (female) (1) and Power
Voltage 20 – 30 V
(10) supply
Possible causes 3. Turn starting switch to ON position.
and standard Shift range:
value in normal 1st (1st speed)
chassis ground
state Other than above Voltage Max. 1 V
Shift range:
2nd (2nd speed)
chassis ground
Defective transmission shift Other than above Voltage Max. 1 V
3 lever switch Shift range:
(Internal disconnection) Between L04 (7) and Voltage 20 – 30 V
3rd (3rd speed)
chassis ground
Shift range:
4th (4th speed)
chassis ground
ing harness.
40-306 44 WD600-6
Failure code [DF10KA] Transmission shift lever switch: Disconnection SEN05056-03

each female side.
Between fuse No. 5 of fuse box 2 and L04 Resis-
Max. 1 z
(female) (1) tance
Disconnection in wiring har-
ness Max. 1 z
4 (8) tance
contact of connector) Between L03 (female) (15) and L04 (female) Resis-
Max. 1 z
(7) tance
Max. 1 z
(6) tance
Max. 1 z
(5) tance
2. Disconnect connectors L03 and L04, and connect T-adapter to
either female side.
3. Remove fuse No.5 of fuse box 2.
Between fuse No. 5 of fuse box 2 or L04 Resis-
Min. 1 Mz
Possible causes Grounding fault in wiring har-
and standard 5 ness Min. 1 Mz
value in normal (Contact with ground circuit)
state Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
Shift range:
1st (1st speed)
and chassis ground
Shift range:
Defective transmission con- Between L03 (25) Voltage 20 – 30 V
6 2nd (2nd speed)
troller and chassis ground
Shift range:
3rd (3rd speed)
and chassis ground
Shift range:
4th (4th speed)
chassis ground
WD600-6 40-306 45
SEN05056-03 Failure code [DF10KA] Transmission shift lever switch: Disconnection
Circuit diagram related to transmission shift lever switch
40-306 46 WD600-6
Failure code [DF10KA] Transmission shift lever switch: Disconnection SEN05056-03
WD600-6 40-306 47
SEN05056-03 Failure code [DF10KB] Transmission shift lever switch: Short circuit
Failure code [DF10KB] Transmission shift lever switch: Short circuit 1
Action code Failure code Transmission shift lever switch: Short circuit
Trouble
E01 DF10KB (Transmission controller system)
Contents of • Since the transmission shift lever switch input signal system is in hot short circuit, multiple transmis-
trouble sion shift lever switch signals are input.
Action of • Uses the shift range input to the higher gear speed
Problem that
• The transmission is not set to the selected gear speed.
appears on
• Shift indicator indicates the shift range input to the higher gear speed.
machine
• The input state (ON/OFF) from each shift switch can be checked with the monitoring function
Related (Code: 40907 D-IN-16, D-IN-17, D-IN-18 or D-IN-19).
• Method of reproducing failure code: Turn the starting switch ON and operate shift lever

2. Insert T-adapters into connector L04.
Shift range:
1st (1st speed)
chassis ground
Shift range:
2nd (2nd speed)
chassis ground
Defective transmission shift Other than above Voltage Max. 1 V
1 lever switch Shift range:
(Internal short circuit) Between L04 (7) and Voltage 20 – 30 V
3rd (3rd speed)
chassis ground
Shift range:
Possible causes Between L04 (8) and Voltage 20 – 30 V
4th (4th speed)
and standard chassis ground
value in normal Other than above Voltage Max. 1 V
state a If power supply voltage is normal and sensor output voltage is
ing harness.
side.
Between L04 (female) (8) and chassis
Voltage Max. 1 V
Hot short in wiring harness ground
2
(Contact with 24 V circuit) Between L04 (female) (7) and chassis
Voltage Max. 1 V
ground
Voltage Max. 1 V
ground
Voltage Max. 1 V
ground
40-306 48 WD600-6
Failure code [DF10KB] Transmission shift lever switch: Short circuit SEN05056-03

Shift range:
1st (1st speed)
and chassis ground
Possible causes Other than above Voltage Max. 1 V
and standard Shift range:
Defective transmission con- Between L03 (25) Voltage 20 – 30 V
value in normal 3 2nd (2nd speed)
state troller and chassis ground
Shift range:
3rd (3rd speed)
and chassis ground
Shift range:
4th (4th speed)
chassis ground
Circuit diagram related to transmission shift lever switch
WD600-6 40-306 49
Failure code [DGE5KX] (or VHMS_LED display: “n4” → “01”) Atmospheric temperature sensor: Out
SEN05056-03 of input signal range
Failure code [DGE5KX] (or VHMS_LED display: “n4” → “01”)

Atmospheric temperature sensor: Out of input signal range 1
Action code Failure code Atmospheric temperature sensor: Out of input signal range
Trouble
— DGE5KX (VHMS controller system)
Contents of • Input signal voltage from the atmospheric temperature sensor reads 4.9 V and above or 0.3 V or
trouble less.
Action of
controller
Problem that
appears on • Monitoring function fails to monitor the atmospheric temperature.
machine
• The machine monitor does not display any failure code (the relevant failure code can be checked by
Related • The LED of the VHMS controller displays “n4” o “01”.
information • The input state (temperature) from the atmospheric temperature sensor can be checked with the
monitoring function (Code: 37501 ATR TEMP).

2. Disconnect connector C58 and connect T-adapter to male side.
Atmospheric
Resis- 3.6 – 4.7
temperature:
Defective atmospheric tem- tance kz
25°C (Normal temp)
perature sensor
1 Atmospheric
(Internal disconnection or Between C58 (male) Resis- 10.2 –
short circuit) temperature:
(1) and (2) tance 13.4 kz
About 0°C
Atmospheric
Resis- 2.1 – 2.6
temperature:
tance kz
About 40°C
2. Disconnect connector C58 and connect T-adapter to female
side.
Open circuit or short circuit a If voltage is 0 V, harness has open circuit or ground fault or short
Possible causes
2 or ground fault or hot short circuit, and if voltage is 24 V, harness has hot short circuit.
and standard
circuit in harness a Voltage of approximately 5 V is applied to temperature sensor
value in normal
state signal lines through resistor in VHMS controller.
Approx. 5
Between C58 (female) (2) and (1) Voltage
V
a If cause 2 is not the cause of failure, this check is not required.
Disconnection in wiring har- 2. Disconnect connectors V02, C58 and connect T-adapters to
ness each female side.
3
(Disconnection or defective Between V02 (female) (10) and C58 (female) Resis-
Max. 1 z
Between C58 (female) (2) and chassis Resis-
Max. 1 z
ground tance
Grounding fault in wiring har- 2. Disconnect connectors V02 and C58, and connect T-adapters
4 ness to either female side.
Between V02 (female) (10) or C58 (female) Resis-
Min. 1 Mz
40-306 50 WD600-6
Failure code [DGE5KX] (or VHMS_LED display: “n4” → “01”) Atmospheric temperature sensor: Out
of input signal range SEN05056-03

and standard If no abnormality is found by above checks, VHMS controller is
value in normal 5 Defective VHMS controller defective. (Since this is an internal failure, troubleshooting cannot
state be performed.)
Circuit diagram related to atmospheric temperature sensor
WD600-6 40-306 51
SEN05056-03 Failure code [DGF1KA] Transmission oil temperature sensor: Disconnection
Failure code [DGF1KA] Transmission oil temperature sensor:

Disconnection 1
Action code Failure code Transmission oil temperature sensor: Disconnection

Trouble
E01 DGF1KA (Transmission controller system)
• Due to disconnection or hot short circuit in the transmission oil temperature sensor signal system,
Contents of the transmission oil temperature reading is higher than normal range
trouble (Transmission oil temperature sensor signal voltage: Min. 4.56 V (Max. 15°C) and torque converter
oil temperature sensor signal voltage: Min. 3.7 V (55°C))
Action of • Judges that the transmission oil temperature is lower.
Problem that
appears on • Gear shift shocks may be made.
machine
• The input state (oil temperature) from the transmission oil temperature sensor can be checked with
the monitoring function (Code: 93600 T/M OIL TEMP).
Related
• The input state (voltage) from the transmission oil temperature sensor can be checked with the
information
monitoring function (Code: 93601 T/M OIL TEMP).

2. Disconnect connector TM.T and connect T-adapter to male
Defective transmission oil side.
temperature sensor (Internal Transmission oil
1 Resis- 35 – 50
disconnection or short cir- temperature:
Between TM.T tance kz
cuit) 25°C (Normal temp)
(male) (1) and (2)
Transmission oil Resis- 3.1 – 4.5
temperature: 100°C tance kz
2. Disconnect connector TM.T and connect T-adapter to female
side.
Open circuit or short circuit a If voltage is 0 V, harness has open circuit or ground fault or short
Possible causes
and standard
value in normal
state signal lines through resistor in transmission controller.
Approx. 5
Between TM.T (female) (1) and (2) Voltage
V
Disconnection in wiring har- 2. Disconnect connectors L02, TM.T and connect T-adapters to
3
(Disconnection or defective Between L02 (female) (9) and TM.T (female) Resis-
Max. 1 z
Between TM.T (female) (2) or L02 (female) Resis-
Max. 1 z
If no abnormality is found by above checks, transmission controller
4 is defective. (Since this is an internal failure, troubleshooting can-
troller
not be performed.)
40-306 52 WD600-6
Failure code [DGF1KA] Transmission oil temperature sensor: Disconnection SEN05056-03
Circuit diagram related to transmission oil temperature sensor
WD600-6 40-306 53
SEN05056-03 Failure code [DGF1KB] Transmission oil temperature sensor: Short circuit
Failure code [DGF1KB] Transmission oil temperature sensor: Short

circuit 1
Action code Failure code Transmission oil temperature sensor: Short circuit
Trouble
E01 DGF1KB (Transmission controller system)
• Due to grounding fault in transmission oil temperature sensor signal system, the signal level is lower
Contents of
than normal range
trouble
(Transmission oil temperature sensor signal voltage: Max. 0.97 V (Min. 150°C))
Action of • Judges that the transmission oil temperature is higher.
Problem that
appears on • Gear shift shocks may be made.
machine
• The input state (oil temperature) from the transmission oil temperature sensor can be checked with
the monitoring function (Code: 93600 T/M OIL TEMP).
Related
• The input state (voltage) from the transmission oil temperature sensor can be checked with the
information
monitoring function (Code: 93601 T/M OIL TEMP).

2. Disconnect connector TM.T and connect T-adapter to male
side.
Defective transmission oil
Transmission oil
1 temperature sensor (Internal Resis- 35 – 50
temperature:
short circuit) Between TM.T (male) 25°C (Normal temp) tance kz
Possible causes (1) and (2)
Transmission oil Resis- 3.1 – 4.5
and standard
value in normal
Grounding fault in wiring har- 2. Disconnect connectors L02 and TM.T, and connect T-adapter to
(Contact with ground circuit) Between L02 (female) (9) or TM.T (female) Resis-
Min. 1 Mz
If no abnormality is found by above checks, transmission controller
3 is defective. (Since this is an internal failure, troubleshooting can-
troller
not be performed.)
40-306 54 WD600-6
Failure code [DGF1KB] Transmission oil temperature sensor: Short circuit SEN05056-03
Circuit diagram related to transmission oil temperature sensor
WD600-6 40-306 55
SEN05056-03
WD600-6 Wheel dozer

©2018 KOMATSU
All Rights Reserved
40-306 56
SEN05057-01
WHEEL DOZER
WD600-6

WD600-6 55001 and up

Failure code [DGH2KX] Hydraulic oil temperature sensor: Out of input signal range .................................... 4
Failure code [DGR2KA] Rear brake oil temperature sensor: Disconnection .................................................. 6
Failure code [DGR2KX] Rear brake oil temperature sensor: Out of input signal range.................................. 8
Failure code [DGT1KA] Torque converter oil temperature sensor: Disconnection ....................................... 10
Failure code [DGT1KB] Torque converter oil temperature sensor: Short circuit ........................................... 12
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range)...................... 14
Failure code [DGT4KA] (or VHMS_LED display: "n3" → "12") Exhaust gas temperature sensor (F): Discon-
nection ...................................................................................................................................................... 16
Failure code [DGT4KB] (or VHMS_LED display: "n3" → "11") Exhaust gas temperature sensor (F): Short cir-
cuit ............................................................................................................................................................ 19
Failure code [DGT5KA] (or VHMS_LED display: "n3" → "22") Exhaust gas temperature sensor (R): Discon-
nection ...................................................................................................................................................... 22
Failure code [DGT5KB] (or VHMS_LED display: "n3" → "21") Exhaust gas temperature sensor (R): Short cir-
cuit ............................................................................................................................................................ 25
Failure code [DH21KA] Work equipment pump oil pressure sensor: Disconnection .................................... 28
Failure code [DH21KB] Work equipment pump oil pressure sensor: Short circuit........................................ 30
Failure code [DHE5KB] (or VHMS_LED display: “n3” → “32”) Blow-by pressure sensor: Short circuit........ 32
Failure code [DHE5KY] (or VHMS_LED display: “n3” → “31”) Blow-by pressure sensor: Short circuit with
power supply line ...................................................................................................................................... 34
Failure code [DHT2L6] Transmission filter clogging sensor: Signal disagrees with operating state of engine
.................................................................................................................................................................. 36
WD600-6 40-307 1
SEN05057-01
Failure code [DHT8KX] (or VHMS_LED display: “n5” → “33”) Steering oil pressure sensor: Out of input sig-
nal range ................................................................................................................................................... 38
Failure code [DHTBKA] Modulation clutch oil pressure sensor: Disconnection............................................ 42
Failure code [DHTBKB] Modulation clutch oil pressure sensor: Short circuit ............................................... 44
Failure code [DHU2KX] (or VHMS_LED display: “n7” → “11”) Front brake oil pressure sensor (F): Out of
input signal range...................................................................................................................................... 46
Failure code [DHU3KX] (or VHMS_LED display: “n7” → “12”) Rear brake oil pressure sensor (R): Out of
input signal range...................................................................................................................................... 48
Failure code [DK30KA] AJSS lever angle sensor: Disconnection................................................................. 50
Failure code [DK30KY] AJSS lever angle sensor: Short circuit with power supply line ................................ 52
40-307 2 WD600-6
SEN05057-01
WD600-6 40-307 3
SEN05057-01 Failure code [DGH2KX] Hydraulic oil temperature sensor: Out of input signal range
Failure code [DGH2KX] Hydraulic oil temperature sensor: Out of input

signal range 1
Action code Failure code Hydraulic oil temperature sensor: Out of input signal range
Trouble
E01 DGH2KX (Machine monitor system)
• Due to grounding fault in hydraulic oil temperature sensor signal system, the signal level is lower
Contents of
than normal range
trouble
(Hydraulic oil temperature sensor signal voltage: Max. 0.97 V (Min. 150°C))
Action of • Judges that the hydraulic oil temperature is higher
Problem that
appears on • The hydraulic oil temperature gauge reads MAX position
machine
• The input state (oil temperature) from the hydraulic oil temperature sensor can be checked with the
monitoring function (Code: 04401 HYD TEMP).
Related
• The input state (voltage) from the hydraulic oil temperature sensor can be checked with the monitor-
information
ing function (Code: 04404 HYD TEMP).

2. Disconnect connector HD.T and connect T-adapter to male
side.
Defective transmission oil
Hydraulic oil
1 temperature sensor (Internal Resis- 35 – 50
temperature:
short circuit) Between HD.T tance kz
25°C (Normal temp)
(male) (1) and (2)
Hydraulic oil Resis- 3.1 – 4.5
2. Disconnect connector HD.T and connect T-adapter to female
side.
Possible causes 3. Turn starting switch to ON position.
and standard Open circuit or short circuit a If voltage is 0 V, harness has open circuit or ground fault or short
value in normal 2 or ground fault or hot short circuit, and if voltage is 24 V, harness has hot short circuit.
state circuit in harness a Voltage of approximately 5 V is applied to temperature sensor
signal lines through resistor in machine monitor.
Approx. 5
Between HD.T (female) (1) and (2) Voltage
V
Grounding fault in wiring har- 2. Disconnect connectors C05 and HD.T, and connect T-adapter
Between C05 (female) (7) or HD.T (female) Resis-
Min. 1 Mz
If no abnormality is found by above checks, machine monitor is
4 Defective machine monitor defective. (Since this is an internal failure, troubleshooting cannot
be performed.)
40-307 4 WD600-6
Failure code [DGH2KX] Hydraulic oil temperature sensor: Out of input signal range SEN05057-01
Circuit diagram related to hydraulic oil temperature sensor
WD600-6 40-307 5
SEN05057-01 Failure code [DGR2KA] Rear brake oil temperature sensor: Disconnection
Failure code [DGR2KA] Rear brake oil temperature sensor: Disconnection 1
Action code Failure code Rear brake oil temperature sensor: Disconnection
Trouble
E01 DGR2KA (Machine monitor system)
• Due to disconnection in rear brake oil temperature sensor signal system, the signal level is higher
Contents of
than normal range
trouble
(Rear brake oil temperature sensor signal voltage: Min 4.56 V (Max. 15°C))
Action of • Judges that the rear brake oil temperature is lower
Problem that
appears on —
machine
• The input state (oil temperature) from the rear brake oil temperature sensor can be checked with the
monitoring function (Code: 30202 R BRAKE OIL).
Related
• The input state (voltage) from the rear brake oil temperature sensor can be checked with the moni-
information
toring function (Code: 30205 R BRAKE OIL).

2. Disconnect connector R17 and connect T-adapter to male side.
Defective rear brake oil tem- Hydraulic oil
Resis- 35 – 50
1 perature sensor (Internal dis- temperature:
Between R17 (male) tance kz
connection) 25°C (Normal temp)
(1) and (2)
Hydraulic oil Resis- 3.1 – 4.5
Possible causes temperature: 100°C tance kz
value in normal 2. Disconnect connectors C05, R17 and connect T-adapters to
state Disconnection in wiring har- each female side.
ness
2 Between C05 (female) (8) and R17 (female) Resis-
(1) tance
Between R17 (female) (2) and chassis Resis-
Max. 1 z
ground tance
be performed.)
40-307 6 WD600-6
Failure code [DGR2KA] Rear brake oil temperature sensor: Disconnection SEN05057-01
Circuit diagram related to rear brake oil temperature sensor
WD600-6 40-307 7
SEN05057-01 Failure code [DGR2KX] Rear brake oil temperature sensor: Out of input signal range
Failure code [DGR2KX] Rear brake oil temperature sensor: Out of input
signal range 1
Action code Failure code Rear brake oil temperature sensor: Out of input signal range
Trouble
E01 DGR2KX (Machine monitor system)
• Due to grounding fault in rear brake oil temperature sensor signal system, the signal level is lower
Contents of
than normal range
trouble
(Rear brake oil temperature sensor signal voltage: Max. 0.97 V (Min. 150°C))
Action of • Judges that the rear brake oil temperature is higher
Problem that
appears on —
machine
• The input state (oil temperature) from the rear brake oil temperature sensor can be checked with
the monitoring function (Code: 30202 R BRAKE OIL).
Related
• The input state (voltage) from the rear brake oil temperature sensor can be checked with the moni-
information
toring function (Code: 30205 R BRAKE OIL).

Defective rear brake oil tem- Hydraulic oil
Resis- 35 – 50
1 perature sensor (Internal temperature:
short circuit) 25°C (Normal temp)
(1) and (2)
Possible causes Hydraulic oil Resis- 3.1 – 4.5
and standard temperature: 100°C tance kz
state
Grounding fault in wiring har- 2. Disconnect connectors C05 and R17, and connect T-adapter to
(Contact with ground circuit) Between C05 (female) (8) or R17 (female) Resis- Min. 1
(1) and chassis ground tance Mz
be performed.)
40-307 8 WD600-6
Failure code [DGR2KX] Rear brake oil temperature sensor: Out of input signal range SEN05057-01
Circuit diagram related to rear brake oil temperature sensor
WD600-6 40-307 9
SEN05057-01 Failure code [DGT1KA] Torque converter oil temperature sensor: Disconnection
Failure code [DGT1KA] Torque converter oil temperature sensor:

Disconnection 1
Action code Failure code Torque converter oil temperature sensor: Disconnection
Trouble
E01 DGT1KA (Transmission controller system)
Contents of
• Disconnection or hot short circuit in torque converter oil temperature sensor is detected.
trouble
Action of
controller
Problem that
appears on —
machine
• The input state (oil temperature) from the torque converter oil temperature sensor can be checked
with the monitoring function (Code: 40100 TC OIL TEMP).
Related
• The input state (voltage) from the torque converter oil temperature sensor can be checked with the
information
monitoring function (Code: 40101 TC OIL TEMP).

Defective torque converter Torque converter oil
Resis- 35 – 50
1 oil temperature sensor (Inter- temperature:
nal short circuit) 25°C (Normal temp)
(1) and (2)
Torque converter oil Resis- 3.1 – 4.5
2. Disconnect connector R13 and connect T-adapter to female
side.
Disconnection or short circuit a If voltage is 0 V, harness has open circuit or ground fault or short
Possible causes
and standard
value in normal
state signal lines through resistor in machine monitor.
Approx. 5
Between R13 (female) (1) and (2) Voltage
V
2. Disconnect connectors R13, C05, and connect T-adapter to
ness
3 Between C05 (female) (2) and R13 (female) Resis-
(1) tance
Resis-
Between R13 (female) (2) and ground Max. 1 z
tance
be performed.)
40-307 10 WD600-6
Failure code [DGT1KA] Torque converter oil temperature sensor: Disconnection SEN05057-01
Circuit diagram related to torque converter oil temperature sensor
WD600-6 40-307 11
SEN05057-01 Failure code [DGT1KB] Torque converter oil temperature sensor: Short circuit
Failure code [DGT1KB] Torque converter oil temperature sensor:

Short circuit 1
Action code Failure code Torque converter oil temperature sensor: Short circuit
Trouble
E01 DGT1KB (Transmission controller system)
Contents of
• Ground fault in torque converter oil temperature sensor is detected.
trouble
Action of
controller
Problem that
appears on —
machine
Related
information

and standard
value in normal 1 Carry out troubleshooting for failure code [DGT1KX].
state
40-307 12 WD600-6
Failure code [DGT1KB] Torque converter oil temperature sensor: Short circuit SEN05057-01
WD600-6 40-307 13
SEN05057-01 Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range)
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of

input signal range) 1
Action code Failure code Torque converter oil temperature sensor: Out of input signal range
Trouble
E01 DGT1KX (Machine monitor system)
Contents of • Due to grounding fault in torque converter oil temperature sensor signal system, the signal level is
trouble lower than normal range (torque converter oil temperature voltage: Max. 0.97 V (Min. 150°C))
Action of • Judges that the torque converter oil temperature is higher
Problem that
appears on • The torque converter oil temperature gauge reads MAX position
machine
• The input state (oil temperature) from the torque converter oil temperature sensor can be checked
with the monitoring function (Code: 40100 TC OIL TEMP).
Related
• The input state (voltage) from the torque converter oil temperature sensor can be checked with the
information
monitoring function (Code: 40101 TC OIL TEMP).

Defective torque converter Torque converter oil
Resis- 35 – 50
1 oil temperature sensor (Inter- temperature:
nal short circuit) 25°C (Normal temp)
(1) and (2)
Possible causes Torque converter oil Resis- 3.1 – 4.5
and standard temperature: 100°C tance kz
state
Grounding fault in wiring har- 2. Disconnect connectors C05 and R13, and connect T-adapter to
(Contact with ground circuit) Between C05 (female) (2) or R13 (female) Resis-
Max. 1 z
be performed.)
40-307 14 WD600-6
Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range) SEN05057-01
Circuit diagram related to torque converter oil temperature sensor
WD600-6 40-307 15
Failure code [DGT4KA] (or VHMS_LED display: "n3" → "12") Exhaust gas temperature sensor (F):
SEN05057-01 Disconnection
Failure code [DGT4KA] (or VHMS_LED display: "n3" → "12")

Exhaust gas temperature sensor (F): Disconnection 1
Action code Failure code Exhaust gas temperature sensor (F): Disconnection
Trouble
– DGT4KA (VHMS controller system)(Display: PLM)
Contents of • Input signal voltage from the exhaust gas temperature sensor on the engine front side reads 0.5 V
trouble or less.
Action of
controller
Problem that
appears on • Monitoring function fails to monitor the exhaust gas temperature on the engine front side
machine
• The LED of the VHMS controller displays "n3" o "12".
Related • The input state (temperature) from the exhaust gas temperature sensor (F) can be checked with the
information monitoring function (Code: 42610 EXHAUST TEMP F).
• If failure code [DBB6KP] (VHMS controller 24 V power supply output: Low output voltage) is dis-
played, carry out troubleshooting for it first.

1) Turn the starting switch to OFF position and disconnect the bat-
tery ground cable.
2) Disconnect connector V11 and connect the T-adapter to female
Defective sensor amplifier side.
power supply (defective wir- 3) Connect the battery ground cable and turn the starting switch to
1
ing harness or defective ON position.
VHMS & PLM controller) a Ignore the failure code displayed
Approx.
Between V11 (female) (A) and (C) Voltage
24 V
a Check that failure code [DGT5KA] is not displayed.
1) Turn the starting switch to OFF position.
Defective exhaust gas tem- 2) Swap connectors V29 and V30, and connectors V27 and V28,
Possible causes perature sensor on engine and connectors V11 and V12 sequentially one by one.
and standard front side, or defective 3) Turn the starting switch to ON position and perform trouble-
value in normal 2 exhaust gas temperature shooting.
state sensor amplifier on engine 4) Return to step 1) and conduct the test three times to locate the
front side, or defective inter- failed portion.
mediate wiring harness. If failure code [DGT4KA] changed to [DGT5KA], the defective por-
tion must be ahead (on the right side of the replaced connectors in
the related circuit diagram).
2. Disconnect connectors V11, V01 and V02, and connect T-adapt-
ers to each female side.
Disconnection in wiring har- Between V11 (female) (A) and V01 (female) Resis-
ness Max. 1 z
3 (2) tance
Between V11 (female) (B) and V02 (female) Resis-
(7) tance
Between V11 (female) (C) and V02 (female) Resis-
Max. 1 z
(12) tance
40-307 16 WD600-6
Disconnection SEN05057-01

1) Turn starting switch OFF.
2) Insert T-adapter into V11.
3) Start engine and carry out troubleshooting.
Exhaust gas temper-
Voltage 1.0 - 1.6 V
Defective exhaust gas tem- ature: 50 - 100°C
4 perature sensor amplifier on Exhaust gas temper-
Voltage 2.1 - 2.7 V
the engine front side Between V11 (B) and ature: 300 - 400°C
(C) Exhaust gas temper-
Voltage 2.9 - 3.6 V
ature: 500 - 600°C
Exhaust gas temper-
Voltage 3.8 - 4.4 V
ature: 700 - 800°C
If no abnormality is found in the above troubleshooting, the VHMS
controller may be defective. (Since this is an internal defect, trouble-
shooting cannot be performed.)
a Reference
Possible causes 2) Insert T-adapter into connector V02.
and standard 3) Start engine and carry out troubleshooting.
value in normal
5 Defective VHMS controller Exhaust gas temper-
state Voltage 1.0 - 1.6 V
ature: 50 - 100°C
Exhaust gas temper-
Voltage 2.1 - 2.7 V
Between V02 (7) and ature: 300 - 400°C
(12) Exhaust gas temper-
Voltage 2.9 - 3.6 V
ature: 500 - 600°C
Exhaust gas temper-
Voltage 3.8 - 4.4 V
ature: 700 - 800°C
a Since the sensor output voltage range is mV, actual measure-
ment is unavailable.
Exhaust gas temper- 1.0 - 35
Voltage
ature: 50 - 100°C mV
Characteristic of temperature
Exhaust gas temper- 11.2 - 15.6
Ref in exhaust gas temperature Voltage
Between V29 (1) and ature: 300 - 400°C mV
sensor
(2) Exhaust gas temper- 19.7 -
Voltage
ature: 500 - 600°C 24.2 mV
Exhaust gas temper- 28.1 -
Voltage
ature: 700 - 800°C 32.6 mV
WD600-6 40-307 17
Circuit diagram related to exhaust gas temperature sensor (F)
40-307 18 WD600-6
Failure code [DGT4KB] (or VHMS_LED display: "n3" → "11") Exhaust gas temperature sensor (F):
Short circuit SEN05057-01
Failure code [DGT4KB] (or VHMS_LED display: "n3" → "11")

Exhaust gas temperature sensor (F): Short circuit 1
Action code Failure code Exhaust gas temperature sensor (F): Short circuit
Trouble
– DGT4KB (VHMS controller system) (Display: PLM)
Contents of • Input signal voltage from the exhaust gas temperature sensor on the engine front side reads 4.9 V
trouble and above.
Action of
controller
Problem that
machine
Related • The input state (temperature) from the exhaust gas temperature sensor (F) can be checked with the
information monitoring function (Code: 42610 EXHAUST TEMP F).

Defective exhaust gas tem- 2) Disconnect connectors V29, V27 and V11 sequentially one by
perature sensor on engine one.
front side, or defective 3) Turn the starting switch to ON position and perform trouble-
1 exhaust gas temperature shooting.
sensor amplifier on engine 4) Return to step 1) and conduct the test three times to locate the
front side, or defective inter- failed portion.
mediate wiring harness. If failure code [DGT4KB] changed to [DGT4KA], the defective por-
tion must be ahead (on the right side of the disconnected connector
in the related circuit diagram).
2) Disconnect connectors V11, V01 and V02 and connect T-adapter
Possible causes Short circuit in wiring har-
2 to V11 (female).
and standard ness
value in normal Resis-
Between V11 (female) (A) and (B) Min. 1 Mz
state tance
2) Disconnect connector V11.
Hot short in wiring harness 3) Insert T-adapter into V02 or connect T-adapter to V11 (female).
3 4) Start engine and carry out troubleshooting.
Between V11 (female) (B) or V02 (7) and
Voltage Max. 1 V
chassis ground
2) Disconnect connectors V11, V27, V02.
Grounding fault in wiring har- 3) Connect T-adapter to anyone (female).
4 ness Between V11(female) (B) or V02 (female) Resis-
Min. 1 Mz
(Contact with ground circuit) (7) and chassis ground tance
Between V27 (female) (1) or (2) and chassis Resis-
Min. 1 Mz
ground tance
WD600-6 40-307 19
SEN05057-01 Short circuit

Exhaust gas temper-
Voltage 1.0 - 1.6 V
Voltage 2.1 - 2.7 V
the engine front side Between V11 (B) and ature: 300 - 400°C
Voltage 2.9 - 3.6 V
ature: 500 - 600°C
Exhaust gas temper-
Voltage 3.8 - 4.4 V
ature: 700 - 800°C
a Reference
value in normal
ature: 50 - 100°C
Exhaust gas temper-
Voltage 2.1 - 2.7 V
Voltage 2.9 - 3.6 V
ature: 500 - 600°C
Exhaust gas temper-
Voltage 3.8 - 4.4 V
ature: 700 - 800°C
Voltage
Between V29 (1) and ature: 300 - 400°C 15.6 mV
sensor
Voltage
ature: 500 - 600°C 24.2 mV
Voltage
ature: 700 - 800°C 32.6 mV
40-307 20 WD600-6
WD600-6 40-307 21
Failure code [DGT5KA] (or VHMS_LED display: "n3" → "22") Exhaust gas temperature sensor (R):
Failure code [DGT5KA] (or VHMS_LED display: "n3" → "22")

Exhaust gas temperature sensor (R): Disconnection 1
Action code Failure code Exhaust gas temperature sensor (R): Disconnection
Trouble
– DGT5KA (VHMS controller system)(Display: PLM)
Contents of • Input signal voltage from the exhaust gas temperature sensor on the engine rear side reads 0.5 V
trouble or less.
Action of
controller
Problem that
machine
Related • The input state (temperature) from the exhaust gas temperature sensor (R) can be checked with
information the monitoring function (Code: 42611 EXHAUST TEMP R).

1) Turn the starting switch to OFF position and disconnect the bat-
tery ground cable.
2) Disconnect connector V12 and connect the T-adapter to female
Defective sensor amplifier side.
power supply (defective wir- 3) Connect the battery ground cable and turn the starting switch to
1
ing harness or defective ON position.
VHMS & PLM controller) a Ignore the failure code displayed
Approx.
Between V12 (female) (A) and (C) Voltage
24 V
Defective exhaust gas tem- 2) Swap connectors V29 and V30, and connectors V27 and V28,
Possible causes perature sensor on engine and connectors V11 and V12 sequentially one by one.
and standard rear side, or defective 3) Turn the starting switch to ON position and perform trouble-
value in normal 2 exhaust gas temperature shooting.
state sensor amplifier on engine 4) Return to step 1) and conduct the test three times to locate the
rear side, or defective inter- failed portion.
mediate wiring harness. If failure code [DGT5KA] changed to [DGT4KA], the defective por-
tion must be ahead (on the right side of the replaced connectors in
the related circuit diagram).
2. Disconnect connectors V12, V01 and V02, and connect T-
Disconnection in wiring har- Between V12 (female) (A) and V01 (female) Resis-
ness Max. 1 z
3 (2) tance
Between V12 (female) (B) and V02 (female) Resis-
(7) tance
Between V12 (female) (C) and V02 (female) Resis-
Max. 1 z
(12) tance
40-307 22 WD600-6
Disconnection SEN05057-01

Exhaust gas temper-
Voltage 1.0 - 1.6 V
Voltage 2.1 - 2.7 V
the engine rear side Between V12 (B) and ature: 300 - 400°C
Voltage 2.9 - 3.6 V
ature: 500 - 600°C
Exhaust gas temper-
Voltage 3.8 - 4.4 V
ature: 700 - 800°C
controller may be defective. (Since this is an internal defect, trou-
bleshooting cannot be performed.)
a Reference
value in normal
ature: 50 - 100°C
Exhaust gas temper-
Voltage 2.1 - 2.7 V
Voltage 2.9 - 3.6 V
ature: 500 - 600°C
Exhaust gas temper-
Voltage 3.8 - 4.4 V
ature: 700 - 800°C
Voltage
Exhaust gas temper- 11.2 - 15.6
Between V30 (1) and ature: 300 - 400°C mV
sensor
Voltage
ature: 500 - 600°C 24.2 mV
Voltage
ature: 700 - 800°C 32.6 mV
WD600-6 40-307 23
Circuit diagram related to exhaust gas temperature sensor (R)
40-307 24 WD600-6
Failure code [DGT5KB] (or VHMS_LED display: "n3" → "21") Exhaust gas temperature sensor (R):
Failure code [DGT5KB] (or VHMS_LED display: "n3" → "21")

Exhaust gas temperature sensor (R): Short circuit 1
Action code Failure code Exhaust gas temperature sensor (R): Short circuit
Trouble
– DGT5KB (VHMS controller system) (Display: PLM)
Contents of • Input signal voltage from the exhaust gas temperature sensor on the engine rear side reads 4.9 V
trouble and above.
Action of
controller
Problem that
appears on • Monitoring function fails to monitor the exhaust gas temperature on the engine rear side
machine
Related • The input state (temperature) from the exhaust gas temperature sensor (R) can be checked with
information the monitoring function (Code: 42611 EXHAUST TEMP R).

Defective exhaust gas tem- 2) Disconnect connectors V30, V28 and V12 sequentially one by
perature sensor on engine one.
rear side, or defective 3) Turn the starting switch to ON position and perform trouble-
1 exhaust gas temperature shooting.
sensor amplifier on engine 4) Return to step 1) and conduct the test three times to locate the
rear side, or defective inter- failed portion.
mediate wiring harness. If failure code [DGT5KB] changed to [DGT5KA], the defective por-
tion must be ahead (on the right side of the disconnected connector
in the related circuit diagram).
2) Disconnect connectors V12, V01 and V02 and connect T-adapter
Possible causes Short circuit in wiring har-
2 to V12 (female).
and standard ness
value in normal Resis-
Between V12 (female) (A) and (B) Min. 1 Mz
state tance
2) Disconnect connector V12.
Hot short in wiring harness 3) Insert T-adapter into V02 or connect T-adapter to V12 (female).
3 4) Start engine and carry out troubleshooting.
Between V12 (female) (B) or V02 (5) and
Voltage Max. 1 V
chassis ground
2) Disconnect connectors V12, V28, V02.
Grounding fault in wiring har- 3) Connect T-adapter to anyone (female).
4 ness Between V12 (female) (B) or V02 (female) Resis-
Min. 1 Mz
(Contact with ground circuit) (5) and chassis ground tance
Between V28 (female) (1) or (2) and chassis Resis-
Min. 1 Mz
ground tance
WD600-6 40-307 25
SEN05057-01 Short circuit

Exhaust gas temper-
Voltage 1.0 - 1.6 V
Voltage 2.1 - 2.7 V
the engine rear side Between V12 (B) and ature: 300 - 400°C
Voltage 2.9 - 3.6 V
ature: 500 - 600°C
Exhaust gas temper-
Voltage 3.8 - 4.4 V
ature: 700 - 800°C
a Reference
Possible causes 1) Turn starting switch OFF.
and standard 2) Insert T-adapter into connector V02.
value in normal 3) Start engine and carry out troubleshooting.
state
Voltage 1.0 - 1.6 V
ature: 50 - 100°C
Exhaust gas temper-
Voltage 2.1 - 2.7 V
Voltage 2.9 - 3.6 V
ature: 500 - 600°C
Exhaust gas temper-
Voltage 3.8 - 4.4 V
ature: 700 - 800°C
Characteristic of temperature Voltage
Ref in exhaust gas temperature
sensor Between V30 (1) and Exhaust gas temper- 11.2 -
Voltage
(2) ature: 300 - 400°C 15.6 mV
Voltage
ature: 500 - 600°C 24.2 mV
40-307 26 WD600-6
WD600-6 40-307 27
SEN05057-01 Failure code [DH21KA] Work equipment pump oil pressure sensor: Disconnection
Failure code [DH21KA] Work equipment pump oil pressure sensor:

Disconnection 1
Action code Failure code Work equipment pump oil pressure sensor: Disconnection
Trouble
E01 DH21KA (Work equipment controller system)
• Due to disconnection or grounding fault in the work equipment oil pressure sensor system, the sig-
Contents of
nal voltage is lower than normal range
trouble
(Work equipment pump oil pressure sensor signal voltage: Max. 0.3 V)
Action of • Judges that work equipment pump oil pressure reads 0
Problem that
• Remote positioner inaccuracy of stopping
appears on
• When work equipment is relieved, cut-off does not function
machine
• The input state (oil pressure) from the work equipment pump oil pressure sensor can be checked
with the monitoring function (Code: 94700 PUMP PRESS).
Related
• The input state (voltage) from the work equipment pump oil pressure sensor can be checked with
information
the monitoring function (Code: 94701 PUMP PRESS).
• Method of reproducing failure code: Start engine and relieve blade tilt

If failure code [DB95KX] is also displayed, perform troubleshooting
for it first.
2. Disconnect connector F16, and connect T-adapter to female side.
Defective 5V sensor power
supply system
a If power supply voltage is abnormal, proceed to troubleshooting
for cause 3.
Between F16 (female) (B) and Power 4.5 – 5.5
Voltage
(A) supply V
2. Insert T-adapter into connector F16.
Defective work equipment 4. Start engine, tilt the blade and carry out troubleshooting.
pump oil pressure sensor 0.50 –
2 Always Voltage
(Internal disconnection or 4.50 V
Possible causes
short circuit) Between F16 (C) and 0.50 –
and standard Neutral Voltage
value in normal (A) 0.90 V
state When blade tilt 3.02 –
Voltage
relieved 3.42 V
2. Disconnect connectors L05 and F16, and connect T-adapters to
each female side.
Between L05 (female) (2) and F16 (female) Resis-
Max. 1 z
(C) tance
Disconnection in wiring har- a If power supply voltage measured in
ness check on cause 1 is normal, this check is
Resis-
3
(Disconnection or defective not required. Max. 1 z
tance
contact of connector) Between L05 (female) (21) and F16
(female) (A)
Resis-
tance
Between L05 (female) (22) and F16
(female) (B)
40-307 28 WD600-6
Failure code [DH21KA] Work equipment pump oil pressure sensor: Disconnection SEN05057-01

2. Disconnect connectors L05 and F16, and connect T-adapter to
Possible causes
4 ness Between L05 (female) (2) or F16 (female) Resis-
(Contact with ground circuit) (C) and chassis ground tance
value in normal
state Between L05 (female) (22) or F16 (female) Resis-
Min. 1 Mz
(B) and chassis ground tance
If no failure is found by above checks, work equipment controller is
5 defective. (Since this is an internal defect, troubleshooting cannot
controller
be performed.)
Circuit diagram related to work equipment pump oil pressure sensor
WD600-6 40-307 29
SEN05057-01 Failure code [DH21KB] Work equipment pump oil pressure sensor: Short circuit
Failure code [DH21KB] Work equipment pump oil pressure sensor:

Short circuit 1
Action code Failure code Work equipment pump oil pressure sensor: Short circuit
Trouble
E01 DH21KB (Work equipment controller system)
• Due to hot short circuit in the work equipment pump oil pressure sensor signal system, the signal
Contents of
voltage is higher than normal range
trouble
(Work equipment pump oil pressure sensor signal voltage: Min. 4.7 V)
Action of • Judges that work equipment pump oil pressure is higher
Problem that
• Remote positioner inaccuracy of stopping
appears on
• Cut-off function does not work when work equipment system is relieved.
machine
• The input state (oil pressure) from the work equipment pump oil pressure sensor can be checked
with the monitoring function (Code: 94700 PUMP PRESS).
Related
• The input state (voltage) from the work equipment pump oil pressure sensor can be checked with
information
the monitoring function (Code: 94701 PUMP PRESS).
• Method of reproducing failure code: Start engine and relieve blade tilt

2. Insert T-adapter into connector F16.
Defective work equipment 0.50 –
Always Voltage
1 pump oil pressure sensor 4.50 V
(Internal short circuit) Between F16 (C) and 0.50 –
Neutral Voltage
Possible causes (A) 0.90 V
and standard When blade tilt 3.02 –
value in normal Voltage
relieved 3.42 V
state
2. Disconnect connector F16.
Hot short in wiring harness
2 3. Connect T-adapter to female side of connector F16.
Between F16 (female) (C) and (A) Voltage Max. 1 V
controller
be performed.)
40-307 30 WD600-6
Failure code [DH21KB] Work equipment pump oil pressure sensor: Short circuit SEN05057-01
Circuit diagram related to work equipment pump oil pressure sensor
WD600-6 40-307 31
SEN05057-01 Failure code [DHE5KB] (or VHMS_LED display: “n3” → “32”) Blow-by pressure sensor: Short circuit
Failure code [DHE5KB] (or VHMS_LED display: “n3” → “32”)

Blow-by pressure sensor: Short circuit 1
Action code Failure code Blow-by pressure sensor: Short circuit

Trouble
— DHE5KB (VHMS controller system)
Contents of
• Input signal voltage from the blow-by pressure sensor reads 0.1 V or less.
trouble
Action of
controller
Problem that
appears on • Monitoring function fails to monitor the blow-by pressure
machine
Related • The input state (pressure) from the blow-by pressure sensor can be checked with the monitoring
information function (Code: 42801 BLOWBY PRESS).
• If failure code [DBB5KP] (VHMS controller 5V power supply output: Low output voltage) is dis-
• Method of reproducing failure code: Start engine and performs troubleshooting

2. Disconnect connector V25, and connect T-adapters to female
side.
1
for cause 3.
Between V25 (female) (B) and Power 4.5 – 5.5
Voltage
(A) supply V
4. Start engine and carry out troubleshooting.
Defective blow-by pressure 0.50 –
Always Voltage
sensor Between V25 (C) and 4.50 V
2
(Internal disconnection or (A) 0.50 –
Possible causes High idle Voltage
short circuit) 0.90 V
and standard
value in normal a If power supply voltage is normal and sensor output voltage is
state abnormal, it is difficult to judge whether cause is ground fault or
ing harness.
Resis-
Disconnection in wiring har- not required. Max. 1 z
tance
ness Between V01 (female) (5) and V25 (female)
3
(Disconnection or defective (B)
contact of connector) Between V25 (female) (C) and V02 (female) Resis-
Max. 1 z
(18) tance
check on cause 1 is normal, this check is Resis-
Max. 1 z
not required. tance
Between V25 (female) (A) and chassis ground
40-307 32 WD600-6
Failure code [DHE5KB] (or VHMS_LED display: “n3” → “32”) Blow-by pressure sensor: Short circuit SEN05057-01

Grounding fault in wiring har- adapter to either female side.
Possible causes
4 ness Between V01 (female) (5) or V25 (female) Resis-
(Contact with ground circuit) (B) and chassis ground tance
value in normal
state Between V25 (female) (C) or V02 (female) Resis-
Min. 1 Mz
If no failure is found by above checks, VHMS controller is defective.
5 Defective VHMS controller (Since this is an internal defect, troubleshooting cannot be per-
formed.)
Circuit diagram related to blow-by pressure sensor
WD600-6 40-307 33
Failure code [DHE5KY] (or VHMS_LED display: “n3” → “31”) Blow-by pressure sensor: Short circuit
SEN05057-01 with power supply line
Failure code [DHE5KY] (or VHMS_LED display: “n3” → “31”)

Blow-by pressure sensor: Short circuit with power supply line 1
Action code Failure code Blow-by pressure sensor: Short circuit with power supply line
Trouble
— DHE5KY (VHMS controller system)
Contents of
• Input signal voltage from the blow-by pressure sensor reads 4.7 V and above.
trouble
Action of
controller
Problem that
appears on • Monitoring function fails to monitor the blow-by pressure
machine
Related • The LED of the VHMS controller displays “n3” o “31”.
information • The input state (pressure) from the blow-by pressure sensor can be checked with the monitoring
function (Code: 42801 BLOWBY PRESS).
• Method of reproducing failure code: Start engine and performs troubleshooting

2. Insert T-adapters into connector V25.
4. Start engine and carry out troubleshooting.
0.50 –
Defective blow-by pressure Always Voltage
Between V25 (C) and 4.50 V
1 sensor
(Internal short circuit) (A) 0.50 –
High idle Voltage
0.90 V
Possible causes
and standard a If power supply voltage is normal and sensor output voltage is
value in normal abnormal, it is difficult to judge whether cause is ground fault or
state hot short circuit of harness. Judge after troubleshooting for wir-
ing harness.
2 3. Connect T-adapter to female side of V25.
Between V25 (female) (C) and (A) Voltage Max. 1 V
If no failure is found by above checks, VHMS controller is defec-
3 Defective VHMS controller tive. (Since this is an internal defect, troubleshooting cannot be
performed.)
40-307 34 WD600-6
Failure code [DHE5KY] (or VHMS_LED display: “n3” → “31”) Blow-by pressure sensor: Short circuit
with power supply line SEN05057-01
Circuit diagram related to blow-by pressure sensor
WD600-6 40-307 35
Failure code [DHT2L6] Transmission filter clogging sensor: Signal disagrees with operating state of
SEN05057-01 engine
Failure code [DHT2L6] Transmission filter clogging sensor: Signal

disagrees with operating state of engine 1
Action code Failure code Transmission filter clogging sensor: Signal disagrees with operat-
Trouble
E01 DHT2L6 ing state of engine (Machine monitor system)
Contents of • Due to abnormal transmission clogging sensor signal, transmission clogging sensor signal voltage
trouble does not agree with the engine operation or stopping in normal condition.
Action of
• If cause of failure disappears, system resets itself.
controller
Problem that
appears on • The transmission filter clogging caution lamp does not light up.
machine
• The input state (ON/OFF) from the transmission filter clogging sensor can be checked with the mon-
Related
itoring function (Code: 40903 D-IN-24).
information
• Method of reproducing failure code: Start engine and drive the machine in high idle

2) Disconnect connector B09.
Defective transmission clog- 3) Connect T-adapter.
ging sensor
1 Resis-
(Internal disconnection or Filter is normal Max. 1 z
Between B09 (male) tance
short circuit)
(1) and (2) Resis-
Filter is clogged Min. 1 Mz
tance
2) Disconnect connectors C03 and B09.
Disconnection in wiring har- 3) Connect T-adapter.
ness
2 Between C03 (female) (5) and B09 (female) Resis-
(1) tance
Resis-
Possible causes Between B09 (male) (2) and chassis ground Max. 1 z
tance
and standard
state Grounding fault in wiring har- 2. Disconnect connectors B09 and C03, and connect T-adapter to
(Contact with ground circuit) Between C03 (female) (5) or B09 (female) Resis-
Min. 1 Mz
2. Disconnect connector B09, and connect T-adapter to female
Hot short in wiring harness side.
4
(Contact with 24 V circuit) 3. Turn starting switch to ON position.
Between B09 (female) (1) and (2) Voltage Max. 1 V
2) Disconnect connectors C03 and insert T-adapter into connector
C03.
5 Defective machine monitor 3) Turn the starting switch ON.
Between C03 (5) and Filter is normal Voltage Max. 1V
chassis ground Filter is clogged Voltage Min. 7 V
40-307 36 WD600-6
Failure code [DHT2L6] Transmission filter clogging sensor: Signal disagrees with operating state of
engine SEN05057-01
Circuit diagram related to transmission clogging sensor
WD600-6 40-307 37
Failure code [DHT8KX] (or VHMS_LED display: “n5” → “33”) Steering oil pressure sensor: Out of
SEN05057-01 input signal range
Failure code [DHT8KX] (or VHMS_LED display: “n5” → “33”)

Steering oil pressure sensor: Out of input signal range 1
Action code Failure code Steering oil pressure sensor: Out of input signal range
Trouble
— DHT8KX (VHMS controller system)
Contents of
• Input signal voltage from the steering oil pressure sensor reads 4.9 V and above or less than 0.3 V.
trouble
Action of
controller
Problem that
appears on • Monitoring function fails to monitor the steering oil pressure
machine
• The LED of the VHMS controller displays “n5” o “33”
Related • The input state (oil pressure) from the steering oil pressure sensor can be checked with the monitor-
information ing function (Code: 93000 S/T OIL PRESS).

side.
1
for cause 3.
Between V23 (female) (B) and Power 4.85 –
Voltage
(A) supply 5.15 V
Possible causes
and standard
state 4. Operate steering, and carry out troubleshooting.
0.50 –
Always Voltage
4.50 V
Defective steering oil pres-
2 sure sensor (Internal discon- Between V23 (male) Neutral Voltage
0.50 –
nection or short circuit) (C) and (A) 0.90 V
3.2 – 3.4
When relieved Voltage
V
ing harness.
40-307 38 WD600-6
input signal range SEN05057-01

Resis-
Disconnection in wiring har- tance
Between V01 (female) (5) and V23 (female)
ness
3 (8)
contact of connector) a If power supply voltage measured in
Resis-
tance
Possible causes (C)
and standard Between V23 (female) (A) and chassis Resis-
value in normal Max. 1 z
ground tance
state
Grounding fault in wiring har- 2. Disconnect connectors V01, V02 and V23, and connect T-
4 ness adapter to either female side.
(Contact with ground circuit) Between V02 (female) (16) or V23 (female) Resis-
Min. 1 Mz
(C) and chassis ground tance
5 3. Connect T-adapter to female side of connector V23.
performed.)
WD600-6 40-307 39
SEN05057-01 input signal range
Circuit diagram related to steering oil pressure sensor
40-307 40 WD600-6
input signal range SEN05057-01
WD600-6 40-307 41
SEN05057-01 Failure code [DHTBKA] Modulation clutch oil pressure sensor: Disconnection
Failure code [DHTBKA] Modulation clutch oil pressure sensor:

Disconnection 1
Action code Failure code Modulation clutch oil pressure sensor: Disconnection
Trouble
E03 DHTBKA (Transmission controller system)
• Due to disconnection or ground fault in modulation clutch oil pressure sensor system, modulation
Contents of
clutch oil pressure signal voltage is lower than normal range (Modulation clutch oil pressure sensor
trouble
signal voltage: Max. 0.3 V).
• Uses modulation clutch oil pressure signal value output immediately before abnormality occurs.
Action of • Keeps the directional lever or directional selector switch in N (Neutral) to prevent cut off resetting.
controller • Even if cause of failure disappears, system does not reset itself until directional selector switch is
set to N (Neutral).
Problem that
appears on • Keeps the directional lever or directional selector switch in N (Neutral) to prevent cut off resetting.
machine
• The input state (pressure) from the modulation clutch oil pressure sensor can be checked with the
monitoring function (Code: 92400 MOD/C PRESS).
Related
• The input state (voltage) from the modulation clutch oil pressure sensor can be checked with the
information
• Method of reproducing failure code: Start engine and drive the machine

2. Disconnect connector T03, and connect T-adapter to female
side.
1
for cause 3.
Between T03 (female) (B) and Power
Voltage 20 – 30 V
(A) supply
Between T03 (male) (A), (B), (C) and Resis-
chassis ground tance
and standard
state 2. Insert T-adapter into connector T03.
Defective modulation clutch 4. Start engine, travel and carry out troubleshooting.
oil pressure sensor
2 Modulation clutch oil
(Internal disconnection or 0.9 – 1.2
pressure: Voltage
short circuit) V
Between T03 (B) 0 MPa {0 kg/cm²}
and (A) Modulation clutch oil
pressure: Voltage 5V
4.9 MPa {50 kg/cm²}
ing harness.
40-307 42 WD600-6
Failure code [DHTBKA] Modulation clutch oil pressure sensor: Disconnection SEN05057-01

2. Disconnect connectors L02 and T03, and connect T-adapters to
each female side.
Resis-
Between L02 (female) (8) and T03 (female)
ness
3 (C)
contact of connector) a If power supply voltage measured in
Resis-
Possible causes not required. Max. 1 z
tance
and standard Between L02 (female) (16) and T03 (female)
value in normal (B)
state Between L02 (female) (21) and T03 (female) Resis-
Max. 1 z
(A) tance
2. Disconnect connectors L02 and T03, and connect T-adapter to
4 ness Between L02 (female) (8) or T03 (female) Resis-
(Contact with ground circuit) (C) and chassis ground Max. 1 z
tance
Between L02 (female) (16) or T03 (female) Resis-
Max. 1 z
(B) and chassis ground tance
If no failure is found by above checks, transmission controller is
troller
be performed.)
Circuit diagram related to modulation clutch oil pressure sensor
WD600-6 40-307 43
SEN05057-01 Failure code [DHTBKB] Modulation clutch oil pressure sensor: Short circuit
Failure code [DHTBKB] Modulation clutch oil pressure sensor: Short

circuit 1
Action code Failure code Modulation clutch oil pressure sensor: Short circuit
Trouble
E03 DHTBKB (Transmission controller system)
Contents of • Due to hot short circuit in the modulation clutch oil pressure sensor system, the modulation clutch oil
trouble pressure sensor detect pressure is higher than normal range
• Uses modulation clutch oil pressure signal value output immediately before abnormality occurs.
• Keeps the directional lever or directional selector switch in N (Neutral) to prevent cut off resetting.
Action of
controller
set to N (Neutral).
Problem that
appears on • Keeps the directional lever or directional selector switch in N (Neutral) to prevent cut off resetting.
machine
• The input state (pressure) from the modulation clutch oil pressure sensor can be checked with the
Related
• The input state (voltage) from the modulation clutch oil pressure sensor can be checked with the
information
• Method of reproducing failure code: Start engine and drive the machine

Between T03 (male) (A), (B), (C) and Resis-
Min. 1 Mz
2. Insert T-adapter into connector T03.
Defective modulation clutch 4. Start engine, travel and carry out troubleshooting.
1 oil pressure sensor (Internal Modulation clutch oil
0.9 – 1.2
short circuit) pressure: Voltage
V
Between T03 (B) 0 MPa {0 kg/cm²}
Possible causes and (A) Modulation clutch oil
and standard pressure: Voltage 5V
value in normal 4.9 MPa {50 kg/cm²}
state
ing harness.
2. Disconnect connector T03.
Hot short in wiring harness 3. Connect T-adapter to female side of connector T03.
Between T03 (female) (C) and (A) Voltage Max. 1 V
Between T03 (female) (B) and (A) Voltage Max. 1 V
troller
be performed.)
40-307 44 WD600-6
Failure code [DHTBKB] Modulation clutch oil pressure sensor: Short circuit SEN05057-01
Circuit diagram related to modulation clutch oil pressure sensor
WD600-6 40-307 45
Failure code [DHU2KX] (or VHMS_LED display: “n7” → “11”) Front brake oil pressure sensor (F): Out
Failure code [DHU2KX] (or VHMS_LED display: “n7” → “11”)

Front brake oil pressure sensor (F): Out of input signal range 1
Action code Failure code Front brake oil pressure sensor: Out of input signal range
Trouble
— DHU2KX (VHMS controller system)
Contents of • Input signal voltage from the front brake oil pressure sensor reads 4.9 V and above or less than 0.3
trouble V.
Action of
controller
Problem that
appears on • Monitoring function fails to monitor the brake signal
machine
Related • The input state (ON/OFF) from the brake oil pressure sensor can be checked with the monitoring
information function (Code: 92900 BRAKE SIG).

side.
1
for cause 3.
Voltage
(1) supply 5.15 V
0.50 –
Always Voltage
Defective front brake oil 4.50 V
pressure sensor (Internal Between V14 (C) and
2 (A) When front brake
disconnection or short cir- 0.50 –
accumulator Voltage
Possible causes cuit) 0.90 V
oil pressure: 0 (MPa)
ing harness.
2. Disconnect connectors V02 and V14, and connect T-adapters
to each female side.
Resis-
ness
3 (B)
Between V02 (female) (8) and V14 (female) Resis-
(C) tance
Resis-
tance
Between V14 (female) (A) and chassis
ground
40-307 46 WD600-6
Failure code [DHU2KX] (or VHMS_LED display: “n7” → “11”) Front brake oil pressure sensor (F): Out

Grounding fault in wiring har- 2. Disconnect connectors V02 and V14, and connect T-adapter to
Min. 1 Mz
Possible causes (C) and chassis ground tance
value in normal 2. Disconnect connector V14.
state Hot short in wiring harness
performed.)
Circuit diagram related to the front brake oil pressure sensor
WD600-6 40-307 47
Failure code [DHU3KX] (or VHMS_LED display: “n7” → “12”) Rear brake oil pressure sensor (R): Out
Failure code [DHU3KX] (or VHMS_LED display: “n7” → “12”)

Rear brake oil pressure sensor (R): Out of input signal range 1
Action code Failure code Rear brake oil pressure sensor: Out of input signal range
Trouble
— DHU3KX (VHMS controller system)
Contents of • Input signal voltage from the rear brake oil pressure sensor reads 4.9 V and above or less than 0.3
trouble V.
Action of
controller
Problem that
appears on • Monitoring function fails to monitor the brake signal
machine
Related • The input state (ON/OFF) from the brake oil pressure sensor can be checked with the monitoring
information function (Code: 92900 BRAKE SIG).
• If failure code [DBB5KP] (VHMS controller 5V power supply output: Low output voltage) is dis-

side.
1
for cause 3.
Voltage
(A) supply 5.15 V
0.50 –
Always Voltage
4.50 V
Defective rear brake oil pres- Between V13 (C) and
2 sure sensor (Internal discon- (A) When rear brake
0.50 –
nection or short circuit) accumulator Voltage
Possible causes 0.90 V
pressure: 0 (MPa)
ing harness.
2. Disconnect connectors V02 and V13, and connect T-adapters to
each female side.
Resis-
ness
3 (B)
Between V02 (female) (6) and V13 (female) Resis-
(C) tance
Resis-
tance
Between V13 (female) (A) and chassis
ground
40-307 48 WD600-6
Failure code [DHU3KX] (or VHMS_LED display: “n7” → “12”) Rear brake oil pressure sensor (R): Out

Grounding fault in wiring har- 2. Disconnect connectors V02 and V13, and connect T-adapter to
Min. 1 Mz
Possible causes (C) and chassis ground tance
value in normal 2. Disconnect connector V13.
state Hot short in wiring harness
If no failure is found by above checks, VHMS controller is defective.
6 Defective VHMS controller (Since this is an internal defect, troubleshooting cannot be per-
formed.)
Circuit diagram related to the rear brake oil pressure sensor
WD600-6 40-307 49
SEN05057-01 Failure code [DK30KA] AJSS lever angle sensor: Disconnection
Failure code [DK30KA] AJSS lever angle sensor: Disconnection 1
Action code Failure code AJSS lever angle sensor: Disconnection

Trouble
E01 DK30KA (Work equipment controller system)
Contents of • Due to disconnection or ground fault in AJSS lever angle sensor system, AJSS lever angle signal
trouble voltage is lower than normal range (AJSS angle sensor signal voltage: Max. 0.3 V).
• Judges that AJSS is operated to the left
Action of • Stops the steering neutral safety function
controller • Controls AJSS EPC output to the level corresponding to 1.47 MPa {15 kg/cm2}
Problem that • The engine does not start.
appears on • Steering fine control is disabled (the machine jounces when performing steering operation).
machine • Disabled to swing at full speed
• The input state (voltage) from the AJSS lever angle sensor can be checked with the monitoring
function (Code: 94300 AJSS LEVER, 94301 AJSS LEVER).
Related
• Method of reproducing failure code: Turn the starting switch ON and operate AJSS
information
• This error is not displayed on a steering wheel specification machine. If it is displayed, select “NO
ADD” AJSS option in option setting.

for it first.
Defective 5V sensor power side.
1
for cause 3.
Between S30 (female) (B) and Power 4.85 –
Voltage
(C) supply 5.15 V
Resis- 5 kz ± 20
Between S30 (male) (B) and (C)
tance %
Possible causes Between S30 (male) (A), (B), (C) and Resis-
Min. 1 Mz
and standard chassis ground tance
value in normal
state
4. Operate AJSS lever, and carry out troubleshooting (steering
Defective AJSS angle sensor lock).
2 (Internal disconnection or 0.30 –
short circuit) Normal Voltage
4.70 V
2.20 –
Lever in neutral Voltage
Between S30 (A) and 2.80 V
(C) Full steering to right 2.83 –
Voltage
(straight travel state) 3.83 V
Full steering to left 1.17 –
Voltage
ing harness.
40-307 50 WD600-6
Failure code [DK30KA] AJSS lever angle sensor: Disconnection SEN05057-01

each female side.
Max. 1 z
(A) tance

Resis-
3
(Disconnection in wiring har- not required. Max. 1 z
tance
ness and defective contact) Between L05 (female) (21) and S30 (female)
Possible causes (C)
and standard a If power supply voltage measured in
value in normal check on cause 1 is normal, this check is
Resis-
state not required. Max. 1 z
tance
(B)
Grounding fault in wiring har- 2. Disconnect connectors L05 and S30, and connect T-adapter to
Min. 1 Mz
(A) and chassis ground tance
controller
be performed.)
Circuit diagram related to AJSS lever angle sensor
WD600-6 40-307 51
SEN05057-01 Failure code [DK30KY] AJSS lever angle sensor: Short circuit with power supply line
Failure code [DK30KY] AJSS lever angle sensor: Short circuit with
power supply line 1
Action code Failure code AJSS lever angle sensor: Short circuit with power supply line
Trouble
E01 DK30KY (Work equipment controller system)
• Due to hot short circuit in the AJSS lever angle sensor system, the AJSS lever angle signal voltage
Contents of
is higher than normal range
trouble
(AJSS lever angle sensor signal voltage: Min. 4.7 V)
• Judges that AJSS lever is operated to the right
Action of • Stops the AJSS neutral safety function
controller • Controls AJSS EPC output to the level corresponding to 1.47 MPa {15 kg/cm2}
Problem that • Once the engine stops, the engine does not start.
appears on • Steering fine control is disabled (the machine jounces when performing steering operation).
machine • Disabled to swing at full speed
• The input state (voltage) from the AJSS lever angle sensor can be checked with the monitoring
function (Code: 94300 AJSS LEVER, 94301 AJSS LEVER).
Related
• Method of reproducing failure code: Turn the starting switch ON and operate AJSS lever
information

Resis- 5 kz ± 20
tance %
Between S30 (male) (A), (B), (C) and Resis-
Min. 1 Mz
lock).
Defective AJSS angle sensor
1 0.30 –
(Internal short circuit) Normal Voltage
4.70 V
Possible causes 2.20 –
and standard Between S30 (A) and 2.80 V
value in normal (C) Full steering to right 2.83 –
state Voltage
Voltage
ing harness.
Hot short in wiring harness 3. Connect T-adapter to female side of connector S30.
2
Between S30 (female) (A) and (C) Voltage Max. 1 V
controller
be performed.)
40-307 52 WD600-6
Failure code [DK30KY] AJSS lever angle sensor: Short circuit with power supply line SEN05057-01
Circuit diagram related to AJSS lever angle sensor
WD600-6 40-307 53
SEN05057-01
WD600-6 Wheel dozer

©2016 KOMATSU
All Rights Reserved
40-307 54
SEN05058-01
WHEEL DOZER
WD600-6

WD600-6 55001 and up

Failure code [DK59KA] Lift EPC lever potentiometer (Main): Disconnection.................................................. 3
Failure code [DK59KY] Lift EPC lever potentiometer (Main): Short circuit with power supply line ................. 6
Failure code [DK59L8] Lift EPC lever potentiometer (Main): Analog signals disagree ................................... 8
Failure code [DK5AKA] Lift EPC lever potentiometer (Sub): Disconnection..................................................11
Failure code [DK5AKY] Lift EPC lever potentiometer (Sub): Short circuit with power supply line ................ 14
Failure code [DK5BKA] Tilt & pitch EPC lever potentiometer (Main): Disconnection ................................... 16
Failure code [DK5BKY] (Tilt & pitch EPC lever potentiometer (Main):
Short circuit with power supply line).......................................................................................................... 20
Failure code [DK5BL8] Tilt & pitch EPC lever potentiometer (Main): Analog signals disagree..................... 22
Failure code [DK5CKA] Tilt & pitch EPC lever potentiometer (Sub): Disconnection..................................... 25
Failure code [DK5CKY] Tilt & pitch EPC lever potentiometer (Sub): Short circuit with power supply line .... 28
Failure code [DKD0KA] Frame angle sensor: Disconnection ....................................................................... 30
Failure code [DKD0KY] Frame angle sensor: Short circuit with power supply line....................................... 32
Failure code [DKD0KZ] AJSS lever and frame angle sensor: Disconnection or short circuit ....................... 34
Failure code [DLFAKA] Modulation clutch output shaft speed sensor: Disconnection ................................. 38
Failure code [DLFALC] Modulation clutch output shaft speed sensor: Speed signals disagree ................... 40
Failure code [DLT3KA] Transmission output shaft speed sensor (2): Disconnection ................................... 42
Failure code [DLT3LC] Transmission output shaft speed sensor (2): Speed signals disagree ..................... 44
Failure code [DLT4KB] Transmission output shaft speed sensor (1): Short circuit ....................................... 46
Failure code [DLT4KX] Transmission output shaft speed sensor (1): Out of input signal range................... 48
Failure code [DV00KB] Alarm buzzer: Short circuit ...................................................................................... 50
WD600-6 40-308 1
SEN05058-01
Failure code [DW4PKA] Blade raise EPC solenoid: Disconnection.............................................................. 52

Failure code [DW4PKB] Blade raise EPC solenoid: Short circuit ................................................................. 54
Failure code [DW4PKY] Blade raise EPC solenoid: Short circuit with power supply line ............................. 55
Failure code [DW4QKA] Blade lower EPC solenoid: Disconnection............................................................. 56
Failure code [DW4QKB] Blade lower EPC solenoid: Short circuit ................................................................ 57
Failure code [DW4QKY] Blade lower EPC solenoid: Short circuit with power supply line ............................ 58
Failure code [DW4RKA] Tilt & pitch EPC solenoid: Disconnection ............................................................... 59
Failure code [DW4RKB] Tilt & pitch EPC solenoid: Short circuit................................................................... 60
Failure code [DW4RKY] Tilt & pitch EPC solenoid: Short circuit with power supply line .............................. 61
Failure code [DW4SKA] Tilt & pitch EPC solenoid: Disconnection ............................................................... 62
Failure code [DW4SKB] Tilt & pitch EPC solenoid: Short circuit................................................................... 63
Failure code [DW4SKY] Tilt & pitch EPC solenoid: Short circuit with power supply line............................... 64
Failure code [DW7BKA] Fan reverse solenoid: Disconnection ..................................................................... 66
Failure code [DW7BKB] Fan reverse solenoid: Short circuit......................................................................... 68
Failure code [DW7BKY] Fan reverse solenoid: Short circuit with power supply line .................................... 70
40-308 2 WD600-6
Failure code [DK59KA] Lift EPC lever potentiometer (Main): Disconnection SEN05058-01
Failure code [DK59KA] Lift EPC lever potentiometer (Main): Disconnection
Action code Failure code Lift EPC lever potentiometer (Main): Disconnection
Trouble
E03 DK59KA (Work equipment controller system)
• Due to disconnection or grounding fault in the lift EPC lever potentiometer system, the signal volt-
Contents of
age is lower than normal range
trouble
(Lift EPC lever potentiometer (Main) signal voltage: Max. 0.3 V).
• If the lift EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
controller • Even if cause of failure disappears, system does not reset itself until lift EPC lever is set to N (Neu-
tral).
Problem that
appears on • Error is simply displayed.
machine
• The input state (voltage) from the lift EPC lever potentiometer (Main) can be checked with the mon-
itoring function (Code: 42000 BOOM POT1).
Related
• The input state (voltage) from the lift EPC lever potentiometer (Sub) can be checked with the moni-
information
toring function (Code: 42001 BOOM POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate lift lever

for it first.
1
for cause 3.
Between S02 (female) (4) and Power 4.85–
Voltage
(1) supply 5.15 V
Resis- 3.2 ± 0.64
Between S02 (male) (1) and (4)
tance kz
Possible causes
Between S02 (male) (1), (2), (3), (4) and Resis-
value in normal
Defective lift EPC lever 4. Operate lift lever, and carry out troubleshooting.
potentiometer 2.40 –
2 Lever in neutral Voltage
(Internal disconnection or 2.60 V
short circuit)
3.64 –
Raise operation Voltage
Between S02 (3) 4.14 V
and (1) Lower operation 0.86 –
Voltage
(Before detent) 1.36 V
0.64 –
Float operation Voltage
1.14 V
ing harness.
WD600-6 40-308 3
SEN05058-01 Failure code [DK59KA] Lift EPC lever potentiometer (Main): Disconnection

each female side.
Max. 1 z
(3) tance
Resis-
3
tance
Possible causes (1)
Resis-
tance
(4)
Min. 1 Mz
controller
be performed.)
40-308 4 WD600-6
Failure code [DK59KA] Lift EPC lever potentiometer (Main): Disconnection SEN05058-01
Circuit diagram related to lift EPC lever potentiometer
WD600-6 40-308 5
SEN05058-01 Failure code [DK59KY] Lift EPC lever potentiometer (Main): Short circuit with power supply line
Failure code [DK59KY] Lift EPC lever potentiometer (Main): Short circuit
with power supply line 1
Action code Failure code Lift EPC lever potentiometer (Main): Short circuit with the power
Trouble supply line
E03 DK59KY (Work equipment controller system)
• Due to hot short circuit in the lift EPC lever potentiometer (Main) system, the signal voltage is higher
Contents of
than normal range
trouble
(Lift EPC lever potentiometer (Main) signal voltage: Min. 4.7 V).
• If the lift EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
tral).
Problem that
machine
Related
information

Resis- 3.2 ± 0.64
tance kz
Min. 1 Mz
4. Operate lift lever, and carry out troubleshooting.
Defective lift EPC lever
1 potentiometer 2.40 –
(Internal short circuit) 2.60 V

and standard Between S02 (3) 4.14 V
value in normal and (1) Lower operation 0.86 –
Voltage
state (Before detent) 1.36 V
0.64 –
1.14 V
ing harness.
2 3. Connect T-adapter to female side of connector S02.
Between S02 (female) (3) and (1) Voltage Max. 1 V
controller
be performed.)
40-308 6 WD600-6
Failure code [DK59KY] Lift EPC lever potentiometer (Main): Short circuit with power supply line SEN05058-01
WD600-6 40-308 7
SEN05058-01 Failure code [DK59L8] Lift EPC lever potentiometer (Main): Analog signals disagree
Failure code [DK59L8] Lift EPC lever potentiometer (Main): Analog

signals disagree 1
Action code Failure code Lift EPC lever potentiometer (Main): Analog signals disagree
Trouble
E03 DK59L8 (Work equipment controller system)
• Lift EPC lever potentiometer (Main and Sub) input signals disagree with each other.
Contents of
(Lift EPC lever potentiometer signal voltage (sum of Main and Sub): Max. 4.7 V) or
trouble
(Lift EPC lever potentiometer signal voltage (sum of Main and Sub): Min. 5.3 V)
• Cannot recognize the lift EPC lever position correctly.
• Operates with either Main or Sub potentiometer, whichever detecting a position within neutrality ±5
%, as the regular potentiometer.
Action of • Turns the output OFF if both Main and Sub potentiometers should fail to detect a position within
controller neutrality ±5 %.
• Even if cause of failure disappears, system does not reset itself until lift EPC lever is set to N (Neu-
tral).
• Work equipment moves with the lever set to neutral.
Problem that
• If either Main or Sub potentiometer is abnormal, machine operates normally after the lever is set to
appears on
neutral.
machine
• If both Main and Sub potentiometers are abnormal, lift cylinder does not move.
Related
information

for it first.
2. Disconnect connector S02, and connect T-adapter to female side.
supply system
for cause 3.
Between S02 (female) (4) and Power 4.85–
Voltage
(1) supply 5.15 V
Possible causes Resis- 3.2 ± 0.64
and standard tance kz
value in normal Between S02 (male) (1), (2), (3), (4) and Resis-
state Min. 1 Mz
Defective lift EPC lever 2. Insert T-adapter into connector S02.
potentiometer 3. Turn starting switch to ON position.
2
(Internal disconnection or 4. Operate lift lever, and carry out troubleshooting.
short circuit)
2.40 –
2.60 V
3.64 –
Between S02 (3) 4.14 V
and (1) Lower operation 0.86 –
Voltage
0.64 –
1.14 V
40-308 8 WD600-6
Failure code [DK59L8] Lift EPC lever potentiometer (Main): Analog signals disagree SEN05058-01

2.40 –
2.60 V
0.86 –
Between S02 (2) and 1.36 V
Defective lift EPC lever (1) Lower operation 3.64 –
Voltage
potentiometer (Before detent) 4.14 V
2
(Internal disconnection or 3.86 –
short circuit) Float operation Voltage
4.36 V
ing harness.
each female side.
Max. 1 z
(2) tance
Max. 1 z
Disconnection in wiring har- (3) tance
ness a If power supply voltage measured in
3
Possible causes (Disconnection in wiring har- check on cause 1 is normal, this check is
Resis-
and standard ness and defective contact) not required. Max. 1 z
tance
value in normal Between L05 (female) (21) and S02 (female)
state (1)
Resis-
tance
(4)
2. Disconnect connectors L05 and S02, and connect T-adapter to
4 ness Between L05 (female) (13) or S02 (female) Resis-
(Contact with ground circuit) (2) and chassis ground Min. 1 Mz
tance
Min. 1 Mz
If no failure is found by above checks, work equipment is defective.
6 (Since this is an internal defect, troubleshooting cannot be per-
controller
formed.)
WD600-6 40-308 9
SEN05058-01 Failure code [DK59L8] Lift EPC lever potentiometer (Main): Analog signals disagree
40-308 10 WD600-6
Failure code [DK5AKA] Lift EPC lever potentiometer (Sub): Disconnection SEN05058-01
Failure code [DK5AKA] Lift EPC lever potentiometer (Sub):

Disconnection 1
Action code Failure code Lift EPC lever potentiometer (Sub): Disconnection
Trouble
E03 DK5AKA (Work equipment controller system)
Contents of • Due to disconnection or grounding fault in the lift EPC lever potentiometer (Sub) system, the signal
trouble voltage is lower than normal range (Lift EPC lever potentiometer (Sub) signal voltage: Max. 0.3 V).
• If the lift EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Action of
controller
Problem that
appears on —
machine
Related
information

for it first.
1
for cause 3.
Voltage
(1) supply 5.15 V
Resis- 3.2 ± 0.64
tance kz
Possible causes Between S02 (male) (1), (2), (3), (4) and Resis-
Min. 1 Mz
state
Defective lift EPC lever 4. Operate lift lever, and carry out troubleshooting (work equip-
potentiometer ment lock).
2 2.40 –
(Internal disconnection or Lever in neutral Voltage
0.86 –
Between S02 (male) 1.36 V
(2) and (1) Lower operation 3.64 –
Voltage
3.86 –
4.36 V
ing harness.
WD600-6 40-308 11
SEN05058-01 Failure code [DK5AKA] Lift EPC lever potentiometer (Sub): Disconnection

each female side.
Max. 1 z
(2) tance
Resis-
3
tance
Possible causes (1)
Resis-
tance
(4)
Min. 1 Mz
controller
be performed.)
40-308 12 WD600-6
Failure code [DK5AKA] Lift EPC lever potentiometer (Sub): Disconnection SEN05058-01
WD600-6 40-308 13
SEN05058-01 Failure code [DK5AKY] Lift EPC lever potentiometer (Sub): Short circuit with power supply line
Failure code [DK5AKY] Lift EPC lever potentiometer (Sub): Short circuit
Action code Failure code Lift EPC lever potentiometer (Sub): Short circuit with the power
Trouble supply line
E03 DK5AKY (Work equipment controller system)
Contents of • Due to hot short circuit in the lift EPC lever potentiometer (Sub) system, the signal voltage is higher
trouble than normal range (Lift EPC lever potentiometer (Sub) signal voltage: Min. 4.7 V).
• If the lift EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
tral).
Problem that
appears on —
machine
Related
information

Resis- 3.2 ± 0.64
tance kz
Min. 1 Mz
4. Operate lift lever, and carry out troubleshooting (work equip-
Defective lift EPC lever
ment lock).
potentiometer
1 2.40 –
(Internal disconnection or Lever in neutral Voltage
and standard Raise operation Voltage
Between S02 (male) 1.36 V
value in normal (2) and (1) Lower operation 3.64 –
state Voltage
3.86 –
4.36 V
ing harness.
controller
be performed.)
40-308 14 WD600-6
Failure code [DK5AKY] Lift EPC lever potentiometer (Sub): Short circuit with power supply line SEN05058-01
WD600-6 40-308 15
SEN05058-01 Failure code [DK5BKA] Tilt & pitch EPC lever potentiometer (Main): Disconnection
Failure code [DK5BKA] Tilt & pitch EPC lever potentiometer (Main):
Disconnection 1
Action code Failure code Tilt & pitch EPC lever potentiometer (Main): Disconnection
Trouble
E03 DK5BKA (Work equipment controller system)
• Due to disconnection or grounding fault in the tilt & pitch EPC lever potentiometer (Main) system,
Contents of
the signal voltage is lower than normal range
trouble
(Tilt & pitch EPC lever potentiometer (Main) signal voltage: Max. 0.3 V).
• Judges that the tilt & pitch EPC lever was fully operated in the dumping direction.
• If the tilt & pitch EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
Action of
controller
• Even if cause of failure disappears, system does not reset itself until tilt & pitch EPC lever is set to N
(Neutral).
Problem that
machine
• The input state (voltage) from the tilt & pitch EPC lever potentiometer (Main) can be checked with
the monitoring function (Code: 42002 BUCKET POT1).
Related
• The input state (voltage) from the tilt & pitch EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42003 BUCKET POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate tilt & pitch lever

for it first.
1
for cause 3.
Voltage
(1) supply 5.15V
Possible causes
and standard Resis- 3.2 ± 0.64
value in normal tance kz
state Between S02 (male) (5), (6), (7), (8) and Resis-
Min. 1 Mz
Defective tilt & pitch EPC
lever potentiometer
(Internal disconnection or
short circuit) 4. Operate tilt & pitch lever, and carry out troubleshooting (work
equipment lock)
2.40 –
2.60 V
Between S02 (7) and Tilt & pitch operation 3.64 –
Voltage
(5) (Before detent) 4.14 V
Full tilt & pitch opera- 0.69 –
Voltage
tion 1.14 V
40-308 16 WD600-6
Failure code [DK5BKA] Tilt & pitch EPC lever potentiometer (Main): Disconnection SEN05058-01

each female side.
Max. 1 z
(7) tance
3 Resis-
tance
Possible causes (5)
Resis-
tance
(8)
Min. 1 Mz
controller
be performed.)
WD600-6 40-308 17
SEN05058-01 Failure code [DK5BKA] Tilt & pitch EPC lever potentiometer (Main): Disconnection
Circuit diagram related to tilt & pitch EPC lever potentiometer
40-308 18 WD600-6
Failure code [DK5BKA] Tilt & pitch EPC lever potentiometer (Main): Disconnection SEN05058-01
WD600-6 40-308 19
Failure code [DK5BKY] Tilt & pitch EPC lever potentiometer (Main): Short circuit with power supply
SEN05058-01 line
Failure code [DK5BKY] Tilt & pitch EPC lever potentiometer (Main):
Action code Failure code Tilt & pitch EPC lever potentiometer (Main): Short circuit with the
Trouble power supply line
E03 DK5BKY (Work equipment controller system)
• Due to hot short circuit in the tilt & pitch EPC lever potentiometer (Main) system, the signal voltage is
Contents of
higher than normal range
trouble
(Tilt & pitch EPC lever potentiometer (Main) signal voltage: Min. 4.7 V).
• Judges that the tilt & pitch EPC lever was fully operated in the tilting direction.
• If the tilt & pitch EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
Action of
controller
(Neutral).
Problem that
machine
Related
information

Resis- 3.2 ± 0.64
tance kz
Min. 1 Mz
lever potentiometer
Possible causes equipment lock)
and standard 2.40 –
value in normal 2.60 V
state Between S02 (7) and Tilt & pitch operation 3.64 –
Voltage
Voltage
tion 1.14 V
controller
be performed.)
40-308 20 WD600-6
Failure code [DK5BKY] Tilt & pitch EPC lever potentiometer (Main): Short circuit with power supply
line SEN05058-01
WD600-6 40-308 21
SEN05058-01 Failure code [DK5BL8] Tilt & pitch EPC lever potentiometer (Main): Analog signals disagree
Failure code [DK5BL8] Tilt & pitch EPC lever potentiometer (Main):
Analog signals disagree 1
Action code Failure code Tilt & pitch EPC lever potentiometer (Main): Analog signals dis-
Trouble
E03 DK5BL8 agree (Work equipment controller system)
• Tilt & pitch EPC lever potentiometer (Main & Sub) input signals disagree with each other.
Contents of
(Tilt & pitch EPC lever potentiometer signal voltage (sum of Main and Sub): Max. 4.7 V) or (Tilt &
trouble
pitch EPC lever potentiometer signal voltage (sum of Main and Sub): Min. 5.3 V)
• Cannot recognize the tilt & pitch EPC lever position correctly.
• Operates with either Main or Sub potentiometer, whichever detecting a position within neutrality ±5
%, as the regular potentiometer.
Action of • Turns the output OFF if both Main and Sub potentiometers should fail to detect a position within
controller neutrality ±5 %.
(Neutral).
• Work equipment moves with the lever set to neutral.
Problem that
• If either Main or Sub potentiometer is abnormal, machine operates normally after the lever is set to
appears on
neutral.
machine
• If both Main and Sub potentiometers are abnormal, blade does not move.
Related
information

for it first.
1
for cause 3.
Voltage
(1) supply 5.15 V
Possible causes
Min. 1 Mz
lever potentiometer
equipment lock)
2.40 –
2.60 V
Between S02 (7) and Tilt & pitch operation 3.64 –
Voltage
Voltage
tion 1.14 V
40-308 22 WD600-6
Failure code [DK5BL8] Tilt & pitch EPC lever potentiometer (Main): Analog signals disagree SEN05058-01

2.40 –
Defective tilt & pitch EPC 2.60 V
lever potentiometer Between S02 (6) and 0.86 –
2 Tilt & pitch operation Voltage
(Internal disconnection or (5) 1.36 V
short circuit) Full tilt & pitch opera- 3.86 –
Voltage
tion 4.36 V
each female side.
Max. 1 z
(6) tance
Max. 1 z
Disconnection in wiring har- (7) tance
ness a If power supply voltage measured in
3
(Disconnection in wiring har- check on cause 1 is normal, this check is
Resis-
ness and defective contact) not required. Max. 1 z
tance
Possible causes (5)
Resis-
tance
(8)
2. Disconnect connectors L05 and S02, and connect T-adapter to
4 ness Between L05 (female) (1) or S02 (female) Resis-
(Contact with ground circuit) (6) and chassis ground Min. 1 Mz
tance
Min. 1 Mz
controller
be performed.)
WD600-6 40-308 23
SEN05058-01 Failure code [DK5BL8] Tilt & pitch EPC lever potentiometer (Main): Analog signals disagree
40-308 24 WD600-6
Failure code [DK5CKA] Tilt & pitch EPC lever potentiometer (Sub): Disconnection SEN05058-01
Failure code [DK5CKA] Tilt & pitch EPC lever potentiometer (Sub):
Disconnection 1
Action code Failure code Tilt & pitch EPC lever potentiometer (Sub): Disconnection
Trouble
E03 DK5CKA (Work equipment controller system)
• Due to disconnection or grounding fault in the tilt & pitch EPC lever potentiometer (Sub) system,
Contents of
(Sub) signal voltage is lower than normal range (tilt & pitch EPC lever potentiometer (Sub) signal
trouble
voltage: Max. 0.3 V).
• If the tilt & pitch EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Action of
controller
Problem that
appears on —
machine
Related
information

for it first.
1
for cause 3.
Voltage
(1) supply 5.15 V
Possible causes
Min. 1 Mz
lever potentiometer
equipment lock)
2.40 –
2.60 V
Between S02 (6) and 0.86 –
Tilt & pitch operation Voltage
(5) 1.36 V
Voltage
tion 4.36 V
WD600-6 40-308 25
SEN05058-01 Failure code [DK5CKA] Tilt & pitch EPC lever potentiometer (Sub): Disconnection

each female side.
Max. 1 z
(6) tance
3 Resis-
tance
Possible causes (5)
Resis-
tance
(8)
Min. 1 Mz
controller
be performed.)
40-308 26 WD600-6
Failure code [DK5CKA] Tilt & pitch EPC lever potentiometer (Sub): Disconnection SEN05058-01
WD600-6 40-308 27
Failure code [DK5CKY] Tilt & pitch EPC lever potentiometer (Sub): Short circuit with power supply
SEN05058-01 line
Failure code [DK5CKY] Tilt & pitch EPC lever potentiometer (Sub):
Action code Failure code Tilt & pitch EPC lever potentiometer (Sub): Short circuit with the
Trouble power supply line
E03 DK5CKY (Work equipment controller system)
• Due to disconnection or grounding fault in the tilt & pitch EPC lever potentiometer (Sub) system,
Contents of
(Sub) signal voltage is lower than normal range (tilt & pitch EPC lever potentiometer (Sub) signal
trouble
voltage: Min. 4.7 V).
• If the tilt & pitch EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
controller • Even if cause of failure disappears, system does not reset itself until tilt & pitch EPC lever is set to N
(Neutral).
Problem that
appears on —
machine
Related
information

Resis- 3.2 ± 0.64
tance kz
Between S02 (male) (5), (6), (7), (8) and Resis- Min. 1
chassis ground tance Mz
Defective tilt & pitch EPC 2. Insert T-adapter into connector S02.
1 lever potentiometer (Internal 3. Turn starting switch to ON position.
Possible causes equipment lock)
and standard 2.40 –
value in normal 2.60 V
state Between S02 (6) and 0.86 –
Tilt & pitch operation Voltage
(5) 1.36 V
Voltage
tion 4.36 V
controller
be performed.)
40-308 28 WD600-6
Failure code [DK5CKY] Tilt & pitch EPC lever potentiometer (Sub): Short circuit with power supply
line SEN05058-01
WD600-6 40-308 29
SEN05058-01 Failure code [DKD0KA] Frame angle sensor: Disconnection
Failure code [DKD0KA] Frame angle sensor: Disconnection 1
Action code Failure code Frame angle sensor: Disconnection

Trouble
E01 DKD0KA (Work equipment controller system)
Contents of • Due to disconnection or ground fault in frame angle sensor system, the frame angle sensor signal
trouble voltage is outside the lower limit (frame angle sensor signal: Max. 0.3 V).
• Stops the AJSS neutral safety function.
Action of
• Controls AJSS EPC output to the level corresponding to 1.47 MPa {15 kg/cm2}.
controller
• The engine can be started while AJSS lever is operated (The machine turns just after engine is
Problem that
started).
appears on
• Steering fine control is not possible (the machine jounces when performing steering operation).
machine
• The winker cannot be automatically reset.
• The input state (angle) from the frame angle sensor can be checked with the monitoring function
(Code: 94400 FRAME ANGLE).
Related • AJSS (if equipped) specification only
information • Method of reproducing failure code: Turn the starting switch ON.

for it first.
1
for cause 3.
Between L12 (female) (B) and Power 4.85 –
Voltage
(C) supply 5.15 V
Resis- 5 kz ± 20
Between L12 (male) (B) and (C)
tance %
Possible causes
Between L12 (male) (A), (B), (C) and Resis-
value in normal
4. Change frame angle and carry out troubleshooting.
Defective frame angle sensor
2 (Internal disconnection or 0.46 –
Always Voltage
While machine is 2.20 –
Voltage
Between L12 (A) and traveling straight 2.80 V
(C) 0.46 –
Full steering to right Voltage
1.46 V
3.54 –
Full steering to left Voltage
4.54 V
ing harness.
40-308 30 WD600-6
Failure code [DKD0KA] Frame angle sensor: Disconnection SEN05058-01

each female side.
Resis-
Between L05 (3) and L12 (female) (A) Max. 1 z
tance
Disconnection in wiring harness a If power supply voltage measured in
3 (Disconnection in wiring har- check on cause 1 is normal, this check is Resis-
ness and defective contact) Max. 1 z
not required. tance
Possible causes Between L05 (21) and L12 (female) (C)
value in normal check on cause 1 is normal, this check is Resis-
state Max. 1 z
not required. tance
Between L05 (22) and F12 (female) (B)
Grounding fault in wiring 2. Disconnect connectors L05 and L12, and connect T-adapter to
4 harness either female side.
(Contact with ground circuit) Between L05 (3) or L12 (female) (A) and Resis-
Min. 1 Mz
controller
be performed.)
Circuit diagram related to frame angle sensor
WD600-6 40-308 31
SEN05058-01 Failure code [DKD0KY] Frame angle sensor: Short circuit with power supply line
Failure code [DKD0KY] Frame angle sensor: Short circuit with power
supply line 1
Action code Failure code Frame angle sensor: Short circuit with power supply line
Trouble
E01 DKD0KY (Work equipment controller system)
Contents of • Due to hot short circuit in frame angle sensor system, the frame angle sensor signal voltage is out-
trouble side the higher limit (frame angle sensor signal: Max. 4.7 V).
• Stops the AJSS neutral safety function.
Action of
• Controls AJSS EPC output to the level corresponding to 1.47 MPa {15 kg/cm2}.
controller
• The engine can be started while AJSS lever is operated (The machine turns just after engine is
Problem that
started).
appears on
• Steering fine control is not possible (the machine jounces when performing steering operation).
machine
(Code: 94400 FRAME ANGLE).
Related • AJSS (if equipped) specification only
information • Method of reproducing failure code: Turn the starting switch ON.

Resis- 5 kz ± 20
Between L12 (male) (B) and (C)
tance %
Between L12 (male) (A), (B), (C) and Resis-
Min. 1 Mz
4. Change frame angle and carry out troubleshooting.
Defective frame angle sensor 0.46 –
1 Always Voltage
(Internal short circuit) 4.54 V
Possible causes While machine is 2.20 –

Voltage
and standard Between L12 (A) and traveling straight 2.80 V
value in normal (C) 0.46 –
Full steering to right Voltage
state 1.46 V
3.54 –
Full steering to left Voltage
4.54 V
ing harness.
2. Disconnect connector L12.
2 3. Connect T-adapter to female side of connector L12.
Between L12 (female) (A) and (C) Voltage Max. 1 V
controller
be performed.)
40-308 32 WD600-6
Failure code [DKD0KY] Frame angle sensor: Short circuit with power supply line SEN05058-01
Circuit diagram related to frame angle sensor
WD600-6 40-308 33
SEN05058-01 Failure code [DKD0KZ] AJSS lever and frame angle sensor: Disconnection or short circuit
Failure code [DKD0KZ] AJSS lever and frame angle sensor:

Disconnection or short circuit 1
Action code Failure code AJSS angle sensor & frame angle sensor: Disconnection or short circuit
Trouble
E01 DKD0KZ (Work equipment controller system)
Contents of • Due to displacement of the AJSS lever angle sensor and frame angle sensor, the AJSS lever posi-
trouble tion cannot be detected normally (steering deviation angle: Min. +25°).
• Cannot recognize the ADJSS lever position correctly.
Action of • Stops the AJSS neutral safety function.
controller • Controls AJSS EPC output to the level corresponding to 1.47 MPa {15 kg/cm2}.
• The engine can start even when the AJSS lever is not in neutral (the machine turns immediately
Problem that after the engine starts).
appears on • The engine cannot start when the AJSS lever is in neutral.
machine • Steering speed is different according to the steering direction, to the right or to the left.
• The input state (angle) from the AJSS lever angle sensor can be checked with the monitoring func-
tion (Code: 94300 AJSS LEVER, Code: 94301 AJSS LEVER).
(Code: 94400 FRAME ANGLE, Code: 94401 FRAME ANGLE).
Related • The steering deviation angle can be checked with the monitoring function (Code: 94800 STEERING
information DEFLECTION).
• AJSS (if equipped) specification only

1 Carry out troubleshooting for failure code [DKD0KA], if it is displayed.
for it first.
Possible causes
value in normal 2. Disconnect connector S30, and connect T-adapters to female side.
state 2 3. Turn starting switch to ON position.
supply system
for cause 4.
Between S30 (female) (B) and Power 4.85 –
Voltage
(C) supply 5.15 V
40-308 34 WD600-6
Failure code [DKD0KZ] AJSS lever and frame angle sensor: Disconnection or short circuit SEN05058-01

Resis- 5 kz ± 20
tance %
Between S30 (male) (A), (B), (C) and chas- Resis-
Min. 1 Mz
sis ground tance
2. Insert T-adapters into connector S30.
Defective AJSS angle sensor lock)
3 (Internal disconnection or
0.30 –
short circuit) Always Voltage
4.70 V
2.20 –
Between S30 (A) and 2.80 V
(C) Full steering to right 2.83 –
Voltage
(straight travel) 3.83 V
Voltage
(straight travel) 2.17 V
Possible causes hot short circuit of harness. Judge after troubleshooting for wir-
and standard
ing harness.
value in normal
each female side.
Resis-
Between L05 (3) and S30 (female) (A) Max. 1 z
tance
Disconnection in wiring harness a If power supply voltage measured in
4 (Disconnection in wiring har- check on cause 2 is normal, this check is Resis-
ness and defective contact) Max. 1 z
not required. tance
Between L05 (21) and S30 (female) (C)
check on cause 2 is normal, this check is Resis-
Max. 1 z
not required. tance
Between L05 (22) and S30 (female) (B)
Grounding fault in wiring 2. Disconnect connectors L05 and S30, and connect T-adapter to
5 harness female side of S30.
Between S30 (female) (A) and (C) Min. 1 Mz
tance
Defective frame angle sensor a The frame angle sensor adjustment may be defective. Check it.
6
adjustment (See Testing and adjusting.)
controller
be performed.)
WD600-6 40-308 35
SEN05058-01 Failure code [DKD0KZ] AJSS lever and frame angle sensor: Disconnection or short circuit
Circuit diagram related to AJSS lever angle sensor and frame angle sensor
40-308 36 WD600-6
Failure code [DKD0KZ] AJSS lever and frame angle sensor: Disconnection or short circuit SEN05058-01
WD600-6 40-308 37
SEN05058-01 Failure code [DLFAKA] Modulation clutch output shaft speed sensor: Disconnection
Failure code [DLFAKA] Modulation clutch output shaft speed sensor:

Disconnection 1
Action code Failure code Modulation clutch output shaft speed sensor: Disconnection
Trouble
E03 DLFAKA (Transmission controller system)
• Due to disconnection or hot short circuit in the modulation clutch output shaft speed sensor system,
Contents of the modulation clutch output shaft speed sensor signal voltage is outside the higher limit.
trouble (Modulation clutch output shaft speed sensor signal voltage: Min. 1.5 V)
• Signal from the modulation clutch output shaft speed sensor is 0 rpm.
• Uses modulation clutch output immediately before abnormality occurs.
• Stops modulation clutch control with the directional lever or directional selector switch in N (Neutral),
Action of
and directly connect the modulation clutch.
controller
Problem that
• The modulation clutch is directly connected once the directional lever or directional selector switch
appears on
is placed in N (Neutral).
machine
Related
information

Defective modulation clutch
a The modulation clutch output shaft speed sensor adjustment
1 output shaft speed sensor
may be defective. Check it (see Testing and adjusting).
adjustment
2. Disconnect connector MOD OUT, and connect T-adapter to
Defective modulation clutch male side.
output shaft speed sensor
2 Resis- 500 –
(Internal disconnection or Between MOD OUT (male) (1) and (2)
tance 1,000 z
short circuit)
Between MOD OUT (male) (1), (2) and Resis-
Min. 1 Mz
Hot short in wiring harness female side.
3
Possible causes
Between MOD OUT (female) (1) and (2) Voltage 1–4V
and standard
value in normal a If cause 3 is not the cause of failure, this check is not required.
Disconnection or short circuit 2. Disconnect connector L03, and connect T-adapter to female
4 side.
in wiring harness
Resis- 500 –
Between L03 (female)(29) and (30)
tance 1,000 z
Disconnection in wiring har- 2. Disconnect connectors MOD OUT and L03, and connect T-
ness adapters to each female side.
5
(Disconnection in wiring har- Between L03 (female) (29) and MOD OUT Resis-
Max. 1 z
ness and defective contact) (female) (2) tance
Between L03 (female) (30) and MOD OUT Resis-
Max. 1 z
(female) (1) tance
troller
be performed.)
40-308 38 WD600-6
Failure code [DLFAKA] Modulation clutch output shaft speed sensor: Disconnection SEN05058-01
Circuit diagram related to modulation clutch output shaft speed sensor
WD600-6 40-308 39
SEN05058-01 Failure code [DLFALC] Modulation clutch output shaft speed sensor: Speed signals disagree
Failure code [DLFALC] Modulation clutch output shaft speed sensor:

Speed signals disagree 1
Action code Failure code Modulation clutch output shaft speed sensor: Speed signals dis-
Trouble agree
E03 DLFALC (Transmission controller system)
• Due to ground fault in the modulation clutch output shaft speed sensor, the modulation clutch output
shaft speed sensor signal voltage is outside the lower limit.
• This failure code appears under the following conditions.
Contents of
1) Engine speed: Min. 700 rpm
trouble
2) Modulation clutch pressure: Min. 2 MPa {19.6 kg/cm2}
3) Modulation clutch speed: 0 rpm
4) Modulation clutch speed sensor signal line: Disconnection is not detected
• Uses modulation clutch output immediately before abnormality occurs.
• Stops modulation clutch control with the directional lever or directional selector switch in N (Neutral),
Action of
and directly connect the modulation clutch.
controller
Problem that
• The modulation clutch is directly connected once the directional lever or directional selector switch
appears on
is placed in N (Neutral).
machine
Related
information

a The modulation clutch output shaft speed sensor adjustment
1 output shaft speed sensor
may be defective. Check it (see Testing and adjusting).
adjustment
Defective modulation clutch male side.
2 output shaft speed sensor Resis- 500 –
Between MOD OUT (male) (1) and (2)
(Internal short circuit) tance 1,000 z
Between MOD OUT (male) (1), (2) and Resis-
and standard
state Grounding fault in wiring har- 2. Disconnect connectors MOD OUT and L03, and connect T-
3 ness adapter to either female side.
(Contact with ground circuit) Between L03 (female) (30) or MOD OUT Resis-
Min. 1 Mz
Disconnection or short circuit 2. Disconnect connector L03, and connect T-adapter to female side.
4
in wiring harness Resis- 500 –
tance 1,000 z
troller
be performed.)
40-308 40 WD600-6
Failure code [DLFALC] Modulation clutch output shaft speed sensor: Speed signals disagree SEN05058-01
Circuit diagram related to modulation clutch output shaft speed sensor
WD600-6 40-308 41
SEN05058-01 Failure code [DLT3KA] Transmission output shaft speed sensor (2): Disconnection
Failure code [DLT3KA] Transmission output shaft speed sensor (2):

Disconnection 1
Action code Failure code Transmission output shaft speed sensor (2): Disconnection
Trouble
E03 DLT3KA (Transmission controller system)
• Due to disconnection or hot short circuit in the transmission output shaft speed sensor (2), the trans-
Contents of mission output shaft speed sensor (2) signal voltage is outside the higher limit.
trouble (Transmission output shaft speed sensor (2) signal: Min. 1.5 V)
• Signal from the transmission output shaft speed sensor is 0 rpm.
• When the transmission output shaft speed sensor (1) is normal: Performs control by the transmis-
sion output shaft speed sensor (1).
• When abnormality (DLT4KB, DLT4KX) detection conditions excluding the detection time of the
transmission output shaft speed sensor (1) are detected:
Action of
1) In the auto-shift mode, change the shift mode to the manual mode.
controller
2) In the auto-shift mode, change the mode for transmitting signal to the machine monitor to the
manual mode.
Problem that
appears on —
machine
• The input state (speed) from the transmission output shaft speed sensor (1) can be checked with
the monitoring function (Code: 31400 T/M SPEED OUT).
Related
information
the monitoring function (Code: 31404 T/M SPEED OUT2).

Defective transmission out-
a The transmission output shaft speed sensor (2) adjustment may
1 put shaft speed sensor (2)
be defective. Check it (see Testing and adjusting).
adjustment
2. Disconnect connector REV OUT2, and connect T-adapter to
Defective transmission out- male side.
put shaft speed sensor (2)
2 Resis- 500 –
(Internal disconnection or Between REV OUT2 (male) (1) and (2)
tance 1,000 z
short circuit)
Possible causes Between REV OUT2 (male) (1), (2) and Resis-
Min. 1 Mz
state 2. Disconnect connector REV OUT2, and connect T-adapter to
3
Between REV OUT2 (female) (1) and (2) Voltage 1–4V
4 side.
in wiring harness
Resis- 500 –
Between L03 (39) and (40)
tance 1,000 z
40-308 42 WD600-6
Failure code [DLT3KA] Transmission output shaft speed sensor (2): Disconnection SEN05058-01

Disconnection in wiring har- 2. Disconnect connectors REV OUT2 and L03, and connect T-
Possible causes ness adapters to each female side.
5
and standard (Disconnection in wiring har- Between L03 (female) (39) and REV OUT2 Resis-
Max. 1 z
value in normal ness and defective contact) (female) (2) tance
state Between L03 (female) (40) and REV OUT2 Resis-
Max. 1 z
(female) (1) tance
troller
be performed.)
Circuit diagram related to transmission output shaft speed sensor (2)
WD600-6 40-308 43
SEN05058-01 Failure code [DLT3LC] Transmission output shaft speed sensor (2): Speed signals disagree
Failure code [DLT3LC] Transmission output shaft speed sensor (2):

Speed signals disagree 1
Action code Failure code Transmission output shaft speed sensor (2): Speed signals dis-
Trouble agree
E03 DLT3LC (Transmission controller system)
• Due to ground fault in the transmission output shaft speed sensor (2), the transmission output shaft
speed sensor (2) signal voltage is outside the lower limit.
Contents of • This failure code appears under the following conditions.
trouble 1) Transmission output shaft speed sensor (1): Min. 200 rpm
2) Transmission output shaft speed sensor (2): 0 rpm
3) Transmission clutch speed sensor (2) signal line: Disconnection is not detected.
• When abnormality (DLT4KB, DLT4KX) detection conditions excluding the detection time of the
Action of
controller
manual mode.
Problem that
appears on —
machine
Related
information

adjustment
2 put shaft speed sensor (2) Resis- 500 –
Between REV OUT2 (male) (1) and (2)
Between REV OUT2 (male) (1), (2) and Resis-
Min. 1 Mz
Possible causes chassis ground tance
value in normal Grounding fault in wiring har- 2. Disconnect connectors REV OUT2 and L03, and connect T-
state 3 ness adapter to either female side.
(Contact with ground circuit) Between L03 (female) (40) or REV OUT2 Resis-
Min. 1 Mz
Disconnection or short circuit side.
4
in wiring harness
Resis- 500 –
tance 1,000 z
troller
be performed.)
40-308 44 WD600-6
Failure code [DLT3LC] Transmission output shaft speed sensor (2): Speed signals disagree SEN05058-01
WD600-6 40-308 45
SEN05058-01 Failure code [DLT4KB] Transmission output shaft speed sensor (1): Short circuit
Failure code [DLT4KB] Transmission output shaft speed sensor (1):

Short circuit 1
Action code Failure code Transmission output shaft speed sensor (1): Short circuit
Trouble
E03 DLT4KB (Transmission controller system)
• Due to ground fault in the transmission output shaft speed sensor (1), the transmission output shaft
speed sensor (1) signal voltage is outside the lower limit.
Contents of • This failure code appears under the following conditions.
trouble 1) Transmission output shaft speed sensor (1): Min. 200 rpm
2) Transmission output shaft speed sensor (2): 0 rpm
3) Transmission clutch speed sensor (2) signal line: Disconnection is not detected.
• When abnormality (DLT3KA, DLT3LC) detection conditions excluding the detection time of the
Action of
controller
manual mode.
Problem that
appears on —
machine
Related
information

adjustment
2 put shaft speed sensor (1) Resis- 500 –
Between REV OUT1 (male) (1) and (2)
Between REV OUT1 (male) (1), (2) and Resis-
Min. 1 Mz
value in normal Grounding fault in wiring har- 2. Disconnect connectors REV OUT1 and L03, and connect T-
state 3 ness adapter to either female side.
(Contact with ground circuit) Between L03 (female) (20) or REV OUT1 Resis-
Min. 1 Mz
4
in wiring harness
Resis- 500 –
tance 1,000 z
troller
be performed.)
40-308 46 WD600-6
Failure code [DLT4KB] Transmission output shaft speed sensor (1): Short circuit SEN05058-01
WD600-6 40-308 47
SEN05058-01 Failure code [DLT4KX] Transmission output shaft speed sensor (1): Out of input signal range
Failure code [DLT4KX] Transmission output shaft speed sensor (1): Out
of input signal range 1
Action code Failure code Transmission output shaft speed sensor (1): Out of input signal
Trouble range
E03 DLT4KX (Transmission controller system)
• Due to disconnection or hot short circuit in the transmission output shaft speed sensor (1), the trans-
Contents of mission output shaft speed sensor (1) signal voltage is outside the higher limit.
trouble (Transmission output shaft speed sensor (1) signal: Min. 1.5 V)
• Signal from the transmission output shaft speed sensor is 0 rpm.
• When abnormality (DLT3KA, DLT3LC) detection conditions excluding the detection time of the
Action of
controller
manual mode.
Problem that
appears on —
machine
Related
information

adjustment
put shaft speed sensor (1)
2 Resis- 500 –
(Internal disconnection or Between REV OUT1 (male) (1) and (2)
tance 1,000 z
short circuit)
Possible causes Between REV OUT1 (male) (1), (2) and Resis-
Min. 1 Mz
state 2. Disconnect connector REV OUT1, and connect T-adapter to
3
Between REV OUT1 (female) (1) and (2) Voltage 1–4V
4 side.
in wiring harness
Resis- 500 –
tance 1,000 z
40-308 48 WD600-6
Failure code [DLT4KX] Transmission output shaft speed sensor (1): Out of input signal range SEN05058-01

Disconnection in wiring har- 2. Disconnect connectors REV OUT1 and L03, and connect T-
Possible causes ness adapters to each female side.
5
and standard (Disconnection in wiring har- Between L03 (female) (20) and REV OUT1 Resis-
Max. 1 z
value in normal ness and defective contact) (female) (1) tance
state Between L03 (female) (29) and REV OUT1 Resis-
Max. 1 z
(female) (2) tance
troller
be performed.)
WD600-6 40-308 49
SEN05058-01 Failure code [DV00KB] Alarm buzzer: Short circuit
Failure code [DV00KB] Alarm buzzer: Short circuit 1
Action code Failure code Alarm buzzer: Short circuit

Trouble
E01 DV00KB (Machine monitor system)
Contents of
• The alarm buzzer output circuit is shorted with the power supply line.
trouble
Action of • Stops alarm buzzer output.
Problem that
appears on • Alarm buzzer does not sound.
machine
• The output state (ON/OFF) to the alarm buzzer can be checked with the monitoring function
Related
(Code: 40952, D-OUT-0).
information

1. Turn starting switch OFF, disconnect connector L20, and
remove buzzer.
Defective alarm buzzer 2. Connect T-adapter to male side.
1
(Internal short circuit) 3. Connect +24 V to L20 (male) (1) and connect GND to L20
(male) (2).
Possible causes a If buzzer does not sound, buzzer is defective. (Replace)
value in normal 2. Disconnect connector L20, and connect T-adapter to female
state Hot short in wiring harness side.
Voltage Max. 1 V
ground
If no failure is found by above checks, machine monitor may be
3 Defective machine monitor defective. (Since trouble is in system, troubleshooting cannot be
carried out.)
40-308 50 WD600-6
Failure code [DV00KB] Alarm buzzer: Short circuit SEN05058-01
Circuit diagram related to alarm buzzer
WD600-6 40-308 51
SEN05058-01 Failure code [DW4PKA] Blade raise EPC solenoid: Disconnection
Failure code [DW4PKA] Blade raise EPC solenoid: Disconnection 1
Action code Failure code Blade raise EPC solenoid: Disconnection

Trouble
E03 DW4PKA (Work equipment controller system)
Contents of • Since the blade raise EPC solenoid output signal system is disconnected, no current flows when the
trouble blade raise EPC solenoid output is ON.
Problem that
appears on • Blade does not rise
machine
• The output state (current) to the blade raise EPC solenoid can be checked with the monitoring func-
Related
tion (Code: 41900 RAISE EPC DIR).
information
• Method of reproducing failure code: Engine started + blade raise

Defective blade raise EPC 2. Disconnect connector F07, and connect T-adapter to male side.
1 solenoid (Internal disconnec-
Resis-
tion) Between F07 (male) (1) and (2) 5 – 15 z
tance
2
in wiring harness
Resis-
Possible causes Between L07 (female) (6) and (3) 5 – 15 z
tance
and standard
Disconnection in wiring har- 2. Disconnect connectors F07 and L07, and connect T-adapters to
3
(Disconnection in wiring har- Between L07 (female) (6) and F07 (female) Resis-
Max. 1 z
ness and defective contact) (1) tance
Max. 1 z
(2) tance
controller
be performed.)
40-308 52 WD600-6
Failure code [DW4PKA] Blade raise EPC solenoid: Disconnection SEN05058-01
Circuit diagram related to blade raise EPC solenoid
WD600-6 40-308 53
SEN05058-01 Failure code [DW4PKB] Blade raise EPC solenoid: Short circuit
Failure code [DW4PKB] Blade raise EPC solenoid: Short circuit 1
Action code Failure code Blade raise EPC solenoid: Short circuit
Trouble
E03 DW4PKB (Work equipment controller system)
Contents of • Since the blade raise EPC solenoid signal system was shorted with the chassis ground, abnormal
trouble current flowed when the blade raise EPC solenoid output was ON.
• Stops outputting the signal to the blade raise EPC solenoid.
Action of • Stops outputting the signal to the blade raise detent.
Problem that
appears on • Blade does not rise
machine
Related
information
• Method of reproducing failure code: Engine started + blade raise

2. Disconnect connector F07, and connect T-adapter to male side.
Defective blade raise EPC
Resis-
1 solenoid (Internal short cir- Between F07 (male) (1) and (2) 5 – 15 z
tance
cuit)
Between F07 (male) (1), (2) and chassis Resis-
Min. 1 Mz
ground tance
Possible causes Grounding fault in wiring har- 2. Disconnect connectors F07 and L07, and connect T-adapter to
and standard 2 ness either female side.
value in normal (Contact with ground circuit) Between L07 (female) (6) or F07 (female) (1) Resis-
state Min. 1 Mz
and chassis ground tance
3
in wiring harness
Resis-
Between L07 (female) (6) and (3) 5 – 15 z
tance
controller
be performed.)
40-308 54 WD600-6
Failure code [DW4PKY] Blade raise EPC solenoid: Short circuit with power supply line SEN05058-01
Failure code [DW4PKY] Blade raise EPC solenoid: Short circuit with
power supply line 1
Action code Failure code Blade raise EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4PKY (Work equipment controller system)
Contents of • Since the blade raise EPC solenoid signal system was shorted with the power source, abnormal
trouble voltage was applied when the blade raise EPC solenoid output was OFF.
• Turns the output to the work equipment neutral lock solenoid ON.
• Stops outputting the signal to the blade raise/lower, blade tilt/pitch EPC solenoid.
Action of
• Stops outputting the signal to all work equipment detent.
controller
Problem that
• When work equipment neutral lock solenoid is turned ON, all the work equipment do not work.
appears on
• The blade raise EPC solenoid may be burnt out.
machine
• The output state (current) to the blade lower EPC solenoid can be checked with the monitoring func-
tion (Code: 41901 LOWER EPC DIR).
Related
• The output state (current) to the tilt &pitch EPC solenoid can be checked with the monitoring func-
information
tion (Code: 41902 TILT EPC DIR).
• The output state (current) to the tilt &pitch EPC solenoid can be checked with the monitoring func-
tion (Code: 41903 DUMP EPC DIR).
• Method of reproducing failure code: Engine started

2. Disconnect connector F07, and connect T-adapter to female
Possible causes Hot short in wiring harness side.
1
and standard (Contact with 24 V circuit) 3. Turn starting switch to ON position.
value in normal
state Between F07 (female) (1) and (2) Voltage Max. 3 V
controller
be performed.)
WD600-6 40-308 55
SEN05058-01 Failure code [DW4QKA] Blade lower EPC solenoid: Disconnection
Failure code [DW4QKA] Blade lower EPC solenoid: Disconnection 1
Action code Failure code Blade lower EPC solenoid: Disconnection

Trouble
E03 DW4QKA (Work equipment controller system)
Contents of • Since the blade lower EPC solenoid output signal system is disconnected, no current flows when
trouble the blade lower EPC solenoid output is ON.
Problem that
appears on • Blade does not lower.
machine
Related
information
• Method of reproducing failure code: Start engine and lower the blade.

Defective blade lower EPC 2. Disconnect connector F08, and connect T-adapter to male side.
Resis-
tance
2
in wiring harness
Resis-
tance
and standard
3
Max. 1 z
Max. 1 z
(2) tance
controller
be performed.)
Circuit diagram related to blade lower EPC solenoid
40-308 56 WD600-6
Failure code [DW4QKB] Blade lower EPC solenoid: Short circuit SEN05058-01
Failure code [DW4QKB] Blade lower EPC solenoid: Short circuit 1
Action code Failure code Blade lower EPC solenoid: Short circuit
Trouble
E03 DW4QKB (Work equipment controller system)
Contents of • Since the blade lower EPC solenoid signal system was shorted with the chassis ground, abnormal
trouble current flowed when the blade lower EPC solenoid output was ON.
• Stops outputting the signal to the blade lower EPC solenoid.
Action of • Stops outputting the signal to the blade float magnet detent.
Problem that
appears on • Blade does not lower.
machine
Related
information
• Method of reproducing failure code: Engine started + blade lower

Defective blade lower EPC
Resis-
tance
cuit)
Min. 1 Mz
ground tance
value in normal (Contact with ground circuit) Between L07 (female) (16) or F08 (female) Resis-
state Min. 1 Mz
3
in wiring harness
Resis-
tance
controller
be performed.)
WD600-6 40-308 57
SEN05058-01 Failure code [DW4QKY] Blade lower EPC solenoid: Short circuit with power supply line
Failure code [DW4QKY] Blade lower EPC solenoid: Short circuit with
power supply line 1
Action code Failure code Blade lower EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4QKY (Work equipment controller system)
Contents of • Since the blade lower EPC solenoid signal system was shorted with the power source, abnormal
trouble voltage was applied when the blade lower EPC solenoid output was OFF.
• Stops outputting the signal to the blade raise/lower, blade tilt/pitch EPC solenoid.
Action of
controller
Problem that
appears on
• The blade lower EPC solenoid may be burnt out.
machine
Related
• The output state (current) to the tilt & pitch EPC solenoid can be checked with the monitoring func-
information

1
value in normal
controller
be performed.)
40-308 58 WD600-6
Failure code [DW4RKA] Tilt & pitch EPC solenoid: Disconnection SEN05058-01
Failure code [DW4RKA] Tilt & pitch EPC solenoid: Disconnection 1
Action code Failure code Tilt & pitch EPC solenoid: Disconnection
Trouble
E03 DW4RKA (Work equipment controller system)
Contents of • Since the tilt & pitch EPC solenoid output signal output signal system is disconnected, no current
trouble flows when the tilt & pitch EPC solenoid output is ON.
Problem that
appears on • Blade does not tilt and pitch.
machine
Related
information
• Method of reproducing failure code: Engine started + tilt & pitch

Defective tilt & pitch EPC 2. Disconnect connector F09, and connect T-adapter to male side.
Resis-
tance
2
in wiring harness
Resis-
tance
and standard
3
Max. 1 z
Max. 1 z
(2) tance
controller
be performed.)
Circuit diagram related to tilt & pitch EPC solenoid
WD600-6 40-308 59
SEN05058-01 Failure code [DW4RKB] Tilt & pitch EPC solenoid: Short circuit
Failure code [DW4RKB] Tilt & pitch EPC solenoid: Short circuit 1
Action code Failure code Tilt & pitch EPC solenoid: Short circuit
Trouble
E03 DW4RKB (Work equipment controller system)
Contents of • Since the tilt & pitch EPC solenoid signal system was shorted with the chassis ground, abnormal cur-
trouble rent flowed when the tilt & pitch EPC solenoid output was ON.
• Stops outputting the signal to the tilt & pitch EPC solenoid.
Action of • Stops outputting the signal to the tilt & pitch detent.
Problem that
• Blade does not tilt LH or pitch REAR.
appears on
• The wiring harness or controller may be burnt out.
machine
Related
information

Resis-
tance
cuit)
Min. 1 Mz
ground tance
value in normal (Contact with ground circuit) Between L07 (female) (5) or F09 (female) (1) Resis-
state Min. 1 Mz
3
in wiring harness
Resis-
tance
controller
be performed.)
40-308 60 WD600-6
Failure code [DW4RKY] Tilt & pitch EPC solenoid: Short circuit with power supply line SEN05058-01
Failure code [DW4RKY] Tilt & pitch EPC solenoid: Short circuit with
power supply line 1
Action code Failure code Tilt & pitch EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4RKY (Work equipment controller system)
Contents of • Since the tilt & pitch EPC solenoid signal system was shorted with the power source, abnormal volt-
trouble age was applied when the tilt & pitch EPC solenoid output was OFF.
• Stops outputting the signal to the blade raise/lower, blade tilt & pitch EPC solenoid.
Action of
controller
Problem that
• When the work equipment neutral lock solenoid is turned ON, all the work equipment do not work.
appears on
• The tilt & pitch EPC solenoid may be burnt out.
machine
Related
information

1
value in normal
controller
be performed.)
WD600-6 40-308 61
SEN05058-01 Failure code [DW4SKA] Tilt & pitch EPC solenoid: Disconnection
Failure code [DW4SKA] Tilt & pitch EPC solenoid: Disconnection 1
Action code Failure code Tilt & pitch EPC solenoid: Disconnection
Trouble
E03 DW4SKA (Work equipment controller system)
Contents of • Since the tilt & pitch EPC solenoid output signal system is disconnected, no current flows when the
trouble tilt & pitch EPC solenoid output is ON.
Problem that
appears on • Blade does not tilt RH or pitch FORWARD.
machine
Related
information

Defective tilt & pitch EPC 2. Disconnect connector F10, and connect T-adapter to male side.
Resis-
tance
2
in wiring harness
Resis-
tance
and standard
3
Max. 1 z
Max. 1 z
(2) tance
controller
be performed.)
40-308 62 WD600-6
Failure code [DW4SKB] Tilt & pitch EPC solenoid: Short circuit SEN05058-01
Failure code [DW4SKB] Tilt & pitch EPC solenoid: Short circuit 1
Action code Failure code Tilt & pitch EPC solenoid: Short circuit
Trouble
E03 DW4SKB (Work equipment controller system)
Contents of • Since the tilt & pitch EPC solenoid signal system was shorted with the chassis ground, abnormal
trouble current flowed when the tilt & pitch EPC solenoid output was ON.
• Stops outputting the signal to the tilt & pitch EPC solenoid.
Action of
controller
Problem that
• Blade does not tilt RH pr pitch FORWARD.
appears on
machine
Related
information
• Method of reproducing failure code: Start engine and dump the blade.

Resis-
tance
cuit)
Min. 1 Mz
ground tance
value in normal (Contact with ground circuit) Between L07 (female) (15) or F10 (female) Resis-
state Min. 1 Mz
3
in wiring harness
Resis-
tance
controller
be performed.)
WD600-6 40-308 63
SEN05058-01 Failure code [DW4SKY] Tilt & pitch EPC solenoid: Short circuit with power supply line
Failure code [DW4SKY] Tilt & pitch EPC solenoid: Short circuit with
power supply line 1
Action code Failure code Tilt & pitch EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4SKY (Work equipment controller system)
Contents of • Since the blade dump EPC solenoid signal system was shorted with the power source, abnormal
trouble voltage was applied when the blade dump EPC solenoid output was OFF.
• Stops outputting the signal to the blade raise/lower, blade tilt & pitch EPC solenoid.
Action of
controller
Problem that
appears on
• The tilt & pitch EPC solenoid may be burnt out.
machine
• The output state (current) to the blade lower EPC solenoid can be checked with the monitoring
function (Code: 41901 LOWER EPC DIR).
Related
information

1
value in normal
controller
be performed.)
40-308 64 WD600-6
Failure code [DW4SKY] Tilt & pitch EPC solenoid: Short circuit with power supply line SEN05058-01
WD600-6 40-308 65
SEN05058-01 Failure code [DW7BKA] Fan reverse solenoid: Disconnection
Failure code [DW7BKA] Fan reverse solenoid: Disconnection 1
Action code Failure code Fan reverse solenoid: Disconnection

Trouble
E01 DW7BKA (Transmission controller system)
Contents of • Since the fan reverse solenoid system is disconnected, no current flows when the fan reverse sole-
trouble noid output is ON.
Action of • Disables the automatic fan reverse function (if equipped).
Problem that
• The automatic fan reverse function is disabled in the case of automatic fan reverse function
appears on
(if equipped) specification.
machine
• The output state (ON/OFF) to the fan reverse solenoid can be checked with the monitoring function
Related
(Code: 40949, D-OUT-3).
information

Defective fan reverse sole- 2. Disconnect connector G07, and connect T-adapter to male side.
1 noid
Resis-
(Internal disconnection) Between G07 (male) (1) and (2) 35 – 45 z
tance
2
in wiring harness
Between L04 (female) (37) and chassis Resis-
Possible causes 35 – 45 z
ground tance
and standard
Disconnection in wiring har- 2. Disconnect connectors G07 and L04, and connect T-adapters to
3
(Disconnection or defective Between L04 (female) (37) and G07 (female) Resis-
Max. 1 z
Between G07 (female) (2) and chassis Resis-
Max. 1 z
ground tance
troller
be performed.)
40-308 66 WD600-6
Failure code [DW7BKA] Fan reverse solenoid: Disconnection SEN05058-01
Circuit diagram related to fan reverse solenoid
WD600-6 40-308 67
SEN05058-01 Failure code [DW7BKB] Fan reverse solenoid: Short circuit
Failure code [DW7BKB] Fan reverse solenoid: Short circuit 1
Action code Failure code Fan reverse solenoid: Short circuit

Trouble
E01 DW7BKB (Transmission controller system)
Contents of • Since the fan reverse solenoid system was short circuited, abnormal current flowed when the fan
trouble reverse solenoid output was ON.
• Turns the output to the fan reverse solenoid OFF.
Action of
• Disables the automatic fan reverse function (if equipped).
controller
Problem that • The fan cannot turn in reverse by operating the fan reverse switch.
appears on • The automatic fan reverse function is disabled in the case of automatic fan reverse function
machine (if equipped) specification.
Related
(Code: 40949, D-OUT-3).
information

2. Disconnect connector G07, and connect T-adapter to male side.
Defective fan reverse sole-
Resis-
1 noid Between G07 (male) (1) and (2) 35 – 45 z
tance
Between G07 (male) (1), (2) and chassis Resis-
Min. 1 Mz
ground tance
Possible causes Grounding fault in wiring har- 2. Disconnect connectors G07 and L04, and connect T-adapter to
value in normal (Contact with ground circuit) Between L04 (female) (37) or G07 (female) Resis-
state Min. 1 Mz
3
in wiring harness
35 – 45 z
ground tance
troller
be performed.)
40-308 68 WD600-6
Failure code [DW7BKB] Fan reverse solenoid: Short circuit SEN05058-01
WD600-6 40-308 69
SEN05058-01 Failure code [DW7BKY] Fan reverse solenoid: Short circuit with power supply line
Failure code [DW7BKY] Fan reverse solenoid: Short circuit with power
supply line 1
Action code Failure code Fan reverse solenoid: Short circuit with power supply line
Trouble
E01 DW7BKY (Transmission controller system)
Contents of • Since the fan reverse solenoid system was shorted with the power source, abnormal voltage was
trouble applied when the fan reverse switch output was OFF.
Action of • Disables the automatic fan reverse function (if equipped).
Problem that
• The automatic fan reverse function is disabled in the case of automatic fan reverse function
appears on
(if equipped) specification.
machine
Related
(Code: 40949, D-OUT-3).
information

2. Disconnect connector G07, and connect T-adapter to female
1
value in normal
state Between G07 (female) (1) and (2) Voltage Max. 3 V
troller
be performed.)
40-308 70 WD600-6
Failure code [DW7BKY] Fan reverse solenoid: Short circuit with power supply line SEN05058-01
WD600-6 40-308 71
SEN05058-01
WD600-6 Wheel dozer

©2016 KOMATSU
All Rights Reserved
40-308 72
SEN05059-01
WHEEL DOZER
WD600-6

WD600-6 55001 and up

Failure code [DWM1KA] Work equipment neutral lock solenoid: Disconnection ............................................ 4
Failure code [DWM1KB] Work equipment neutral lock solenoid: Short circuit................................................ 6
Failure code [DWM1KY] Work equipment neutral lock solenoid: Short circuit with power supply line ........... 8
Failure code [DWN7KA] Blade float magnet detent solenoid: Disconnection............................................... 10
Failure code [DWN7KB] Blade float magnet detent solenoid: Short circuit .................................................. 12
Failure code [DWN7KY] Blade float magnet detent solenoid: Short circuit with power supply line .............. 14
Failure code [DWNFKA] Modulation clutch cut-off release solenoid: Disconnection .................................... 16
Failure code [DWNFKB] Modulation clutch cut-off release solenoid: Short circuit........................................ 18
Failure code [DWNFKY] (Modulation clutch cut-off release solenoid:
Short circuit with power source line) ......................................................................................................... 20
Failure code [DX16KA] Fan pump EPC solenoid: Disconnection................................................................. 22
Failure code [DX16KB] Fan pump EPC solenoid: Short circuit .................................................................... 23
Failure code [DX16KY] Fan pump EPC solenoid: Short circuit with power supply line ................................ 24
Failure code [DXA1KA] Pump PC-EPC solenoid: Disconnection ................................................................. 25
Failure code [DXA1KB] Pump PC-EPC solenoid: Short circuit..................................................................... 26
Failure code [DXF0KA] AJSS EPC solenoid: Disconnection........................................................................ 27
Failure code [DXF0KB] AJSS EPC solenoid: Short circuit ........................................................................... 28
Failure code [DXH1KA] Lockup ECMV solenoid: Disconnection.................................................................. 30
Failure code [DXH1KB] Lockup ECMV solenoid: Short circuit ..................................................................... 32
Failure code [DXH1KY] Lockup ECMV solenoid: Short circuit with power supply line ................................. 34
Failure code [DXH4KA] 1st clutch ECMV solenoid: Disconnection .............................................................. 36
WD600-6 40-309 1
SEN05059-01
Failure code [DXH4KB] 1st clutch ECMV solenoid: Short circuit .................................................................. 38
Failure code [DXH4KY] 1st clutch ECMV solenoid: Short circuit with power supply line.............................. 40
40-309 2 WD600-6
SEN05059-01
WD600-6 40-309 3
SEN05059-01 Failure code [DWM1KA] Work equipment neutral lock solenoid: Disconnection
Failure code [DWM1KA] Work equipment neutral lock solenoid:

Disconnection 1
Action code Failure code Work equipment neutral lock solenoid: Disconnection
Trouble
E01 DWM1KA (Work equipment controller system)
Contents of • Since the work equipment neutral lock solenoid system is disconnected, no current flows when the
trouble work equipment neutral lock solenoid output is ON.
• Stops outputting the signal to the work equipment EPC solenoid according to an input signal from
Action of
the work equipment lock lever.
controller
Problem that
• Each work equipment EPC solenoid lock normally works according to an input signal from the work
appears on
equipment lock lever.
machine
• The output state (ON/OFF) to the work equipment neutral lock solenoid can be checked with the
Related monitoring function (Code: 40952, D-OUT-0).
information • Method of reproducing failure code: Turn the starting switch ON and move the work equipment lock
lever to the LOCK position.

Defective work equipment 2. Disconnect connector B02, and connect T-adapter to male side.
1 neutral lock solenoid
Resis-
(Internal disconnection) Between B02 (male) (1) and (2) 35 – 45 z
tance
2. Disconnect connectors L07 and HD4, and connect T-adapter to
Disconnection or short circuit female side of L07.
2
in wiring harness
Possible causes 35 – 45 z
ground tance
and standard
Disconnection in wiring har- 2. Disconnect connectors B02 and L07, and connect T-adapters
ness to each female side.
3
(Disconnection in wiring har- Between L07 (female) (7) and B02 (female) Resis-
Max. 1 z
Between B02 (female) (2) and chassis Resis-
Max. 1 z
ground tance
controller
be performed.)
40-309 4 WD600-6
Failure code [DWM1KA] Work equipment neutral lock solenoid: Disconnection SEN05059-01
Circuit diagram related to work equipment neutral lock solenoid
WD600-6 40-309 5
SEN05059-01 Failure code [DWM1KB] Work equipment neutral lock solenoid: Short circuit
Failure code [DWM1KB] Work equipment neutral lock solenoid: Short

circuit 1
Action code Failure code Work equipment neutral lock solenoid: Short circuit
Trouble
E01 DWM1KB (Work equipment controller system)
Contents of • Since the work equipment neutral lock solenoid system was shorted with the chassis ground, abnor-
trouble mal current flowed when the work equipment neutral lock solenoid output was ON.
• Stops outputting the signal to the work equipment neutral lock solenoid.
Action of • Stops outputting the signal to the work equipment solenoid according to an input signal from the
controller work equipment lock lever.
Problem that • Each work equipment solenoid EPC lock normally works according to an input signal from the work
appears on equipment lock lever.
machine • The wiring harness or controller may be burnt out.
• The output state (ON/OFF) to the work equipment neutral lock solenoid can be checked with the
Related monitoring function (Code: 40952, D-OUT-0).
information • Method of reproducing failure code: Turn the starting switch ON and move the work equipment lock
lever to the LOCK position

2. Disconnect connector B02, and connect T-adapter to male side.
Resis-
1 neutral lock solenoid Between B02 (male) (1) and (2) 35 – 45 z
tance
Between B02 (male) (1), (2) and chassis Resis-
Min. 1 Mz
ground tance
Grounding fault in wiring har- 2. Disconnect connectors B02 and L07, and connect T-adapter to
(Contact with ground circuit) Between L07 (female) (7) or B02 (female) Resis-
Max. 1 z
and standard 2. Disconnect connector HD4 and connect T-adapter to male side.
value in normal a Check by using multimeter in continuity mode.
state Defective diode HD4
3 (internal open circuit in har- Between HD4 (male) (2) (+) and (3) Continuity
ness) Between HD4 (male) (3) (+) and (2) No continuity
Between HD4 (male) (2) (+) and (1) Continuity
Between HD4 (male) (1) (+) and (2) No continuity
2. Disconnect connectors L07 and HD4, and connect T-adapter to
Disconnection or short circuit female side of L07.
4
in wiring harness
35 – 45 z
ground tance
controller
be performed.)
40-309 6 WD600-6
Failure code [DWM1KB] Work equipment neutral lock solenoid: Short circuit SEN05059-01
WD600-6 40-309 7
SEN05059-01 Failure code [DWM1KY] Work equipment neutral lock solenoid: Short circuit with power supply line
Failure code [DWM1KY] Work equipment neutral lock solenoid: Short

circuit with power supply line 1
Action code Failure code Work equipment neutral lock solenoid: Short circuit with power sup-
Trouble ply line
E01 DWM1KY (Work equipment controller system)
Contents of • Since the work equipment neutral lock solenoid system was shorted with the power source, abnor-
trouble mal voltage was applied when the work equipment neutral lock solenoid output was OFF.
• Do not stop output to the work equipment neutral lock solenoid.
Action of • Stops outputting the signal to the work equipment EPC solenoid according to an input signal from
controller the work equipment lock lever.
Problem that
appears on • All work equipment do not move.
machine
• The output state (ON/OFF) to the work equipment neutral lock EPC solenoid can be checked with
the monitoring function (Code: 40952, D-OUT-0).
Related • Method of reproducing failure code: Turn the starting switch ON and move the work equipment lock
information lever to the LOCK position
• The work equipment can be operated by disconnecting the work equipment neutral lock solenoid
connector (Disconnection in wiring harness).

2. Disconnect connector B02, and connect T-adapter to female
and standard (Contact with 24 V circuit)
value in normal Between B02 (female) (1) and chassis
state Voltage Max. 3 V
ground
controller
be performed.)
40-309 8 WD600-6
Failure code [DWM1KY] Work equipment neutral lock solenoid: Short circuit with power supply line SEN05059-01
WD600-6 40-309 9
SEN05059-01 Failure code [DWN7KA] Blade float magnet detent solenoid: Disconnection
Failure code [DWN7KA] Blade float magnet detent solenoid:

Disconnection 1
Action code Failure code Blade float magnet detent solenoid: Disconnection
Trouble
E01 DWN7KA (Work equipment controller system)
Contents of • Since the blade float magnet detent solenoid power supply system is disconnected, no current flows
trouble when the blade float magnet detent solenoid output is ON.
• Keeps normal output condition to the blade float magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner lower stop lamp.
controller
Problem that
• The blade remote positioner lower does not function.
appears on
• The blade is not held at float detent position.
machine
• The output state (ON/OFF) to the blade float magnet detent solenoid can be checked with the mon-
Related
itoring function (Code: 40952 D-OUT-2).
information
• Method of reproducing failure code: Engine started + blade float detent

Defective blade float magnet 2. Disconnect connector S06, and connect T-adapter to male side.
1 detent solenoid
Resis-
(Internal disconnection) Between S06 (male) (1) and (2) 35 – 45 z
tance
Possible causes ness
2 Between L07 (female) (27) and S06 (female) Resis-
and standard (Disconnection or defective Max. 1 z
(1) tance
value in normal contact)
state Between S06 (female) (2) and chassis Resis-
Max. 1 z
ground tance
3 Blade lever: Neutral Voltage Max. 1 V
controller
Between L07 (27) Blade lever:
and chassis ground Float detent opera- Voltage 20 – 30 V
tion
40-309 10 WD600-6
Failure code [DWN7KA] Blade float magnet detent solenoid: Disconnection SEN05059-01
Circuit diagram related to blade magnet detent solenoid
WD600-6 40-309 11
SEN05059-01 Failure code [DWN7KB] Blade float magnet detent solenoid: Short circuit
Failure code [DWN7KB] Blade float magnet detent solenoid: Short

circuit 1
Action code Failure code Blade float magnet detent solenoid: Short circuit
Trouble
E01 DWN7KB (Work equipment controller system)
Contents of • Since the blade float magnet detent solenoid power supply system was shorted with the chassis
trouble ground, abnormal current flowed when the lift arm float magnet detent solenoid output was ON.
• Stops outputting the signal to the blade float magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner lower stop lamp.
controller
Problem that
• The blade remote positioner lower does not function.
appears on
• The blade is not held at float detent position.
machine
• The output state (ON/OFF) to the lift arm float magnet detent solenoid can be checked with the mon-
Related
information
• Method of reproducing failure code: Engine started + blade float detent

Defective blade float magnet
Resis-
1 detent solenoid Between S06 (male) (1) and (2) 35 – 45 z
tance
Between S06 (male) (1), (2) and chassis Resis-
Min. 1 Mz
ground tance
Possible causes
and standard Grounding fault in wiring har- 2. Disconnect connectors S06 and L07, and connect T-adapter to
value in normal
state (Contact with ground circuit) Between L07 (female) (27) or S06 (female) Resis-
Min. 1 Mz
controller
tion
40-309 12 WD600-6
Failure code [DWN7KB] Blade float magnet detent solenoid: Short circuit SEN05059-01
WD600-6 40-309 13
SEN05059-01 Failure code [DWN7KY] Blade float magnet detent solenoid: Short circuit with power supply line
Failure code [DWN7KY] Blade float magnet detent solenoid: Short

circuit with power supply line 1
Action code Failure code Blade float magnet detent solenoid: Short circuit with power supply
Trouble line
E01 DWN7KY (Work equipment controller system)
Contents of • Since the blade float magnet detent solenoid power supply system was shorted with the power
trouble source, abnormal voltage was applied when the blade float magnet detent solenoid output was ON.
• Stops outputting the signal to the blade float magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner lower stop lamp to stop lower stop control.
controller
• If you perform blade float detent operation, detent condition is not automatically released (can be
Problem that
manually released).
appears on
• If you do not perform blade detent operation, return of the blade lever to neutral is affected by the
machine
suction power of the magnet (lever control is deteriorated).
• The output state (ON/OFF) to the blade float magnet detent solenoid can be checked with the mon-
Related
information

1
Possible causes Between S06 (female) (1) and (2) Voltage Max. 3 V
and standard
state 2. Insert T-adapter into connector L07.
controller
tion
40-309 14 WD600-6
Failure code [DWN7KY] Blade float magnet detent solenoid: Short circuit with power supply line SEN05059-01
WD600-6 40-309 15
SEN05059-01 Failure code [DWNFKA] Modulation clutch cut-off release solenoid: Disconnection
Failure code [DWNFKA] Modulation clutch cut-off release solenoid:

Disconnection 1
Action code Failure code Modulation clutch cut-off release solenoid: Disconnection
Trouble
E01 DWNFKA (Transmission controller system)
Contents of • Since the modulation clutch cut-off release solenoid power supply system is disconnected, no cur-
trouble rent flows when the modulation clutch cut-off release solenoid is ON.
Action of
controller
Problem that
• The cut-off release function cannot be used.
appears on
• The engine is not used as brake when left foot brake is used.
machine
• The output state (ON/OFF) to the modulation clutch cut-off release solenoid can be checked with the
Related
monitoring function (Code: 40949, D-OUT-0).
information

Defective modulation clutch 2. Disconnect connector T02, and connect T-adapter to male side.
1 cut-off release solenoid
Resis-
(Internal disconnection) Between T02 (male) (1) and (2) 30 – 40 z
tance
2. Disconnect connectors T02 and L04, and connect T-adapters to
ness
2 Between L04 (female) (7) and T02 (female) Resis-
Possible causes (1) tance
contact)
and standard Between T02 (female) (2) and chassis Resis-
value in normal Max. 1 z
ground tance
state
Directional lever or
Defective transmission con- directional selector Voltage Max. 1 V
3
troller switch: N position
Between L04 (7) and
directional selector
Voltage 20 – 30 V
switch: F or R
(when travelling)
40-309 16 WD600-6
Failure code [DWNFKA] Modulation clutch cut-off release solenoid: Disconnection SEN05059-01
Circuit diagram related to modulation clutch cut-off release solenoid
WD600-6 40-309 17
SEN05059-01 Failure code [DWNFKB] Modulation clutch cut-off release solenoid: Short circuit
Failure code [DWNFKB] Modulation clutch cut-off release solenoid:

Short circuit 1
Action code Failure code Modulation clutch cut-off release solenoid: Short circuit
Trouble
E01 DWNFKB (Transmission controller system)
• Since the modulation clutch cut-off release solenoid power supply system was shorted with the
Contents of
chassis ground, abnormal current flowed when the modulation clutch cut-off release solenoid was
trouble
ON.
Action of • Turns the output to the modulation clutch cut-off release solenoid OFF.
Problem that
• The cut-off release function cannot be used.
appears on
• The engine is not used as brake when left foot brake is used.
machine
• The output state (ON/OFF) to the modulation clutch cut-off release solenoid can be checked with
Related
information

Resis-
1 cut-off release solenoid Between T02 (male) (1) and (2) 30 – 40 z
tance
Between T02 (male) (1), (2) and chassis Resis-
Min. 1 Mz
ground tance
Grounding fault in wiring har- 2. Disconnect connectors T02 and L04, and connect T-adapter to
(Contact with ground circuit) Between L04 (female) (7) or T02 (female) Resis-
Min. 1 Mz
Possible causes
2. Disconnect connector HD4 and connect T-adapter to male side.
and standard
a Check by using multimeter in continuity mode.
value in normal
state 3 Defective diode (HD4) Between HD4 (male) (2) (+) and (1) Continuity
Between HD4 (male) (2) (+) and (3) Continuity
4
Between L04 (7) and
Voltage 20 – 30 V
switch: F or R
(when travelling)
40-309 18 WD600-6
Failure code [DWNFKB] Modulation clutch cut-off release solenoid: Short circuit SEN05059-01
WD600-6 40-309 19
Failure code [DWNFKY] Modulation clutch cut-off release solenoid: Short circuit with power source
SEN05059-01 line
Failure code [DWNFKY] Modulation clutch cut-off release solenoid:

Short circuit with power source line 1
Action code Failure code Modulation clutch cut-off release solenoid: Short circuit with power
Trouble supply line
E03 DWNFKY (Transmission controller system)
• Since the modulation clutch cut-off release solenoid power supply system was shorted with the
Contents of
power source, abnormal voltage was applied when the modulation clutch cut-off release solenoid
trouble
output was OFF.
• Keeps the transmission in neutral.
• Releases the transmission from neutral if you move the directional lever or directional selector
Action of switch to N (Neutral).
• Even if cause of failure disappears, system does not reset itself until the directional lever or direc-
tional selector switch is set to N (Neutral).
Problem that
• The cut-off function cannot be used.
appears on
• The modulation clutch cannot be cut off when left foot brake is used.
machine
• The output state (ON/OFF) to the modulation clutch cut-off release solenoid can be checked with
Related
information

2. Disconnect connector T02, and connect T-adapter to female
1
Between T02 (female) (1) and (2) Voltage Max. 3 V
and standard 2. Insert T-adapter into connector L04.
state
2
Between L04 (7) and
Voltage 20 – 30 V
switch: F or R
(when travelling)
40-309 20 WD600-6
Failure code [DWNFKY] Modulation clutch cut-off release solenoid: Short circuit with power source
line SEN05059-01
WD600-6 40-309 21
SEN05059-01 Failure code [DX16KA] Fan pump EPC solenoid: Disconnection
Failure code [DX16KA] Fan pump EPC solenoid: Disconnection 1
Action code Failure code Fan pump EPC solenoid: Disconnection

Trouble
E01 DX16KA (Transmission controller system)
Contents of • Since the fan pump EPC solenoid system is disconnected, no current flows when the fan pump EPC
trouble solenoid output is ON.
Action of • Turns the output to the fan pump EPC solenoid OFF.
Problem that
appears on • The fan speed is set to the maximum.
machine
• The output state (current) to the fan pump EPC solenoid can be checked with the monitoring func-
Related
tion (Code: 41400 FAN EPC DIR).
information

Defective fan pump EPC 2. Disconnect connector R12, and connect T-adapter to male side.
Resis-
tion) Between R12 (male) (1) and (2) 5 – 10 z
tance
2
in wiring harness
Resis-
tance
and standard
Disconnection in wiring har- 2. Disconnect connectors R12 and L04, and connect T-adapters to
3
(Disconnection or defective Between L04 (female) (23) and R12 (female) Resis-
Max. 1 z
Between L04 (female) (27) and R12 (female) Resis-
Max. 1 z
(1) tance
troller
be performed.)
Circuit diagram related to fan pump EPC solenoid
40-309 22 WD600-6
Failure code [DX16KB] Fan pump EPC solenoid: Short circuit SEN05059-01
Failure code [DX16KB] Fan pump EPC solenoid: Short circuit 1
Action code Failure code Fan pump EPC solenoid: Short circuit
Trouble
E01 DX16KB (Transmission controller system)
Contents of • Since the fan pump EPC solenoid system was shorted with the chassis ground, abnormal current
trouble flowed when the fan pump EPC solenoid output was ON.
Problem that
appears on • The fan speed is set to the maximum.
machine
Related
information

2. Disconnect connector R12, and connect T-adapter to male side.
Defective fan pump EPC
Resis-
1 solenoid (Internal short cir- Between R12 (male) (1) and (2) 5 – 10 z
tance
cuit)
Between R12 (male) (1), (2) and chassis Resis-
Min. 1 Mz
ground tance
Possible causes Grounding fault in wiring har- 2. Disconnect connectors R12 and L04, and connect T-adapter to
value in normal (Contact with ground circuit) Between L04 (female) (27) or R12 (female) Resis-
state Min. 1 Mz
3
in wiring harness
Resis-
tance
troller
be performed.)
WD600-6 40-309 23
SEN05059-01 Failure code [DX16KY] Fan pump EPC solenoid: Short circuit with power supply line
Failure code [DX16KY] Fan pump EPC solenoid: Short circuit with
power supply line 1
Action code Failure code Fan pump EPC solenoid: Short circuit with power supply line
Trouble
E01 DX16KY (Transmission controller system)
Contents of • Since the fan pump EPC solenoid system was shorted with the power source, abnormal voltage was
trouble applied when the fan pump EPC solenoid output was OFF.
Problem that
appears on • The fan speed is set to the minimum.
machine
Related
information

2. Disconnect connector R12, and connect T-adapter to female
1
value in normal
state Between R12 (female) (1) and (2) Voltage Max. 3 V
troller
be performed.)
40-309 24 WD600-6
Failure code [DXA1KA] Pump PC-EPC solenoid: Disconnection SEN05059-01
Failure code [DXA1KA] Pump PC-EPC solenoid: Disconnection 1
Action code Failure code Pump PC-EPC solenoid: Disconnection

Trouble
E01 DXA1KA (Work equipment controller system)
Contents of • Since the loader pump PC-EPC solenoid system is disconnected, no current flows when the loader
trouble pump PC-EPC solenoid output is ON.
Action of • Keeps normal output condition to the loader pump PC-EPC solenoid.
Problem that • Fuel consumption may become poor when engine speed is low.
appears on • Engine acceleration performance is deteriorated.
machine • The lift arm may increase speed suddenly.
• The output state (current) to the loader pump PC-EPC solenoid can be checked with the monitoring
Related
function (Code: 94500 PUMP EPC DIR).
information

Defective loader pump PC- 2. Disconnect connector T01, and connect T-adapter to male side.
1 EPC solenoid (Internal dis-
Resis-
connection) Between T01 (male) (1) and (2) 5 – 15 z
tance
2
in wiring harness
Resis-
tance
and standard
Disconnection in wiring har- 2. Disconnect connectors T01 and L07, and connect T-adapters to
3
(Disconnection or defective Between L07 (female) (23) and T01 (female) Resis-
Max. 1 z
Between L07 (female) (36) and T01 (female) Resis-
Max. 1 z
(1) tance
controller
be performed.)
Circuit diagram related to loader pump PC-EPC solenoid
WD600-6 40-309 25
SEN05059-01 Failure code [DXA1KB] Pump PC-EPC solenoid: Short circuit
Failure code [DXA1KB] Pump PC-EPC solenoid: Short circuit 1
Action code Failure code Pump PC-EPC solenoid: Short circuit

Trouble
E01 DXA1KB (Work equipment controller system)
Contents of • Since the loader pump PC-EPC solenoid system was shorted with the chassis ground, abnormal
trouble current flowed when the loader pump PC-EPC solenoid output was ON.
Action of • Stops outputting the signal to the loader pump PC-EPC solenoid.
• Fuel consumption may become poor when engine speed is low.
Problem that
• Engine acceleration performance is deteriorated.
appears on
• The lift arm may increase speed suddenly.
machine
• The output state (current) to the loader pump PC-EPC solenoid can be checked with the monitoring
Related
function (Code: 94500 PUMP EPC DIR).
information

Defective loader pump PC-
Resis-
1 EPC solenoid (Internal short Between T01 (male) (1) and (2) 5 – 15 z
tance
circuit)
Between T01 (male) (1), (2) and chassis Resis-
Min. 1 Mz
ground tance
Possible causes Grounding fault in wiring har- 2. Disconnect connectors T01 and L07, and connect T-adapter to
value in normal (Contact with ground circuit) Between L07 (female) (36) or T01 (female) Resis-
state Min. 1 Mz
3
in wiring harness
Resis-
tance
controller
be performed.)
Circuit diagram related to loader pump PC-EPC solenoid
40-309 26 WD600-6
Failure code [DXF0KA] AJSS EPC solenoid: Disconnection SEN05059-01
Failure code [DXF0KA] AJSS EPC solenoid: Disconnection 1
Action code Failure code AJSS EPC solenoid: Disconnection

Trouble
E01 DXF0KA (Work equipment controller system)
Contents of • Since the AJSS EPC solenoid system is disconnected, no current flows when the AJSS EPC sole-
trouble noid output is ON.
Action of • Stops outputting the signal to the AJSS EPC solenoid.
Problem that
appears on • Steering according to AJSS operation becomes less effective.
machine
• The output state (current) to the AJSS EPC solenoid can be checked with the monitoring function
(Code: 40908 AJSS EPC DIR).
Related
information
• This error is not displayed on a steering wheel specification machine. If it is displayed, select “NO”
AJSS option in option setting.

Defective AJSS EPC sole- 2. Disconnect connector B01, and connect T-adapter to male side.
1 noid
Resis-
(Internal disconnection) Between B01 (male) (1) and (2) 5 – 15 z
tance
2
in wiring harness
Resis-
tance
and standard
Disconnection in wiring har- 2. Disconnect connectors B01 and L07, and connect T-adapters to
3
(Disconnection or defective Between L07 (female) (23) and B01 Resis-
Max. 1 z
contact of connector) (female) (2) tance
Between L07 (female) (26) and B01 Resis-
Max. 1 z
(female) (1) tance
controller
be performed.)
Circuit diagram related to AJSS EPC solenoid
WD600-6 40-309 27
SEN05059-01 Failure code [DXF0KB] AJSS EPC solenoid: Short circuit
Failure code [DXF0KB] AJSS EPC solenoid: Short circuit 1
Action code Failure code AJSS EPC solenoid: Short circuit

Trouble
E01 DXF0KB (Work equipment controller system)
Contents of • Since the AJSS EPC solenoid system was shorted with the chassis ground, abnormal current
trouble flowed when the AJSS EPC solenoid output was ON.
Action of • Stops outputting the signal to the AJSS EPC solenoid.
Problem that
• Steering according to AJSS operation becomes less effective.
appears on
machine
• The output state (current) to the AJSS EPC solenoid can be checked with the monitoring function
(Code: 40908 AJSS EPC DIR).
Related
information

2. Disconnect connector B01, and connect T-adapter to male side.
Defective AJSS EPC sole-
Resis-
1 noid Between B01 (male) (1) and (2) 5 – 15 z
tance
Between B01 (male) (1), (2) and Resis-
Min. 1 Mz
Possible causes Grounding fault in wiring har- 2. Disconnect connectors B01 and L07, and connect T-adapter to
value in normal (Contact with ground circuit) Between L07 (female) (26) or B01 (female) Resis-
state Min. 1 Mz
3
in wiring harness
Resis-
tance
controller
be performed.)
Circuit diagram related to AJSS EPC solenoid
40-309 28 WD600-6
Failure code [DXF0KB] AJSS EPC solenoid: Short circuit SEN05059-01
WD600-6 40-309 29
SEN05059-01 Failure code [DXH1KA] Lockup ECMV solenoid: Disconnection
Failure code [DXH1KA] Lockup ECMV solenoid: Disconnection 1
Action code Failure code Lockup ECMV solenoid: Disconnection

Trouble
E01 DXH1KA (Transmission controller system)
Contents of • Since the lockup ECMV solenoid system is disconnected, no current flows when the lockup solenoid
trouble output is ON.
• Stops outputting the signal to the lockup ECMV solenoid.
Action of
• Determines that the lockup fill switch is OFF.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Torque converter lockup is not turned on
machine
• The output state (current) to the lockup ECMV solenoid can be checked with the monitoring function
Related (Code: 31609 ECMV LU DIR).
information • Method of reproducing failure code: Start engine, turn the torque convertor lockup switch ON, and
drive the machine.

Defective lockup ECMV 2. Disconnect connector LC.PS, and connect T-adapter to male
1 solenoid side.
(Internal disconnection) Resis-
Between LC.PS (male) (1) and (2) 5 – 15 z
tance
2
in wiring harness
and standard tance
Disconnection in wiring har- 2. Disconnect connectors LC.PS and L04, and connect T-adapters
3
(Disconnection or defective Between L04 (female) (23) and LC.PS Resis-
Max. 1 z
Between L04 (female) (35) and LC.PS Resis-
Max. 1 z
(female) (1) tance
troller
be performed.)
40-309 30 WD600-6
Failure code [DXH1KA] Lockup ECMV solenoid: Disconnection SEN05059-01
Circuit diagram related to lockup ECMV solenoid
WD600-6 40-309 31
SEN05059-01 Failure code [DXH1KB] Lockup ECMV solenoid: Short circuit
Failure code [DXH1KB] Lockup ECMV solenoid: Short circuit 1
Action code Failure code Lockup ECMV solenoid: Short circuit

Trouble
E01 DXH1KB (Transmission controller system)
Contents of • Since the lockup ECMV solenoid system is short with the chassis ground, abnormal current flowed
trouble when the lockup solenoid output was ON.
• Stops outputting the signal to the lockup ECMV solenoid.
Action of
• Determines that the lockup fill switch is OFF.
controller
Problem that
appears on • Torque converter lockup is not turned on.
machine
Related
(Code: 31609 ECMV LU DIR).
information
• Method of reproducing failure code: Engine started + torque convertor lockup switch ON + Travel

2. Disconnect connector LC.PS, and connect T-adapter to male
Defective lockup ECMV side.
1 solenoid Resis-
Between LC.PS (male) (1) and (2) 5 – 15 z
(Internal short circuit) tance
Between LC.PS (male) (1), (2) and chassis Resis-
Min. 1 Mz
ground tance
Possible causes
and standard Grounding fault in wiring har- 2. Disconnect connectors LC.PS and L04, and connect T-adapter
value in normal
state (Contact with ground circuit) Between L04 (female) (35) or LC.PS Resis-
Max. 1 z
3
in wiring harness
Resis-
tance
troller
be performed.)
40-309 32 WD600-6
Failure code [DXH1KB] Lockup ECMV solenoid: Short circuit SEN05059-01
WD600-6 40-309 33
SEN05059-01 Failure code [DXH1KY] Lockup ECMV solenoid: Short circuit with power supply line
Failure code [DXH1KY] Lockup ECMV solenoid: Short circuit with power
supply line 1
Action code Failure code Lockup ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXH1KY (Transmission controller system)
Contents of • Since the lockup ECMV solenoid system was shorted with the power source, abnormal voltage was
trouble applied when the lockup ECMV solenoid output was OFF.
• Releases the transmission from neutral if you move the directional lever or directional selector
Action of switch to N (Neutral).
Problem that
• Keeps neutral until the directional lever or directional selector switch is moved to N (Neutral).
appears on
• The lockup function is kept ON.
machine
Related
(Code: 31609 ECMV LU DIR)
information
• Method of reproducing failure code: Engine started + torque convertor lockup switch ON + Travel

2. Disconnect connector LC.PS, and connect T-adapter to female
1
value in normal
state Between LC.PS (female) (1) and (2) Voltage Max. 3 V
troller
be performed.)
40-309 34 WD600-6
Failure code [DXH1KY] Lockup ECMV solenoid: Short circuit with power supply line SEN05059-01
WD600-6 40-309 35
SEN05059-01 Failure code [DXH4KA] 1st clutch ECMV solenoid: Disconnection
Failure code [DXH4KA] 1st clutch ECMV solenoid: Disconnection 1
Action code Failure code 1st clutch ECMV solenoid: Disconnection

Trouble
Contents of • When the 1st clutch ECMV solenoid system is disconnected, no current flows when 1st clutch
trouble ECMV solenoid output is ON.
• Stops outputting the signal to the 1st clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 1st (The machine can travel in any gear speed other than 1st.)
machine
Related
• Method of reproducing failure code: Turn starting switch START, set the transmission manual/auto
information
shift selector switch in the MANUAL position, and select 1st using the shift down switch or move the
gear shift lever to 1st.

Defective 1st clutch ECMV 2. Disconnect connector 1.PS, and connect T-adapter to male
1 solenoid (Internal disconnec- side.
tion) Resis-
Between 1.PS (male) (1) and (2) 5 – 15 z
tance
2
in wiring harness
and standard tance
Disconnection in wiring har- 2. Disconnect connectors 1.PS and L04, and connect T-adapters
3
(Disconnection or defective Between L04 (female) (3) and 1.PS (female) Resis-
Max. 1 z
Between L04 (female) (25) and 1.PS Resis-
Max. 1 z
(female) (1) tance
troller
be performed.)
40-309 36 WD600-6
Failure code [DXH4KA] 1st clutch ECMV solenoid: Disconnection SEN05059-01
Circuit diagram related to 1st clutch ECMV solenoid
WD600-6 40-309 37
SEN05059-01 Failure code [DXH4KB] 1st clutch ECMV solenoid: Short circuit
Failure code [DXH4KB] 1st clutch ECMV solenoid: Short circuit 1
Action code Failure code 1st clutch ECMV solenoid: Short circuit
Trouble
Contents of • When the 1st clutch ECMV solenoid system was shorted with the chassis ground, abnormal current
trouble flowed when 1st clutch ECMV solenoid output was ON.
• Stops outputting the signal to the 1st clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 1st (The machine can travel in any gear speed other than 1st).
machine
Related
information

2. Disconnect connector 1.PS, and connect T-adapter to male
Defective 1st clutch ECMV side.
1 solenoid (Internal short cir- Resis-
cuit) tance
Resis-
Between 1.PS (1), (2) and chassis ground Min. 1 Mz
tance
Possible causes
and standard Grounding fault in wiring har- 2. Disconnect connectors 1.PS and L04, and connect T-adapter to
value in normal
state (Contact with ground circuit) Between L04 (female) (25) or 1.PS (female) Resis-
Min. 1 Mz
3
in wiring harness
Resis-
tance
troller
be performed.)
40-309 38 WD600-6
Failure code [DXH4KB] 1st clutch ECMV solenoid: Short circuit SEN05059-01
WD600-6 40-309 39
SEN05059-01
Failure code [DXH4KY] 1st clutch ECMV solenoid: Short circuit with
power supply line 1
Action code Failure code 1st clutch ECMV solenoid: Short circuit with power supply line
Trouble
Contents of • When the 1st clutch ECMV solenoid system was shorted with the power source, abnormal voltage
trouble was applied when 1st clutch ECMV solenoid output was OFF.
• Stops outputting the signal to the 2nd, 3rd, and 4th clutch ECMV solenoids.
• Also stops outputting the signal to the F (Forward) and R (Reverse) clutch ECMV solenoids when
Action of the speed clutch output is OFF.
Problem that
appears on • The transmission does not shift into 2nd, 3rd, nor 4th (the machine can travel at 1st).
machine
Related infor-
mation

2. Disconnect connector 1.PS, and connect T-adapter to female
1
value in normal
state Between 1.PS (female) (1) and (2) Voltage Max. 3 V
troller
be performed.)
40-309 40
Failure code [DXH4KY] 1st clutch ECMV solenoid: Short circuit with power supply line SEN05059-01
WD600-6 40-309 41
SEN05059-01
WD600-6 Wheel dozer

©2016 KOMATSU
All Rights Reserved
40-309 42
SEN05060-01
WHEEL DOZER
WD600-6

WD600-6 55001 and up

Failure code [DXH5KA] 2nd clutch ECMV solenoid: Disconnection ............................................................... 4
Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short circuit................................................................... 6
Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short circuit with power supply line .............................. 8
Failure code [DXH6KA] 3rd clutch ECMV solenoid: Disconnection.............................................................. 10
Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short circuit ................................................................. 12
Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short circuit with power supply line ............................. 14
Failure code [DXH7KA] R clutch ECMV solenoid: Disconnection ................................................................ 16
Failure code [DXH7KB] R clutch ECMV solenoid: Short circuit .................................................................... 18
Failure code [DXH7KY] R clutch ECMV solenoid: Short circuit with power supply line................................ 20
Failure code [DXH8KA] F clutch ECMV solenoid: Disconnection................................................................. 22
Failure code [DXH8KB] F clutch ECMV solenoid: Short circuit .................................................................... 24
Failure code [DXH8KY] F clutch ECMV solenoid: Short circuit with power supply line ................................ 26
Failure code [DXHHKA] 4th clutch ECMV solenoid: Disconnection ............................................................. 28
Failure code [DXHHKB] 4th clutch ECMV solenoid: Short circuit ................................................................. 30
Failure code [DXHHKY] 4th clutch ECMV solenoid: Short circuit with power supply line ............................. 32
Failure code [DXHJKA] RH pitch REAR EPC solenoid: Disconnection ........................................................ 34
Failure code [DXHJKB] RH pitch REAR EPC solenoid: Short circuit ........................................................... 35
Failure code [DXHJKY] RH pitch REAR EPC solenoid: Short circuit with power supply line ....................... 36
Failure code [DXHKKA] RH pitch FORWARD EPC solenoid: Disconnection............................................... 37
Failure code [DXHKKB] RH pitch FORWARD EPC solenoid: Short circuit .................................................. 38
Failure code [DXHKKY] RH pitch FORWARD EPC solenoid: Short circuit with power supply line .............. 39
WD600-6 40-310 1
SEN05060-01
Failure code [DXHPKA] Modulation clutch solenoid: Disconnection............................................................. 40

Failure code [DXHPKB] Modulation clutch solenoid: Short circuit ................................................................ 42
Failure code [DXHPKY] Modulation clutch solenoid: Short circuit with power source line............................ 44
Failure code [DXHPMA] Modulation clutch solenoid: Malfunction ................................................................ 46
Failure code [F@BBZL] (or VHMS_LED display: “n3” → “38”) Blow-by pressure: High error ...................... 48
Failure code [F@BYNR] (or VHMS_LED display: “n3” o “62”)
(Exhaust gas temperature (F): Abnormal heat)......................................................................................... 50
Failure code [F@BYNS] (or VHMS_LED display: “n3” o “61”)
(Exhaust gas temperature (F): Overheat) ................................................................................................. 52
Failure code [F@BZNR] (or VHMS_LED display: “n3” o “72”)
(Exhaust gas temperature (R): abnormal heat)......................................................................................... 54
Failure code [F@BZNS] (or VHMS_LED display “n3” o “71”)
(Exhaust gas temperature (R): Overheat)................................................................................................. 56
40-310 2 WD600-6
SEN05060-01
WD600-6 40-310 3
SEN05060-01 Failure code [DXH5KA] 2nd clutch ECMV solenoid: Disconnection
Failure code [DXH5KA] 2nd clutch ECMV solenoid: Disconnection 1
Action code Failure code 2nd clutch ECMV solenoid: Disconnection

Trouble
Contents of • When the 2nd clutch ECMV solenoid system is disconnected, no current flows when 2nd clutch
• Stops outputting the signal to the 2nd clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 2nd (The machine can travel in any gear speed other than 2nd.)
machine
• The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring func-
Related
information
shift selector switch in the MANUAL position, and select 2nd using the shift down switch or move the
gear shift lever to 2nd.

Defective 2nd clutch ECMV 2. Disconnect connector 2.PS, and connect T-adapter to male side.
Resis-
tion) Between 2.PS (male) (1) and (2) 5 – 15 z
tance
2
in wiring harness
Resis-
tance
and standard
Disconnection in wiring har- 2. Disconnect connectors 2.PS and L04, and connect T-adapters to
3
Max. 1 z
Max. 1 z
(female) (2) tance
troller
be performed.)
40-310 4 WD600-6
Failure code [DXH5KA] 2nd clutch ECMV solenoid: Disconnection SEN05060-01
Circuit diagram related to 2nd clutch ECMV solenoid
WD600-6 40-310 5
SEN05060-01 Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short circuit
Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short circuit 1
Action code Failure code 2nd clutch ECMV solenoid: Short circuit
Trouble
Contents of • When the 2nd clutch ECMV solenoid system was shorted with the chassis ground, abnormal current
trouble flowed when 2nd clutch ECMV solenoid output was ON.
• Stops outputting the signal to the 2nd clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 2nd (The machine can travel in any gear speed other than 2nd.)
machine
Related
information

Defective 2nd clutch ECMV side.
cuit) tance
Between 2.PS (male) (1), (2) and chassis Resis-
Min. 1 Mz
ground tance
Possible causes
value in normal
Min. 1 Mz
3
in wiring harness
Resis-
tance
troller
be performed.)
40-310 6 WD600-6
Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short circuit SEN05060-01
WD600-6 40-310 7
SEN05060-01 Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short circuit with power supply line
Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short circuit with
power supply line 1
Action code Failure code 2nd clutch ECMV solenoid: Short circuit with power supply line
Trouble
Contents of • When the 2nd clutch ECMV solenoid system was shorted with the power source, abnormal voltage
trouble was applied when 2nd clutch ECMV solenoid output was OFF.
• Stops outputting the signal to the 1st, 3rd, and 4th clutch ECMV solenoids.
Problem that
appears on • The transmission does not shift into 1st, 3rd, nor 4th (the machine can travel at 2nd).
machine
Related
information

1
value in normal
troller
be performed.)
40-310 8 WD600-6
Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short circuit with power supply line SEN05060-01
WD600-6 40-310 9
SEN05060-01 Failure code [DXH6KA] 3rd clutch ECMV solenoid: Disconnection
Failure code [DXH6KA] 3rd clutch ECMV solenoid: Disconnection 1
Action code Failure code 3rd clutch ECMV solenoid: Disconnection

Trouble
Contents of • When the 3rd clutch ECMV solenoid system is disconnected, no current flows when 3rd clutch
• Stops outputting the signal to the 3rd clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 3rd (The machine can travel in any gear speed other than 3rd.)
machine
Related
information
shift selector switch in the MANUAL position, and select 3rd using the shift down switch or move the
gear shift lever to 3rd.

Defective 3rd clutch ECMV 2. Disconnect connector 3.PS, and connect T-adapter to male side.
Resis-
tion) Between 3.PS (male) (1) and (2) 5 – 15 z
tance
2
in wiring harness
Resis-
tance
and standard
Disconnection in wiring har- 2. Disconnect connectors 3.PS and L04, and connect T-adapters to
3
(Disconnection or defective Between L04 (female) (13) and 3.PS Resis-
Max. 1 z
Max. 1 z
(female) (1) tance
troller
be performed.)
40-310 10 WD600-6
Failure code [DXH6KA] 3rd clutch ECMV solenoid: Disconnection SEN05060-01
Circuit diagram related to 3rd clutch ECMV solenoid
WD600-6 40-310 11
SEN05060-01 Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short circuit
Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short circuit 1
Action code Failure code 3rd clutch ECMV solenoid: Short circuit
Trouble
Contents of • When the 3rd clutch ECMV solenoid system was shorted with the chassis ground, abnormal current
trouble flowed when 3rd clutch ECMV solenoid output was ON.
• Stops outputting the signal to the 3rd clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 3rd (The machine can travel in any gear speed other than 3rd.)
machine
Related
information

Defective 3rd clutch ECMV side.
cuit) tance
Min. 1 Mz
ground tance
value in normal 2 ness either female side.
Min. 1 Mz
Disconnection or short circuit 2. Disconnect connector L04, and connect T-adapter to female side.
3
in wiring harness Resis-
tance
troller
be performed.)
40-310 12 WD600-6
Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short circuit SEN05060-01
WD600-6 40-310 13
SEN05060-01 Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short circuit with power supply line
Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short circuit with
power supply line 1
Action code Failure code 3rd clutch ECMV solenoid: Short circuit with power supply line
Trouble
Contents of • When the 3rd clutch ECMV solenoid system was shorted with the power source, abnormal voltage
trouble was applied when 3rd clutch ECMV solenoid output was OFF.
• Stops outputting the signal to the 1st, 2nd, and 4th clutch ECMV solenoids.
tional selector switch is set to Neutral.
Problem that
appears on • The transmission does not shift into 1st, 2nd, nor 4th (the machine can travel at 3rd).
machine
Related
information

1
value in normal
troller
be performed.)
40-310 14 WD600-6
Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short circuit with power supply line SEN05060-01
WD600-6 40-310 15
SEN05060-01 Failure code [DXH7KA] R clutch ECMV solenoid: Disconnection
Failure code [DXH7KA] R clutch ECMV solenoid: Disconnection 1
Action code Failure code R clutch ECMV solenoid: Disconnection

Trouble
Contents of • When the R (Reverse) clutch ECMV solenoid system is disconnected, no current flows when R
trouble (Reverse) clutch ECMV solenoid output is ON.
• Stops outputting the signal to the R (Reverse) clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission cannot be set in the R (Reverse) position (the machine can travel in F (Forward)).
machine
• The output state (current) to the R (Reverse) clutch ECMV solenoid can be checked with the moni-
Related toring function (Code: 31606, ECMV R DIR).
information • Method of reproducing failure code: Turn starting switch ON, and set the directional lever or direc-
tional selector switch to R (Reverse).

Defective R (Reverse) clutch 2. Disconnect connector R.PS, and connect T-adapter to male
1 ECMV solenoid (Internal dis- side.
connection) Resis-
Between R.PS (male) (1) and (2) 5 – 15 z
tance
2
in wiring harness
and standard tance
Disconnection in wiring har- 2. Disconnect connectors R.PS and L04, and connect T-adapters
3
(Disconnection or defective Between L04 (female) (3) and R.PS Resis-
Max. 1 z
Between L04 (female) (15) and R.PS Resis-
Max. 1 z
(female) (1) tance
troller
be performed.)
40-310 16 WD600-6
Failure code [DXH7KA] R clutch ECMV solenoid: Disconnection SEN05060-01
Circuit diagram related to R (Reverse) clutch ECMV solenoid
WD600-6 40-310 17
SEN05060-01 Failure code [DXH7KB] R clutch ECMV solenoid: Short circuit
Failure code [DXH7KB] R clutch ECMV solenoid: Short circuit 1
Action code Failure code R clutch ECMV solenoid: Short circuit

Trouble
Contents of • When the R (Reverse) clutch ECMV solenoid system was shorted with the chassis ground, abnor-
trouble mal current flowed when R (Reverse) clutch ECMV solenoid output was ON.
• Stops outputting the signal to the R (Reverse) clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission cannot be set in the R (Reverse) position (the machine can travel in F (Forward)).
machine
• The output state (current) to the R (Reverse) clutch ECMV solenoid can be checked with the moni-
Related toring function (Code: 31606, ECMV R DIR).
tional selector switch to R (Reverse).

2. Disconnect connector R.PS, and connect T-adapter to male
Defective R (Reverse) clutch side.
1 ECMV solenoid (Internal Resis-
Between R.PS (male) (1) and (2) 5 – 15 z
short circuit) tance
Between R.PS (male) (1), (2) and chassis Resis-
Min. 1 Mz
ground tance
Possible causes
and standard Grounding fault in wiring har- 2. Disconnect connectors R.PS and L04, and connect T-adapter to
value in normal
state (Contact with ground circuit) Between L04 (female) (15) or R.PS (female) Resis-
Min. 1 Mz
3
in wiring harness
Resis-
tance
troller
be performed.)
40-310 18 WD600-6
Failure code [DXH7KB] R clutch ECMV solenoid: Short circuit SEN05060-01
WD600-6 40-310 19
SEN05060-01 Failure code [DXH7KY] R clutch ECMV solenoid: Short circuit with power supply line
Failure code [DXH7KY] R clutch ECMV solenoid: Short circuit with

power supply line 1
Action code Failure code R clutch ECMV solenoid: Short circuit with power supply line
Trouble
Contents of • Since the R (Reverse) ECMV solenoid system was shorted with the power source, abnormal volt-
trouble age was applied when the R (Reverse) ECMV solenoid output was OFF.
• Outputs the signal to the R (Reverse) clutch ECMV solenoid when the directional lever or directional
switch is in R (Reverse).
Action of • Sets the transmission in N (Neutral) when the gear shift lever is in N (Neutral) or F (Forward).
Problem that
appears on • The machine can travel only in R (Reverse).
machine
Related tion (Code: 31606, ECMV R DIR).
tional switch to R (Reverse).

2. Disconnect connector R.PS, and connect T-adapter to female
1
value in normal
state Between R.PS (female) (1) and (2) Voltage Max. 3 V
troller
be performed.)
40-310 20 WD600-6
Failure code [DXH7KY] R clutch ECMV solenoid: Short circuit with power supply line SEN05060-01
WD600-6 40-310 21
SEN05060-01 Failure code [DXH8KA] F clutch ECMV solenoid: Disconnection
Failure code [DXH8KA] F clutch ECMV solenoid: Disconnection 1
Action code Failure code F clutch ECMV solenoid: Disconnection

Trouble
Contents of • When the F (Forward) clutch ECMV solenoid system is disconnected, no current flows when F (For-
trouble ward) clutch ECMV solenoid output is ON.
• Stops outputting the signal to the F (Forward) clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission cannot be set in the F (Forward) position (the machine can travel in R (Reverse)).
machine
Related tion (Code: 31608, ECMV F DIR).
tional switch to F (Forward).

Defective F (Forward) clutch 2. Disconnect connector F.PS, and connect T-adapter to male side.
1 ECMV solenoid (Internal dis-
Resis-
connection) Between F.PS (male) (1) and (2) 5 – 15 z
tance
2
in wiring harness
Resis-
tance
and standard
Disconnection in wiring har- 2. Disconnect connectors F.PS and L04, and connect T-adapters to
3
(Disconnection or defective Between L04 (female) (13) and F.PS Resis-
Max. 1 z
Between L04 (female) (5) and F.PS (female) Resis-
Max. 1 z
(1) tance
troller
be performed.)
40-310 22 WD600-6
Failure code [DXH8KA] F clutch ECMV solenoid: Disconnection SEN05060-01
Circuit diagram related to F (Forward) clutch ECMV solenoid
WD600-6 40-310 23
SEN05060-01 Failure code [DXH8KB] F clutch ECMV solenoid: Short circuit
Failure code [DXH8KB] F clutch ECMV solenoid: Short circuit 1
Action code Failure code F clutch ECMV solenoid: Short circuit

Trouble
Contents of • When the F (Forward) clutch ECMV solenoid system was shorted with the chassis ground, abnor-
trouble mal current flowed when F (Forward) clutch ECMV solenoid output was ON.
• Stops outputting the signal to the F (Forward) clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission cannot be set in the F (Forward) position (the machine can travel in R (Reverse)).
machine
• The output state (current) to the F (Forward) clutch ECMV solenoid can be checked with the moni-
Related toring function (Code: 31608, ECMV F DIR).

2. Disconnect connector F.PS, and connect T-adapter to male
Defective F (Forward) clutch side.
1 ECMV solenoid (Internal Resis-
Between F.PS (male) (1) and (2) 5 – 15 z
short circuit) tance
Between F.PS (male) (1), (2) and chassis Resis-
Min. 1 Mz
ground tance
Possible causes
and standard Grounding fault in wiring har- 2. Disconnect connectors F.PS and L04, and connect T-adapter to
value in normal
state (Contact with ground circuit) Between L04 (female) (5) or F.PS (female) Resis-
Min. 1 Mz
3
in wiring harness
Resis-
tance
troller
be performed.)
40-310 24 WD600-6
Failure code [DXH8KB] F clutch ECMV solenoid: Short circuit SEN05060-01
WD600-6 40-310 25
SEN05060-01 Failure code [DXH8KY] F clutch ECMV solenoid: Short circuit with power supply line
Failure code [DXH8KY] F clutch ECMV solenoid: Short circuit with

power supply line 1
Action code Failure code F clutch ECMV solenoid: Short circuit with power supply line
Trouble
Contents of • Since the F (Forward) ECMV solenoid system was shorted with the power source, abnormal voltage
trouble was applied when the F (Forward) ECMV solenoid output was OFF.
• Outputs the signal to the F (Forward) clutch ECMV solenoid when the directional lever or directional
switch is in F (Forward).
Action of • Sets the transmission in N (Neutral) when the gear shift lever is in N (Neutral) or R (Reverse).
Problem that
appears on • The machine can travel only F (Forward).
machine
• The output state (current) to the F (Forward) clutch ECMV solenoid can be checked with the moni-
Related toring function (Code: 31608, ECMV F DIR).

2. Disconnect connector F.PS, and connect T-adapter to female
1
value in normal
state Between F.PS (female) (1) and (2) Voltage Max. 3 V
troller
be performed.)
40-310 26 WD600-6
Failure code [DXH8KY] F clutch ECMV solenoid: Short circuit with power supply line SEN05060-01
WD600-6 40-310 27
SEN05060-01 Failure code [DXHHKA] 4th clutch ECMV solenoid: Disconnection
Failure code [DXHHKA] 4th clutch ECMV solenoid: Disconnection 1
Action code Failure code 4th clutch ECMV solenoid: Disconnection

Trouble
E03 DXHHKA (Transmission controller system)
Contents of • When the 4th clutch ECMV solenoid system is disconnected, no current flows when 4th clutch
• Stops outputting the signal to the 4th clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 4th (The machine can travel in any gear speed other than 4th.)
machine
Related
information
shift selector switch in the MANUAL position, and select 4th using the shift down switch or move the
gear shift lever to 4th.

Defective 4th clutch ECMV 2. Disconnect connector 4.PS, and connect T-adapter to male
1 solenoid (Internal disconnec- side.
tion) Resis-
tance
2
in wiring harness
and standard tance
Disconnection in wiring har- 2. Disconnect connectors 4.PS and L04, and connect T-adapters
3
Max. 1 z
Max. 1 z
(female) (1) tance
troller
be performed.)
40-310 28 WD600-6
Failure code [DXHHKA] 4th clutch ECMV solenoid: Disconnection SEN05060-01
Circuit diagram related to 4th clutch ECMV solenoid
WD600-6 40-310 29
SEN05060-01 Failure code [DXHHKB] 4th clutch ECMV solenoid: Short circuit
Failure code [DXHHKB] 4th clutch ECMV solenoid: Short circuit 1
Action code Failure code 4th clutch ECMV solenoid: Short circuit
Trouble
E03 DXHHKB (Transmission controller system)
Contents of • When the 4th clutch ECMV solenoid system was shorted with the chassis ground, abnormal current
trouble flowed when 4th clutch ECMV solenoid output was ON.
• Stops outputting the signal to the 4th clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 4th (The machine can travel in any gear speed other than 4th.)
machine
Related
information

Defective 4th clutch ECMV side.
cuit) tance
Min. 1 Mz
ground tance
Possible causes
value in normal
Min. 1 Mz
3
in wiring harness
Resis-
tance
troller
be performed.)
40-310 30 WD600-6
Failure code [DXHHKB] 4th clutch ECMV solenoid: Short circuit SEN05060-01
WD600-6 40-310 31
SEN05060-01 Failure code [DXHHKY] 4th clutch ECMV solenoid: Short circuit with power supply line
Failure code [DXHHKY] 4th clutch ECMV solenoid: Short circuit with
power supply line 1
Action code Failure code 4th clutch ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXHHKY (Transmission controller system)
Contents of • When the 4th clutch ECMV solenoid system was shorted with the power source, abnormal voltage
trouble was applied when 4th clutch ECMV solenoid output was OFF.
• Stops outputting the signal to the 1st, 2nd, and 3rd clutch ECMV solenoids.
Problem that
appears on • The transmission does not shift into 1st, 2nd, nor 3rd (the machine can travel at 4th).
machine
Related
information

1
value in normal
troller
be performed.)
40-310 32 WD600-6
Failure code [DXHHKY] 4th clutch ECMV solenoid: Short circuit with power supply line SEN05060-01
WD600-6 40-310 33
SEN05060-01 Failure code [DXHJKA] RH pitch REAR EPC solenoid: Disconnection
Failure code [DXHJKA] RH pitch REAR EPC solenoid: Disconnection 1
Action code Failure code RH pitch REAR EPC solenoid: Disconnection

Trouble
E03 DXHJKA (Work equipment controller system)
Contents of • Since the RH pitch REAR EPC solenoid output signal system is disconnected, no current flows
trouble when the 3-spool valve (attachment) extract EPC solenoid output is ON.
• Continues outputting.
Action of
controller
Problem that
appears on • The pitch cylinder is not extracted.
machine
• The output state (current) to the RH pitch REAR EPC solenoid can be checked with the monitoring
Related
function (Code: 41906, 3RD EPC1 DIR).
information
• Method of reproducing failure code: Engine started + RH pitch REAR

Defective RH pitch REAR 2. Disconnect connector F22, and connect T-adapter to male side.
1 EPC solenoid
Resis-
(Internal disconnection) Between F22 (male) (1) and (2) 5 – 15 z
tance
2
in wiring harness
Resis-
tance
and standard
3
Max. 1 z
Max. 1 z
(1) tance
controller
be performed.)
Circuit diagram related to RH pitch REAR EPC solenoid
40-310 34 WD600-6
Failure code [DXHJKB] RH pitch REAR EPC solenoid: Short circuit SEN05060-01
Failure code [DXHJKB] RH pitch REAR EPC solenoid: Short circuit 1
Action code Failure code RH pitch REAR EPC solenoid: Short circuit
Trouble
E03 DXHJKB (Work equipment controller system)
Contents of • Since the RH pitch REAR EPC solenoid output signal system was shorted with the chassis ground,
trouble abnormal current flowed when the 3-spool valve (attachment) extract EPC solenoid output was ON.
Problem that
• The pitch cylinder is not extracted.
appears on
machine
Related
information

Defective RH pitch REAR 2. Disconnect connector F22, and connect T-adapter to male side.
1 EPC solenoid
Resis-
tance
2. Disconnect connectors F22 and L07, and connect T-adapter to
Possible causes 2 ness 3. Turn starting switch to ON position.
and standard (Contact with ground circuit)
value in normal Between L07 (female) (25) or F22 (female) Resis-
Min. 1 Mz
state (1) and chassis ground tance
3
in wiring harness
Resis-
tance
controller
be performed.)
WD600-6 40-310 35
SEN05060-01 Failure code [DXHJKY] RH pitch REAR EPC solenoid: Short circuit with power supply line
Failure code [DXHJKY] RH pitch REAR EPC solenoid: Short circuit with
power supply line 1
Action code Failure code RH pitch REAR EPC solenoid: Short circuit with power supply line
Trouble
E03 DXHJKY (Work equipment controller system)
Contents of • Since the RH pitch REAR EPC solenoid output signal system was shorted with the power source,
trouble abnormal voltage was applied when the RH pitch REAR EPC solenoid output was OFF.
• Stops outputting the signal to the lift arm raise/lower, blade tilt, RH pitch REAR/FORWARD EPC
Action of solenoid.
controller • Stops outputting the signal to all work equipment detent.
Problem that
• The pitch cylinder is not extracted.
appears on
• The RH pitch REAR EPC solenoid may be burnt out.
machine
Related
information

1
value in normal
controller
be performed.)
40-310 36 WD600-6
Failure code [DXHKKA] RH pitch FORWARD EPC solenoid: Disconnection SEN05060-01
Failure code [DXHKKA] RH pitch FORWARD EPC solenoid:

Disconnection 1
Action code Failure code RH pitch FORWARD EPC solenoid: Disconnection

Trouble
E03 DXHKKA (Work equipment controller system)
Contents of • Since the RH pitch FORWARD EPC solenoid output signal system is disconnected, no current flows
trouble when the RH pitch FORWARD EPC solenoid output is ON.
• Continues outputting.
Action of
controller
Problem that
appears on • The pitch cylinder is not retracted.
machine
• The output state (current) to the RH pitch FORWARD EPC solenoid can be checked with the moni-
Related
toring function (Code: 41907, 3RD EPC2 DIR).
information
• Method of reproducing failure code: Engine started + RH pitch FORWARD

Defective RH pitch FOR- 2. Disconnect connector F23, and connect T-adapter to male side.
1 WARD EPC solenoid
Resis-
tance
2
in wiring harness
Resis-
tance
and standard
3
Max. 1 z
Max. 1 z
(1) tance
controller
be performed.)
Circuit diagram related to RH pitch FORWARD EPC solenoid
WD600-6 40-310 37
SEN05060-01 Failure code [DXHKKB] RH pitch FORWARD EPC solenoid: Short circuit
Failure code [DXHKKB] RH pitch FORWARD EPC solenoid: Short circuit 1
Action code Failure code RH pitch FORWARD EPC solenoid: Short circuit
Trouble
E03 DXHKKB (Work equipment controller system)
Contents of • Since the RH pitch FORWARD EPC solenoid output signal system was shorted with the chassis
trouble ground, abnormal current flowed when the RH pitch FORWARD EPC solenoid output was ON.
Problem that
• The pitch cylinder is not retracted.
appears on
machine
Related
information
• Method of reproducing failure code: Engine started + RH pitch FORWARD

Defective RH pitch FOR- 2. Disconnect connector F23, and connect T-adapter to male side.
1 WARD EPC solenoid
Resis-
(Internal short circuit) Between F23 (male) (1) and (2) 5 – 15 z
tance
Grounding fault in wiring har- 2. Disconnect connectors F23 and L07, and connect T-adapter to
Possible causes 2 ness either female side.
and standard (Contact with ground circuit) Between L07 (female) (35) or F23 (female) Resis-
state
3
in wiring harness
Resis-
tance
controller
be performed.)
40-310 38 WD600-6
Failure code [DXHKKY] RH pitch FORWARD EPC solenoid: Short circuit with power supply line SEN05060-01
Failure code [DXHKKY] RH pitch FORWARD EPC solenoid: Short circuit

Action code Failure code RH pitch FORWARD EPC solenoid: Short circuit with power supply
Trouble line
E03 DXHKKY (Work equipment controller system)
• Since the RH pitch FORWARD EPC solenoid output signal system was shorted with the power
Contents of
source, abnormal voltage was applied when the RH pitch FORWARD EPC solenoid output was
trouble
OFF.
• Stops outputting the signal to the lift arm raise/lower, blade tilt, RH pitch FORWARD/REAR EPC
Action of solenoid.
controller • Stops outputting the signal to all work equipment detent.
Problem that
• The pitch cylinder is not retracted.
appears on
• The RH pitch FORWARD EPC solenoid may be burnt out.
machine
Related
information

1
value in normal
controller
be performed.)
WD600-6 40-310 39
SEN05060-01 Failure code [DXHPKA] Modulation clutch solenoid: Disconnection
Failure code [DXHPKA] Modulation clutch solenoid: Disconnection 1
Action code Failure code Modulation clutch ECMV solenoid: Disconnection

Trouble
E03 DXHPKA (Transmission controller system)
Contents of • Since the modulation clutch ECMV solenoid output signal system is disconnected, no current flows
trouble when the modulation clutch ECMV solenoid output is ON.
• Stops outputting the signal to the modulation clutch ECMV solenoid.
Action of
controller
Problem that
• The machine cannot travel.
appears on
• The machine may be able to travel with modulation direct coupling signal.
machine
• The output state (current) to the modulation clutch ECMV solenoid can be checked with the monitor-
Related
ing function (Code: 31640 ECMV MOD/C DIR).
information

Defective modulation clutch 2. Disconnect connector MC.PS, and connect T-adapter to male
1 ECMV solenoid side.
(Internal disconnection) Resis-
Between MC.PS (male) (1) and (2) 5 – 15 z
tance
2. Disconnect connectors MC.PS, D10DE1 and L07, and connect
T-adapters to each female side.
Disconnection in wiring har- Between L07 (female) (23) and MC.PS Resis-
ness Max. 1 z
Possible causes (Disconnection in wiring har-
and standard Resis-
ness and defective contact) Between L07 (female) (36) and D10DE1 Max. 1 z
value in normal tance
state Between D10DE1 (female) (1) and MC.PS Resis-
Max. 1 z
(female) (1) tance
2. Disconnect connector D10DE1 and connect T-adapter to male
side.
3 Defective diode D10DE1 a Check by using multimeter in continuity mode.
Between D10DE1 (male) (2) (+) and (1) Continuity
Between D10DE1 (male) (1) (+) and (2) No continuity
troller
be performed.
40-310 40 WD600-6
Failure code [DXHPKA] Modulation clutch solenoid: Disconnection SEN05060-01
Circuit diagram related to modulation clutch ECMV solenoid
WD600-6 40-310 41
SEN05060-01 Failure code [DXHPKB] Modulation clutch solenoid: Short circuit
Failure code [DXHPKB] Modulation clutch solenoid: Short circuit 1
Action code Failure code Modulation clutch ECMV solenoid: Short circuit
Trouble
E03 DXHPKB (Transmission controller system)
Contents of • Since the modulation clutch ECMV solenoid output signal system was shorted with the chassis
trouble ground, abnormal current flowed when the modulation clutch ECMV solenoid output was ON.
• Stops outputting the signal to the modulation clutch ECMV solenoid.
Action of
controller
Problem that
• The machine cannot travel.
appears on
• The machine may be able to travel with modulation direct coupling signal.
machine
Related
information

2. Disconnect connector MC.PS, and connect T-adapter to male
Defective modulation clutch side.
1 ECMV solenoid Resis-
Between MC.PS (male) (1) and (2) 5 – 15 z
(Internal short circuit) tance
Between MC.PS (male) (1), (2) and Resis-
Min. 1 Mz
value in normal 2. Disconnect connectors MC.PS, D10DE1 and L07, and connect
state T-adapter to either female side.
Grounding fault in wiring har-
2 ness Between L07 (female) (36) or D10DE1 Resis-
Min. 1 Mz
(Contact with ground circuit) (female) (2) and chassis ground tance
Between D10DE1 (female) (1) or MC.PS Resis-
Min. 1 Mz
troller
be performed.)
40-310 42 WD600-6
Failure code [DXHPKB] Modulation clutch solenoid: Short circuit SEN05060-01
WD600-6 40-310 43
SEN05060-01 Failure code [DXHPKY] Modulation clutch solenoid: Short circuit with power source line
Failure code [DXHPKY] Modulation clutch solenoid: Short circuit with

power source line 1
Action code Failure code Modulation clutch ECMV solenoid: Short circuit with power supply
Trouble line
E03 DXHPKY (Transmission controller system)
Contents of • Since the modulation clutch ECMV solenoid output signal system was shorted with the power
trouble source, abnormal voltage was applied when the modulation clutch ECMV solenoid output was OFF.
controller • Even if cause of failure disappears, system does not reset itself until the directional lever or direc-
Problem that
machine
Related
information

2. Disconnect connector D10DE1, and connect T-adapter to
Possible causes Hot short in wiring harness female side.
and standard (Contact with 24 V circuit)
value in normal Between D10DE1 (female) (2) and chassis
state Voltage Max. 3 V
ground
troller
be performed.)
40-310 44 WD600-6
Failure code [DXHPKY] Modulation clutch solenoid: Short circuit with power source line SEN05060-01
WD600-6 40-310 45
SEN05060-01 Failure code [DXHPMA] Modulation clutch solenoid: Malfunction
Failure code [DXHPMA] Modulation clutch solenoid: Malfunction 1
Action code Failure code Modulation clutch ECMV solenoid: Malfunction

Trouble
E01 DXHPMA (Transmission controller system)
Contents of • Difference between the pressure detected by the modulation clutch pressure sensor and pressure
trouble commanded from the modulation clutch ECMV solenoid is 0.3 MPa {3 kg/cm2} or more.
Action of
controller
Problem that
appears on —
machine
• The state (current) of the modulation clutch pressure can be checked with the monitoring function
Related
(Code: 92400, MOD/C PRESS).
information
• The state (voltage) of the modulation clutch pressure can be checked with the monitoring function
(Code: 92401, MOD/C PRESS).

Emergency modulated clutch
Emergency modulated clutch direct engagement switch may be
1 direct engagement switch
turned ON. Check it directly.
ON
ECMV solenoid system Carry out troubleshooting for failure code [DXHPKA], [DXHPKB] or
2
(Internal disconnection or [DXHPKY] if they are displayed.
short circuit)
Defective modulated clutch Carry out troubleshooting for failure code [DHTBKA] or [DHTBKB]
3
pressure sensor system if they are displayed.
2. Disconnect connector T03, and connect T-adapters to female
side.
Possible causes
and standard Defective 24V sensor power 3. Turn starting switch to ON position.
4
value in normal supply system a If power supply voltage is abnormal, proceed to troubleshooting
state for failure code [DAQ2KK].
Between T03 (female) (B) and Power
Voltage 20 – 30 V
(A) supply
troubleshooting.
• Set transmission auto/manual shift selector switch to “Manual”.
Defective modulated clutch • Turn parking brake switch OFF.
5 • Press right brake to prevent machine from moving.
pressure sensor
• Engine P mode
Between T03 (C) and Gear speed: F4 or R4 2.78 –
Voltage
(A) (Engine: High idle) 3.28 V
troller
be performed.)
40-310 46 WD600-6
Failure code [DXHPMA] Modulation clutch solenoid: Malfunction SEN05060-01
WD600-6 40-310 47
SEN05060-01 Failure code [F@BBZL] (or VHMS_LED display: “n3” → “38”) Blow-by pressure: High error
Failure code [F@BBZL] (or VHMS_LED display: “n3” → “38”) Blow-by

pressure: High error 1
Action code Failure code Blow-by pressure: High error

Trouble
— F@BBZL (VHMS controller system)
Contents of
• Blow-by pressure exceeded 9.41 kPa {960 mmH2O}.
trouble
Action of
controller
Problem that
appears on • If the machine is operated as it is, the engine may be damaged.
machine
• The input state (pressure) from the blow-by pressure sensor can be checked with the monitoring
Related
function (Code: 42801 BLOWBY PRESS)
information
• If failure code: DHE5KB (Blow-by pressure sensor: Ground fault) or failure code: DHE5KY (Blow-by
pressure sensor: Short circuit with power supply line) is displayed, troubleshooting for it is performed
first.
• Method of reproducing failure code: Start engine and carry out troubleshooting.

Check the engine for abnormality. Correct, if any.
1 Blow-by pressure increases
Possible causes Check the breather hose for clogging, bend, or break. If any, repair it.
and standard Defective blow-by pressure
value in normal 2 Check the blow-by pressure sensor for abnormality. Replace, if any.
sensor
state
If the above items 1 and 2 is normal, the VHMS controller may be
3 Defective VHMS controller defective. (Troubleshooting cannot be carried out since the defect is
in the machine monitor.)
40-310 48 WD600-6
Failure code [F@BBZL] (or VHMS_LED display: “n3” → “38”) Blow-by pressure: High error SEN05060-01
Circuit diagram related to blow-by sensor
WD600-6 40-310 49
Failure code [F@BYNR] (or VHMS_LED display: “n3” → “62”) Exhaust gas temperature (F):
SEN05060-01 Abnormal heat
Failure code [F@BYNR] (or VHMS_LED display: “n3” → “62”) Exhaust

gas temperature (F): Abnormal heat 1
Action code Failure code Exhaust gas temperature (F): Abnormal heat
Trouble
— F@BYNR (VHMS controller system)
• In the signal circuit of the exhaust gas temperature sensor at the engine front side, exhaust gas tem-
Contents of perature beyond the limit line 2 was detected min. 10 seconds.
trouble (Exhaust gas temperature limit line 2: Straight line between 750°C at rated output speed at minimum
and 800°C at max. torque speed at maximum)
Action of
controller
Problem that
machine
• The input state (temperature) from the exhaust gas temperature sensor (F) can be checked with the
Related
monitoring function (Code: 42610 EXHAUST TEMP F).
information
• If failure code: DGT4KA (Exhaust gas temperature sensor (F): Disconnection) or failure code:
DGT4KB (Exhaust gas temperature sensor (F): Ground fault) is displayed, troubleshooting for it is
performed first.

Exhaust gas temperature at
the engine front side abnor-
1 Check the engine for abnormality. Correct, if any.
mally rises.
(When the system is normal)
troubleshooting.
Exhaust gas
Possible causes 1.0 – 1.6
temperature: Voltage
and standard V
50 – 100°C
value in normal
state Exhaust gas
2.1 – 2.7
2 Defective VHMS controller V
Between V02 (7) and 300 – 400°C
(12) Exhaust gas
2.9 – 3.6
V
500 – 600°C
Exhaust gas
3.8 – 4.4
V
700 – 800°C
40-310 50 WD600-6
Failure code [F@BYNR] (or VHMS_LED display: “n3” → “62”) Exhaust gas temperature (F):
Abnormal heat SEN05060-01
WD600-6 40-310 51
Failure code [F@BYNS] (or VHMS_LED display: “n3” → “61”) Exhaust gas temperature (F):
SEN05060-01 Overheat
Failure code [F@BYNS] (or VHMS_LED display: “n3” → “61”) Exhaust

gas temperature (F): Overheat 1
Action code Failure code Exhaust gas temperature (F): Overheat

Trouble
— F@BYNS (VHMS controller system)
• In the signal circuit of the exhaust gas temperature sensor at the engine front side, exhaust gas tem-
Action of
controller
Problem that
machine
• The input state (temperature) from the exhaust gas temperature sensor (F) can be checked with the
Related
monitoring function (Code: 42610 EXHAUST TEMP F).
information
• If failure code: DGT4KA (Exhaust gas temperature sensor (F): Disconnection) or failure code:
DGT4KB (Exhaust gas temperature sensor (F): Ground fault) is displayed, troubleshooting for it is
performed first.

the engine front side abnor-
mally rises.
(When the system is normal)
troubleshooting.
Exhaust gas
and standard V
50 – 100°C
value in normal
state Exhaust gas
2.1 – 2.7
Between V02 (7) and 300 – 400°C
(12) Exhaust gas
2.9 – 3.6
V
500 – 600°C
Exhaust gas
3.8 – 4.4
V
700 – 800°C
40-310 52 WD600-6
Failure code [F@BYNS] (or VHMS_LED display: “n3” → “61”) Exhaust gas temperature (F):
Overheat SEN05060-01
WD600-6 40-310 53
Failure code [F@BZNR] (or VHMS_LED display: “n3” → “72”) Exhaust gas temperature (R):
SEN05060-01 abnormal heat
Failure code [F@BZNR] (or VHMS_LED display: “n3” → “72”) Exhaust

gas temperature (R): abnormal heat 1
Action code Failure code Exhaust gas temperature (R): Abnormal heat
Trouble
— F@BZNR (VHMS controller system)
• In the signal circuit of the exhaust gas temperature sensor at the engine rear side, exhaust gas tem-
Action of
controller
Problem that
machine
• The input state (temperature) from the exhaust gas temperature sensor (R) can be checked with the
Related
monitoring function (Code: 42611 EXHAUST TEMP R).
information
• If failure code: DGT5KA (Exhaust gas temperature sensor (R): Disconnection) or failure code:
DGT5KB (Exhaust gas temperature sensor (R): Ground fault) is displayed, troubleshooting for it is
performed first.

the engine rear side
increases abnormally. (When
the system is normal)
troubleshooting.
Exhaust gas
and standard V
50 – 100°C
value in normal
state Exhaust gas
2.1 – 2.7
Between V02 (5) and 300 – 400°C
(12) Exhaust gas
2.9 – 3.6
V
500 – 600°C
Exhaust gas
3.8 – 4.4
V
700 – 800°C
40-310 54 WD600-6
Failure code [F@BZNR] (or VHMS_LED display: “n3” → “72”) Exhaust gas temperature (R):
abnormal heat SEN05060-01
WD600-6 40-310 55
SEN05060-01 Failure code [F@BZNS] (or VHMS_LED display “n3” → “71”) Exhaust gas temperature (R): Overheat
Failure code [F@BZNS] (or VHMS_LED display “n3” → “71”)

Exhaust gas temperature (R): Overheat 1
Action code Failure code Exhaust gas temperature (R): Overheat

Trouble
— F@BZNS (VHMS controller system)
• In the signal circuit of the exhaust gas temperature sensor at the engine rear side, exhaust gas tem-
Contents of perature beyond the limit line 1 was detected min. 1 second.
Action of
controller
Problem that
machine
• The input state (temperature) from the exhaust gas temperature sensor (R) can be checked with the
Related
monitoring function (Code: 42611 EXHAUST TEMP R).
information
• If failure code: DGT5KA (Exhaust gas temperature sensor (R): Disconnection) or failure code:
DGT5KB (Exhaust gas temperature sensor (R): Ground fault) is displayed, troubleshooting for it is
performed first.

the engine rear side
increases abnormally. (When
the system is normal)
troubleshooting.
Exhaust gas
and standard V
50 – 100°C
value in normal
state Exhaust gas
2.1 – 2.7
Between V02 (5) and 300 – 400°C
(12) Exhaust gas
2.9 – 3.6
V
500 – 600°C
Exhaust gas
3.8 – 4.4
V
700 – 800°C
40-310 56 WD600-6
Failure code [F@BZNS] (or VHMS_LED display “n3” → “71”) Exhaust gas temperature (R): Overheat SEN05060-01
WD600-6 40-310 57
SEN05060-01
WD600-6 Wheel dozer

©2016 KOMATSU
All Rights Reserved
40-310 58
SEN05061-01
WHEEL DOZER
WD600-6

WD600-6 55001 and up
400 Troubleshooting of electrical system

(E-mode)
Before carrying out troubleshooting of electrical system ................................................................................ 2
Information in troubleshooting table................................................................................................................ 5
E-1 Engine does not start. .............................................................................................................................. 6
E-2 Wiper does not operate .......................................................................................................................... 16
E-3 Windshield washer does not operate ..................................................................................................... 24
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off................................... 30
E-5 Working lamp does not light up or go off. ............................................................................................... 46
E-6 Step lamp does not light up or go off ...................................................................................................... 54
E-7 Turn signal lamp and hazard lamp do not light up or go off ................................................................... 56
E-8 Brake lamp does not light or it keeps lighting up.................................................................................... 66
E-9 Backup lamp does not light or it keeps lighting up. ................................................................................ 70
E-10 Backup buzzer does not sound or it keeps sounding. .......................................................................... 74
E-11 Horn does not sound or it keeps sounding. .......................................................................................... 78
E-12 Alarm buzzer does not sound or it keeps sounding ............................................................................. 82
E-13 Air conditioner does not operate or stop .............................................................................................. 84
E-14 Electric priming pump does not operate or does not stop automatically .............................................. 86
E-15 When starting switch is turned to ON position, machine monitor displays nothing .............................. 88
WD600-6 40-400 1
400 Troubleshooting of electrical system (E-mode)
SEN05061-01 Before carrying out troubleshooting of electrical system
Before carrying out troubleshooting of electrical system 1
Connection table of fuse box and circuit breaker

a This connection table shows the devices to which each power supply of the fuse box and circuit breaker
supplies power (A switch power supply is a device which supplies power while the starting switch is in
the ON position and a constant power supply is a device which supplies power while the starting switch
is in the OFF and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuse box and
circuit breaker to see if the power is supplied normally.
Fuse box 1

1 10A Starting switch terminal B circuit
2 10A Hazard lamp circuit
Constant power supply 3 10A Step lamp circuit
(30A) 4 10A Transmission controller (B) circuit
5 10A Work equipment controller (B) circuit
6 10A Machine monitor (B), VHMS controller (B) circuit
Switch power supply
7 5A Engine controller circuit
Starting switch ACC
8 10A Horn circuit
9 20A Air conditioner circuit
10 10A Auto grease circuit
Switch power supply 11 20A Rear glass heater circuit
(105A) 12 10A Radio circuit
13 20A Air suspension seat, DC-DC converter circuit
14 10A VHMS controller (A) circuit
15 10A Spare
40-400 2 WD600-6
Before carrying out troubleshooting of electrical system SEN05061-01
Fuse box 2

1 10A Turn signal lamp circuit
2 10A Back-up lamp and blinking lamp circuit
3 20A Front working lamp circuit
4 20A Rear working lamp circuit
Switch power supply 5 10A Transmission controller (A) circuit

Circuit breaker CBF3 6 10A Parking brake circuit
(105A) 7 10A Work equipment controller (A) circuit
8 10A Machine monitor (A) circuit
9 20A Wiper and washer circuit
10 10A Spare
11 20A Main lamp circuit
Relay circuit power 12 10A Right clearance lamp
supply of small lamp 13 10A Left clearance lamp
Lighting switch circuit 14 10A Right headlamp
power supply 15 10A Left headlamp
Circuit breaker
Circuit breaker Capacity of

Type of power supply Destination of power
No. breaker
Starting switch circuit, work equipment controller circuit,
Constant power supply CBF1 30A
machine monitor circuit, VHMS controller circuit
Switch power supply CBF2 105A Fuse box (1): Circuits 8 – 15
Switch power supply CBF3 105A Fuse box (2): Circuits 1 – 11
Constant power supply CBF4 20A Engine controller circuit
WD600-6 40-400 3
SEN05061-01 Before carrying out troubleshooting of electrical system
Locations of fuse boxes and circuit breakers, and fuse Nos.
40-400 4 WD600-6
Information in troubleshooting table SEN05061-01
Information in troubleshooting table 1
a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Trouble Problem that appears on machine

Related
Information related to detected trouble or troubleshooting
information

<Described contents>
• Standard value in normal state required to judge the
assumed cause (good or not)
• Remarks required to judge whether the cause is good
1
<Phenomenon of defective harness>
• Disconnection in wiring
The connector connection is defective or wiring harness is
disconnected.
• Ground fault
A harness not connected to the ground (earth) circuit
comes into contact with the ground (earth) circuit.
• Hot short circuit
2 A harness not connected to the power (24 V) circuit comes
into contact with the power (24V) circuit.
• Short circuit
Possible causes Causes by which a trouble A harness of an independent circuit abnormally comes into
and standard is assumed to be defected contact with one of another circuit.
value in normal (The order number indi-
state cates a serial number, not <Notes on troubleshooting>
a priority sequence.) (1) Method of indicating connector numbers and handling of T-
junction
For troubleshooting, insert or connect T-junction adapter
3 shown below unless especially specified.
• When “male” or “female” is not indicated for a connec-
tor number, disconnect the connector, and insert the T-
junction adapters in both the male and female.
• When “male” or “female” is indicated for a connector
number, disconnect connector, and insert the T-junction
adapter in only either the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–)
4 leads as shown below unless especially specified.
• Connect the plus (+) lead to a pin or harness indicated in
the front.
• Connect the minus (–) lead to a pin or harness indicated
in the rear.
Related circuit diagram
This is the excerpted circuit diagram related to trouble

• Connector No.: Indicates (Model – No. of pins) (Color).
• “Connector No. and pin No.” from each branching/merging
point: indicate the ends of branch or source of merging
within the parts of the same wiring harness
• Arrow (): Roughly indicates mounting place on machine.
WD600-6 40-400 5
SEN05061-01 E-1 Engine does not start.
E-1 Engine does not start. 1
Contents of
• Engine does not start. (Steering wheel specification)
trouble
• The engine does not start, because the starting motor does not run due to troubles in the starting
motor system and starting switch terminal C signal system.
• Check that No. 1 fuse of fuse box 1 is normal.
Related (If it is broken, check the related wiring harness for grounding fault.)
information • The input state (ON/OFF) from starting switch terminal C can be checked with the monitoring function
(Code: 40906, D-IN-15).
• If failure code [D5ZHKA], [D5ZHKB], [D5ZHKZ], [DDK6KA] is displayed, carry out troubleshooting
for it first.

Specific gravity Min. 1.26
1 Defective battery
Voltage Min. 25 V
Defective fuse No. 5 in fuse If fuse is broken, circuit probably has ground fault etc.
2
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
3 Defective battery Battery relay Switch position Voltage
Between terminals OFF 20 – 30 V
B and E ON Max. 1 V
a Prepare with starting switch OFF (with wiring harness con-
nected), then turn starting switch START and carry out trouble-
shooting
Starting motor Voltage
Possible
causes and Between terminals
Power supply input 20 – 30 V
standard value Defective starting motor B and E
4
in normal state (Internal defect) Between terminals
Battery input Max. 1 V
R and E
Between terminals
Starting input 20 – 30 V
C and E
If the starting motor does not run even if power supply input, battery
input and starting input is normal, the starting motor is defective.
Defective alternator and carry out troubleshooting
5
(Internal short circuit) Wiring harness between alternator terminal
Voltage Max. 1 V
R and chassis ground
a Prepare with starting switch OFF, then keep starting switch OFF
and turn it to START and carry out troubleshooting in each case.
Defective starting switch Starting switch Position of switch Resistance
6
Between terminals OFF Min. 1 Mz
B (C51) and C (C53) START Max. 1 z
40-400 6 WD600-6
E-1 Engine does not start. SEN05061-01

L04 FNR (Direction) lever Voltage
Between (1) and (10) Any position 20 – 30 V
Defective FNR (directional)
lever switch N (Neutral) 20 – 30 V
7 Between (2) and (10)
(Internal disconnection or Other than above Max. 1 V
short circuit) F (Forward) 20 – 30 V
Between (3) and (10)
Other than above Max. 1 V
R (Reverse) 20 – 30 V
Other than above Max. 1 V
R21 (male) Diode range Continuity
Measure at (1) in
Between (1) and (2) Secured
diode range.
Measure at (3) in
diode range.
Measure at (1) in
diode range.
Possible without turning starting switch ON.
causes and
standard value R23 (male) Diode range Continuity
Defective diode (R21, R22,
in normal state Measure at (2) in
8 R23, R24, R25 or R26) Between (2) and (1) Secured
diode range.
Measure at (2) in
diode range.
Measure at (2) in
diode range.
Measure at (2) in
diode range.
L103 (male) Resistance
Defective neutral safety relay Between (1) and (2) 200 – 400 z
9 (L103) a Prepare with starting switch OFF, then turn starting switch to
(Internal defect) START and carry out troubleshooting.
When neutral safety relay (L103) is replaced with a relay of the
same type, if the condition becomes normal, the neutral safety relay
is defective.
WD600-6 40-400 7

Defective AJSS neutral safety Between (1) and (2) 200 – 400 z
10 relay (L104) a Prepare with starting switch OFF, then turn starting switch to
When AJSS neutral safety relay (L104) is replaced with a relay of
the same type, if the condition becomes normal, the AJSS neutral
safety relay is defective.
Defective neutral holding relay Between (1) and (2) 200 – 400 z
When neutral holding relay (L112) is replaced with a relay of the
same type, if the condition becomes normal, the neutral holding
relay is defective.
Wiring harness between starting motor termi- Resis-
Max. 1 z
nal B – starting motor terminal B tance
Possible
causes and Wiring harness between D12 – starting Resis-
Max. 1 z
standard value motor terminal B tance
in normal state Wiring harness between starting motor termi- Resis-
Max. 1 z
nal E – chassis ground tance
Wiring harness between CL12 (female) (3) – Resis-
Max. 1 z
L103 (female) (5), – L112 (female) (1) tance
Wiring harness between L103 (female) (3) – Resis-
Max. 1 z
Wiring harness between L104 (female) (3) –
Resis-
Disconnection in wiring har- R23 (female) (2), – R24 (female) (2), – R25 Max. 1 z
tance
ness (female) (2), – R26 (female) (2)
12
(Disconnection or defective Wiring harness between R23 (female) (1) or Resis-
R24 (female) (1) – E01 (female) (1) tance
Wiring harness between R25 (female) (1) or Resis-
Max. 1 z
Max. 1 z
Wiring harness between R22 (female) (2) – Resis-
Max. 1 z
Max. 1 z
Wiring harness between L103 (female) (2),
Resis-
L104 (female) (2) or L112 (female) (2) – Max. 1 z
tance
chassis ground
Max. 1 z
40-400 8 WD600-6

Wiring harness between starting motor termi-
Resis-
nal B – starting motor terminal B and chassis Min. 1 Mz
tance
ground
Wiring harness between D12 – starting Resis-
Min. 1 Mz
motor terminal B and chassis ground tance
Wiring harness between CL12 (female) (3) –
Resis-
L103 (female) (5), – L112 (female) (1) and Min. 1 Mz
tance
chassis ground
Resis-
tance
chassis ground
Grounding fault in wiring har- Wiring harness between L104 (female) (3) –
13 ness R23 (female) (2), – R24 (female) (2), – R25 Resis-
Min. 1 Mz
(Contact with ground circuit) (female) (2), – R26 (female) (2), – circuit tance
branch end and chassis ground
Wiring harness between R23 (female) (1) or
Resis-
R24 (female) (1) – E01 (female) (1) and Min. 1 Mz
Possible tance
chassis ground
causes and
standard value Wiring harness between R25 (female) (1) or
Resis-
in normal state R26 (female) (1) – E02 (female) (1) and Min. 1 Mz
tance
chassis ground
Wiring harness between L112 (female) (5) Resis-
Min. 1 Mz
and R22 (female) (3) and chassis ground tance
Wiring harness between R22 (female) (2) Resis-
Min. 1 Mz
and L103 (female) (1) and chassis ground tance
Min. 1 Mz
L104 (female) (1) and chassis ground tance
and carry out troubleshooting
14 Wiring harness between alternator terminal
R – E01 (female) (2), – E02 (female) (2), – Voltage Max. 1 V
circuit branch end and chassis ground
Defective work equipment L07 AJSS Voltage
15
controller
Between (4) – Neutral Max. 1 V
chassis ground Other than above 20 – 30 V
Defective engine controller As the engine controller power supply can be detective, carry out
16
power supply troubleshooting for “Failure code CA111”.
WD600-6 40-400 9
Contents of
• Engine does not start. (AJSS specification)
trouble
• The engine does not start, because the starting motor does not run due to troubles in the starting
motor system and starting switch terminal C signal system.
• Check that No. 1 fuse of fuse box 1 is normal.
Related (If it is broken, check the related wiring harness for grounding fault.)
information • The input state (ON/OFF) from starting switch terminal C can be checked with the monitoring function
(Code: 40906, D-IN-15).
• If failure code [DDK4KA], [D5ZHKA], [D5ZHKB], [D5ZHKZ] is displayed, carry out troubleshooting
for it first.

Specific gravity Min. 1.26
1 Defective battery
Voltage Min. 25 V
Defective fuse No. 5 in fuse If fuse is broken, circuit probably has ground fault etc.
2
3 Defective battery Battery relay Switch position Voltage
Between terminals OFF 20 – 30 V
B and E ON Max. 1 V
a Prepare with starting switch OFF (with wiring harness con-
nected), then turn starting switch START and carry out trouble-
shooting
Starting motor Voltage
Possible
causes and Between terminals
Power supply input 20 – 30 V
standard value Defective starting motor B and E
4
in normal state (Internal defect) Between terminals
Battery input Max. 1 V
R and E
Between terminals
Starting input 20 – 30 V
C and E
If the starting motor does not run even if power supply input, battery
input and starting input is normal, the starting motor is defective.
Defective alternator and carry out troubleshooting
5
(Internal short circuit) Wiring harness between alternator terminal
Voltage Max. 1 V
R and chassis ground
a Prepare with starting switch OFF, then keep starting switch OFF
and turn it to START and carry out troubleshooting in each case.
Defective starting switch Starting switch Position of switch Resistance
6
Between terminals OFF Min. 1 Mz
B (C51) and C (C53) START Max. 1 z
40-400 10 WD600-6

S31 (male) AJSS FNR switch Resistance
F (Forward) Max. 1 z
Between (1) and (2)
Defective AJSS FNR switch Other than above Min. 1 M z
7 (Internal disconnection or N (Neutral) Max. 1 z
short circuit) Between (1) and (3)
Other than above Min. 1 M z
R (Reverse) Max. 1 z
Between (1) and (4)
Other than above Min. 1 M z
Between (1), (2), (3),
Any position Min. 1 M z
(4) – chassis ground
Measure at (1) in
diode range.
Measure at (3) in
diode range.
Measure at (1) in
diode range.
Possible a Prepare with starting switch OFF, then carry out troubleshooting
causes and without turning starting switch ON.
standard value R23 (male) Diode range Continuity
in normal state Defective diode (R21, R22,
Measure at (2) in
8 R23, R24, R25 or R26) Between (2) and (1) Secured
diode range.
Measure at (2) in
diode range.
Measure at (2) in
diode range.
Measure at (2) in
diode range.
Defective neutral safety relay Between (1) and (2) 200 – 400 z
When neutral safety relay (L103) is replaced with a relay of the
same type, if the condition becomes normal, the neutral safety relay
is defective.
WD600-6 40-400 11

Defective AJSS neutral safety Between (1) and (2) 200 – 400 z
10 relay (L104) a Prepare with starting switch OFF, then turn starting switch to
When AJSS neutral safety relay (L104) is replaced with a relay of
the same type, if the condition becomes normal, the AJSS neutral
safety relay is defective.
Defective neutral holding relay Between (1) and (2) 200 – 400 z
When neutral holding relay (L112) is replaced with a relay of the
same type, if the condition becomes normal, the neutral holding
relay is defective.
Wiring harness between starting motor termi- Resis-
Max. 1 z
nal B – starting motor terminal B tance
Possible
causes and Wiring harness between D12 – starting Resis-
Max. 1 z
standard value motor terminal B tance
in normal state Wiring harness between starting motor termi- Resis-
Max. 1 z
nal E – chassis ground tance
Wiring harness between CL12 (female) (3) – Resis-
Max. 1 z
Max. 1 z
Resis-
Disconnection in wiring har- R23 (female) (2), – R24 (female) (2), – R25 Max. 1 z
tance
ness (female) (2), – R26 (female) (2)
12
(Disconnection or defective Wiring harness between R23 (female) (1) or Resis-
Wiring harness between R25 (female) (1) or Resis-
Max. 1 z
Max. 1 z
Wiring harness between R22 (female) (2) – Resis-
Max. 1 z
Max. 1 z
Wiring harness between L103 (female) (2),
Resis-
L104 (female) (2) or L112 (female) (2) – Max. 1 z
tance
chassis ground
Wiring harness between S31 (female) (3) – Resis-
Max. 1 z
40-400 12 WD600-6

Wiring harness between starting motor termi-
Resis-
nal B – starting motor terminal B and chassis Min. 1 Mz
tance
ground
Wiring harness between D12 – starting Resis-
Min. 1 Mz
motor terminal B and chassis ground tance
Wiring harness between CL12 (female) (3) –
Resis-
tance
chassis ground
Resis-
tance
chassis ground
Grounding fault in wiring har- Wiring harness between L104 (female) (3) –
13 ness R23 (female) (2), – R24 (female) (2), – R25 Resis-
Min. 1 Mz
(Contact with ground circuit) (female) (2), – R26 (female) (2), – circuit tance
Wiring harness between R23 (female) (1) or
Resis-
R24 (female) (1) – E01 (female) (1) and Min. 1 Mz
Possible tance
chassis ground
causes and
standard value Wiring harness between R25 (female) (1) or
Resis-
in normal state R26 (female) (1) – E02 (female) (1) and Min. 1 Mz
tance
chassis ground
Min. 1 Mz
and R22 (female) (3) and chassis ground tance
Wiring harness between R22 (female) (2) Resis-
Min. 1 Mz
and L103 (female) (1) and chassis ground tance
Min. 1 Mz
14 Wiring harness between alternator terminal
R – E01 (female) (2), – E02 (female) (2), – Voltage Max. 1 V
Defective work equipment L07 AJSS Voltage
15
controller
Between (4) – Neutral Max. 1 V
chassis ground Other than above 20 – 30 V
Defective engine controller As the engine controller power supply can be detective, carry out
16
power supply troubleshooting for “Failure code CA111”.
WD600-6 40-400 13
40-400 14 WD600-6
WD600-6 40-400 15
SEN05061-01 E-2 Wiper does not operate
E-2 Wiper does not operate 1
Contents of
(1) Front wiper does not operate. (Steering wheel specification)
trouble
Related
• Since the front wiper switch, timer, or wiring harness is defective, the front wiper does not operate.
information

Defective fuse No. 9 of fuse If the fuse is burnt, the circuit probably has a grounding fault, etc.
1
C27 Wiper switch Voltage
Between (2) and
Lo 20 – 30 V
chassis ground
Defective front wiper motor Between (1) and
2 Hi 20 – 30 V
(Internal defect) chassis ground
Between (6) and
Normal 20 – 30 V
chassis ground
• If wiper switch is turned OFF while wiper is operating, voltage is
applied between C27 (5) and chassis ground until wiper motor
stops.
LW21 (female) Wiper switch Voltage
Possible Between (3) and
Normal 20 – 30 V
causes and chassis ground
standard value Defective wiper timer (relay) Between (4) and
in normal state 3 INT 20 – 30 V
Between (2) and
Washer side 20 – 30 V
chassis ground
INT (If wiper switch is
Between (5) and Repeat (20 – 30 V)
set in INT, voltage is
chassis ground 0V
output intermittently.)
C13 Voltage
Between (5) and chassis ground 20 – 30 V
Defective front wiper switch
4 LW21 (female) Wiper switch Resistance
(Internal defect)
Between (7) and (5) Lo Max. 1 z
Between (7) and (4) Hi Max. 1 z
Between (7) and (2) INT Max. 1 z
Between (1) and (5) INT and OFF Max. 1 z
Other than above Min. 1 Mz
40-400 16 WD600-6
E-2 Wiper does not operate SEN05061-01

Wiring harness between LW21 (female) (2) – Resis-
Max. 1 z
Max. 1 z
Max. 1 z
Disconnection in wiring C27 (female) (1) tance
harness Wiring harness between LW21 (female) (5) – Resis-
5 Max. 1 z
(Disconnection or defective L21 (female) (2) tance
contact of connector) Wiring harness between LW21 (female) (7) – Resis-
Max. 1 z
fuse No. 9 of fuse box 2, – circuit branch end tance
Max. 1 z
BL2 (female) (1) tance
Wiring harness between C27 (female) (3) – Resis-
Possible Max. 1 z
causes and
standard value Wiring harness between L21 (female) (1) – Resis-
Max. 1 z
in normal state chassis ground tance
Min. 1 Mz
Min. 1 Mz
Grounding fault in wiring Min. 1 Mz
C27 (female) (1) and chassis ground tance
6 harness
(Contact with ground circuit) Wiring harness between LW21 (female) (5) –
Resis-
L21 (female) (2), – circuit branch end and Min. 1 Mz
tance
chassis ground
Wiring harness between LW21 (female) (7) –
Resis-
fuse No. 9 of fuse box 2, – circuit branch end Min. 1 Mz
tance
and chassis ground
Min. 1 Mz
BL2 (female) (1) and chassis ground tance
WD600-6 40-400 17
Contents of
(2) Rear wiper does not operate. (Steering wheel specification)
trouble
Related
• Since the rear wiper switch, or wiring harness is defective, the rear wiper does not operate.
information

Between (2) and
ON 20 – 30 V
Defective rear wiper motor chassis ground
1
(Internal defect) Between (1) and
Normal 20 – 30 V
chassis ground
stops.
LW21 Voltage
Defective rear wiper switch a Prepare with starting switch OFF, then carry out troubleshooting
2 without turning starting switch ON.
(Internal defect)
LW21 Wiper switch Resistance
Possible
Between (7) and (9) ON Max. 1 z
causes and
standard value Between (8) and (9) OFF Max. 1 z
in normal state Other than above Min. 1 Mz
Max. 1 z
3 Max. 1 z
(Disconnection or defective C40 (female) (3) tance
contact of connector) Wiring harness between LW21 (female) (9) – Resis-
Max. 1 z
Wiring harness between CN40 (female) (4) Resis-
Max. 1 z
4 harness
(Contact with ground circuit) Wiring harness between LW21 (female) (9) – Resis-
Min. 1 Mz
Min. 1 Mz
C40 (female) (1), – circuit branch end tance
40-400 18 WD600-6
Circuit diagram related to wiper (Steering wheel specification)
WD600-6 40-400 19
Contents of
(3) Front wiper does not operate. (AJSS specification)
trouble
Related
• Since the front wiper switch, timer, or wiring harness is defective, the front wiper does not operate.
information

1
Between (2) and
Lo 20 – 30 V
chassis ground
Defective front wiper motor Between (1) and
2 Hi 20 – 30 V
Between (6) and
Normal 20 – 30 V
chassis ground
stops.
L21 Wiper switch Voltage
Possible Between (3) and
Normal 20 – 30 V
causes and chassis ground
standard value Defective wiper timer (relay) Between (4) and
in normal state 3 INT 20 – 30 V
Between (2) and
Washer side 20 – 30 V
chassis ground
INT (If wiper switch is
Between (5) and Repeat 20 to 30 V
set in INT, voltage is
chassis ground 0V
output intermittently.)
C13 Voltage
Defective front wiper switch
4 C13 Wiper switch Resistance
(Internal defect)
Between (5) and (2) Lo Max. 1 z
Between (5) and (3) Hi Max. 1 z
Between (5) and (6) INT Max. 1 z
Between (1) and (2) INT and OFF Max. 1 z
Other than above Min. 1 Mz
40-400 20 WD600-6

Max. 1 z
Max. 1 z
Disconnection in wiring Wiring harness between C13 (female) (4) – Resis-
Max. 1 z
harness BL1 (female) (1) tance
5
(Disconnection or defective Wiring harness between C13 (female) (5) – Resis-
Max. 1 z
Possible Max. 1 z
causes and
standard value Wiring harness between L21 (female) (1) – Resis-
Max. 1 z
in normal state chassis ground tance
Min. 1 Mz
Min. 1 Mz
Grounding fault in wiring
6 harness Wiring harness between C13 (female) (4) –
Resis-
(Contact with ground circuit) BL1 (female) (1), – circuit branch end and Min. 1 Mz
tance
chassis ground
Wiring harness between C13 (female) (5) –
Resis-
fuse No. 9 of fuse box 2, – circuit branch end Min. 1 Mz
tance
and chassis ground
Min. 1 Mz
WD600-6 40-400 21
Contents of
(4) Rear wiper does not operate. (AJSS specification)
trouble
Related
• Since the rear wiper switch, or wiring harness is defective, the rear wiper does not operate.
information

Between (2) and
ON 20 – 30 V
Defective rear wiper motor chassis ground
1
(Internal defect) Between (4) and
Normal 20 – 30 V
chassis ground
stops.
C28 Voltage
Defective rear wiper switch a Prepare with starting switch OFF, then carry out troubleshooting
2 without turning starting switch ON.
(Internal defect)
C28 Wiper switch Resistance
Possible
causes and
standard value Between (1) and (2) OFF Max. 1 z
in normal state Other than above Min. 1 Mz
Max. 1 z
harness Wiring harness between C28 (female) (2) – Resis-
3 Max. 1 z
(Disconnection or defective C40 (female) (2) tance
contact of connector) Wiring harness between C28 (female) (3) – Resis-
Max. 1 z
Max. 1 z
4 harness
(Contact with ground circuit) Wiring harness between C28 (female) (2) – Resis-
Min. 1 Mz
Min. 1 Mz
C40 (female) (1), – circuit branch end tance
40-400 22 WD600-6
Circuit diagram related to wiper (AJSS specification)
WD600-6 40-400 23
SEN05061-01 E-3 Windshield washer does not operate
E-3 Windshield washer does not operate 1
Contents of
(1) Windshield washer does not operate. (Steering wheel specification)
trouble
• Since the windshield washer motor, switch, timer (for only front), or wiring harness is defective, the
Related windshield washer does not operate.
information • Perform the following troubleshooting when the wiper operates normally. (If the wiper does not oper-
ate normally, carry out troubleshooting for “E-2 Wiper does not operate” first.)

Defective front washer motor and carry out troubleshooting
1
(Internal defect) BL1 Voltage
Defective rear washer motor and carry out troubleshooting
2
Defective diode without turning starting switch ON (See test procedure for diode).
3
(HD1, HD2, HD3) HD1, HD2, HD3 (male) Resistance
Between (1) and (2) Min. 1 Mz (continuity is broken)
LW21 Voltage
causes and Defective front wiper switch without turning starting switch ON.
standard value 4
(Internal defect) Washer switch of
in normal state LW21 (male) Resistance
front wiper switch
ON Max. 1 z
Between (7) and (6)
OFF Min. 1 Mz
Between (7), (6) and
Normal Min. 1 Mz
chassis ground
LW21 Voltage
Between (7) and
20 – 30 V
chassis ground
Defective rear wiper switch without turning starting switch ON.
5
(Internal defect)
Washer switch of rear
LW21 (male) Resistance
wiper switch
ON Max. 1 z
OFF Min. 1 Mz
Normal Min. 1 Mz
chassis ground
40-400 24 WD600-6
E-3 Windshield washer does not operate SEN05061-01

Defective rear wiper switch LW21 (male) Resistance
5 wiper switch
(Internal defect)
Normal Min. 1 Mz
chassis ground
Washer switch of
L21 (male) Voltage
front wiper switch
Defective wiper timer (relay) Between (3) and
6 Normal 20 – 30 V
(for only front wiper) chassis ground
Between (2) and
ON 20 – 30 V
chassis ground
Between (5) and
0.2 – 0.8 sec after ON 20 – 30 V
Possible chassis ground
causes and a Prepare with starting switch OFF, then carry out troubleshooting
standard value without turning starting switch ON.
in normal state
Max. 1 z
Disconnection in wiring BL1 (female) (1), – L21 (female) (2) tance
7 Max. 1 z
(Disconnection or defective fuse No. 9 of fuse box 2 tance
contact of connector) Wiring harness between LW21 (female) (10) Resis-
Max. 1 z
– BL3 (female) (1) tance
Wiring harness between BL1 (female) (2), Resis-
Max. 1 z
BL3 (female) (2) – chassis ground tance
Wring harness between LW21 (female) (6) –
Resis-
BL1 (female) (1), – L21 (female) (2), – circuit Min. 1 Mz
Grounding fault in wiring tance
8 harness
(Contact with ground circuit) Wiring harness between LW21 (female) (7) – Resis-
Min. 1 Mz
Wiring harness between LW21 (female) (10)
Resis-
– BL3 (female) (1), – circuit branch end and Min. 1 Mz
tance
chassis ground
WD600-6 40-400 25
Circuit diagram related to windshield washer (Steering wheel specification)
40-400 26 WD600-6
Contents of
(2) Windshield washer does not operate. (AJSS specification)
trouble
• Since the windshield washer motor, switch, timer (for only front), or wiring harness is defective, the
Related windshield washer does not operate.
information • Perform the following troubleshooting when the wiper operates normally. (If the wiper does not oper-
ate normally, carry out troubleshooting for “E-2 Wiper does not operate” first.)

Defective front washer motor and carry out troubleshooting
1
Defective rear washer motor and carry out troubleshooting
2
Defective diode without turning starting switch ON (See test procedure for diode).
3
(HD1, HD2, HD3) HD1, HD2, HD3 (male) Resistance
Between (1) and (2) Min. 1 Mz (continuity is broken)
C13 Voltage
causes and Defective front wiper switch without turning starting switch ON.
standard value 4
(Internal defect) Washer switch of
in normal state C13 (male) Resistance
front wiper switch
ON Max. 1 z
Between (5) and (4)
OFF Min. 1 Mz
Normal Min. 1 Mz
chassis ground
C28 Voltage
20 – 30 V
chassis ground
Defective rear wiper switch without turning starting switch ON.
5
(Internal defect)
C28 (male) Resistance
wiper switch
ON Max. 1 z
Between (5) and (6)
OFF Min. 1 Mz
Normal Min. 1 Mz
chassis ground
WD600-6 40-400 27

Defective rear wiper switch C28 (male) Resistance
5 wiper switch
(Internal defect)
Normal Min. 1 Mz
chassis ground
Washer switch of
L21 (male) Voltage
front wiper switch
Defective wiper timer (relay) Between (3) and
6 Normal 20 – 30 V
(for only front wiper) chassis ground
Between (2) and
ON 20 – 30 V
chassis ground
Between (5) and
0.2 – 0.8 sec after ON 20 – 30 V
chassis ground
causes and
standard value Max. 1 z
in normal state BL1 (female) (1), – L21 (female) (2) tance
Disconnection in wiring Wiring harness between C13 (female) (5),
Resis-
harness C28 (female) (3), (5) or C47 (female) (3), (5) Max. 1 z
7 tance
(Disconnection or defective – fuse No. 9 of fuse box 2
Max. 1 z
BL3 (female) (1) tance
Wiring harness between BL1 (female) (2),
Resis-
BL3 (female) (2) or BL5 (female) (2) – chas- Max. 1 z
tance
sis ground
Wring harness between C13 (female) (4) –
Resis-
BL1 (female) (1), – L21 (female) (2), – circuit Min. 1 Mz
tance
8 harness Wiring harness between C13 (female) (5),
(Contact with ground circuit) C28 (female) (3), (5) or C47 (female) (3), (5) Resis-
Min. 1 Mz
– fuse No. 9 of fuse box 2, – circuit branch tance
end and chassis ground
Resis-
BL3 (female) (1), – circuit branch end and Min. 1 Mz
tance
chassis ground
40-400 28 WD600-6
Circuit diagram related to windshield washer (AJSS specification)
WD600-6 40-400 29
SEN05061-01 E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light
up or go off 1
Contents of (1) None of headlamp, clearance lamp, tail lamp, and license lamp does not light up.
trouble (Steering wheel specification)
• Since the lamp system main circuit is disconnected or shorted with the chassis ground, none of the
lamps lights up.
• Headlamp at SMALL position: Clearance lamp, tail lamp, license lamp, machine monitor night lamp
light up.
• Headlamp at HEAD position: Above lamps and headlamp light up.
Related
• Input state (Voltage) from lamp switch (small lamp) to machine monitor can be checked with monitor-
information
ing function (Code: 40200 SMALL LAMP).
• Input state (ON/OFF) from lamp switch (headlamp) to machine monitor can be checked with monitor-
• Input state (ON/OFF) from dimmer switch (high beam) to machine monitor can be checked with mon-

1
L02 (male) Headlamp switch Resistance
OFF Min. 1 Mz
Defective lamp switch Between (1) and (5)
SMALL or HEAD Max. 1 z
short circuit) OFF Min. 1 Mz
Possible Between (1) and (2) SMALL Min. 1 Mz
causes and
HEAD Max. 1 z
standard value
in normal state Between (1), (2), (5)
Normal Min. 1 Mz
and chassis ground
3
(Disconnection or defective Wiring harness between fuse No. 11 of fuse Resis-
box 2 – L02 (female) (1) tance
4 harness Wiring harness between fuse No. 11 of fuse
box 2 – L02 (female) (1), – circuit branch end Min. 1 Mz
tance
and chassis ground
40-400 30 WD600-6
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off SEN05061-01
Contents of
(2) Either of headlamp low and high beams does not light up or go off. (Steering wheel specification)
trouble
• The switch, lamp, or wiring harness of the lamp switch and dimmer switch (low and high beams) is
defective.
• Carry out the following troubleshooting when the clearance lamp, tail lamp, and license lamp light up
Related and go off normally.
information • Input state (ON/OFF) from lamp switch (headlamp) to machine monitor can be checked with monitor-

Defective fuse No. 14 or If the fuse is burnt, the circuit probably has a grounding fault, etc.
1
No. 15 of fuse box 2 (See cause 5.)
Defective lamp switch OFF Min. 1 Mz
short circuit) Between (1) and (2) SMALL Min. 1 Mz
HEAD Max. 1 z
Normal Min. 1 Mz
chassis ground
Defective dimmer switch L02 (male) Dimmer switch Resistance

3 (Internal disconnection or Low Min. 1 Mz
High Max. 1 z
Possible Normal Min. 1 Mz
chassis ground
causes and
standard value a Prepare with starting switch OFF, then carry out troubleshooting
in normal state without turning starting switch ON.
Max. 1 z
Disconnection in wiring fuse No. 11 of fuse box 2 tance
harness Wiring harness between fuse No. 15 of fuse Resis-
4 Max. 1 z
(Disconnection or defective box 2 – left HEAD (female) (2) tance
contact of connector) Wiring harness between fuse No. 14 of fuse Resis-
Max. 1 z
box 2 – right HEAD (female) (2) tance
Wiring harness between relay L118 (female) Resis-
Max. 1 z
(3) – chassis ground tance
Min. 1 Mz
fuse No. 11 of fuse box 2 and chassis ground tance
Resis-
(Contact with ground circuit) box 2 – left HEAD (female) (2) and chassis Min. 1 Mz
tance
ground
Wiring harness between fuse No. 14 of fuse
Resis-
box 2 – right HEAD (female) (2) and chassis Min. 1 Mz
tance
ground
WD600-6 40-400 31

• Headlamp switch is OFF
Possible Wiring harness between L02 (female) (1) –
Voltage Max. 1 V
causes and fuse No. 11 of fuse box 2 and chassis ground
standard value Hot short in wiring harness
6 Wiring harness between fuse No. 15 of fuse
in normal state (Contact with 24 V circuit)
box 2 – left HEAD (female) (2) and chassis Voltage Max. 1 V
ground
box 2 – right HEAD (female) (2) and chassis Voltage Max. 1 V
ground
40-400 32 WD600-6
Contents of
(3) Headlamp low beam does not light up or go off. (Steering wheel specification)
trouble
• The switch, lamp, or wiring harness of the headlamp (low beam) is disconnected or shorted with the
chassis ground.
• Carry out the following troubleshooting when the high beam lights up (goes off) normally.
Related
information

If a specific headlamp does not light up, its bulb may be broken or
1 Broken bulb
may have a defective contact. Check the bulb directly.

High Max. 1 z
Normal Min. 1 Mz
chassis ground
Possible
causes and L118 (male) Resistance
standard value Between (1) and (2) 200 – 400 z
3 Defective dimmer relay (L118)
in normal state
When dimmer relay (L118) is replaced with a relay of the same type,
if the condition becomes normal, the dimmer relay is defective.
4
(Disconnection or defective Wiring harness between L118 (female) (6) – Resis-
HEAD (female) (1) tance
5 harness Wiring harness between L118 (female) (6) –
HEAD (female) (1), – circuit branch end and Min. 1 Mz
tance
chassis ground
WD600-6 40-400 33
Contents of
(4) Headlamp high beam does not light up or go off. (Steering wheel specification)
trouble
• The switch, lamp, or wiring harness of the headlamp (high beam) is disconnected or shorted with the
chassis ground.
• Carry out the following troubleshooting when the low beam lights up (goes off) normally.
Related
information

1 Broken bulb

High Max. 1 z
Normal Min. 1 Mz
chassis ground
Between (1) and (2) 200 – 400 z
Possible a Prepare with starting switch OFF, then turn starting switch ON
causes and and carry out troubleshooting
standard value When dimmer relay (L118) is replaced with a relay of the same type,
in normal state if the condition becomes normal, the dimmer relay is defective.
Disconnection in wiring Wiring harness between L02 (female) (6) – Resis-
Max. 1 z
harness L118 (female) (1) tance
4
Wiring harness between HEAD (3) and L118 Resis-
Max. 1 z
(female) (5) tance
Grounding fault in wiring Wiring harness between L02 (female) (6) – Resis-
Min. 1 Mz
(Contact with ground circuit) Wiring harness between L118 (female) (5) –
Resis-
HEAD (3), – circuit branch end and chassis Min. 1 Mz
tance
ground
40-400 34 WD600-6
Contents of (5) Clearance lamp does not light up or go off. (Steering wheel specification)
trouble (6) Tail lamp does not light up or go off. (Steering wheel specification)
• The switch, lamp, or wiring harness of the clearance lamp or tail lamp system is defective.
Related • Carry out the following troubleshooting when the headlamp and turn signal lights up.
information • The input state (voltage) from the headlamp switch (small lamp) can be checked with the monitoring
function (Code: 40200, SMALL LAMP).

If a specific lamp does not light up, its bulb may be broken or may
1 Broken bulb
have a defective contact. Check the bulb directly.
Defective fuse No. 12 or No. If the fuse is burnt, the circuit probably has a grounding fault, etc.
2
13 of fuse box 2 (See cause 6.)
Defective headlamp switch OFF Min. 1 Mz
short circuit) Between (1) and (5) SMALL Max. 1 z
HEAD Max. 1 z
Normal Min. 1 Mz
chassis ground
Between (1) and (2) 200 – 400 z
Defective small lamp relay
4 a Prepare with starting switch OFF, then turn starting switch ON
(L115)
When small lamp relay (L115) is replaced with a relay of the same
Possible
type, if the condition becomes normal, the small lamp relay is defec-
causes and
tive.
standard value
in normal state a Prepare with starting switch OFF, then carry out troubleshooting
Max. 1 z
Max. 1 z
Max. 1 z
fuse No. 14 or No. 15 of fuse box 2 tance
Disconnection in wiring without turning starting switch ON.
harness Wiring harness between fuse No. 12 of fuse
5 Resis-
(Disconnection or defective box 2 – right COMBI (female) (1), – G01 Max. 1 z
(female) (4)
Resis-
box 2 – left COMBI (female) (1), – G02 Max. 1 z
tance
(female) (4)
Wiring harness between COMBI (female) (2) Resis-
Max. 1 z
– chassis ground tance
Wiring harness between G01 (female) (6) – Resis-
Max. 1 z
Max. 1 z
WD600-6 40-400 35

Min. 1 Mz
Resis-
fuse No. 14 or No. 15 of fuse box 2 and Min. 1 Mz
chassis ground
harness
6
(Disconnection or defective a Prepare with starting switch OFF, then carry out troubleshooting
contact of connector) without turning starting switch ON.
Resis-
box 2 – right COMBI (female) (1), – G01 Min. 1 Mz
tance
(female) (4) and chassis ground
Resis-
Possible box 2 – left COMBI (female) (1), – G02 Min. 1 Mz
tance
causes and (female) (4) and chassis ground
standard value a Prepare with starting switch OFF, then turn starting switch ON
in normal state and carry out troubleshooting
Voltage Max. 1 V
L115 (female) (1) and chassis ground
Between L115 (female) (3) – fuse No. 14 or
No. 15 of fuse box 2 wiring harness and Voltage Max. 1 V
Hot short in wiring harness chassis ground and chassis ground
7
(Contact with 24 V circuit) a Prepare with starting switch OFF, then turn starting switch ON
box 2 – right COMBI (female) (1), – G01 Voltage Max. 1 V
box 2 – left COMBI (female) (1), – G02 Voltage Max. 1 V
40-400 36 WD600-6
Circuit diagram related to headlamp, clearance lamp and tail lamp (Steering wheel specification)
WD600-6 40-400 37
Contents of (7) None of headlamp, clearance lamp, tail lamp, and license lamp does not light up.
trouble (AJSS specification)
• Since the lamp system main circuit is disconnected or shorted with the chassis ground, none of the
lamps lights up.
• Headlamp at SMALL position: Clearance lamp, tail lamp, license lamp, machine monitor night lamp
light up.
• Headlamp at HEAD position: Above lamps and headlamp light up.
Related
• Input state (Voltage) from lamp switch (small lamp) to machine monitor can be checked with monitor-
information
ing function (Code: 40200 SMALL LAMP).

1
C15 (male) Headlamp switch Resistance
OFF Min. 1 Mz
Defective lamp switch Between (4) and (3)
SMALL or HEAD Max. 1 z
short circuit) OFF Min. 1 Mz
Possible Between (4) and (2) SMALL Min. 1 Mz
causes and
HEAD Max. 1 z
standard value
in normal state Between (2), (3), (4)
Normal Min. 1 Mz
and chassis ground
3
(Disconnection or defective Wiring harness between fuse No. 11 of fuse Resis-
box 2 – C15 (female) (4) tance
box 2 – C15 (female) (4), – circuit branch Min. 1 Mz
tance
40-400 38 WD600-6
Contents of
(8) Either of headlamp low and high beams does not light up or go off. (AJSS specification)
trouble
• The switch, lamp, or wiring harness of the lamp switch and dimmer switch (low and high beams) is
defective.
• Carry out the following troubleshooting when the clearance lamp, tail lamp, and license lamp light up
Related and go off normally.
information • Input state (ON/OFF) from lamp switch (headlamp) to machine monitor can be checked with monitor-

Defective fuse No. 14 or If the fuse is burnt, the circuit probably has a grounding fault, etc.
1
No. 15 of fuse box 2 (See cause 5.)
Defective lamp switch OFF Min. 1 Mz
short circuit) Between (4) and (2) SMALL Min. 1 Mz
HEAD Max. 1 z
Normal Min. 1 Mz
chassis ground
Defective dimmer switch C16 (male) Dimmer switch Resistance

High Max. 1 z
Possible Normal Min. 1 Mz
chassis ground
causes and
Max. 1 z
Disconnection in wiring fuse No. 11 of fuse box 2 tance
4 Max. 1 z
(Disconnection or defective box 2 – left HEAD (female) (2) tance
Max. 1 z
box 2 – right HEAD (female) (2) tance
Wiring harness between relay L118 (female) Resis-
Max. 1 z
Min. 1 Mz
fuse No. 11 of fuse box 2 and chassis ground tance
Resis-
(Contact with ground circuit) box 2 – left HEAD (female) (2) and chassis Min. 1 Mz
tance
ground
Resis-
box 2 – right HEAD (female) (2) and chassis Min. 1 Mz
tance
ground
WD600-6 40-400 39

Possible Wiring harness between C15 (female) (4) –
Voltage Max. 1 V
causes and fuse No. 11 of fuse box 2 and chassis ground
standard value Hot short in wiring harness
6 Wiring harness between fuse No. 15 of fuse
in normal state (Contact with 24 V circuit)
box 2 – left HEAD (female) (2) and chassis Voltage Max. 1 V
ground
box 2 – right HEAD (female) (2) and chassis Voltage Max. 1 V
ground
40-400 40 WD600-6
Contents of
(9) Headlamp low beam does not light up or go off. (AJSS specification)
trouble
• The switch, lamp, or wiring harness of the headlamp (low beam) is disconnected or shorted with the
chassis ground.
• Carry out the following troubleshooting when the high beam lights up (goes off) normally.
Related
information

1 Broken bulb

High Max. 1 z
Normal Min. 1 Mz
chassis ground
Possible
causes and L118 (male) Resistance
standard value Between (1) and (2) 200 – 400 z
in normal state
When dimmer relay (L118) is replaced with a relay of the same type,
if the condition becomes normal, the dimmer relay is defective.
4
HEAD (female) (1) tance
HEAD (female) (1), – circuit branch end and Min. 1 Mz
tance
chassis ground
WD600-6 40-400 41
Contents of
(10) Headlamp high beam does not light up or go off. (AJSS specification)
trouble
• The switch, lamp, or wiring harness of the headlamp (high beam) is disconnected or shorted with the
chassis ground.
• Carry out the following troubleshooting when the low beam lights up (goes off) normally.
Related
information

1 Broken bulb

High Max. 1 z
Normal Min. 1 Mz
chassis ground
Between (1) and (2) 200 – 400 z
Possible a Prepare with starting switch OFF, then turn starting switch ON
causes and and carry out troubleshooting
standard value When dimmer relay (L118) is replaced with a relay of the same type,
in normal state if the condition becomes normal, the dimmer relay is defective.
Disconnection in wiring Wiring harness between C16 (female) (2) – Resis-
Max. 1 z
4
Wiring harness between HEAD (3) and L118 Resis-
Max. 1 z
(female) (5) tance
Grounding fault in wiring Wiring harness between C16 (female) (2) – Resis-
Min. 1 Mz
(Contact with ground circuit) Wiring harness between L118 (female) (5) –
Resis-
HEAD (3), – circuit branch end and chassis Min. 1 Mz
tance
ground
40-400 42 WD600-6
Contents of (11) Clearance lamp does not light up or go off. (AJSS specification)
trouble (12) Tail lamp does not light up or go off. (AJSS specification)
• The switch, lamp, or wiring harness of the clearance lamp or tail lamp system is defective.
Related • Carry out the following troubleshooting when the headlamp and turn signal light up.
information • The input state (voltage) from the headlamp switch (small lamp) can be checked with the monitoring
function (Code: 40200, SMALL LAMP).

1 Broken bulb
Defective fuse No. 12 or No. If the fuse is burnt, the circuit probably has a grounding fault, etc.
2
13 of fuse box 2 (See cause 6.)
Defective headlamp switch OFF Min. 1 Mz
short circuit) Between (4) and (3) SMALL Max. 1 z
HEAD Max. 1 z
Normal Min. 1 Mz
chassis ground
Between (1) and (2) 200 – 400 z
Defective small lamp relay
(L115)
When small lamp relay (L115) is replaced with a relay of the same
Possible
type, if the condition becomes normal, the small lamp relay is defec-
causes and
tive.
standard value
Max. 1 z
Max. 1 z
Max. 1 z
fuse No. 14 or No. 15 of fuse box 2 tance
harness Wiring harness between fuse No. 12 of fuse
5 Resis-
(Disconnection or defective box 2 – right COMBI (female) (1), – G01 Max. 1 z
(female) (4)
Resis-
box 2 – left COMBI (female) (1), – G02 Max. 1 z
tance
(female) (4)
Wiring harness between COMBI (female) (2) Resis-
Max. 1 z
– chassis ground tance
Max. 1 z
Max. 1 z
WD600-6 40-400 43

Min. 1 Mz
Resis-
fuse No. 14 or No. 15 of fuse box 2 and Min. 1 Mz
chassis ground
harness
6
(Disconnection or defective a Prepare with starting switch OFF, then carry out troubleshooting
contact of connector) without turning starting switch ON.
Resis-
box 2 – right COMBI (female) (1), – G01 Min. 1 Mz
tance
Resis-
Possible box 2 – left COMBI (female) (1), – G02 Min. 1 Mz
tance
causes and (female) (4) and chassis ground
standard value a Prepare with starting switch OFF, then turn starting switch ON
in normal state and carry out troubleshooting
Voltage Max. 1 V
Between L115 (female) (3) – fuse No. 14 or
No. 15 of fuse box 2 wiring harness and Voltage Max. 1 V
Hot short in wiring harness chassis ground
7
(Contact with 24 V circuit) a Prepare with starting switch OFF, then turn starting switch ON
box 2 – right COMBI (female) (1), – G01 Voltage Max. 1 V
box 2 – left COMBI (female) (1), – G02 Voltage Max. 1 V
40-400 44 WD600-6
Circuit diagram related to headlamp, clearance lamp and tail lamp (AJSS specification)
WD600-6 40-400 45
SEN05061-01 E-5 Working lamp does not light up or go off.
E-5 Working lamp does not light up or go off. 1
Contents of
(1) Either of front working lamp and rear working lamp does not light up
trouble
• The working lamp system power supply wiring harness is disconnected or shorted with the chassis
Related ground.
information • If the clearance lamp does not light up or go off either, carry out troubleshooting for the clearance
lamp first.

C33 (male) Working lamp switch Resistance
OFF Min. 1 Mz
REAR Max. 1 z
Between (1) and (2)
FRONT (& SIDE) Min. 1 Mz
ALL Min. 1 Mz
OFF Min. 1 Mz
Defective working lamp switch
REAR Min. 1 Mz
1 (Internal disconnection or Between (1) and (3)
short circuit) FRONT (& SIDE) Max. 1 z
Possible
causes and ALL Max. 1 z
standard value OFF Min. 1 Mz
in normal state
REAR Min. 1 Mz
Between (1) and (4)
ALL Max. 1 z
Between (1), (2), (3),
ground
harness Wiring harness between L02 (female) (5) – Resis-
2 Max. 1 z
(Disconnection or defective C33 (Steering wheel specification) tance
Max. 1 z
C33 (female) (1) (AJSS specification) tance
Contents of
(2) Front working lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the front working lamp system is defective
Related
• If the clearance lamp does not light up or go off either, carry out troubleshooting for the clearance
information
lamp first.

If a specific working lamp does not light up, its bulb may be broken
1 Broken bulb
or may have a defective contact. Check the bulb directly.
Possible Defective fuse No. 3 of fuse If the fuse is burnt, the circuit probably has a grounding fault, etc.
causes and 2
standard value
Defective front working lamp without turning starting switch ON.
3
relay (L109) L109 (male) Resistance
Between (5) and (6) 200 – 400 z
40-400 46 WD600-6
E-5 Working lamp does not light up or go off. SEN05061-01

Defective front working lamp
3 When front working lamp relay (L109) is replaced with a relay of the
relay (L109)
same type, if the condition becomes normal, the front working lamp
relay is defective.
C33 (male) Working lamp switch Resistance
Defective working lamp switch OFF Min. 1 Mz

4 (Internal disconnection or REAR Min. 1 Mz
FRONT (& SIDE) Max. 1 z
ALL Max. 1 z
Normal Min. 1 Mz
chassis ground
Max. 1 z
Max. 1 z
Possible Wiring harness between L109 (female) (1) – Resis-
Max. 1 z
causes and C41 (female) (1), – C42 (female) (1) tance
standard value
harness Wiring harness between C41 (female) (2), Resis-
in normal state 5 Max. 1 z
(Disconnection or defective C42 (female) (2) – chassis ground tance
Max. 1 z
Max. 1 z
FW01 (female) (1), – FW02 (female) (1) tance
Wiring harness between FW01 (female) (2), Resis-
Max. 1 z
FW02 (female) (2) – chassis ground tance
Wiring harness between fuse No. 4 of fuse Resis-
Max. 1 z
Resis-
tance
chassis ground
Grounding fault in wiring Resis-
C41 (female) (1), – C42 (female) (1) and Min. 1 Mz
6 harness tance
chassis ground
Resis-
box 2 – L109 (female) (2), – circuit branch Min. 1 Mz
tance
Resis-
FW01 (female) (1), – FW02 (female) (1), – Min. 1 Mz
tance
WD600-6 40-400 47

Possible
causes and Wiring harness between L109 (female) (1) –
standard value Hot short in wiring harness C41 (female) (1), – C42 (female) (1) and Voltage Max. 1 V
7
in normal state (Contact with 24 V circuit) chassis ground
FW01 (female) (1), – FW02 (female) (1), – Voltage Max. 1 V
40-400 48 WD600-6
Contents of
(3) Rear working lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the rear working lamp system is defective.
Related
• If the clearance lamp does not light up or go off either, carry out troubleshooting for the clearance
information
lamp first.

If a specific working lamp does not light up, its bulb may be broken
1 Broken bulb
2
Between (5) and (6) 200 – 400 z
Defective rear working lamp
relay (L110)
When rear working lamp relay (L110) is replaced with a relay of the
same type, if the condition becomes normal, the rear working lamp
relay is defective.
Possible C33 (male) Working lamp switch Resistance
causes and
Defective working lamp switch OFF Min. 1 Mz
standard value
in normal state 4 (Internal disconnection or REAR Max. 1 z
ALL Min. 1 Mz
Normal Min. 1 Mz
chassis ground
Max. 1 z
Max. 1 z
harness chassis ground tance
5
G03 (female) (1), – G04 (female) (1) tance
Wiring harness between G03 (female) (2) or Resis-
Max. 1 z
G04 (female) (2) – chassis ground tance
Max. 1 z
WD600-6 40-400 49

Resis-
tance
chassis ground
Resis-
Grounding fault in wiring G03 (female) (1), – G04 (female) (1), – cir- Min. 1 Mz
tance
6 harness cuit branch end and chassis ground
Possible (Contact with ground circuit) Wiring harness between fuse No. 4 of fuse
causes and box 2 – L110 (female) (2), – circuit branch
standard value end and chassis ground
in normal state • If one of above conditions is applicable, Resis-
Min. 1 Mz
ADD front working lamp (if equipped) is tance
also in failure.
For machines equipped with, ADD front
working lamp also does not light up.
7 Wiring harness between L110 (female) (1) –
(Contact with 24 V circuit) Resis-
G03 (female) (1), – G04 (female) (1), – cir- Max. 1 z
tance
cuit branch end and chassis ground
40-400 50 WD600-6
Circuit diagram related to working lamp (Steering wheel specification)
WD600-6 40-400 51
Circuit diagram related to working lamp (AJSS specification)
40-400 52 WD600-6
WD600-6 40-400 53
SEN05061-01 E-6 Step lamp does not light up or go off
E-6 Step lamp does not light up or go off 1
Contents of
Step lamp does not light up or go off
trouble
• The switch, lamp, or wiring harness of the step lamp or tail lamp system is defective.
Related
• The step lamp switch is installed in 2 places: upper left section from the operator's seat and the step
information
section. Both switches can be used to turn on/off the step lamp.

1 Broken bulb
2
C19 (male) Step lamp switch Resistance
Defective step lamp switch Up or Down Min. 1 Mz
(at upper left section from Between (3) and (4)
Down or Up Max. 1 z
3 operator's seat)
(Internal disconnection or Up or Down Max. 1 z
Between (5) and (6)
short circuit) Down or Up Min. 1 Mz
Between (3), (4), (5),
ground
causes and D09 (male) Step lamp switch Resistance
standard value Defective step lamp switch Up or Down Min. 1 Mz
in normal state (at step section) Between (A) and (B)
4 Down or Up Max. 1 z
short circuit) Up or Down Max. 1 z
Between (A) and (C)
Down or Up Min. 1 Mz
Between (A), (B), (C)
Normal Min. 1 Mz
and chassis ground
Max. 1 z
box 1 – D09 (female) (A) tance
Disconnection in wiring Wiring harness between D09 (female) (B) – Resis-
Max. 1 z
harness C19 (female) (3) tance
5
(Disconnection or defective Wiring harness between D09 (female) (C) – Resis-
Wiring harness between C19 (female) (4), Resis-
Max. 1 z
(5) – C45 (female) (1) tance
Max. 1 z
40-400 54 WD600-6
E-6 Step lamp does not light up or go off SEN05061-01

Min. 1 Mz
Grounding fault in wiring box 1 – D09 (female) (A) and chassis ground tance
harness Wiring harness between D09 (female) (B) – Resis-
6 Min. 1 Mz
(Disconnection or defective C19 (female) (3) and chassis ground tance
Possible contact of connector) Wiring harness between D09 (female) (C) – Resis-
causes and Min. 1 Mz
standard value
Wiring harness between C19 (female) (4), Resis-
in normal state Min. 1 Mz
(5) – C45 (female) (1) and chassis ground tance
Hot short in wiring harness Max. 1 V

7 Wiring harness between C19 (female) (4),
(Contact with 24 V circuit) (After
(5) – C45 (female) (1)
Voltage switched
• Switch over the switch and measure the
over: 20 –
voltage again
30 V)
Circuit diagram related to step lamp
WD600-6 40-400 55
SEN05061-01 E-7 Turn signal lamp and hazard lamp do not light up or go off
E-7 Turn signal lamp and hazard lamp do not light up or go off 1
Contents of (1) Either of turn signal lamp and hazard lamp does not light up or go off. (Steering wheel specification)
trouble (STD)
Related
• The switch, lamp, or wiring harness of the turn signal lamp and hazard lamp system is defective.
information

1
box 2 and No.2 of fuse box 1 (See causes 6.)
Between (5) and (6) 200 – 400 z
2 Defective hazard relay (L113)
When hazard relay (L113) is replaced with a relay of the same type,
if the condition becomes normal, the hazard relay is defective.
L19 (male) Voltage
Between (3) and (1) 20 – 30 V
Defective flasher unit
Between (4) and (1) Repeat 20 to 30 V  0 V.
short circuit) a Prepare with starting switch OFF, then carry out troubleshooting
Between (3) or (4) and
Min. 1 Mz
chassis ground
Possible
causes and a Prepare with starting switch OFF, then carry out troubleshooting
standard value without turning starting switch ON.
in normal state Turn signal lamp and
hazard lamp switches
Turn signal lever: Left Min. 1 Mz
Turn signal lever:
Min. 1 Mz
Neutral
Between (2) and (3) Turn signal lever:
Max. 1 z
Right
Hazard lamp switch:
Max. 1 z
ON
Defective turn signal lamp and
hazard lamp switches Turn signal lever: Left Max. 1 z
4
(Internal disconnection or Turn signal lever:
Neutral
Between (2) and (4) Turn signal lever:
Min. 1 Mz
Right
Hazard lamp switch:
Max. 1 z
ON
Hazard lamp switch:
Max. 1 z
ON
Between (1) – (5)
Hazard lamp switch:
Min. 1 Mz
OFF
Between (2), (3), (4)
Normal Min. 1 Mz
and chassis ground
40-400 56 WD600-6
E-7 Turn signal lamp and hazard lamp do not light up or go off SEN05061-01

Max. 1 z
and L19 (female) (3) tance
Disconnection in wiring Resis-
Between L113 (female) (6) – fuse 2 (1) Max. 1 z
harness tance
5
fuse 1 (2) tance
Max. 1 z
Possible
causes and Max. 1 z
standard value
6 harness Min. 1 Mz
Min. 1 Mz
Hot short in wiring harness Wiring harness between L113 (female) (3) –
7 Voltage Max. 1 V
(Contact with 24 V circuit) L19 (female) (3) and chassis ground
Voltage Max. 1 V
Contents of
(2) Either of turn signal lamp and hazard lamp does not light up or go off. (AJSS specification)
trouble
Related
• The switch, lamp, or wiring harness of the turn signal lamp and hazard lamp system is defective.
information

1
box 2 and No.2 of fuse box 1 (See causes 4.)
L19 (male) Voltage
Between (3) and (1) 20 – 30 V
Defective flasher unit
Between (4) and (1) Repeat (20 – 30 V)  0 V.
short circuit) a Prepare with starting switch OFF, then carry out troubleshooting
Possible
causes and
standard value L19 (male) Resistance
in normal state Between (3) or (4) and
Min. 1 Mz
chassis ground
Max. 1 z
3
Max. 1 z
circuit branch end point tance
WD600-6 40-400 57

4 harness Min. 1 Mz
Possible (Contact with ground circuit)
circuit branch end point and chassis ground tance
standard value
in normal state a Prepare with starting switch OFF, then turn starting switch ON
Hot short in wiring harness Wiring harness between L113 (female) (3) –
5 Voltage Max. 1 V
(Contact with 24 V circuit) L19 (female) (3) and chassis ground
Voltage Max. 1 V
circuit branch end point and chassis ground
Contents of
(3) Turn signal lamp does not light up or go off (Steering wheel specification)
trouble
Related
• The switch, lamp, or wiring harness of the turn signal lamp system is defective.
information

If a specific turn signal lamp does not light up, its bulb may be
1 Broken bulb
broken or may have a defective contact. Check the bulb directly.
Turn signal lamp and
hazard lamp switches
Turn signal lever: Left Min. 1 Mz
Turn signal lever:
Min. 1 Mz
Defective turn signal lamp and Between (2) and (3) Neutral
hazard lamp switches Turn signal lever:
2 Max. 1 z
(Internal disconnection or Right
short circuit) Turn signal lever: Left Max. 1 z
Turn signal lever:
Possible Min. 1 Mz
Between (2) and (4) Neutral
causes and
standard value Turn signal lever:
Min. 1 Mz
in normal state Right
Between (2), (3), (4)
Normal Max. 1 z
and chassis ground
Max. 1 z
G01 (female) (1), – right COMBI (female) (3) tance
Max. 1 z
harness G02 (female) (1), – left COMBI (female) (3) tance
3
(Disconnection or defective Wiring harness between G01 (female) (6) – Resis-
Max. 1 z
Wiring harness between right and left Resis-
Max. 1 z
COMBI (female) (2) – chassis ground tance
40-400 58 WD600-6

Grounding fault in wiring Resis-
G01 (female) (1), – right COMBI (female) (3), Min. 1 Mz
4 harness tance
– circuit branch end and chassis ground
Possible Resis-
G02 (female) (1), – left COMBI (female) (3), Min. 1 Mz
causes and tance
standard value
in normal state a Prepare with starting switch OFF, then turn starting switch ON
Hot short in wiring harness G01 (female) (1), – right COMBI (female) (3), Voltage Max. 1 V
5
(Contact with 24 V circuit) – circuit branch end and chassis ground
G02 (female) (1), – left COMBI (female) (3), Voltage Max. 1 V
Contents of
(4) Turn signal lamp does not light up or go off (AJSS specification)
trouble
• The switch, lamp, or wiring harness of the turn signal lamp system is defective.
• The input state from the turn signal switch to the controller can be checked with the monitoring func-
Related
tion (Code: 40913 D-IN30, D-IN31).
information
• The output state from the controller to the winker relay can be checked with the monitoring function
(Code: 40954 D-0UT16, D-OUT17).

If a specific turn signal lamp does not light up, its bulb may be bro-
1 Broken bulb
ken or may have a defective contact. Check the bulb directly.
S22 (male) Turn signal lever Resistance
Neutral Min. 1 Mz
Defective turn signal lever Between (5) and (4) Right Min. 1 Mz
switch
2 Left Max. 1 z
short circuit) Neutral Min. 1 Mz
Possible
causes and Between (5) and (6) Right Max. 1 z
standard value Left Min. 1 Mz
in normal state
Between (4), (5), (6)
Normal Min. 1 Mz
and chassis ground
Between (1) and (2) 200 – 400 z
Defective turn signal lamp
relay (right) (L121)
When turn signal lamp relay (right) (L121) is replaced with a relay of
the same type, if the condition becomes normal, the turn signal lamp
relay (right) is defective.
WD600-6 40-400 59

Between (1) and (2) 200 – 400 z
Defective turn signal lamp
relay (left) (L122)
When turn signal lamp relay (left) (L122) is replaced with a relay of
the same type, if the condition becomes normal, the turn signal lamp
relay (left) is defective.
Min. 1 Mz
Min. 1 Mz
Resis-
Between S22 (female) (5) – chassis ground Min. 1 Mz
tance
Wiring harness between L121 (female) (1) or Resis-
Max. 1 z
L122 (female) (1) – fuse No. 1 of fuse box 2 tance
Max. 1 z
Disconnection in wiring L06 (female) (18) tance
5 Max. 1 z
contact of connector) Wiring harness between L121 (female) (3) – Resis-
Max. 1 z
G01 (female) (1), – right COMBI (female) (3) tance
Possible
causes and Wiring harness between L122 (female) (3) – Resis-
Max. 1 z
standard value G02 (female) (1), – left COMBI (female) (3) tance
in normal state Wiring harness between G01 (female) (6) – Resis-
Max. 1 z
Max. 1 z
Wiring harness between right COMBI Resis-
Max. 1 z
(female) (2) – chassis ground tance
Wiring harness between left COMBI (female) Resis-
Max. 1 z
(2) – chassis ground tance
Between S22 (female) (4) – L06 (female) (38) Resis-
Min. 1 Mz
Between S22 (female) (6) – L06 (female) (2) Resis-
Min. 1 Mz
Wiring harness between L121 (female) (1) or
Resis-
L122 (female) (1) – fuse No. 1 of fuse box 2 Min. 1 Mz
tance
Grounding fault in wiring and chassis ground
6 harness Wiring harness between L121 (female) (2) – Resis-
(Contact with ground circuit) Min. 1 Mz
Min. 1 Mz
Resis-
G01 (female) (1), – right COMBI (female) (3), Min. 1 Mz
tance
Resis-
G02 (female) (1), – left COMBI (female) (3), Min. 1 Mz
tance
40-400 60 WD600-6

Hot short in wiring harness G01 (female) (1), – right COMBI (female) (3), Voltage Max. 1 V
7
(Contact with 24 V circuit) – circuit branch end and chassis ground
G02 (female) (1), – left COMBI (female) (3), Voltage Max. 1 V
Possible
causes and a Prepare with starting switch OFF, then turn starting switch ON
standard value and carry out troubleshooting.
in normal state Press turn signal switch R Voltage Max. 1 V
L06 (2)
Release turn signal switch R Voltage 8 – 10 V
Defective work equipment Press turn signal switch L Voltage Max. 1 V

8 L06 (38)
controller Release turn signal switch L Voltage 8 – 10 V
Press turn signal switch R Voltage Max. 1 V
L06 (18)
Press turn signal switch R again Voltage 20 – 30 V
Press turn signal switch L Voltage Max. 1 V
L06 (8)
Press turn signal switch L again Voltage 20 – 30 V
Contents of
(5) Hazard lamp does not light up or go off (Steering wheel specification)
trouble
Related • The switch or lamp of the hazard lamp is defective.
information • Carry out the following troubleshooting when the turn signal lamp flashes normally.

Defective fuse in fuse box 1
1 If fuse is broken, circuit probably has ground fault.
(2)
Resis-
Disconnection in wiring Between fuse box 2 (2) – L113 (female) (5) Max. 1 z
tance
harness
Resis-
2 (Disconnection in wiring or Between fuse box 2 (2) – L113 (female) (1) Max. 1 z
tance
defective contact in
connector) Resis-
Between L113 (female) (2) – L03 (female) (1) Max. 1 z
tance
Resis-
Possible Between L03 (female) (5) – chassis ground Max. 1 z
causes and tance
Ground fault in wiring harness Wiring harness between L113 (female) (2) – Resis-
3 Min. 1 Mz
(Contact with GND circuit) L03 (female) (1) and chassis ground tance
Min. 1 Mz
Defective hazard lamp switch L03 (male) Hazard lamp switch Resistance
4 (Internal disconnection or Between (2) and ON Max. 1 z
short circuit) (3), (4) OFF Min. 1 Mz
Between (2), (3), (4)
Normal Min. 1 Mz
and chassis ground
WD600-6 40-400 61

Possible L113 (male) Resistance
causes and Between (1) – (2) 200 – 400 z
standard value Defective hazard lamp relay
in normal state (L113)
Replace hazard lamp relay (L113) with another relay of same type.
If condition becomes normal at this time, hazard lamp relay is defec-
tive.
Contents of
(6) Hazard lamp does not light up or go off (AJSS specification)
trouble
Related • The switch or lamp of the hazard lamp is defective.
information • Carry out the following troubleshooting when the turn signal lamp flashes normally.

Defective fuse in fuse box 1
1 If fuse is broken, circuit probably has ground fault.
(2)
Disconnection in wiring Resis-
harness Between fuse box 1 (2) – CN14 (female) (2) Max. 1 z
tance
2 (Disconnection in wiring or
Between C14 (female) (4) – L113 (female) Resis-
defective contact in Max. 1 z
connector) (1) tance
Between C14 (female) (4) – L114 (female) Resis-
Max. 1 z
(5) tance
Ground fault in wiring harness Between C14 (female) (4) – L113 (female) Resis-
3 Min. 1 Mz
(Contact with GND circuit) (1) and chassis ground tance
Possible Between C14 (female) (4) – L114 (female) Resis-
standard value
in normal state
Defective hazard lamp switch C14 (male) Hazard lamp switch Resistance
4 (Internal disconnection or ON Max. 1 z
OFF Min. 1 Mz
Normal Min. 1 Mz
chassis ground
Between (1) – (2) 200 – 400 z
Defective hazard lamp relay
(L113)
Replace hazard lamp relay (L113) with another relay of same type.
If condition becomes normal at this time, hazard lamp relay is defec-
tive.
40-400 62 WD600-6

Possible L114 (male) Resistance
causes and Between (1) – (2) 200 – 400 z
standard value Defective turn signal lamp
in normal state relay (L114)
Replace turn signal lamp relay (L114) with another relay of same
type. If condition becomes normal at this time, turn signal lamp relay
is defective.
WD600-6 40-400 63
Circuit diagram related to turn signal lamp and hazard lamp (Steering wheel specification)
40-400 64 WD600-6
Circuit diagram related to turn signal lamp and hazard lamp (AJSS specification)
WD600-6 40-400 65
SEN05061-01 E-8 Brake lamp does not light or it keeps lighting up.
E-8 Brake lamp does not light or it keeps lighting up. 1
Contents of
Brake lamp does not light or it keeps lighting up.
trouble
• The lamp or wiring harness of the brake lamp system is abnormal.
Related
• The input state of brake lamp switch signal to the controller can be checked with the monitoring
information

If a specific brake lamp does not light up, its bulb may be broken or
1 Broken bulb
2
Defective brake lamp relay
Between (1) and (2) 200 – 400 z
(L102)
short circuit) and carry out troubleshooting
When brake lamp relay (L102) is replaced with a relay of the same
type, if the condition becomes normal, the brake lamp relay is defec-
tive.
Possible L16 (male) Brake pedal Resistance
causes and Defective brake lamp switch
standard value 4 (Internal disconnection or Pressed Max. 1 z
in normal state Released Min. 1 Mz
Normal Min. 1 Mz
chassis ground
Max. 1 z
box 2 – L102 (female) (2), – L16 (female) (1) tance
Max. 1 z
Disconnection in wiring L102 (female) (5) tance
5 Max. 1 z
(Disconnection or defective chassis ground tance
contact of connector) Wiring harness between L102 (female) (1) – Resis-
Max. 1 z
G01 (female) (5), – G02 (female) (5) tance
Max. 1 z
Max. 1 z
40-400 66 WD600-6
E-8 Brake lamp does not light or it keeps lighting up. SEN05061-01

Resis-
box 2 – L102 (female) (2), – L16 (female) (1) Min. 1 Mz
and chassis ground
6 harness
(Contact with ground circuit) Wiring harness between L16 (female) (2) – Resis-
Min. 1 Mz
Possible L102 (female) (5) and chassis ground tance
causes and Wiring harness between L102 (female) (1) –
standard value Resis-
G01 (female) (5), – G02 (female) (5), – cir- Min. 1 Mz
in normal state tance
Hot short in wiring harness Voltage Max. 1 V
7 L102 (female) (5) and chassis ground
G01 (female) (5), – G02 (female) (5), – cir- Voltage Max. 1 V
cuit branch end
WD600-6 40-400 67
SEN05061-01 E-8 Brake lamp does not light or it keeps lighting up.
Circuit diagram related to brake lamp
40-400 68 WD600-6
E-8 Brake lamp does not light or it keeps lighting up. SEN05061-01
WD600-6 40-400 69
SEN05061-01 E-9 Backup lamp does not light or it keeps lighting up.
E-9 Backup lamp does not light or it keeps lighting up. 1
Contents of
Backup lamp does not light or it keeps lighting up. (Steering wheel specification)
trouble
Related • The transmission controller monitors the primary circuit of the backup lamp relay for a trouble.
information (If disconnection or short circuit occurs, failure code D160KA or D160KB is displayed.)

If a specific backup lamp does not light up, its bulb may be broken
1 Broken bulb
2
Defective backup lamp relay Between (1) and (2) 200 – 400 z
3 (L101) (Internal disconnection a Prepare with starting switch OFF, then turn starting switch ON
or short circuit) and carry out troubleshooting
When backup lamp relay (L101) is replaced with a relay of the same
type, if the condition becomes normal, the backup lamp relay is
defective.
Max. 1 z
Max. 1 z
Disconnection in wiring G01 (female) (2), – G02 (female) (2) tance
Possible harness Wiring harness between L101 (female) (5) – Resis-
causes and 4 Max. 1 z
standard value contact of connector) Wiring harness between L101 (female) (6) – Resis-
in normal state Max. 1 z
Max. 1 z
Max. 1 z
Resis-
box 2 – L101 (female) (2) and chassis Min. 1 Mz
tance
Grounding fault in wiring ground
tance
Resis-
tance
chassis ground
40-400 70 WD600-6
E-9 Backup lamp does not light or it keeps lighting up. SEN05061-01
Circuit diagram related to backup lamp relay (Steering wheel specification)
WD600-6 40-400 71
SEN05061-01 E-9 Backup lamp does not light or it keeps lighting up.
Contents of
Backup lamp does not light or it keeps lighting up. (AJSS specification)
trouble

If a specific backup lamp does not light up, its bulb may be broken
1 Broken bulb
2
defective.
Max. 1 z
Max. 1 z
Disconnection in wiring G01 (female) (2), – G02 (female) (2) tance
Possible harness Wiring harness between L101 (female) (5) Resis-
causes and 4 Max. 1 z
(Disconnection or defective and S31 (female) (4) tance
standard value contact of connector) Wiring harness between L101 (female) (6) – Resis-
in normal state Max. 1 z
Max. 1 z
Max. 1 z
Resis-
tance
tance
Resis-
S31 (female) (4), – circuit branch end and Min. 1 Mz
tance
chassis ground
40-400 72 WD600-6
E-9 Backup lamp does not light or it keeps lighting up. SEN05061-01
Circuit diagram related to backup lamp relay (AJSS specification)
WD600-6 40-400 73
SEN05061-01 E-10 Backup buzzer does not sound or it keeps sounding.
E-10 Backup buzzer does not sound or it keeps sounding. 1
Contents of
Backup buzzer does not sound or it keeps sounding (Steering wheel specification)
trouble

Defective backup buzzer
1 (Internal disconnection or G06 Gear shift lever Voltage
short circuit) R Max. 1 V
Between (1) and (2)
Other than R 20 – 30 V
2
defective.
Max. 1 z
Possible box 2 – L101 (female) (2) tance
Disconnection in wiring Max. 1 z
standard value harness G06 (female) (1) tance
in normal state 4
Max. 1 z
Max. 1 z
Resis-
tance
G06 (female) (1), – circuit branch end and Min. 1 Mz
tance
chassis ground
Resis-
tance
chassis ground
G06 (female) (1), – circuit branch end and Voltage Max. 1 V
chassis ground
40-400 74 WD600-6
E-10 Backup buzzer does not sound or it keeps sounding. SEN05061-01
Circuit diagram related to backup buzzer (Steering wheel specification)
WD600-6 40-400 75
SEN05061-01 E-10 Backup buzzer does not sound or it keeps sounding.
Contents of
Backup buzzer does not sound or it keeps sounding (AJSS specification)
trouble

Defective backup buzzer
1 (Internal disconnection or G06 Gear shift lever Voltage
short circuit) R Max. 1 V
Between (1) and (2)
Other than R 20 – 30 V
2
defective.
Max. 1 z
Possible box 2 – L101 (female) (2) tance
Disconnection in wiring Max. 1 z
standard value G06 (female) (1) tance
harness
in normal state 4
S31 (female) (4) tance
Max. 1 z
Max. 1 z
Resis-
tance
G06 (female) (1), – circuit branch end and Min. 1 Mz
tance
chassis ground
Resis-
S31 (female) (4), – circuit branch end and Min. 1 Mz
tance
chassis ground
G06 (female) (1), – circuit branch end and Voltage Max. 1 V
chassis ground
40-400 76 WD600-6
E-10 Backup buzzer does not sound or it keeps sounding. SEN05061-01
Circuit diagram related to backup buzzer (AJSS specification)
WD600-6 40-400 77
SEN05061-01 E-11 Horn does not sound or it keeps sounding.
E-11 Horn does not sound or it keeps sounding. 1
Contents of
Horn does not sound or it keeps sounding (Steering wheel specification)
trouble
Related
• The relay, switch, horn, or wiring harness of the horn system is abnormal.
information

1
Defective horn relay (L116)
Between (1) and (2) 200 – 400 z
short circuit) a Prepare with starting switch OFF, then turn starting switch ON
When horn relay (L116) is replaced with a relay of the same type, if
the condition becomes normal, the horn relay is defective.
Defective horn switch
3 (Internal disconnection or L05 (male) Horn switch Resistance
short circuit) Between (1) and ON Max. 1 z
chassis ground OFF Min. 1 Mz
Possible
and carry out troubleshooting. (Disconnect connector and mea-
causes and
sure on female side)
standard value
in normal state Defective horn F03, F04 Horn switch Voltage
4 (Internal disconnection or ON Max. 1 V
Between
short circuit)
F03 (1) and (2) OFF 20 – 30 V
Between ON Max. 1 V
F04 (1) and (2) OFF 20 – 30 V
Resis-
box 1 – L116 (female) (1), – F03 (female) (2), Max. 1 z
tance
– F04 (female) (2)
harness Max. 1 z
5 L05 (female) (1) tance
Max. 1 z
F03 (female) (1), – F04 (female) (1) tance
Wiring harness between horn switch – chas- Resis-
Max. 1 z
sis ground tance
40-400 78 WD600-6
E-11 Horn does not sound or it keeps sounding. SEN05061-01

Possible box 1 – L116 (female) (1), – F03 (female) (2), Resis-
Min. 1 Mz
causes and Grounding fault in wiring – F04 (female) (2), – circuit branch end and tance
standard value 6 harness chassis ground
in normal state (Contact with ground circuit) Wiring harness between L116 (female) (2) – Resis-
Min. 1 Mz
L05 (male) (1) and chassis ground tance
Wiring harness between F03 (female) (1),
Resis-
F04 (female) (1) – L116 (female) (5) and Min. 1 Mz
tance
chassis ground
Circuit diagram related to horn (Steering wheel specification)
WD600-6 40-400 79
SEN05061-01 E-11 Horn does not sound or it keeps sounding.
Contents of
Horn does not sound or it keeps sounding (AJSS specification)
trouble
Related
• The relay, switch, horn, or wiring harness of the horn system is abnormal.
information

1
Defective horn relay (L116)
Between (1) and (2) 200 – 400 z
short circuit) a Prepare with starting switch OFF, then turn starting switch ON
When horn relay (L116) is replaced with a relay of the same type, if
the condition becomes normal, the horn relay is defective.
Defective AJSS horn switch S31 (male) Horn switch Resistance

3 (Internal disconnection or ON Max. 1 z
OFF Min. 1 Mz
Between (9) or (10)
Normal Min. 1 Mz
and chassis ground
Possible
causes and a Prepare with starting switch OFF, then turn starting switch ON
standard value and carry out troubleshooting. (Disconnect connector and mea-
in normal state sure on female side)
Defective horn F03, F04 (female) Horn switch Voltage
4 (Internal disconnection or ON 20 – 30 V
Between F03
short circuit)
(female) (1) and (2) OFF Max. 1 V
Between F04 ON 20 – 30 V
(female) (1) and (2) OFF Max. 1 V
Resis-
box 1 – L116 (female) (1), – F03 (female) (2), Max. 1 z
tance
– F04 (female) (2)
harness Max. 1 z
5 S31 (female) (9) tance
Max. 1 z
F03 (female) (1), – F04 (female) (1) tance
Max. 1 z
chassis ground. tance
40-400 80 WD600-6
E-11 Horn does not sound or it keeps sounding. SEN05061-01

Possible box 1 – L116 (female) (1), – F03 (female) (2), Resis-
Min. 1 Mz
causes and Grounding fault in wiring – F04 (female) (2), – circuit branch end and tance
standard value 6 harness chassis ground
in normal state (Contact with ground circuit) Wiring harness between L116 (female) (2) – Resis-
Min. 1 Mz
S31 (male) (9) and chassis ground tance
Wiring harness between F03 (female) (1),
Resis-
F04 (female) (1) – L116 (female) (5) and Min. 1 Mz
tance
chassis ground
Circuit diagram related to horn (AJSS specification)
WD600-6 40-400 81
SEN05061-01 E-12 Alarm buzzer does not sound or it keeps sounding
E-12 Alarm buzzer does not sound or it keeps sounding 1
Contents of
• Alarm buzzer does not sound or it keeps sounding
trouble
• The alarm buzzer output circuit is disconnected or shorted with the chassis ground.
Related • The output state (ON/OFF) to the alarm buzzer can be checked with the monitoring function (Code:
information 40952, D-OUT-0).
• If failure code [DV00KB] (Alarm buzzer: Short circuit) is displayed, carry out troubleshooting for it first.

1
• Check 2 seconds after starting switch is turned ON.
Defective alarm buzzer
2 L20 (female) Alarm buzzer Normal/Defective
Sounds Buzzer is normal
Ground (2)
Does not sound. Buzzer is defective
3 Max. 1 z
(Disconnection or defective box 2 – L20 (female) (1) tance
Possible contact of connector) Wiring harness between L20 (female) (2) – Resis-
causes and Max. 1 z
standard value
in normal state
4 harness Min. 1 Mz
box 2 – L20 (female) (1), – circuit branch end tance
Min. 1 Mz
C01 Starting switch Voltage
For 2 sec after ON
5 Defective machine monitor (Alarm buzzer does 20 – 30 V
Between (14) and not sound)
chassis ground For 2 – 3 sec after ON
(Alarm buzzer Max. 1 V
sounds)
40-400 82 WD600-6
E-12 Alarm buzzer does not sound or it keeps sounding SEN05061-01
Circuit diagram related to alarm buzzer
WD600-6 40-400 83
SEN05061-01 E-13 Air conditioner does not operate or stop
E-13 Air conditioner does not operate or stop 1
Contents of
Air conditioner does not operate or stop.
trouble
Related • The following is troubleshooting for only the section between the air conditioner and operator's cab.
information For troubleshooting for the air conditioner unit, see the Shop Manual for the air conditioner.

1
• When fuse No. 9 of fuse box A is broken
Grounding fault in wiring Resis- Min. 1
box 1 – A05 (female) (4), – A08 (female) (2),
2 harness tance Mz
– A11 (female) (4)
• If fuse No. 9 of fuse box 1 is broken while the above troubleshoot-
ing result is normal, blower main relay, magnet clutch relay,
blower motor or fuse (5A) in air conditioner unit and its connecting
wiring harness are defective.
Wiring harness Starting switch Voltage
Disconnection or grounding between A02
ON 20 – 30 V
fault in air conditioner control (female) (3) – A01
Possible
panel power supply or ground (female) (19) OFF Max. 1 V
causes and
3 wire harness
contact of connector or
contact with ground circuit) Wiring harness between A02 (female) (3) – Resis-
Max. 1 z
A01 (female) (19) tance
Wiring harness between A01 (female) (19) – Resis-
Max. 1 z
a Prepare with starting switch OFF, then hold starting switch OFF
and ON and carry out troubleshooting in each case.
Relay Starting switch Voltage
Wiring harness ON 20 – 30 V
Disconnection or grounding between A05
fault in relay wiring harness (female) (1) and
chassis ground OFF Max. 1 V
4 (Disconnection or defective
contact of connector or Wiring harness
contact with ground circuit) ON 20 – 30 V
between A08
(female) (1) and
chassis ground OFF Max. 1 V
If the above troubleshooting result is normal, each relay and its con-
necting wiring harness are defective.
40-400 84 WD600-6
E-13 Air conditioner does not operate or stop SEN05061-01
Circuit diagram related to air conditioner
WD600-6 40-400 85
SEN05061-01 E-14 Electric priming pump does not operate or does not stop automatically
E-14 Electric priming pump does not operate or does not stop
automatically 1
Contents of
Electric priming pump does not operate or does not stop automatically
trouble
Related
information

1 Low battery charge level Battery charge level may be low. Check battery directly.
Defective circuit breaker If circuit breaker CBF4 is turned OFF, circuit probably has ground
2
CBF4 fault. (Check cause No. 5)
Disconnection in wiring har- a Prepare with battery ground cable disconnected, then connect it
ness (Power supply system) and carry out troubleshooting (since power supply is unswitched).
3
(Disconnection in wiring or
defective contact in connector) Between EP3 (1) – (2) Voltage 20 – 30 V
a Prepare with battery ground cable disconnected, then connect

battery and turn electric priming pump ON and carry out trouble-
shooting.
harness (Drive power supply • Lamp blinks but stops in about 5 seconds.
system) Between EP2 (1) – (2) Voltage 20 – 30 V
4
(Disconnection in wiring or a Prepare with battery ground cable disconnected, then carry out
defective contact in troubleshooting without reconnecting (since power supply is
connector) unswitched).
Between EP3 (female) (2) and chassis Resis-
Max. 1 z
ground tance
a Prepare with battery ground cable disconnected, then carry out
troubleshooting without reconnecting (since power supply is
Possible
unswitched).
causes and
standard value Wiring harness between EP3 (female) (1) –
Resis-
in normal state circuit breaker CBF4 (R15) and chassis Min. 1 Mz
tance
Ground fault in wiring harness ground
5
(Contact with GND circuit) Wiring harness between EP3 (female) (3) – Resis-
Min. 1 Mz
EP2 (female) (1) and chassis ground tance
Wiring harness between EP3 (female) (4) – Resis-
Min. 1 Mz
EP2 (female) (2) and chassis ground tance
Resis-
Between EP2 (female) (1) – (2) 1–3z
tance
a Prepare with battery ground cable disconnected, then connect
battery and turn electric priming pump ON and carry out trouble-
shooting.
Defective electric priming Between EP3 (3) – (4) Voltage 20 – 30 V
pump switch • Lamp blinks but output voltage is improper.
6
(Malfunction or automatic stop • Results of troubleshooting steps 1 – 4 are normal and lamp does
failure) not blink.
a When electric priming pump does not stop automatically, electric
priming pump switch may be defective.
(Turn toggle switch OFF to stop pump and then replace switch.)
• Lamp blinks but stops in about 5 seconds.
Overload on electric priming
7 a If pump is overloaded, power supply is turned OFF automatically
pump
to protect circuit (Priming switch is reset automatically).
40-400 86 WD600-6
E-14 Electric priming pump does not operate or does not stop automatically SEN05061-01

a Prepare with battery ground cable disconnected, then carry out
troubleshooting without reconnecting (since power supply is
Possible unswitched).
causes and Resis-
Between EP2 (male) (1) – (2) 1–3z
standard value 8 Trouble in electric priming tance
in normal state pump
Resis-
Between EP2 (male) (1) – pump body Min. 1 Mz
tance
Resis-
Between EP2 (male) (2) – pump body Min. 1 Mz
tance
Circuit diagram related to electric priming pump
WD600-6 40-400 87
SEN05061-01 E-15 When starting switch is turned to ON position, machine monitor displays nothing
E-15 When starting switch is turned to ON position, machine monitor

displays nothing 1
Failure q When starting switch is turned to ON position, machine monitor displays nothing
q When engine is started, battery voltage may lower suddenly, depending on ambient temperature
Related infor-
and condition of the battery.
mation
In this case, machine monitor goes off for a moment. This phenomenon is not a failure, however.

Defective unsw power supply sys-
1 Carry out troubleshooting for failure code [DAF3KK].
tem
2 Defective fuse No.1 If fuse is blown, circuit probably has ground fault. (See Cause 8.)
Loose terminal or disconnection at 1. Turn starting switch to OFF position.

3
terminal Check terminals of battery, battery relay, ground (R09, R10, D10), etc.
a Be ready with starting switch in OFF position, then perform troubleshooting
4 Insufficient battery capacity
Battery voltage (two pieces) Min. 24 V
Electrolyte specific gravity (one piece) Min. 1.26
1. Turn starting switch to OFF position and disconnect ground cable.
2. Disconnect connectors C01, C02 and connect T-adapters to female side.
3. Connect the battery ground cable, and turn the starting switch to ON position
(connect ACC).
5 Defective wiring harness a Keep machine monitor disconnected.
Between C01 (female) (6) and (9) Voltage 20 – 30 V
2. Disconnect connector CL12 and connect T-adapter to male side.
3. Turn starting switch to OFF and ON positions and troubleshoot.
Defective starting switch (internal Turn starting switch to
6 Resistance Min. 1 Mz
failure) OFF position.
Between CL12 (male) (1)
and (4) Turn starting switch to
ON position. (connect Resistance Max. 1 z
ACC)
If check result on cause 5 is normal, this check is not required.
2. Disconnect fuse No.1 of fuse box1, and connectors CL2 and C01.
3. Connect T-adapters to female side of CL2 and C01.
Between battery (-) and ground Resistance Max. 1 z
Open circuit in wiring harness Between battery (+) and fuse No.1 of fuse box1 Resistance Max. 1 z
7 (wire breakage or defective con-
Between CL12 (female) (1) and fuse No.1 of fuse
tact of connector) Resistance Max. 1 z
box1
Between C01 (female) (6) and (7) Resistance Max. 1 z
Between C01 (female) (6) and C02 (female) (10) Resistance Max. 1 z
Between C01 (female) (6) and CL2 (female) (4) Resistance Max. 1 z
40-400 88 WD600-6
E-15 When starting switch is turned to ON position, machine monitor displays nothing SEN05061-01

If check result on cause 5 is normal, this check is not required.
2. Disconnect connectors L04, L07, V01, ER1, LR2, LR3, CL2 and C01.
3. Connect T-adapters to female side of CL2 and C01.
4. Remove fuse No.1 - No.7 of fuse box1.
8 Between battery (+) or fuse No.1 of fuse box1 and
(contact with ground circuit) Resistance Min. 1 Mz
ground
Between CL12 (female) (1) and ground Resistance Min. 1 Mz
Between CL12 (female) (4) and ground, or between

C01 (female) (6) or (7) and ground
If no failure is found by above checks, machine monitor is defective. (Since this
WD600-6 40-400 89
SEN05061-01 E-15 When starting switch is turned to ON position, machine monitor displays nothing
Circuit diagram related to machine monitor power supply
40-400 90 WD600-6
E-15 When starting switch is turned to ON position, machine monitor displays nothing SEN05061-01
WD600-6 40-400 91
SEN05061-01
WD600-6 Wheel dozer

©2016 KOMATSU
All Rights Reserved
40-400 92
SEN05062-01
WHEEL DOZER
WD600-6

WD600-6 55001 and up
500 Troubleshooting of hydraulic and

mechanical system (H-mode)
Method of using troubleshooting chart............................................................................................................ 4
Table of failure modes and causes ................................................................................................................. 6
H-1 Machine does not start........................................................................................................................... 10
H-2 Torque converter lockup is not switched (engine stalls) ......................................................................... 12
H-3 Torque converter lockup is not turned on ............................................................................................... 13
H-4 Travel speed is slow, thrusting force is weak, uphill traveling power is weak,
and gear is not shifted............................................................................................................................... 14
H-5 Shocks are large at the times of starting and shifting gear .................................................................... 16
H-6 Time lag is large at the times of starting and shifting gear ..................................................................... 18
H-7 Torque converter oil temperature is high................................................................................................ 20
H-8 Steering does not turn [machine with steering wheel]............................................................................ 21
H-9 Steering does not turn [machine with AJSS] .......................................................................................... 22
H-10 Turning, response of steering is poor [machine with steering wheel]................................................... 23
H-11 Turning, response of AJSS is poor [machine with AJSS]..................................................................... 24
H-12 Steering is heavy [machine with steering wheel].................................................................................. 25
H-13 When machine turns, it shakes or makes large shocks [machine with steering wheel] ....................... 26
H-14 When machine turns, it shakes or makes large shocks [machine with AJSS] ..................................... 27
H-15 Wheel brake does not work or does not work well............................................................................... 28
H-16 Wheel brake is not released or it drags................................................................................................ 29
H-17 Parking brake does not work or does not work well............................................................................. 30
H-18 Parking brake is not released or it drags (including emergency release system) ................................ 31
WD600-6 40-500 1
500 Troubleshooting of hydraulic and mechanical system (H-mode)
SEN05062-01
H-19 Blade does not rise............................................................................................................................... 32

H-20 Blade speed is low or rising force of lift is insufficient........................................................................... 33
H-21 When rising, blade comes to move slowly at specific height................................................................ 34
H-22 Lift cylinder cannot hold down blade (Blade floats) .............................................................................. 34
H-23 Hydraulic drifts of blade occur often ..................................................................................................... 34
H-24 Blade wobbles during operation ........................................................................................................... 34
H-25 Blade does not tilt and pitch ................................................................................................................. 35
H-26 Blade speed is low or tilt and pitch force is insufficient ........................................................................ 36
H-27 Blade comes to operate slowly in the midst of tilt and pitch ................................................................. 37
H-28 Tilt & pitch cylinder cannot hold down blade ........................................................................................ 37
H-29 Hydraulic drifts of blade occur often ..................................................................................................... 37
H-30 Blade wobbles during travel when loaded (Work equipment valve is set to “HOLD”) .......................... 37
H-31 During operation of machine, engine speed lowers remarkably or engine stalls ................................. 38
H-32 Large shocks are made when work equipment starts and stops.......................................................... 38
H-33 When work equipment circuit is relieved singly, other work equipment moves .................................... 38
H-34 Fan speed is abnormal (Fan sound and vibration are abnormally large or engine overheats) ............ 39
40-500 2 WD600-6
SEN05062-01
WD600-6 40-500 3
SEN05062-01 Method of using troubleshooting chart
Troubleshooting of hydraulic and mechanical system (H-mode) 1
Method of using troubleshooting chart 1
This troubleshooting chart determines the location from the problem occurring on the machine and catego-
rizes the problem under one of the main components, such as the steering system or work equipment
hydraulic system. Use the following procedure to carry out accurate troubleshooting swiftly.
Step 1. Ask operator questions Step 3. Method of reading matrix

q The questions to ask the operator are given 1. Operate the machine when carrying out trou-
under the problem. If the answer to the ques- bleshooting of the items in the Diagnosis col-
tion matches the content given, the cause umn. If any problems occur as the result of the
given after the arrow is the probable cause. troubleshooting, put a check against the item.
Keeping the content of the questions in mind, a When carrying out the troubleshooting,
read the matrix and proceed with Step 2 and check the easier items first. It is not neces-
Step 3 to pinpoint the correct cause. sary to follow the number order.
[Example]
Example: Steering does not turn
Remedy
Ask the operator and check the following points. No. Diagnosis
q Did the problem suddenly start? Steering does not turn in both directions (left
1
o Related equipment broken and right)
q Was the steering wheel heavy before? Steering turns only in one direction (left or
2
o Wear of related parts, defective seal right)
3 Steering is heavy when turned in both direc-

Step 2. Checks before troubleshooting tions (left and right)
q Before measuring the oil pressure or starting Steering wheel is heavy in one direction (left
4 or right)
the troubleshooting, confirm the checks before
5 Work equipment moves
starting items, check for leakage of oil, or for
loose bolts. This will prevent wasting time
when troubleshooting. The items given under 2. Find the matching cause in the Cause column.
“Checks before troubleshooting” are checks If a problem is found, the Q marks on the same
that are particularly important to make about line as the troubleshooting are the causes. (In
the condition of the machine before starting the Diagnosis item 2 in the same diagram below
actual troubleshooting. the cause is c or e.)
When there is one Q mark:
Example: Checks before starting troubleshooting Carry out troubleshooting for the other items
marked with Q in the same Cause column to
q Is oil level and type of oil in hydraulic tank cor-
check if the problem occurs, then make
rect?
repairs.
q Is there any oil leakage from steering valve or
When there are two or more Q marks:
demand valve?
Go to Step 3 to narrow down the cause.
q Is steering linkage adjusted properly?
40-500 4 WD600-6
Method of using troubleshooting chart SEN05062-01
3. Operate the machine and carry out trouble- 6. Repeat the operation in Steps 3, 4, and 5 until
shooting of the items not checked in Step 1. the cause is narrowed down to 1 item (1 com-
Operate the machine in the same way as in mon item).
Step 1, and if any problem occurs, put a check a If cause items are 2 or more, continue until
against the item. (In Troubleshooting item 5 in number of items becomes minimum.
the diagram below, the problem was re-
enacted.) 7. Remedy
After narrowing down the common causes,
4. Find the matching cause in the cause column. taken the action given in the remedy line.
In the same way as in Step 2, if a problem is Marks and remedies in remedy line
found, the Q marks on the same line for the : Replace E: Repair A: Adjust C: Clean
troubleshooting item are the causes. (In Diag-
nosis item 5 in the diagram below the cause is
b or e.)
5. Narrow down the causes.

Of the causes found in Step 2 and Step 4,
there are common items (Q marks on the line
for each Diagnosis item and in the same
Cause column as each other) that have
causes common with the problem items found
in the troubleshooting in Step 1 and Step 3.
a The items that are not common (items that
do not have Q marks in the same cause
common as each other) are probably not
the cause, so they can be eliminated. (The
causes for Diagnosis item 2 in the dia-
gram below are c or e, and the causes in
Diagnosis item 5 are b or e, so Cause e is
the common cause.)
WD600-6 40-500 5
SEN05062-01 Table of failure modes and causes
Table of failure modes and causes 1
Clogging of torque converter charging pump strainer

Part that can cause failures
Clogging or air intake on torque converter charging
Drop of transmission main relief valve set pressure

Defective operation of torque converter relief valve
Clogged or broken torque converter oil cooler
Defective torque converter charging pump
Defect of transmission controller system

Defective operation of relevant ECMV
Internal breakage of torque converter
Wear or seizure of relevant clutch

Internal breakage of transmission
Clogging of last chance filter
Defective regulator valve
pump suction side
Defective engine
Defective PTO
Failure mode
Machine does not start Q Q Q Q Q Q Q Q Q Q Q
Torque converter lockup is not switched (engine stalls) Q Q
Q Q Q Q Q
Power train
Torque converter lockup is not turned on

Travel speed is slow, thrusting force is weal, uphill traveling power is
weak, and gear is not shifted Q Q Q Q Q Q Q Q Q Q Q Q
Shocks are large at the times of starting and shifting gear Q Q Q Q Q Q Q

Time lag is large at the times of starting and shifting gear Q Q Q Q Q Q
Torque converter oil temperature is high Q Q Q Q Q Q Q Q
Steering does not turn [machine with steering wheel] Q
Steering does not turn [machine with AJSS] Q
Turning, response of steering is poor [machine with steering wheel] Q
Steering
Turning, response of steering is poor [machine with AJSS] Q

Steering is heavy [machine with steering wheel]
When machine turns, it shakes or makes large shocks [machine with
steering wheel]
When machine turns, it shakes or makes large shocks [machine with AJSS]
Wheel brake does not work or does not work well Q
Wheel brake is not released or it drags
Brake
Parking brake does not work or does not work well

Parking brake is not released or it drags (including emergency release
system)
Blade does not rise Q
Blade speed is low or rising force of blade is insufficient
When rising, blade comes to move slowly at specific height
Lift cylinder cannot hold down the blade (Blade floats)
Hydraulic drifts of blade occur often
Blade wobbles during operation
Q
Work equipment
Blade does not tilt and pitch

Blade speed is low or tilt and pitch force is insufficient
Blade comes to operate slowly in the midst of tilt and pitch
Tilt & pitch cylinder cannot hold down blade
Blade wobbles during travel when loaded (Work equipment valve is set to
“HOLD”)
Engine speed lowers remarkably or engine stalls during work equipment Q
control
Large shocks are made when work equipment starts and stops
moves
Fan speed is abnormal (Fan sound and vibration are abnormally large or
engine overheats)
40-500 6 WD600-6
Defective clutch piston
Defective seal of relevant clutch piston
Q Q
Q Q Q
Q Q
Q Q
Defective seal of relevant clutch shaft
WD600-6
Q
Q Q Q
Clogging of transmission breather
Defective operation of transmission oil
Q
Q
temperature sensor
Defective transmission output shaft speed sensor
Defective seal of work equipment and steering
Q
Q
system hydraulic pump shaft
Clogging or air intake on steering pump suction side
Q Q
Q Q
Defective steering pump
Table of failure modes and causes
Q Q
Defective steering pump servo
Defective Orbit-roll
Q Q
Defective steering stop valve
Defective steering main relief valve
Defective demand spool
Q
Defective steering spool of steering valve
Defective safety-suction valve
Q Q Q Q Q
Q Q Q Q Q Q Q
Q Q Q Q Q Q Q Q Q Q
Q Q Q Q Q Q Q
Defective seal of steering cylinder piston
Clogging of AJSS EPC solenoid valve line filter
Defective AJSS EPC solenoid valve
Q Q Q Q Q Q Q Q Q Q Q Q Q
Q Q
Q Q Q Q Q Q Q
Defective operation of rotary valve
Q
Defective steering wheel or steering shaft
Defective seal of brake piston
Q
Defective operation of brake piston
Internal breakage of wheel brake
Q Q Q Q
Wear of wheel brake disc
Q
Seized wheel brake disc plate
Q
Q
Q
Q Q Defective brake pump
Q Q
Q Q
Q Q
Clogging or air intake on brake pump suction side

Air in wheel brake circuit
Defective brake valve
Troubleshooting No.
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-11
H-34
H-33
H-32
H-31
H-30
H-29
H-28
H-27
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
Q H-16
Q Q Q Q H-15
H-14
H-13
H-12
H-10
40-500
7
SEN05062-01
SEN05062-01 Table of failure modes and causes
Part that can cause failures
Defective operation of parking brake solenoid valve

Defective parking brake emergency release valve
Defective operation of check valve (between last
Gas leakage from accumulator, defective seal of
Defective operation of wheel brake emergency
Defective harness of parking brake switch line

Defective operation of parking brake piston
chance filter and parking brake solenoid)
Defective seal of parking brake piston

Defective accumulator charge valve
Seized parking brake disc plate

Defective parking brake spring
Wear of parking brake disc

Defective slack adjuster
Defective axle oil
switch
piston
Failure mode
Machine does not start Q Q Q Q
Torque converter lockup is not switched (engine stalls)
Power train
Torque converter lockup is not turned on

Travel speed is slow, thrusting force is weal, uphill traveling power is Q
weak, and gear is not shifted
Shocks are large at the times of starting and shifting gear Q
Time lag is large at the times of starting and shifting gear
Torque converter oil temperature is high
Steering does not turn [machine with steering wheel] Q
Steering does not turn [machine with AJSS] Q
Turning, response of steering is poor [machine with steering wheel] Q
Steering
Turning, response of steering is poor [machine with AJSS] Q

Steering is heavy [machine with steering wheel] Q
steering wheel] Q

AJSS] Q
Wheel brake does not work or does not work well Q Q Q Q

Wheel brake is not released or it drags Q
Brake
Parking brake does not work or does not work well Q Q Q Q Q

Parking brake is not released or it drags (including emergency release
system) Q Q Q Q Q
Blade does not rise

Blade speed is low or rising force of blade is insufficient
When rising, blade comes to move slowly at specific height
Lift cylinder cannot hold down blade (Blade floats)
Blade wobbles during operation
Work equipment
Blade does not tilt and pitch

Blade speed is low or tilt and pitch force is insufficient
Blade comes to operate slowly in the midst of tilt and pitch
Tilt & pitch cylinder cannot hold down blade
Blade wobbles during travel when loaded (Work equipment valve is
set to “HOLD”)
Engine speed lowers remarkably or engine stalls during work equip-
ment control
Large shocks are made when work equipment starts and stops
moves
Fan speed is abnormal (Fan sound and vibration are abnormally large or
engine overheats)
40-500 8 WD600-6
Clogging or air intake on work equipment pump
Q
Q
Q
Q
Q
Q
Q
Q
Q
suction side
Defective work equipment controller
WD600-6
Defective work equipment pump
Q Q
Defective work equipment pump servo
Q
Q
Defective work equipment valve body
Defective work equipment main relief valve
Q Q Q Q Q
Q Q Q Q Q
Q Q Q Q Q
Q Q Q Q Q
Defective work equipment unload valve
Q Q Q Q Q Q
Q Q Q Q Q Q
Q Q Q Q Q Q
Q Q Q Q Q Q
Q Q Q Q Q Q
Q
Defective lift arm spool of work equipment valve
Q
Q
Q
Q
Q Q
Q Q
Q
Defective blade spool of work equipment valve
Defective lift arm load check valve of work
Table of failure modes and causes
Q
Q
Q
Q
Q
Q
equipment valve
Defective safety-suction valve on blade head side
Q
of work equipment valve
Defective safety-suction valve on blade bottom
Q
Q
Q
Q
Q
side of work equipment valve
Q
Q
Q
Defective lift cylinder
Q
Defective tilt & pitch cylinder
Q
Q
Q
Q
Q
Defective seal of lift cylinder piston
Q
Q
Q
Q
Q
Defective seal of tilt & pitch cylinder piston
Q
Defective stroke of lift EPC lever
Q
Defective stroke of tilt & pitch EPC lever
Defect in electrical system of lift or tilt & pitch EPC
Q
lever
Clearance error of pin or bush of working
Q
equipment linkage
Malfunction of fan pump EPC solenoid valve
Defect in fan pump
Q Q Q
Defect in fan motor
Troubleshooting No.
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-11
H-33
H-32
H-31
H-30
H-29
H-28
H-27
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-10
H-34
40-500
9
SEN05062-01
SEN05062-01 H-1 Machine does not start
H-1 Machine does not start 1
Ask the operator about the following: Cause

Has the machine come not to start sud-
Parking brake emergency

q
denly?
Torque converter
Torque converter
Main relief valve

charging pump
Parking brake
o Seizure of clutch, breakage of parts
release valve
Transmission
Check valve
ECMV
Did the machine cause any abnormal
noise at the time and where?
Checks before troubleshooting

q Does the machine monitor function nor-
mally? a b c d e f g h i j k l m n o p q
Defective operation of spool of parking brake emergency release valve

q Has the machine monitor displayed any
failure code of the electrical system?
Defective operation of check valve (between last chance filter and

q Are the transmission oil level and the oil
type appropriate?
q Did you smell deteriorated or burnt trans-
mission oil?
Defective operation of parking brake solenoid valve

q Have the transmission filter and strainer
been clogged?
q Can you find any damage or oil leak from
The relevant clutch piston seal is defective
The parking brake piston seal is defective

The relevant clutch shaft seal is defective
the appearance?

Set pressure drop of main relief valve
Clogging or air intake on suction side
q Has the drive shaft been broken?
Wear or seizure of relevant clutch

q Have the wheel brake and the parking
The charging pump is defective
brake been locked?

parking brake solenoid)

The PTO is defective
Clogging of strainer
No. Remedy E E E x E E E x E
x E E x x
Diagnosis x C x x x x * x * * x x
1 The machine does not start at all gear speeds Q Q Q Q Q Q Q Q Q Q Q Q Q
2 The machine does not start at specific gear speeds Q Q Q Q Q
When the transmission oil temperature is low, the
3 charging pump or the transmission filter causes any Q Q
abnormal noise (s)
When the transmission oil temperature rises, the
4 machine comes not to start Q Q Q Q
Metal (Aluminum, copper, iron, etc.) powders are

5 adhered to the transmission filter or the strainer Q Q Q
The speed is higher at all gear

6 When the stall speed of speeds Q Q Q Q Q Q Q Q
the torque converter is
measured The speed is higher at spe-
7 cific gear speeds Q Q Q Q Q
The oil pressure is low at all

8 Q Q Q Q Q Q Q
gear speeds
When the ECMV out- The oil pressure is low at spe-
9 Q Q Q Q
put (Clutch) oil pres- cific gear speeds
sure is measured
The oil pressure does not
10 become stable as the gauge Q Q
fluctuates
When the torque converter relief (Inlet) oil pressure is
11 measured, the oil pressure is low. Q Q Q Q Q Q
*: Proceed to the paragraph of “Defective clutch and ECMV specifying method (Check by failure code).”
40-500 10 WD600-6
H-1 Machine does not start SEN05062-01
* Defective clutch and ECMV specifying method

(Check by failure code)
a For the checking method of failure code display, see the para-
graph of “Special functions of machine monitor.”
a When replacing the ECMV for diagnosis, remove mud and dust
around the ECMV completely and clean it, and then tighten the
mounting bolt with the specified torque. Cause
a For the following diagnoses, start the engine and select the man- Transmission ECMV
ual mode: a b c d e f g h i j k l
Clutch
Table of applicable clutches
F R 1st 2nd 3rd 4th
In the automatic mode q
N
Wear or seizure of 2nd clutch disc or wear of piston seal

Q Q Q Q
Wear or seizure of 3rd clutch disc or wear of piston seal

Wear or seizure of 4th clutch disc or wear of piston seal
Wear or seizure of 1st clutch disc or wear of piston seal
In the manual mode
Wear or seizure of R clutch disc or wear of piston seal

Wear or seizure of F clutch disc or wear of piston seal
q q
Defective operation of 2nd clutch ECMV (Fill switch)

F1
Defective operation of 3rd clutch ECMV (Fill switch)

Defective operation of 4th clutch ECMV (Fill switch)
Defective operation of 1st clutch ECMV (Fill switch)
Defective operation of R clutch ECMV (Fill switch)
Defective operation of F clutch ECMV (Fill switch)
F2 q q
Gear speed
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q
a When the gear speed is N in the manual mode, the clutch of the
gear speed (Marked with Q), to which the gear shift lever is set, is
ON.
q Even if the gear shift lever is used when the gear speed is N, the
clutch position cannot be changed.
No. Remedy Failure x x x x x x x x x x x x

Diagnosis code
(1) The code is not displayed at R1-R4 but is displayed at F1-F4 15SAL1 Q Q
When the failure code is 15SAL1 after the diagnosis in (1), the failure code
1
(2) comes not to be displayed when the F fill switch connector (CN-F.SW) is dis-
connected. When the failure code is 15SALH, the failure code comes not to be 15SALH Q
displayed when the ECMV is replaced with any one other than F clutch ECMV
(1) The code is not displayed at F1-F4 but is displayed at R1-R4 15SBL1 Q Q
When the failure code is 15SBL1 after the diagnosis in (1), the failure code
2
(2) comes not to be displayed when the R fill switch connector (CN-R.SW) is dis-
connected. When the failure code is 15SBLH, the failure code comes not to be 15SBLH Q
displayed when the ECMV is replaced with any one other than R clutch ECMV
(1) The code is not displayed at F2, F3, and F4 but is displayed at F1 15SEL1 Q Q
When the failure code is 15SEL1 after the diagnosis in (1), the failure code
3 comes not to be displayed when the 1st fill switch connector (CN-1.SW) is dis-
(2) connected. When the failure code is 15SELH, the failure code comes not to be 15SELH Q
displayed when the ECMV is replaced with any one other than the 1st clutch
ECMV
(1) The code is not displayed at F1, F3, and F4 but is displayed at F2 15SFL1 Q Q
When the failure code is 15SFL1 after the diagnosis in (1), the failure code
4 comes not to be displayed when the 2nd fill switch connector (CN-2.SW) is
(2) disconnected. When the failure code is 15SFLH, the failure code comes not to 15SFLH Q
be displayed when the ECMV is replaced with any one other than the 2nd
clutch ECMV
(1) The code is not displayed at F1, F2, and F4 but is displayed at F3 15SGL1 Q Q
When the failure code is 15SGL1 after the diagnosis in (1), the failure code
5 comes not to be displayed when the 3rd fill switch connector (CN-3.SW) is dis-
(2) connected. When the failure code is 15SGLH, the failure code comes not to be 15SGLH Q
displayed when the ECMV is replaced with any one other than the 3rd clutch
ECMV
(1) The code is not displayed at F1, F2, and F3 but is displayed at F4 15SHL1 Q Q
When the failure code is 15SHL1 after the diagnosis in (1), the failure code
6 comes not to be displayed when the 4th fill switch connector (CN-4.SW) is dis-
(2) connected. When the failure code is 15SHLH, the failure code comes not to be 15SHLH Q
displayed when the ECMV is replaced with any one other than the 4th clutch
ECMV
WD600-6 40-500 11
SEN05062-01 H-2 Torque converter lockup is not switched (engine stalls)
H-2 Torque converter lockup is not switched (engine stalls) 1
Checks before troubleshooting Cause

q Is the oil level of transmission case appropriate? a b
Defective operation of lockup clutch ECMV

Wear or seizure of lockup clutch disc
Remedy
No. x x
Diagnosis
1 Lockup oil pressure does not drop to 0 Q
2 Lockup cannot be turned off even when the lockup oil pressure is 0 Q
40-500 12 WD600-6
H-3 Torque converter lockup is not turned on SEN05062-01
H-3 Torque converter lockup is not turned on 1

q Has the lockup come not to turn on suddenly? a b c d e f g
o Seizure or breakage inside torque converter
Drop of transmission main relief valve set pressure

q
q Did any abnormal noise occur at the time? o Breakage of parts
Defective operation of lockup clutch ECMV

Defective seal of lockup clutch piston

Wear or seizure of lockup clutch disc
q Is the oil level of transmission case appropriate?
Defective seal of lockup clutch shaft

q Is there any external oil leakage?

Crack on lockup clutch case
Check of abnormality
q Main relief oil pressure
q Lockup oil pressure
q Travel speed
Remedy E
No. Diagnosis Transmission x x x x x C x
controller self-diagnosis code
1 Main relief oil pressure is low Q
2 Main relief oil pressure is normal, but lockup oil pressure is low or 0 Q Q Q Q Q
3 Main relief oil pressure and oil pressure is normal, but lockup oil pressure is low or 0 Q
4 Time to lockup actuation takes long 15SJLH Q
WD600-6 40-500 13
H-4 Travel speed is slow, thrusting force is weak, uphill traveling power is weak, and gear is not
SEN05062-01 shifted
H-4 Travel speed is slow, thrusting force is weak, uphill traveling power
is weak, and gear is not shifted 1
Ask the operator about the following:
Torque converter
Torque converter
Torque converter
Main relief valve

Regulator valve
charging pump
Parking brake
Transmission
q Has the abnormality occurred suddenly?
oil cooler
o Breakage of related equipment
Others
ECMV
Did any abnormal noise occur at the time and
where?
q Have any abnormal signs come to occur gradually?
o Wear of related equipment, defective seal
a b c d e f g h i j k l m n o p q r s
q Execute digging and measure traveling speeds on a
Defective seal of work equipment and steering system hydraulic

Breakage of oil cooler and piping (After torque converter outlet)
Clogging of oil cooler and piping (After torque converter outlet)
level ground and on a slope to check whether the
abnormality actually occurs or is a matter of opera-
tor's sense
pump shaft (Mixing of hydraulic oil in transmission case)

q Is any failure code of the electrical system displayed
on the machine monitor?
q Are the transmission oil level and the oil type appro- Clogging or air intake on pump suction side
priate?


Drop of main relief valve set pressure
Defective operation of regulator valve

q Haven't the transmission filter and strainer been
clogged?

Oil leak inside torque converter

q Is any external oil leak found on the mating faces of

piping and valves around the torque converter and
the transmission?
q Isn't the wheel brake or the parking brake being
Clogging of breather
Note Engine degradation

dragged?
q Are the tire air pressure and the tread shape appro-
priate?
q Is the operating method correct?
NOTE: When the inspection result was “Engine degra-
dation,” proceed to Troubleshooting of engine
(S-mode).
No. Diagnosis Remedy C E x E E x E E E E x E x C E

x x x x x x x x * x * x x x
1 Any abnormality occurs at all gear speeds Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q
2 Any abnormality occurs at specific gear speeds Q Q Q Q
3 When the transmission oil temperature is low, the charging Q Q

pump or the transmission filter causes any abnormal noise
The torque converter oil temperature is heated abnormally Q Q Q Q Q Q Q Q Q
4 Q Q Q
high
5 The transmission oil level rises and falls Q Q Q Q Q Q
Metal (Aluminum, copper, iron, etc.) powders are adhered
6 Q Q Q
to the transmission filter or the strainer
7 The engine low idle and high idle speeds are measured to Q Q Q
be abnormal
8 When the stall speed of the The speed is high Q Q Q Q Q Q Q Q Q Q
9 torque converter is measured The speed is low Q
The oil pressure drops as
10 Q Q Q Q
the oil temperature rises
11 The oil pressure is low at Q Q Q Q Q Q Q Q Q

When the ECMV output all gear speeds
(Clutch) oil pressure is mea- The oil pressure is low at
12 sured Q Q Q Q
specific gear speeds
The oil pressure does not
13 become stable as the Q Q
gauge fluctuates
When the torque converter relief (Inlet) oil pressure is
14 measured, the oil pressure is low. (No. 11 – 13 are nor- Q Q Q
mal.)
When the oil pressure at the torque converter outlet is
15 measured, the oil pressure is low. (No. 14 is normal.) Q
*: Proceed to the paragraph of “Defective clutch and ECMV specifying method (Check by failure code).”
40-500 14 WD600-6
H-4 Travel speed is slow, thrusting force is weak, uphill traveling power is weak, and gear is not
shifted SEN05062-01

a For the checking method of failure code display, see the
paragraph of “Special functions of machine monitor.”
a When replacing the ECMV for diagnosis, remove mud and
dust around the ECMV completely and clean it, and then
tighten the mounting bolt with the specified torque. Cause
a For the following diagnoses, start the engine and select the Transmission ECMV
manual mode: a b c d e f g h i j k l
Clutch
F R 1st 2nd 3rd 4th
N

Q Q Q Q

In the manual mode

q q

F1

F2 q q
Gear speed
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q
a When the gear speed is N in the manual mode, the clutch of

the gear speed (Marked with Q), to which the gear shift lever
is set, is ON.
q Even if the gear shift lever is used when the gear speed is N,
the clutch position cannot be changed.
Remedy Failure
No. Diagnosis code x x x x x x x x x x x x
1
2
ECMV
4 comes not to be displayed when the 2nd fill switch connector (CN-2.SW) is dis-
(2) connected. When the failure code is 15SFLH, the failure code comes not to be 15SFLH Q
displayed when the ECMV is replaced with any one other than the 2nd clutch
ECMV
ECMV
ECMV
WD600-6 40-500 15
SEN05062-01 H-5 Shocks are large at the times of starting and shifting gear
H-5 Shocks are large at the times of starting and shifting gear 1

Did shocks become large suddenly?
Torque converter
q
Main relief valve

charging pump
Parking brake
Transmission
Sensor
ECMV
Did any abnormal noise occur at the time and where?
q Did shocks become large gradually?
a b c d e f g h i j k l
Defective return (Release) of relevant clutch piston

q Did any of the following abnormal phenomena occur at the same
Defective transmission oil temperature sensor

time: The traveling speed is slow, the braking is weak, the uphill
Clogging or air intake on pump suction side

travelling power is weak, the gear is not shifted. o Execute H-3
Defective operation of relevant ECMV a

Defect of transmission controller system
Defective operation of main relief valve


q Is any failure code of the electrical system displayed on the

machine monitor?
q Are the transmission oil level and the oil type appropriate?
q Haven't the transmission filter and strainer been clogged?
q Is any external oil leak found on the mating faces of pipings and
valves around the torque converter and the transmission?
q Isn't the engine speed high at the time of low idling?
q Isn't play of each drive shaft large?
Remedy C E E
No. Diagnosis x x x x x x x
* ** * * **
1 Shocks are large at all gear speeds Q Q Q Q Q Q Q Q
2 Shocks are large at specific gear speeds Q Q Q Q Q Q
3 The oil pressure is low at all gear speeds Q Q Q Q Q Q
When the ECMV output
4 (Clutch) oil pressure is mea- The oil pressure is low at specific gear speeds Q Q Q
sured
5 The oil pressure is high at all gear speeds Q
a Defective operation of relevant ECMV or defective operations of fill switch and solenoid due to bolting
wastes of pressure control valve spool.
: Proceed to the paragraph of “Defective clutch and ECMV specifying method (Check by failure code).”
* : See “Troubleshooting by failure code (Display of code).”
**
40-500 16 WD600-6
H-5 Shocks are large at the times of starting and shifting gear SEN05062-01

Clutch
F R 1st 2nd 3rd 4th
N

Q Q Q Q

In the manual mode

q q

F1

F2 q q
Gear speed
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q

is set, is ON.
Remedy Failure
1
2
ECMV
ECMV
ECMV
ECMV
WD600-6 40-500 17
SEN05062-01 H-6 Time lag is large at the times of starting and shifting gear
H-6 Time lag is large at the times of starting and shifting gear 1

Did the time lag become large suddenly?
Torque converter
q
Main relief valve

charging pump
Parking brake
Transmission
Sensor
ECMV
q Has the time lag become large gradually?
a b c d e f g h i j
Defective operation of transmission oil temperature sensor

q Did any of the following abnormal phenomena occur at the same time:
The traveling speed is slow, the braking is weak, the uphill travelling
power is weak, the gear is not shifted. o Execute H-4

Is any failure code of the electrical system displayed on the machine

q


monitor?
q Are the transmission oil level and the oil type appropriate?

Haven't the transmission filter and strainer been clogged?

q
q Is any external oil leak found on the mating faces of pipings and valves
around the torque converter and the transmission?
Remedy C E E
No. Diagnosis x x x x x x x **
* *
1 Time lag is large at all gear speeds Q Q Q Q Q Q Q
2 Time lag is large at specific gear speeds Q Q Q Q
3 When the transmission oil temperature is low, any abnormal noise occurs from the charging Q Q
pump or the transmission filter
4 The torque converter oil temperature is heated abnormally high Q Q Q Q
5 When the ECMV output (Clutch) oil The oil pressure is low at all gear speeds Q Q Q Q Q
6 pressure is measured The oil pressure is low at specific gear speeds Q Q Q
a Defective operation of relevant ECMV or defective operations of fill switch and solenoid due to bolting
wastes of pressure control valve spool.
: Proceed to the paragraph of “Defective clutch and ECMV specifying method (Check by failure code).”
*
: See “Troubleshooting by failure code (Display of code).”
**
40-500 18 WD600-6
H-6 Time lag is large at the times of starting and shifting gear SEN05062-01

Clutch
F R 1st 2nd 3rd 4th
N

Q Q Q Q

In the manual mode

q q

F1

F2 q q
Gear speed
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q

is set, is ON.
Remedy Failure
1
2
ECMV
ECMV
ECMV
ECMV
WD600-6 40-500 19
SEN05062-01 H-7 Torque converter oil temperature is high
H-7 Torque converter oil temperature is high 1
Torque converter
Does the oil temperature rise when the torque converter stalls
Torque converter
Torque converter
q
Main relief valve

charging pump
Transmission
and does the temperature fall at the time of no load?
oil cooler
Others
o Selection of improper gear speed
q Does the oil temperature rise only at the time of lifting?
o Improvement of operating method a b c d e f g h i j k l
Defective seal of work equipment and steering system hydraulic

Breakage of oil cooler and piping (After torque converter outlet)
Clogging of oil cooler and piping (After torque converter outlet)

q Measure the torque converter oil temperature to find if the oil
pump shaft (Mixing of hydraulic oil in transmission case)

temperature is really high.
o The torque converter oil temperature gauge is defective

q Are the coolant level in the radiator and the belt tension appropri-
ate?

q Are the oil level in the transmission and the oil type appropriate?

Oil leak inside torque converter

q Haven't the transmission filter and strainer been clogged?
NOTE: When the inspection result was “Engine degradation,” pro-
ceed to Troubleshooting of engine (S-mode).
Clogging of breather
Note Engine degradation

Remedy C E E E E E E C E
No. Diagnosis x x x x x x x x x x x
When the transmission oil temperature is low, the charging pump or the transmis-
1 sion filter causes any abnormal noise Q Q
Traveling speed, braking force and uphill travelling power do not occur at all gear
2 Q Q Q Q Q Q Q Q Q Q Q
speeds
Traveling speed, braking force and uphill travelling power do not occur at specific
3 Q
gear speeds
4 The transmission oil level rises and falls Q Q Q
Metal powders (Aluminum, copper, iron, etc.) are adhered to the transmission filter
5 Q Q Q
and the strainer
6 The engine low idle and high idle speeds are measured to be abnormal Q Q Q
7 When the stall speed of the torque converter is measured, the speed is high Q Q Q Q Q Q Q Q Q
8 The oil pressure drops as the oil temperature rises Q
When the ECMV
9 output (Clutch) oil The oil pressure is low at all gear speeds Q Q Q Q Q
10 pressure is The oil pressure is low at specific gear speeds Q
measured
11 The oil pressure does not become stable as the gauge vibrates Q Q
12 When the torque converter relief (Inlet) oil pressure is measured, the oil pressure is Q Q Q
low. (No. 9 – 11 are normal.)
13 When
the oil pressure at the torque converter outlet is measured, the oil pressure is
Q
low. (No. 12 is normal.)
40-500 20 WD600-6
H-8 Steering does not turn [machine with steering wheel] SEN05062-01
H-8 Steering does not turn [machine with steering wheel] 1

Did the problem suddenly start? o Breakage of related equipment
Hydraulic cylinder
q
Hydraulic pump
Steering valve
Charge valve
Stop valve
Did the machine cause any abnormal noise at the time and where?
Orbit-roll
q Is oil level in hydraulic tank correct? Is the type of oil correct?
q Is the steering shaft broken? a b c d e f g h i j k
q Is the steering stop valve properly adjusted?
Defect in steering cylinder (defective piston seal)

q Has the lock bar been removed from the frame?
Defective actuation of demand spool

Defective actuation of steering spool

Defective brake pump
Defective stop valve

Defective PTO
No. Remedy E E E E E E E E E x x
Diagnosis x x x x x x x x
1 Steering does not turn in both directions (left and right) Q Q Q Q Q Q Q Q Q
2 Steering turns only in one direction (left or right) Q Q
3 Steering is heavy when turned in both directions (left and right) Q Q Q Q
4 Steering wheel is heavy in one direction (left or right) Q
5 Work equipment moves Q Q Q Q Q Q Q
6 Work equipment does not move Q Q Q Q
7 Abnormal noise comes from around PTO Q
8 Abnormal noise comes from around hydraulic tank Q Q
Oil pressure is low, or there is no pressure in both directions (left
9 Q Q Q Q Q Q Q Q Q
When steering relief and right)
pressure is measured Oil pressure is low, or there is no pressure in one direction (left or
10 Q Q
right)
11 When Orbit-roll output pressure is measured, oil pressure is found to be low or there is no Q Q Q Q Q
oil pressure
12 When Orbit-roll basic Oil pressure is low Q Q Q Q
13 pressure is measured There is no oil pressure Q Q Q
a There is a close connection between the steering circuit and the work equipment circuit, so if any abnor-
mality is left in the steering, check the operation of the work equipment also.
WD600-6 40-500 21
SEN05062-01 H-9 Steering does not turn [machine with AJSS]
H-9 Steering does not turn [machine with AJSS] 1
Hydraulic cylinder
q Did the problem suddenly start?
Hydraulic pump
solenoid valve
Steering valve
Charge valve
Rotary valve
AJSS EPC

q Is oil level in hydraulic tank correct? Is the type of oil correct? a b c d e f g h i j k l
q Is the steering shaft broken?

q Has the lock bar been removed from the frame?

q Is the AJSS followup link properly adjusted?

Defective actuation of rotary valve

Clogged line filter

Defective PTO
No. Remedy E E E E E C x E E E x x
1 Steering does not turn in both directions (left and right) Q Q Q Q Q Q Q Q Q Q Q
2 Steering turns only in one direction (left or right) Q
3 AJSS is heavy when turned in both directions (left and right) Q Q Q
4 AJSS is heavy in one direction (left or right)
5 Work equipment moves Q Q Q Q Q Q Q Q
Oil pressure is low, or there is no pressure in both
9 Q Q Q Q Q Q Q Q Q Q Q
When steering relief pressure is directions (left and right)
measured Oil pressure is low, or there is no pressure in one
10 Q
direction (left or right)
11 When AJSS EPC solenoid valve output pressure is measured, oil pressure is found to Q Q Q Q Q Q Q
be low or there is no oil pressure
12 When AJSS EPC solenoid valve Oil pressure is low Q Q Q Q
13 basic pressure is measured There is no oil pressure Q Q Q
40-500 22 WD600-6
H-10 Turning, response of steering is poor [machine with steering wheel] SEN05062-01
H-10 Turning, response of steering is poor [machine with steering

wheel] 1
Hydraulic cylinder
Hydraulic pump
Steering valve
Charge valve
Stop valve
Orbit-roll
Did the machine cause any abnormal noise at the time and
where?
q Did the problem gradually appear?
o Wear of related parts, defective seal
a b c d e f g h i j k l m




Defective main relief valve
Defective steering spool


Defective PTO
No. Diagnosis Remedy E E E E E E E E E E E x E

x x x x x x x x x x x
1 Turning, response of steering wheel is poor in both directions (left and right) Q Q Q Q Q Q Q Q Q Q Q
2 Turning, response of steering wheel is poor in one direction (left or right) Q Q
3 Steering wheel is heavy in both directions (left and right) Q Q Q Q
5 Work equipment moves Q Q Q Q Q Q Q Q Q
Oil pressure is low, or there is no pressure in both directions Q Q Q Q Q Q Q
9 Q Q Q
When steering relief (left and right)
pressure is measured Oil pressure is low, or there is no pressure in one direction
10 (left or right) Q Q
11 When
Orbit-roll output pressure is measured, oil pressure is found to be low or
Q Q Q Q Q
there is no oil pressure
When Orbit-roll basic pressure is measured, oil pressure is found to be low or there
12 is no pressure Q Q Q Q
13 When steering pump servo assembly is replaced, oil pressure is found to be normal Q
WD600-6 40-500 23
SEN05062-01 H-11 Turning, response of AJSS is poor [machine with AJSS]
H-11 Turning, response of AJSS is poor [machine with AJSS] 1
Hydraulic cylinder
Steering pump
solenoid valve
Steering valve
Charge valve
Rotary valve
AJSS EPC
Did the machine cause any abnormal noise at the time and
where?
q Did the problem gradually appear?
o Wear of related parts, defective seal
a b c d e f g h i j k l m n




Defective rotary valve

Clogged line filter
Defective PTO
No. Remedy E E E E E E C x E E E E x E
Diagnosis x x x x x x x x x x x
1 Turning, response of steering wheel is poor in both directions (left and right) Q Q Q Q Q Q Q Q Q Q Q Q Q
2 Turning, response of steering wheel is poor in one direction (left or right) Q
3 Steering wheel is heavy in both directions (left and right) Q Q Q
4 Work equipment moves Q Q Q Q Q Q Q Q Q Q
8 Oil pressure is low, or there is no pressure in both Q Q Q Q Q Q Q Q Q Q Q Q

When steering relief directions (left and right)
pressure is measured Oil pressure is low, or there is no pressure in one
9 Q
direction (left or right)
10 When
AJSS EPC solenoid valve output pressure is measured, oil pressure is
found to be low or there is no oil pressure Q Q Q Q Q Q Q
11 When steering pump servo assembly is replaced, oil pressure is found to be Q

normal
40-500 24 WD600-6
H-12 Steering is heavy [machine with steering wheel] SEN05062-01
H-12 Steering is heavy [machine with steering wheel] 1
Check of abnormality Cause

Is the steering difficult to turn? o See H-8
Hydraulic pump
Steering valve
Charge valve
Stop valve
Orbit-roll
Others
Measure the operating effort and turning speed, and check the “Standard value table” to
see if they are abnormal.
Ask the operator about the following: a b c d e f
Did the problem suddenly start? o Breakage of related equipment broken
Defective actuation of steering wheel or steering shaft

q
q Was there previously any symptom that may lead to heavy steering?

q Is the tire inflation pressure correct?

No. Diagnosis Remedy E E E E E E
x x x x x x
1 Steering is heavy when turned in both directions (left and right) Q Q Q Q Q
3 Steering is heavy even when joint between steering shaft and Orbit-roll is disconnected Q
4 When steering relief Oil pressure is low, or there is no pressure in both directions (left and right) Q Q Q Q
5 pressure is measured Oil pressure is low, or there is no pressure in one direction (left or right) Q
6 When Orbit-roll output pressure is measured, oil pressure is found to be low Q Q Q Q
7 When Orbit-roll basic Oil pressure is low Q Q
8 pressure is measured There is no oil pressure Q
WD600-6 40-500 25
SEN05062-01 H-13 When machine turns, it shakes or makes large shocks [machine with steering wheel]
H-13 When machine turns, it shakes or makes large shocks [machine

with steering wheel] 1

Hydraulic pump
q
Steering valve
Charge valve
Stop valve
Orbit-roll
Cylinder
q Is there any abnormal noise from around the steering equipment

q Is the steering wheel play correct?
a b c d e f g h i
q Is there any abnormality in the connection between the steering shaft and

the Orbit-roll?



No. Remedy E E E E E E E E E
1 When machine turns, it shakes or jerks in both directions (left and right) Q Q Q Q Q Q Q
2 When machine turns, it shakes or jerks in both directions (left and right) Q Q
3 During operations or when traveling (steering is neutral), the machine shakes or jerks Q Q Q
4 Machine jerks or there is excessive shock when steering is operated to end of its stroke Q
5 Work equipment also jerks Q Q
6 When steering relief Oil pressure is unstable in both directions (left and right) Q Q Q Q Q Q Q
7 pressure is measured Oil pressure is unstable in one direction (left or right) Q Q
8 When Orbit-roll output Oil pressure is unstable in both directions (left and right) Q Q Q
9 pressure is measured Oil pressure is unstable in one direction (left or right) Q
10 When Orbit-roll basic pressure is measured, oil pressure is found to be unstable Q Q
40-500 26 WD600-6
H-14 When machine turns, it shakes or makes large shocks [machine with AJSS] SEN05062-01
H-14 When machine turns, it shakes or makes large shocks [machine

with AJSS] 1

AJSS EPC solenoid valve

q
q Is there any abnormal noise from around the steering equipment
Hydraulic pump
Steering valve
Charge valve
Rotary valve
Cylinder
q Is the AJSS play correct?
q Is the AJSS followup link properly adjusted?
a b c d e f g h i

Defective actuation of EPC solenoid valve

Defective actuation of rotary valve

No. Remedy E E x E E E E E E
Diagnosis x x x x x x x
1 When machine turns, it shakes or jerks in both directions (left and right) Q Q Q Q Q Q Q Q
2 When machine turns, it shakes or jerks in one directions (left or right) Q
3 During operations or when traveling (steering is neutral), the machine shakes or jerks Q Q Q
4 Work equipment also jerks Q Q
5 When steering relief Oil pressure is unstable in both directions (left and right) Q Q Q Q Q Q Q Q
6 pressure is measured Oil pressure is unstable in one direction (left or right) Q
7 When Orbit-roll output Oil pressure is unstable in both directions (left and right) Q Q Q Q
8 pressure is measured Oil pressure is unstable in one direction (left or right)
9 When AJSS EPC solenoid valve basic pressure is measured, oil pressure is found to be unstable Q Q
WD600-6 40-500 27
SEN05062-01 H-15 Wheel brake does not work or does not work well
H-15 Wheel brake does not work or does not work well 1
Slack adjuster
Charge valve
q Test the effectiveness of the brake referring to “Measuring
Wheel brake
Accumulator
Brake pump
Brake valve
Others
brake performance” in “Testing and adjusting” to check
whether the abnormality actually occurs or is a matter of oper-
ator's sense
a b c d e f g h i j k l m n
Gas leakage from accumulator, defective seal of piston

q Has the brake come not to work suddenly?
o Breakage of brake
q Has the brake come not to work gradually?

The brake piston seal is defective
q Is oil level and type of oil in hydraulic tank correct?
Defective right brake valve
Internal breakage of brake

Defective left brake valve
Air intake on suction side
q Is the play of brake pedal appropriate?
Defective slack adjuster

q Isn't the oil leaked from brake piping or tube deformed?
Wear of brake disc

q Are the tire air pressure and the tread state appropriate?
Air in brake circuit

Improper axle oil
Defective PTO
Remedy E E E E E E E E E E
No. Diagnosis x E x x x x x x x x x x E x
1 The brake does not work only when the left brake pedal is stepped on Q
2 When the left brake pedal is stepped on, only a little resistance is felt Q Q Q Q Q Q Q Q
3 When the right brake pedal is stepped on, only a little resistance is felt Q Q Q Q Q Q Q
4 When the left brake pedal is stepped on, a strong resistance is felt Q
5 When the right brake pedal is stepped on, a strong resistance is felt Q
6 To get the specified braking force, an extremely strong leg-power is required Q Q Q Q Q
7 When the brake works, an abnormal noise occurs from the brake Q Q Q
8 Work equipment and steering wheel does not move Q Q
9 Work equipment and steering wheel move slowly Q Q Q
11 Abnormal noise comes from around hydraulic tank or brake pump Q Q
12 Much metal powders are mixed in the oil when it is drained from the axle case Q
13 When the accumulator charge pressure is measured, the oil pressure is low. Q Q Q
14 The brake does not work immediately when the engine is stopped Q
15 The brake works after some time lag Q Q
16 When brake pressure is measured, the oil pressure is low Q
17 When brake piston pressure effect is measured, the pressure effect is large Q Q
18 When wear of brake disc is measured, the amount of wear is large Q Q
19 Air is discharged when the air is bled from the brake system Q
40-500 28 WD600-6
H-16 Wheel brake is not released or it drags SEN05062-01
H-16 Wheel brake is not released or it drags 1

Was the brake locked suddenly? o Breakage of related equipment
Slack adjuster
q
Wheel brake
Brake valve

q Has the brake pedal returned completely? a b c d e
q Isn't the parking brake turned ON?
Defective operation of slack adjuster

Defective right brake valve
Seizure of brake disc plate

Defective left brake valve
Remedy E E E E
No. Diagnosis x x x x x
1 The machine does not travel at all Q Q
2 The machine travels a little Q Q Q
3 When residual pressure in the brake accumulator circuit is released using only the left brake pedal, the brake is Q
released
When residual pressure in the brake accumulator circuit is released using only the right brake pedal, the brake is
4 released Q
5 When air bleeder at wheel is opened, oil leaks out and the brake is released Q
6 When air bleeder is opened, large amount of oil flows out Q Q
7 When wear of brake disc is measured and the brake pedal is released, the piston returns Q
8 When wear of brake disc is measured and the brake pedal is released, the piston does not return Q Q
WD600-6 40-500 29
SEN05062-01 H-17 Parking brake does not work or does not work well
H-17 Parking brake does not work or does not work well 1

Has the brake come not to work suddenly? o Breakage of related equipment
Parking brake
q
Solenoid
Valve
q Has the brake come not to work gradually?
a b c d e

q Isn't the parking brake emergency release switch turned ON?
q Hasn't the mechanical release of parking brake performed?
Defective operation of parking brake piston

Defective parking brake solenoid valve
Defective parking brake spring
Wear of parking brake disc

Remedy E E
No. Diagnosis x x x x x
1 The parking brake is not applied even if the engine stops Q Q Q
2 When wear of parking brake disc is checked, the disc thickness is lower than Standard value Q
3 When the parking brake inlet pres- With the parking brake switch ON, there is no oil pressure (Normal) Q Q
4 sure is measured With the parking brake switch ON, there is a oil pressure Q Q Q
5 When the parking brake solenoid With the parking brake switch ON, there is no oil pressure (Normal) Q Q
6 valve output pressure is measured With the parking brake switch ON, there is a oil pressure Q
40-500 30 WD600-6
H-18 Parking brake is not released or it drags (including emergency release system) SEN05062-01
H-18 Parking brake is not released or it drags (including emergency

release system) 1
Parking brake
q Is there any abnormality in the power train system?
Solenoid
o See H-1, H-4, H-5 and H-6 (Power train hydraulic system)
Wheel
Valve
a b c d e
Defective operation of wheel brake emergency brake switch

Seizure of parking brake disc and plate

Defective parking brake solenoid valve

Remedy E E
No. Diagnosis x x x x
The parking brake is released when the emergency release switch is turned ON
1 Q Q
(The parking brake switch does not release the brake)
2 The parking brake is released, when “Method of releasing parking brake manually” is executed Q Q Q
(The parking brake switch and emergency release switch does not release the brake)
3 When the parking brake inlet pressure is measured Oil pressure is normal Q Q
4 (While operating the parking switch) Oil pressure is low Q Q
5 When the parking brake output pressure is measured Oil pressure is normal Q Q
6 (While operating the emergency release switch) Oil pressure is low Q Q
7 When the parking brake solenoid valve output pressure is measured, the oil pressure is low Q
When the wheel brake piping oil pressure is measured, the oil pressure is lower than the emergency brake Q
8
working pressure (3.6 ± 0.49 MPa {37 ± 5 kg/cm2})
a If any abnormality is left in releasing of the parking brake, check the operation of the power train also,
because the power train main relief pressure is used as the parking brake release pressure. (The emer-
gency release circuit uses the wheel brake circuit oil pressure.)
WD600-6 40-500 31
SEN05062-01 H-19 Blade does not rise
H-19 Blade does not rise 1
equipment pump
Did the lift arm stop suddenly?
Work equipment
q
Bypass valve
Tank – Work
o Seizure or breakage of each component
Cylinder
valve
Did abnormal sound come out when the lift arm stopped?
(From what part)
q Has the speed lowered?
o Wear of parts and fatigue of springs a b c d e f g h i j
Defective operation of lift load check valve

Internal breakage of valve body (lift spool)

q Is the oil level in the hydraulic tank proper?
Defective operation of unload valve

q Is the stroke of the lift control lever proper?
Damaged lift cylinder piston seal

q Is the engine speed proper?
Defective operation of spool

q Has the machine monitor displayed any failure code?
o See Troubleshooting by failure code (Display of code)
Defective PTO
No. Remedy C E E E E E E x x x
Diagnosis E x x x x x x
1 Blade does not move and lift does not rise Q Q Q Q Q
2 Lift can raise chassis but does not rise Q Q
3 Blade moves but lift does not rise Q Q
4 Blade can rise when not loaded but cannot when loaded Q Q Q Q Q
5 Work equipment pump is making abnormal sound Q Q
6 Hydraulic drift of lift cylinder is large Q Q Q Q
7 When blade and tilt & pitch are operated simultaneously, lift does not rise Q
8 When work equipment pump and servo assembly is replaced, lift rises normally Q
40-500 32 WD600-6
H-20 Blade speed is low or rising force of lift is insufficient SEN05062-01
H-20 Blade speed is low or rising force of lift is insufficient 1
equipment pump
Is the stroke of the lift lever proper?
Work equipment
q
Tank – Work
Cylinder
valve
q The troubles of the rising force and rising speed are strongly related to each
other. The rising speed lowers first. Measure the lift arm rising speed while it a b c d e f g h
is loaded and check abnormality with the “Standard values table.”
Defective operation and defective adjustment of main relief valve
Internal wear or breakage of valve body (lift spool)

Defective operation of lift load check valve

Damaged lift cylinder piston seal

Remedy C E E A E C
No. Diagnosis E x x E x E x x
x x
1 Tilt and pitch force and speed of blade are abnormal and rising speed of lift is low Q Q Q Q Q
2 Tilt and pitch force and speed of blade are normal and rising speed of lift is low Q Q Q
3 After oil temperature rises, rising speed lowers more in step 1 Q
5 Hydraulic drift of cylinder is large Q Q Q
6 Relief oil pressure of relief valve of work equipment valve is low Q Q Q Q
7 When work equipment pump and servo assembly is replaced, lift arm moves normally Q
WD600-6 40-500 33
SEN05062-01 H-21 When rising, blade comes to move slowly at specific height
H-21 When rising, blade comes to move slowly at specific height 1

q Deformation of lift cylinder in appearance
Cause
q Expansion of lift cylinder tube or damage inside
a For other abnormal phenomena during blade rise, see “H-20 Blade speed is low or rising force of lift is
insufficient”
H-22 Lift cylinder cannot hold down blade (Blade floats) 1
See “H-20 Blade speed is low or rising force of lift is insufficient.”

q Is the stroke of the lift control lever appropriate?
Cause
q Defective seat of suction valve on the lift cylinder head side of work equipment valve
q Oil leak from lift cylinder piston seal
H-23 Hydraulic drifts of blade occur often 1

q Have hydraulic drifts come to occur often suddenly? o Wastes pinched in valve or damage of parts
q Have hydraulic drifts come to occur often gradually? o Wear of parts
q Is the lift spool at the neutral position? o The spool detent is defective
q Check the hydraulic drift of the blade with the “Standard values table.”
Cause
q Oil leakage in lift cylinder
q Imperfect fitting of suction valve on bottom side
q Imperfect fitting of lift spool
H-24 Blade wobbles during operation 1
The blade moves up and down as the topography goes in digging or leveling with the lift control lever in the
HOLD position.
Diagnosis and Cause
Check at first the hydraulic drift and if the lift cylinder can lift the machine
1. When the hydraulic drift is more than the standard value, see “H-23 Hydraulic drifts of the blade occur
often.”
2. If the lift cylinder can lift the machine, see “H-20 Blade speed is low or rising force of blade is insuffi-
cient.”
3. When the lift cylinder comes to enable to lift the machine after the lift is operated several times with the
normal hydraulic drift and after the lift cylinder operates to full stroke
o The cause is vacuum generated inside the cylinder
a Frequent hydraulic drifts o The suction valve on the lift cylinder head side is defective
40-500 34 WD600-6
H-25 Blade does not tilt and pitch SEN05062-01
H-25 Blade does not tilt and pitch 1
equipment pump
Did the blade stop suddenly?
Work equipment
q
Tank – Work
o Seizure or breakage of each component
Cylinder
valve
Did abnormal sound come out when the lift arm stopped?
(From what part)
q Has the speed lowered? o Wear of parts and fatigue of springs
a b c d e f g h i j
Defective operation of tilt & pitch bottom suction valve (Suction safety valve)
Defective operation of tilt & pitch bottom safety valve (Suction safety valve)
q Is the oil level in the hydraulic tank proper?
q Is the stroke of the tilt & pitch control lever proper?
q Has the machine monitor displayed any failure code?
Internal breakage of valve body (tilt & pitch spool)

Damaged tilt & pitch cylinder piston seal


Defective PTO
C
No. Diagnosis Remedy C E E E E E E E x x
E x x x x x x
x
1 Lift does not move and blade does not tilt and pitch Q Q Q Q Q
2 Blade can raise chassis but does not tilt and pitch Q Q
3 Lift moves but blade does not tilt and pitch Q Q
4 Blade can tilt and pitch when not loaded but cannot when used for digging Q Q Q Q Q Q
6 Hydraulic drift of tilt & pitch cylinder is large Q Q Q Q
7 When lift and blade are operated simultaneously, blade does not tilt and pitch Q
8 When work equipment pump and servo assembly is replaced, blade moves normally Q
WD600-6 40-500 35
SEN05062-01 H-26 Blade speed is low or tilt and pitch force is insufficient
H-26 Blade speed is low or tilt and pitch force is insufficient 1
equipment pump
Is the stroke of the tilt & pitch control lever proper?
Work equipment
q
Tank – Work
Cylinder
valve
q Is the work equipment linkage bushing normal (Is abnormal sound
made)?
Check of abnormality a b c e f g h i j
q Check by actual operation that the tilt and pitch force is insufficient.
Defective operation of tilt & pitch bottom suction valve (Suction safety valve)
Defective operation of tilt & pitch bottom safety valve (Suction safety valve)
q Measure the operating speed of the blade and check it with the “Standard
value table.”
Defective operation and defective adjustment of main relief valve
Internal wear or breakage of valve body (tilt & pitch spool)

Damaged tilt & pitch cylinder piston seal


A C
No. Diagnosis Remedy C E E E E E E x x
E x x x x
x x
1 Rising force and speed of lift are abnormal and tilt and pitch force and speed of blade are low Q Q Q Q Q
2 Rising force and speed of lift are normal and tilt and pitch force and speed of blade are low Q Q Q Q
3 After oil temperature rises, tilting back speed lowers more in step 1. Q
5 Hydraulic drift of the cylinder is large Q Q Q Q
6 Relief oil pressure of relief valve of work equipment valve is low Q Q Q Q Q Q
7 When work equipment pump and servo assembly is replaced, blade moves normally Q
40-500 36 WD600-6
H-27 Blade comes to operate slowly in the midst of tilt and pitch SEN05062-01
H-27 Blade comes to operate slowly in the midst of tilt and pitch 1

q Deformation of tilt & pitch cylinder in appearance
Cause
q Expansion of tilt & pitch cylinder tube or damage inside
For other abnormal phenomena during blade operation, see “H-26 Blade speed is low or tilt and pitch
force is insufficient.”
H-28 Tilt & pitch cylinder cannot hold down blade 1
See “H-26. The blade moves slowly or the tilt and pitch force is insufficient.”
q Is the stroke of the tilt & pitch control lever appropriate?
Cause
q Defective seat of safety valve (with suction valve) on the tilt and pitch cylinder head side of work equip-
ment valve
q Oil leak from tilt & pitch cylinder piston seal
H-29 Hydraulic drifts of blade occur often 1

q Have hydraulic drifts come to occur often suddenly? o Wastes pinched in valve or damage of parts
q Have hydraulic drifts come to occur often gradually? o Wear of parts
q Is the tilt & pitch spool at the neutral position? o The spool detent is defective
q Refer to the “Standard value table” and check if the hydraulic drift of the blade occurs often practically
Cause
q Oil leak in tilt & pitch cylinder
q Improper adhesion of safety valve (With suction valve) on the bottom side
q Improper oil tight of tilt & pitch spool
H-30 Blade wobbles during travel when loaded (Work equipment valve
is set to “HOLD”) 1
Cause
q Defective seal of tilt & pitch cylinder piston
q Defective operation of safety valve (With suction valve) on tilt & pitch cylinder head side. For other
abnormal phenomena, refer to diagnoses for relevant abnormal phenomena.
WD600-6 40-500 37
SEN05062-01 H-31 During operation of machine, engine speed lowers remarkably or engine stalls
H-31 During operation of machine, engine speed lowers remarkably or

engine stalls 1

Is the working equipment main relief pressure normal?
Cause
q Defective work equipment pump servo
q Defective working equipment pump unit
q Defective working equipment pump servo EPC input voltage
q Defective engine system
H-32 Large shocks are made when work equipment starts and stops 1
Cause
q Defective operation of control valve spool
q Defective working equipment electric lever system
H-33 When work equipment circuit is relieved singly, other work

equipment moves 1
Cause
q Pressure is not released properly from main spool of moving equipment o Replace main spool
40-500 38 WD600-6
H-34 Fan speed is abnormal (Fan sound and vibration are abnormally large or engine overheats) SEN05062-01
H-34 Fan speed is abnormal (Fan sound and vibration are abnormally
large or engine overheats) 1
1. Measure the fan speed and check that it is abnormal. Cause
Malfunction of fan pump EPC solenoid valve

2. Check that the fan is not deformed or worn unevenly.
3. Measurement conditions
q Engine: P mode
q Coolant temperature: Min. 95°C
q Hydraulic oil temperature: Min. 95°C
q Torque converter oil temperature: Min. 105°C
Defect in fan motor

Defect in fan pump
Remedy
No. x x x
Diagnosis
1 Fan pump EPC output current is abnormal Q
2 Fan drive circuit pressure is abnormal Q Q
*: Fan pump EPC output current: 586.5 ± 20 mA (When all control levers are in neutral)
WD600-6 40-500 39
SEN05062-01
WD600-6 Wheel dozer

©2016 KOMATSU
All Rights Reserved
40-500 40
SEN05063-00
WHEEL DOZER
WD600-6

WD600-6 55001 and up
600 Troubleshooting of engine (S-mode)

Method of using troubleshooting chart............................................................................................................ 2
S-1 Engine does not start easily...................................................................................................................... 6
S-2 Engine does not start ............................................................................................................................... 8
S-3 Engine does not pick up smoothly.......................................................................................................... 12
S-4 Engine stops during operation................................................................................................................ 13
S-5 Engine does not rotate smoothly (Hunting occurs) ................................................................................ 14
S-6 Engine lacks output (or lacks power) ..................................................................................................... 15
S-7 Exhaust smoke is black (Incomplete combustion) ................................................................................. 16
S-8 Oil is consumed much (or exhaust gas color is blue)............................................................................. 18
S-9 Engine oil becomes contaminated quickly ............................................................................................. 19
S-10 Fuel consumption is excessive............................................................................................................. 20
S-11 Coolant contains oil (blows back or reduces) ....................................................................................... 21
S-12 Oil pressure drops ................................................................................................................................ 22
S-13 Oil level rises (Water, fuel in oil) ........................................................................................................... 24
S-14 Coolant temperature rises too high (Overheating) ............................................................................... 26
S-15 Abnormal noise is made....................................................................................................................... 27
S-16 Vibration is excessive ........................................................................................................................... 28
S-17 Air cannot be bled from fuel circuit ....................................................................................................... 30
WD600-6 40-600 1
Method of using troubleshooting chart 1
This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting.
The questions and check items are used to pinpoint high probability causes that can be located from the fail-
ure symptoms or simple inspection without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are used to check the high probability causes to make final
confirmation.
Questions:
Sections A + B in the right corresponds to the items
were answers can be obtained from the user or
operator.
A is the basic content. B is the items that can be
obtained from the user or operator depending on
their level.
Check items:
Simple items checked by the serviceman to deter-
mine the causes. C in the chart to the right corre-
sponds to them.
Causes:
The contents to be determined after asking ques-
tions and checking items.
The serviceman determines causes of high proba-
bility from A, B, and C.
Troubleshooting:
The content for ultimately verifying whether the
determined causes are truly the defective factors
by using troubleshooting tools or making direct
checking starting with probable causes of higher
order.
This troubleshooting chart marks the content of the

questions and check items with E, Q or w accord-
ing to their closer relationship with the causes.
E: A cause that can be referred to in relation to
the question or check item.
Q : A cause that is related the question or check
item.
w : A cause particularly probable among those
marked with Q above.
a Count the priority level of each marking as w >
Q when determining the cause.
Don't count E when determining the cause.
The item with this marking may be counted,
however, if no difference is present than this
and the cause cannot be determined.
40-600 2 WD600-6
WD600-6 40-600 3
<Example of troubleshooting> Exhaust smoke is black
Let us assume that the questions and item check were conducted when a defect of black exhaust gas is
detected. Now suppose that three symptoms have causal relationship with this problem: namely, [Exhaust
gas gradually became black], [Power was lost gradually], and [Dust indicator turned red].
40-600 4 WD600-6
If we look from these 3 symptoms to find the causes, we find that there is a relationship with 5 causes.
Procedure for determining the causes from these relationship and leading to the troubleshooting will be
explained in step 1 to 3 in the following diagram.
WD600-6 40-600 5
SEN05063-00 S-1 Engine does not start easily.
S-1 Engine does not start easily. 1
General causes for poor startability include the follow- Cause

ing
Clogged air breather hole in fuel tank cap

q Electrical system is not normal
Defective contact of valve, valve seat
Stuck or seized supply pump plunger

Leakage, clogging, air in fuel piping
q Fuel level is low
Clogging of feed pump gauze filter
Defective intake air heater system
Defective or deteriorated battery

Air intake is in short
Defective alternator (generator)

q
(coolant mixing in the exhaust)
Defective alternator (regulator)

Clogged air cleaner element
Wrong fuel selection
Wear of piston ring, cylinder

q
q Coolant mixing in the exhaust pipe
a Common rail type fuel injection system (CRI) rec-
Cracked EGR cooler

ognizes the fuel injection timing electrically. There-
Clogged fuel filter
Defective injector
fore, there are cases where the engine does not
start before the crankshaft makes two revolutions
maximum after starting operation. This is not an
abnormal state, however.
Confirm recent repair history
Degree of use
Operated for long period E E E E E
of machine
Gradually became worse Q Q w w Q Q
Ease of starting
Starts when warm w w
Questions
Non-specified fuel is being used Q Q Q Q

Replacement of filters not carried out according to Operation & Maintenance
w w w Q Q
Manual
Engine oil must be added more frequently w
Preheat monitor does not indicate normal operation during preheating or at
low temperature w
Charge level monitor indicates abnormal charging during operation w w

Dust indicator lamp is red w
Clogged air breather hole in fuel tank cap w
Leakage from fuel piping w Q
No response or heavy resistance felt when operating priming pump w Q Q
Starting motor cranks engine slowly Q w
When engine is and air breathing plug is removed from fuel filter, fuel fails to w w
cranked with be discharged
starting motor, When spill hose is separated from injector, spill flow drops w
Check items
When exhaust manifold is touched immediately after starting engine, temper-

w
ature of some cylinders is low
Engine does not pick up smoothly, and combustion is irregular Q Q w
There is hunting from engine (rotation is irregular) Q w Q Q
Blow-by gas is excessive w
Inspect air cleaner directly q

Removing EGR cooler outlet gas piping causes coolant containing antifreeze q
to flow out (*1)
When compression pressure is measured, the oil pressure is low. q q
Air is discharged when air is bled from fuel system q
Troubleshooting
Inspect fuel filter directly q

Inspect fuel feed pump gauze filter directly q
Carry out troubleshoot by “Rail Press Very Low Error (*2)” q
Speed of some cylinders does not change when operated in reduced cylin-
q
der mode
Intake air heater mount does not warm up during preheating operation q
Is voltage 26 – 30V between alternator terminal B and terminal E Yes q
with engine at low idle? No q
Specific gravity of electrolyte and voltage of battery are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
For *1 and *2, see the next page
*1: EGR cooler inlet gas piping
40-600 6 WD600-6
S-1 Engine does not start easily. SEN05063-00
Loosen 4 mount bolts (1) of gas piping to EGR cooler inlet and check the flowout of coolant.
Condensed water from cooled exhaust gas may come out in small quantity but it poses no problem if
colorless and transparent.
*2: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
WD600-6 40-600 7
SEN05063-00 S-2 Engine does not start
S-2 Engine does not start 1
a) Engine does not crank Cause
Cracked EGR cooler (coolant mixing in the exhaust)

General causes why engine does not turn
Defective starting motor (Safety relay section)

q Seizure inside engine:
See the troubleshooting for “S-4 Engine stops during opera-
Defective starting motor (Motor section)

tions”.
Defective battery terminal connection

q Electrical system is not normal
Defective wiring of starting circuit

q Defective power train:
Damaged flywheel ring gear

Carry out troubleshooting in H-mode.
Defective starting switch

Defective battery relay
Questions
Degree of use of machine Operated for long period E E E

Condition of horn when starting Does not sound. Q Q w
switch is turned ON Horn volume is low w
Battery electrolyte level is low w
Battery terminal is loose w
No operating sound from battery relay when starting switch is turned ON Q w
When starting switch is turned to START, pinion does not move out Q Q w
Check items
Speed of rotation is low Q w

When starting switch is set to Makes grating noise w w
START, the starting pinion
comes out, but Soon disengages pinion again w
Makes rattling noise and does not turn w Q Q w
Removing EGR cooler outlet gas piping causes coolant containing antifreeze to flow out(*1) q
q
Carry out troubleshooting

Inspect flywheel ring gear directly
Troubleshooting
There is no voltage (20 – 30V) between battery relay terminal

in E-mode
q
B and terminal E
When terminal B and terminal C of starting switch are con-
Turn the starting switch OFF, q
connect the cord, then turn nected, engine starts
starting switch ON and carry When the safety relay outlet terminal B and terminal C are
out troubleshooting q
connected, engine starts
When the safety relay outlet terminal B and terminal C are
q
connected, engine does not start
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
For *1, see the next page
40-600 8 WD600-6
S-2 Engine does not start SEN05063-00

Loosen 4 mount bolts (1) of gas piping to EGR cooler inlet and check the flowout of coolant.
WD600-6 40-600 9
SEN05063-00 S-2 Engine does not start
b) Engine turns but no exhaust smoke comes out Cause
Defective operation of overflow valve (not closing)

General causes why engine turns but no exhaust smoke
comes out
Seizure or abnormal wear of feed pump
Wrong connection of supply pump PCV

q Fuel is not being supplied

q Supply of fuel extremely small
Defective operation of flow damper

q Improper selection of fuel (particularly in winter)
Clogged feed pump gauze filter
Broken supply pump shaft, key
Defective supply pump PCV

Insufficient fuel in tank
Defective fuel injector

Improper fuel used
Clogged fuel filter

Confirm recent repair history E
Questions

Exhaust smoke suddenly stops coming out (when starting again) w Q w w w E E
Replacement of filters not carried out according to Operation & Maintenance w w E Q
Manual
Fuel tank is found to be empty w
Rust and water are detected when fuel tank is drained Q Q Q Q Q
When fuel filter is removed, no fuel is inside the fuel filter w w
Check items
Leakage from fuel piping w

and the air breathing plug is removed from the fuel
filter, fuel fails to discharge Q Q w Q
When engine is cranked
with starting motor, When spill hose is separated from injector, spill
flow drops Q w w w w Q
Air is discharged when the air is bled from the fuel system q
Inspect the fuel filter directly q
Troubleshooting
Inspect the fuel feed pump gauze filter directly q

Inspect feed pump directly q
Carry out troubleshoot by “Rail Press Very Low Error (*1)” q q q q
Carry out troubleshoot by “PCV1 Error (:2) or PCV2 Error (*3)” q
Inspect overflow valve directly q
Engine can start when operated in reduced cylinder mode q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Add
Remedy
40-600 10 WD600-6
S-2 Engine does not start SEN05063-00
c) Exhaust smoke comes out but engine does not start Cause
Defective coolant temperature sensor or defective wiring harness

(Fuel is being injected)
General causes why exhaust smoke comes out but engine

does not start
q Rotating force in short due to defective electrical system
q Supply of fuel small
Wear of valve system (valve, rocker lever, etc.)

q Small air intake
Clogged injection nozzle, defective spray

q Improper selection of fuel

Defective intake air heater system

Worn piston ring, cylinder liner
Improper fuel used
Clogged fuel filter

Check recent repair history
Degree of machine operation Machine operated for long period E E E E
Suddenly failed to start w w Q
Questions
Non-specified fuel is being used Q Q

Replacement of filters not carried out according to Operation & Maintenance Manual w w w
Engine oil replenishment increasing w
Preheat monitor not indicating normal operation during preheating or at low temper-
ature w
Dust indicator turned red w

Clogged air breather hole in fuel tank cap Q
Rust and water are detected when fuel tank is drained w w
When removed, no fuel is inside the fuel filter w
Starting motor cranks engine slowly w
When engine is cranked, abnormal noise is heard from around cylinder head w
Check items
Fuel fails to discharge, when bleeding air plug of the

fuel filter is removed Q w w
When engine is cranked with
starting motor, Spill flow drops, when spill hose is separated from
w
injector
When exhaust manifold is touched immediately after starting engine, temperature of
w
some cylinders is low

Inspect valve system directly q
When compression pressure is measured, the oil pressure is low. q
Troubleshooting
Testing a single unit injector indicates defective spraying q
Coolant temperature gauge indication is not normal q
Intake air heater mount does not warm up during preheating operation q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
WD600-6 40-600 11
SEN05063-00 S-3 Engine does not pick up smoothly
S-3 Engine does not pick up smoothly 1
General causes why engine does not pick up smoothly Cause

q Insufficient intake of air
Clogged injection nozzle, defective spray

Defective contact of valve and valve seat
Seizure and interference of turbocharger

q Insufficient supply of fuel

Defective operation of flow damper

q Fuel injection condition not normal


q Controller in derate control mode
(excessive injector leakage)

Improper valve clearance
(Controlling injection capacity (output) due to an error
in the electrical system)
q EGR valve is stuck in open state
Clogged fuel filter

Stuck EGR valve
(Shortage of air intake due to excessive EGR gas)

Degree of use of machine Operated for long period E E E E E E
Questions
Engine pick-up suddenly became poor Q w Q Q Q

Non-specified fuel is being used w w w w
Replacement of filters has not been carried out according to Operation &
w w w
Maintenance Manual
Dust indicator is red w
No response or heavy resistance felt when operating priming pump w Q Q
When exhaust manifold is touched immediately after starting engine, tempera- Q w
ture of some cylinders is low
Blue under light load w
Color of exhaust gas
w Q w w
Check items
Black
Abnormal noise is heard from around cylinder head w
Abnormal noise is heard from around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is
Q w w
applied
There is hunting from engine (rotation is irregular) Q Q w Q
Blow-by gas is excessive w w

Carry out troubleshoot by “EGR Valve Servo Error (*1)” in E-mode. q
Troubleshooting
Inspect valve clearance directly q

When turbocharger is rotated by hand, it is found to be heavy q
Speed of some cylinders does not change when operated in reduced cylinder
q q
mode
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Remedy
40-600 12 WD600-6
S-4 Engine stops during operation SEN05063-00
S-4 Engine stops during operation 1
General causes why engine stops during operations Cause

q Seizure inside engine
Broken auxiliary equipment (pump, compressor, etc.)

Breakage of valve system (valve, rocker lever, etc.)
Defective power supply wiring for engine controller

q Overheating
q Defective power train:

Broken, seized piston or connecting rod
Carry out troubleshooting in H-mode.

Broken, seized crankshaft metal
Leakage, clogging in fuel piping
Broken supply pump shaft, key
Defective starting switch wiring

Broken, seized feed pump
Broken, seized gear train
Defective power train

Clogged fuel filter
Degree of use of machine Operated for long period E E
Abnormal noise was heard and engine
stopped suddenly w w w w Q w Q w w
Questions
Condition when engine Engine overheated and stopped w Q Q

stopped
Engine stopped slowly w Q Q Q Q
There was hunting and engine stopped w Q Q Q Q Q Q
Non-specified fuel is being used Q Q Q Q
Replacement of filters not carried out according to Operation & Mainte- w w
nance Manual
Fuel level monitor indicates low fuel level w
Metal particles are found when oil pan is drained w w w
Check items
Does not turn at all w w

When engine is cranked Turns in opposite direction w
manually Moves by the amount of gear backlash w w
Supply pump shaft does not turn w
Engine rotates, but stops when loaded on the machine side w

Carry out troubleshooting in H-mode
Inspect piston and connecting rod directly. q

Inspect crankshaft metal directly q
Troubleshooting
Inspect gear train directly q

Inspect feed pump directly q
Carry out troubleshoot by “Rail Press Very Low Error (*1)” q q
Engine rotates when auxiliary equipment (pump, compressor) is removed q
Check power supply wiring for engine controller q
Check starting switch wiring q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Add
Remedy
WD600-6 40-600 13
SEN05063-00 S-5 Engine does not rotate smoothly (Hunting occurs)
S-5 Engine does not rotate smoothly (Hunting occurs) 1
General causes why engine does not rotate smoothly Cause

q Mixing of air in the fuel system
Defective operation of flow damper (excessive injector leakage)

q Rotation sensor is not normal
Defective Bkup speed sensor or defective wiring harness

(abnormality where it fails to make error indication)
Defective Ne speed sensor or defective wiring harness

q EGR valve is not normal
q Bypass valve is not normal
Clogged fuel injector, defective injection

Defective operation of bypass valve

Defective operation of EGR valve
Low idle speed setting is too low

Clogged fuel filter

Degree of use of machine Operated for long period E E E E
Questions
Occurs at a certain speed range Q Q Q Q Q

Occurs at low idle w Q Q Q Q Q Q Q
Condition of hunting
Occurs even when speed is raised Q Q Q Q Q
Occurs on slope w Q Q
Replacement of filters not carried out according to Operation & Maintenance Manual w w
Check
item
Rust and water are detected when fuel tank is drained Q Q

Leakage from fuel pipe w
Carry out troubleshoot by “EGR Valve Servo Error (*1)” q

Carry out troubleshoot by “Bypass Valve Servo Error (*2)” q
Troubleshooting
Speed of some cylinders does not change when operated in reduced cylinder mode q q
Carry out troubleshoot by “Eng Ne Speed Sensor Error (*3)” q
Carry out troubleshoot by “Eng Ne Speed Sensor Error (*4)” q
Correct or replace
Correct or replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Add
Remedy
*3: Troubleshooting by failure code (Display of code), Code [CA689]
*4: Troubleshooting by failure code (Display of code), Code [CA778]
40-600 14 WD600-6
S-6 Engine lacks output (or lacks power) SEN05063-00
S-6 Engine lacks output (or lacks power) 1
General causes why engine lacks output Cause

Insufficient intake of air
Defective fuel temperature sensor or defective wiring harness

q
Defective charge pressure sensor or defective wiring harness

Defective mounting of charge pressure sensor (air leak)

q Overheating
Defective drive of injector (signal or solenoid)

See the troubleshooting for “S-14 Coolant Tem-

Defective contact of valve and valve seat
Clogged fuel injector, defective injection

Seizure or interference of turbocharger
perature Too High (Overheat)”

Leakage, clogging in fuel piping

Air leakage from air intake pipe
(Controlling injection capacity (output) due to an

error in the electrical system)
Clogged fuel filter

Degree of use of machine Operated for long period E E E E E
Questions
Suddenly Q Q Q Q
Power was lost
Gradually Q Q Q Q Q Q Q
Replacement of filters not carried out according to Operation & Maintenance Manual w
Engine oil must be added more frequently Q Q Q
Output reduces after a break w
Black w w w
some cylinders is low w
w
Check items
Interfering noise is heard from around turbocharger

High idle speed of engine is low Q
High idle speed under no load is normal, but speed suddenly drops when load is w w Q
applied
Engine does not pick up smoothly, and combustion is irregular w Q Q w
There is hunting from engine (rotation is irregular) Q Q Q Q

Inspect intake air piping directly q
When boost pressure is measured, the oil pressure is low q q q
When compression pressure is measured, the oil pressure is low q q
Troubleshooting

Check the mount of boost pressure sensor directly q
Carry out troubleshoot by “Chg Air Press Sensor Error (*2)” q
Carry out troubleshoot by “Fuel Temp Press Sensor Error (*3)” q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Clean
Remedy
For *1, *2 and *3, see the next page
WD600-6 40-600 15
SEN05063-00 S-7 Exhaust smoke is black (Incomplete combustion)
S-7 Exhaust smoke is black (Incomplete combustion) 1
General causes why exhaust smoke is black Cause

q Insufficient intake of air
Air leakage between turbocharger and cylinder head
Clogged fuel spill piping (on the cylinder head side)
Defective coolant temperature sensor or defective

Defective contact of valve or valve seat

q Overheating

See the troubleshooting for “S-14 Coolant Tem-
perature Too High (Overheat)”

Improper injection pressure

Abnormal wear of injector
(Controlling injection capacity (output) due to an
Crushed, clogged muffler
Improper injection timing

Clogged, seized injector
error in the electrical system)
q EGR valve is stuck in open state
Stuck EGR valve

(Shortage of air intake due to excessive EGR gas)
wiring harness
Suddenly became black w Q Q Q
Questions
Color of exhaust gas Gradually became black w Q Q Q

Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Leakage of air between turbocharger and cylinder head, loose clamp w
Operated in low-temperature mode during normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine, temper-
ature of some cylinders is low w

Check items

Torque converter stall or high pump relief speed (excessive fuel injection) Q Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly, and combustion is irregular Q Q Q Q Q Q w
Spill flow is excessive when spill hose is separated from injector w

Carry out troubleshoot by “EGR Valve Servo Error (*1)” q
Troubleshooting

When muffler is removed, exhaust color returns to normal q
Carry out troubleshoot by “Rail Press Very Low Error (*2)” q q
Speed of some cylinders does not change when operated in reduced cylin- q
der mode
Inspect fuel spill piping (on the cylinder head side) directly q
Carry out troubleshoot by “Coolant Temp Sensor Error (*3)” q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Remedy
For *1, *2 and *3, see the next page
40-600 16 WD600-6
S-7 Exhaust smoke is black (Incomplete combustion) SEN05063-00
WD600-6 40-600 17
SEN05063-00 S-8 Oil is consumed much (or exhaust gas color is blue)
S-8 Oil is consumed much (or exhaust gas color is blue) 1
General causes why oil consumption is excessive Cause

Abnormal oil combustion
Turbocharger
q
Oil leakage from EGR valve and bypass valve stem

q Extended operation for long hours in low or high
Worn or damaged valve (stem, guide, and seal)

idle (continuous no load operation for 20 minutes
and longer inhibited)
Leakage from oil pan, cylinder head, etc.

q Oil leakage to outside
q Wear of lubricating system
Clogged breather or breather hose

Dust sucked in from intake system
Worn, damaged rear seal surface

Leakage from oil drain plug

Wear of seal at blower end
Worn seal at turbine end
Leakage from oil cooler
Leakage from oil piping

Leakage from oil filter
Broken piston ring
Broken oil cooler

Questions

Oil consumption suddenly increased w Q
Engine oil must be added more frequently Q w Q
Engine oil becomes contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w w
Pipe clamps for intake system are loose w
Inside of turbocharger air intake outlet pipe is contaminated with oil w
Q w
Check items
Inside of turbocharger exhaust outlet pipe is contaminated with oil

There is oil in the coolant w
Color of exhaust gas blue under light load Q w w
Excessive Q Q w w
Amount of blow-by gas
None w
When intake manifold is removed, dust is found inside q

When intake manifold is removed, inside is contaminated abnormally q
Excessive play of turbocharger shaft q q
Troubleshooting
When EGR valve and bypass valve are removed, exhaust port is contami-
nated with oil q
Inspect breather, breather hose directly q

Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
40-600 18 WD600-6
S-9 Engine oil becomes contaminated quickly SEN05063-00
S-9 Engine oil becomes contaminated quickly 1
General causes why oil becomes contaminated quickly Cause

q Entry of exhaust gas due to internal wear
Clogged lubricating drain tube of turbocharger

q Clogging of lubrication route
Defective seal at turbocharger turbine end

q Improper fuel is being used
q Improper oil is being used
Clogged breather, breather hose

q Operated under excessive load
Defective oil filter safety valve

Worn valve, valve guide
Exhaust smoke is black

Worn EGR valve guide
Clogged oil cooler

Clogged oil filter
Questions

Non-specified fuel is being used Q
Engine oil must be added more frequently Q w
Oil filter clogging monitor indicates clogging when the oil temperature rises w Q
Metal particles are found when oil is drained in oil filter Q Q
Inside of exhaust pipe is contaminated with oil w
Engine oil temperature rises quickly w
Check item

Black w
Excessive Q Q w
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q

When EGR valve is removed, exhaust port is contaminated with oil q
Troubleshooting
(See S-7)
Inspect breather, breather tube directly q
Inspect oil cooler directly q
Inspect oil filter directly q
There is catching or breakage to the oil filter safety valve spring q
Inspect turbocharger lubricating drain tube directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
—
Remedy
WD600-6 40-600 19
SEN05063-00 S-10 Fuel consumption is excessive
S-10 Fuel consumption is excessive 1
General causes why fuel consumption is excessive Cause

q Leakage of fuel
Defective coolant temperature sensor or defective wiring harness

q Fuel injection condition (fuel pressure and injection timing) not normal
q Excessive fuel injection
Fuel leakage from fuel filter, piping, etc.
Defective common rail fuel pressure

Leakage of fuel inside head cover
Defective supply pump plunger

Defective feed pump oil seal
Defective injector operation

Defective injector spray
Questions

More than for other machines of same model Q Q Q
Condition of fuel consumption Gradually increased Q Q
Suddenly increased Q Q
Fuel leakage to outside w
There is irregular combustion w
Oil increasing, smelling of diesel oil w w
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is w w
low
Check items
Low idle speed is too high Q

Torque converter stall or hydraulic pump relief speed is high Q
Black Q Q Q
White Q
Remove head cover and inspect directly q

Troubleshooting
Inspect feed pump oil seal directly q

Spill flow is excessive when spill hose is separated from injector q
Carry out troubleshoot by “Coolant Temp Sensor Error (*2)” q
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
40-600 20 WD600-6
S-11 Coolant contains oil (blows back or reduces) SEN05063-00
S-11 Coolant contains oil (blows back or reduces) 1
General causes why oil in coolant Cause

q Internal leakage of lubricating system
Hole drilled by damages or pitching of cylinder liner O-ring

q Internal leakage of cooling system
Broken hydraulic oil cooler, power train oil cooler

Insufficient protrusion of cylinder liner
Broken cylinder head, head gasket
Internal cracks in cylinder block
Broken oil cooler core, O-ring

Questions
Degree of use of machine Operated for long period E E

Suddenly increased Q Q Q
Oil level
Gradually increased Q Q
Hard water is being used as coolant Q Q
Oil level has risen, oil is milky Q Q w
Excessive air bubbles inside radiator, coolant spurts back w w
Check
item
Hydraulic oil or power train oil is milky w

When hydraulic oil or power train oil is drained, water is discharged w
Pressure-tightness test of cylinder head shows there is leakage q

shooting
q q
Trouble-
Inspect cylinder block directly Carry out trou-

bleshooting in
Inspect cylinder liner directly. q H-mode
Replace
Replace
Replace
Replace
Replace
—
Remedy
WD600-6 40-600 21
SEN05063-00 S-12 Oil pressure drops
S-12 Oil pressure drops 1
General causes why oil pressure drops Cause

q Leakage, clogging, wear of lubrication system
Defective hydraulic sensor or defective wiring harness

q Hydraulic control is not normal
q Selection of oil by the temperature etc. specified in the
Leakage, crushing or clogging of hydraulic pipe

Operation and Maintenance Manual is not observed.
Defective oil level sensor or wiring harness

Clogging or breakage of pipe inside oil pan
q Oil deteriorated by overheating
Leakage from EGR hydraulic piping

Clogged strainer inside oil pan
Defective oil pump relief valve
Defective EGR oil pump

Wear of metal journal
Lack of oil in oil pan
Defective oil pump
Clogged oil filter

Water, fuel in oil
Degree of use of
Questions
machine Operated for long period E E E E
Oil pressure monitor indicates low pressure level Q w

Replacement of filters not carried out according to Operation & Maintenance Manual w
Indicates a drop of hydraulic pressure during low idle w Q Q
Indicates a drop of oil pressure during low and high idle Q w w w Q Q Q
Oil pressure monitor
Indicates a drop of oil pressure on a slope w
Indicates a drop of oil pressure occasionally w Q Q
Oil level monitor indicates low level w w
Oil pan oil level is in short w
Leakage or crushing with external hydraulic pipe w w
Check items
Oil is cloudy white or smells of diesel oil w

Metal particles are found when oil pan is drained w
Metal particles are found when oil is drained from oil filter w Q Q
See S-13
Metal particles are detected in oil filter q

Troubleshooting
Inspect oil pan strainer, pipe directly q q

Oil pump rotation is heavy, there is play q
Oil pump relief valve, spring is fatigued or damaged q
Inspect oil filter directly q
Relief valve of EGR oil pump is damaged or has oil leak q
Inspect EGR hydraulic piping directly q
Carry out troubleshoot by “Eng Oil Press Sensor Error (*1)” q
If oil level sensor is replaced, oil level monitor indicates normally q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Add
—
Remedy
40-600 22 WD600-6
S-12 Oil pressure drops SEN05063-00
WD600-6 40-600 23
SEN05063-00 S-13 Oil level rises (Water, fuel in oil)
S-13 Oil level rises (Water, fuel in oil) 1
General causes why oil level rises Cause

q Coolant mixing in the oil (oil turns cloudy)
Clogging of water pump drain hole (breather hole) or defective seal

q Fuel in oil (smells diluted diesel fuel)
a If oil mixes with the coolant, carry out troubleshooting by S-11
Defective seal of auxiliary equipment (pump or compressor)

Hole drilled by damages or pitching of cylinder liner O-ring
Coolant contains oil
Cracked EGR cooler (mixing of coolant)

Leakage of fuel inside head cover
Worn, damaged rear seal surface

Internal cracks in cylinder block
Broken oil cooler core, O-ring
Defect inside supply pump

Questions

Fuel must be added more frequently w w
Coolant must be added more frequently Q Q
There is oil in the coolant Q Q Q w
Engine oil smells of diesel fuel w w
Oil is milky Q Q
After starting engine, drops of water come from muffler Q Q
Leave radiator cap open. When engine is run at idle, an abnormal number of bubbles appear w Q
or water spurts back
Check items
Exhaust gas is white Q

Clogged water pump drain hole (breather hole) w
Water comes out when water pump drain hole (breather hole) is cleaned w
Damper oil is decreasing w
Hydraulic tank oil level is decreasing on applicable machine side w
Removing EGR cooler inlet gas piping causes coolant containing antifreeze to flow out (*1) q
When compression pressure is measured, the oil pressure is low q
Troubleshooting
Remove head cover and inspect directly q

Inspect cylinder block directly q q
Inspect rear oil seal directly q
Remove water pump and inspect directly q
Remove supply pump and inspect directly q
Inspect the seal of auxiliary machine directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
For *1, see the next page
40-600 24 WD600-6
S-13 Oil level rises (Water, fuel in oil) SEN05063-00

Loosen 4 mounting bolts (1) of gas piping to EGR cooler inlet and check the flowout of coolant.
WD600-6 40-600 25
SEN05063-00 S-14 Coolant temperature rises too high (Overheating)
S-14 Coolant temperature rises too high (Overheating) 1
General causes why coolant temperature becomes too Cause

high
Drop in performance of fan pump, fan motor

q Lack of cooling air (deformation, damages of fan)
Defective radiator cap (pressure valve)

q Drop in heat dissipation efficiency
Water leakage to outside EGR cooler
Defective coolant temperature gauge

Hole drilled by damages or pitching
Rise of power train oil temperature

q Defect in the coolant circulation system
Defective operation of thermostat

q Power train oil temperature is rising:
Clogged, crushed radiator fins

Carry out troubleshoot in H-mode
Deformed or damaged fan

Clogged, broken oil cooler
of cylinder liner O-ring
Clogged radiator core

Broken water pump
Lack of coolant
Questions
Suddenly increased Q Q w Q
Condition of overheating
Always tends to overheat Q w w Q
Rises quickly Q w
Coolant temperature gauge Does not go down from red
w
range
Radiator coolant level monitor indicates low level Q w
Engine oil level has risen, oil is cloudy white w Q
Fan speed is low w w
Cloudy white oil is floating on coolant w
Excessive air bubbles inside radiator, coolant spurts back w
When light bulb is held behind radiator, no light passes through w
Check items
Radiator shroud and inside of underguard on applicable machine side are

w w
clogged with dirt or mud
Coolant leakage from cracks in the radiator hose or loose clamps w
Coolant flows out from radiator overflow hose w
Power train oil temperature gauge on applicable machine side enters red w
range faster than engine coolant temperature gauge
Inspect coolant leakage from EGR cooler directly q

Inspect cylinder block directly q
Inspect oil cooler directly q
Troubleshooting
Temperature difference between top and bottom radiator tanks is excessive q

When function test is carried out on thermostat, it does not open even at q
cracking temperature
Temperature difference between top and bottom radiator tanks is slight q
Inspect radiator core directly q
When function test is carried out on the radiator cap, cracking pressure is low q
Inspect fan directly q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Add
—
—
Remedy
40-600 26 WD600-6
S-15 Abnormal noise is made SEN05063-00
S-15 Abnormal noise is made 1
General causes why abnormal noise is made Cause

q Abnormality due to defective parts
Air leakage between turbocharger and cylinder head
Defect inside muffler (dividing board out of position)

Breakage of valve system (valve, rocker lever, etc.)
q Abnormal combustion
q Air sucked in from intake system
Cracks or gas leakage from EGR gas piping
Excessive wear of piston ring, cylinder liner

a Judge if noise is from inside or outside before proceeding
with troubleshooting

a When engine is not fully warmed up, engine noise rises
Missing, seized gear train bushing

slightly because of operation in the low temperature mode.
This is not abnormal, however.
Improper gear train backlash
Deformed or damaged fan

a When engine is accelerated, it enters acceleration mode,
Dirt caught in the injector

Clogged, seized injector
where engine noise remains slightly higher for about 5
seconds maximum. This is not abnormal, however.

Degree of use of machine Operated for long period E
Questions
Gradually increased Q Q Q
Condition of abnormal noise
Suddenly increased Q Q Q Q
Non-specified fuel is being used Q
Metal particles are found when oil is drained in oil filter Q w w
Leakage of air between turbocharger and cylinder head w
Abnormal noise is heard from around EGR gas piping w
Abnormal noise is heard from around cylinder head w w
Abnormal noise is heard from around muffler w
Check items

some cylinders is low w Q

Black Q w Q
Engine pickup is poor and combustion is abnormal w
Abnormal noise is loud when accelerating engine Q Q Q Q

Inspect EGR gas piping directly q
Troubleshooting
When muffler is removed, abnormal noise disappears q

Inspect gear train directly q q
Inspect fan directly q
Abnormal noise is emitted only when starting engine q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Remedy
WD600-6 40-600 27
SEN05063-00 S-16 Vibration is excessive
S-16 Vibration is excessive 1
General causes why vibration is excessive Cause

q Defective parts (abnormal wear, breakage, etc.)
Broken part inside upper drive shaft or damper

Loose engine mounting bolts, broken cushion
Stuck valve system (valve, rocker lever, etc.)
q Alignment with applicable machine side is not normal
Wear of front support spigot joint portion

q Abnormal combustion
Worn main metal, connecting rod metal

a If there is abnormal noise together with the vibration, carry out trouble-
shooting also for “S-15 Abnormal noise is made”.
Improper gear train backlash

Worn camshaft bushing
Questions

Suddenly increased Q Q
Condition of vibration
Gradually increased Q Q Q Q
Metal particles are found when oil is drained in oil filter w w
Metal particles are found when oil pan is drained w w
Q Q
Check items
Oil pressure is low at low idle

Vibration occurs at mid-range speed Q Q
Vibration follows engine speed Q Q Q Q
Exhaust smoke color is black w

Troubleshooting
Inspect main metal, connecting rod metal directly q

Inspect gear train directly q
Inspect camshaft bushing directly q
Inspect engine mount bolt, cushion directly. q
Inspect front support spigot directly q
Inspect inside of upper drive shaft or damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
40-600 28 WD600-6
S-16 Vibration is excessive SEN05063-00
WD600-6 40-600 29
SEN05063-00 S-17 Air cannot be bled from fuel circuit
S-17 Air cannot be bled from fuel circuit 1
(After filter is replaced or fuel is used up and then air is bled, engine does not start or it starts but
stalls.)
General causes why air cannot be bled Cause
q Electric priming pump does not operate.
Defective wiring harness of electric priming pump

Improper setting of air bleeding valve (Closed)
q Fuel is not supplied or is supplied very little.
Malfunction of electric priming pump switch

q Fuel valve or air bleeding valve is not set properly.
Leaking or clogged fuel piping or air in it

q Air bleeding piping is clogged.
Improper setting of fuel valve (Closed)
Malfunction of electric priming pump

q Fuel return piping is clogged.
Clogged fuel tank cap breather hole
Clogged water separator screen

Clogged air bleeding piping
Low battery charge level

Clogged fuel filter
Low fuel level
Questions
Degree of use of
machine Operated for long period E E

Fuel tank is empty w
Fuel tank cap breather hole is clogged w
Fuel is leaking from fuel piping w
Check items
Switch lamp does not blink w w Q

When electric priming Lamp blinks but pump operation sound is not heard w w
pump switch is operated
Pump operation sound is heard but fuel does not flow out
of hose soon Q Q Q Q w w w Q Q
Air bleeding valve is closed q

Fuel valve (supply side) is closed q
Fuel valve (return side) is closed q
Water drain valve and air intake plug of water separator are loosened q
Troubleshooting
Water drain valve of fuel prefilter is loosened q

There is flaw or dirt on sealing face of fuel prefilter or main filter q
Check air bleeding piping and orifice directly (See Note 1) q
Check fuel piping (supply side and return side) directly (for clogging and breakage) q
Check electric priming pump directly q
Check electric priming system directly (See E-14) q q
Check water separator screen directly q
Check fuel filter for clogging (See failure code CA559, Note 2) q
Replace
Replace
Replace
Replace
Charge
Correct
Correct
Correct
Correct
Correct
Clean
Add
Remedy
40-600 30 WD600-6
S-17 Air cannot be bled from fuel circuit SEN05063-00
Note 1: Check of air bleeding piping for clogging
q Remove joint bolt (1) and blow clean compressed air into hole (b) of the orifice to check for clogging.
q Remove air bleeding pipings (2), (3) and blow compressed air against its both ends to check for clog-
ging.
WD600-6 40-600 31
SEN05063-00
WD600-6 Wheel dozer

©2009 KOMATSU
All Rights Reserved
40-600 32
SEN05141-00
WHEEL DOZER
WD600-6
WD600-6 55001 and up
50 Disassembly and assembly 1
100 General information on disassembly

and assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tools list .............................................................................................................................................. 7
Sketches of special tools ...............................................................................................................................11
WD600-6 50-100 1
100 General information on disassembly and assembly
SEN05141-00 How to read this manual
How to read this manual (Rev. 2009.01)1
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are necessary for q In “Removal” section, the work procedures,
r e m o v a l o r i n s ta l l a t i o n o f pa r ts a r e precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for removal
q Also the following information is de- are described as [1], [2]••• etc. and their part
scribed in the special tool list. numbers, part names and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q Various symbols used in “Removal” section are
tuted and should always be used explained and listed below.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market a : Guidance or precautions for the work
2) Distinction of new and existing special [*1] : This mark shows that instructions or precau-
tools tions for parts installation work are given in
N: Tools newly developed for this “Installation” section.
6 : Amount of oil or coolant to be drained
model. They have a new part num-
4:
ber respectively.
Weight of part or component
R: Tools made available by redesign-
ing the existing tools which were
developed for other models. Each Installation
of them has a new part number q Unless otherwise instructed, installation of
assigned by setting forward the parts is to be done in the reverse order to
part number of the existing tool. removal.
Blank : Tools already available for other q Instructions and precautions for parts installa-
models. They can be used without tion is shown with the mark ([*1], [*2]...) which
any modification. corresponds to the mark in “Removal” section.
3) Circle mark Q in sketch column: q Common tools that are necessary for installa-
q The sketch of the special tool is pre- tion are described as [1], [2]••• etc. and their
sented in the section of “Sketches of part numbers, part names and quantities are
special tools”. not described.
q Part No. of special tools starting with q Marks shown in the “Installation” section stand
79 T- - : for the following.
* *** ****
means that they are not available
from Komatsu Ltd. (i.e. tools to be k : Precautions related to work safety
made locally). a : Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished
Sketches of special tools

q Various special tools are illustrated for the local
manufacture.
50-100 2 WD600-6
How to read this manual SEN05141-00
2. Disassembly and assembly of assemblies
Special tools Disassembly

q Special tools which are necessary for dis- q In “Disassembly” section, the work procedures,
assembly and assembly of parts are precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for disas-
q Also the following information is described sembly are described as [1], [2]••• etc. and
in the special tool list. their part numbers, part names and quantities
1) Necessity are not described.
t : Special tools that cannot be substi- q The meanings of the symbols used in “Disas-
tuted and should always be used. sembly” section are as follows.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market. a : Guidance or precautions for the work
2) Distinction of new and existing special 6 : Amount of oil or coolant drained
tools
N: Tools newly developed for this
model. They have a new part num- Assembly
ber respectively. q In “Assembly” section, the work procedures,
R: Tools made available by redesign- precautions and know-how to do the work, and
ing the existing tools which were the amount of oil and coolant to be replenished
developed for other models. Each are described.
of them has a new part number q Common tools that are necessary for assem-
assigned by setting forward the bly are described as [1], [2]••• etc. and their
part number of the existing tool. part numbers, part names and quantities are
Blank : Tools already available for other not described.
models. They can be used without q The meanings of the symbols used in “Assem-
any modification. bly” section are as follows.
3) Circle mark Q in sketch column:
k
q The sketch of the special tool is pre- : Precautions related to work safety
sented in the section of “Sketches of a : Guidance or precautions for the work
2 : Type of coating material
special tools”.
3 : Tightening torque
q Part No. of special tools starting with
5
79 T- - :
* *** ****
means that they are not available
: Amount of oil or coolant to be replenished
from Komatsu Ltd. (i.e. tools to be
made locally).
Sketches of special tools
q Various special tools are illustrated for the local
manufacture.
WD600-6 50-100 3
SEN05141-00 Coating materials list
Coating materials list (Rev. 2009.02)1

a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
Gasket sealant
LG-6 790-129-9160 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9170 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.
50-100 4 WD600-6
Coating materials list SEN05141-00
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
• Can be coated with paint.
Gasket sealant
LG-10 • Used as lubricant/sealant when the radiator

ThreeBond 790-129-9320 200 g Tube hoses are inserted.
1206E • Can be coated with paint.
LG-11 • Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube • Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Used to prevent scuffing and seizure of press-fit-
ted portions, shrink-fitted portions, and threaded
LM-P 09940-00040 200 g Tube
portions.
Molybdenum
• Used to lubricate linkages, bearings, etc.

lubricant
disulfide
• Spray type
• Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
— 09995-00250 190 g Can
ing each other.
• Applicable for the propeller shaft splines, needle
bearings, pins and bolts of various links, etc.
• Feature: Seizure and scuffing prevention com-
prevention
compound
Seizure
pound with metallic super-fine-grain, etc.

LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
Grease
LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
• Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
400 g Bellows-type resistance higher than molybdenum disulfide
Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
WD600-6 50-100 5
SEN05141-00 Coating materials list
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
Grease
• Used for oil seals of the transmission, etc.

• Feature: Urea (organic system) grease with heat
G2-U-S resistance and long life. Enclosed type.
427-12-11871 2 kg Can
ENS grease • Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
Adhesive for cab glass

SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manu-
435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
container
GP-402 facture)
SUNSTAR • “S” is used for high-temperature season
PENGUINE and “W” for low-temperature season as
Polyethylene
SEAL 580 417-926-3910 320 ml adhesive for glass.
container
SUPER “S” or (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
• Used as adhesive for glass.

Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Sikaflex 256HV container
Adhesive for cab glass
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
SEKISUI • Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
SEALANT facture)
• Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)
50-100 6 WD600-6
Special tools list SEN05141-00
Special tools list 1
a Tools with part number 79 T- - means that they are not available from Komatsu Ltd. (i.e.
tools to be made locally).
* *** ****
a Necessity: t ............ Special tools that cannot be substituted and should always be used
q ............ Special tools that will be useful if available and are substitutable with tools
available on the market
a New/Redesign: N ............ Tools newly developed for this model. They have a new part number respec-
tively.
R ............ Tools made available by redesigning the existing tools which were developed
for other models. Each of them has a new part number assigned by setting for-
ward the part number of the existing tool.
Blank ..... Tools already available for other models. They can be used without any mod-
ification.
a Tools marked with Q in the sketch column are presented in the sketches of the special tools (See
“Sketches of special tools”)
New•Remodel
Essentiality
Illustration
Quantity
Sym-
Work item Part number Part name Nature of work, remarks
bol
795-799-5410 Adapter t 1 Removal and installation

Removal of fuel injector 1
795-799-5420 Remover t 1 of fuel injector assembly
and cylinder head
assembly Removal and installation
2 795T-675-1110 Socket q 1 N Q
of high-pressure pipings
Engine rear seal and Removal of engine front
3 795-931-1100 Seal puller assembly q 1
front seal and rear seals
795T-621-1180 Push tool t 1 Q Press fitting of oil seal
795T-621-1171 Push tool t 1 N Q Press fitting of dust seal
Engine front seal 4
A 795-902-1460 Bolt t 3 Press fitting of oil seal
01582-02218 Nut t 3 and dust seal
795T-621-1161 Push tool t 1 R Q
795T-621-1190 Push tool t 1 N Q Press fitting of engine
Engine rear seal 5
01050-32235 Bolt t 5 rear seal
01050-32245 Bolt t 5
Assembly of damper 6 793-612-1120 Push tool t 1 Press fitting of bearing
assembly 7 793T-612-1310 Push tool q 1 N Q Press fitting of oil seal
Cylinder head assembly 8 790-331-1120 Wrench (angle) q 1 Angle tightening of bolt
Removal and installation
C 792-900-1350 Wrench t 1
of turbine shaft nut
Disassembly and Removal and installation
assembly of torque D 793-613-1210 Wrench t 1
of stator shaft nut
converter assembly
793-615-1110 Wrench t 1 Measurement of rotation
E
01306-10616 Bolt t 1 torque of input shaft
Disassembly and
Operation check of clutch
assembly of transmission F 799-301-1500 Oil leak tester t 1
piston
and transfer assembly
Measurement of rotation
Disassembly and 1 793-615-1130 Spline wrench t 1 torque of intermediate
assembly of transfer G shaft
assembly Measurement of rotation
2 796-730-2300 Wrench assembly t 1
torque of input shaft
WD600-6 50-100 7
SEN05141-00 Special tools list
New•Remodel
Essentiality
Illustration
Quantity
Sym-
bol
790-501-5200 Unit repair stand t 1

1
790-901-4110 Bracket t 1
2 793T-622-1810 Plate t 1 N Q
Bearing preload adjust-
3 792-103-0901 Wrench t 1
ment
Press fitting of differen-
4 793T-622-1180 Push tool t 1 Q
tial case bearing
Press fitting of pinion
5 793T-622-1840 Push tool t 1 N Q shaft main bearing inner
race
790-201-2460 Plate t 1 Press fitting of main bear-
6
790-201-2690 Plate t 1 ing outer race
Disassembly and
assembly of differential 790-101-5621 Plate t 1
Press fitting of sub-bear-
assembly 7 790-101-5421 Grip t 1
H ing outer race
01010-81240 Bolt t 1
Press fitting of sub-bear-
8 790-201-2860 Spacer t 1
ing inner race
792-525-1000 Micrometer t 1 Bearing preload adjust-
9
792-525-1220 Adapter t 1 ment
10 793T-622-1820 Push tool t 1 N Q
tial cage oil seal
793T-622-1830 Push tool t 1 N Q
tial cage dust seal
11
790-101-5221 Grip t 1
01010-81240 Bolt t 1
Centering of transmission
of center support assem- 12 793T-620-1410 Centering tool t 1 N Q
bly
– center support
1 793T-622-1910 Fixture t 3 N Q
of wheel hub
792-520-2110 Installer t 1 Installation of floating
Disassembly and assem- 2
bly of rear brake assem- J 792-530-1600 Push tool t 1 seal
bly 792T-422-1220 Plate t 1 Q
3 790-101-5421 Grip t 1 Press fitting of oil seal
01010-81240 Bolt t 1
50-100 8 WD600-6
Special tools list SEN05141-00
New•Remodel
Essentiality
Illustration
Quantity
Sym-
bol
790-101-2300 Push tool t 1

790-101-2310 • Block 1
790-101-2320 • Screw 1
790-101-2330 • Nut 2
790-101-2340 • Washer 1
790-101-2350 • Leg 2
790-101-2360 • Plate 4 Installation of lower cen-
1
790-101-2410 • Joint 2 ter hinge bearing
02215-11622 • Nut 2
793-520-2640 Push tool t 1
790-438-1030 Guide t 1
790-438-1050 Bar t 2
790-101-2102 Puller (294 kN {30 ton}) t 1
790-101-1102 Pump t 1
Installation of center
K 790-101-2300 Push tool t 1
hinge bearing
790-101-2310 • Block 1
790-101-2330 • Nut 1
790-101-2340 • Washer 1
790-101-2350 • Leg 2
790-101-2360 • Plate 4
790-101-2410 • Joint 2
Installation of upper cen-
2 02215-11622 • Nut 2
ter hinge bearing
790-438-1050 Bar t 2
01580-12016 Nut t 2
790-438-1010 Push tool t 1
790-438-1020 Guide t 1
790-438-1040 Screw t 1
790-101-2102 Puller t 1
790-101-1102 Pump t 1
Steering valve assembly 1 793T-664-1110 Bracket t 1 N Q of steering valve assem-
bly
796-946-1310 Guide
2 t 1
T (For 723-46-40100)
796-946-1320 Guide Replacement of pres-
Control valve assembly 3 t 1 sure compensation valve
(For 723-46-40100) seal
796-946-1330 Sleeve
4 t 1
(For 723-46-40100)
WD600-6 50-100 9
SEN05141-00 Special tools list
New•Remodel
Essentiality
Illustration
Quantity
Sym-
bol
790-502-1003 Cylinder repair stand q 1 Disassembly and assem-

1 bly of hydraulic cylinder
790-101-1102 Pump q 1 assembly
790-102-4300 Wrench assembly t 1 Removal and installation
2
790-102-4310 Pin t 2 of piston assembly
3 790-720-1000 Expander q 1
796-720-1690 Ring (For lift arm) q 1
07281-02169 Clamp q 1
796-720-1720 Ring (For bucket) q 1
Installation of piston ring
4 07281-02429 Clamp q 1
Ring
796-720-1660 q 1
(For steering)
Hydraulic cylinder 07281-01159 Clamp q 1
U
assembly 790-201-1702 Push tool kit t 1
• Push tool
790-201-1881 1
(For lift arm and bucket)
5 • Push tool Press fitting of bushing
790-201-1821 1
(For steering)
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1500 Push tool kit q 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
6 Press fitting of dust seal
• Plate
790-201-1690 1
(For lift arm and bucket)
790-201-1630 • Plate (For steering) 1
Operator cab glass 1 793-498-1210 Lifter (Suction cup) t 2 Installation of operator
X
(stuck glass) 2 20Y-54-13180 Stopper rubber t 2 cab glass (stuck glass)
50-100 10 WD600-6
Sketches of special tools SEN05141-00
Sketches of special tools 1
Note) Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
A2 socket
A4 Push tool (For oil seal)
WD600-6 50-100 11
A4 push tool (For dust seal)
A5 push tool (For both standard and sleeved seal)
50-100 12 WD600-6
A5 push tool (For sleeved seal)
A7 push tool (For oil seal)
WD600-6 50-100 13
H2 plate
H4 push tool
50-100 14 WD600-6
H5 push tool
H10 push tool
WD600-6 50-100 15
H11 push tool
H12 centering tool
50-100 16 WD600-6
J1 fixture
J3 plate
WD600-6 50-100 17
T1 bracket
50-100 18 WD600-6
WD600-6 50-100 19
SEN05141-00
WD600-6 Wheel dozer

©2009 KOMATSU
All Rights Reserved
50-100 20
SEN05142-01
WHEEL DOZER
WD600-6
WD600-6 55001 and up
201 Engine and cooling system, Part 1

Removal and installation of engine assembly ................................................................................................. 2
Removal and installation of radiator assembly ............................................................................................... 6
Removal and installation of air aftercooler .....................................................................................................11
Removal and installation of cooling fan and fan motor assembly ................................................................. 12
Removal and installation of damper assembly ............................................................................................. 14
Disassembly and assembly of damper assembly ......................................................................................... 16
Removal and installation of fuel tank assembly ............................................................................................ 20
Removal and installation of engine hood assembly ...................................................................................... 22
Removal and installation of bulkhead assembly ........................................................................................... 24
WD600-6 50-201 1
SEN05142-01 Removal and installation of engine assembly
Removal and installation of 3. Remove air hose (2). [*1]

engine assembly 1
4. Remove komaclone hose and tube assembly
(3). [*2]
Removal 5. Disconnect dust indicator hoses (4).
k Stop the machine on level ground and set 6. Remove air cleaner (5). [*3]
the frame lock bar. 7. Disconnect connector E15 (6).
k Lower the work equipment to the ground 8. Disconnect wiring harness (7).
completely and stop the engine. Apply the 9. Remove air cleaner bracket (8).
parking brake and put the blocks under the
wheels.
k Disconnect the negative terminal (–) of the
battery before starting with the work.
1. Remove the radiator assembly, referring to

“Removal and installation of radiator assembly”.
q Overall view of machine right side
2. Open the bulkhead cover to remove cover (1)

of the air cleaner.
10. Remove bracket and heat insulation cover (9)

assembly.
50-201 2 WD600-6
Removal and installation of engine assembly SEN05142-01
11. Disconnect drive shaft (10). [*4] 16. Disconnect fuel supply hose (16).
a Remove the bottom mounting bolt as
shown below.
1) Pull pin (11) out of a location near the
engine mount, which is situated in the
front right side, and then push in forcing
screw (B).
2) Turn forcing screw (B) for deburring and
then remove the bottom mounting bolt of
the drive shaft.
17. Disconnect connector EP1 (17) and EP2 (18).

18. Disconnect clamps (19) and (20).
19. Disconnect 2 fuel hoses (21).

13. Disconnect connector E16 (13).
14. Loosen the adjustment bolt of air conditioner
compressor (14) and then remove air condi-
tioner compressor belt (15). [*5]
15. Remove air conditioner compressor (14).
a Don't disconnect the air conditioner hose.
q Left side
20. Disconnect torque converter cooler (TC) cool-
ant tubes (22) and (23).
a Connection: O-ring
21. Disconnect coolant tube (24).
a Replacement of gasket (G)
22. Disconnect heater hose (25).
WD600-6 50-201 3
SEN05142-01 Removal and installation of engine assembly
23. Disconnect starting motor terminal (26). a Front right side and left side lifting hooks
24. Disconnect connector ER1 (27). are provided in the bottom.
25. Disconnect connector ER2 (28).
26. Disconnect connector ER3 (29).
27. Disconnect wiring harnesses (30).
28. Disconnect grounding wire ER06 (31).
29. Disconnect engine grounding wire (32).
30. Remove engine mount bolts (33) and (34). [*6]
31. Lift and remove engine assembly (35), using T-

shaped lifting tool [1].
a Confirm that the wirings and hoses are
disconnected properly, and sling the
engine assembly slowly.
4 Engine assembly: 3,200 kg
a F: Rear side lifting hook
50-201 4 WD600-6
Removal and installation of engine assembly SEN05142-01
Installation
q Carry out installation in the reverse order to
removal.
[*1]
3 Air hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*2]
3 Komaclone tube assembly hose clamp:
5.9 ± 0.49 Nm {0.6 ± 0.05 kgm}
[*3]
3 Air cleaner band:
12.8 – 17.7 Nm {1.3 – 1.8 kgm}
[*4]
3 Drive shaft assembly mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
[*5]
a Adjust the air conditioner compressor belt ten-
sion, referring to “Adjusting air conditioner
compressor belt tension” in Testing and adjust-
ing.
[*6]
3 Engine mount bolt:
824 – 1030 Nm (84 – 105 kgm)
Target: 927 Nm (94.5 kgm)
q Refilling with coolant

Add coolant through the coolant filler to the
specified level. Run the engine to increase
coolant temperature and then confirm the cool-
ant level again.
5 Coolant: 160 l
WD600-6 50-201 5
SEN05142-01 Removal and installation of radiator assembly
Removal and installation of 7. Disconnect connector G05 (5) and disconnect

radiator assembly 1
the clip of the wiring harness.
Removal
k Park the machine on flat ground and set the
safety bar to the frame.
completely and stop the engine. Apply the
wheels.
k Loosen the filler cap of the hydraulic tank
gradually to release the residual pressure
from the hydraulic tank.
8. Disconnect right and left chains (6).

9. Disconnect hoses (7) and (8).
10. Remove reservoir tank (9).
2. Drain the engine coolant.

6 Coolant: 160 l
3. Remove the engine hood and covers, referring 11. Disconnect hoses (10).
to “Removal and installation of engine hood 12. Remove covers (11) and (12).
assembly”. a Take care in this operation not to damage
the aftercooler core.
5. Disconnect cover (3).
6. Disconnect 2 hoses (4) from the reservoir tank.
50-201 6 WD600-6
Removal and installation of radiator assembly SEN05142-01
13. Remove right and left side bars (13). 17. Disconnect fan drain hose (19), fan inlet hose
14. Remove cover and frame assembly (14). (20) and fan outlet hose (21).
a Take care in this operation not to damage 18. Remove clamp (22).
the aftercooler core.
19. Disconnect connectors G06 (23) and GR1 (24)

15. Disconnect air conditioner hose clamps (15) situated in the rear left side of the radiator.
from radiator guard (16). 20. Disconnect clamp (30).
a BB: Back buzzer
16. Open radiator grille (17) and remove 3 fan

guards (18). 21. Remove 3 mounting bolts of left side and then
open fan motor and support assembly (25).[*1]
WD600-6 50-201 7
22. Fix fan motor and support assembly (25) in the 25. Lift and float the radiator guard and fan assem-
manner shown below. bly (28).
1) Remove pin (51) from the hinged portion a (B): The mounting bolt position in the rear
of fan motor and support assembly (25). side of the radiator.
4
2) Remove lock pin (52) and then fix the
Radiator guard and fan assembly:
assembly to the bracket (BKT) using lock
pin (52). 650 kg
26. Disconnect sponge (29).
23. Remove right and left mounting bolts (26).

a Leave a counter mark (M) to the position.
24. Remove the cover of section (A) and remove
right and left mounting bolts (27).
a The mounting bolt is provided in the rear
side of the radiator, too.
50-201 8 WD600-6
Removal and installation of radiator assembly SEN05142-01
27. Lift radiator guard and fan assembly (28) 34. Disconnect connectors (36) from the radiator
slowly. outlet.
28. Take out radiator guard and fan assembly (28) a Replacement of gasket (G)
while avoiding contact against tube (C) of the a When disconnecting the outlet at the con-
aftercooler. nection with radiator hose (38) (it takes
more than an hour)
1) Loosen right and left side clamps (37) and
then push radiator hose (38) all the way in
the radiator. [*5]
a Hose (38) is disconnected later (as
the radiator assembly is lifted up).
35. Disconnect air conditioner condenser assem-

bly (40) directing bracket (39) outward.
a Remove the air conditioner hose clamp
prior to the above operation.
36. Lift radiator assembly (41) temporarily and
remove right and left side mounting bolts (42).
[*6]
37. Disconnect hose (38) (noted in the foregoing)
29. Disconnect aeration hose (30). while the radiator assembly being lifted up.
30. Loosen radiator hose clamps (31) and (32). [*2]
31. Loosen air hose clamp (33). [*3]
32. Disconnect air tube (34).
33. Remove air hose (35). [*4]
WD600-6 50-201 9
38. Float radiator assembly (41). Installation

4
Radiator assembly: 450 kg
removal.
39. Disconnect radiator hose (43).
40. Take out radiator assembly (41). [*1]
a AC: Aftercooler 3 Fan motor and support assembly mounting
a Take care in this operation not to damage bolt: 245 – 309 Nm {25 – 31.5 kgm}
the core. a Make sure that clearance (a) between the
shroud and fan is uniform (Standard clearance:
6 mm). When not uniform, loosen mounting
bolts (12) to adjust the clearance.
3 Mounting bolt (12):
490 – 608 Nm {50 – 62 kgm}
[*2]
3 Radiator hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*3]
3 Air hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*4]
3 Air hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*5]
3 Radiator hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*6]
3 Radiator assembly (28) mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
q Refilling with coolant

Add coolant through the coolant filler to the
specified level. Run the engine to increase
coolant temperature and then confirm the cool-
ant level again.
5 Coolant: 160 l
50-201 10 WD600-6
Removal and installation of air aftercooler SEN05142-01
Removal and installation of air 6. Push up fender (6).

a Fender: If equipped
aftercooler 1
7. Open doors (7) and (8).
Removal
k Park the machine on flat ground and set the
safety bar to the frame.
wheels.
8. Remove bar (9).

9. Remove mounting bolts (10).
10. Slowly take out air aftercooler assembly (5)
through the side face while using care not to
damage air conditioner hose (H).
a Take care in this operation not to damage
the core.
a Take care in this operation not to damage
the radiator guard (G).
2. Disconnect reservoir tank hose (2).

3. Disconnect air hose (3). [*1]
4. Remove air tube and bracket assembly (4). [*2]
5. Lift air aftercooler assembly (5) temporarily.
4 Air aftercooler assembly: 45 kg
Installation
removal.
[*1], [*2]
3 Air hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
WD600-6 50-201 11
SEN05142-01 Removal and installation of cooling fan and fan motor assembly
Removal and installation of cooling 6. Remove lock plate (9). [*2]

fan and fan motor assembly 1
7. Remove fan mounting nut (10) to remove cool-
ing fan (11). [*3]
Removal
k Stop the machine on level ground and set
the frame lock bar.
wheels.
1. Open grille (1) to take out fan guard (2).
8. Remove 4 mounting bolts to remove fan motor

assembly (7) (noted in the foregoing).
2. Disconnect connector G07 (3).

a Disconnect the wiring harness clamp.
3. Disconnect IN port hose (4), Dr port hose (5)
and OUT port hose (6) from fan motor assem-
bly (7).
a Prepare an oil pan and a detent plug since
the above operation allows oil to flow out.
4. Disconnect the top and bottom fan guards from
radiator guard.
5. Remove 3 mounting bolts of left side and then
open fan motor and support assembly (8). [*1]
a Fix it using the lock pin.
50-201 12 WD600-6
Removal and installation of cooling fan and fan motor assembly SEN05142-01
Installation
removal.
[*1]
3 Fan motor and support assembly (8) mount-
ing bolt: 245 – 309 Nm {25 – 31.5 kgm}
a Make sure that clearance (a) between the
shroud and fan is uniform (Standard clearance:
6 mm). When not uniform, loosen mounting
bolts (12) to adjust the clearance.
490 – 608 Nm {50 – 62 kgm}
[*2]
a It is not allowed to turn the hole alignment side
on lock plate (9) to the loosening side.
[*3]
3 Mounting nut:
441 – 539 Nm {45.0 – 55.0 kgm}
q Refilling with oil (Hydraulic oil tank)

Add oil through oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.
WD600-6 50-201 13
SEN05142-01 Removal and installation of damper assembly
Removal and installation of

damper assembly 1
Removal
the frame lock bar.
wheels.
1. Remove the engine hood and covers, referring

to “Removal and installation of engine hood 10. Remove bracket (10) and heat insulation cover
assembly”. (9) assembly.
2. Open the bulkhead cover to remove cover (1) 11. Remove bracket (10).
of the air cleaner.
12. Referencing “Removal and installation of

3. Remove air hose (2). [*1] hydraulic pump assembly”:
4. Remove komaclone hose and tube assembly 1) Remove steering and fan pump assembly
(3). [*2] (11) and work equipment hydraulic pump
5. Disconnect dust indicator hoses (4). assembly (12).
6. Remove air cleaner (5). [*3] 2) Remove drive shaft (13). [*4]
8. Disconnect wiring harness (7). 4 Drive shaft: 30 kg
9. Remove air cleaner bracket (8).
50-201 14 WD600-6
Removal and installation of damper assembly SEN05142-01
13. Lift and remove flywheel assembly (14). [*5] Installation

4
Flywheel assembly: 45 kg
removal.
14. Lift and remove damper cover and shaft
assembly (15). [*6] [*1]
3
4
Air hose clamp:
Damper cover and shaft assembly: 70 kg
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*2]
5.9 ± 0.49 Nm {0.6 ± 0.05 kgm}
[*3]
3 Air cleaner band:
12.8 – 17.7 Nm {1.3 – 1.8 kgm}
[*4]
3 Drive shaft assembly mounting bolt:
107 – 127 Nm {10.9 – 13.0 kgm}
[*5]
15. Lift and remove damper body assembly (16) 3 Flywheel mounting bolt:
from the flywheel (FW). [*7] 98 – 123 Nm {10 – 12.5 kgm}
4 Damper body assembly: 80 kg [*6]
2 Mating face: Gasket sealant (LG-1)
3 Damper cover and shaft assembly (15)
mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
1. Remove plug (17) situated at the bottom of the
machine and plugs (18) situated on the side
face, and then fill ENS grease through plug
hole (17) until the grease level comes to the
bottom of plugs (18).
2 ENS grease:
427-12-11871 (GREASE) (250 ± 30 cc)
2. Install plugs (17) and (18).
3 Plug: 5.9 – 11.8 Nm {0.6 – 1.2 kgm}
[*7]
3 Damper body assembly mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
WD600-6 50-201 15
SEN05142-01 Disassembly and assembly of damper assembly
Disassembly and assembly of 4. Invert cover (7) to remove oil seal (8).
damper assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
6 793-612-1120 Push tool t 1
A
7 793T-612-1310 Push tool q 1 N Q
a ENS grease:
427-12-11871 (GREASE) (contained in 2-kg
can) should be used. 5. Using push tool [11], remove bearing (9),
a Before using ENS grease, make sure other spacer (10) and bearing (11) from cover (7).
greases are completely cleaned off. It is pro-
hibited to mix ENS grease with other greases.
Disassembly
Damper cover and shaft assembly (1)
1. Remove oil seal (2) from damper cover and
shaft assembly (1).
2. Remove snap rings (3) and (4).
3. Using blocks [1] and push tool [2], remove shaft

(6) from damper cover and shaft assembly (1).
a Cover the floor with wood chips so that the
shaft may not be damaged should it fall off.
50-201 16 WD600-6
Disassembly and assembly of damper assembly SEN05142-01
Damper body assembly Assembly

6. Remove the flange mounting bolt and then Damper body assembly
remove flange (13), 4 small rubbers (14), 4 a See the figure to the left.
large rubbers (15), inner body assembly (16), 1. Set outer body (17) to flange (19) aligning the
outer body (17) and flange (19), in this order. mounting bolt hole.
a Don't remove spacer (12) and plug (18) 2 Mating face: Gasket sealant (LG-1)
from inner body (16). They must be handled 2. Set inner body assembly (16) aligning the lever
as integral part of inner body assembly. tip of inner body assembly (16) to the mark (M)
on outer body (17).
a The mark (M) is provided at 4 points on
the circumference on the both sides of the
outer body.
3. Assemble 4 small rubbers (14) and 4 large rub-
bers (15) to the positions indicated on the fig-
ure.
2 Before assembling the rubbers, apply
the entire face of the rubbers, outer
per iphery of inner body and inner
peri phery of outer bo dy with E NS
grease (G2-U-S).
2 After assembling the rubbers, fill each of
4 clearances (P) between the rubbers
and inner body with 100 cc of ENS
grease.
4. Install flange (13).
2 Mating face: Gasket sealant (LG-1)
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
2 Fill the top face (shaft insertion portion)
of s pac er ( 1 8) wi th 3 0 c c of E NS
grease.
q View from cover (13).
WD600-6 50-201 17
SEN05142-01 Disassembly and assembly of damper assembly
Damper cover and shaft assembly 11. In the same way, press fit bearing (11) to
5. Install plug (20), 3 plugs (21) and breather (22) damper cover (7).
to the damper cover (7). a When press fitting bearing (11), make sure
3 Plug (21): that inner diameter of spacer (10) and
5.9 – 11.8 Nm {0.6 – 1.2 kgm} bearing (11) is aligned.
3 Plug (22):
2.9 – 5.9 Nm {0.3 – 0.6 kgm}
12. Invert damper cover (7).
13. Using tool A7, press fit oil seal (8) to cover (7).
6. Set tool A7 on the press bench and then set a Overall length: 125 mm
damper cover (7) on tool A7. 2 Seal lip surface: ENS grease
a Use care in this operation not to incline the a Seal driven depth: (a) = 5 ± 0.5 mm
damper cover. 2 Space between bearing and oil seal
(indicated as T): ENS grease (20 ml)
7. Apply adhesive to the outer periphery of bear-

ing (9).
2 Outer periphery of bearing:
Locktite No. 648
8. Using push tools A6 and A7, press fit bearing
(9) to damper cover (7).
a Overall length: 150 mm
2 Ball of bearing (9):
To be filled with ENS grease
9. Using push tools A6 and A7, press fit bearing
(9) to damper cover (7).
a Using the clearance gauge, make sure the
clearance is within the standard value.
Clearance (b): 0 – 0.6 mm
10. Install spacer (10) aligning it to the bearing
inner diameter.
50-201 18 WD600-6
Disassembly and assembly of damper assembly SEN05142-01
14. Press fit shaft (6) from the top of cover (7) set-
ting push tool A6 at the bottom.
2 Inner periphery of bearing:
Locktite No. 648
2 Spline of shaft: Molybdenum disulfide-
based desiccating and lubricating agent
(LM-P)
Sumic o Lubric ant Low C o ll Dry
Spray or equivalent
a Leave the spline as is for 2 to 3 minutes
after applying the above agent.
a Before press fitting, remove foreign sub-
stances deposited on the outside of the
shaft and inside of the bearing.
15. Invert the damper cover and shaft assembly

and install snap rings (3) and (4).
2 Ball of bearing (11):
To be filled with ENS grease
2 Space between bearing and oil seal
(indicated as U): ENS grease (60 ml)
16. Set the damper cover and shaft assembly on
the blocks [8].
17. Using push tools [4], [9] and [10], press fit oil
seal (2).
a Oil seal driven depth:
± 0.5 mm from the damper cover end face
2 Oil seal lip surface: ENS grease
WD600-6 50-201 19
SEN05142-01 Removal and installation of fuel tank assembly
Removal and installation of fuel 6. Open right and left covers (8) as well as cover
tank assembly 1
(9).
Removal
wheels.
1. Drain fuel from the tank.

6 Fuel tank: 133 l (When filled up)
7. Remove right and left oil cooler (OC) mounting
bolts (10).
2. Disconnect wiring connector R16 (1) situated a Don't disconnect the oil hose and coolant
in the front side of the fuel tank. hose from the oil cooler (OC).
3. Disconnect clamps (2).
4. Disconnect fuel supply hose (3) and fuel return 8. Disconnect clamps (11) of the blow-by hose
hoses (4) and (5) in the upper right of the fuel tank. (BH).
a Before disconnecting, attach them a tag or 9. Disconnect clamps (12) and (13) of the muffler
equivalent to make the later position iden- drain hose (MD).
tification easier.
5. Disconnect hose clamp (7).
50-201 20 WD600-6
Removal and installation of fuel tank assembly SEN05142-01
10. Disconnect radiator drains (15). Installation

removal.
[*1]
3 Fuel tank mounting bolt
1,520 – 1,910 Nm {155 – 195 kgm}
Target: 1,720 Nm {175 kgm}
[*2]
a Adjust the shim so that the clearance on the
fuel tank mounting surface may become 0.5
mm or less.
11. Disconnect engine drain (16). q Refilling with oil (Hydraulic oil tank)
12. Disconnect bracket (17). Fill oil from the oil filler.
13. Remove oil filler port (18).
14. Lift fuel tank (19) temporarily.
15. Remove 6 right and left mounting bolts (20). [*1]
a Shims are provided for 6 right and left
mounting bolts (20). Confirm their num-
bers and positions. [*2]
16. Lift and remove fuel tank (13).
4 Fuel tank assembly: 430 kg (Fuel not
included)
WD600-6 50-201 21
SEN05142-01 Removal and installation of engine hood assembly
Removal and installation of 4. Remove step (6) on the right side of the
engine hood assembly 1
machine body and then install it on boss (A) of
the left side.
Removal a Use it as the step when removing covers
k Stop the machine on level ground and set (7) and (8).
the frame lock bar.
wheels.
1. Remove pre-cleaner (1) and muffler (2).

2. Remove hoods (3) and (4).
a A tapped hole for lifting is provided in the
four corners.
4 Hood (3): 35 kg
4 Hood (4): 45 kg
5. Remove covers (7) and (8).

a Hook (F) is provided at the top of the rear
side of cover (7). The pin (P) situated at
the bottom of the side hood (SH) protect
cover (7) from falling off as the mounting
bolt is removed.
50-201 22 WD600-6
Removal and installation of engine hood assembly SEN05142-01
6. Push up fender (10). Installation

a Fender: If equipped q Carry out installation in the reverse order to
7. Remove engine right side door (11). removal.
4 Engine right side door: 45 kg
a Just like cover (7), cover (12) is also pro-
tected fr om falling off as the bolt is
removed.
9. Disconnect air conditioner hose clamps (13)

from right side hood (14).
10. Remove stay (15).

11. Lift and remove side hood (16).
4 Side hood (one side): 55 kg
a Remove the right side, too.
WD600-6 50-201 23
SEN05142-01 Removal and installation of bulkhead assembly
Removal and installation of 3. Push up fender (5).

bulkhead assembly 1
4. Lift and remove handrail and step assembly (6).
Removal 5. Remove cover (7).
k Stop the machine on level ground and set a Hook (F) is provided at the top of the rear
the frame lock bar. side of cover (7). The pin (P) situated at
k Lower the work equipment to the ground com- the bottom of the side hood (SH) protects
pletely and stop the engine. Apply the parking cover (7) from falling off as the mounting
brake and put the blocks under the wheels. bolt is removed.
k Collect the air conditioner refrigerant
(R134a) from air conditioner circuit in
advance.
a Ask professional traders for collecting and fill-
ing operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the
atmosphere.
k If refrigerant gas (R134a) gets in your eyes,

you may lose your sight. Accordingly, put
on protective goggles while you are collect-
ing the refrigerant (R134a) or filling the air
conditioner circuit with the refrigerant
(R134a). Collecting and filling work must be
conducted by a qualified person.

four corners.
4 Hood (3): 35 kg
4 Hood (4): 45 kg

7. Remove step (9).
50-201 24 WD600-6
Removal and installation of bulkhead assembly SEN05142-01
8. Remove cover (10). 15. Open the engine right side door.
16. Disconnect air conditioner hose (16). [*1]
a The hose with larger diameter
9. Remove clamp (11).

10. Lift and remove handrail and step assembly
(12). 17. Disconnect air conditioner hose clamps (17)
11. Remove handrail mounting bolt (13). from right side hood (18).
12. Lift and remove handrail and ladder assembly 18. Lift and remove right side hood (18).
(14). a Remove the left side, too.
4
13. Remove step (40) on the right side of the
Side hood (one side): 55 kg
machine body and then install it on boss (A) of
the left side. a Haul in air conditioner hose (16) on the
a Use it as the step when removing cover engine side to the cab side.
(15).
a Just like cover (7), cover (15) is also pro-
tected fr om falling off as the bolt is
removed.
WD600-6 50-201 25
SEN05142-01 Removal and installation of bulkhead assembly
19. Disconnect air conditioner hose clamps (19). 29. Lift and remove bulkhead assembly (33). [*2]
4
20. Disconnect air conditioner hose (20).
Bulkhead assembly: 220 kg
21. Disconnect receiver dryer and bracket assem-
bly (21) from the bulkhead assembly.
22. Disconnect clamps (22) and (23).
23. Disconnect washer tank (24).
a Disconnect connectors BL1 and BL3 from
the back.
a Haul in air conditioner hose (20) from the
engine side.
24. Remove air cleaner cover (25).
25. Disconnect hose clamps (26).
26. Disconnect dust indicator hose (27).
27. Remove right and left brackets (34).
50-201 26 WD600-6
Removal and installation of bulkhead assembly SEN05142-01
Installation
removal
[*1]
a When installing the air conditioner circuit
hoses, use care so that dirt, water, may not
enter.
a Before tightening, make sure O-ring (70) is
provided in the air conditioner hose piping con-
nection.
a Check that there is no defect or deterioration
on the O-ring.
a When connecting the refrigerant piping, coat
the O-ring with compressor oil for refrigerant
(R134a) (DENSO: ND-OIL8, VALEO THER-
MAL SYSTEMS: ZXL100PG (PAG 46 or
equivalent)).
3 Mounting bolt: 8 – 12 Nm {0.8 – 1.2 kgm}
[*2]
3 Bulkhead assembly mounting bolt:
455 – 565 Nm {46.5 – 58 kgm}
q Filling of air conditioning gas

Fill the air conditioner circuit with refrigerant
(R134a).
a Filling quantity: 850 ± 50 g
WD600-6 50-201 27
SEN05142-01
WD600-6 Wheel dozer

©2017 KOMATSU
All Rights Reserved
50-201 28
SEN05143-02
WHEEL DOZER
WD600-6
WD600-6 55001 and up

Removal and installation of fuel supply pump assembly ................................................................................ 2
Removal and installation of cylinder head assembly ...................................................................................... 8
Removal and installation of fuel injector assembly ....................................................................................... 24
Removal and installation of engine front seal ............................................................................................... 28
Removal and installation of engine rear seal ................................................................................................ 31
WD600-6 50-202 1
SEN05143-02 Removal and installation of fuel supply pump assembly
Removal and installation of fuel 3. Push up fender (5).

supply pump assembly 1
4. Remove door (6).
Removal 5. Remove cover (7).
k Stop the machine on level ground and set a Hook (F) is provided at the top of the rear
the frame lock bar. side of cover (7). The pin (P) situated at
k Lower the work equipment to the ground the bottom of the side hood (SH) protect
completely and stop the engine. Apply the cover (7) from falling off as the mounting
parking brake and put the blocks under the bolt is removed.
wheels.
k Disconnect the negative terminal (–) from
the battery before starting with the work.
a The work of aligning No.1 or No.6 cylinder

compression top dead center is not necessary.
a The special tool for pulling the gear out is not
necessary.

four corners.
4 Hood (3): 35 kg
4 Hood (4): 45 kg
6. Remove stay (8).

a FSP: Fuel supply pump
50-202 2 WD600-6
Removal and installation of fuel supply pump assembly SEN05143-02
7. Remove wiring harness cover (9).

a Use care so that the washer may not fall
off.
8. Disconnect the clamp of breather tube (10)
and the fixing bolt (10-1).
9. Disconnect the breather hose (10-2) from Y
side, too.
10. Remove mounting bolts (11) and then lift
breather tube assembly (12) slightly.
11. Remove wiring harness cover (13).
a Use care so that the washer may not fall
off.
a Care must be exercised in removing cover
(13). Removing cover (13) forcibly without
slightly lifting breather tube assembly (12) 12. Remove bracket (14).
may generate cracks in (B) portion since a 7 mounting bolts
breather (12) is made of plastics. 13. Disconnect connector PFUEL (15).
a An O-ring is installed in breather (12)
installation position.

15. Remove high-pressure piping cover (17).
· Y View · Z View
WD600-6 50-202 3
16. Disconnect connectors INJ (18) and G (19). 24. Disconnect tube (31). [*2]
17. Disconnect connectors PCV1 (20) and PCV2 a Prepare an oil pan since oil flows out dur-
(21). ing this operation.
25. Remove 3 clamps (32).
26. Remove hose (33). [*3]
27. Remove tube (34). [*4]
28. Disconnect clamps (35), (36).
18. Remove clamps (22) to (24).

20. Remove high-pressure pipings (27).
a Before removing the tube, clean adjacent
sections thoroughly so that foreign sub- 29. Remove tube (37).
stances may not enter the supply pump 30. Remove bracket (38).
and common rail. 31. Remove fuel supply pump assembly (39).
21. Remove bracket (28).
22. Remove tube (29). [*1]

23. Disconnect connector G (30).
50-202 4 WD600-6
32. Remove the followings from fuel supply pump Installation

assembly (39). 1. Install the followings to fuel supply pump
1) Oil tube (40) assembly (39).
2) Plate (41) 1) Key (47)
3) Overflow pipe adapter (42) 2) Coupling (46)
3) Washer (45)
4) Nut (44)
3 Nut (44):
176 – 196 Nm{18 – 20kgm}
4) Nut (44)
5) Washer (45)
6) Coupling (46)
7) Key (47)
5) Plate (41)
6) Oil tube (40)
a Exchange gaskets (GA) and (G10).
q GA: Accessory gaskets of the
supply pump.
q G10: Part number is 07005-
01012.
7) Overflow valve (43)
3 Plate (41) mounting bolt:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
3 Oil tube (40) joint bolt:
Top: 7.9 – 12.7 Nm {0.8 – 1.3 kgm}
Bottom: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3 Overflow valve (43):
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
WD600-6 50-202 5
2. Assemble the fuel supply pump assembly by

aligning (A) and (AA) at the position where a
spline tooth is missing.
High-pressure piping
k When handing the high-pressure pipe and
clamp, pay attention the following.
q It is strictly prohibited to bend the high-
pressure piping to use it again or using it
in other locations.
q Install the specified clamp securely in the
specified position with the specified
torque.
q Don't apply lubricant and the like to the
high-pressure piping sleeve nut and the
threaded portion of the mating side.
a Axial force in the tightening can be
excessive, potentially damaging
the high-pressure piping.
k Before installing the high-pressure piping,
check it for the following defects. If there is
3. Install fuel supply pump assembly (39). any of these defects, it can cause fuel leak-
3 Fuel supply pump mounting bolt: age. Accordingly, replace the high-pressure
59 – 74 Nm {6 – 7.5 kgm} piping.
3 Bracket (38) mounting bolt: q Check the taper seal of the connecting
59 – 74 Nm {6.0 – 7.5 kgm} part (Part (a): Part of 2 mm from the end)
4. Install oil tube (37). for visible lengthwise slit (b) and dent (c).
3 Oil tube (37) joint bolt: q Check part (d) (end of the taper seal: Part
9.8 – 12.7 Nm {1.0 – 1.3 kgm} at 2 mm from the end) for stepped-type
a Exchange 4 gaskets (G). wear (fatigue) which your nail can feel.
50-202 6 WD600-6
5. Tighten high-pressure pipings (27) temporarily. k Make sure that a clearance of 10 mm mini-
6. Tighten clamps (22) to (24) temporarily. mum is provided between the high-pres-
7. Tighten high-pressure pipings (27) perma- sure piping and adjacent wiring harness. If
nently. not, secure the clearance by adjusting the
3 High-pressure piping sleeve nut: wiring harness position.
39.2 – 44.1 Nm {4.0 – 4.5 kgm}
8. Tighten clamps (22) to (24) permanently. q Bleeding air
3 Clamping bolt: Bleed air from the fuel system, referring to
9.8 ± 1.0 Nm {1 ± 0.1 kgm} “Bleeding air from fuel system” in Testing and
9. Tighten bracket (28) permanently. adjusting.
10. Install covers (25) and (26).
q Carry out the succeeding installation in the

reverse order of removal.
[*1]
3 Tube (29)
Joint bolt (Overflow valve):
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
Joint bolt (Supply pump side):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
Sleeve nut (Fuel block side):
24 – 27 Nm {2.4 – 2.7 kgm}
[*2]
3 Tube (31)
Joint bolt (Supply pump side):
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
3 Tube (31) sleeve nut:
43 – 47 Nm {4.4 – 4.8 kgm}
[*3]
3 Tube (34) joint bolt (Filter head side):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3 Joint bolt (Supply pump side):
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
[*4]
3 Tube (35) joint bolt (Supply pump side):
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
43 – 47 Nm {4.4 – 4.8 kgm}
WD600-6 50-202 7
SEN05143-02 Removal and installation of cylinder head assembly
Removal and installation of 4. Remove air hose (2). [*1]

cylinder head assembly 1
5. Remove komaclone hose and tube assembly
(3). [*2]
Special tools 6. Disconnect dust indicator hoses (4).
7. Remove air cleaner (5). [*3]
New/Remodel
Necessity
Sym- 9. Disconnect wiring harness (7).
Part No. Part name
Sketch
bol 10. Remove air cleaner bracket (8).
Q'ty
795-799-5410 Adapter t 1
1
795-799-5420 Remover t 1
A
2 795T-675-1110 Socket q 1 N Q
8 790-331-1120 Wrench (angle) q 1
Removal
the frame lock bar.
wheels.
1. Drain the engine coolant.

6 Coolant: 160 l

to “Removal and installation of engine hood
assembly”.
3. Open the bulkhead cover to remove cover (1)

of the air cleaner.
11. Remove bracket and heat insulation cover (9)
assembly.
12. Disconnect muffler drain tube (10).
50-202 8 WD600-6
Removal and installation of cylinder head assembly SEN05143-02
13. Remove flange (11). 15. Disconnect fuel hose (13).

16. Disconnect tubes (14) and (15). [*4]
17. Remove filter assembly (16).
14. Lift and remove muffler (12).

4 Muffler assembly: 100 kg
18. Remove fuel tube clamps (17).
19. Remove fuel tubes (18). [*5]
20. Disconnect fuel tube (19).
21. Disconnect connector TOIL (20).
a Pull out connector by driving lock (L)
upward.
22. Disconnect connector POIL (21) in the follow-
ing manner.
1) When disconnecting connector POIL (21),
slide lock (L1) rightward.
2) Pull out connector POIL (21) while push-
ing lock (L2).
23. Remove tube assembly (22).
q Overall view of right side
WD600-6 50-202 9
24. Lift and remove filter assembly (23). 27. Remove turbocharger coolant tube assembly
(26). [*7]
28. Remove turbocharger lubrication tubes (27)
and (28).
29. Remove turbocharger coolant tube (29).
30. Disconnect exhaust tube (30).
25. Disconnect wiring harnesses (24).
26. Lift and remove air tube and bracket assembly

(25). [*6]
31. Disconnect connectors V30 (31-1) and V29

(31-2).
a Push the lock when disconnecting them.
50-202 10 WD600-6
32. Lift and remove turbocharger and exhaust 37. Disconnect 6 injector connectors (38).
manifold assembly (32). [*8] 38. Disconnect connector CN6 (39).
4
39. Remove wiring harness bracket (40).
Turbocharger and exhaust manifold
assembly: 120 kg
40. Disconnect high-pressure piping clamps (41)

to (43).
33. Remove breather and tube assembly (33). 41. Remove tubes (44) to (46). [*9]
34. Remove wiring harness covers (34) and (35). 42. Remove brackets (47) and (48).
35. Disconnect connector (36). 43. Disconnect high-pressure piping clamps (49)
36. Remove high-pressure piping cover (37). and (50).
44. Remove fuel tube (51). [*10]
WD600-6 50-202 11
45. Remove clamp (52). 54. Disconnect connectors PCV1 (60) and PCV2
46. Remove covers (53) and (54). (61).
47. Loosen clamps (55) and (56). 55. Disconnect wiring harness clamps (62).
48. Remove high-pressure piping tube assembly (57). 56. Remove tubes (63) to (65). [*11]
49. Disconnect connector (58). 57. Remove fuel supply pump assembly (66).
50. Disconnect fuel hose (120). a Do not loosen overflow valve (ofv).
51. Disconnect connector PIM (121). a Do not remove oil tube (t) and plate (p).
52. Disconnect wiring harness clamp (59) from 58. Disconnect clamps (67).
rear side of the fuel supply pump. 59. Disconnect tubes (68). [*12]
53. Disconnect the connector from the bottom of a The corrosion resistor in photo may not be
clamp (59). installed by models.
50-202 12 WD600-6
60. Disconnect sleeves (69). 64. Disconnect sleeve nut (75) on the high-pres-
61. Remove high-pressure piping (70). sure piping injector side.
a Tool A2 allows implementing this work
from the side face rather than from the
top.

63. Remove 4 mounting bolts (73) from the radia-
tor side of intake manifold assembly (72).
a Tool A2
WD600-6 50-202 13
65. Remove high-pressure pipings (74). 71. Lift and remove air intake manifold assembly
66. Lift air intake manifold assembly (72) tempo- (72).
4
rarily.
Air intake manifold assembly: 110 kg
a Using eyebolt [1] and lifting tool [2], lift the
assembly temporarily on to the mounting
bolt hole of bracket (71) (noted in the fore-
going).
67. Remove the mounting bolts of air intake mani-
fold assembly (72).
68. Install guide bolts [3].
a Use the filter mounting bolt as the guide
bolt.
a The convexed tube bites into the inner
face of the connector. Thus, care must be
exercised in using the guide bolt to avoid
damaging the tube. (See the following
section)
69. Remove all mounting bolts of air intake mani-
fold assembly (72). 72. Remove brackets (77).
73. Remove turbocharger lubrication tube (78) and
coolant tube (79).
74. Remove air vent tube (80).
70. Remove connector (76).

a Take care a convexed tube bites into the
inner face of the connector (indicated as
A).
50-202 14 WD600-6
75. Remove cylinder head cover (81).

a Check that you can move the rocker arm 84. Using tool A1, remove fuel injector assembly
of the No.1 or No.6 cylinder with the fin- (92).
gers by the distance of the valve clear- a Remove the assembly by hitching tip of
ance. tool A1 on hole (H) of the fuel injector.
a Do not grip the solenoid valve at the top of
the injector to pull off the injector with pliers.
76. Remove terminal mounting nuts (82).

a Loosen the nuts alternately.
77. Remove wiring harness assembly mounting 85. Lift and remove cylinder head assembly (93).
4
bolts (83) and spacer (84).
Cylinder head assembly: 50 kg
78. Loosen locknut (85) and then loosen adjust-
ment screw (86) thoroughly. 86. Remove the cylinder head gasket.
79. Remove rocker arm and shaft assembly (87).
80. Remove push rods (88).

81. Remove crosshead assembly (89).
82. Remove rocker housing (90).
83. Remove fuel injector holder (91).
WD600-6 50-202 15
Installation
Cylinder head assembly
1. Install the cylinder head gasket.
2. Lift and install cylinder head assembly (93).
4 Cylinder head assembly: 50 kg
a Check the punch mark on the mounting
bolt head. If 5 marks are punched, replace
it with a new one without using it.
a Tighten the mounting bolts in the following
order.
2 Cylinder head assembly mounting bolt:
Molybdenum disulfide lubricant (LM-
P)
a
3 Cylinder head mounting bolts (1 – 7):
After tightening the main bolt, apply a
punch mark (a) on its head (this mark shall
1st time: 245 ± 9.8 Nm {25 ± 1 kgm}
not be applied to a new bolt).
2nd time: 382.5 ± 9.8 Nm {39 ± 1 kgm}
3rd time: 90 – 120° retightening
a For retightening, use tool A8 (see Special
tool list). When not using tool A8, apply a
marking to the cylinder head and bolt with
a felt pen and then retighten the bolt by
90° – 120° (target is 120°).
3 Cylinder head assembly mounting bolts
(8 and 9):
93.2 – 103 kgm {9.5 – 10.5 kgm}
50-202 16 WD600-6
Fuel injector 6. Install push rods (88).

a Make sure that inside of the injector hole is a Check that the push rod end is securely
free from dusts. placed in the cam follower socket.
2 O-ring: Engine oil (EO30-DH) 7. Apply gasket sealant and then install rocker
3. Assemble gasket (94) and O-rings (95) and housing (90).
(96) to fuel injector (92). 2 Rocker housing: Gasket sealant (LG-7)
a Use care not to install O-ring (95) in a Diameter of the gasket sealant line shall
groove (A) at the center. be 2 to 3 mm and it should be applied
4. Insert fuel injector (92) to adapter (97) and along the housing groove as shown below.
injector holder (91). a Do not forget to install O-ring (OR).
5. Attach spherical washer (100) to bolt (99) and 3 Rocker housing mounting bolt:
then tighten injector holder (91) temporarily. 78.4 – 93.2 Nm {8.0 – 9.5 kgm}
a Tightening of injector holder (91) is done 8. Install crossheads (89).
permanently after installing the intake
manifold and tightening the high-pressure
piping temporarily.
2 Spherical washer:
Engine oil (EO30-DH)
WD600-6 50-202 17
9. Adjust the crosshead in the following procedure. a After tightening the locknut, check the
1) Loosen locknut (102) and then loosen valve clearance again.
adjustment screw (103) to a position
where it does not contact with valve stem
(104).
2) Maintain the contact with valve stem (105)
on the push rod side by pressing the con-
tact surface against the rocker arm using
a finger.
3) Tighten adjustment screw (103) to confirm
the position where adjustment screw (103)
is contacted against valve stem (104).
4) Drive in adjustment screw (103) further by
20 – 30° from the contacting position
against valve stem (104).
5) Tighten locknut (102) while suppressing
move of adjustment screw (103).
3 Locknut:
Injector wiring harness
11. Install spacer (84).
53.0 – 64.7 Nm {5.4 – 6.6 kgm}
a When installing the spacer, direct its slit
(B) toward the upside.
Rocker arm assembly

10. Install rocker arm assembly (87).
a Insert respective rocker arm at a position 12. Install terminal mounting nuts (82) and wiring
where the riveted side of the shaft faces harness fixing bolts (83).
the front side of the engine. a Tighten the terminal mounting nuts alter-
a When installing, direct the wider seat of nately.
the shaft to the rocker arm housing. 3 Terminal mounting nut:
a Make sure that the ball of adjustment 2 ± 0.2 Nm {0.2 ± 0.02 kgm}
screw (86) is securely fitted to the push
rod socket.
a When tightening the mounting bolt, make
sure adjustment screw (86) is not pushing
the push rod.
2 Threaded portion and seat of rocker
arm assembly mounting bolt:
3 Rocker arm assembly mounting bolt:
235.2 – 254.8 Nm {24 – 26 kgm}
a Adjust valve clearance, referring to “Test-
ing and adjusting valve clearance” in Test-
ing and adjusting.
3 Locknut (85):
57.8 – 77.4 Nm {5.9 – 7.9 kgm}
50-202 18 WD600-6
Air intake manifold assembly k Before installing the high-pressure piping,

13. Place connector (76) on air lifted intake mani- check it for the following defects. If there is
fold assembly (72) being lifted. any of these defects, it can cause fuel leak-
4
age. Accordingly, replace the high-pressure
Air intake manifold and diffuser assembly: piping.
140 kg q Check the taper seal of the connecting
a Pay attention to biting of the tube into (A) part (Part (a): Part of 2 mm from the end)
portion. for visible lengthwise slit (b) and dent (c).
q Check part (d) (end of the taper seal: Part
at 2 mm from the end) for stepped-type
wear (fatigue) which your nail can feel.
14. Install air intake manifold assembly (72).

a Tighten the mounting bolts in the order
indicated in the figure (clockwise starting
at the center).
in other locations.
specified position with the specified
torque.
excessive, potentially damaging
the high-pressure piping.
WD600-6 50-202 19
15. Install O-ring (106) to high-pressure piping 20. Install cylinder head cover (81).
sleeve (101). a A different tightening torque is employed
2 O-ring: Engine oil (EO30-DH) for No. 2 cylinder mounting bolt alone.
16. Tighten sleeve nut (75) temporarily aligning it 3 Cylinder head cover mounting bolt:
connector (98) of the injector. No.1, 3, 4, 5 and 6 cylinders:
a When it is difficult to hitch sleeve nut to the 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
threaded portion, turn the spanner while No. 2 cylinder:
pushing sleeve nut (75) end toward the 58.8 – 73.5 Nm {6 – 7.5 kgm}
injector by use of a short bar and the like. 21. Install air vent tube (80).
17. Tighten the common rail side sleeve nuts (69) 3 Air bleeding tube joint bolt (Cylinder
temporarily, too. head side):
18. Tighten injector holder (91) permanently. 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3 Injector holder mounting bolt: 22. Install turbocharger coolant tube (79) and lubri-
58.9 – 73.5 Nm {6.0 – 7.5 kgm} cation tube (78).
19. Tighten high-pressure piping sleeve nuts (69) 23. Install brackets (77).
and (75) permanently using the spanner type
torque wrench.
3 Sleeve nut: 39.2 – 44.1 Nm {4 – 4.5 kgm}
a After finishing the work, check that O-ring
(106) is not projected from the end of the
sleeve nut (75).
50-202 20 WD600-6
High-pressure piping clamp Fuel supply pump

24. Install the clamp on the high-pressure pipe in a If overflow valve (ofv) was loosened or oil tube
the following procedure. (t) and plate (p) were removed, restore them,
1) Manually tighten 17 high-pressure piping referring to “Installation of fuel supply pump
clamps (107) temporarily in the position assembly”.
indicated in the figure.
2) Manually tighten common rail slide clamp
bracket (108) and clamp (52) temporarily
and then tighten clamp (52).
3 Common rail side clamp bolt:
9.8 ± 1.0 Nm {1 ± 0.1 kgm}
3) Tighten common rail side clamp bracket
(108) to the specified torque.
4) Tighten high-pressure piping clamps
(107).
3 High-pressure piping side clamp bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
5) Install cover (53) on the common rail side
sleeve nut.
a When installing it, direct the slit down- 25. Install the fuel supply pump assembly by align-
ward. ing (A) and (AA) at the position where a spline
tooth is missing.
WD600-6 50-202 21
3 Fuel supply pump (66) mounting bolt: [*1]

59 – 74 Nm {6 – 7.5 kgm} 3 Air hose clamp:
3 Bottom bracket (111) mounting bolt: 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
59 – 74 Nm {6 – 7.5 kgm}
[*2]
5.9 ± 0.49 Nm {0.6 ± 0.05 kgm}
[*3]
3 Air cleaner band:
12.8 – 17.7 Nm {1.3 – 1.8 kgm}
[*4]
3 Tube (15) joint bolt:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
High-pressure piping 43 – 47 Nm {4.4 – 4.8 kgm}
k Handle the high-pressure piping and clamp
[*5]
3
in the same way as the piping between the
fuel injector and common rail (noted in the Tube (18) joint bolt:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3
foregoing) is handled.
26. Tighten high-pressure pipings (57) temporarily. Tube (18) (Supply pump side):
27. Tighten clamps (55), (56) and (109) temporarily. 14.8 – 19.6 Nm {1.51 – 1.99 kgm}
28. Tighten bracket (110) temporarily.
[*6]
3
29. Tighten high-pressure pipings (57) perma-
nently. Air hose clamp:
3 High-pressure piping sleeve nut:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
39.2 – 44.1 Nm {4.0 – 4.5 kgm}
[*7]
3
30. Tighten clamps (55), (56) and (109) permanently.
3 Clamping bolt:
Coolant tube assembly (26) joint bolt:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3
9.8 ± 1.0 Nm {1 ± 0.1 kgm}
31. Tighten bracket (110) permanently. Coolant tube assembly (26) sleeve nut:
32. Install covers (54). 24.5 – 59.0 Nm {2.5 – 6.0 kgm}
[*8]
Exhaust manifold assembly
a When the exhaust manifold assembly was dis-
assembled, apply connection (A) (2 locations)
with the adhesive (heat resistant sealing
agent) before assembling it.
2 Exhaust manifold connection:
Liquid adhesive (Holtz MH 705)

50-202 22 WD600-6
a Tighten the mounting bolts in the following [*11]

order. a Exchange 4 gaskets.
2 Exhaust manifold mounting bolt: 3 Oil tube (63) joint bolt (Supply pump side):
Seizure prevention compound (LC-G) 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
(NEVER-SEEZ [Bostik, Inc] or equivalent) 3 Oil tube (63) joint bolt (Block side):
3 Exhaust manifold mounting bolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
1st time: 39.2 – 58.8 Nm {4.0 – 6.0 kgm} 3 Tube (65) joint bolt (Supply pump side):
2nd time: 14.8 – 19.6 Nm {1.51 – 1.99 kgm}
98.1 – 122.6 Nm {10 – 12.5 kgm} Sleeve nut: 43 – 47 Nm {4.4 – 4.8 kgm}
3 Tubes (64) joint bolt:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
[*12]
3 Tube (68) joint bolt (Corrosion resistor side):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
k Make sure that a clearance of 10 mm mini-

mum is provided between the high-pres-
sure piping and adjacent wiring harness. If
not, secure the clearance by adjusting the
wiring harness position.
Reference q Bleeding air

Installation of turbocharger assembly Bleed air from the fuel system, referring to
1. Lift and install turbocharger assembly (112). “Bleeding air from fuel system” in Testing and
4
adjusting.
Turbocharger assembly: 55 kg
2 Turbocharger mounting bolt and nut:
Seizure prevention compound (LC-G)
(NEVER-SEEZ [Bostik, Inc] or equivalent)
3 Turbocharger mounting bolt and nut:
78.5 – 88.3 Nm {8.0 – 9.0 kgm}
[*9]
3 Bleeding air tube (44) joint bolt:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
3 Tubes (45) and (46) sleeve nut:
24 – 27 Nm {2.4 – 2.7 kgm}
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*10]
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
WD600-6 50-202 23
SEN05143-02 Removal and installation of fuel injector assembly
Removal and installation of fuel q Overall view of right side

injector assembly 1
Special tools
New/Remodel
Necessity
Sketch
Sym-
Q'ty
Part No. Part name
bol
795-799-5410 Adapter t 1 N
1
A 795-799-5420 Remover t 1 N
2 795T-675-1110 Socket q 1 N Q
Removal 3. Disconnect high-pressure piping clamps (1) to

k Stop the machine on level ground and set (3).
the frame lock bar. 4. Remove tubes (4) and (5). [*1]
k Lower the work equipment to the ground 5. Remove bracket (6).
wheels.

to “Removal and installation of engine hood
assembly.”
2. Remove the filter, air tube, injector wiring har-

ness brackets, referring to “Removal and
installation of cylinder head assembly.”
q Overall view of top surface
6. Disconnect high-pressure piping clamps (7)
and (8).
a A clamp is provided on the fuel supply
pump side.
50-202 24 WD600-6
Removal and installation of fuel injector assembly SEN05143-02
7. Remove clamp (9). a When tool A2 is not available, disconnect

8. Remove covers (10). sleeve (12) through the top.
q Tool A2
9. Disconnect 6 sleeves (11) and (12).

10. Remove high-pressure pipings (13). 12. Remove terminal mounting nuts (15).
11. Remove cylinder head cover (14). a Loosen the nuts alternately.
13. Remove wiring harness assembly mounting
bolts (16) and spacer (17).
14. Remove fuel injector holder (21).
15. Using tool A1, remove fuel injector assembly

(22).
a Remove the assembly by hitching tip of
tool A1 on hole (H) of the fuel injector.
a Do not grip the solenoid valve at the top of
the injector to pull off the injector with pliers.
a The figure shows the removed rocker arm
and shaft assembly.
WD600-6 50-202 25
SEN05143-02 Removal and installation of fuel injector assembly
Installation 5. Install terminal mounting nuts (15) and wiring

harness fixing bolts (16).
Fuel injector a Tighten the terminal mounting nuts alter-
a Check that the inside of the injector sleeve is nately.
free from dirt. 3 Terminal mounting nut:
2 O-ring: Engine oil (EO30-DH) 2 ± 0.2 Nm {0.2 ± 0.02 kgm}

1. Assemble gasket (24) and O-rings (25) and
(26) to fuel injector (22).
a Use care not to install O-rings (25) in
groove (A) at the center.
2. Insert fuel injector (22) to adapter (27) and
injector holder (21).
3. Attach spherical washer (30) to bolt (29) and
then tighten injector holder (31) temporarily.
2 Spherical washer: Engine oil (EO30-DH)
a Tightening of injector holder (21) perma-
nently after tightening the high-pressure
piping temporarily.
in other locations.
specified position with the specified torque.
Injector wiring harness excessive, potentially damaging
4. Install spacer (17). the high-pressure piping.
a When installing the spacer, direct its slit k Before installing the high-pressure piping,
(B) toward the upside. check it for the following defects. If there is
any of these defects, it can cause fuel leak-
age. Accordingly, replace the high-pressure
piping.
q Check the taper seal of the connecting
part (Part (a): Part of 2 mm from the end)
for visible lengthwise slit (b) and dent (c).
q Check part (d) (end of the taper seal: Part
at 2 mm from the end) for stepped-type
wear (fatigue) which your nail can feel.
50-202 26 WD600-6
Removal and installation of fuel injector assembly SEN05143-02
6. Install O-ring (32) to sleeve (31) of high-pres- High-pressure piping clamp

sure pipings (13). 12. Install the clamp on the high-pressure pipe in
2 O-ring: Engine oil (EO30-DH) the following procedure.
7. Tighten sleeve nut (12) temporarily aligning it 1) Manually tighten 17 high-pressure piping
connector (28) of the injector. clamps (33) temporarily in the position
a When it is difficult to hitch sleeve nut (12) indicated in the figure.
to the threaded portion, turn the spanner 2) Manually tighten common rail slide clamp
while pushing sleeve nut (12) end toward bracket (34) and clamp (9) temporarily
the injector using a short bar and the like. and then tighten clamp (9).
8. Tighten the common rail side sleeve nuts (11) 3 Common rail side clamp bolt:
temporarily, too. 9.8 ± 1.0 Nm {1 ± 0.1 kgm}
9. Tighten injector holder (21) permanently. 3) Tighten common rail side clamp bracket
3 Injector holder mounting bolt: (34) to the specified torque.
59 – 74 Nm {6.0 – 7.5 kgm} 4) Tighten high-pressure piping clamp (33).
10. Tighten high-pressure piping sleeve nuts (11) 3 High-pressure piping side clamp bolt:
and (12) permanently using the spanner type 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
torque wrench. 5) Install covers (10) on the common rail side
3 Sleeve nut: 39.2 – 44.1 Nm {4 – 4.5 kgm} sleeve nut.
a After finishing the work, check that O-ring a When installing it, direct the slit down-
(32) is not projected from the end of the ward.
sleeve nut (12).
11. Install cylinder head cover (14).
a A different tightening torque is employed
for No. 2 cylinder mounting bolt alone.
No.1, 3, 4, 5 and 6 cylinders:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
No. 2 cylinder:
58.8 – 73.5 Nm {6 – 7.5 kgm}

[*1]
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
24 – 27 Nm {2.4 – 2.7 kgm}
a Reference the precautions in “Removal and

installation of cylinder head” for the installation.
k Make sure that a clearance of 10 mm mini-

mum is provided between the high-pres-
sure piping and adjacent wiring harness. If
not, secure the clearance by adjusting the
wiring harness position.
q Bleeding air
Bleed air from the fuel system, referring to
“Bleeding air from fuel system” in Testing and
adjusting.
WD600-6 50-202 27
SEN05143-02 Removal and installation of engine front seal
Removal and installation of 4. Disconnect hose clamps (3).

engine front seal 1
5. Remove bar (4).
6. Remove 3 covers (5).
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
3 795-931-1100 Seal puller assembly t 1
Push tool
795T-621-1180 t 1 Q
(For oil seal)
A Push tool
4 795T-621-1171 t 1 N Q
(For dust seal)
795-902-1460 Bolt t 3
01582-02218 Nut t 3
7. Lift pulley and damper assembly (6) tempo-
rarily.
8. Lift and remove pulley and damper assembly
Removal
k
(6). [*1]
Stop the machine on level ground and set
the frame lock bar. 4 Pulley and damper assembly (6): 50 kg
wheels.
1. Remove muffler (1).

2. Remove cover (2-1).
3. Sling hood (2-2) to remove.
4 Hood (2-2): 45 kg
four corners of the hood (2-2).
9. Remove dust seal (7).

10. Remove front seal (8) in the following proce-
dure.
50-202 28 WD600-6
Removal and installation of engine front seal SEN05143-02
1) Replace the tip of tool A3 with the hook Installation

type one. 1. Clean, degrease and then dry the contact sur-
2) Hitch the hook to the hoop of front seal face between the front cover and front seal.
(8). 2. Using a clean cloth, remove foreign matter
3) Remove the seal using impacts of the deposited the crankshaft flange.
slide hammer (SH). a Clean foreign matter deposited on the seal
q Tool A3 lip surface (surface around the crank
shaft) and then degrease and dry the sur-
face.
a Check the crankshaft end face corner and
lip siding surface for scratches due to the
housing, burrs or rusts.
3. Install front oil seal (8) according to the follow-

ing procedure.
a Before installing the seal, check that the
end corners and lip sliding surfaces of the
crankshaft are free from flaw, burr, and
rust of the housing.
a When installing the seal, do not apply oil
or grease to the shaft and seal lip. Wipe
a CS: Crankshaft off the oil from the shaft.
1) Install the oil seal directing its side
stamped with IN toward the inside of the
engine.
a The OUT stamped side is directed
toward the outside of the engine.
WD600-6 50-202 29
SEN05143-02 Removal and installation of engine front seal
2) Using tool A4, press fit oil seal (8) to the

front case in such that dimension (a) in the
figure is met.
a Oil seal press fitting dimension (a):
18.5 mm (when measured from the front
cover end face)
3) Using tool A4 (for dust seal), press fit dust

seal (7) to the front case in such that
dimension (b) in the figure is met.
a Dust seal press fitting dimension (b):
2 mm (Projection out of the front
cover end face)

[*1]
3 Pulley and damper mounting bolt:
1st time: 53.9 – 93.1 Nm {5.5 – 9.5 kgm}
2nd time: 225.4 – 264.6 Nm {23 – 27 kgm}
3rd time: 617.4 – 656.6 Nm {63 – 67 kgm}
50-202 30 WD600-6
Removal and installation of engine rear seal SEN05143-02
Removal and installation of 3. Remove rear seal (2).

engine rear seal 1
a Take care in the removal not to damage
the seal installation position on the fly-
Special tools wheel housing and the seal contact sur-
face on the crankshaft.
New/Remodel
a Before removing, slightly drive the seal in
Necessity
Sym- once to free it from fixation.
Part No. Part name
Sketch
bol a When rear seal (2) is fixed too hard to the
Q'ty
flywheel housing (FWH), remove the fol-
Seal puller lowing procedure.
3 795-931-1100 q 1 a The left one in the following figure is
assembly
the standard seal and the right one is
795T-621-1161 Push tool t 1 R Q
A the sleeved seal.
795T-621-1190 Push tool t 1 N Q 1) Replace the tip of tool A3 with the drill
5
01050-32235 Bolt t 5 type one.
01050-32245 Bolt t 5 2) Drill several holes about 3 mm in
diameter into rear seal (2).
3) Set tool A3 to the drilled hole. (Tip:
Drill type)
Removal 4) Remove rear seal with impact of slide
k Stop the machine on level ground and set hammer (SH).
the frame lock bar. a When the sleeve is attached, cut sleeve
k Lower the work equipment to the ground (5) using a gad and hammer to remove it.
completely and stop the engine. Apply the a Take care not to damage crankshaft (4).
parking brake and put the blocks under the a Remove all the chips.
wheels.
1. Remove the damper assembly, referring to

“Removal and installation of damper assembly.”
2. Lift and remove flywheel (1). [*1]

4 Flywheel assembly: 40 kg
q Tool A3
WD600-6 50-202 31
SEN05143-02 Removal and installation of engine rear seal
Installation q Procedure for installing standard seal

a Check the Teflon seal (Laydown lip seal) by a Don't apply gear or oil to the seal lip surface.
checking the wear of the shaft and replace it 1) Contact larger inner diameter side (b) of
with the “Standard seal” or “Sleeved seal”. plastic inside cylinder (3) of rear seal (2)
a When wear on the shaft is not serious and only against the end face of crank shaft (4).
makes it look lustrous (depth of wear is 10 mm a Take care not to mistake the direction
or less when checked with finger cushion) and of the plastic inside cylinder.
no scratch is recognized, assemble the stan-
dard seal (A). When the above is not applica-
ble, assemble sleeved seal (B).
a (3): Shows the plastic inside cylinder doubling
the assembly guide.
a (5): Shows the sleeve.
a Don't remove assembly guide (3) from rear
seal (2) until the assembly is complete.
a Handle rear seal (2) and sleeve (5) as an inte-
gral part. Don't try to separate them.
2) Applying equal force to both hands, push

in the hoop of rear seal (2).
3) After pushing in rear seal (2), remove
plastic inside cylinder (3).
a When removing the inside cylinder,
take care not to damage the seal lip.
a Clean, degrease and then dry the contact sur-

face between the rear seal and flywheel hous-
ing.
a Clean foreign matter deposited on the seal lip
surface (surface around the crank shaft) and
then degrease and dry the surface.
a Check the crankshaft end face corner and lip
siding surface for scratches due to the hous-
ing, burrs or rusts.
50-202 32 WD600-6
4) Tighten the bolts evenly to press fit rear 3) Remove tool A5 (for sleeved seal) and
seal (2) until the end of tool A5 reaches install tool A5 (for standard seal).
the end of crankshaft (4). 4) Tighten the 5 bolts evenly to press fit
a Oil seal press fitting dimension (when sleeve and rear seal assembly (6) until the
measured from the shaft end face) end of tool A5 (for standard seal) reaches
(a): 20 mm the end of crankshaft (4).
a After press fitting the rear seal, a Tighten tool A5 (for standard seal)
remove the red sealant layer from its first until it reaches the bolt (45 mm)
periphery. and then tighten the bolt (35 mm).
a Rear seal driving depth (a): 20 mm
from end of crankshaft.
a After press fitting the seal, remove the
red sealant layer from its periphery.
q Procedure for installing sleeved seal

a When installing the rear seal, do not apply oil
or grease to the shaft and sleeve inside cylin-
der surface (C).
1) Set sleeve and rear seal assembly (6) to
tool A5 (for sleeved seal)
2 Sleeve inside cylinder surface (C):
2) Set sleeve (5) of the rear seal to the end of
crankshaft (4) and tighten the 5 bolts (45
mm) evenly to press fit sleeve and rear
seal assembly (6) until the end of tool A5
reaches the end of crankshaft (4).
WD600-6 50-202 33
SEN05143-02 Removal and installation of engine rear seal

[*1]
Flywheel assembly
a Check the punch mark on the mounting bolt
head. If 5 marks are punched, replace it with a
new one without using it.
a In order to prevent the flywheel from rotating,
fix the space between the flywheel and fly-
wheel housing using the bolt hole.
a Tighten the mounting bolts in the following
order.
2 Flywheel assembly mounting bolt:
3 Flywheel assembly mounting bolt:
q Measure radial runout or facial runout of the
1st time : 196.1 ± 19.6 Nm {20 ± 2 kgm} flywheel using dial gauge [1].
2nd time : 460.9 ± 19.6 Nm {47 ± 2 kgm} a Standard radial and facial runout:
3rd time : 90 – 120° retightening
a After tightening the bolt, make a punch mark Measuring
Tolerance (mm)
(a) on its head. (When a new bolt is used, do items
not make a punch mark on its head.) Radial
0.13
runout
Facial 0.0005 × Diameter of
runout measuring point
a When the measured value is out of the

standard, determine the cause by disas-
sembling the flywheel again.
50-202 34 WD600-6
WD600-6 50-202 35
SEN05143-02
WD600-6 Wheel dozer

©2016 KOMATSU
All Rights Reserved
50-202 36
SEN05144-01
WHEEL DOZER
WD600-6
WD600-6 55001 and up

Removal and installation of parking brake assembly ...................................................................................... 2
Removal and installation of torque converter and transmission assembly ..................................................... 4
WD600-6 50-301 1
SEN05144-01 Removal and installation of parking brake assembly
Removal and installation of 3. Disconnect hose (2).

parking brake assembly 1
4. Remove plugs (3) and then screw in the pre-
pared parking brake release bolt (B) (M12 ×
Removal 1.75, L = 70 mm minimum) until it is uniformly
k Lower the work equipment to the ground stopped.
completely and stop the engine. Apply the 5. Remove 12 mounting bolts (4). [*1]
parking brake and put the blocks under the 6. Remove 4 mounting bolts (5).
wheels. 7. Remove top and bottom plugs (6) and then
k Set the frame lock bar. remove parking brake assembly (7), using the
k Loosen the filler cap of the hydraulic tank forcing screw.
4
from the hydraulic tank. Parking brake assembly: 120 kg
k Release residual pressure in brake accumu-
lator circuits. For detail, see Testing and
adjusting “Releasing residual pressure in
brake accumulator circuit”.
1. Remove the drain plug to drain oil from the

transmission case.
q Rear side
2. Remove rear drive shaft (1). [*1]
4 Rear drive shaft: 65 kg
50-301 2 WD600-6
Removal and installation of parking brake assembly SEN05144-01
Installation
q Installation is done in the reverse order of
removal.
[*1]
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
q Refilling with oil

Tighten the drain plug and then feed power line
oil (TO30) from the oil filler.
WD600-6 50-301 3
SEN05144-01 Removal and installation of torque converter and transmission assembly
Removal and installation of 6. Remove guard (40).

torque converter and 7. Remove upper drive shaft (2). [*2]
a (D) shows damper.
transmission assembly 1
4 Upper drive shaft: 30 kg
Removal
k Lower the work equipment to the ground 8. Remove guard (41).
parking brake and put the blocks under the a T/M: Transmission
wheels.
k Set the frame lock bar.
k Release residual pressure in the brake
accumulator circuit. For detail, see “Releas-
ing residual pressure in brake accumulator
circuit”.
1. Drain the oil from the hydraulic tank.

6 Hydraulic tank: 443 l
2. Remove the floor frame assembly, referring to

“Removal and installation of floor frame
assembly.“
3. Remove the work equipment pump assembly,

steering and fan pump assembly, referring to
“Removal and installation of hydraulic pump
assembly.”
4. Remove the drain plug to drain oil from the

transmission case.
6 Transmission case: 83 l 9. Remove guard (3).
10. Remove center drive shaft (4). [*3]
4 Center drive shaft: 65 kg
q Drive shaft
5. Remove rear drive shaft (1). [*1]
4 Rear drive shaft: 65 kg
50-301 4 WD600-6
Removal and installation of torque converter and transmission assembly SEN05144-01
q Rear side of transmission 16. Disconnect hoses (12) and (13).

11. Remove tube, bracket and hose assembly (6).
12. Remove hose (7).
q Right side of transmission

13. Remove right and left transmission side covers 18. Disconnect connector (16).
(8). 19. Disconnect bracket (17).
a Rear frame side cover installed machine
only
q Top side of transmission

20. Disconnect 3 hoses (18).
q Left side of transmission
14. Disconnect torque converter cooler hoses (9)
and (10).
15. Disconnect clamp (11).
WD600-6 50-301 5
21. Disconnect hoses (19) and (20) from the check

valve (CV).
a DV: Diverter valve
25. Disconnect 2 tubes (29) from the hydraulic

tank.
26. Remove tube assembly (30).
22. Remove 2 blowout hoses (21) from the steer-
ing valve (SV).
q Front side of transmission

27. Disconnect parking brake hose (31).
23. Remove right and left brackets (23). 28. Disconnect clamps (32).
24. Disconnect the hoses and tubes from the
hydraulic tank.
(24): 2 oil cooler hoses
(25): Oil cooler return hose
(26) Top: Steering drain tube
(26) Bottom: Pump drain hose
(27): Oil cooler and steering return tube
(28): 2 emergency steering return hoses
and suction tube
50-301 6 WD600-6
29. Disconnect filler tube (33). q Bottom right and left sides of transmission
a Fasten filler tube (33) to the emergency 33. Remove mounting bolts (37). [*5]
steering hose by use of a string. 34. Remove right and left brackets (38). [*6]
a Above is needed since the opposite side
bracket interferes with the suction tube as
the assembly is lifted.
q Top side of transmission

31. Remove mounting bolts (35). [*4]
a Check the number of the shims in
35. Lift and remove torque converter and transmis-
advance.
sion assembly (36).
4 Torque converter and transmission
assembly: 2,000 kg
a Incline the torque converter side approx.
30° when lifting.
32. Lift air torque converter and transmission

assembly (36) temporarily.
WD600-6 50-301 7
Installation
removal.
[*1]
3 Rear drive shaft mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
3 Mounting bolt: 490 – 608 Nm {50 – 62 kgm}
[*2]
3 Mounting bolt of drive shaft between dampers:
98 – 123 Nm {10 – 12.5 kgm}
[*3]
3 Center drive shaft mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
[*4]
3 Top side mounting bolt:
157 – 196 Nm {16.0 – 20.0 kgm}
[*5], [*6]
3 Mounting bolt at bottom right and left side:
245 – 309 Nm {25.0 – 31.5 kgm}

Tighten the drain plug and then feed power line
oil (TO30) from the oil filler.
q Refilling with oil (hydraulic tank)

Refill hydraulic oil through the oil filler port to
the specified level. Let the oil circulate in the
hydraulic system by starting the engine. Then
check the oil level again.
q Air bleeding
Bleed the air from the circuit between the tank
and the pump. For details, see Testing and
adjusting, “Bleeding air from work equipment
circuit”.
50-301 8 WD600-6
WD600-6 50-301 9
SEN05144-01
WD600-6 Wheel dozer

©2017 KOMATSU
All Rights Reserved
50-301 10
SEN05145-02
WHEEL DOZER
WD600-6
WD600-6 55001 and up

Disassembly and assembly of torque converter assembly ............................................................................. 2
Disassembly and assembly of transmission assembly ................................................................................. 29
Disassembly and assembly of transfer assembly ......................................................................................... 56
Disassembly and assembly of parking brake assembly ............................................................................... 72
WD600-6 50-302 1
SEN05145-02 Disassembly and assembly of torque converter assembly
Disassembly and assembly of 5) Remove torque converter PTO lubrication

torque converter assembly 1
tube (1c).
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
C 792-900-1350 Wrench t 1
D 793-613-1210 Wrench t 1
793-615-1110 Wrench t 1
E
01306-10616 Bolt t 1
6) Using sling [1], sling torque converter and

Disassembly PTO assembly (2).
1. Preparation work 7) Remove 16 mounting bolts (3).
1) Set the transmission and torque converter a Do not remove 2 sub-assembly bolts
assembly on the block vertically. (25).
4 Transmission and torque converter
assembly: 1,800 kg
2) Remove oil tube (1) between the torque
converter and transfer.
3) Remove modulated clutch lubrication
hose (1a).
4) Disconnect torque converter speed sensor

wiring harness (1b).
50-302 2 WD600-6
Disassembly and assembly of torque converter assembly SEN05145-02
8) Using forcing screws [2] (M12, P = 1.75 2. Seal cage

mm), disconnect torque converter and Remove mounting bolts (6) and seal cage (7).
PTO assembly (2) from transmission
assembly (4).
9) Sling torque converter and PTO assembly
(2) and remove it from transmission
assembly (4).
3. Modulated clutch assembly

1) 1) Remove 7 mounting bolts (8).
2) Using forcing screws [4] (M12, P = 1.75
mm), disconnect modulated clutch assem-
bly (9) from torque converter and PTO
4 Torque converter and PTO assem- assembly (2).
bly: 490 kg
10) Remove modulated clutch speed sensor
(5).
3) Using sling [5] (M10, P = 1.5 mm), remove

modulated clutch assembly (9).
WD600-6 50-302 3
4) Disassemble modulated clutch assembly 5] Remove seal ring (15) from piston
according to the following procedure. (14) and remove seal ring (17) from
1] Remove snap ring (10). clutch outer drum shaft (16).
2] Remove plate (11).
6] Reverse the case and remove snap

3] Remove 7 discs (12) and 8 plates ring (18).
(13) alternately.
7] Support case (19) and push out

4] Using eyebolts (M12, P = 1.75 mm), clutch outer drum shaft (16) with push
remove piston (14). tool [6] (Outside diameter: 60 mm).
50-302 4 WD600-6
8] Remove seal rings (21) from clutch 3) Using sling [7], remove torque converter
outer drum shaft (16). case (23).
9] Remove bearing (22) from cover (19). 5. Coupling and drive gear
10] Remove 2 dowel pins (20). 1) Remove coupling (24).
2) Remove 6 mounting bolts (25).
mm), remove cage (26).
4. Torque converter case

1) Remove 6 mounting bolts (24) from the
inside of torque converter case (23).
2) Remove 2 sub-assembly bolts (25). 4) Remove shim (27).
a Check the quantity and thickness of
the shim.
WD600-6 50-302 5
5) Remove oil seal (28) from cage (26). 11) Remove outer race (36) from torque con-
6) Remove outer race (29) from cage (26). verter case (35)
7) Remove 16 mounting bolts (30). 6. PTO gear

a Before removing shaft (31), remove a Since the right and left cages and gears of
gear (34) from it. (Forcing screws: PTO A (Right side) and PTO B (Left side)
M10, P = 1.5 mm) are different, keep the removed parts sep-
8) Remove input shaft (31). arately.
9) Remove bearings (32) and (33) from input a The covers of the PTO A and PTO B are
shaft (31). u s e d f o r t r a n s p o r ta t i o n o f t h e u n i t .
Accordingly, they are not installed to the
actual machine.
10) Remove gear (34).

a Move the gear aside to remove.
1) PTO gear A (Right side)
1] Reverse the torque converter case.
2] Remove lubrication tube (43).
3] Remove 8 mounting bolts (44).
50-302 6 WD600-6
4] Using forcing screws [10] (M12, P = 9] Remove bearing (48) from gear (47).
1.75 mm), remove cage (45).
5] Remove outer race (46) from cage
(45).
10] Remove 2 mounting bolts (39) and 4

mounting bolts (39a).
11] Using forcing screws [9] (M12, P =
6] Reverse the torque converter case. 1.75 mm), remove cage (40).
7] Remove snap ring (41) and plate a Covers (39b) and (39c) are used
(41a). for transportation of the unit.
A c c o r d i n g l y, t h e y a r e n o t
installed to the actual machine.
8] Using push tool [9] (Outside diameter:

80 mm), remove gear (47).
a Take care not to drop the gear. 12] Remove snap ring (41) from cage
(40) and remove bearing (42).
WD600-6 50-302 7
2) PTO gear B (Left side) 8. Modulated clutch gear

Remove PTO gear B similarly to PTO gear 1) Using forcing screws [12] (M10, P = 1.5
A (Right side). mm), remove modulated clutch gear (53).
2) Remove upper bearing (54a) from modu-
<Steps 7 – 17 are disassembly procedures for lated clutch gear (53).
the torque converter>
7. Locknut
1) Straighten the locking part of lock plate
(50a) and remove 2 lock bolts (49) and
stopper plate (50).
2) Remove side pin (51) from locknut (52).
3) Remove outer races (55a) and (55b) from

modulated clutch gear (53).
9. Cage
1) Remove cage (56).
2) Remove outer race (57) from cage (56).
3) Using tool C, remove locknut (52).
50-302 8 WD600-6
10. Torque converter assembly 3) Remove bearings (54b) and (60) from
1) Set the torque converter assembly on the torque converter input shaft (59).
blocks. 4) Remove 2 dowel pins (61).
3) Using eyebolts [16] (M10, P = 1.5 mm),
remove turbine shaft assembly (82) from
stator shaft assembly (93).
12. Lockup clutch housing

1) Remove snap ring (62) and plate (63).

set turbine shaft assembly (82) to tool
[16a] (Height: 124 mm).

mm), remove lockup clutch housing (65).
11. Torque converter input shaft

mm), remove torque converter input shaft
(59).
WD600-6 50-302 9
4) Remove bearing (66) from lockup clutch 2) Remove seal rings (70) from piston (69).
housing (65).
14. Discs and plate

5) Remove seal rings (68) from lockup clutch Remove 2 discs (71) and 1 plate (72).
housing (65).
15. Turbine
13. Piston 1) Using tool [16a] (M10, P = 1.5 mm), sup-
1) Using eyebolts (M6, P = 1 mm), remove port turbine shaft assembly (82).
piston (69). 2) Using eyebolts [16] (M10, P = 1.5 mm),
remove drive case (77).
50-302 10 WD600-6
3) Remove 23 mounting bolts (80) 5) Remove bushings (88), balls (89) and
4) Remove turbine (82) from boss (81). freewheel (90) from race (87).
a Check the arrow of the turbine rota- a Take care not to lose the balls.
tion direction at part (G).
17. Pump
16. Stator 1) Using tool D, remove locknut (91).
1) Remove stator assembly (84) from pump a Note that locknut (91) has left-handed
(83). threads.
a Check that the side having a shoulder
at stator part (F) is on the input side.

3) Remove stator shaft assembly (93) from
2) Remove upper snap ring (85a). housing (73).
3) Remove race (87) from stator (86).
4) Remove lower snap ring (85b).
WD600-6 50-302 11
4) Support retainer (97) and push out stator Assembly

shaft (93) with push tool [17].
5) Remove inner race (94a). <Steps 1 – 12 are assembly procedures for the
6) Remove inner race (94b) from stator shaft torque converter>
(93). a After installing each bearing, drop about 6 cc
7) Remove seal ring (95). of transmission oil (TO10 or TO30) onto it and
rotate it about 10 turns.
a When installing a bearing by expansion fit,
drop about 6 cc of transmission oil (TO10 or
TO30) onto it and rotate it about 10 turns
before cooling it in dry ice.
1. Pump
1) Install bearing (98) to guide (100).
a Match the product Nos. (C) and
match symbols “A” (D) of the inner
race (A) and outer race (B) of the
bearing and use those races as an
assembly.
8) Remove 12 mounting bolts (96) from 2) Install pump (99) and retainer (97).
pump (99). a Check the arrow of rotation direction
9) Remove retainer (97). of the pump.
10) Remove bearing (98) from guide (100). Direction of arrow: Counterclockwise
when seen from input side
3) Install 12 mounting bolts (96).
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
50-302 12 WD600-6
4) Install seal ring (95) to stator shaft (93). 9) Install locknut (91) and tighten it with tool
5) Using push tool [17a] (Inside diameter: 91 D.
mm), install inner race (94b). a Note that locknut (91) has left-handed
2 Seal ring: Grease (G2-LI) threads.
2 Locknut: Adhesive (LT-2)
3 Locknut:
441 – 490 Nm {45 – 50 kgm}
6) Install stator shaft (93) to housing (73) and

tighten 14 mounting bolts (74).
3 Mounting bolt: 2. Stator
59 – 74 Nm {6.0 – 7.5 kgm} 1) Install freewheel (90), balls (89) and bush-
ings (88) to race (87).
a When installing, take care of the balls.
7) Install pump assembly (92) to shaft (93).

8) Using push tool [17b] (Inside diameter: 91
mm), press fit inner race (94a).
WD600-6 50-302 13
a When installing the freewheel, direct 5) Install stator assembly (84) to pump
arrow (b) of the free rotation direction assembly (83).
indicated on the front side of the cage a Apply transmission oil (TO10 or
toward the output (pump) side. TO30) to bushings (88) shown in the
a Do not remove sprag (d). above figure.
a When inserting, take care that drag a Check that the side having a shoulder
clip (c) on the periphery of the one- at stator part (F) is on the input side.
way clutch will not be hitched in the a Check the rotation direction from the
ball groove of the outer race. input side. (Take care that the rota-
a When inserting, do not use a hammer tion direction is opposite to the normal
etc. but use your hands. rotation direction.)
Clockwise direction: Locked
Counterclockwise direction: Free
2) Install lower snap ring (85b) to stator (86).

a Check the arrow of stator rotation
direction on part (E). 3. Piston
Direction of arrow: Counterclockwise Install seal rings (70) to piston (69).
when seen from input side a Set pressure receiving side (e) of the seal
3) Install race (87). ring in the direction of the arrow shown
4) Install upper snap ring (85a). below.
2 Seal ring: Grease (G2-LI)
50-302 14 WD600-6
4. Lockup clutch housing 5. Turbine

1) Using push tool [18] (Outside diameter: 1) Install boss (81) to turbine (82).
139 mm), press fit bearing (66) to lockup a Check the arrow of rotation direction
clutch housing (65). of the turbine at (G).
2) Install 2 dowel pins (61). Direction of arrow: Counterclockwise
when seen from input side
3 Mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
3) Install seal rings (68) to lockup clutch

housing (65).
a Set pressure receiving side (f) of the
seal ring in the direction of the arrow
shown below.
2 Seal ring: Grease (G2-LI) 3) Support turbine (82) with tool [16a]
(Height: 124 mm).
set drive case (77).
4) Using eyebolts (M6, P = 1 mm), install pis-

ton (69) to housing (65).
a Set the dowel pin (67) to the hole on
the piston side.
WD600-6 50-302 15
6. Discs and plate 4) Tighten 30 mounting bolts (64) into lockup

1) Install 2 discs (71) and 1 plate (72) alter- clutch housing (65).
nately. 2 Mounting bolt: Adhesive (LT-2)
a Apply transmission oil (TO30) to the 3 Mounting bolt:
discs. 59 – 74 Nm {6.0 – 7.5 kgm}
2) Using eyebolts [19] (M12, P = 1.75 mm), 7. Torque converter input shaft
install lockup clutch housing (65). 1) Install plate (63) and snap ring (62).
a Take care that the piston will not
come off.
3) Using push tool [20] (Inside diameter: 81
mm), press fit the inner race of bearing
(66).
2) Drive 2 dowel pins (6) into lockup clutch

housing (65).
50-302 16 WD600-6
3) Using push tool [30] (Inside diameter: 66 8. Cage

mm), press fit bearing (60) to torque con- 1) Using push tool [21] (Outside diameter:
verter input shaft (59). 149 mm), press fit outer race (57) to cage
(56).
4) Using push tool [31] (Inside diameter: 76

mm), press fit bearing (54b) to torque con- 2) Install cage (56).
verter input shaft (59).
9. Torque converter assembly

5) Using eyebolts [13] (M10, P = 1.5 mm), 1) Set stator shaft assembly (93) on the
install torque converter input shaft (59). blocks.
6) Tighten 16 mounting bolts (58).
3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
WD600-6 50-302 17
2) Using eyebolts [16] (M10, P = 1.5 mm), 2) Install upper bearing (54a) to modulated
install turbine shaft assembly (82) to stator clutch gear (53).
shaft assembly (93). a Press fit the bearing until the clear-
3) Tighten 30 mounting bolts (76). ance is eliminated.
2 Mounting bolt: Adhesive (LT-2) 3) Using eyebolts [12] (M10, P = 1.5 mm),
3 Mounting bolt: install modulated clutch gear (53).
49 – 59 Nm {5 – 6 kgm}
11. Locknut
10. Modulated clutch gear 1) Install locknut (52).
1) Using push tool [22] (Outside diameter: a Install the locknut and adjust the pre-
114 mm), press fit outer races (55a) and load after assembling the case.
(55b) to modulated clutch gear (53).
a Press fit the outer races until the
clearance is eliminated.
2) Using tool C, tighten locknut (52).
50-302 18 WD600-6
3) Adjustment of preload on modulated 12. Drive gear

clutch gear bearing 1) Using push tool [23] (Outside diameter:
Adjust the bearing according to the follow- 129 mm), press fit outer race (36) to
ing procedure. torque converter case (35).
a After installing the bearing, drop 6 cc
of transmission oil (TO30) onto it and
revolve it about 10 turns.
1] Tighten locknut (52) to 98 – 123 Nm
{10.0 – 12.5 kgm}.
2] Rotate modulated clutch gear (53) 20
turns and check the tightening torque
of 98 – 123 Nm {10.0 – 12.5 kgm} for
locknut (52) again.
3] If the tightening torque has changed,
repeat 1] and 2] above.
4] If the tightening torque has not
changed, loosen locknut (52).
5] Tighten locknut (52) to 39 – 49 Nm
{4 – 5 kgm} and rotate modulated 2) Set gear (34) to the case.
clutch gear (53) 20 turns. a Move the gear aside to install.
6] Loosen locknut (52) until the phase of
the 8 side pin holes of locknut (52) is
matched to that of the 5 side pin holes
of torque converter input shaft (59).
a The loosening angle must be in
the range of 0 – 9°, however.
7] When the holes are matched by the
above operation, insert side pin (51)
from the side and install stopper plate
(50) and lock plate (50a).
8] Check that modulated clutch gear
(53) has not play.
9] Under this condition, measure the
rotation torque of torque converter
input shaft (59).
Rotation torque: Must be in range of
0.98 – 2.94 Nm {0.1 – 0.3 kgm}.
a When measuring the rotation
torque, fix modulated clutch gear
(53) so that it will not be turned
by dragging.
10] Tighten 2 lock bolts (49).
11] Bend part (g) of lock plate (50a) to
lock the bolt securely.
a Use a new lock plate.
WD600-6 50-302 19
3) Using push tool [32] (Inside diameter: 76 7) Press fit oil seal (28) to cage (26).
mm), press fit bearings (32) and (33) to 2 Oil seal: Grease (G2-LI)
input shaft (31). a Fill 40 – 60% of the space between
4) Install input shaft (31) to gear (34). the main lip and dust lip with grease.
5) Tighten 16 mounting bolts (30). 2 Oil seal press fitting face:
a Since the gear and shaft are press fit- Gasket sealant (LG-5)
ted to each other, tighten all the bolts a Apply the gasket sealant thinly to the
gradually. inside of the housing hole and wipe
2 Mounting bolt: Adhesive (LT-2) off the projected part.
3 Mounting bolt: 245.0 – 309.0 Nm
{25.0 – 31.5 kgm}
6) Using push tool [24] (Outside diameter:

129 mm), press fit outer race (29) to cage
(26).
50-302 20 WD600-6
8) Adjustment of preload on input shaft (31)

bearing
Adjust the bearing according to the follow-
ing procedure.
a After installing the bearing, drop 6 cc
of transmission oil (TO30) onto it and
revolve it about 10 turns.
1] Fit the O-ring and install cage (26)
without setting shim (27).
2 O-ring: Grease (G2-LI)
2] Tighten mounting bolts (25) to 4.80 ±
0.98 Nm {0.5 ± 0.1 kgm}.
3] Rotate input shaft (31) 20 turns and
check the tightening torque of 4.80 ±
0.98 Nm {0.5 ± 0.1 kgm} for mount-
ing bolts (25) again.
changed, measure clearance (h)
between the case and cage (27) at 3
places (j) and obtain the average.
a Check that the dispersion of
clearance (h) is 0.15 mm or less.
a If the dispersion of clearance (h)
is larger than 0.15 mm, check the
bearing for improper installation
and then take remedies to
reduce the dispersion to 0.15
mm or less.
6] Loosen the bolts to set input shaft
(31) free and measure rotation torque
(A) of input shaft (31) with tool E.
7] Install shim (27) increased by the
clearance obtained in the above
steps.
Shim thickness (k): Average clear-
ance + (Increased shim: 0.15 – 0.35
mm)
Standard clearance: 1.05 – 1.70 mm
Standard shim thickness: 1.2 mm
8] Tighten mounting bolts (25) to 98.0 –
122.5 Nm {10.0 – 12.5 kgm}.
9] Check that input shaft (31) has no
play.
10] Under this condition, measure rota-
tion torque (B) of input shaft (31) with
tool E.
Rotation torque (B – A): Must be in
range of 0.98 – 1.96 Nm {0.1 – 0.2
kgm}.
WD600-6 50-302 21
13. PTO gear A (Right side) 4) Using push tool [25] (Outside diameter: 99
1) Install bearing (42) to cage (40) and install mm), press fit outer race (46) to cage (45).
snap ring (41). 5) Using push tool [26] (Inside diameter: 56
mm), press fit bearing (48) to gear (47).
2) Fit the O-ring and install cage (40) by

using forcing screws [9] (M12, P = 1.75 6) Reverse the torque converter case.
mm). 7) Set gear (47) to the case and press fit it
2 O-ring: Grease (G2-LI) with push tool [11] (Outside diameter: 55
3) Tighten 4 mounting bolts (39a) and 2 mm).
mounting bolts (39). 8) After press fitting gear (47), install snap
a Covers (39b) and (39c) are used for ring (41a).
transportation of the unit. Accord-
ingly, they are not installed to the
actual machine.

install cage (45).
50-302 22 WD600-6
10) Tighten 8 mounting bolts (44). 16. Torque converter case

11) Install lubrication tube (43). 1) Using sling [7], install torque converter
3 Joint bolt: case (23).
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
2) Tighten 2 sub-assembly bolts (25).

14. PTO gear B (Left side) 3) Tighten 6 mounting bolts (24) on the
Install the PTO gear B (Left side) similarly to inside of torque converter case (23).
PTO gear A (Right side). a Since the case and cage are press fit-
ted to each other, tighten all the bolts
15. Coupling gradually.
Install coupling (24). 2 Mounting bolt: Adhesive (LT-2)
WD600-6 50-302 23
17. Modulated clutch assembly 5] Install seal ring (15) to piston (14).
1) Assemble the modulated clutch assembly 2 Seal ring: Grease (G2-LI)
according to the following procedure. a Set groove (k) of the seal ring as
1] Using push tool (Outside diameter: shown below.
114 mm), install bearing (22) to cover
(19).
2] Install 2 dowel pins (20).
6] Install seal ring (17) to clutch outer

drum shaft (16).
3] Using push tool [29] (Inside diameter: a Set groove (m) of the seal ring as
76 mm), press fit cover (19) to clutch shown below.
outer drum shaft (20).
a Press the inner race.
7] Using eyebolts (M12, P = 1.75 mm),

install piston (14).
4] Install snap ring (18).
50-302 24 WD600-6
8] Install 8 plates (13) and 7 discs (12) 3) Install 2 dowel pins (102) to the case.
alternately. a Drive in each dowel pins to the hole
a Soak the disc in clean transmis- end of the case.
sion oil for at least 2 minutes. 4) Install O-ring (103) to the case.
9] Install plate (11).

10] Install snap ring (10). 5) Using sling [5] (M10, P = 1.5 mm), install
a Using a bar which can be modulated clutch assembly (9).
inserted in the internal tooth a To check that the disc of the modu-
space, adjust the internal teeth of lated clutch assembly is not caught,
the disc. check that there is not clearance
between the cover and case before
tightening the cover mounting bolts.
2) Remove the plug and tighten 2 disc bolts

(101) (M12, P = 1.75 mm, 01024-81270).
3 Disc bolt:
Max. 49 Nm {Max. 5 kgm}
a By this work, piston (14) is pressed to
prevent the disc from moving.
WD600-6 50-302 25
6) Tighten 7 mounting bolts (8). 19. Related work

a Remove 2 disc bolts (101) (01024- 1) Install modulated clutch speed sensor (5).
81270) installed in the above step 2 Between cover and threaded part
and install the plug. of sensor: Gasket sealant (LG-5)
2 Plug (when reused):
2) Procedure for adjusting modulated clutch

speed sensor
18. Seal cage 1] Tighten modulated clutch speed sen-
1) Install seal rings (21). sor (5a) until it touches the plate of
2 Seal ring: Grease (G2-LI) clutch outer drum shaft (16) and then
return it 3/4 – 1 turn.
2] Tighten locknut (5b).
3 Locknut:
49.0 – 68.6 Nm {5 – 7 kgm}
2) Fit the O-ring and install seal cage (7).

3) Tighten mounting bolts (6).
50-302 26 WD600-6
3) Using sling [1], install torque converter 4) Using sling [1], while slinging torque con-
and PTO assembly (2) to transmission verter and PTO assembly (2), tighten 16
assembly (4). mounting bolts (3).
4 Torque converter and PTO assem- a The 2 sub-assembly bolts (25) do not
bly: 490 kg need to be tightened since they have
2
not been removed.
Transmission input shaft seal ring:
Grease (G2-LI)
a Project each seal ring evenly from the
shaft.
a If 2 seal rings (104) and 2 seal rings
(105) are pushed in forcibly, they may
be broken. Take care.
5) Set the transmission and torque converter

assembly on the block horizontally.
4 Transmission and torque converter
assembly: 1,800 kg
6) Install torque converter PTO lubrication
tube (1c).
7) Install torque converter speed sensor wir-

ing harness (1b).
WD600-6 50-302 27
8) Install modulated clutch lubrication hose

(1a).
9) Install oil tube (1) between the torque con-
verter and transfer.
50-302 28 WD600-6
Disassembly and assembly of transmission assembly SEN05145-02
Disassembly and assembly of

transmission assembly 1
Special tool
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
F 799-301-1500 Oil leak tester t 1
Disassembly
1. Preparation work
1) Disconnect the torque converter assembly
from the transmission assembly. For
details, see “Disassembly and assembly
of torque converter assembly”.
2) Remove transmission wiring harness (1).
7) Remove 3 torque converter regulator

mounting bolts (4) and torque converter
regulator valve (5).
3) Install eyebolts (M10, P = 1.5 mm) to part

(a) and sling the transmission control
valve assembly.
4) Remove 11 transmission control valve
assembly mounting bolts (2).
5) Lift off transmission control valve assem-
bly (3).
a Remove the O-ring, too.
4 Transmission control valve assem-
bly: 65 kg
6) Remove 4 lubrication valve mounting bolts
(2a) and lubrication valve assembly (2b).
WD600-6 50-302 29
SEN05145-02 Disassembly and assembly of transmission assembly
8) Using eyebolts [1] (M16, P = 2.0 mm), 3) Using slings [3] (M12, P = 1.75 mm), sling
remove 6 sleeves (6). transmission case (9).
9) Remove lubrication tube (7). 4) Remove 14 case mounting bolts (10).

5) Using 2 forcing screws [4] (M12, P = 1.75
mm), disconnect transmission case (9).
2. Transmission case
1) Using slings [2] (M12, P = 1.75 mm), sling
transmission and transfer assembly (8). 6) Using slings [5] (M12, P = 1.75 mm),
2) Set transmission and transfer assembly remove transmission case (9).
(8) on the block with the transfer case 4 Transmission case: 160 kg
down.
4 Transmission and transfer assem-
bly: 1,250 kg
50-302 30 WD600-6
3. Check of operating condition of piston 5. Input shaft and No. 1 carrier assembly
Using tool F, check the operating condition of 1) Install 2 eyebolts [6] (M18, P = 2.5 mm).
the piston before disassembling. a Stop tightening eyebolts [6] before
Air pressure: 0.29 – 0.49 MPa {3 – 5 kg/cm2} they reach the housing.
2) Using bar [7], remove input shaft and car-
Piston (from above) Stroke (mm) rier assembly (12).
No.1 6.1
No.2 6.1
No.3 4.2
No.4 8.1
No.5 3.7
No.6 3.7
3) Disassemble the input shaft and carrier

assembly according to the following pro-
cedure.
1] Remove snap ring (13).
2] While supporting the housing, push
out shaft (14).
4. Tie bolts
Remove 20 tie bolts (11).
a When only the transfer assembly needs to
be disassembled, leave 2 tie bolts (11a),
and the transmission assembly can be
removed from the transfer case.
a Since 2 (11a) of the 20 tie bolts are short,
make marks on them.
a Do not use an impact wrench to loosen
the tie bolts, since it can damage the
cushion sleeve.
3] Remove snap ring (15).

4] While supporting the housing, push
out carrier assembly (16) with push
tool [8] (Outside diameter: 129 mm).
WD600-6 50-302 31
5] Remove snap ring (17) from the 11] Remove shaft (25), ball (26), 2 thrust
housing and remove bearing (18). washers (27), bearing (28) and plane-
6] Remove seal ring (gold) (19) from the tary gear (29) from carrier (16).
bearing. a Take care not to lose the ball.
7] Remove snap ring (20) from carrier 6. Springs

assembly (16) and remove ring gear Remove 12 springs (30) and 36 springs (31).
(21). a Springs (31) are installed between the
plates.
8] Remove snap ring (22) from carrier

assembly (16) and remove bearing 7. Discs and plates
(23). Remove 6 discs (32), 5 plates (33) and piston
9] Remove spacer (24) from carrier plate (34).
assembly (16).
10] Remove seal ring (gold) (24a) from
spacer (24).
50-302 32 WD600-6
8. No. 1 piston housing 9. Springs

1) Using eyebolts [9] (M18, P = 2.5 mm), Remove 12 springs (41) and 36 springs (42).
remove piston housing (35). a Springs (42) are installed between the
plates.

remove piston (36) from housing (35). 10. Discs and plates
Remove 6 discs (43), 5 plates (44) and piston
plate (45).
3) Remove piston (38) and seal rings (39)

and (40) from housing (37).
11. No. 2 piston housing
Using eyebolts [11] (M18, P = 2.5 mm), remove
piston housing (46).
a Remove ring gear and carrier assembly
(47), too.
WD600-6 50-302 33
12. No. 1 ring gear and No. 2 carrier assembly 4] Remove bearing (55) from carrier
1) Using eyebolts [12] (M10, P = 1.5 mm), assembly (47).
remove ring gear and carrier assembly
(47) from No. 2 piston housing (46).
5] Remove spacer (145) from carrier

(47).
2) Remove piston (49) and seal rings (50) 6] Remove 2 seal rings (gold) (146) from
and (51) from housing (48). spacer (145).
7] Remove sun gear (147).
8] Remove bearing (148) from sun gear
(147).
9] Remove sun gear (149).
3) Disassemble the ring gear and carrier

cedure.
1] Reverse ring gear and carrier assem-
bly (47). 10] Reverse ring gear and carrier assem-
2] Remove ring gear (53). bly (47).
3] Remove snap ring (52) and ring gear 11] Remove snap ring (56) which is fixing
(54). the planetary gear shaft.
50-302 34 WD600-6
12] Remove shaft (58), plug (59), ball 15. No. 3 piston housing
(60), thrust washers (61), bearings 1) Using eyebolts [13] (M18, P = 2.5 mm),
(62) and planetary gears (63) from remove No. 3 piston housing (70).
carrier (57).
a Take care not to lose the ball.
2) Remove piston (71) and seal rings (72)

and (73) from housing (70).
13. Springs
1) Remove 12 springs (64) and 18 springs
(65).
a Springs (65) are installed between the
plates.
2) Remove guide pin (66).
3) Remove cushion sleeve (70a) from No. 3

piston housing (70).
a Check slit position (A).
14. Discs and plates

Remove 3 plates (67), 3 discs (68) and piston
plate (69).
WD600-6 50-302 35
16. No. 4 clutch (Revolution clutch) 4] Using push tool [16] (Outside diame-
1) Using eyebolts [14] (M18, P = 2.5 mm), ter: 5 mm), drive roll pin (79) into the
remove revolution clutch assembly (74) inside of carrier (78).
and No. 4 housing (75) together. 5] Remove shaft (80), plug (81), thrust
washers (82), bearing (83) and plane-
tary gear (84) from carrier (78).
a Take care not to lose the roll pin.
2) Disassemble the No. 6 carrier assembly

1] Reverse the revolution clutch assem-
bly. 3) Disassemble the No. 5 carrier assembly
2] Remove snap ring (76). and ring gear according to the following
procedure.
1] Using bar [17], remove No. 5 ring
gear (85) from revolution clutch
assembly (74).
3] Using bar [15], remove No. 6 carrier

assembly (77) from revolution clutch
assembly (74).
50-302 36 WD600-6
2] Using push tool [19] (Outside diame- 4) Disassemble the revolution clutch assem-
ter: 5 mm), drive roll pin (92) into car- bly according to the following procedure.
rier (91). 1] Remove snap ring (98) and then
3] Remove shaft (93), plug (94), thrust remove revolution clutch (99) from
washers (95), bearing (96) and plane- housing (75) with bar [20].
tary gear (97) from carrier (91).
a Take care not to lose the roll pin.
2] Remove bolts (101) and housing

(102) from ring gear (116).
4] Remove snap ring (86) and remove
sun gear (87) and bearing (88) from
No. 5 ring gear (85).
5] Remove snap ring (87a) of sun gear
(87) and then remove bearing (88).
3] Remove 8 discs (103), 8 wave springs

(104) and 7 plates (105) from ring
gear (116).
WD600-6 50-302 37
4] Remove inner gear (106) from ring 10] Remove snap ring (154).
gear (116). 11] Using puller [22], remove housing
5] Remove bearing (107) from inner (111) from shaft (110).
gear (106).
a Remove the bearing carefully
and horizontally not to slant it.
12] Using puller [18], remove shaft (110)

from No. 5 carrier (91).
6] Using press fitting tool [21] (Inside

diameter: 160 mm), compress the
disc spring and remove snap ring
(108).
a Installed load of disc spring:
240 kg
7] Remove 5 disc springs (109).
13] Remove snap ring (90) from shaft

(110) and remove sun gear (89).
8] Remove piston (151) from housing

(150).
9] Remove seal rings (152) and (153).
50-302 38 WD600-6
14] Remove snap ring (121) and then 19. No. 5 piston housing
remove bearing (123) from housing 1) Using eyebolts [23] (M18, P = 2.5 mm),
(122). remove No. 5 piston housing (129).
remove piston (130) from piston housing
(129).
17. Springs
Remove 12 springs (124) and 18 springs
(125).
a Springs (125) are installed between the 3) Remove seal ring (132) from housing
plates. (129) and remove seal ring (131) from pis-
ton (130).
18. Discs and plates
Remove 3 plates (126), 3 discs (127) and pis-
ton plate (128).
WD600-6 50-302 39
20. Springs 23. No. 6 piston housing

Remove 12 springs (133) and 18 springs 1) Using eyebolts [25] (M18, P = 2.5 mm),
(134). remove No. 6 piston housing (139).
a Springs (134) are installed between the 2) Remove ring gear (140).
plates. 3) Using eyebolts [26] (M10, P = 1.5 mm),
remove piston (141) from piston housing
21. Discs and plates (139).
Remove 3 plates (135), 3 discs (136) and pis-
ton plate (137).
22. Guide pins

Remove 6 guide pins (138).
4) Remove seal ring (143) from housing

(139) and remove seal ring (142) from pis-
ton (141).
50-302 40 WD600-6
Assembly 2) Using eyebolts [26] (M10, P = 1.5 mm),

Precautions for assembly install piston (141) to piston housing (139).
q Apply transmission oil (TO10) to the rotary 3) Using eyebolts [25] (M18, P = 2.5 mm),
parts and sliding parts before installing. install No. 6 piston housing (139).
4) Install ring gear (140).
q Coat each seal ring with grease (G2-LI) and 5) Drive 2 dowel pins (155) into housing
install it evenly. (139).
q Coat the inside and outside fixed surfaces of
each bearing with adhesive (ThreeBond
1373B or equivalent) when installing.
q When installing the discs of each clutch, set
their notches to each other.
q Check that each snap ring is fitted securely to
the groove.
1. Preparation work
Clean all the parts and remove burrs etc.

1) Install seal ring (143) to housing (139) and
install seal ring (142) to piston (141).
a Set groove (a) of the seal ring against

direction (b) of the pressure.
WD600-6 50-302 41
3. Guide pins a Set groove (c) of the seal ring against

Install 6 guide pins (138). direction (d) of the pressure.
a Length of guide pin: 125 mm
4. Discs, plates and springs

1) Install piston plate (137).
2) Install 3 discs (136), 18 springs (134) and
3 plates (135) alternately.
3) Install 12 springs (133).

install piston (130) to No. 5 piston housing
(129).
install No. 5 piston housing (129).
4) Drive 2 dowel pins (156) into housing

(129).
50-302 42 WD600-6
6. Discs, plates and springs 3] Install No. 6 carrier assembly (77) to

1) Install lower plate (128). shaft (110).
2) Install 3 discs (127), spring (125) and 3 4] Install snap ring (76).
plates (126) alternately.
3) Install springs (124).
5] Install sun gear (87) and bearing (88)

to shaft (110).
6] Using push tool [30] (Inside diameter:
95 mm), press fit bearing (88).
7. No. 6 and No. 5 carriers

1) Assemble the No. 6 carrier assembly
according to the following procedure. 7] Install snap ring (87a).
1] Install thrust washers (82), bearing 8] Install No. 5 ring gear (85) to sun gear
(83), planetary gear (84), plug (81) (87).
and shaft (80) to carrier (78). 9] Install snap ring (86).
2] Using push tool [16] (Outside diame- 10] Install sun gear (89) and snap ring
ter: 5 mm), drive in roll pin (79). (90).
WD600-6 50-302 43
11] Install seal ring (158) to shaft (110). 3] Fit spacer (159) to No. 4 housing
2 Seal ring: Grease (G2-LI) (122) and tighten 2 mounting bolts
(160).
3 Mounting bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
2) Install shaft (110) and No. 6 carrier assem-

bly (77) to No. 5 piston housing (129).
4] Set No. 5 carrier (91) to the tool and

install No. 4 housing (122).
121 mm), press fit bearing (123).
3) Assemble the No. 5 carrier assembly

1] Install thrust washers (95), bearing
(96), planetary gear (97), plug (94)
and shaft (93) to carrier (91).
2] Using push tool [19] (Outside diame-
ter: 5 mm), drive in roll pin (92). 6] Install snap ring (121) to No. 5 carrier
(91).
50-302 44 WD600-6
8. No. 4 housing 4) Install 5 disc springs (109).

1) Install No. 4 housing (122) and No. 5 car- 5) Using press fitting tool [21] (Inside diame-
rier (91) to shaft (110). ter: 160 mm), compress the disc spring
2) Drive in 2 dowel pins (161). and install snap ring (108).
a Installed load of disc spring: 240 kg
9. No. 4 clutch (Revolution clutch)

1) Using push tool [32] (Outside diameter: 6) Set the inner gear to block [36], and using
119 mm), press fit bearing (120) to hous- push tool [33] (Inside diameter: 106 mm),
ing (102). press fit bearing (107) to inner gear (106)
with presser.
7) Install inner gear (106) to ring gear (116).

3) Install piston (151) to housing (150).
WD600-6 50-302 45
8) Install 7 plates (105), 8 wave springs (104) 11) Using eyebolts, install revolution clutch
and 8 discs (103) to ring gear (116). assembly (74) to No. 4 housing (122).
12) Install snap ring (98).
9) Install housing (102) to ring gear (116) and

tighten bolts (101). 10. Spacer
2 Mounting bolt: Adhesive (LT-2) 1) Install 2 seal rings (146) to spacer (145).
3 Mounting bolt: 2 Seal ring: Grease (G2-LI)
156.8 – 196.0 Nm {16 – 20 kgm}
2) Install spacer (145) to shaft (110).

10) Install 2 seal rings (162) to housing (102).
50-302 46 WD600-6
11. Sun gear a Set groove (e) of the seal ring against
1) Using push tool [34] (Outside diameter: 99 direction (f) of the pressure.
mm), press fit bearing (148) to sun gear
(147).
2) Install piston (71) to piston housing (70).

3) Drive 2 dowel pins (163) into piston hous-
2) Install sun gear (147) to shaft (110). ing (70).
12. No. 3 piston housing 4) Install cushion sleeve (70a) to No. 3 piston
1) Install seal ring (73) to housing (70) and housing (70).
install seal ring (72) to piston (71). a Set slit position (A) as checked when
2 Seal ring: Grease (G2-LI) removed.
WD600-6 50-302 47
5) Using eyebolts [13] (M18, P = 2.5 mm), 15. No. 1 ring gear and No. 2 and No. 3 carrier
install No. 3 piston housing (70). assembly
1) Assemble the ring gear and carrier
cedure.
1] Install thrust washers (61), bearings
(62) and planetary gears (63) to car-
rier (57).
2] Install plug (59) and ball (60) to shaft
(58) and then install them to carrier
(57).
13. Guide pins

Install 6 guide pins (66).
a Length of guide pin: 225 mm
14. Discs, plates and springs

1) Install piston plate (69).
2) Install 3 discs (68), 18 springs (65) and 3
plates (67) alternately.
3) Install 12 springs (64).
3] Install snap ring (56) to fix the plane-
tary gear shaft to ring gear and carrier
assembly (57).
50-302 48 WD600-6
4] Install No. 1 ring gear (54) to carrier 16. No. 2 piston housing
assembly (57). 1) Install seal ring (51) to housing (48) and
5] Install snap ring (52). install seal ring (50) to piston (49).
2) Install piston (49) to housing (48).
2) Install sun gear (148) to sun gear (147).
a Set groove (g) of the seal ring against

direction (h) of the pressure.
3) Install No. 2 and No. 3 carriers (57) to No.

3 piston housing (70).
3) Using eyebolts (M18, P = 2.5 mm), install

No. 2 piston housing (46) to No. 3 piston
housing (70).
4) Drive 2 dowel pins (164) into piston hous-
ing (70).
WD600-6 50-302 49
17. Discs, plates and springs 18. Sun gear

1) Install lower plate (45). 1) Using push tool [35] (Inside diameter: 86
2) Install 6 discs (43), springs (42) and 6 mm), press fit bearing (150) to sun gear
plates (44) alternately. (149).
3) Install springs (41).
2) Install sun gear (149) to No. 2 and No. 3

carrier (57).
19. No. 1 carrier assembly and input shaft

1) Assemble the input shaft and carrier
cedure.
1] Install thrust washers (27), bearing
(28) and planetary gear (29) to carrier
(16).
2] Install ball (26) to shaft (25) and then
install them to carrier (16).
50-302 50 WD600-6
3] Drive 1 dowel pin (151) to carrier (16). 2] Install snap ring (13) to input shaft
4] Install seal ring (gold) (152) to spacer (14).
(24). 3] Install seal ring (154), 2 seal rings
2 Seal ring: Grease (G2-LI) (155), 2 seal rings (156) and 2 seal
5] Install spacer (24) to carrier (16). rings (157) to the input shaft (14).
6] Install ring gear (21) and snap ring 2 Seal ring: Grease (G2-LI)
(20).
3) Install the input shaft (14) to sun gear

2) Assemble the input shaft according to the (149).
71 mm), press fit bearing (153) to the
input shaft (14).
4) Install No. 1 carrier (16) to No. 2 and No. 3

carrier (57).
WD600-6 50-302 51
20. No. 1 piston housing 21. Discs, plates and springs

1) Install seal ring (40) to housing (37) and 1) Install piston plate (34).
install seal ring (39) to piston (38). 2) Install 6 discs (32), springs (31) and 5
2 Seal ring: Grease (G2-LI) plates (33) alternately.
2) Install piston (38) to housing (37). 3) Install spring (30).
a Set groove (j) of the seal ring against 22. Housing

direction (k) of the pressure. 1) Using push tool [27] (Inside diameter: 131
mm), press fit bearing (18) to housing
(12).
3) Using eyebolts (M18, P = 2.5 mm), install

No. 1 piston housing (37) to No. 2 piston
housing (48). 2) Install snap ring (17) to housing (12).
4) Drive in 2 dowel pins (158). 3) Install seal ring (gold) (19) to housing (12).
50-302 52 WD600-6
4) Install 2 eyebolts [29] (M10, P = 2.5 mm). 23. Tie bolts

a Stop tightening eyebolts [29] before Install 20 tie bolts (11).
they reach the housing. a If only the transfer assembly was disas-
5) Sling and install housing (12). sembled, fix the clutch with 2 tie bolts
2 Spline (a) of input shaft: (11a).
Grease (LM-G) a There are 2 short ones (11a) in the 20 tie
bolts. Check their marks made when
removed.
a Tighten each tie bolt with the fingers until it
reaches the tap hole so that it will not
damage the cushion sleeve.
a Use an impact wrench only after the
threads are engaged perfectly.
3 Mounting bolt:
157 – 177 Nm {16 – 18 kgm}
24. Check of operating condition of piston

Using tool F, check the operating condition of
the piston before disassembling.
Air pressure: 0.29 – 0.49 MPa {3 – 5 kg/cm2}
Piston (from above) Stroke (mm)

No.1 6.1
No.2 6.1
No.3 4.2
No.4 8.1
No.5 3.7
No.6 3.7
WD600-6 50-302 53
25. Transmission case 26. Related work

1) Using sling [5] (M12, P = 1.75 mm), install 1) Sling the transmission and transfer
transmission case (9). assembly and set them on the side.
4 Transmission case: 160 kg 4 Transmission and transfer assem-
bly: 1,250 kg
2) Install lubrication tube (7).
3 Joint bolt:
34.3 – 44.1 Nm {3.5 – 4.5 kgm}

install 6 sleeves (6).
3) Install torque converter regulator valve (5).

53.9 – 63.7 Nm {5.5 – 6.5 kgm}
3) Install case mounting bolts (10a) and

(10b).
3 Mounting bolt:
53.9 – 122.6 Nm {5.5 – 12.5 kgm}
50-302 54 WD600-6
4) Fit the O-ring, install eyebolts (M10, P = 7) Install the torque converter assembly to
1.5mm) to part (a), and install transmis- the transmission assembly. For details,
sion control valve assembly (3). see “Disassembly and assembly of torque
2 O-ring: Grease (G2-LI) converter assembly”.
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
bly: 65 kg
5) Install lubrication valve assembly (2b) and
tighten 4 mounting bolts (2a).
6) Install transmission wiring harness (1).
WD600-6 50-302 55
SEN05145-02 Disassembly and assembly of transfer assembly
Disassembly and assembly of 6) Remove 4 lubrication valve mounting bolts

transfer assembly 1
(2a) and lubrication valve assembly (2b).
Special tool
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
F 799-301-1500 Oil leak tester t 1
1 793-615-1130 Spline wrench t 1
G
2 796-730-2300 Wrench assembly t 1
Disassembly
1. Preparation work
1) Disconnect the torque converter assembly
from the transmission assembly. For
details, see “Disassembly and assembly
of torque converter assembly”.
2) Remove transmission wiring harness (1).
7) Remove 3 torque converter regulator

mounting bolts (4) and torque converter
regulator valve (5).
3) Install eyebolts (M10, P = 1.5 mm) to part

(a) and sling the transmission control
valve assembly.
4) Remove 11 transmission control valve
assembly mounting bolts (2).
5) Lift off transmission control valve assem-
bly (3).
a Remove the O-ring, too.
bly: 65 kg
50-302 56 WD600-6
Disassembly and assembly of transfer assembly SEN05145-02
8) Using eyebolts [1] (M16, P = 2.0 mm), 3) Using slings [3] (M12, P = 1.75 mm), sling
remove 6 sleeves (6). transmission case (9).
9) Remove lubrication tube (7). 4) Remove 14 case mounting bolts (10).

5) Using 2 forcing screws [4] (M12, P = 1.75
mm), disconnect transmission case (9).
1) Using slings [2] (M12, P = 1.75 mm), sling
transmission and transfer assembly (8). 6) Using sling [5] (M12, P = 1.75 mm),
2) Set transmission and transfer assembly remove transmission case (9).
(8) on the block with the transfer case 4 Transmission case: 160 kg
down.
4 Transmission and transfer assem-
bly: 1,250 kg
WD600-6 50-302 57
3. Check of operating condition of piston 5. Remove speed sensors (12).

Using tool F, check the operating condition of
the piston before disassembling.

No.1 6.1
No.2 6.1
No.3 4.2
No.4 8.1
No.5 3.7
No.6 3.7
6. Input shaft bearing cage assembly

mm), remove bearing cage assembly (14).
4. Tie bolts
1) Remove 18 tie bolts (11).
a Since the transmission assembly is
not disassembled at this time, leave 2
tie bolts (11a) to fix the sub-assembly.
a Do not use an impact wrench to
loosen the tie bolts, since it can dam- 3) Remove outer race (15) from bearing
age the cushion sleeve. cage assembly (14).
2) Install 2 eyebolts (M10, P = 2.5 mm) to the
tie bolt holes and lift off the transmission
assembly.
4 Transmission assembly: 500 kg
50-302 58 WD600-6
7. Input shaft gear assembly 10. Parking brake assembly

1) Using forcing screws [7] (M12, P = 1.75 a For disassembly of the parking brake
mm), remove input shaft gear assembly assembly, see “Disassembly and assem-
(16). bly of parking brake assembly”.
2) Remove bearings (17) and (18) from input 1) Remove 2 plugs (26) and tighten the
shaft gear assembly (16). mounting bolts.
a Tighten the bolts alternately little by
little.
a Tighten the bolts to pull the piston.
a Do not remove 4 hexagon socket
head bolts (sub-assembly bolts) (28).
4) Using forcing screws [9], remove seal
cage (30).
8. Parking brake emergency release valve

1) Reverse the case.
2) Remove mounting bolts (20) and parking
brake emergency release valve (21).
mm), remove sleeve (22).
5) Remove oil seal (31) and dust seal (32)

from seal cage (30).
9. Coupling (rear side)

Remove mounting bolt (23), holder (24) and
coupling (25).
WD600-6 50-302 59
6) Using forcing screws [10] (M12, P = 13. Seal cage

1.75m m), disco nnect parkin g b rake 1) Remove 4 mounting bolts (39).
assembly (33). 2) Remove seal cage (40).
7) Using eyebolts [11], remove parking brake 3) Remove shim (41).
assembly (33). a Check the quantity and thickness of
the inserted shim.
11. Gear cover

2) Move gear cover (35) aside.
14. Input shaft bearing cage
2) Remove seal cage (45).
3) Remove bearings (46a) and (46b) and
spacer (47) from seal cage (45).
a Since the 2 bearings are not inter-
changeable, keep them as a set.
12. Coupling (front side)

Remove mounting bolt (36), holder (37) and
coupling (38).
15. Output shaft gear

take out output shaft gear (48) and output
shaft together.
a Sling output shaft gear (48) around
gear cover (35).
50-302 60 WD600-6
2) Remove gear cover (35).
5) Remove outer race (55) from bearing

3) Remove output shaft (49) from output cage assembly (54).
shaft gear (48).
17. Intermediate shaft gear assembly

4) Remove outer race (50). 1) Using forcing screws [14] (M12, P = 1.75
mm), remove intermediate shaft gear
assembly (56).
2) Remove bearings (57) and (58) from inter-
mediate shaft gear assembly (56).
16. Intermediate shaft bearing cage assembly

2) Remove cover (52).
mm), remove bearing cage assembly (54).
a Check the quantity and thickness of
the inserted shim.
WD600-6 50-302 61
3) Remove outer race (59). Assembly

1. Intermediate shaft gear assembly
1) Outer race (intermediate shaft side)
Using push tool [1] (Outside diameter: 199
mm), press fit outer race (59) to the case.
18. Cover (input shaft side)

2) Using forcing screw [15] (M12, P = 1.75
mm), remove cover (61).
2) Install bearings (57) and (58) to intermedi-
ate shaft gear (56).
3) Apply grease to the roller surfaces of the
bearing, rolling surfaces (d) of the inner
and outer races, inner race flanges, and
roller contact surface (e).
2 Parts (d) and (e) of bearing:
Grease (LM-G)
mm), install intermediate shaft gear
assembly (56).
3) Remove outer race (62) from cover (61).
50-302 62 WD600-6
2. Intermediate shaft bearing cage assembly 5] Using tool G1 and a torque wrench,
1) Using push tool [2] (Outside diameter: 199 measure the rotation torque of inter-
mm), press fit outer race (55) to bearing mediate shaft gear (56).
cage (54). Rotation torque:
0.98 – 1.96 Nm {0.1 – 0.2 kgm}
Standard shim thickness: 1 mm
a Check that the gear has no play.
6] Adjust the quantity of the shims to set
the rotation torque in the above
range.
7] After finishing adjustment, tighten the
m o u n t i n g b o l ts t o t h e s p e c i f i e d
torque.
a After installing the bearing, drop
about 6 cc of transmission oil
(TO30) onto it and revolve it
about 10 turns.
2) Fit the O-ring and install intermediate shaft
bearing cage assembly (54) without set-
ting the shim.
3. Cover (input shaft side)

1) Using push tool [3] (Outside diameter: 189
mm), press fit outer race (62) to bearing
cage (61).
3) Adjustment of preload on intermediate
shaft bearing
Adjust the shim of bearing cage (54)
1] Install bearing cage (54) without set-
ting shim (62) and tighten the mount-
ing bolts to 4.9 Nm {0.5 kgm}.
a Use all the mounting bolts.
2] Rotate intermediate shaft gear (56)
20 turns and check the tightening
torque of 4.9 Nm {0.5 kgm} for the
mounting bolts.
changed, set shim (62) (Standard
thickness: 1 mm) and tighten the
torque.
WD600-6 50-302 63
2) Fit the O-ring and install cover (61) without 5. Bearing cage assembly (input shaft gear
setting the shim. side)
2 O-ring: Grease (G2-LI) 1) Using push tool [4] (Outside diameter: 199
a Tighten the bolts temporarily at this mm), press fit outer race (15) to bearing
time. cage (14).
4. Input shaft gear assembly 2) Using forcing screws [6] (M12, P = 1.75
1) Press fit bearings (17) and (18) to input mm), install input shaft bearing cage
shaft gear (16). assembly (14).
2) Apply grease to the roller surfaces of the 3) Install 6 mounting bolts (13).
bearing, rolling surfaces (d) of the inner 2 Mounting bolt: Adhesive (LT-2)
and outer races, inner race flanges, and

roller contact surface (e).
2 Parts (d) and (e) of bearing:
Grease (LM-G)
mm), install input shaft gear (16).
50-302 64 WD600-6
4) Adjustment of preload on input shaft bear- 6. Bearing cage assembly (output shaft side)
ing 1) Using the push tool, press fit outer race
Adjust the shim of bearing cage (61) (46a), spacer (47) and bearing (46b) to
according to the following procedure. bearing cage (45).
a Since the preload on the input shaft 2) Fit the O-ring and install bearing cage
bearing is adjusted without removing assembly (45).
the intermediate shaft bearing, the 2 O-ring: Grease (G2-LI)
rotation torque is roughly doubled. 3) Install 6 mounting bolts (44).
1] Install bearing cage (61) without set-
ting shim (63) and tighten the mount-
ing bolts to 4.9 Nm {0.5 kgm}.
a Use all the mounting bolts.
2] Rotate input shaft gear (16) 20 turns
and check the tightening torque of 4.9
Nm {0.5 kgm} for mounting bolts
(60).
changed, set shim (63) (Standard
thickness: 1.1 mm) and tighten the
torque. 7. Output shaft gear assembly
5] Using tool G2 and a torque wrench, 1) Apply grease to spline (f) of output shaft
measure the rotation torque of inter- (49).
mediate shaft gear (16). 2 Spline (f) of shaft: Grease (LM-G)
Rotation torque:
1.96 – 3.92 Nm {0.2 – 0.4 kgm}
Standard shim thickness: 1.1 mm
a Check that the gear has no play.
6] Adjust the quantity of the shims to set
the rotation torque in the above
range.
7] After finishing adjustment, tighten the
torque.
2) Install output shaft (49) to output shaft

gear (48).
WD600-6 50-302 65
3) Put gear cover (35) in the case. 2) Using the push tool, press fit oil seal (42)
4) Using sling [12], sling and install output to seal cage (40).
shaft gear (48). 2 Oil seal fitting surface:
a Sling output shaft gear (48) around Gasket sealant (LG-5)
gear cover (35). a Apply the gasket sealant thinly over
the inside surface of the seal cage
(40) and wipe off the projected part.
a Dimension "b" is 7.4 to 7.5 mm.
5) Set gear cover (35) and install 3 mounting

bolts (34).
3) Apply or fill grease to/into the oil seal and
dust seal lip as shown in the following figure.
Portion "a":Apply grease (G2-S or G2-LI)
to the lip ends (4 places).
Portion "b":Fill grease (G2-S or G2-LI) into
the spaces "between the main
lip and dust lip of oil seal",
"between the dust seal and oil
seal", and "between the double
lips of dust seal" up to 40 to
60%.
Excessively applied grease
can be mistaken for oozing oil.
Take care.
8. Seal cage assembly (output shaft side) Wipe off the grease forced in or
1) Press fit dust seal (43) to seal cage (40) out.
by using the push tool. Portion “c”: Grease may be forced out
a When installing dust seal (43), direct into the space between oil seal
its lip out. and dust seal.
a Dimension "a" is 22 ± 0.1 mm.
50-302 66 WD600-6
4) Adjust the shim according to the following 10. Parking brake assembly
procedure. a For assembly of the parking brake assem-
1] Fit the O-ring and install seal cage bly, see "Disassembly and assembly of
(40) without setting the shim. parking brake assembly".
2 O-ring: Grease (G2-LI) 1) Apply grease to spline (h) of the shaft.
2] Install the coupling temporarily and 2 Spline (h) of shaft: Grease (LM-G)
rotate the shaft about 20 turns.
3] Tighten mounting bolts (39) to 0.49 –
0.98 Nm {0.05 – 0.10 kgm}.
4] Using the thickness gauge, measure
clearance (a) between seal cage (40)
and mounting face.
Shim thickness (b):
a – (0.05 to 0.10 mm)
5] Install shim (41) of thickness (b)
obtained by the above step and
tighten mounting bolts (39).
Shim thickness: 0.15, 0.2, 0.5 mm
6] After adjusting the shim, tighten
mounting bolts (39) to the specified
torque. 2) Using eyebolts [11], install parking brake
assembly (33).
9. Coupling (front side)

1) Apply grease to spline (g) of the shaft. 3) Install 12 mounting bolts (27).
2 Spline (g) of shaft: Grease (LM-G) 2 Mounting bolt: Adhesive (LT-2)
2) Fit the O-ring and press fit coupling (38). 3 Mounting bolt:
3) Install holder (37) and bolt (36). 98.0 – 123 Nm {10.0 – 12.5 kgm}
2 O-ring: Grease (G2-LI) 4) Remove the bolts which have been clamp-
2 Mounting bolt: Adhesive (LT-2) ing the piston and install 2 plugs (26).
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
WD600-6 50-302 67
5) Press fit oil seal (31) to seal cage (30) by Portion “c”: Grease may be forced out
using push tool. into the space between oil seal
2 Oil seal press fitting surface: Liq- and dust seal.
uid gasket (LG-5) (Thinly apply
to inside of seal cage (30), and
wipe off excess.)
a Dimension "a" is 17.7 to 17.8 mm.
8) Fit the O-ring, install seal cage (30), and

tighten 4 mounting bolts (29).
6) Press fit dust seal (32) to seal cage (30)

by using the push tool.
a When installing the dust seal, direct
its lip out.
a Dimension "b" is 9.3 to 9.4 mm.

Fit the O-ring and install coupling (25), holder
(24) and bolt (23).
a Set coupling (25) to the position of the
coupling on the opposite side.
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
7) Apply or fill grease to/into the oil seal and
dust seal lip as shown in the following fig-
ure.
Portion "a":Apply grease (G2-S or G2-LI)
to the lip ends (4 places).
Portion "b": Fill grease (G2-S or G2-LI) into
the spaces "between the main
lip and dust lip of oil seal",
"between the dust seal and oil
seal", and "between the double
lips of dust seal" up to 40 to 60%.
Excessively applied grease can
be mistaken for oozing oil. Take
care.
Wipe off the grease forced in or
out.
50-302 68 WD600-6

1) Fit the O-ring and install sleeve (22), using
forcing screws [8].
2) Fit the O-ring, install parking brake emer-
gency release valve (21) and tighten
mounting bolts (20).
14. Tie bolts

1) Install 2 eyebolts (M10, P = 2.5 mm) to the
tie bolt holes and sling and install the
transmission assembly.
4 Transmission assembly: 500 kg
2) Install 20 tie bolts (11).
a Use 2 tie bolts (11a) to fix the trans-
mission as a sub-assembly.
13. Speed sensor
a There are 2 short ones (11a) in the 20
1) Install speed sensors (12).
tie bolts. Check their marks made
a Take care that the direction of the
when removed.
sensor wiring harness outlet will not
a Tighten each tie bolt with the fingers
be opposite to the mounting direction
until it reaches the tap hole so that it
of the connector.
2 Between case and threaded part of
will not damage the cushion sleeve.
a Use an impact wrench only after the
speed sensor: Adhesive (LG-5)
3 Locknut:
threads are engaged perfectly.
3 Mounting bolt:
49.0 – 68.6 Nm {5 – 7 kgm}
157 – 177 Nm {16 – 18 kgm}
2) Method of adjusting speed sensor

1] Tighten speed sensor (12a) until it
touches gear (12b) and then return it
by 1/2 – 1 turn.
2] Tighten locknut (12c).
3 Locknut:
49.0 – 68.6 Nm {5 – 7 kgm}
WD600-6 50-302 69
15. Check of operating condition of piston 2) Using eyebolts [1] (M16, P = 2.0 mm),
Using tool F, check the operating condition of install 6 sleeves (6).
the piston.

No.1 6.1
No.2 6.1
No.3 4.2
No.4 8.1
No.5 3.7
No.6 3.7
3) Install case mounting bolts (10a) and

(10b).
3 Mounting bolt:
53.9 – 122.6 Nm {5.5 – 12.5 kgm}

1) Using sling [5] (M12, P = 1.75 mm), install
transmission case (9).
4 Transmission case: 160 kg
17. Related work

1) Install lubrication tube (7).
50-302 70 WD600-6
2) Install torque converter regulator valve (5). 5) Install transmission wiring harness (1).
3 Mounting bolt (4): 6) Connect the transmission assembly to the
53.9 – 63.7 {5.5 – 6.5 kgm} torque converter assembly. For details,
see “Disassembly and assembly of torque
converter assembly”.
3) Fit the O-ring, install eyebolts (M10, P =

1.5 mm) to part (a), and install transmis-
sion control valve assembly (3).
44.1 – 55.9 {4.5 – 5.5 kgm}
bly: 65 kg
4) Install lubrication valve assembly (2b) and
4 mounting bolts (2a).
WD600-6 50-302 71
SEN05145-02 Disassembly and assembly of parking brake assembly
Disassembly and assembly of 2) Remove 12 mounting bolts (8).

parking brake assembly 1
a Do not remove 4 hexagon socket
head bolts (sub-assembly bolts) (9).
Disassembly 3) Remove 4 mounting bolts (10).
1. Preparation work 4) Using forcing screws [2], remove seal
Disconnect the torque converter assembly cage (11).
from the transmission assembly. For details,
see “Disassembly and assembly of transmis-
sion assembly”.

1) Remove mounting bolts (1) and parking
brake emergency release valve (2).
mm), remove sleeve (3).


Remove mounting bolt (4), holder (5) and cou-
pling (6).

mm), disconnect parking brake assembly
(14).
7) Using eyebolts [4], remove parking brake
assembly (14).
4. Parking brake assembly

1) Remove 2 plugs (7) and tighten the
mounting bolts.
little.
50-302 72 WD600-6
Disassembly and assembly of parking brake assembly SEN05145-02
5. Cover assembly 6. Springs

1) Remove 4 hexagon socket head bolts (15) Remove 18 outer springs (19) and 18 inner
from cover (16). springs (20).
a Since the cover is floated by the
springs, loosen the hexagon socket
head bolts gradually and evenly.
7. Piston
1) Using eyebolts [6] (M12, P = 1.75 mm), lift
off piston (22) from housing (21).
2) Using eyebolts [5], lift off cover (16).
2) Remove seal rings (23) and (24) from pis-

3) Remove bearing (17) and dowel pin (18) ton (22).
from cover (16).
WD600-6 50-302 73
8. Spacer assembly 10. Plate

1) Remove spacer (25) from housing (21). 1) Reverse the housing.
2) Remove 4 mounting bolts (28) and plate
(29).
2) Using push tool [7], remove inner race

(26) from spacer (25).
11. Snap ring and end plate
Remove snap ring (30) and end plate (31).
9. Gear
Using eyebolts [8] (M12, P = 1.75 mm),
remove gear (27) from housing (21). 12. Plates, discs and wave springs
Remove 8 plates (32), 7 discs (33) and 7 wave
springs (34) alternately.
50-302 74 WD600-6
Assembly 3. Springs
1. Cover Install 18 outer springs (19) and 18 inner
Assemble the cover assembly according to the springs (20).
1) Using push tool [1] (Outside diameter: 189
mm), press fit bearing (17) to cover (16).
2) Install 2 dowel pins (18).
4. Piston
1) Install seal rings (23) and (24) to piston
(22).
a Set grooves (a) of the seal rings as
2. Spacer assembly shown below.
1) Using push tool [2] (Inside diameter: 106 2 Seal ring: Grease (G2-LI)
mm), press fit inner race (26) to spacer 2) Install piston (22) to cover (16).
(25).
2) Press fit spacer assembly (25) to cover
assembly (16).
WD600-6 50-302 75
5. Plugs 7. Gear
1) Remove 2 plugs (7). Install gear (27).
2) Fit the washers to 2 parking brake assem-
bly mounting bolts and tighten them into
the plug holes.
little.
8. Plates, discs and wave springs

Install 8 plates (33), 7 discs (32) and 7 wave
springs (34) alternately.
6. Housing
1) Fit the O-ring to cover (16) and install
housing (21), using sling [9].
9. Snap ring and end plate

Install end plate (31) and fix it with snap ring
(30).
2) Tighten 4 hexagon socket head bolts (15).
50-302 76 WD600-6
10. Plate 12. Seal cage

Install plate (29) and tighten mounting bolts 1) Press fit oil seal (12) and dust seal (13) to
(28). seal cage (11).
2 Mounting bolt: Adhesive (LT-2) 2 Oil seal: Grease (G2-LI)
2 Press fitting face of oil seal:
2 Dust seal: Grease (G2-LI)
2 Mating faces of oil seal and dust
seal: Grease (G2-LI)
a Apply the gasket sealant thinly to the
inside of the oil seal fitting section of
the cover and wipe off the projected
part.
11. Plugs
1) Reverse the parking brake assembly.
2) Remove the 2 bolts used to install the
springs and install plugs (7).
2 Plug: Adhesive (LT-2)
2) Install seal cage (11) and tighten mounting

bolts (10).
WD600-6 50-302 77
13. Parking brake assembly 14. Coupling (rear side)

1) Apply grease to spline (h) of the shaft. Fit the O-ring and install coupling (6), holder (5)
2 Spline (h) of shaft: Grease (LM-G) and bolt (4).
a Set coupling (6) to the position of the cou-
pling on the opposite side.
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
2) Using eyebolts [4], install parking brake

assembly (14).

1) Fit the O-ring and install sleeve (3), using
forcing screws [1].
2) Fit the O-ring, install parking brake emer-
gency release valve (2), and tighten
mounting bolts (1).

3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
16. Related work

Connect the transmission assembly to the
transfer assembly. For details, see “Disassem-
bly and assembly of transmission assembly”.
50-302 78 WD600-6
WD600-6 50-302 79
SEN05145-02
WD600-6 Wheel dozer

©2018 KOMATSU
All Rights Reserved
50-302 80
SEN05146-01
WHEEL DOZER
WD600-6
WD600-6 55001 and up

Removal and installation of front axle assembly ............................................................................................. 2
Removal and installation of rear axle assembly.............................................................................................. 4
Removal and installation of center support assembly..................................................................................... 6
Disassembly and assembly of center support assembly ................................................................................ 8
Disassembly and assembly of differential assembly..................................................................................... 12
WD600-6 50-303 1
SEN05146-01 Removal and installation of front axle assembly
Removal and installation of front 4. Disconnect brake hose (3).

axle assembly 1
Removal
k Park the machine on level ground.
k Release the remaining pressure in the
brake accumulator system, referring to
“Releasing residual pressure in brake
accumulator circuit” in Testing and adjust-
ing.
1. Remove the blade assembly, referring to

“Removal and installation of work equipment 5. Remove mounting bolts (4) and disconnect
assembly.” front drive shaft (5). [*2]
a Lift the drive shaft with rope, etc. to pre-
2. Place the lift arm (1) to the support stands [1]. vent falling.
Operate the work equipment control lever to lift
the machine body and set the block [2] to the 4 Front drive shaft: 65 kg
front frame.
a Release the parking brake since the
machine body moves forward.
a Lift the lift arm high enough to allow the
front axle to hang and be withdrawn, lock
the work equipment control lever, apply
parking brake and stop the engine.
k Set the lock bar to the frame and put

the blocks under the rear wheels.
3. Lift and remove tire assembly (2). [*1]

4 Tire assembly: 1,550 kg
50-303 2 WD600-6
Removal and installation of front axle assembly SEN05146-01
6. Lift front axle assembly (6) temporarily and Installation

remove the mounting bolts. [*3] q Carry out installation in the reverse order to
a Don't lift by section (A) as it has floating removal.
seal. To lift, mount plate [1], etc. to the
tapped holes for the wheel hub rim mount- [*1]
ing bolts. 3 Hub nut: 824 – 1,030 Nm {84 – 105 kgm}
7. Gently lift and remove front axle assembly (6). [*2]

3
4
Mounting bolt:
Front axle assembly: 3,700 kg
245 – 309 Nm {25 – 31.5 kgm}
[*3]
3 Mounting bolt:
2,890 – 3,630 Nm {295 – 370 kgm}
q Bleeding air from the wheel brake circuit

Bleed air from the front brake, referring to
“Bleeding air from wheel brake circuit” in Test-
ing and adjusting.
WD600-6 50-303 3
SEN05146-01 Removal and installation of rear axle assembly
Removal and installation of rear 6. Disconnect rear drive shaft (2). [*2]
axle assembly 1
a Lift the drive shaft with rope, etc. to pre-
vent falling.
4
Removal
k Park the machine on level ground. Set the Rear drive shaft assembly: 65 kg
the lock bar to the frame and put the blocks
under the wheels. 7. Disconnect front support lubrication tube (3).
k Loosen the filler cap of the hydraulic tank a Disconnect the clamp on the frame.
“Releasing residual pressure in brake
accumulator circuit” in Testing and adjust-
ing.
1. Set the rear axle on block [1] to the left and

right.
a To prevent the rear axle from jumping
upward when the tires are removed.
2. Lift the machine body with the work equipment

and set the axle assembly on block [2]. 8. Disconnect brake hose (4) from the slack
adjustor. [*3]
3. Hold the work equipment level and lift the

machine body with blocks [3] and jacks (50 ton)
[4]. 9. Disconnect rear support lubrication tubes (6)
4. Sling tire assembly (1) temporarily and remove and (7).
the hub nuts.
5. Lift and remove tire assembly (1). [*1] 10. Fasten the axle support and rear axle using
chain, etc. and tightening with lever block [7].
50-303 4 WD600-6
Removal and installation of rear axle assembly SEN05146-01
11. Lift one side temporarily and set a garage jack Installation
to the other side to remove the support mount- q Carry out installation in the reverse order to
ing bolt. [*4] removal.
12. Gently lower rear axle assembly (9) by holding [*1]

the left and right sides balanced. 3 Hub nut: 824 – 1,030 Nm {84 – 105 kgm}
4 Rear axle assembly: 3,900 kg
[*2]
a Pull out the rear axle assembly from the 3 Mounting bolt:
bottom of the frame, using the crane and 245 – 309 Nm {25 – 31.5 kgm}
the garage jack.
[*3]
a Bleed air from the slack adjustor, referring to
“Bleeding air from wheel brake circuit” in Test-
ing and adjusting.
[*4]
3 Support mounting bolt:
2,450.0 – 3,038.0 Nm {250.0 – 310.0 kgm}
13. Lift and remove support (10) (front and rear)

from the rear axle.
4 Front support: 140 kg
4 Rear support: 230 kg
WD600-6 50-303 5
SEN05146-01 Removal and installation of center support assembly
Removal and installation of center 2. Remove front drive shaft (2). [*2]
support assembly 1 4 Front drive shaft: 65 kg
Special tools a When removing the drive shaft, lift the
drive shaft with a rope, etc. to prevent fall-
New/Remodel
ing.
Necessity
Sym-
Part No. Part name
Sketch
bol 3. Disconnect lubrication tube (3).
Q'ty
4. Lift the center support temporarily and remove
H 12 793T-620-1410 Centering tool t 1 N Q
mounting bolts (4). [*3]
Removal
k Park the machine on level ground. Turn the
steering wheel fully to the left, set the work
equipment completely on to the ground and
put the blocks under the wheels.
k Disconnect the cable from the negative (–)
terminal of the battery.
1. Disconnect center drive shaft (1). [*1]

4 Center drive shaft: 65 kg
a When removing the drive shaft, lift the
drive shaft with a rope, etc. to prevent fall- 5. Lift and remove center support assembly (5).
ing. 4 Center support assembly: 47 kg
a Check the number of shims, if any,
between the center support and the frame
for assembling data.
50-303 6 WD600-6
Removal and installation of center support assembly SEN05146-01
Installation
removal.
[*1]
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
[*2]
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
[*3]
a To make the transmission coupling surface and
the center support (CS) coupling surface paral-
lel, mount tool H12 and a dial gauge [1] to the
transmission (T/M). Adjust parallelism and
radial runout by turning the coupling on the
side of center support (CS).
a Install shims to the center support mounting
face for adjustment.
a Tighten the mounting bolts after shim adjust-
ment.
3 Mounting bolt:
490.0 – 608.0 Nm {50.0 – 62 kgm}
a Parallelism: Max. 0.1
WD600-6 50-303 7
SEN05146-01 Disassembly and assembly of center support assembly
Disassembly and assembly of 3. Shaft

center support assembly 1
1) Set shaft case assembly (6) on the press.
2) Pull out shaft (7) using the press.
Disassembly a Cover the floor with wood chips so
1. Coupling that the shaft may not be damaged
Remove center bolt (1) and then remove should it fall off.
retainer (2), O-ring (3) and coupling (4).
a Make match marks to coupling (4) and the
shaft end surface.
3) Remove spacer (8), bearing (9) and

retainer (5) from the shaft.
2. Retainer
Remove the mounting bolts of retainer (5).
a Remove all mounting bolts by rotating the
shaft.
4. Oil seal
Remove oil seal (10) and O-ring (11) from
retainer (5).
50-303 8 WD600-6
Disassembly and assembly of center support assembly SEN05146-01
5. Case Assembly
1) Remove oil seal (12) from the case. 1. Bearing outer race
2) Remove bearing (13), bearing outer races Install bearing outer races (14) and (15) to
(14) and (15) from the case. case (16).
a Make sure that there is no clearance
between the outer races and the case
end.
2. Oil seal
Install oil seal (10) to retainer (5).
2 Oil seal lip surface: Grease (G2-LI)
a Driven dimension of oil seal:
(a) = 2 ± 0.5 mm
WD600-6 50-303 9
SEN05146-01 Disassembly and assembly of center support assembly
3. Bearing 2) Hold the shaft upright and install the case

1) Install retainer (5) to the shaft and press fit (16).
bearing (9). a Apply grease amply to (a) portion of
a After installing the bearing, check that the retainer and the rolling surfaces
no clearance is present between the (b) of the bearing.
shaft end. a Take care that the O-ring is not
2) Install the spacer. engaged.
2 Bearing inner circumference:
Grease (G2-LI)
5. Retainer
Fix retainer (5) to the case.
4. Case 3 Mounting bolt:
1) Install O-ring (11) to retainer (5). 59 – 73.5 Nm {6 – 7.5 kgm}
a Fit the O-ring securely to the groove.
50-303 10 WD600-6
Disassembly and assembly of center support assembly SEN05146-01
6. Bearing seal 9. Filling grease

1) Press fitting bearing (13) in the shaft. Fill grease through tapped hole (d) of the case.
2 Bearing (13): Grease (G2-LI) a Fill grease until it comes out of the
2) Install oil seal (12) to the case. breather (17).
a Seal press fit dimension: ±0.5 mm 2 Inside the case:
from the case end Grease (G2-LI) (900 cc)
2 Seal lip surface and portion (C) of the case:
Grease (G2-LI)
7. Coupling
Assembly coupling (4) and install O-ring (3)
and retainer (2), and then fix with center sup-
port (1).
a Install coupling (4) by matching to the
match mark.
3 Center bolt:
824 – 1,030 Nm {84 – 105 kgm}
8. Testing
Check that end play is within the specified
range.
a End play: Max. 0.22 mm
a If end play is 0, check that free rotational
torque reads 3.9 Nm {0.4 kgm} maximum
with grease applied to the seal and bear-
ing.
WD600-6 50-303 11
SEN05146-01 Disassembly and assembly of differential assembly
Disassembly and assembly of Disassembly

differential assembly 1
1. Differential gear assembly
1) Install tool H2 to tool H1.
Special tools 2) Set differential gear assembly (1) to tool H2.
a Considering the weight of the differ-
New/Remodel
ential gear assembly, maintain the
Necessity
Symbol Part No. Part name balance of the assembly after setting
Sketch
it to tool H1.
4 Differential gear assembly: 560 kg
Q'ty
790-501-5200 Unit repair stand t 1
1
790-901-4110 Bracket t 1
2 793T-622-1810 Plate t 1 N Q
3 792-103-0901 Wrench t 1
4 793T-622-1180 Push tool t 1 Q
5 793T-622-1840 Push tool t 1 N Q
790-201-2460 Plate t 1
6
790-201-2690 Plate t 1
790-101-5621 Plate t 1
H
7 790-101-5421 Grip t 1
01010-81240 Bolt t 1
8 790-201-2860 Spacer t 1 2. Coupling
1 792-525-1000 Micrometer t 1 1) Remove the bolt and remove holder (2).
9
2 792-525-1220 Adapter t 1
10 793T-622-1820 Push tool t 1 N Q
793T-622-1830 Push tool t 1 N Q
11 790-101-5221 Grip t 1
01010-81240 Bolt
2) Remove O-ring and remove coupling (3).
50-303 12 WD600-6
Disassembly and assembly of differential assembly SEN05146-01
3. Cage assembly 2) Remove 20 bolts and lift and remove sup-

1) Remove 6 bolts and remove cage assem- port bevel pinion assembly (9).
bly (4). 4 Support bevel pinion assembly:
100 kg
2) Remove oil seal (6), dust seal (7) and the

O-ring from cage (5). 3) Remove shim (10).
a Check the number of the shims in
advance.
4. Support bevel pinion assembly

1) Remove retainer (8) from the pinion shaft.
4) Push down support bevel pinion assembly
(9) using a press. Remove bevel pinion
assembly (12) together with bearing (11)
from support assembly.
a Set the blocks, etc, under the bevel
pinion assembly to prevent falling to
the floor.
WD600-6 50-303 13
5. Disassembly of bevel pinion assembly 7. Differential gear assembly

1) Remove spacer (14) from bevel pinion 1) Invert the bracket of tool H1.
assembly (12).
2) Remove right and left locks (19).

2) Remove bearing (16) from bevel pinion a After removing the lock, mark the lock
shaft (15), using a press. position on the adjustment nut.
6. Disassembly of support assembly 3) Loosen the adjustment nut (20) using tool
Remove bearing outer races (17) and (18) H3 until the nut can be turned manually.
from support assembly (13).
50-303 14 WD600-6
4) Lift differential gear assembly (21) tempo- 8) Lift and remove differential gear assembly
rarily. (21).
5) Remove 4 bearing cap mounting bolts 8. Disassembly of differential gear assembly

(22) each to the left and right. 1) Remove 24 bolts and remove bevel gear
6) Remove left and right bearing caps (23). (25) from case (26).
a Separate the left and right bearing a Make match marks to the bevel gear
cap. and the case before disassembling.
2) Remove bearing (27).
7) Lift off differential gear assembly (21)

slightly to remove the left and right bear- 3) Remove 8 bolts and remove case assem-
ings (24). bly (28) from case (26).
a Care should be taken not to drop the a Make match marks to the case before
bearing when lifting. disassembling.
a Separate the left and right bearings.
WD600-6 50-303 15
4) Remove washer (29) from the inside of 7) Remove cross shaft pinion gear assembly
case assembly (28). (33) from case (26).
a Make match marks to the cross shaft
and case before disassembling.
5) Remove bearing (30) from case (31).
8) Remove side gear (34) from case (26).
6) Remove side gear (32) from case (26).
9) Remove washer (35) from the inside of

case (26).
50-303 16 WD600-6
10) Remove washer (37), pinion gear (38) and Assembly

bushing (39) from cross shaft (36). 1. Carrier case
1) Install tool H2 to tool H1.
2) Set carrier case (40) to tool H2.
9. Carrier case
1) Remove carrier case (40) from tool H2.
2) Remove tool H2 from tool H1. 2. Assembly of differential gear assembly
1) Use tool H4 to press fit bearing (24) to
case (26).
2) Install washer (35) to the inside of case

(26).
WD600-6 50-303 17
3) Install side gear (34) to case (26). 6) Install side gear (32) to case (26).
4) Install bushing (39), pinion gear (38) and 7) Use tool H4 to press fit bearing (30) to
washer (37) in this order to cross shaft case (31).
(36).
8) Install washer (29) to the inside of case

assembly (28).
5) Install cross shaft and pinion gear assem-
bly (33) to case (26).
a Match the markings on the cross
shaft and the case.
50-303 18 WD600-6
9) Install case assembly (28) to case (26). 2) Install spacer (14) to bevel pinion assem-
a Match the marking on the case. bly (12).
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
4. Assembly of support assembly

1) Use tool H6 to install bearing outer race
10) Install bevel gear (25) to case (26). (18) to support assembly (13).
a Match the markings on the bevel gear 2) Use tool H7 to install bearing outer race
and the case. (17) to support assembly (13).
2 Mounting bolt: a Press fit outer race until it comes in
Liquid adhesive (LT-2) contact with the support.
3 Mounting bolt:
490 – 608 Nm {50 – 62 kgm}
5. Assembly of support and bevel pinion

assembly
1) Install support assembly (13) and bearing
3. Assembly of bevel pinion assembly
(11) to bevel pinion assembly (12).
1) Use tool H5 to press fit bearing (16) to
bevel pinion shaft (15).
WD600-6 50-303 19
2) Use tool H8 to press fit bearing (11) to 3) Tighten adjustment nut (20) to the carrier
support assembly (13). case temporarily.
3) Install retainer (8) to the pinion shaft after 4) Install left and right bearing caps (23).
press fitting. a Check the markings on the left and
right bearing caps and match them to
the dowel pins.
5) Tighten 4 bearing cap mounting bolts (22)
each to the left and right.
a Tighten the bolts after rotating the
bevel gear 20 to 30 rounds to run in
the bearing.
2 Mounting bolt:
Liquid adhesive (LT-2)
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
6. Installation of differential gear assembly.

1) Lift differential gear assembly (21) to the
installation position of the carrier case.
a Keep the gear assembly off the car-
rier case.
a Install the left and right locks for the

adjustment nut after completing the
“Pre-load adjustment of bearing”,
“Backlash adjustment” and “Testing
and adjusting of tooth contact.”
7. Preload adjustment of bearing

1) Install tools H9-2 to the threaded portions
2) Install bearing outer races (24) to the left (A) of the right and left cap tops.
and right of the differential gear. a Tighten until play is eliminated.
a Match the left and right bearings by 2) Using tool H9-1, measure dimension (L).
checking the match marks on the left 3) Add 0.38 ± 0.10 mm to measured value
and right inner races. (L) and set the scale of tool H9-1 to the
obtained value.
a The added dimension will be the
deflection of the case made by giving
a preload.
50-303 20 WD600-6
a Precautions in adjusting pre-load

If the deflection should exceed the
standard dimension due to overtight-
ening of the adjustment nut, return
the nut to the position before the
adjustment.
To do this, lightly hit the bearing cap
and bevel gear with a plastic hammer,
etc. while rotating the bevel gear.
Make sure that no clearance exists in
(b) portion and then make adjustment
again.
4) Using tool H3, tighten nut (20).

a Using tool H3, tighten adjustment nut
(20) so that the increase will be 0.38 ±
0.10 mm.
8. Installation of bevel pinion assembly

1) Invert the tool H1.
5) Put push-pull scale [2] to the tip of bevel

gear (25) and measure the starting force.
Starting force:
24.5 – 44.1 N {2.5 – 4.5 kg}
(Reference value)
a If the starting force is out of the above
range, return to step 3) and adjust
again.
WD600-6 50-303 21
2) Install shim (10). 9. Installation of cage assembly

a Install the shim removed during disas- 1) Use tool H10 press fit dust seal (7) to cage
sembly. (5), using oil seal (6) and tool H11.
a Standard shim thickness: 1.45 mm 2 Oil seal lip surface: Grease (G2-LI)
a Shim margin for adjustment: 0.8 – 2.1 mm 2 Dust seal lip surface: Grease (G2-LI)
2) Install cage assembly (4) with 6 bolts.

3 Mounting bolt:
3) Install O-ring, and then lift and install sup-
port bevel pinion assembly (9).
59 – 74 Nm {6 – 7.5 kgm}
4) Tighten support bevel pinion assembly (9)

10. Installation of coupling
with 20 bolts.
3 Mounting bolt:
1) Install O-ring and coupling (3).
2 Contact surface of the retainer and
490 – 608 Nm {50 – 62 kgm}
coupling: LM-G or LM-P
50-303 22 WD600-6
2) Install holder (2) and tighten bolt. 3) If backlash is off the reference value, shift
a Tighten the bolts gradually after rotat- the bevel gear for adjustment.
ing the bevel gear and bevel pinion a Adjust bevel gear shifting with adjust-
20 to 30 rounds. ment nut (20), using tool H3.
2 Mounting bolt:
Liquid adhesive (LT-2)
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
4) To keep the pre-load given to bearing (24)

unchanged, turn the nuts on both sides by
the same quantity and in the same direction.
a In the case backlash is in short of the
11. Backlash adjustment reference value
1) Hold the probe of dial gauge [1] to the tip Loosen adjustment nut (20A) on the
of the bevel gear tooth at a right angle. side of the bevel gear and tighten
2) Read the scale when the bevel gear is adjustment nut (20B). (Direction A)
turned in the right direction of rotation with a In the case backlash is in excess of
the bevel pinion fixed. the reference value
a Measure at 3 to 4 points. Loosen adjustment nut (20B) on the
q Backlash reference value: side of the bevel gear and tighten
0.41 – 0.56 mm adjustment nut (20B). (Direction B)
WD600-6 50-303 23
12. Testing of tooth contact 2) If the bevel pinion is excessively away

Apply thin layer of red lead on the tooth sur- from the bevel gear, the contact mark will
face of the bevel gear. Turn the bevel gear in be as shown in the following figure. Make
the forward and backward directions and correction according to the following pro-
check the contact mark left on the bevel gear. cedure:
a Proper tooth contact q Reduce the number of shims of the
Fifty percent of the total length of a tooth is cage assembly (on the bevel pinion
in contact centering around the pitch line side) and shift it in the direction of (C).
toward the heel with approx. 5 mm of the q Adjust the bearing adjustment nut
toe side remaining unmarked or not in and shift the bevel gear in the direc-
contact. tion of (D) away from the bevel pinion.
13. Adjusting of tooth contact 3) If the bevel pinion is excessively close to

1) If proper tooth contact mark was not the bevel gear, the contact mark will be as
obtained upon checking, proceed to a shown in the following figure. Make cor-
tooth adjustment. rection according to the following proce-
a Make adjustment by shifting the bevel dure:
gear and increasing/decreasing the q Increase the number of shims of the
number of shims (shifting of bevel cage assembly (on the bevel pinion
pinion gear) of the cage assembly. side) and shift it in the direction of (E).
a After adjustment, check the backlash q Adjust the bearing adjustment nut
again. and shift the bevel gear in the direc-
a When making adjustment by shifting tion of (F) closer to the bevel pinion.
the bevel gear, don't change pre-load
given the bearing. Accordingly, turn
the respective left and right adjust-
ment nuts by the same quantity
(check with the shifting of the notch)
and in the same direction.
a Shim thickness: 0.05, 0.2, 0.3 and
1.0 mm
50-303 24 WD600-6
4) If the bevel gear is excessively close to 14. Lock

the bevel pinion, the contact mark will be Install left and right locks (19) of adjustment
as shown in the following figure. Make nut (20).
correction according to the following pro- 3 Mounting bolt:
cedure: 98 – 123 Nm {10 – 12.5 kgm}
q Decrease the number of shims of the
cage assembly (on the bevel pinion
side) and shift it in the direction of (C).
q Adjust the bearing adjustment nut
and shift the bevel gear in the direc-
tion of (D) away from the bevel pinion.
5) If the bevel gear is excessively away from

the bevel pinion, the contact mark will be
as shown in the following figure. Make
correction according to the following pro-
cedure:
q Increase the number of shims of the
cage assembly (on the bevel pinion
side) and shift it in the direction of (E).
q Adjust the bearing adjustment nut
and shift the bevel gear in the direc-
tion of (F) closer to the bevel pinion.
WD600-6 50-303 25
SEN05146-01
WD600-6 Wheel dozer

©2017 KOMATSU
All Rights Reserved
50-303 26
SEN05147-00
WHEEL DOZER
WD600-6
WD600-6 55001 and up

Removal and installation of final drive carrier assembly ................................................................................. 2
Disassembly and assembly of final drive carrier assembly............................................................................. 4
Removal and installation of front final drive brake assembly .......................................................................... 5
Disassembly and assembly of final drive assembly........................................................................................ 7
WD600-6 50-304 1
SEN05147-00 Removal and installation of final drive carrier assembly
Removal and installation of final 4. Pull out drive shaft (4).

drive carrier assembly 1
a To make it easier to pull out, attach an
eyebolt, etc. to the end of the drive shaft to
Removal pull it out with.
k Park the machine on level ground. Set the
work equipment completely on to ground
and put the blocks under the wheels.
1. Lift the machine body with the work equipment,

set a support stand under the axle. Lift the tire
assembly temporarily and remove the hub
mounting bolts.
Operate the crane to remove the tire assembly
(1). [*1]
5. Sling and remove the drive shaft (4).

4 Drive shaft: 60 kg
2. Remove drain plug (2) from the cover (3) and

drain oil from the final drive case. [*2]
6 Final drive case: 25 l
6. Remove snap ring (5) and then remove sun
gear (6) and spacer (7).
3. Remove 12 bolts and remove cover (3), then
remove the O-ring. [*3]
50-304 2 WD600-6
Removal and installation of final drive carrier assembly SEN05147-00
7. Remove 3 hexagonal socket head bolts and Installation

sling the final drive carrier assembly (8) to q Installation is done in the reverse order of
remove. [*4] removal.
a Hold the assembly parallel to the ring gear
using a bar, etc., remove the carrier [*1]
assembly. 3 Hub mounting bolt:
4 Final drive carrier assembly: 160 kg 824.0 – 1,030.0 Nm {84.0 – 105.0 kgm}
[*2]
3 Oil pressure pickup plug:
127.4 – 176.4 Nm {13 – 18 kgm}
3 Drain plug (2): 58.8 – 78.4 Nm {6 – 8 kgm}
[*3]
3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}
[*4]
3 Carrier assembly mounting bolt (with hexag-
onal socket head):
98 – 123 Nm {10 – 12.5 kgm}

5 Final drive case (one side): 25 l (AXO80)
WD600-6 50-304 3
SEN05147-00 Disassembly and assembly of final drive carrier assembly
Disassembly and assembly of 2. Remove 2 bearings (4) from planetary gear (3).
final drive carrier assembly 1
a Store the bearing, etc. that has developed
a run-in in a separate group of the bear-
Disassembly ings (2 bearings), shaft and a ball to pre-
1. Using the press, pull out the shaft (1) and vent them from being re-assembled with
remove planetary gear (3). other parts.
a When the shaft is pushed out, lock ball (2)
falls for which care should be taken not to
lose it.
a Enter a number to case (5). Care should
be taken not to mix removed parts with
others.
Assembly
1. Install 2 bearings (4) to the planetary gear (3)
and set them to carrier case (5).
a Match the position exactly to the hole on
the case.
2. Align the notch hole for the ball on the side of

carrier case (5) to the ball hole of shaft (1).
Press fit the shaft in until the ball hole makes
contact with the case end.
3. Install ball (2) to the hole and press fit shaft (1).
50-304 4 WD600-6
Removal and installation of front final drive brake assembly SEN05147-00
Removal and installation of front 4. Sling the final drive brake assembly (5) tempo-
final drive brake assembly 1
rarily and remove 28 bolts (6). [*3]
a Don't hook on the floating seal retainer
Removal directly for slinging.
1. Remove the final drive shaft assembly, refer- a When removing the final drive brake
ring to section 1 to 6, “Removal and installation assembly, use chain block on one side to
of final drive carrier assembly.” balance the assembly.
4 Final drive brake assembly: 850 kg
2. Remove 3 bolts and remove the brake tube
cover (1). [*1]
5. Sling and remove the final drive brake assem-

3. Remove the clamp, brake tube (2) and nipple
bly (5).
(3). [*2]
a Carefully remove the piston air bleeder
a Remove the brake tube on the side of the
plug (4) to prevent damages.
slack adjuster too.
a Leave the piston air bleeder plug (4)
installed as it is not removable.
6. Remove the piston air bleeder plug (4). [*4]
WD600-6 50-304 5
SEN05147-00 Removal and installation of front final drive brake assembly
Installation
removal.
[*1]
3 Mounting bolt: 59 – 74 Nm {6 – 7.5 kgm}
[*2]
3 Clamp mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
3 Nipple (3): 84 – 132 Nm {8.5 – 13.5 kgm}
[*3]
3 Mounting bolt: 824 – 981 Nm {84 – 100 kgm}
[*4]
3 Air bleeder plug (4):
84 – 132 Nm {8.5 – 13.58 kgm}
50-304 6 WD600-6
Disassembly and assembly of final drive assembly SEN05147-00
Disassembly and assembly of 3. Fix the final drive assembly (3) and brake
final drive assembly 1
assembly (4) using jig J1.
a Install the tool at 3 points.
Special tools q Install the jig J1 until the final drive assem-
bly is assembled.
New/remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
J 1 793T-622-1910 Fixture t 3 N Q
Disassembly
1. Set final drive brake assembly (1) on a flat
place with the final drive side on top.
4. Remove 8 mounting bolts, and then retainer

(5) and shim (6).
a Check the thickness and quantity of the
shims in advance.
2. Remove 3 hexagonal socket head bolts and

sling final drive carrier assembly (2) to remove.
4 Final drive carrier assembly: 160 kg
5. Sling the ring gear assembly (7) to remove.

4 Ring gear assembly: 110 kg
WD600-6 50-304 7
SEN05147-00 Disassembly and assembly of final drive assembly
6. Disassembly of carrier assembly 2. Assembly of final drive carrier assembly (2)

For details on disassembly of carrier assembly a For details on assembly of carrier assem-
(2), referring to “Disassembly and assembly of bly (2), referring to “Disassembly and
final drive carrier assembly.” assembly of final drive carrier assembly.”
3. Insert ring gear assembly (7) and remove tool
7. Disassembly of ring gear assembly J1.
1) Remove 6 lock plates (8) and then remove
ring gear hub (9) from the ring gear (10).
2) Remove bearing (11) from the ring gear
hub (9).
4. How to adjust wheel bearing

1) Temporarily tighten retainer (5) with 3
mounting bolts with specified torque with-
out installing shim (6).
3 Temporary tightening torque
Assembly
57.9 – 67.7 Nm {5.9 – 6.9 kgm}
a Before assembly, check that every part is
a While rotating wheel hub 5 to 6 times,
washed clean and not attached with dirt or
tighten the retainer evenly until a
damaged.
specified torque is reached.
1. Assembly of ring gear assembly (7)
1) Press fit bearing (11) in to ring gear hub
(9).
a Make sure that there is no clearance
between the hub after press fitting the
bearing.
2) Engage ring gear hub (9) to the ring gear
(10) and install 6 lock plates (8).
a When assembling, hold the lock plate
with the wider portion to the inside.
a Fully degrease tapped holes.
3 Mounting bolt:
27 – 34 Nm {2.8 – 3.5 kgm}
50-304 8 WD600-6
Disassembly and assembly of final drive assembly SEN05147-00
2) Measure the dimension (a) between the 5) Assemble the calculated shim (6) and
retainer end and the tube end using a retainer (5) and tighten them to a specified
depth gauge [1] or depth micro gauge torque with all of the mounting bolts.
through the measuring hole of retainer (5). 2 Mounting bolt: Adhesive (LT-2)
a Take measurement at 2 locations and 3 Mounting bolt:
calculate the mean. 245 – 289 Nm {25 – 29.5 kgm}
3) Remove the retainer (5) and measure the a While rotating wheel hub 5 to 6 times,
thickness (b) of the retainer. tighten the retainer evenly until a
a Take measurement at 2 locations and specified torque is reached.
calculate the mean.
4) Calculate the thickness (c) of shim (6)
using the following equation:
Thickness of shim (c) (mm) =
(a) – (b) +0.3 (mm)
a Obtain necessary thickness with a
minimum number of shim.
a Thickness of shim:
0.2, 0.3 and 1.0 (mm)
6) Rotate the wheel hub again and check

that the rotation is normal.
5. Install the final drive carrier assembly (2) with 3

bolts with hexagonal socket head.
3 Carrier assembly mounting bolt (with
hexagonal socket head):
98 – 123 Nm {10 – 12.5 kgm}
WD600-6 50-304 9
SEN05147-00
WD600-6 Wheel dozer

©2009 KOMATSU
All Rights Reserved
50-304 10
SEN05148-01
WHEEL DOZER
WD600-6
WD600-6 55001 and up
400 Brake system

Disassembly and assembly of brake assembly .............................................................................................. 2
Removal and installation of brake valve assembly ....................................................................................... 10
Disassembly and assembly of accumulator and charge valve assembly ......................................................11
Disassembly and assembly of slack adjustor assembly ............................................................................... 14
WD600-6 50-400 1
400 Brake system
SEN05148-01 Disassembly and assembly of brake assembly
Disassembly and assembly of 3. Tube assembly

brake assembly 1
1) Remove 2 hexagonal socket head bolts
and lift off tube assembly (2).
Special tools a Take care not to drop the assembly
since bearing inner race may be
New/Remodel
removed together.
4 Tube assembly: 115 kg
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
1 793T-622-1910 Fixture t 3 N Q
792-520-2110 Installer t 1
2
792-530-1600 Push tool t 1
J
792T-422-1220 Plate t 1 Q
3 790-101-5421 Grip t 1
01010-81240 Bolt t 1
Disassembly
k Remove internal parts (such as piston,
disc, plate, floating seal, etc.) with care to 2) Remove retainer (3) from tube (4).
prevent them from being damaged by
impact, falling, etc.
1. Remove the final drive brake assembly, refer-

ring to “Removal and installation of final drive
brake assembly.”
a For details on disassembly of final drive

assembly, refer to “Disassembly and
assembly of final drive assembly.”
2. Final drive brake assembly

Install tool J1 to final drive brake assembly (1),
invert to hold the brake assembly side on top.
a After placing the assembly on a flat place, 3) Remove bearing inner race (5).
remove the tool J1.
50-400 2 WD600-6
400 Brake system
Disassembly and assembly of brake assembly SEN05148-01
4. Cylinder assembly 5) Remove seal ring (11) from piston (10).

1) Remove 24 mounting bolts and lift off cyl-
inder assembly (6).
4 Cylinder assembly: 100 kg
6) Remove seal ring (13) from cylinder (12).

7) Remove 12 mounting bolts, and then
remove sleeve (14) from cylinder (12).
2) Use an eyebolt, bar, etc. to push in spring
(8), pull out lower pin (7).
3) Remove spring (8) and guide (9).
5. Plate and disc

1) Remove plate (15).
a Before removing the plate and disc,
4) Remove piston (10). provide the plate and outer gear, and
4 Piston: 25 kg the disc and wheel hub with counter
marks.
WD600-6 50-400 3
400 Brake system
2) Remove disc (16). 2) Remove floating oil seal (19) and oil seal
a Remove disc carefully, avoiding dam- (20) from the outer gear.
ages as it is made of a soft material.
7. Retainer
3) Remove 12 plates and 11 discs alter- 1) Remove floating seal (19) from retainer
nately. (21).
4) Remove plate (17) at the end. 2) Remove 6 mounting bolts and retainer
a Thickness of plate (17) is 10 mm. (21).
8. Wheel hub assembly

6. Outer gear
Remove outer races (23) and (24) from the
1) Remove outer gear (18).
wheel hub (22).
a Take care not to drop the floating seal
on the bottom.
50-400 4 WD600-6
400 Brake system
Assembly 2) After installation measure the height (a) at

a Before assembly, check that every part is 4 points on the circumference and check
washed clean and not attached with dirt or that dimensional difference reads within
damaged. 1 mm.
a Before assembly, apply engine oil to the sliding a Apply a thin layer of axle oil (AXO80)
surfaces of each part. to the top end surface (b) of the float-
a Completely remove white powder on the suring seal (19).
face of the O-ring of floating seal using engine
oil, etc.
k Install floating seal carefully as a flaw, how-
ever minor, on the floating seal due to
impact or falling may cause oil leakage.
1. Wheel hub
1) Use tool [1] (outside diameter: 355 mm) to
press fit outer race (24) to wheel hub (22).
2) Use tool [2] (outside diameter: 285 mm) to
press fit outer race (23) to wheel hub (22).
3) Install retainer (21).

3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
2. Retainer
1) Use tool J2 to install floating seal (19) to
retainer (21).
a Fully degrease the contact surface
between floating seal and the hub O-
ring.
a Use tool J2 to evenly tighten O-ring of
the floating seal by avoiding twist.
WD600-6 50-400 5
400 Brake system
3. Outer gear 3) After installation measure the height (a) at

1) Use tool J3 to press fit oil seal (20) to 4 points on the circumference and check
outer gear (18). that dimensional difference reads within
a Press fit oil seal to be flush with the 1 mm.
outer gear case end surface. a Apply a thin layer of axle oil (AXO80)
2 Oil seal lip surface: to the top end surface (b) of the float-
Grease (G2-LI) ing seal (19).
2) Use tool J2 to install floating seal (19) to 4) Install outer gear (18).
outer gear (18). a Take care not to drop the floating seal
a Fully degrease the contact surface on the bottom.
between floating seal and the O-ring a Install the outer gear avoiding oil seal
of outer gear. at the bottom to ride up.
a Use tool J2 to evenly tighten O-ring of
the floating seal by avoiding twist.
50-400 6 WD600-6
400 Brake system
4. Plate and disc 5. Cylinder assembly

1) Install plate (17) first. 1) Install sleeve (14) to cylinder (12).
a Thickness of plate (17) is 10 mm. 3 Mounting bolt:
a Plate may be used either on the front 58.8 – 78.4 Nm {6 – 8 kgm}
or back side. 2) Install seal ring (13) to cylinder (12).
2 Outer circumference of seal ring:
Grease (G2-LI)
2) Install plate (15).

a Install by matching the counter marks
on the plate and outer gear. 3) Install seal ring (11) to piston (10).
3) Install disc (16). 2 Outer circumference of seal ring:
a Install disc carefully, avoiding dam- Grease (G2-LI)
ages as it is made of soft material.
a Install by matching the counter marks
on the disc and wheel hub.
4) Install plate (15) and disc (16) alternately
in this order from the bottom up.
a 12 plates (15) and 11 discs (16)
4) Match groove (G) in piston (10) to bleeder

cover mounting hole (H) in cylinder (12),
and install piston (10).
4 Piston (10): 25 kg
a Top and bottom of groove (G) are the
same.
WD600-6 50-400 7
400 Brake system
7) Install cylinder assembly (6).

4 Cylinder assembly: 100 kg
3 Mounting bolt:
245 – 289 Nm {25 – 29.5 kgm}
5) Place guide (9) through spring (8) and

install them to piston (7).
6) Use the eyebolt and bar to push in spring
and fix it to the lower side of guide (9)
through pin (7). 6. Tube assembly
1) Install bearing inner races (5) to the wheel
hub.
50-400 8 WD600-6
400 Brake system
2) Install retainer (3) to the tube (4).
3) Install tube assembly (2).

3 Hexagonal socket head bolt:
98 – 123 Nm {10 – 12.5 kgm}
7. Final drive and brake assembly

1) Install tool J1 to final drive and brake
assembly (1), invert to hold the final drive
assembly side on top.
2) After placing the assembly on a flat place,
remove the tool J1.
a Assemble final drive assembly, refer-

ring to “Disassembly and assembly of
final drive assembly.”
WD600-6 50-400 9
400 Brake system
SEN05148-01 Removal and installation of brake valve assembly
Removal and installation of brake 4. Disconnect hoses (7) to (11) from the left brake
valve assembly 1
valve.
a Remove each nipple.
Removal
wheels.
“Releasing remaining pressure in the
hydraulic system” in Testing and adjusting.
5. Disconnect connector C18 (12) from the right

brake valve.
6. Remove 3 mounting bolts, and remove right
2. Disconnect hoses (2) to (5) from the right brake valve (13).
brake valve. 7. Remove 3 mounting bolts, and remove left
3. Disconnect drain hose (6). brake valve (14).
a Remove each nipple.
a Bottom view
Installation
removal.
q After installing brake valves, check the brake

performance.
50-400 10 WD600-6
400 Brake system
Disassembly and assembly of accumulator and charge valve assembly SEN05148-01
Disassembly and assembly of 3. Remove plug (4).

accumulator and charge valve 4. Remove retainer (5).
assembly 1
5. Remove nut (6).
Disassembly 6. Remove screw (7).
1. Remove bushing (2) from body (1). k Remove carefully by holding the mat-
2. Remove filter (3) from bushing (2). ing faces pressed together by hand as
a Remove the ring. the inside is tensioned by spring.
7. Remove spring (8) and retainer (9).
8. Remove nut (10).

9. Remove screw (11).
k Remove carefully by holding the mat-
ing faces pressed together by hand as
the inside is tensioned by spring.
10. Remove spring (12) and ball (13).
WD600-6 50-400 11
400 Brake system
SEN05148-01 Disassembly and assembly of accumulator and charge valve assembly
11. Remove relief valve (14). Assembly

1. Install relief valve (14).
12. Remove plug (15). 3 Relief valve:
k Remove carefully by holding the mat- 78.5 – 88.3 Nm {8 – 9 kgm}
ing faces pressed together by hand as
the inside is tensioned by spring. 2. Install filter (19) to spool (17).
a Take care of the mounting direction of the
13. Remove spring (16). filter (angled portion to the back).
14. Remove spool (17). 3. Install ring (18).
15. Remove ring (18) from spool (17). 4. Install spool (17).
16. Remove filter (19). 5. Install spring (16).
6. Install plug (15).
3 Plug: 53.9 – 68.6 Nm {5.5 – 7 kgm}
50-400 12 WD600-6
400 Brake system
Disassembly and assembly of accumulator and charge valve assembly SEN05148-01
7. Install ball (13) and spring (12). 15. Install filter (3) to bushing (2).
8. Install screw (11). a Take care of the mounting direction of the
9. Install nut (10). filter (angled portion to the back).
3 Nut: 9.8 – 11.8 Nm {1 – 1.2 kgm} a Fix with the ring.
16. Install bushing (2) to body (1).
10. Install retainer (9) and spring (8). 3 Bushing:
11. Install screw (7). 29.4 – 39.2 Nm {3.0 – 4.0 kgm}
12. Install nut (6).
3 Nut: 9.8 – 11.8 Nm {1 – 1.2 kgm}
13. Install retainer (5).

14. Install plug (4).
3 Plug: 30.4 – 37.3 Nm {3.1 – 3.8 kgm}
WD600-6 50-400 13
400 Brake system
SEN05148-01 Disassembly and assembly of slack adjustor assembly

slack adjustor assembly 1
Disassembly
1. Bleeder
Remove bleeder (2) from body (1).
4. Valve
a Don't disassemble valve unless neces-
sary. If disassembled, replace with whole
cylinder assembly.
1) Remove cover (8) from cylinder (4) and
remove plug (9), spring (10), valve (11)
2. Cylinder and seat (12).
Remove the mounting bolt and disconnect body a To remove the valve, blow air through
(1) from cylinder (4) together with bracket (3). the oil hole of the cylinder and the
k Remove carefully by holding the mat- body.
ing faces pressed together by hand as a Cover the cylinder oil port with hand
the inside is tensioned by spring. to prevent the air from being blown
into rapidly.
a Care should be taken not to change
the combination of valve (11) and cyl-
inder (4). To replace, replace by the
valve and cylinder assembly as a set.
(Because of diameter clearance of
0.04 to 0.10 (mm) between the cylin-
der and the valve))
2) Remove O-ring (13) and ring (14) from
valve (11).
3. Piston
1) Remove O-rings (6) from body (1).
2) Remove spring (5) from cylinder (4).
3) Push out piston (7) and remove O-ring.
a Remove the piston gently by pressing
it with a rod of 10 mm diameter from
(B).
a Take care not to damage the
threaded portion with the rod.
50-400 14 WD600-6
400 Brake system
Disassembly and assembly of slack adjustor assembly SEN05148-01
Assembly 2. Piston
1. Valve 1) Install O-ring (14) to piston (7).
1) Install O-ring (13) and ring (14) to valve 2) Insert piston (7) to cylinder (4).
(11). a Make sure that the piston moves
2) Install seat (12) and valve (11) in this smoothly.
order, to cylinder (4).
3) Fill area (E) with grease (G2-LI).
2 Area (E): Grease (G2-LI)
4) Install spring (10), plug (9) and cover (8) in
the order.
2 Plug (9) threaded portion:
Cemedine 366
3 Plug (9): 49 – 63 Nm {5 – 6.5 kgm}
3. Cylinder
1) Install O-rings (6) to body (1).
2) Install spring (5) to cylinder (4).
3) Install body (1) and cylinder (4) together
with bracket (3).
4. Bleeder
Install bleeder (2).
3 Bleeder screw: 10 – 20 Nm {1 – 2 kgm}
WD600-6 50-400 15
SEN05148-01
WD600-6 Wheel dozer

©2019 KOMATSU
All Rights Reserved
50-400 16
SEN05149-01
WHEEL DOZER
WD600-6
WD600-6 55001 and up

Removal and installation of center hinge pin .................................................................................................. 2
Removal and installation of counterweight assembly ..................................................................................... 9
WD600-6 50-500 1
SEN05149-01 Removal and installation of center hinge pin
Removal and installation of center Removal

hinge pin 1
Special tools parking brake and put the blocks under the
wheels.
k
New/Remodel
Set the frame lock bar.
k
Necessity
Sym- Loosen the filler cap of the hydraulic tank
Part No. Part name
Sketch
bol gradually to release the residual pressure
Q'ty
790-101-2300 Push tool t 1
completely. Release the remaining pres-
790-101-2310 • Block 1 sure in the piping, referring to “Releasing
790-101-2320 • Screw 1 remaining pressure” in work equipment
790-101-2330 • Nut 2 cylinder in Testing and adjusting.
790-101-2340 • Washer 1
790-101-2350 • Leg 2
790-101-2360 • Plate 4 1. Remove the work equipment assembly, refer-
1
790-101-2410 • Joint 2 ring to “Removal and installation of work equip-
ment assembly.”
02215-11622 • Nut 2
793-520-2640 Push tool t 1 2. Remove the floor frame assembly, referring to
790-438-1030 Guide t 1 “Removal and installation of floor frame
790-438-1050 Bar t 2 assembly.”
790-101-2102 Puller (30-ton) t 1
3. Disconnect brake hose (1).
790-101-1102 Pump t 1 4. Disconnect 4 pressure inspection hoses (2).
K 790-101-2300 Push tool t 1 5. Disconnect valve hoses (3) and (4) of the work
790-101-2310 • Block 1 equipment.
6. Disconnect valve drain hose (5) of the work
790-101-2330 • Nut 1
equipment.
790-101-2340 • Washer 1
790-101-2350 • Leg 2
790-101-2360 • Plate 4
790-101-2410 • Joint 2
2 02215-11622 • Nut 2
790-438-1050 Bar t 2
01580-12016 Nut t 2
790-438-1010 Push tool t 1
790-438-1020 Guide t 1
790-438-1040 Screw t 1
790-101-2102 Puller t 1
790-101-1102 Pump t 1
50-500 2 WD600-6
Removal and installation of center hinge pin SEN05149-01
7. Disconnect the left and right grease hoses (6). 12. Use the jacks (50-ton × 2) [3] to the front and
8. Remove pin (7) on the side of the left and right rear frames to adjust height and set blocks [5].
steering cylinder heads. [*1]
a Check the number and the position of the
shims (8) in advance.
a Contract the rod of steering cylinder (9).
q Lower hinge pin

13. Remove retainer (12).
9. Remove drive shaft guard (10).

10. Remove drive shaft (11). [*2]
4 Drive shaft: 65 kg
14. Use the puller to remove the lower hinge pin

(13).
11. Set blocks [1] and jacks (50-ton × 2) [2] to the

counterweight.
WD600-6 50-500 3
q Upper hinge pin q Lower side front frame

15. Remove retainer (14). 19. Remove plate (19).
a Check the number of the shims in 20. Remove dust seal (20).
advance. 21. Remove retainer (21).
22. Remove dust seal (22) from retainer (21).
23. Remove bearing (23).
16. Remove the upper hinge pin (15), using the

puller.
q Upper side front frame
17. Remove bushing (16).
18. Remove the frame lock bar, pull front frame
25. Remove retainer (25).
(17) forward and disconnect the frame.
26. Remove dust seal (26) from retainer (25).
a Upper bushing of the upper hinge pin is
27. Remove bearing (27).
caught by the rear frame (18) (part B). Lift
28. Remove dust seal (28).
rear frame (18) slightly and disconnect the
frame.
q Lower side rear frame

50-500 4 WD600-6
Installation 4) Measure the clearance between retainer

(21) and the hinge plate clearance at 4
q Lower side front frame equally divided points on the circumfer-
1. Use push tool K1 and block [1] to press fit ence.
bearing (23) to the front frame. 5) Combine the shims (shim pack) so that
a Don't change the bearing and spacer com- their total thickness will be 0.08 – 018
bination as the bearing clearance has (mm) less than the measured value.
been adjusted. a Standard shim thickness (B): 1 mm
2 Bearing: a Thickness of shim: 0.1, 0.5 mm
Molybdenum disulfide lubricant (LM-P) 6) Install the shim pack and tighten retainer
(21) permanently.
2 Mounting bolt:
Adhesive (Loctite No.262)
3 Mounting bolt:
235 – 285 Nm {23.5 – 29.5 kgm}
2. Install dust seal (22) to retainer (21).

a Install dust seal lip (L1) so as to face out-
side.
2 Dust seal lip surface:
Molybdenum disulfide lubricant (LM-P)
q Upper side front frame
6. Use push tool K2 and press fit bearing (27) to
the front frame.
2 Bearing:
3. Install dust seal (20).

4. Install plate (19).
5. Install retainer (21) in the following order.
1) Install retainer (21) avoiding one-sided
tightening.
3 Mounting bolt:
34.3 ± 3.4 Nm {3.5 ± 0.4 kgm}
2) Loosen retainer (21) mounting bolt.
3) Install retainer (21) again avoiding one-
sided tightening.
3 Mounting bolt:
34.3 ± 3.4 Nm {3.5 ± 0.4 kgm}
WD600-6 50-500 5
7. Install dust seal (26) to retainer (25).

a Install the dust seal lip so as to face out-
side.
q Lower side rear frame

11. Install bushing (29).
8. Install retainer (25) in the following order.

1) Install retainer (25) at every other position
avoiding one-sided tightening.
3 Mounting bolt:
68.6 ± 7 Nm {7 ± 0.8 kgm}
2) Loosen retainer (25) mounting bolt.
3) Install retainer (25) again at every other
position avoiding one-sided tightening.
3 Mounting bolt:
68.6 ± 7 Nm {7 ± 0.8 kgm}
4) Measure clearance (A) between retainer
(25) and the front frame at 4 equally
divided points on the circumference.
5) Combine the shims (shim pack) so that
their total thickness will be 0.08 – 018
(mm) less than the measured value.
a Standard shim thickness (A): 2.2 mm
a Thickness of shim: 0.1, 0.5 mm
6) Install the shim pack and tighten retainer
(25) permanently.
2 Mounting bolt:
Adhesive (Loctite No.262)
3 Mounting bolt:
235 – 285 Nm {23.5 – 29.5 kgm}
9. Install bushing (24).
2 (u), (v) face:
10. Install dust seal (28).
50-500 6 WD600-6
q Lower hinge pin

12. Install retainer (12) to lower hinge pin with 4
bolts (32).
2 Tapped hole side of the mounting bolt
(32): Liquid adhesive (Loctite No. 262)
455 – 565 Nm {46.5 – 58 kgm}
13. Align the center of front frame (FF) and rear
frame (RF).
14. Install the lower hinge pin by taking care about
the position (*) of mounting bolts (32).
2 Lower hinge pin:
a Degrease the tapered portion (bushing
q Upper hinge pin
contact surface). Don't allow grease and
16. Measure the thickness (t) of retainer (14) at 3
other lubricant to be attached.
hole (H) locations, before installing it.
15. Install retainer (12) with 6 bolts (33) to the fol-
lowing procedure.
2 Tapped hole side of the mounting bolt
(33): Liquid adhesive (Loctite No. 262)
1) Tighten bolts (33) in order of [1] to [6].
235 – 285 Nm {23.5 – 29.5 kgm}
2) Tighten bolts (33) clockwise in the order of
[3], [5], [2], [4], [6], [1].
a Tighten bolts (33) in repetition until
they become immobile.
235 – 285 Nm {23.5 – 29.5 kgm}
17. Install upper hinge pin (15) by paying attention

to the bolt hole position (see figure above).
2 Upper hinge pin:
2 (t) face:
18. Install bushing (16) from lower.
2 (w), (x) face:
19. Install retainer (14) to the upper hinge with
610 – 765 Nm {62.5 – 78 kgm}
20. Tighten mounting bolts (35) of retainer (14)
1) Tighten mounting bolts (35) of retainer
(14) with specified torque.
a Take care of the tilting of retainer and
uneven bolt tightening.
they all become immobile.
455 – 565 Nm {46.5 – 58 kgm}
WD600-6 50-500 7
2) Measure distance (L) from the end face of

hole (H) of retainer (14) to rear frame
(RF). (Hole: 3 places)
a Subtract thickness (t) of retainer (14)
measured in step 16 from distance (L)
to the rear frame to obtain clearance
(C).
C=L-t
3) Combine the shims (shim pack) so that
their total thickness will be 0.08 – 018
(mm) less than clearance (C).
a Thickness of shim: 0.3, 0.4, 0.5 mm

[*1]
1. Install O-ring (31) and pin (7).
a When replacing dust seals (D), install it so
that lips (L) and (LL) will be facing outside.
2 Dust seal lip: Molybdenum disulfide
lubricant (LM-P)
a (8): Shims
Thickness of shim: 0.2, 0.5, 1.5, 3 mm
4) Remove mounting bolts (34) and (35) of

retainer (14).
2 Tapped hole side of the mounting
bolts (34) and (35):
Liquid adhesive (Loctite No. 262)
5) Assemble the shim pack and install
retainer (14) to the upper hinge pin with
610 – 765 Nm {62.5 – 78 kgm}
6) Tighten mounting bolts (35) of retainer
(14) with specified torque.
[*2]
3
they all become immobile.
Drive shaft mounting bolt:
a Take care of the tilting of retainer and
245 – 309 Nm {25 – 31.5 kgm}
uneven bolt tightening.
455 – 565 Nm {46.5 – 58 kgm}
50-500 8 WD600-6
Removal and installation of counterweight assembly SEN05149-01
Removal and installation of Installation

counterweight assembly 1
Removal removal.
completely and stop the engine. Apply the [*1]
parking brake and put the blocks under the 3 Counterweight mounting bolt:
wheels. 2,450 – 3,040 Nm {250 – 310 kgm}
1. Lift the counterweight assembly (1) temporar-

ily.
2. Remove mounting bolts (2) and lift counter-
weight assembly (1) to remove. [*1]
4 Counterweight assembly: 2,320 kg
WD600-6 50-500 9
SEN05149-01
WD600-6 Wheel dozer

©2017 KOMATSU
All Rights Reserved
50-500 10
SEN05150-01
WHEEL DOZER
WD600-6
WD600-6 55001 and up
600 Hydraulic system

Removal and installation of hydraulic tank assembly...................................................................................... 2
Removal and installation of hydraulic pump assembly ................................................................................... 4
Removal and installation of control valve assembly ....................................................................................... 8
Disassembly and assembly of control valve assembly ................................................................................. 10
Removal and installation of steering valve assembly ................................................................................... 15
Disassembly and assembly of hydraulic cylinder assembly ......................................................................... 16
WD600-6 50-600 1
SEN05150-01 Removal and installation of hydraulic tank assembly
Removal and installation of 5. Disconnect suction tube (5). [*1]

hydraulic tank assembly 1
Removal
wheels.
k Release the remaining pressure in the pip-
ing, referring to “Releasing residual pres-
sure in work equipment circuit” in Testing
and adjusting. 6. Disconnect hoses and tubes from the top of
k Disconnect the negative terminal (–) of the the hydraulic tank.
battery before starting with the work. q (6) : Steering drain
q (7) : Pump drain
1. Drain the oil from the hydraulic tank. q (8) : EPC suction
6 Hydraulic tank: 443 l q (9) : Main return
q (10): Cooler and steering return
2. Raise fender (1). q (11): Brake drain
a Fender: If equipped q (12): Emergency steering return
3. Lift and remove the handrail and step assembly (2). q (13): Emergency steering suction
q (3): Hydraulic tank assembly
7. Lift and remove hydraulic tank assembly (3).[*2]
4 Hydraulic tank assembly: 490 kg

a Rear frame side cover installed machine
only.
50-600 2 WD600-6
Removal and installation of hydraulic tank assembly SEN05150-01
Installation
removal
[*1]
1. Install suction tube (5) with the drain port (DP)
facing downward.
a Loosen bracket (14) and install suction
tube (5) so that hose (H) will be level (no
step between the left and right side of the
hose (H)).
q (3): Hydraulic tank assembly
[*2]
3 Mounting bolt:
490 – 608 Nm {50 – 62.0 kgm}

q Air bleeding
circuit”.
WD600-6 50-600 3
SEN05150-01 Removal and installation of hydraulic pump assembly
Removal and installation of 3. Remove power train, hydraulic oil cooler, EPC
hydraulic pump assembly 1
and brake pump assembly by the following
procedure.
Removal 1) Remove the floor frame assembly, refer-
k Lower the work equipment to the ground ring to “Removal and installation of floor
completely and stop the engine. Apply the frame assembly.“
wheels. 2) Remove cover (4).
k Set the frame lock bar. a Rear frame side cover installed
k Loosen the filler cap of the hydraulic tank machine only.

3) Remove suction tube (5).
General view
(1) Power train, hydraulic oil cooler, EPC and
brake pump assembly
(2) :Work equipment hydraulic pump assembly
(3) :Steering fan pump assembly
50-600 4 WD600-6
Removal and installation of hydraulic pump assembly SEN05150-01
4) Disconnect hose (7) to the brake compo- 6) Disconnect clamps (58) and (59).
nent box. 7) Remove washer tank (60).
5) Disconnect the hydraulic oil cooler hose a Disconnect connectors BL1 and BL3
(8). from the back.
6) Disconnect hose (9) to the charge valve. 8) Remove the air cleaner cover (61).
7) Remove suction hose (10). 9) Disconnect hose clamps (62).
8) Lift and remove the power train, hydraulic 10) Disconnect dust indicator hose (63).
cooler, EPC and brake pump assembly 11) Remove covers (64) to (66).
(1). 12) Remove frame (67).
4 Power train, hydraulic oil cooler,
EPC and brake pump assembly:
50 kg
5. Remove work equipment hydraulic pump

assembly by the following procedure.
1) Disconnect suction tube (11).
4. Remove work equipment hydraulic pump
assembly and steering and fan pump assem-
bly by the following procedure.
1) Remove fender (53).
2) Remove left and right covers (54).
a A hook is provided at the top on the
back of cover (54). A pin located at
the bottom of side hood prevents
cover (54) from falling when the
mounting bolt is removed. Referring
to the “Removal and installation of
bulkhead assembly.“
2) Disconnect fan pump injection hose (12).
3) Disconnect air conditioner hose clamps

(55).
4) Disconnect air conditioner hose (56).
5) Disconnect receiver drier bracket assem-
bly (57) from the frame.
WD600-6 50-600 5
SEN05150-01 Removal and installation of hydraulic pump assembly
3) Disconnect hose (13). 6. Remove steering and fan pump assembly by

4) Disconnect clamp (14). the following procedure.
5) Disconnect valve hoses (15) and (16) of 1) Disconnect EPC basic pressure port hose
the work equipment. PEPC (20).
6) Disconnect load pressure input port hose 2) Disconnect drain hose (22).
(17). 3) Disconnect injection hose (23) to steering
7) Disconnect pump pressure input port hose valve.
(18). 4) Disconnect load pressure input hose PLS
8) Disconnect return hose (19). (24).
9) Disconnect EPC basic pressure port hose 5) Disconnect load pressure pick-up port
PEPC (20). hose (25).
10) Disconnect connectors DT2 from portion 6) Disconnect pump pressure input port hose
(A). (26) (band color: green).
7) Disconnect EPC basic pressure port hose
PEPC (27).
8) Disconnect fan injection hose (28).
9) Disconnect connector R12 (29).
10) Disconnect suction tubes (30) and (31).
11) Lift and remove the steering and fan pump
assembly (3). [*2]
4 Steering and fan pump assembly:
130 kg
11) Lift and remove work equipment hydraulic

pump assembly (2). [*1]
4 Work equipment hydraulic pump
assembly: 180 kg
50-600 6 WD600-6
Removal and installation of hydraulic pump assembly SEN05150-01
Installation
removal.
[*1], [*2]
3 Upper side mounting bolt:
456 – 568 Nm {46.5 – 58 kgm}
a Since a long tool cannot enter the lower side,
first tighten with a small torque wrench. Use
wrench [1], bar [2] and hammer [3] for angle
tightening for the second time.
3 Lower side mounting bolt
First time: 33.3 ± 2.9 Nm {3.4 ± 0.3 kgm}
Second time:45 ± 5° retightening

q Air bleeding
circuit”.
WD600-6 50-600 7
SEN05150-01 Removal and installation of control valve assembly
Removal and installation of 4. Disconnect EPC valve connectors F9 (4) and

control valve assembly 1
F07 (5), then disconnect clamp (6).
k Park the machine in a flat place. Apply

parking brake and apply chocks to the tires.
k Set the boom on the stand and check that it
does not descend.
hose, referring to section “Releasing resid-
ual pressure in work equipment circuit” in
“Testing and adjusting”.
battery before starting with the work. 5. Disconnect hydraulic oil pressure sensor con-
nector F16 (7), EPC valve connectors F08 (8)
Removal and F09 (9) from the bottom of control valve
1. Drain the oil from the hydraulic tank. assembly.
6
Hydraulic tank: 443 l
7. Disconnect EPC valve connectors F07 (11)

and F10 (12).
8. Disconnect the following hoses from rear side
3. Disconnect hose (3) between the work equip- of the control valve assembly:
ment and hydraulic pump from control valve q (13) To L.H. pitch, tilt cylinder head
assembly (2). q (14) To L.H. pitch, tilt cylinder bottom
q (15) To lift cylinder bottom
q (16) To lift cylinder head
q (17) To R.H. pitch cylinder bottom
q (18) To R.H. pitch cylinder head
q (19) To tank
q (20) From front work equipment pump
q (21) From rear work equipment pump
50-600 8 WD600-6
Removal and installation of control valve assembly SEN05150-01
Installation
removal.

q Air bleeding
9. Disconnect the following hoses. Bleed the air from the circuit between the valve
q (22): Marked with 2 red lines and the hydraulic cylinder. For details, see
q (23): Marked with 1 white line Testing and adjusting, “Bleeding air from work
q (24): Marked with 2 white lines equipment circuit”.
10. Lift control valve assembly (25) temporarily

and remove the mounting bolts.
11. Lift and remove control valve assembly (25).
a Be careful not to hit and damage to control
valve assembly with other parts.
4 Control valve assembly: 120 kg
WD600-6 50-600 9
SEN05150-01 Disassembly and assembly of control valve assembly

control valve assembly 1
a This section deals with only precautions to be

followed when reassembling the control valve
assembly.
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
796-946-1310 Guide
2 t 1
(For 723-46-40100)
796-946-1320 Guide
T 3 t 1
(For 723-46-40100)
796-946-1330 Sleeve
4 t 1
(For 723-46-40100)
50-600 10 WD600-6
Disassembly and assembly of control valve assembly SEN05150-01
Procedures for replacing pressure compensa- 3. Set tool T2 to piston (2) and push it in slowly by
tion valve seal hand so that seals (5) may spread out evenly.
a Since there are many types of pressure com- a The seal may be also fitted by pushing it
pensation valve, mark the positions when down to the flat surface of the tool and
removing to correspond to the original. then pushing it in with the tool fitted to the
1. Remove piston (2), plug (3) and spring (4) from piston.
pressure compensation valve (1).
2. Remove piston (2) from seals (5) and (6).
4. Similarly to fitting of seals (5), set tool T3 to

piston (2) from the same direction and push it
in slowly with the hand so that seals (6) will
expand evenly.
a The seal may be also fitted by pushing it
down to the flat surface of the tool and
then pushing it in with the tool fitted to the
piston.
a There are many types of piston.
WD600-6 50-600 11
5. Keep compensation tool T4 fitted to piston (2) Assembly of control valve assembly
for about one minute so that seals (5) and (6)
are adapted well. q Coat the sliding surface with engine oil and
a Check that there is no protrusion or cut on then reassemble the control valve assembly.
the seal.
q Section C-C
2 Portion (P): Seal end 242 (20% diluted alco-
hol) or equivalent
a One rotation of adjustment screw changes
pressure by approx. 20.5 MPa {209 kg/cm2}.
a Identical for the left and right
6. Assemble the piston in the sleeve.

a If it is found difficult to install the piston, do
not attempt to push it in forcibly, but set it
to compensation tool T4 again and install
the piston to the sleeve after adapting the
seal.
7. Fit plug (3) and spring (4) to piston (2), then

assemble pressure compensation valve (1).
a After the installation, push the piston by
hand and check that the piston reacts only
with spring force.
50-600 12 WD600-6
Disassembly and assembly of control valve assembly SEN05150-01
q Section H-H, F-F and E-E
a Care required for the order of tightening

Apply one drip (approx. 0.02 g) of Loctite No.
638 to plugs (7) (8) and (9) and tighten them.
2 Plugs (7), (8) and (9) : Apply one drip
(approx. 0.02 g) of Loctite No. 638
WD600-6 50-600 13
q Control valve cover block (CB)

a Referring to the sectional view.
2 Mating face of upper and lower control valve
cover block (SE):
SEALEND 242 or equivalent
q Tighten the control valve cover block mounting
bolts according to the order shown in the fig-
ure. (A o D o C o B)
3 Control valve cover block mounting bolt:
156.8 – 176.5 Nm {16 – 18 kgm}
q Plate (P)
a Referring to the sectional view.
2 Mating face (SE1) of control valve plate (P):
SEALEND 242 or equivalent
q Tighten the plate mounting bolts according to
the order shown in the figure (A o D o C o B)
3 Plate mounting bolt:
156.8 – 196 Nm {16 – 20 kgm}
q Pressure compensation valve

a Install by checking the mark provided
when respective pressure compensation
valves were removed.
q Main relief valve assembly

After installation to the control valve, referring
to “Testing and adjusting of work equipment oil
pressure” in Testing and adjusting.
50-600 14 WD600-6
Removal and installation of steering valve assembly SEN05150-01
Removal and installation of 12. Disconnect steering pump hose (13) from the
steering valve assembly 1
back.
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
T 1 793T-664-1110 Bracket t 1 N Q
Removal
parking brake and put the blocks under the 13. Using box assembly (20) mounting hole, install
wheels. tool T1.
k Set the frame lock bar. 14. Remove 3 mounting bolts, and remove steer-
k Loosen the filler cap of the hydraulic tank ing valve assembly (14).
gradually to release the residual pressure 15. Slide steering valve assembly (14) to lift and
from the hydraulic tank. remove it.
k
4
Disconnect the negative terminal (–) of the
battery before starting with the work. Steering valve assembly: 70 kg

3. Lift and remove the handrail and step assem-
bly (2).
a Disconnect connector of light (L).
4. Lift and remove box assembly (20).
Installation
removal

5. Disconnect pilot hose (3) from steering valve 5 Hydraulic tank: 443 l
assembly (14).
6. Disconnect bracket (4).
7. Disconnect steering cylinder hoses (5) and (6). q Air bleeding
8. Disconnect drain hose (7). Bleed the air from the circuit between the valve
9. Disconnect hoses (8) to (10) from (Tp) port. and the hydraulic cylinder. For details, see Test-
10. Disconnect pilot hose (11) from the back. ing and adjusting, “Bleeding air from steering cir-
11. Remove U-bolt (12). cuit”.
WD600-6 50-600 15
SEN05150-01 Disassembly and assembly of hydraulic cylinder assembly
Disassembly and assembly of Disassembly

hydraulic cylinder assembly 1
1. Piston rod assembly
1) Remove piping from the cylinder assem-
Special tools bly.
2) Remove the mounting bolts and then dis-
New/Remodel
connect head assembly (1).
Necessity
Sym- 3) Pull out piston rod assembly (2).
Part No. Part name
Sketch
bol a Place a container under the cylinder
Q'ty
to catch the oil.
Cylinder repair
790-502-1003 q 1
1 stand
790-101-1102 Pump q 1
790-102-4300 Wrench assembly t 1
2
790-102-4310 Pin t 2
3 790-720-1000 Expander q 1
796-720-1690 Ring (For lift arm) q 1
07281-02169 Clamp q 1
Ring
796-720-1720 q 1
(For bucket)
4
07281-02429 Clamp q 1
Ring 4) Disassemble the piston rod assembly as
796-720-1660 q 1
(For steering) follows.
07281-01159 Clamp q 1 1] Set piston rod assembly (2) in tool U1.
U 790-201-1702 Push tool kit t 1
• Push tool
790-201-1881 (For lift arm and 1
bucket)
5
• Push tool
790-201-1821 1
(For steering)
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1500 Push tool kit q 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
6 • Plate
790-201-1690 (For lift arm and 1 2] Remove stopper screw (3) of piston
bucket) assembly (4).
• Plate a Common for the lift arm, arm and
790-201-1630 1 bucket cylinders
(For steering)
Screw size: M12 × pitch 1.75
50-600 16 WD600-6
Disassembly and assembly of hydraulic cylinder assembly SEN05150-01
a If the caulking of screw (3) is too 2. Disassembly of piston assembly

strong and it cannot be removed, 1) Remove rings (11).
tighten the screw fully, then fit tap (T) 2) Remove wear rings (12).
to the thread and remove the screw. 3) Remove piston ring (13).
4) Remove O-ring and backup ring (14).
3] Using tool U2, remove piston assem-

bly (4). 3. Disassembly of cylinder head assembly
q When not using tool U2, use the 1) Remove O-ring and backup ring (15).
drill holes (H) (10: 2 places) and 2) Remove snap ring (16) and then remove
loosen piston assembly. dust seal (17).
4] Remove head assembly (1) from pis- 3) Remove rod packing (18).
ton rod assembly (2). 4) Remove buffer ring (19).
5) Remove busing (20).
WD600-6 50-600 17
Assembly
a Be careful not to damage the packing, dust
seals, and O-rings.
a Clean each part, then cover the piping ports
and pin-inserting hole to prevent dust from
entering them.
a Do not try to force the backup ring into posi-
tion. Warm it in warm water (50 – 60°C) before
installing it.
1. Assembly of head assembly
1) Using tool U5, press fit bushing (20).
2) Assemble buffer ring (19).
3) Assemble rod packing (18).
4) Using tool U6, install dust seal (17), and
secure with snap ring (16).
5) Install the backup ring and O-ring (15).
3. Piston rod assembly

1) Install head assembly (1) to piston rod
assembly (2).
2) Set piston rod assembly (2) in tool U1.
2. Assembly of piston assembly

1) Using tool U3, expand piston ring (13).
a Set the piston ring on tool U3, and
t ur n th e h an d le 8 – 1 0 t im e s t o
expand the ring.
2) Set tool U4, and compress piston ring
(13).
3) Install the backup ring and O-ring (14).
4) Assemble wear rings (12).
5) Assemble rings (11).
a Be careful not to open the end gap of
the ring too wide.
2 Ring groove: Grease (G2-LI)
50-600 18 WD600-6
3) Assemble piston assembly (4) as follows. q When using a new part for either or
both of piston rod assembly (2) and
q When using piston rod assembly (2) piston assembly (4)
and piston assembly (4) again
1] Screw in piston assembly (4) until it
a Wash thoroughly and remove all metal makes contact with the rod end sur-
particles and dirt. face (B). Use tool U2 (noted in the
1] Screw in piston assembly (4) by using foregoing) to tighten it.
tool U2, and tighten piston assembly 3 Piston assembly:
(4) until the position of the screw 294 ± 29.4Nm {30 ± 3.0kgm}
thread hole (H1) which is in piston rod
assembly (2) halfway matches.
a Remove all burrs and flashes on
the threaded portion with a file.
2] Machine one of the holes used to

install screw (3).
a Align a drill horizontal with the V-
groove of the thread of piston rod
2] Tighten screw (3). assembly (2) and piston assem-
2 Screw part female screw side: bly (4), then carry out machining.
Loctite No.262 q Screw machining dimension
3 Screw: (mm)
58.9 – 73.6 Nm {6 – 7.5 kgm}
Prepara-
3] Caulk thread at four places (a) of Prepara-
tion hole Tapping
screw (3) with punch. tion hole Screw size
drill diam- depth
depth
eter
24 *1 20 *1
10.3 12 × 1.75
43 *2 36 *2
*1: Steering cylinder

*2: Tilt & pitch cylinder
WD600-6 50-600 19
3] After machining, wash thoroughly to 5) Tighten head assembly (1) with mounting
remove all metal particles and dust. bolts.
4] Tighten screw (3). 3 Mounting bolt:
2 Screw part female screw side:
Cylinder name Tightening torque
Loctite No.262
3 Screw: Steering 270 ± 39 Nm {27.5 ± 4.0 kgm}
58.9 – 73.6Nm {6 – 7.5kgm} 343 ± 34.3 Nm
Tilt & pitch
5] Caulk thread at four places (a) of {35 ± 3.5 kgm}
screw (3) with punch.
4) Assemble the cylinder tube to piston rod 6) Install piping.

assembly (2).
a Align axial center of the cylinder tube,
then insert.
a Check that the ring is not broken and
has not come out, then push in fully.
50-600 20 WD600-6
WD600-6 50-600 21
SEN05150-01
WD600-6 Wheel dozer

©2017 KOMATSU
All Rights Reserved
50-600 22
SEN05151-00
WHEEL DOZER
WD600-6
WD600-6 55001 and up
700 Work equipment

Removal and installation of work equipment assembly .................................................................................. 2
WD600-6 50-700 1
700 Work equipment
SEN05151-00 Removal and installation of work equipment assembly
Removal and installation of work 4. Sling Y-link (6), remove the lock bolt, and pull
equipment assembly 1
out blade pin (7). [*2]
a Check the quantity of the shim.
Removal
k Park the machine on a level place, set the lock
bar to the frame, and put chocks under the
tires.
1. Place blocks (1) and (2) just under the right

and left of the work equipment and set the
work equipment on them securely.
5. Remove lock bolt (8) and pull out O-ring (9)

and frame pin (10). [*3]
2. Sling lift cylinder assembly (3), remove lock

bolt (4), and pull out head pin (5). [*1]
3. After pulling out head pin (5), start the engine

and retract the piston rod fully.
a Fix the piston rod with a wire etc. so that it
will not come out.
q Similarly, disconnect the cylinder on the
opposite side from the blade.
6. Lift off Y-link (6).
4 Y-link: 549 kg
50-700 2 WD600-6
700 Work equipment
Removal and installation of work equipment assembly SEN05151-00
7. Sling H-link (11), remove lock bolt (12), and

pull out the O-ring and pin (13). [*4]
8. Lift off H-link (11).

4 H-link: 486 kg
11. Remove right and left trunnion caps (18). [*5]

a Mark the hoses.
a Plug the piping to prevent entry of dirt etc.
12. Remove the blade assembly.

a Start the engine and move the machine in
reverse slowly to disconnect the blade
assembly from the trunnion.
13. Sling plate (19), remove lock bolt (20), and pull
out pin (21).
14. Lift off plate (19).

4 Plate: 62 kg
WD600-6 50-700 3
700 Work equipment
SEN05151-00 Removal and installation of work equipment assembly
15. Sling trunnion (22) and remove mounting bolts Installation

(23). q Carry out installation in the reverse order to
removal.
16. Lift off trunnion (22). k When aligning the pin holes, never insert
4 Trunnion: 58 kg your fingers in them.
[*1]
17. Sling trunnion support (24), remove lock bolt 2 Inside of bushing when assembling:
(25), and pull out pin (26). [*6] Molybdenum disulphide grease (LM-P)
[*2]
2 Inside of bushing when assembling:
Molybdenum disulphide grease (LM-P)
k When aligning the pin holes, never insert

your fingers in them.
q Select thicknesses (a) and (b) so that each of
them will be 0 – 0.1 mm less than the clear-
ance (average of 3 places on the periphery)
made when flanges (28) and (30) are tightened
by 4 places respectively on their peripheries to
half the specified tightening torque without any
shim after bushings (27) and (29) are press fit-
ted.
18. Lift off trunnion support (24).

4 Trunnion support: 1,266 kg
50-700 4 WD600-6
700 Work equipment
Removal and installation of work equipment assembly SEN05151-00
[*3] [*4] [*5]

2 Inside of bushing when assembling: 3 Trunnion cap mounting bolt:
Molybdenum disulphide grease (LM-P) 632 – 828 Nm {64.5 – 84.5 kgm}
k When aligning the pin holes, never insert a Clearances (e) + (f) = Max. 1.5 mm
your fingers in them. a The shim may be inserted in either of (e) and
(f).
a Clearances (c) + (d) = Max. 1.5 mm
a Take care that the O-ring will not be caught.
a When installing Y-link (31) and H-link (32), put
the stamped sides up and match the stamped
Nos. on Y-link (31) and H-link (32).
Refilling with oil (Hydraulic tank)

a Add oil through the oil filler to the specified
through the piping. Then, check the oil level
again.
Bleeding air
a Bleed air. For details, see Testing and adjust-
ing, "Bleeding air from each part".
WD600-6 50-700 5
SEN05151-00
WD600-6 Wheel dozer

©2009 KOMATSU
All Rights Reserved
50-700 6
SEN05152-02
WHEEL DOZER
WD600-6
WD600-6 55001 and up

Removal and installation of operator's cab assembly ..................................................................................... 2
Removal and installation of operator's cab glass (stuck glass)....................................................................... 6
Removal and installation of floor frame assembly ........................................................................................ 14
Disassembly and assembly of operator’s seat assembly ............................................................................. 17
Removal and installation of air conditioner unit assembly ............................................................................ 50
Removal and installation of AJSS lever switch assembly ............................................................................. 53
WD600-6 50-800 1
SEN05152-02 Removal and installation of operator's cab assembly
Removal and installation of 7. Remove cover (8) and internal air filter.
operator's cab assembly 1
8. Remove plate (9).
9. Remove 3 mounting bolts (11) and remove
Removal duct (10).
k Disconnect the negative terminal (–) of the 10. Remove 4 mounting bolts, then remove duct
battery before starting with the work. (12).
1. Open cover (1).

2. Remove box (2).
a Place the left console (LC) in front.
11. Remove covers (13) to (15).
4. Disconnect hose (5) from the side of the air

conditioner unit.
5. Remove box (6).
6. Remove mat (7).
50-800 2 WD600-6
Removal and installation of operator's cab assembly SEN05152-02
13. Remove brackets (17). 17. Connector CN17 (22): Disconnect accelerator
microswitch.
18. Connector CN18 (23): Disconnect brake pedal
cancel switch.
a For round handle specification only

15. Remove hose and duct assemblies (19) and
(20).
19. Disconnect connectors CN-CL16 (24), CN-
CL17 (25) and CN CL18 (26).
16. Disconnect link (21).

a AJSS specification only (excluding round
handle)
20. Remove bracket mounting bolts (27) between
the column and cab.
WD600-6 50-800 3
SEN05152-02 Removal and installation of operator's cab assembly
21. Remove left and right covers (28). 25. Disconnect connector CN-C58 (37) from the
front right side of the operator's cab.
a For VHMS specification only
26. Disconnect connector CN-V34 (38).

a For ORBCOMM specification only
27. Disconnect window washer hoses (39).

28. Remove the clamp and disconnect window
washer hose (40).
29. Disconnect connectors CN-CL11 (41), CN-
CL12 (42) and CN-CL13 (43).
30. Remove the clamps (44) and (45) to discon-
nect wiring harnesses (46) and window washer
hose (40).
31. Remove left and right mounting bolts (47) and
(48) from lower. [*2]
23. Remove mounting bolts (31) and (32) from 32. Lift and remove operator's cab assembly (49).
lower, then remove left and right mounting [*3]
bolts (33) from top to assemble the operator's 4 Operator's cab assembly: 1,100 kg
cab and floor frame.
24. Remove left and right mounting bolts (34) from
top, to disassemble the operator's cab and
floor frame. [*1]
When self-driving without the cab during

transportation
Arrange for the following parts:
q Wiring harness:
426-06-31540
q Descriptive plate in English:
426-98-33410
50-800 4 WD600-6
Removal and installation of operator's cab assembly SEN05152-02
Installation k After installing the floor mat, check if

q Carry out installation in the reverse order to the brake valve boot (B) is crushed.
removal a Also check if the accelerator pedal boot is
crushed.
[*1] q Example of bad boot condition where
3 Operator's cab mounting bolt (34) (2 bolts, the boot (B) is crushed
upper): 883 – 981 Nm {90 – 100 kgm}
[*2]
3 Operator's cab mounting bolt (47) (4 bolts,
front): 883 – 981 Nm {90 – 100 kgm}
3 Operator's cab mounting bolt (48) (8 bolts,

rear): 1,157 – 1,442 Nm {118 – 147 kgm}
[*3]
Replace seal (S) between the operator's cab and
floor frame.
1. Remove greases and dusts from the pasting q Example of good boot condition where
face. the boot (B) is not crushed
2. Attach seal (S) aligning the upper circumfer-
ence of the floor frame.
q (a): R10 – 20 mm
a Have the seal ends (P) closely adhered
mutually without any gap. (Portion A)
q (b): 20 mm
WD600-6 50-800 5
SEN05152-02 Removal and installation of operator's cab glass (stuck glass)
Removal and installation of operator's cab glass (stuck glass) 1
a Operator's cab window glass is wholly of stuck (1): Right door window glass
glass type. (2): Rear window glass of right door
a In this section, the procedure for replacing the (3): Left door window glass
stuck glasses is explained. (4): Rear window glass of left door
(5): Rear window glass
(6): Seal (both-sided adhesive tape)
(7): Front window glass
(8): Right front side window glass
(9): Left front side window glass
(10): Weather strip
50-800 6 WD600-6
Removal and installation of operator's cab glass (stuck glass) SEN05152-02
Special tools a If the window glass is broken finely, it may

be removed with a knife [4] and a screw-
New • Remodel
driver.
a Widening the cut with a flat blade screw-
Essentiality
Sym-
Illustration
Part number Part name driver, cut the dam rubber and adhesive
Quantity
bol
with knife [4].
1 793-498-1210 Lifter (Suction cup) t 2 (The figure shows the operator's cab of a
X wheel loader.)
2 20Y-54-13180 Stopper rubber t 2
Removal
a Remove the window glass to be replaced
1. Using seal cutter [1], cut the adhesive between
broken window glass (7) and operator's cab
(metal sheet) (8).
2. Remove the window glass.
a If a seal cutter is not available, make holes

on the adhesive and dam rubber with a
drill and pass a fine wire (piano wire, etc.)
[2] through the holes. Then, grip the both
ends of the wire with pliers [3], etc. (or
hold them by winding them onto some-
thing) and move the wire to the right and
left to cut the adhesive and dam rubber.
Since the wire may be broken by the fric-
tional heat, apply lubricant to the wire.
(The figure shows the operator's cab of a
wheel loader.)
WD600-6 50-800 7
Installation Preparation
1. Using a knife and scraper [5], remove the
Processing sequence remaining adhesive and dam rubber from the
metal sheets (glass sticking surfaces) of the
Preparation (cleaning) operator's cab.
a Remove the adhesive and dam rubber to
O a degree that they will not affect adhesion
of the new adhesive. Take care not to
Primer coating scratch the painted surfaces.
q Cab side: SUNSTAR 435-95 (If the painted surfaces are scratched,
q Glass side: SUNSTAR 435-40 adhesion will be lowered.)
O After applying the primer, leave it for at (The figure shows the operator's cab of a
least 5 minutes to dry (proceed to the next wheel loader.)
step within 24 hours).
Apply both-sided adhesive rubber (on the cab

side).
a Only for the front glass and the front side glass
Install weather strip to the window glass.
Inject the following to between the weather strip
and glass:
Silicone sealant (ThreeBond 5211E)
O
2. Remove oil, dust, and dirt, etc. form the stick-
Positioning of window glass ing surfaces of cab (8) and window glass (9)
with white gasoline.
O a If the sticking surfaces are not cleaned
well, the glass may not be stuck perfectly.
Apply adhesive (SUNSTAR Industry sealant Peta- a Clean the all black part on the back side of
Seal 551) (on the cab side) the window glass.
a After cleaning the sticking surfaces, leave
O Within 5 minutes them for at lease 5 minutes to dry.
(The figure shows the operator's cab of a
Adhere window glass wheel loader.)
a Hold the glass pressed for 10 hours minimum.
O 8 hours minimum (a Only for the front

glass and the front side glass)
Seal between the front glass and front side glass.

Adhesive (SUNSTAR PENGUINE SEAL No. 2505)
a Don't move the glass for 24 hours minimum.
50-800 8 WD600-6
Primer coating 3) Apply primer for coating evenly around

3. Apply primer (10). whole of the circumference for coating on
a The using limit of primer is 4 months after operator's cab (8).
the date of manufacture. Do not use the (a): Min. 25 mm
primer after this limit. 2 Paint primer for the cab:
a Use the primer within 2 hours after SUNSTAR 435-95

unpacking it. a Do not apply the primer more than 2
a Even if the primer is packed again just times.
after it is unpacked, use it within 24 hours (If it is applied more than 2 times, its
after it is unpacked for the first time. performance will be lowered.)
(Discard the primer 24 hours after it is a Never apply the wrong primer.
unpacked.) If the glass primer, etc. is applied by
1) Stir the primers for both of paint and glass mistake, wipe it off with white gaso-
sufficiently before using them. line.
a If the primer has been stored in a a After applying the primer, leave it for
refrigerator, leave it at the room tem- at least 5 minutes to dry. Proceed to
perature for at least half a day before applying both-sided adhesive tape
stirring it. within 24 hours.
(If the primer is unpacked just after (The figure shows the operator's cab on a
taken out of the refrigerator, water will power shovel.)
be condensed. Accordingly, leave the
primer at the room temperature for a
sufficient time.)
2) When reusing primer brush (11), wash it in
white gasoline.
a After washing the brush, check it
again for dirt and foreign matter.
a Prepare respective brushes for the
paint primer and glass primer.
a (9): Glass
WD600-6 50-800 9
4) Apply primer for coating glass around Adhere both-sided adhesive tape
whole of the inner circumference for black 4. Stick both-sided adhesive tape (6) along the
coating of window glass (9). inside edge of cab (8).
(a): Min. 25 mm a Do not remove the release tape of dam
2 Glass primer: SUNSTAR 435-40 rubber on the glass sticking side before
a Black coating on glass is for protec- sticking the glass.
tion against optical degradation. a When sticking the dam rubber, do not
a Do not apply the primer more than 2 touch the cleaned surface to the utmost.
times. a Take particular care for preventing the
(If it is applied more than 2 times, its adhesive tape from floating at the corner.
performance will be lowered.) a When sticking both-sided adhesive tape
(6) around the edge completely, don't
allow the both ends of the tape to be over-
lapped when jointed. Or provided a clear-
ance of about 5 mm at the joint (e).
1) Stick dam rubber (6) for right side window
glass (1) to the position as shown in the
figure.
a (The figure shows the operator's cab
on a power shovel.)
a (8): Cab
a Never apply the wrong primer.

If the paint primer, etc. is applied by
mistake, wipe it off with white gaso-
line.
50-800 10 WD600-6
a (6): Adhesive tape Adhesive coating

a (8): Cab 6. Preparation for applying adhesive
a (a): Range for applying primer (noted q Adhesive:
in the foregoing) SUNSTAR Industry sealant Peta-Seal
a (15): Adhesive (to be described later) 551
a The using limit of the adhesive is 4 months
after the date of manufacture. Do not use
the adhesive after this limit.
a Keep the adhesive in a dark place where
the temperature is below 25°C.
a Never heat the adhesive higher than
30°C.
a When reusing the adhesive, remove the
all hardened part form the nozzle tip.
1) Set adhesive cartridge (12) to caulking

gun [7].
a An electric caulking gun is more effi-
cient.
Positioning of window glass
5. Position the new window glass.
1) Check the clearance between the window
glass and the operator's cab on the right,
left, upper, and lower sides, and then posi-
tion the window glass to be the clearances
evenly.
2) Stick tapes [6] between window glass (9)
and operator's cab (8) and draw position-
ing line (n).
a Apply tape [6] to three locations
including the left and right sides and
the bottom of glass for precise posi-
tioning.
3) Cut the tape between window glass (9)
2) Cut the tip of the adhesive nozzle (14) so
and operator's cab (8) with a knife, etc.
that dimensions (q) and (r) will be as fol-
and then remove the window glass.
lows.
a Do not remove the release tape of the
q Dimension (q): 10 mm
both-sided adhesive tape before the
q Dimension (r): 15 mm
glass is installed.
(The figure shows the operator's cab on a
power shovel.)
3) Remove the release tape of dam rubber

on the glass adhesive side.
WD600-6 50-800 11
7. Apply adhesive. Installation of window glass

a Apply adhesive (15) to dimensions (s) and 8. Install the window glass.
(t) in the figure to the both-sided adhesive 1) Install window class (9), matching it to the
tape (6) of operator's cab (8). lines of the positioning tapes drawn in step
q Dimension (s): 10 mm 5.
q Dimension (t): 15 mm a Since the window glass cannot be
2 Adhesive: removed and stuck again, stick it with
SUNSTAR Industry sealant Peta-Seal utmost caution.
551 2) After sticking window glass (9), press all
a Apply adhesive (15) higher than dam rub- around of it until it sticks to the dam rubber
ber (6). closely.
a Apply the adhesive evenly with same a Press the corners of the window glass
height level. firmly.
a (a): Range for applying primer (noted in (The figure shows the operator's cab on a
the foregoing) power shovel.)
a Install window glass within 5 minutes after

applying the adhesive.
a You can perform this work efficiently

by pulling window glass (9) from
inside of the operator's cab with suc-
tion cup X1.
a Wipe off the projected adhesive.
50-800 12 WD600-6
9. Fix the window glass. 10. After installing the window glass, remove any
1) After installing right window glass (1) to excess of the primer and adhesive from the
the operator's cab, insert stopper rubbers operator's cab and window glass.
X2 to 2 places (v) at the bottom of the a By using the white gasoline, wipe off the
glass to fix the glass. adhesive before it is dried up.
(The figure shows the operator's cab on a a When cleaning the glass, do not give an
power shovel.) impact on it.
a Only for the front glass and the front side

glass
11. Seal section (A) between front glass (7) and
front side glass (8) and (9).
2 Section (A): Adhesive (SUNSTAR PEN-
GUINE SEAL No. 2505)
q (b): 5mm
a Don't move the glass for 24 hours mini-
mum.
2) To adhere the window glass and the both-

sided adhesive tape completely, use styro-
foam [9] and rubber band [10] to fix them
tightly for 10 hours minimum to cure.
(The figure shows the operator's cab on a
power shovel.)
WD600-6 50-800 13
SEN05152-02 Removal and installation of floor frame assembly
Removal and installation of floor q AJSS specifications (excluding round han-

frame assembly 1
dle)
4. Disconnect hoses (6) to (9) from the AJSS
Removal valve (lower left side of floor frame).
k Lower the work equipment to the ground 5. Disconnect clamp (10).
completely. 6. Disconnect hoses (11) (band color: green) and
k Loosen the oil filler cap of the hydraulic (12) (no band).
tank gradually to release the pressure in
the hydraulic tank. q Common specifications
k Operate the work equipment control lever 2 7. Disconnect hoses (13) to (15).
– 3 times to release the pressure in the PPC
accumulator circuit.
k Release residual pressure in brake accu-
mulator circuits. For detail, see Testing and
adjusting, "Releasing residual pressure in
brake accumulator circuit".
k In the case that you do not drain the cool-
ant, if you disconnect the heater hose when
the coolant temperature in the radiator is
high, you may be scalded. In this case, wait
until the coolant temperature lowers and
then disconnect the heater hose.
k Collect the air conditioner refrigerant q Round handle specification
(R134a) from air conditioner circuit in 8. Disconnect hoses (16) to (19).
advance.
a Ask professional traders for collecting and fill-
ing operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the
atmosphere.


2. Disconnect heater hoses (4).
a Confirming their destination.
3. Disconnect air conditioner hoses (5). [*1]
50-800 14 WD600-6
Removal and installation of floor frame assembly SEN05152-02
9. Disconnect hoses (20) to (23) from the right q AJSS specifications (excluding round han-
brake valve. dle)
10. Disconnect drain hose (24). 13. Disconnect rod (31).
a Disconnect the clamp. a Check and record the installed length.
11. Disconnect clamps (25). 14. Disconnect air conditioner wiring harness con-
12. Disconnect hoses (26) to (30) from the left nector CL13 (32), front frame wiring harness
brake valve. connector FL11 (33) and transmission wiring
harness connector LT1 (34) from the lower
right corner of the floor frame.
a Disconnect the clamp.
15. Disconnect grounding wire (35).
WD600-6 50-800 15
SEN05152-02 Removal and installation of floor frame assembly
17. Disconnect the following connectors from Installation

lower of the rear floor frame: q Carry out installation in the reverse order to
q From the upper left section: BV2 (37), LR7 removal
(38), LR11 (39) and LR1 (40)
q From lower left section: [*1]
BV1 (41), BL1 (42), LR2 (43), LR3 (44), a Install hoses without twists.
LR4 (45) a Carefully install the air conditioner hose piping,
FL7: For side work lamp (If equipped) preventing dirt, dusts, water content, etc. from
FL6: For side work lamp (If equipped) entering the hoses.
18. Disconnect clamp (46). a Before tightening, make sure O-ring (70) is
19. Disconnect connector BL2 (47). provided in the air conditioner hose piping con-
20. Disconnect bracket (48). nection.
a Amply apply the compressor oil for R134a
(DENSO: ND-OIL8 or VALEO THERMAL
SYSTEMS: ZXL100PG (PAG46 or equiva-
lent)) to the O-rings.
21. Remove floor frame assembly (49).

a Lift the floor frame assembly gently while
checking for any undisconnected clamp,
3
hose, harness, etc.
Air conditioner gas piping tightening torque
4 Floor frame assembly: 320 kg
Screw size Tightening torque
16 × 1.5 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
22 × 1.5 19.6 – 24.5 Nm {2.0 – 2.5 kgm}
24 × 1.5 29.4 – 34.3 Nm {3.0 – 3.5 kgm}

(R134a).
a Filling quantity: 850 ± 50g
q Refilling engine coolant

Refill coolant through the coolant filler port up
to the specified level. Start the engine and cir-
culate the coolant, and then check the coolant
level.
q Air bleeding
q Bleed the air from the circuit between the
valve and the steering cylinder. For
details, see Testing and adjusting, “Bleed-
ing air from steering circuit”.
q Bleed the air from the brake circuit. For
details, see Testing and adjusting, "Bleed-
ing air from wheel brake circuit".
50-800 16 WD600-6
Disassembly and assembly of operator’s seat assembly SEN05152-02
Disassembly and assembly of 2. Removal and installation of seat pad and

operator’s seat assembly 1
backrest upholstery
[ Manufactured by GRAMMER ]
a Although the machine of the joystick steering

specification is not equipped with the left arm-
rest, its operator's seat assembly are also dis-
assembled and assembled according to the
I. Upper seat
1. Removal and installation of storage box
Removal
1) Remove the storage box by referring to "1.
Removal and installation of storage box".
2) Undo the 4 screws (1), and remove the
backrest upholstery (2).
3) Undo the 5 screws (4), and remove the
seat pad (5).
4) Disconnect the connectors (3) and (6).
Installation
1) Connect the connectors (3) and (6).
2) Install the seat pad (5), and fix it with the 5
Removal screws (4).
1) Open the storage box (1). 3) Install the backrest upholstery (2), and fix
2) Remove the hook (3). it with the 4 screws (1).
3) Undo the screws (2) and remove the stor- 4) Install the storage box by referring to "1.
age box (1). Removal and installation of storage box".
Installation
1) Set the storage box (1) and fix it with the
screws (2).
2) Install the hook (3).
WD600-6 50-800 17
SEN05152-02 Disassembly and assembly of operator’s seat assembly
3. Removal and installation of mechanical 4. Removal and installation of armrests

lumbar support (If equipped)
Removal Removal
1) Remove the storage box by referring to "1. 1) Remove the cover (1).
Removal and installation of storage box". 2) Unscrew the hexagon nuts (2) and
2) Remove the backrest upholstery by refer- remove the nuts and washers (3).
ring to "2. Removal and installation of seat 3) Remove the armrests (4).
pad and backrest upholstery".
3) Drill off the rivets (1), loosen the spring Installation
steel sheets (2) from the L-bar (3) and 1) Set the armrests (4).
remove them. 2) Put the washers (3) and tighten hexagon
4) Unhook the L-bars (3) from the catch ele- nuts (2).
ment (4). 3 Hexagon nuts: 25 Nm {2.6 kgm}
5) Undo the hexagon socket screw (5) and 3) Install the cover (1).
remove the adjusting knob (6) with the
toothed wheel (7).
6) Drill off the rivet (8), remove the wrap
spring brake element (9) and the catch
element (4).
Installation
1) Install the wrap spring brake element (9)
and the catch element (4), and fix them
with the rivets (8).
2) Install the adjusting knob (6) and the
toothed wheel (7), and tighten the hexa-
gon socket screw (5).
3) Install the catch element (4) to the L-bars
(3) and fix with the rivets (1).
4) Install the 2 spring steel sheets (2) to the
L-bar (3), and fix with the rivets (1).
5) Install the backrest upholstery by referring
to "2. Removal and installation of seat pad
and backrest upholstery".
6) Install the storage box by referring to "1.
50-800 18 WD600-6
5. Disassembly and assembly of backrest
Removal a Insert the bearing (B/8) into the upper

1) Detach the storage box by referring to "1. hole on the backrest support on the
Removal and installation of storage box". right side (figure B/4).
2) Remove the backrest upholstery by refer- 2) Press the backrest (1) slightly to the left
ring to "2. Removal and installation of seat and install it.
pad and backrest upholstery". a The big cylindrical stamping on the
3) Remove the armrests by referring to "4. backrest adjustment (figure C/2) must
Removal and installation of armrests". (If engage into the big positional bore
equipped) hole on the backrest support on the
4) Disassemble the backrest adjustment by left side (figure C/3).
referring to "6. Disassembly and assembly a The integral catch on the backrest
of backrest adjustment". (figure A/1) must engage into the tor-
5) Unscrew the hexagon nut (5) and remove sion spring (figure A/9).
the washers (6) and (7). 3) Put the washer (10) and tighten the hexa-
6) Remove the hexagon bolt (11) and the gon bolt (11).
washer (10). 4) Put the washers (6) and (7), and tighten
7) Press the backrest (1) slightly to the left the hexagon nut.
and take it off upwards. 3 Hexagon nuts: 25 Nm {2.6 kgm}
8) Remove the bearing (8) and the torsion 5) Assemble the backrest adjustment by
spring (9) from the backrest (1). referring to "6. Disassembly and assembly
of backrest adjustment".
6) Install the armrests by referring to "4.
Installation Removal and installation of armrests". (If
1) Install the bearing (8) and the torsion equipped)
spring (9) to the backrest (1).
a Oil the bearing point (Q) on the back-
rest (1) for the bearing (8) with acid-
free multiple-purpose lubricant.
WD600-6 50-800 19
7) Install the backrest upholstery by referring 7. Disassembly and assembly of seat angle
to "2. Removal and installation of seat pad and seat depth adjuster
6. Disassembly and assembly of backrest

adjustment
Disassembly
1) Remove the storage box by referring to "1.
2) Remove the backrest upholstery by refer-
ring to "2. Removal and installation of seat
pad and backrest upholstery".
3) Remove the armrests by referring to "4.
Removal and installation of armrests". (If
equipped) Disassembly
4) Fold the backrest (1) forwards.
1) Remove the seat pad by referring to "2.
5) Unscrew 3 flat-headed screws (2), remove
Removal and installation of seat pad and
the adaptor plate (3) and the flat-headed
backrest upholstery".
screw (4).
2) Remove the switch by the following proce-
6) Remove the lever (5) and handle (6).
dure. (If equipped)
1] Disconnect the spring (1).
Assembly 2] Tilt the switch-plate (2) forwards and
1) Fold the backrest(1) forwards. remove it.
2) Install the handle (6) and the lever (5). 3] Drill off the rivet (3) and remove the
3) Tighten the 3 flat-headed screws (4), seat switch (4).
install the adaptor plate (3) and then
tighten the flat-headed screw (2).
a The lifter of the flat-headed screw (4)
must engage into the nut of the adap-
tor plate (3).
3 Flat-headed screw:
12 Nm {1.2 kgm}
4) Install the armrests by referring to "4.
Removal and installation of armrests". (If
equipped)
5) Install the backrest upholstery by referring
to "2. Removal and installation of seat pad
50-800 20 WD600-6
3) Remove the flexible support plate (7) by 2] Install the spring (13) to hook (a) of
the following procedure. the lever (14) and hook (b) of the
1] Press the spring plate (5) ("P" posi- plate (15).
tion) inwards (arrow), operate the
lever for seat angle adjustment (6).
3] Install the cover (9), the levers for

seat angle and seat depth adjustment
2] Pull the flexible support plate (7) to (6), (10), the linkage rod (11) and the
backwards and remove it. locking lever (12), then tighten the
4) Remove the plate (15) by the following hexagon socket screws (8).
procedure. 4] Install the spring steel sheet (5) and
1] Drill off the rivet and remove the fix it with the rivet.
spring steel sheet (5). 6) Install the flexible support plate by the fol-
2] Unscrew the hexagon socket screws lowing procedure.
(8), remove the cover (9), the levers 1] Press the spring plate (5) ("P" posi-
for seat angle and seat depth adjust- tion) inwards (arrow), operate the
ment (6), (10), the linkage rod (11) lever for seat angle adjustment (6).
and the locking lever (12). 2] Swivel the flexible support plate (7)
3] Remove the spring (13). upwards and install it.
4] Turn the lever (14) clockwise until it 3] Install the end hook of the linkage rod
snaps-in, pull the plate (15) to the (11) to the position (c) of the lever
very front and remove it. (10), and the other side of hook of the
5) Remove the covers on the right and left linkage rod (11) to the port (d) of the
side by referring to "8. Removal and instal- lever (14).
lation of covers".
6) Unscrew the nut (16), remove the lever
(14) and the screw (17).
7) Drill off the rivet (18) and remove the
spring steel sheets (19).
8) Drill off the rivet (20) and remove the
locating element (21).
Assembly
1) Install the locating element (21) and fix it
with the rivet (20).
2) Install the spring steel sheets (19) and fix
it with the rivet (18).
3) Set the lever (14) and the screw (17), and
fix with nut (16).
4) Install the covers on the right and left side
by referring to "8. Removal and installation
of covers".
5) Assemble the plate (15) by the following
procedure.
1] Turn the lever (14) clockwise until it
snaps-in, install the plate (15).
WD600-6 50-800 21
Removal
2) Remove spring(1) and switch-plate (2). (If
equipped)
3) Remove the flexible support plate by fol-
lowing procedure.
1] Press the spring sheet inwards
(arrow), operate the lever for seat
angle adjustment (3).
2] Pull the flexible support plate (4) to
backwards and remove it.
4) Remove the spring (5).
7) Install the switch (4) by the following pro- 5) Turn the lever (6) clockwise until it snaps-
cedure. (If equipped) in, pull the plate (7) to the very front and
1] Install the seat switch (4) and fix it remove it.
with the rivet (3). 6) Drill off the rivet (8) and remove the wash-
2] Tilt the switch-plate (2) forwards and ers (9).
install it. 7) Unhook the covers (10) by pulling them
3] Install the spring (1). forwards and remove them in an upward
8) Install the seat pad by referring to "2. direction.
backrest upholstery". Installation
1) Install the covers (10) of right and left.
8. Removal and installation of covers 2) Install the washers (9) and fix it with the
rivet (8).
3) Turn the lever (6) clockwise until it snaps-
in, then install the plate (7).
4) Remove the spring (5) (see 7. Disassem-
bly and assembly of seat angle and seat
depth adjuster).
5) Install the flexible support plate (4) (see 7.
Disassembly and assembly of seat angle
and seat depth adjuster).
6) Install spring (1) and switch-plate (2) (see
7. Disassembly and assembly of seat
angle and seat depth adjuster). (If
equipped)
7) Install the seat pad by referring to "2.
50-800 22 WD600-6
9. Removal and installation of slide rails Installation

1) Install the slide rails (10).
2) Put the nuts (9) and tighten the hexagon
socket screws (8).
a Replace the hexagon socket screws
(8) with new ones.
3 Hexagon socket screws:
25 Nm {2.6 kgm}
3) Install the bellows to the upper part of the
suspension system.
4) Put the washers (7) and install the seat
top assembly (1) and remove.
5) Put the washers (5) and nuts (6), then
tighten the hexagon socket screws (4).
(4) with new ones.
25 Nm {2.6 kgm}
6) Push the seat top assembly (1) as far for-
ward as possible.
7) Put the nuts (3) and tighten the hexagon
socket screws (2).
(2) with new ones.
25 Nm {2.6 kgm}
8) Push the seat top assembly (1) as far
back as possible.
9) Install the seat pad by referring to "2.
Removal
2) Push the seat top assembly (1) as far
back as possible.
3) Unscrew the hexagon socket screws (2)
and remove the nuts (3).
4) Push the seat top assembly (1) as far for-
ward as possible.
5) Unscrew the hexagon socket screws (4),
remove the washers (5) and nuts (6).
6) Remove the seat top assembly (1) and
remove the washers (7).
7) Disconnect the bellows from the upper
part of the suspension system and lay it
down.
8) Unscrew the hexagon socket screws (8)
and remove the nuts (9).
9) Remove the slide rails (10).
WD600-6 50-800 23
II. Suspension 2. Removal and installation of front cover
1. Removal and installation of top cover
Removal
1) Remove the upper part of the seat by
Removal referring to "I. Upper seat".
1) Remove the upper part of the seat by 2) Remove the top cover by referring to "1.
referring to "I. Upper seat". Removal and installation of top cover".
2) Pull the connecting cable (3) inwards 3) Bore out 2 rivet heads and drive out blind
through the upper cover (2). rivets (1), remove the front cover (2).
3) Remove the 2 bellows pins (1) and take
the upper cover (2) off. Installation
1) Install the front cover (2) and fix it with the
Installation 2 rivets (1).
1) Install the connecting cable (3) inwards 2) Install the top cover by referring to "1.
through the upper cover (2). Removal and installation of top cover".
2) Install the upper cover (2) and fix it with 3) Install the upper part of the seat by refer-
the 2 bellows pins (1). ring to "I. Upper seat".
3) Install the upper part of the seat by refer-
ring to "I. Upper seat".
50-800 24 WD600-6
3. Removal and installation of bellows
Installation
Removal 1) Install the wire insert (5) to the bellows (2).
1) Remove the upper part of the seat by 2) Install the bellows (2).
referring to "I. Upper seat". 3) Fix the bellows (2) with pins (3) to the
2) Remove the bellows (2) from the upper lower part of the suspension (6) in the
part of the suspension (1) by following reverse order of their removal.
procedure. 4) Fix the connecting cable with the cable tie
1] Take bellows pins (4) off on the front. (10). (If equipped)
2] Take bellows pins (3) off on the left 5) Fix the bellows (2) with pins (3) to the
side of the top. upper part of the suspension (1) in the
3] Remove 2 bellows pins (4) on the reverse order of their removal.
back and take 2 bellows pins (3) off 6) Install the upper part of the seat by refer-
the upper part of the suspension sys- ring to "I. Upper seat".
tem (1).
4] Take 3 bellows pins (3) on the right
side off the upper part of the suspen-
sion (1) and pull the bellows (2) over
the handle for vertical shock absorber
adjustment (9).
3) Remove the bellows (2) from the lower
part of the suspension (6) by the following
procedure.
1] Take 3 bellows pins (3) on the front
side off the lower part of the suspen-
sion (6).
2] Release 2 bellows pins (3) on the left
side from the lower part of the sus-
pension (6).
3] Release 4 bellows pins (3) on the
back side from the lower part of the
suspension (6).
4] Remove a cable tie (10) on the right
side from the connecting cable, and
take 2 bellows pins (3) off the lower
part of the suspension (6). (If
equipped)
4) Lift the bellows (2) over the lower part of
the suspension (6) and remove the bel-
lows (2) in a downward direction.
5) Remove the wire insert (5) from the bel-
lows (2).
WD600-6 50-800 25
4. Removal and installation of Bowden pull

wire and handle for vertical shock absorber
adjustment
Removal 10) Mark the points where the Bowden pull

1) Remove the upper part of the seat by wire (5) is fastened with the swinging
referring to "I. Upper seat". structure (14) with the cable tie (8) and
2) Remove the top cover by referring to "1. take the cable tie (8) off.
Removal and installation of top cover". 11) Pull the fixation (12) off the vertical shock
3) Take the bellows off by referring to "3. absorber (13).
Removal and installation of bellows". 12) Take the Bowden pull wire (5) off the bear-
4) Move the suspension system to the high- ing (9).
est position. 13) Remove the fixation (12) from the fork
k Risk of crushing! Secure the sus- (11).
pension between the swinging 14) Take the Bowden pull wire (5) off the fork
structure and lower part of the (11), remove the fork (11) and compres-
suspension system with suitable sion spring (10).
spacers. 15) Mark the location of the mounting hole for
5) Screw out Torx screw (2). the Bowden pull wire (5) in the upper part
6) Pull the handle for vertical shock absorber of the suspension (4), pull the Bowden pull
adjustment (1) off the upper part of the wire (5) out of the upper part of the sus-
suspension (4). pension (4) and then remove it.
7) Remove the Bowden pull wire (5) from the
handle for vertical shock absorber adjust-
ment (1).
8) Push the Bowden pull wire (5) off the
bearing for Bowden pull wire (6).
9) Bore out the rivet head and drive out the
blind rivet (7), and remove the bearing for
Bowden pull wire (6).
50-800 26 WD600-6
Installation
1) Move the suspension system to the high-
est position.
k Risk of crushing! Secure the sus-
pension between the swinging
structure and lower part of the sus-
pension system with suitable spac-
ers.
2) Put the Bowden pull wire (5) to the upper
part of the suspension (4) through the
location of the mounting hole marked
before removing the Bowden pull wire (5).
3) Install the fork (11) and compression
spring (10), and take the Bowden pull wire
(5) to the fork (11).
4) Install the fixation (12) to the fork (11).
5) Take the Bowden pull wire (5) to the bear-
ing (9).
6) Put the fixation (12) to the vertical shock
absorber (13).
7) Install the Bowden pull wire (5) and fix it
with the cable tie (8) at the marked points.
a Install the Bowden pull wire according
to the marking.
8) Install the bearing for Bowden pull wire (6)
and fix it with the rivet (7).
9) Install the Bowden pull wire (5) to the
bearing for Bowden pull wire (6).
10) Install the Bowden pull wire (5) to the han-
dle for vertical shock absorber adjustment
(1).
11) Install the handle for vertical shock
absorber adjustment (1) to the upper part
of the suspension (4).
12) Tighten Torx screw (2).
3 Torx screw: 2.25 Nm {0.23 kgm}
13) Install the bellows off by referring to "3.
Removal and installation of bellows".
14) Install the top cover by referring to "1.
Removal and installation of top cover".
WD600-6 50-800 27
5. Removal and installation of vertical shock Installation

absorber 1) Move the suspension system to the high-
est position.
structure and lower part of the
suspension system with suitable
spacers.
2) Install the vertical shock absorber (4).
a When re-installing the vertical shock
absorber (4), make sure the labeling
is on top.
3) Assemble the vertical shock absorber (4)
to the swinging structure (7) and put the
stud (3).
4) Install circlip (5) to the stud (3).
a Apply acid-free multi-purpose lubri-
cant to the entire external surface (F)
of the stud (3).
5) Install the fixation (2) and bearing (1) to
the vertical shock absorber (4).
6) Assemble the vertical shock absorber (4)
to the swinging structure (7) and put the
stud (6).
cant to the entire external surface (F)
of the stud (6).
7) Install the circlip (8) to the stud (6).
Removal
1) Remove the upper part of the seat by 10) Install the upper part of the seat by refer-
referring to "I. Upper seat". ring to "I. Upper seat".
2) Remove the top cover by referring to "1.
3) Take the bellows off by referring to "3.
est position.
ers.
5) Remove circlip (8) from stud (6).
6) Pull the stud (6) out of swinging structure
(7) and vertical shock absorber (4).
7) Take the fixation (2) and bearing (1) off the
vertical shock absorber (4).
8) Remove circlip (5) from stud (3).
9) Pull the stud (3) out of the swinging struc-
ture (7) and the vertical shock absorber
(4).
10) Remove the vertical shock absorber (4) in
an upward direction.
50-800 28 WD600-6
6. Removal and installation of compressor
Removal 11) Pull the compressed-air hose (7) off the

1) Remove the upper part of the seat by compressor (3).
referring to "I. Upper seat". a Do not use a screwdriver to lift the
2) Remove the top cover by referring to "1. compressed-air hose (7) off the spike
Removal and installation of top cover". of the compressor (3).
3) Take the bellows off by referring to "3. a Heat the compressed-air hose (7) at
Removal and installation of bellows". the head of compressor (3) (e.g.
4) Move the suspension system to the high- using a hot-air blower) and then, pull
est position. it off in one move.
k Risk of crushing! Secure the sus- 12) Pull out the compressor cable (5) in a
pension between the swinging downward direction and remove compres-
structure and lower part of the sus- sor (3) to the front.
pension system with suitable spac- 13) Remove the support (9) from the lower
ers. part of the suspension (2).
5) Mark the points where the compressor
cable (5) is fastened with the 6 cable ties
(6) and remove the cable ties (6).
6) Disconnect the right-angle plug (10) from
the height level control unit (1).
7) Disconnect the electric connector of the
flat plug (11).
8) Mark the points where the compressed-air
hose (7) is fastened with the cable tie (12)
and remove the cable tie (12).
9) Mark the points where the compressor (3)
is fastened with the 2 cable ties (4) and
remove the cable ties (4).
10) Pull the fitting (8) out of the spike of the
compressor (3) and push it backwards off
the compressed-air hose (7).
WD600-6 50-800 29
Installation
est position.
ers.
2) Install the support (9) to the lower part of
the suspension (2).
3) Install the compressor (3) to the support
(9).
4) Install the compressed-air hose (7) and fix
it with cable tie (4) at the marked points.
a Loosely apply the cable tie (4) until
the locking head of the cable tie (4) is
located slightly over the front curve of
compressor (3) and while the com-
pressor (3) can be still moved.
a Align the compressor (3) and use the
pliers to tighten the locking head of
the cable tie (4) to 310 Nm{31.6 kgm}
in the direction shown (arrow).
5) Put the fitting (8) to the compressed-air
hose (7).
6) Install them to the spike of the compressor
(3).
7) Fix the compressor (3) with the cable ties
(4) at marked points.
a Fix the cable tie according to the
marking.
8) Fix the compressed-air hose (7) with cable
tie (12) at the marked points.
9) Connect the electric connector of the flat
plug (11).
10) Connect the right-angle plug (10) to the
height level control unit (1).
11) Install the compressor cable (5) and fix it
with cable tie (6) at the marked points.
a Tie back any excess length of the
compressor cable (5).
50-800 30 WD600-6
7. Removal and installation of height level

controller
Removal 10) Mark the place where the cable is fas-

1) Remove the upper part of the seat by tened with the right-angle plugs (13) and
referring to "I. Upper seat". (14) and the cable tie and then remove the
2) Remove the top cover by referring to "1. cable tie.
Removal and installation of top cover". 11) Mark the place where the Bowden pull
3) Take the bellows off by referring to "3. wire (19) is fastened with the cable tie and
Removal and installation of bellows". remove the cable tie.
4) Move the suspension system to the high- 12) Unhook the Bowden pull wires (3) and
est position. (19) from the height level control (1).
k Risk of crushing! Secure the sus- 13) Mark and then disconnect the right-angle
pension between the swinging plugs (13) and (14) from the height level
structure and lower part of the sus- control unit (1).
pension system with suitable spac- 14) Remove the 2 hexagon nuts (4) from the
ers. thread of the height level control (1).
5) Loosen up the 2 circlips (17) from the stud 15) Remove the plate (7), loop of the webbing
(18) and then remove them. (5) and the edge protection strip (6).
6) Knock out the stud (18) from the lower 16) Remove the height level control (1) from
part of the suspension (15) and then the upper part of the suspension (8).
remove it. 17) Undo the Torx screw (9) and take the
a Firmly hold the webbing (5) and let it attachment for Bowden pull wire (2) off the
carefully roll back to the rewinder on height level valve (1).
the height level controller (1). a To do this, first release the 2 catchers
7) Remove the 2 buffers (16) from the loop of on the backside of the attachment for
the webbing (5). Bowden pull wire (2) and take the
8) Mark the points where the air input hoses attachment for Bowden pull wire (2)
(10) and (11) are fastened with 5 cable off the height level valve (1).
ties (12) and remove the cable ties (12). 18) Pull the Bowden pull wire (3) out of the
9) Pull the air input hoses (10) and (11) off attachment for Bowden pull wire (2).
the pneumatic spring (see "8. Removal 19) Remove the height level controller in an
and installation of air hose"). upward direction.
WD600-6 50-800 31
Installation
est position.
ers.
2) Install the height level controller.
3) Install the Bowden pull wire (3) to the
attachment for Bowden pull wire (2).
4) Install the attachment for Bowden pull wire
(2) to the height level controller (1).
5) Tighten the Torx screw (9) to height level
controller (1).
a Finger-tighten the Torx screw (9).
6) Install the height level control (1) to the
upper part of the suspension (8).
7) Install the plate (7), loop of the webbing
(5) and the edge protection strip (6).
8) Install the 2 hexagon nuts (4) to the thread
of the height level controller (1).
9) Connect the right-angle plugs (13) and
(14) to the height level controller (1) at the
marked point.
10) Install the Bowden pull wires (3) and (19)
to the height level controller (1).
11) Install the Bowden pull wire (19) and fix it
with the cable tie at the marked points.
12) Install the right-angle plugs (13) and (14)
and fix them with the cable tie at the
marked points.
13) Install the air input hoses (10) and (11) to
the pneumatic spring (see "8. Removal
and installation of air hose").
14) Fix the air input hoses (10) and (11) with
the 5 cable ties (12) at the marked points.
15) Install the 2 buffers (16) to the loop of the
webbing (5).
16) Install the stud (18) to the lower part of the
suspension (15).
17) Install the 2 circlips (17) to the stud (18)
and then remove them.
50-800 32 WD600-6
Adjustment 7) Adjust the output level (2) as follows.

1) Remove the upper part of the seat by Adjust the clearance between valve lever
referring to "I. Upper seat". (6) and cam disc (7) by turning the cross-
2) Remove the top cover by referring to "1. head screw (10).
Removal and installation of top cover". q Specified value: The valve lever (6)
3) Take the bellows off by referring to "3. must seat on the cam disc without
Removal and installation of bellows". pressure (7).
4) Move the suspension system to the high- q Turn the cross-head screw (10) to the
est position. left, the valve lever (6) is moving
k Risk of crushing! Secure the sus- towards the cam disc (7). This
pension between the swinging increases the pressure on the valve
structure and lower part of the sus- tappets (4) at the output valve (2) and
pension system with suitable spac- the air escapes the output valve (2)
ers. earlier.
5) Loosen the self-tapping screw (9) a half q Turn the cross-head screw (10) to the
turn. right, the valve lever (6) is moving
6) Adjust the micro-switch (3) as follows. away from the cam disc (7). This
Adjust the clearance between cam switch decreases the pressure on the valve
(5) and cam disc (7) by turning the cross- tappets (4) at the output valve (2) and
head screw (8). the air escapes the output valve (2)
q Specified clearance (A) = 0.5 mm. later.
q Turn the cross-head screw (8) to the 8) Tighten the self-tapping screw (9) after the
left, the cam switch (5) is moving adjustment has been completed.
towards the cam disc (7). 9) Install the bellows off by referring to "3.
q Turn the cross-head screw (8) to the Removal and installation of bellows".
right, the cam switch (5) is moving 10) Install the top cover by referring to "1.
away from the cam disc (7). Removal and installation of top cover".
q When the cam switch (5) seats on the 11) Install the upper part of the seat by refer-
cam disc (7) under pressure, the com- ring to "I. Upper seat".
pressor (11) turns too early and runs
already during the compression and
expansion of the seat suspension.
WD600-6 50-800 33
8. Removal and installation of compressed-air

hoses
a Disconnect the hose not more than 1 to 2 7) Pull the compressed-air hose (11) off the
times. Check the hose for damage before con- compressor (5) and remove it. (Refer to
necting it. "6. Removal and installation of compres-
sor")
Removal 8) Pull the compressed-air hose with angle
1) Remove the upper part of the seat by (8) off the pneumatic spring (9) and then
referring to "I. Upper seat". off the air tank (10).
2) Remove the top cover by referring to "1. a When pulling the hoses out, the
Removal and installation of top cover". retaining ring of the quick coupling
3) Take the bellows off by referring to "3. (13) must first be completely pressed
Removal and installation of bellows". back (e.g. using a flat pliers) to avoid
4) Move the suspension system to the high- marks.
est position. 9) Mark the points where the compressed-air
k Risk of crushing! Secure the sus- hose with angle (8) is fastened with cable
pension between the swinging ties (6), (7) and (12) and then remove the
structure and lower part of the sus- cable ties (6), (7) and (12).
pension system with suitable spac- 10) Remove the air hose with angle (8).
ers. 11) Mark the points where the air input hoses
5) Mark the points where the compressed-air (3) and (4) are fastened with the cable ties
hose (11) is fastened with the cable tie (2) and (6) and remove the cable ties (2)
(12) and remove the cable tie (12). and (6).
6) Pull the compressed-air hose (11) off the 12) Pull the air input hoses (3) and (4) out of
pneumatic spring (9). the pneumatic spring (9).
a When pulling the hoses out, the 13) Remove the height level controller (1) with
retaining ring of the quick coupling air input hoses (3) and (4).
(13) must first be completely pressed a To ensure the tightness, the air input
back (e.g. using a flat pliers) to avoid hoses (3) and (4) cannot be removed
marks. from the height level control (1).
50-800 34 WD600-6
Installation a Apply pressure to insert the air hose

a Always replace a damaged (marks) hose with with angle (8) into the pneumatic
a new one. It is possible to cut the damaged spring (9) and air tank (10) up to the
part off (about 12 mm) using special tools (14) blue marking.
only once. After the cut off, the blue marking 6) Fix the compressed air hose with angle (8)
should be (arrow) set back by the length of the with cable ties (6), (7) and (12) at the
cut off piece. marked points.
a Do not fix the cable tie (12) at the
1) Move the suspension system to the high- angle.
est position. 7) Install the compressed-air hose (11) to the
compressor (5). (Refer to "6. Removal and
pension between the swinging installation of compressor")
structure and lower part of the sus- 8) Install the compressed-air hose (11) to the
pension system with suitable spac- pneumatic spring (9).
ers. 9) Fix the compressed-air hose with the
2) Install the height level controller (1) with cable tie (12) at the marked points.
air input hoses (3) and (4). 10) Install the bellows off by referring to "3.
a Cut the air input hose (3) or (4) off at Removal and installation of bellows".
the leaky area and connect the new 11) Install the top cover by referring to "1.
air input hose (3) or (4) to an appro- Removal and installation of top cover".
priate adapter. Subsequently, cut the
excess length off.
3) Install the air input hoses (3) and (4) to the Hydrostatic test
pneumatic spring (9).
a After the installation of a compressed-air hose,
4) Fix the air input hoses (3) and (4) with the
the hydraulic test of the suspension should be
cable ties (2) and (6) at the marked points.
performed.
5) Install the compressed-air hose with angle
q Apply 60 kg load to the suspension for 24
(8) to the pneumatic spring (9) and then
hours.
off the air tank (10).
q The lowering within this time may not
a To avoid kinking, always install the
exceed 15 mm.
compressed-air hose with angle (8)
a The compressed-air hoses are locked after
first on the pneumatic spring (9).
they have been connected.
WD600-6 50-800 35
9. Removal and installation of Bowden pull 9) Take the Bowden pull wires (1) and (6) off
wires and handle for height adjustment the holder for Bowden pull wire (4), and
then pull them out of the upper part of the
suspension (2).
10) Remove the holder (4) for Bowden pull
wire.
11) Replace the handle (5), if required.
a The handle (5) and holder for Bowden
pull wire (4) are wedged into the 2
latching noses (arrow) at the lower
part of the holder for Bowden pull wire
(4). Carefully separate the parts.
a To remove the handle, use a screw-
driver to bend open the handle (5)
between the handle (5) and holder for
Bowden pull wire (4) so that the 2
latching noses are released from the
handle (5).
a Take the handle (5) off the holder for
Bowden pull wire (4).
Installation
1) Install the handle (5) to holder (4), if
removed.
a When the handle (5) is deformed,
replace it.
2) Install the Bowden pull wires (1) and (6) to
the holder for Bowden wire (4).
a Adjust the new Bowden pull wire to
the length of the old one (excess
Removal length of the wire).
1) Remove the upper part of the seat by 3) Install the holder (4) to the upper part of
referring to "I. Upper seat". the suspension (2) and tighten the 3
2) Remove the top cover by referring to "1. cross-head screws (7).
Removal and installation of top cover". 4) Install the Bowden pull wire (6) to the
3) Take the bellows off by referring to "3. height level controller. (See "7. Removal
Removal and installation of bellows". and installation of height level controller".)
4) Mark the points where the Bowden pull 5) Install the Bowden pull wire (1) to the
wire (1) is fastened with the 2 cable ties height level controller (See "7. Removal
(3), and then remove the cable ties (3). and installation of height level controller".)
5) Mark the points where the Bowden pull 6) Fix the Bowden pull wire (6) with the 2
wire (6) is fastened with the 2 cable ties cable ties (8) at the marked points.
(8), and then remove the cable ties (8). a Loosely fix the Bowden pull wire with
6) Take the Bowden pull wire (1) off the the cable ties at the marked points
height level controller and pull it out of the and make sure it is not distorted.
holder for Bowden pull wire (See "7. 7) Fix the Bowden pull wire (1) with the 2
Removal and installation of height level cable ties (3) at the marked points.
controller".) a Loosely fix the Bowden pull wire with
a To release the tension of the Bowden the cable ties at the marked points
pull wire (1), press the handle for and make sure it is not distorted.
height adjustment (5) upwards. 8) Install the bellows off by referring to "3.
7) Take the Bowden pull wire (6) off the Removal and installation of bellows".
height level controller. (See "7. Removal 9) Install the top cover by referring to "1.
and installation of height level controller") Removal and installation of top cover".
a To release the tension of the Bowden 10) Install the upper part of the seat by refer-
pull wire (6), press the handle for ring to "I. Upper seat".
height adjustment (5) upwards.
8) Undo the 3 cross-head screws (7).
50-800 36 WD600-6
Checking and adjustment 5) Check the clearance between the Bowden

a When checking and adjustment is performed wire lever (10) and holder for Bowden wire
through removal and installation, pass proce- end cap (9).
dures 1) and 2) of "Checking". q Specified value: Distance (A) between
(Checking) 1 and 3.5 mm with the handle for
1) Remove the upper part of the seat by height adjustment (2) in the up posi-
referring to "I. Upper seat". tion.
2) Remove the top cover by referring to "1. q When the specified value exceeds
Removal and installation of top cover". 3.5 mm, the suspension cannot be
3) Operate the handle for height adjustment lifted above the middle position.
(2) several times in both directions and
check the following: (Adjustment)
q Bowden pull wires (1) and (3) for 1) Adjustment of the Bowden pull wire (3):
easy-running. 1] Loosen the counternut (6) and adjust
q Bowden wire lever (10), valve lever the clearance between the Bowden
(14) and valve tappets (13) at the out- wire lever (10) and holder for Bowden
put valve (12) for smoothness of run- wire end cap (9) using the locknut (5).
ning. q Turn the locknut (5) inwards, the
4) Check the neutral position of the handle Bowden pull wire gets longer.
for seat height adjustment (2) and the ten- q Turn the locknut (5) outwards,
sile force of the retracting spring (11) on the Bowden pull wire gets
the height level valve (4): shorter.
q The retracting spring (11) must fix the q Specified value: Clearance (A)
handle for seat height adjustment (2) between 1 and 3.5 mm.
in neutral position. 2] Secure the locknut (5) with the coun-
q The retracting spring (11) must tightly ternut (6) and make sure not to distort
pull the Bowden pull wires (1 and 3) the Bowden pull wire (3).
and keep the Bowden wire lever (10) 3] Operate the handle for seat height
in neutral position. adjustment (2) several times and
check the specified value, repeat the
adjustment if necessary.
WD600-6 50-800 37
2) Adjustment of the Bowden pull wire (1):

1] Loosen the counternut (7) and adjust
the tension of the Bowden pull wire
(1) on the height valve (4) using the
locknut (8).
q Turn the locknut (8) inwards, the
Bowden pull wire gets longer.
q Turn the locknut (8) outwards,
the Bowden pull wire gets
shorter.
q Specified value: The Bowden
wire (8) must be tightened, but
not distorted on the suspension
device on the height level valve
(4).
2] Secure the locknut (8) with the coun-
ternut (7) and make sure not to distort
the Bowden pull wire (1).
3] Operate the handle for seat height
adjustment (2) several times and
check the specified value, repeat the
adjustment if necessary.
50-800 38 WD600-6
10. Removal and installation of pneumatic

spring
Removal Installation
1) Remove the upper part of the seat by 1) Move the suspension system to the high-
referring to "I. Upper seat". est position.
2) Remove the top cover by referring to "1. k Risk of crushing! Secure the sus-
Removal and installation of top cover". pension between the swinging
3) Take the bellows off by referring to "3. structure and lower part of the sus-
Removal and installation of bellows". pension system with suitable spac-
4) Remove the 2 air input hoses, com- ers.
pressed-air hose and air input hose with 2) Turn the spring system by 180° and place
angle from the pneumatic spring (6) by it onto the upper part (1).
referring to "8. Removal and installation of 3) Slightly compress the pneumatic spring
compressed-air hoses". (6) and install the pneumatic spring (6) to
5) Undo the counter sunk screw (3) from the the swinging structure (5) and lower part
pneuma ti c spr ing (6) and rem ove it of the suspension (2).
together with the washer (4). 4) Tighten the counter sunk screw (7) to the
6) Move the suspension system to the high- pneumatic spring (6).
est position. 3 Counter sunk screw (6):
k Risk of crushing! Secure the sus- 6 Nm {0.61 kgm}
pension between the swinging 5) Turn the spring system by 180° and place
structure and lower part of the sus- it onto the upper part (1).
pension system with suitable spac- 6) Put the washer (4) to the pneumatic spring
ers. (6) and tighten the counter sunk screw (3).
7) Turn the spring system by 180° and place 3 Counter sunk screw (3):
it onto the upper part (1). 6 Nm {0.61 kgm}
8) Undo the counter sunk screw (7) from the
pneumatic spring (6).
9) Slightly compress the pneumatic spring
(6) and remove it from the swinging struc-
ture (5) and lower part of the suspension
(2).
WD600-6 50-800 39
7) Install the 2 air input hoses, compressed-

air hose and air input hose with angle to
the pneumatic spring (6) by referring to "8.
Removal and installation of compressed-
air hoses".
50-800 40 WD600-6
11. Removal and installation of air tank for

additional air supply
2) Remove the top cover by referring to "1. k Risk of crushing! Secure the sus-
4) Move the suspension system to the high- ers.
est position. 2) Install the clamp (5) to the bracket (6), if
k Risk of crushing! Secure the sus- removed.
pension between the swinging a Replace the clamp with new one, if
structure and lower part of the sus- required.
pension system with suitable spac- 3) Install the air tank (3) to bracket (2) and
ers. clamp (5).
5) Remove the air hose with angle (4) from 4) Install the air hose with angle (4) to the air
the air tank (3) by referring to "8. Removal tank (3) by referring to "8. Removal and
and installation of compressed-air hoses". installation of compressed-air hoses".
6) Remove the air tank (3) from bracket (2) 5) Install the bellows off by referring to "3.
and clamp (5). Removal and installation of bellows".
7) Take the clamp (5) off the bracket (6) in a 6) Install the top cover by referring to "1.
downward direction, if required. Removal and installation of top cover".
a To do this, use a screwdriver to press 7) Install the upper part of the seat by refer-
through the hole (arrow) in the ring to "I. Upper seat".
bracket against the catchers (arrow)
of the clamp (5) and pull the clamp (5)
out in a downward direction.
WD600-6 50-800 41
12. Removal and installation of cable harness
2) Remove the top cover referring to "1. k Risk of crushing! Secure the sus-
4) Move the suspension system to the high- ers.
est position. 2) Connect the right-angle plug (6) to the
k Risk of crushing! Secure the sus- height level control unit (1).
pension between the swinging 3) Connect the electric connection (flat plug)
structure and lower part of the sus- of the compressor cable (4) to the cable
pension system with suitable spac- harness of the connector plug (2) and
ers. cable harness of the machine power con-
5) Mark the points where the cable of the nector (3).
machine power connector (3) is fastened 4) Fix the cable harness of the connector
with the cable tie (8) on the upper part of plug (2) and cable harness of the machine
the suspension (7) and remove the cable power connector (3) with the cable ties (5)
tie (8). at the marked points.
6) Mark places where the cable harness of a Run the cable harnesses (2) and (3)
the connector plug (2) and cable harness and fix them with the cable ties (5) so
of the machine power connector (3) are that they are neither squeezed nor
fastened with the cable ties (5) and otherwise damaged.
remove the cable ties (5). 5) Fix the cable of the machine power con-
7) Disconnect the electric connection (flat nector (3) with the cable tie (8) on the
plug) of the compressor cable (4) to the upper part of the suspension (7) at the
cable harness of the connector plug (2) marked points.
and cable harness of the machine power
connector (3).
8) Disconnect the right-angle plug (6) from
the height level control unit (1).
50-800 42 WD600-6

WD600-6 50-800 43
13. Disassembly and assembly of upper part of

the suspension system
Disassembly 8) Move the suspension system to the high-

1) Remove the upper part of the seat by est position.
referring to "I. Upper seat". k Risk of crushing! Secure the sus-
2) Remove the top cover referring to "1. pension between the swinging
Removal and installation of top cover". structure (7) and lower part of the
3) Take the bellows off by referring to "3. suspension system with suitable
Removal and installation of bellows". spacers.
4) Take the Bowden pull wire and handle off 9) Bore out 2 rivet heads and drive out blind
the upper part of the suspension (1) by rivets (10), remove the stops (9).
referring to "4. Removal and installation of 10) Push the upper part of the suspension (1)
Bowden pull wires and handle for vertical forwards until the cut-outs (arrow) on the
shock absorber". left and right sides at the guiding rails (2)
a The Bowden pull wire does not need are located at the same height with the
to be taken off the vertical shock front rollers (8) of the swinging structure
absorber. (7).
5) Remove the vertical shock absorber from 11) Remove the upper part of the suspension
the upper part of the suspension (1) by (1) on the front side over the rollers (8)
referring to "5. Removal and installation of and the back rollers (6) of the swinging
vertical shock absorber". structure (7).
6) Remove the height level controller from
the upper part of the suspension (1) by
referring to "7. Removal and installation of
height level controller".
a Air input hoses do not need to be
taken off the pneumatic spring.
7) Remove Bowden pull wires and handle for
height adjustment by referring to "9.
Removal and installation of Bowden pull
wires and handle for height adjustment".
50-800 44 WD600-6
Assembly
est position.
ers.
2) Push the upper part of the suspension (1)
forwards until the cut-outs (arrow) on the
left and right sides at the guiding rails (2)
are located at the same height with the
front rollers (8) of the swinging structure
(7).
3) Install the upper part of the suspension (1)
on the back rollers (6) and the front rollers
(8) of the swinging structure (7).
cant to the side surfaces (F) of the 2
guiding rails (2) of the rollers (6).
4) Install the stops (9) and fix with the 2 rivets
(10).
5) Install Bowden pull wires and handle for
height adjustment by referring to "9.
Removal and installation of Bowden pull
wires and handle for height adjustment".
6) Install the height level controller to the
upper part of the suspension (1) by refer-
ring to "7. Removal and installation of
height level controller".
7) Install the vertical shock absorber to the
upper part of the suspension (1) by refer-
ring to "5. Removal and installation of ver-
tical shock absorber".
8) Install the Bowden pull wire and handle to
the upper part of the suspension (1) by
referring to "4. Removal and installation of
Bowden pull wires and handle for vertical
shock absorber".
WD600-6 50-800 45
14. Lower part of the suspension system
Removal 8) Unscrew the 2 hexagon nuts (11), remove

1) Remove the upper part of the seat by washers (10) and counter sunk screws
referring to "I. Upper seat". (9).
2) Remove the top cover by referring to "1. 9) Undo the 2 corrugated-head screws (5)
Removal and installation of top cover". and take the U-shaped profiles (6) off the
3) Take the bellows off by referring to "3. guiding rail (8).
Removal and installation of bellows". 10) Push the upper part of suspension (1) with
4) Remove compressor from the lower part the swinging structure (3) backwards until
of the suspension (7) by referring to "6. the 2 fixed bearings (4) on the swinging
Removal and installation of compressor". structure (3) can be taken out through the
a Compressor cable and compressed- cut-outs (arrows) of the guiding rails (8) on
air hose do not need to be removed. the upper part of suspension (1).
a Protect the compressor against 11) Lift the upper part of the suspension (1)
shocks (impacts) by fixing it on the with the swinging structure (3) out and pull
swinging structure with adhesive it out together with the 2 rollers (2) from
tape. the guiding rails (8) by turning sideways.
5) Remove the webbing from the lower part
of the suspension (7) by referring to "7. Installation
Removal and installation of height level 1) Install the upper part of the suspension (1)
controller". with the swinging structure (3) together
6) Undo the counter sunk screw from the with the 2 rollers (2) to the guiding rails
pneumatic spring by referring to "10. (8).
Removal and installation of pneumatic a Apply acid-free multi-purpose lubri-
spring". cant to the bearing surface at the side
7) Remove the 2 cable ties for the vehicle (F) of the 2 guiding rails (8) of the roll-
power connector cable on the lower part ers (2).
of suspension(7) by referring to "12. 2) Install the U-shaped profile (6) to the guid-
Removal and installation of cable har- ing rail (8) and tighten the 2 corrugated-
ness". head screws (5).
50-800 46 WD600-6
3) Put the counter sunk screws (9) and the

washers (10), and tighten the 2 hexagon
nuts (11).
4) Install the 2 cable ties for the machine
power connector cable on the lower part
of suspension(7) by referring to "12.
Removal and installation of cable har-
ness".
5) Tighten the counter sunk screw to the
pneumatic spring by referring to "10.
Removal and installation of pneumatic
spring".
6) Install the webbing to the lower part of the
suspension (7) by referring to "7. Removal
and installation of height level controller".
7) Install compressor to the lower part of the
suspension (7) by referring to "6. Removal
and installation of compressor".
WD600-6 50-800 47
15. Swinging structure
Removal 9) Take the Bowden pull wires for height

1) Remove the upper part of the seat by level adjustment off the height level valve
referring to "I. Upper seat". by referring to "9. Removal and installation
2) Remove the top cover by referring to "1. of Bowden pull wire and handle for height
Removal and installation of top cover". adjustment".
3) Take the bellows off by referring to "3. 10) Remove the pneumatic spring by referring
Removal and installation of bellows". to "10. Removal and installation of pneu-
4) Take the Bowden pull wire for vertical matic spring".
shock absorber adjustment off the vertical 11) Remove the air tank for additional air sup-
shock absorber by referring to "4. ply by referring to "11. Removal and instal-
Removal and installation of Bowden pull lation of air tank for additional air supply".
wire and handle for vertival shock 12) Remove the cable harness by referring to
absorber adjustment". "12. Removal and installation of cable har-
5) Take the vertical shock absorber off the ness".
swinging structure by referring to "5. 13) Take the upper part of the suspension off
Removal and installation of vertical shock the swinging structure by referring to "13.
absorber". Removal and installation of upper part of
6) Remove the compressor by referring to "6. the suspension".
Removal and installation of compressor". 14) Take the lower part of the suspension off
7) Take the webbing off the lower part of the the swinging structure by referring to "14.
suspension by referring to "7. Removal Removal and installation of lower part of
and installation of height level controller". the suspension".
8) Remove the cable tie for the air input 15) Take 4 rollers (5), 2 rollers (6), 2 fixed
hoses of the height level control and pull bearings (9) and 4 felt rings (4) off the
the air input hoses off the pneumatic swinging structure (1).
spring by referring to "8. Removal and 16) Pull the tube piece (8) out of the fixed
installation of compressed-air hoses". bearing (9).
17) Remove the 2 buffers (7) from the swing-
ing structure (1).
18) Remove the edge protection strip (2) from
the swinging structure (1).
50-800 48 WD600-6
Installation 12) Install the Bowden pull wires for height

1) Check: maximum clearance (A) or (B) level adjustment to the height level valve
between the rollers (5) and guiding rails of by referring to "9. Removal and installation
the lower part of the suspension (11) or of Bowden pull wire and handle for height
upper part of the suspension (10) over the adjustment".
complete adjustment length. 13) Install the cable tie for the air input hoses
2) Place the washer compensating for clear- of the height level controller and pull the
ance (2) between the roller (5 or 6) and air input hoses to the pneumatic spring by
axle of the swinging structure (1), if neces- referring to "8. Removal and installation of
sary. compressed-air hoses".
a Clearance spacers (with thickness of 14) Install the webbing to the lower part of the
0.2 mm and 0.5 mm) are included in suspension by referring to "7. Removal
the wear parts set. and installation of height level controller".
3) Install the edge protection strip (2) to the 15) Install the compressor by referring to "6.
swinging structure (1). Removal and installation of compressor".
4) Install the 2 buffers (7) to the swinging 16) Install the vertical shock absorber to the
structure (1). swinging structure by referring to "5.
5) Put the tube piece (8) to the fixed bearing Removal and installation of vertical shock
(9). absorber".
6) Install 4 rollers (5), 2 rollers (6), 2 fixed 17) Install the Bowden pull wire for vertical
bearings (9) and 4 felt rings (4) to the shock absorber adjustment to the vertical
swinging structure (1). shock absorber by referring to "4.
7) Install the lower part of the suspension to Removal and installation of Bowden pull
the swinging structure by referring to "14. wire and handle for vertival shock
Removal and installation of lower part of absorber adjustment".
the suspension". 18) Install the bellows off by referring to "3.
8) Install the upper part of the suspension to Removal and installation of bellows".
the swinging structure by referring to "13. 19) Install the top cover by referring to "1.
Removal and installation of upper part of Removal and installation of top cover".
the suspension". 20) Install the upper part of the seat by refer-
9) Install the cable harness by referring to ring to "I. Upper seat".
"12. Removal and installation of cable har-
ness".
10) Install the air tank for additional air supply
by referring to "11. Removal and installa-
tion of air tank for additional air supply".
11) Install the pneumatic spring by referring to
"10. Removal and installation of pneu-
matic spring".
WD600-6 50-800 49
SEN05152-02 Removal and installation of air conditioner unit assembly
Removal and installation of air 4. Disconnect hose (5) from the side of the air
conditioner unit assembly 1
conditioner unit.
5. Remove box (6).
Removal 6. Remove mat to the front.
k Park the machine on level ground. Apply
wheels.
k Set the lock bar to the frame.
k In the case that you do not drain the cool-
ant, if you disconnect the heater hose when
the coolant temperature in the radiator is
high, you may be scalded. In this case, wait
until the coolant temperature lowers and
then disconnect the heater hose.
k Collect the air conditioner refrigerant
(R134a) from air conditioner circuit in
advance. 7. Remove cover (8) and internal air filter.
a Ask professional traders for collecting and fill- 8. Remove plate (9).
ing operation of refrigerant (R134a). 9. Remove 3 mounting bolts (11) and remove
a Never release the refrigerant (R134a) to the duct (10).
atmosphere.

1. Open cover (1).

2. Remove box (2).
a Place the left console (LC) in front.
10. Remove ducts (12) from the air conditioner unit
assembly (13).
50-800 50 WD600-6
Removal and installation of air conditioner unit assembly SEN05152-02
11. Disconnect wiring harness clamp (14). Installation

12. Remove duct (15). q Installation is done in the reverse order of
13. Disconnect connectors A10 (16) and A11 (17). removal.
[*1]
a When installing the air conditioner circuit
hoses, use care so that dirt, water, may not
enter.
a Before tightening, make sure O-ring (70) is
provided in the air conditioner hose piping con-
nection.
a Check that there is no defect or deterioration
on the O-ring.
a When connecting the refrigerant piping, coat
the O-ring with compressor oil for new refrig-
erant (R134a) (DENSO: ND-OIL8, VALEO
THERMAL SYSTEMS: ZXL100PG (PAG 46
14. Disconnect clamp (18). or equivalent)).
15. Disconnect clamps (20). 3 Mounting bolt: 8 – 12 Nm {0.8 – 1.2 kgm}
16. Remove mounting bolt (21), then disconnect
air conditioner tubes (22). [*1]
17. Disconnect 2 heater hoses (23).
a Confirming their destination.
a Arrange for a container.
[*2]
a Install the air conditioner unit after applying
Cemedine 366E or equivalent to the lower
hatched area (all around the circumference) of
the air conditioner unit.
2 Lower hatched area (all around the circum-
18. Remove air conditioner unit assembly (13). [*2] ference) of the air conditioner unit:
Cemedine 366E or equivalent
WD600-6 50-800 51
SEN05152-02 Removal and installation of air conditioner unit assembly

(R134a).
a Filling quantity: 850 ± 50 g
k After installing the floor mat, check if the
brake valve boot (B) is crushed.
a Also check if the accelerator pedal boot is

crushed.
q Example of bad boot condition where the

boot (B) is crushed
q Example of good boot condition where the

boot (B) is not crushed
50-800 52 WD600-6
Removal and installation of AJSS lever switch assembly SEN05152-02
Removal and installation of AJSS 3. Remove screws (5) (4 pieces) and washers (6)
lever switch assembly 1
(4 pieces).
Removal
k Before starting the removal work, be sure to
perform the works described in "Section 00,
Safety notice", "2. Preparation work" and "3.
Precautions during work".
k Disconnect the cable from the negative (-) ter-
minal of the battery. (If the machine is equipped
with the battery disconnect switch, turn it to
OFF position.)
1. Remove screws (1) (5 pieces) and washers (2)

(5 pieces).
5. Remove bolt (9), and remove clamp (9a) which
2. Move cover (3) to a place where it is not a
is fixing wiring harness (8).
hindrance to work.
a Pass the cover (3) to AJSS lever shaft (4)
and fix it with tape, etc. as shown in the figure
below.
6. Remove screws (11) (2 pieces) and collars (12)

(2 pieces) at portion (a) on the back of knob (10).
WD600-6 50-800 53
SEN05152-02 Removal and installation of AJSS lever switch assembly
7. Push up wiring harness (8) passed through shaft

(4) toward knob (b).
8. Disconnect connectors (15) and (16), and
remove AJSS lever cover (17) and switch
assembly together.
9. Remove screw (18), and disconnect relay unit

(19).
10. Remove directional selector switch (20) and
hooks (c) (3 pieces) of horn switch (21), and
remove AJSS lever switch assembly (22).
50-800 54 WD600-6
Installation
1. Install AJSS lever switch assembly (22)

2. Install upshift switch (23) and downshift switch

(24) of switch assembly (22) to AJSS lever cover
(17).
a Color of upshift switch cable:
Blue/black, green/yellow
a Color of downshift switch cable:
Green/black, brown/white
3. Install relay unit (19) with screw (18). 4. Install directional selector switch (20) to AJSS
a Confirm that the relay unit does not catch the lever cover (17).
harness. a Check that hooks (d) (2 pieces) of directional
3 Screw (18):
selector switch (20) are installed securely.
0.7 to 0.9 Nm {0.07 to 0.09 kgm} a Check that height (e) of rubber boot (25)
a Install upshift switch (23) and downshift above cover (17) is even all around the pe-
switch (24) to the center of mounting hole. riphery. If it is not, even it out by moving di-
a Check that rubber boot (27) is not tensed or rectional selector switch (20) back and forth
deformed. 2 to 3 times to fit.
Height (e) of rubber boot (25): 1.5 mm
WD600-6 50-800 55
SEN05152-02 Removal and installation of AJSS lever switch assembly
a The shape of the directional switch differs ac-

cording to the machine serial number.
5. Install horn switch (26) to AJSS lever cover (17).

a Check that hook (f) of horn switch (26) is in-
stalled securely.
7. Install collars (12) (2 pieces) to back (a) of knob

(10).
a Install the collar (12) with the small diame-
ter end first.
8. Install cover (17) with screws (11) (2 pieces).
a Install horn switch (21) to the center of the
mounting hole and eliminate clearance
6. Connect wiring harness (8) which is passing
around it.
3 Screw (11)
through shaft (4) to connectors (16) and (15).
a Connect connector (16) (4-pole) first, then
0.8 ± 0.1 Nm {0.08 ± 0.01 kgm}
connect connector (15) (6-pole).
a Check that locks (g) of connectors (16)
and (15) are set normally.
50-800 56 WD600-6
Check of operation
1. Connect the negative (-) terminal of the battery.
(If the machine is equipped with the battery
disconnect switch, turn it to ON position.)
2. Start the engine, operate AJSS lever and each
switch as follows, and check their operations.
Steering operation
q Operate AJSS lever to the right and left, and
check that the machine turns in the operating
direction of AJSS lever.
Directional operation
q Set directional selector switch (20) to each
position (N, F, R), and check that the travel
9. Install clamp (9a) with bolt (9), and fix wiring direction changes according to the operation
harness (8). of directional selector switch.
Upshift and downshift operations
q Operate upshift switch (23) and downshift
switch (24), and check that gear is shifted ac-
cording to the switch operation.
Horn switch operation
q Operate horn switch (21), and check that the
horn sounds according to the horn switch op-
eration.
10. Install cover (7) with screws (5) (4 pieces) and

washers (6) (4 pieces).
11. Install cover (3) with screws (1) (5 pieces) and

washers (2) (5 pieces).
WD600-6 50-800 57
SEN05152-02
WD600-6 Wheel dozer

©2017 KOMATSU
All Rights Reserved
50-800 58
SEN05153-00
WHEEL DOZER
WD600-6
WD600-6 55001 and up
900 Electrical system

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SEN04979-11

WHEEL DOZER WD600 -6

Machine model Serial number

00 Index and foreword 00

Composition of shop manual 1

Section Title Form Number

00 Index and foreword .................................................................................................................... SEN04980-11

01 Specification ............................................................................................................................... SEN04983-01

10 Structure, function and maintenance standard........................................................................... SEN04985-03

20 Standard value table................................................................................................................... SEN04999-02

30 Testing and adjusting ................................................................................................................. SEN05000-07

302 Troubleshooting by failure code (Display of code), Part 2..................................................SEN05052-02

50 Disassembly and assembly ........................................................................................................SEN05002-05

90 Diagrams and drawings ..............................................................................................................SEN05003-03

00 Index and foreword

10 Structure, function and maintenance standard

Joystick steering lever linkage....................................................................................................................... 5

20 Standard value table

30 Testing and adjusting

Testing parking brake performance ............................................................................................................... 37

Failure code [AB00MA] Alternator: Malfunction ............................................................................................ 12

E-9 Backup lamp does not light or it keeps lighting up.................................................................................. 70

S-13 Oil level rises (Water, fuel in oil) ........................................................................................................... 24

50 Disassembly and assembly

600 Hydraulic system SEN05150-01

WD600-6 Wheel dozer

Machine model Serial number

00 Index and foreword 00

200 Foreword and general information

Important safety notice

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

2. Preparations for work

4. Precautions for sling work and making

6. Precautions for using overhead hoist crane

7. Selecting wire ropes 2) Connection

a The allowable load is one-sixth of the

8. Precautions for disconnecting and con-

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

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

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

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

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value or allow-

Handling of electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness