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Komatsu WA250-5L, WA250PT-5L Waste Handler Wheel Loader Shop Manual CEBM011604 – PDF DOWNLOAD
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Description
Komatsu WA250-5L, WA250PT-5L Waste Handler Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA250-5L, WA250PT-5L Waste Handler Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA250-5L, WA250PT-5L Waste Handler
Serial Number: A73001 and up, A79001 and up
Book Code: CEBM011604
Language: English
Pages: 1062
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA250-5L, WA250PT-5L Waste Handler Wheel Loader Shop Manual
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING, ADJUSTING AND TROUBLESHOOTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating Problems to Causes are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu WA250-5L, WA250PT-5L Waste Handler Wheel Loader Shop Manual
CEBM011604 - WA250-5L/WA250PT-5L..................................................................... 1 CONTENTS......................................................................................... 2 List of revised pages Rev4.pdf................................................................... 3 01 GENERAL........................................................................................... 29 SPECIFICATION.................................................................................... 30 WA250-5L/WA250PT-5L DIMENSIONS............................................................... 30 SYSTEM OPERATING PERAMETERS.................................................................. 32 WEIGHT TABLE................................................................................. 35 FUEL, COOLANT AND LUBRICANTS..................................................................... 37 10 STRUCTURE AND FUNCTION............................................................................ 41 ENGINE AND DRIVE SYSTEM MOUNTING................................................................. 46 DRIVE SYSTEM DAMPER.............................................................................. 47 COOLING SYSTEM................................................................................... 48 REVERSING FAN SYSTEM......................................................................... 49 REVERSING FAN MANIFOLD....................................................................... 50 PROPORTIONAL RELIEF VALVE.................................................................... 51 2-POSITION, 4-WAY SPOOL VALVE................................................................ 52 FAN CONTROLLER............................................................................... 53 POWER TRAIN...................................................................................... 54 POWER TRAIN SYSTEM DIAGRAM................................................................... 55 DRIVE SHAFT.................................................................................. 57 HST HYDRAULIC PIPING DIAGRAM..................................................................... 58 HST PUMP......................................................................................... 59 HIGH-PRESSURE RELIEF VALVE................................................................... 62 LOW-PRESSURE RELIEF VALVE.................................................................... 63 CHARGE PUMP.................................................................................. 64 SPEED-RELATED VALVE (DA VALVE)............................................................... 65 HIGH-PRESSURE CUT-OFF VALVE...................................................................... 66 HST MOTORS....................................................................................... 67 HST MOTOR 1.................................................................................. 67 HST MOTOR 2.................................................................................. 69 EP SERVO VALVE............................................................................... 71 HA SERVO VALVE............................................................................... 72 FORWARD-REVERSE SHUTTLE VALVE................................................................ 73 TRANSFER......................................................................................... 74 INPUT SHAFT PORTION.......................................................................... 78 OUTPUT SHAFT PORTION......................................................................... 80 CLUTCH OPERATION............................................................................. 83 TRANSFER OIL COOLER.............................................................................. 86 CLUTCH SOLENOID VALVE............................................................................ 87 AXLES............................................................................................ 88 FRONT AXLE................................................................................... 88 REAR AXLE.................................................................................... 89 DIFFERENTIALS.................................................................................... 90 FRONT DIFFERENTIAL........................................................................... 90 REAR DIFFERENTIAL............................................................................ 92 LIMITED-SLIP DIFFERENTIAL........................................................................ 95 FRONT........................................................................................ 95 REAR......................................................................................... 97 FINAL DRIVE...................................................................................... 101 FRONT........................................................................................ 101 REAR......................................................................................... 103 AXLE MOUNTING AND CENTER HINGE CARIER............................................................ 106 STEERING PIPING SYSTEM........................................................................... 111 STEERING COLUMN.................................................................................. 112 PRIORITY VALVE................................................................................... 113 ORBIT-ROLL VALVE................................................................................. 116 STEERING WHEEL IN NEUTRAL.................................................................... 118 STEERING WHEEL TURNED (TURNING LEFT)......................................................... 120 CONNECTION BETWEEN HAND PUMP AND SLEEVE...................................................... 121 2-WAY RESTRICTOR VALVE........................................................................... 123 STEERING CYLINDER................................................................................ 124 EMERGENCY STEERING PIPING........................................................................ 126 EMERGENCY STEERING VALVE......................................................................... 128 BRAKE PIPING..................................................................................... 131 BRAKE VALVE...................................................................................... 132 INCHING VALVE.................................................................................... 137 CHARGE VALVE..................................................................................... 138 ACCUMULATOR (FOR BRAKE).......................................................................... 142 SLACK ADJUSTER................................................................................... 144 BRAKE............................................................................................ 146 FRONT........................................................................................ 146 REAR......................................................................................... 148 PARKING BRAKE CONTROL............................................................................ 150 PARKING BRAKE.................................................................................... 151 HYDRAULIC PIPING................................................................................. 152 WA250PT-5L................................................................................... 152 WA250PT-5L................................................................................... 154 WORK EQUIPMENT LEVER LINKAGE..................................................................... 156 WA250-5L..................................................................................... 156 MULTI-FUNCTION JOYSTICK TYPE............................................................. 156 JOYSTICK TYPE (IF EQUIPPED).............................................................. 157 WA250PT-5.................................................................................... 158 MULTI-FUNCTION JOYSTICK TYPE............................................................. 158 JOYSTICK TYPE (IF EQUIPPED).............................................................. 159 HYDRAULIC TANK................................................................................... 160 BREATHER..................................................................................... 161 PREVENTION OF NEGATIVE PRESSURE IN TANK.................................................. 161 PREVENTION OF RISE OF PRESSURE IN TANK................................................... 161 4-GEAR PUMP UNIT................................................................................. 162 ACCUMULATOR (FOR PPC CIRCUIT).................................................................... 164 LOCK VALVE....................................................................................... 164 BY-PASS VALVE.................................................................................... 165 WA250-5L..................................................................................... 165 WHEN LIFT ARM IS "RAISED"................................................................ 166 WHEN LIFT ARM IS "LOWERED"............................................................... 167 WA250PT-5L................................................................................... 168 WHEN BUCKET IS "DUMP" IN FAST MODE (FROM TILT-BACK POSITION TO JUST BEFORE DUMP END)..... 169 WHEN BUCKET IS "DUMP" IN FAST MODE (FROM JUST BEFORE DUMP END TO DUMP END)............... 170 QUICK COUPLER SOLENOID VALVE..................................................................... 171 E.C.S.S. VALVE (IF EQUIPPED)..................................................................... 172 ACCUMULATOR (FOR E.C.S.S.) (IF EQUIPPED)......................................................... 174 HYDRAULIC PIPING OF COOLING SYSTEM............................................................... 175 COOLING FAN MOTOR................................................................................ 176 WORK EQUIPMENT CONTROL VALVE..................................................................... 179 2-SPOOL VALVE................................................................................ 179 3-SPOOL VALVE................................................................................ 183 RELIEF VALVE................................................................................. 186 SAFETY SUCTION VALVE......................................................................... 187 SUCTION VALVE................................................................................ 188 OPERATION OF THE WORK EQUIPMENT CONTROL VALVE................................................ 189 NEUTRAL POSITION OF THE LIFT ARM AND BUCKET SPOOLS....................................... 189 RAISE POSITION OF THE LIFT ARM SPOOL..................................................... 190 LOWER POSITION OF THE LIFT ARM SPOOL..................................................... 191 FLOAT POSITION OF THE LIFT ARM SPOOL..................................................... 192 ROLL BACK POSITION OF THE BUCKET SPOOL................................................... 193 DUMP POSITION OF THE BUCKET SPOOL........................................................ 194 WORK EQUIPMENT PPC VALVE......................................................................... 195 WHEN IN NEUTRAL.............................................................................. 197 WHEN IN FINE CONTROL......................................................................... 198 WHEN LEVER IS OPERATED TO STROKE END......................................................... 199 WHEN LIFT ARM IS FLOATED..................................................................... 199 WHEN FLOAT STATE OF LIFT ARM IS RESET........................................................ 199 ATTACHMENT PPC VALVE (IF EQUIPPED)............................................................... 200 AT THE NEUTRAL POSITION...................................................................... 202 AT THE FINE CONTROL POSITION................................................................. 202 AT FULL STROKE............................................................................... 203 WORK EQUIPMENT LINKAGE........................................................................... 204 WA250-5L..................................................................................... 204 WA250PT-5L................................................................................... 206 BUCKET........................................................................................... 208 WA250-5L..................................................................................... 208 WA250PT-5L................................................................................... 210 BUCKET POSITIONER, BOOM KICK-OUT, AND DUMP SPEED................................................. 212 WA250-5L..................................................................................... 212 BUCKET POSITIONER........................................................................ 213 BOOM KICK-OUT............................................................................ 213 OPERATION OF PROXIMITY SWITCH............................................................ 214 WA250PT-5L................................................................................... 220 BUCKET POSITIONER OR FORK POSITIONER..................................................... 221 BOOM KICK-OUT............................................................................ 221 DUMP SPEED CONTROL....................................................................... 221 OPERATION OF PROXIMITY SWITCH............................................................ 222 WORK EQUIPMENT CYLINDER.......................................................................... 230 WA250-5L..................................................................................... 230 LIFT CYLINDER............................................................................ 230 BUCKET CYLINDER.......................................................................... 230 WA250PT-5L................................................................................... 232 LIFT CYLINDER............................................................................ 232 BUCKET CYLINDER.......................................................................... 232 COUPLER PLUNGER.......................................................................... 232 AIR CONDITIONER PIPING........................................................................... 234 MACHINE MONITORING SYSTEM........................................................................ 235 OUTLINE...................................................................................... 235 NORMAL MODE.................................................................................. 235 SERVICE MODE................................................................................. 235 SERVICE METER SETTING........................................................................ 236 INDIVIDUAL CIRCUIT DIAGRAMS OF THE MACHINE MONITOR............................................... 238 STARTING AND LIGHTING........................................................................ 238 POWER SUPPLY AND NETWORK..................................................................... 240 SENSING...................................................................................... 241 HST SAFETY CONTROL........................................................................... 242 AUTOMATIC PREHEATING......................................................................... 243 POWER SUPPLY AND NETWORK..................................................................... 244 MACHINE MONITOR.................................................................................. 246 LIST OF ITEMS DISPLAYED ON MONITOR........................................................... 247 SERVICE MODE FUNCTIONS................................................................... 251 OPERATING METHOD......................................................................... 253 ITEMS RELATED TO THE FAULT HISTORY OF ELECTRIC SYSTEM.................................... 254 ITEMS RELATED TO THE FAULT HISTORY OF MACHINE SYSTEM..................................... 257 REAL-TIME MONITOR FUNCTION............................................................... 259 HOW TO INPUT INTERVAL.................................................................... 263 FUNCTION OF SELECTING OPTIONAL DEVICE.................................................... 265 ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)........................................................ 270 HST CONTROLLER................................................................................... 274 SELECTING FORWARD-REVERSE SELECTOR SWITCH........................................................ 276 ENGINE STARTING CIRCUIT.......................................................................... 278 ENGINE STOP CIRCUIT.............................................................................. 280 PREHEATING CIRCUIT (AUTOMATIC PREHEAT SYSTEM).................................................... 281 PARKING BRAKE CIRCUIT............................................................................ 282 ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM...................................................... 285 COUPLER PLUNGER CONTROL SYSTEM................................................................... 286 SENSORS.......................................................................................... 287 ENGINE SPEED SENSOR.......................................................................... 287 TRAVEL SPEED SENSOR.......................................................................... 287 ENGINE OIL PRESSURE SENSOR................................................................... 288 FUEL LEVEL SENSOR............................................................................ 288 COOLANT AND HST OIL TEMPERATURE SENSOR (FOR MONITOR)......................................... 289 COOLANT TEMPERATURE SENSOR (FOR PREHEATING).................................................. 289 AXLE OIL TEMPERATURE SENSOR.................................................................. 290 HST OIL PRESSURE SENSOR...................................................................... 290 STEERING AND EMERGENCY STEERING OIL PRESSURE SENSOR (IF EQUIPPED)............................ 291 HST FILTER CLOGGING SENSOR................................................................... 291 COOLANT LEVEL SENSOR......................................................................... 292 KOMTRAX SYSTEM................................................................................... 293 KOMTRAX TERMINAL SYSTEM...................................................................... 293 KOMTRAX TERMINAL............................................................................. 294 INPUT AND OUTPUT SIGNALS..................................................................... 295 20 TESTING, ADJUSTING AND TROUBLESHOOTING............................................................ 297 STANDARD VALUE TABLE............................................................................. 299 ENGINE....................................................................................... 299 CHASSIS...................................................................................... 300 SPECIAL TOOLS.................................................................................... 306 ENGINE COMPONENTS................................................................................ 309 MEASURING EXHAUST SMOKE...................................................................... 309 MEASURING EXHAUST TEMPERATURE................................................................ 309 ADJUSTING VALVE CLEARANCE.................................................................... 309 MEASURING COMPRESSION PRESSURE............................................................... 309 MEASURING CRANCASE PRESSURE.................................................................. 309 MEASURING ENGINE OIL PRESSURE................................................................ 309 MEASURING BOOST PRESSURE..................................................................... 309 MEASURING FUEL PRESSURE...................................................................... 309 ADJUSTING ENGINE SPEED SENSOR................................................................ 309 BLEEDING AIR FROM FUEL SYSTEM................................................................ 309 MEASURING ENGINE SPEED........................................................................... 310 MEASURING ENGINE SPEED (LOW AND HIGH IDLE)................................................... 310 MEASURING HST STALL SPEED.................................................................... 311 MEASURING HYDRAULIC STALL.................................................................... 311 MEASURING FULL STALL SPEED................................................................... 311 OPERATING FORCE OF ACCELERATOR PEDAL............................................................. 312 TESTING OPERATING FORCE...................................................................... 312 OPERATING ANGLE OF PEDAL......................................................................... 313 ADJUSTING ENGINE STOP SOLENOID................................................................... 314 ADJUSTING ENGINE SPEED SENSOR.................................................................... 315 REFRIGERANT COMPRESSOR BELT...................................................................... 316 MEASURING DIRECTIONAL LEVER EFFORT............................................................... 317 HST OIL PRESSURE................................................................................. 318 MEASURING.................................................................................... 318 ADJUSTING.................................................................................... 321 MEASURING CLUTCH CONTROL PRESSURE................................................................ 323 STEERING WHEEL................................................................................... 324 MEASURING STEERING WHEEL END PLAY............................................................ 324 MEASURING OPERATING FORCE ON STEERING WHEEL.................................................. 324 MEASURING OPERATING TIME FOR STEERING WHEEL.................................................. 325 STEERING OIL PRESSURE............................................................................ 326 MEASURING MAIN RELIEF PRESSURE............................................................... 326 ADJUSTING MAIN RELIEF PRESSURE............................................................... 326 BLEEDING AIR FROM STEERING CIRCUIT........................................................... 327 HYDRAULIC FAN.................................................................................... 328 MEASURING FAN SPEED.......................................................................... 328 MEASURING OIL PRESSURE....................................................................... 328 REVERSING FAN CONTROLLER, IF EQUIPPED............................................................ 329 LED INDICATORS............................................................................... 329 MEASURING BRAKE PEDAL............................................................................ 330 BRAKE PEDAL LINKAGE.............................................................................. 331 MEASURING BRAKE PERFORMANCE...................................................................... 332 ACCUMULATOR CHARGE PRESSURE...................................................................... 333 MEASURING BRAKE OIL PRESSURE..................................................................... 335 MEASURING WEAR OF BRAKE DISC..................................................................... 337 BLEEDING AIR FROM BRAKE CIRCUIT.................................................................. 338 MEASURING PARKING BRAKE PERFORMANCE.............................................................. 339 PARKING BRAKE LINKAGE............................................................................ 340 MEASURING PARKING BRAKE RELEASE PRESSURE......................................................... 341 WORK EQUIPMENT CONTROL LEVER..................................................................... 342 WORK EQUIPMENT PRESSURE.......................................................................... 343 WORK EQUIPMENT PPC OIL PRESSURE.................................................................. 345 TESTING AND ADJUSTING........................................................................ 345 BLEEDING AIR................................................................................. 347 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT................................................ 348 BUCKET POSITIONER................................................................................ 349 BOOM KICK-OUT.................................................................................... 350 TESTING...................................................................................... 350 ADJUSTING.................................................................................... 350 PROXIMITY SWITCH ACTUATION DISPLAY LAMP.......................................................... 351 PROCEDURE FOR CHECKING DIODE..................................................................... 353 SPECIAL FUNCTIONS OF MACHINE MONITOR............................................................. 354 FLOW OF MODES AND FUNCTIONS...................................................................... 355 OPERATOR MODE................................................................................ 358 SERVICE MODE 1............................................................................... 358 SERVICE MODE 2............................................................................... 358 CHARACTER DISPLAY............................................................................ 358 OPERATING SWITCHES........................................................................... 358 OPERATOR MODE OPERATION AND DISPLAYS......................................................... 358 FAILURE CODE TABLE........................................................................... 363 *SEPARATE TABLE: DETAILED PHENOMENA OF PROBLEM CODE (L*)..................................... 364 PROCEDURE FOR SWITCHING TO SERVICE MODE 1 AND SCREEN DISPLAY................................. 364 REAL-TIME MONITORING ITEMS................................................................... 370 PM CLINIC INSPECTION CHART....................................................................... 373 20-101 TROUBLESHOOTING (GENERAL)..................................................................... 375 POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................... 376 SEQUENCE OF EVENTS IN TROUBLESHOOTING............................................................ 378 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE........................................................ 379 PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT................................................. 379 HANDLING CONTROL BOX......................................................................... 384 POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS.................................... 385 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT......................................... 386 CHECKS BEFORE TROUBLESHOOTING.................................................................... 388 CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS............................ 389 PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO................................... 390 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....................................................... 393 T-ADAPTER TABLE.................................................................................. 417 CONNECTOR TYPES AND MOUNTING LOCATIONS........................................................... 420 CONNECTOR LAYOUT DRAWING......................................................................... 426 20-301 TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)........................................... 431 POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM................................................... 432 POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL............................................ 432 USER CODE MEMORY RETENTION FUNCTION.......................................................... 432 HST CONTROLLER SYSTEM DIAGRAM.................................................................... 433 TROUBLESHOOTING CODE DISPLAY..................................................................... 435 ERROR CODE AND POSSIBLE CAUSE TABLE.......................................................... 435 FUSE SYSTEM CHECK................................................................................ 436 FUSE PANNEL CONNECTION TABLE................................................................. 436 INFORMATION CONTAINED IN TESTING PROCEDURES...................................................... 437 CODE KEY TABLE............................................................................... 438 ERROR CODE: [989F00]............................................................................. 439 TRANSMISSION PROTECTION ALERT (00)........................................................... 439 ERROR CODE: [DHH1KX]............................................................................. 440 HST OIL PRESSURE SIGNAL OUT OF RANGE......................................................... 440 ERROR CODE: [DLE2LC]............................................................................. 442 ENGINE SPEED SENSOR OUT OF RANGE............................................................. 442 ERROR CODE: [DW26KZ]............................................................................. 444 MOTOR 2 SOLENOID SYSTEM OPEN OR SHORTED...................................................... 444 ERROR CODE: [DX19KZ]............................................................................. 448 MOTOR 1 SOLENOID SYSTEM OPEN OR SHORTED...................................................... 448 ERROR CODE: [DX20KZ]............................................................................. 450 CLUTCH SOLENOID SYSTEM OPEN OR SHORTED....................................................... 450 TROUBLESHOOTING CODE: [HST-1].................................................................... 452 DEFECTIVE HST POWER CONTROLLER SOURCE........................................................ 452 TROUBLESHOOTING CODE: [HST-2].................................................................... 456 TRAVEL SPEED RANGES DO NOT CHANGE............................................................ 456 TROUBLESHOOTING CODE: [HST-3].................................................................... 460 TRAVEL SPEED DOES NOT REGISTER............................................................... 460 TROUBLESHOOTING CODE: [HST-4].................................................................... 464 CANNOT CONTROL TRAVEL SPEED WHEN 1ST. GEAR IS SELECTED....................................... 464 TROUBLESHOOTING CODE: [HST-5].................................................................... 468 TRACTION CONTROL INNOPERABLE................................................................. 468 20-402 TROUBLESHOOTING OF HST MONITOR SYSTEM (HST MODE).............................................. 471 POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM................................................... 473 POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL............................................ 473 USER CODE MEMORY RETENTION FUNCTION.......................................................... 473 MONITOR SYSTEM CIRCUIT DIAGRAM................................................................... 474 TROUBLESHOOTING CODE DISPLAY..................................................................... 478 ERROR CODE AND POSSIBLE CAUSE TABLE.......................................................... 478 FUSE SYSTEM CHECK................................................................................ 479 FUSE PANNEL CONNECTION TABLE................................................................. 479 INFORMATION CONTAINED IN TESTING PROCEDURES...................................................... 480 CODE KEY TABLE............................................................................... 481 ERROR CODE: [15B0NX]............................................................................. 482 HST OIL FILTER SHOWING CLOGGED CONDITION..................................................... 482 ERROR CODE: [2G42ZG]............................................................................. 484 LOW ACCUMULATOR OIL PRESSURE INDICATED....................................................... 484 ERROR CODE: [989F00]............................................................................. 486 TRANSMISSION PROTECTION CAUTION INDICATED.................................................... 486 ERROR CODE: [989FN1]............................................................................. 487 HST OVERSPEED CONDITION...................................................................... 487 ERROR CODE: [AB00L6]............................................................................. 488 DEFECTIVE BATTERY CHARGING CIRCUIT........................................................... 488 ERROR CODE: [AB00MA]............................................................................. 490 DEFECTIVE BATTERY CHARGING CIRCUIT........................................................... 490 ERROR CODE: [B@BAZG]............................................................................. 492 ABNORMAL ENGINE OIL PRESSURE INDICATED....................................................... 492 ERROR CODE: [B@BCNS]............................................................................. 494 ENGINE COOLANT INDICATING OVERHEAT CONDITION................................................. 494 ERROR CODE: [B@BCZK]............................................................................. 496 ABNORMAL COOLANT LEVEL INDICATION............................................................ 496 ERROR CODE: [B@C7NS]............................................................................. 498 BRAKE COOLING OIL INDICATING OVERHEATING CONDITION........................................... 498 ERROR CODE: [B@CRNS]............................................................................. 500 HST OIL SHOWING OVERHEATING CONDITION........................................................ 500 ERROR CODE: [D5ZHL6]............................................................................. 502 STARTING SWITCH "C" (IGN) INPUT FAILURE INDICATED............................................ 502 ERROR CODE: [DAF0KT]............................................................................. 504 CONTROLLER INTERNAL FAILURE)................................................................. 504 ERROR CODE: [DAJ0KR]............................................................................. 506 HST CONTROLLER COMMUNICATION FAILURE......................................................... 506 ERROR CODE: [DD15LD]............................................................................. 508 MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET.............................................. 508 ERROR CODE: [DD16LD]............................................................................. 510 MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET.............................................. 510 ERROR CODE: [DD17LD]............................................................................. 512 MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET.............................................. 512 ERROR CODE: [DD18LD]............................................................................. 514 MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET.............................................. 514 ERROR CODE: [DDK3KB]............................................................................. 516 IMPROPER INPUT FOR MULTIPUL SHIFT (FNR) LEVER................................................ 516 ERROR CODE: [DDS5L6]............................................................................. 518 DECREASED STEERING OIL PRESSURE.............................................................. 518 ERROR CODE: [DGE2KX]............................................................................. 520 ENGINE COOLANT TEMPERATURE SENSOR OUT OF RANGE............................................... 520 ERROR CODE: [DGE3KX]............................................................................. 522 ENGINE COOLANT TEMPERATURE SENSOR OUT OF RANGE............................................... 522 ERROR CODE: [DGH1KX]............................................................................. 524 HST OIL SHOWING OVERHEATING CONDITION........................................................ 524 ERROR CODE: [DGR1KX]............................................................................. 526 BRAKE COOLING OIL INDICATING SHORT CIRCUIT................................................... 526 ERROR CODE: [DGR4KX]............................................................................. 528 BRAKE COOLING OIL INDICATING OPEN CIRCUIT.................................................... 528 ERROR CODE: [DHE4KA]............................................................................. 530 ENGINE OIL PRESSURE INDICATING A SHORT OR OPEN IN THE SYSTEM................................. 530 TROUBLESHOOTING CODE: [MON-1].................................................................... 532 PARKING BRAKE INDICATOR LAMP DOES NOT WORK................................................... 532 TROUBLESHOOTING CODE: [MON-2].................................................................... 536 BRAKE OIL PRESSURE NOT INDICATING CORRECTLY.................................................. 536 TROUBLESHOOTING CODE: [MON-3].................................................................... 538 ENGINE COOLANT SENSOR NOT INDICATING CORRECTLY............................................... 538 TROUBLESHOOTING CODE: [MON-4].................................................................... 540 HST OIL TEMPERATURE NOT INDICATING CORRECTLY................................................. 540 TROUBLESHOOTING CODE: [MON-5].................................................................... 542 FUEL LEVEL GAUGE DOES NOT INDICATE PROPERLY.................................................. 542 TROUBLESHOOTING CODE: [MON-6].................................................................... 544 ABNORMAL COOLANT LEVEL INDICATION............................................................ 544 TROUBLESHOOTING CODE: [MON-7].................................................................... 546 STEERING OIL PRESSURE NOT READING CORRECTLY.................................................. 546 TROUBLESHOOTING CODE: [MON-8].................................................................... 548 EMERGENCY STEERING OIL PRESSURE NOT READING CORRECTLY........................................ 548 TROUBLESHOOTING CODE: [MON-9].................................................................... 550 MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY.................................... 550 TROUBLESHOOTING CODE: [MON-10]................................................................... 552 MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY.................................... 552 TROUBLESHOOTING CODE: [MON-11]................................................................... 554 MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY.................................... 554 TROUBLESHOOTING CODE: [MON-12]................................................................... 556 MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY.................................... 556 TROUBLESHOOTING CODE: [MON-13]................................................................... 558 ALARM BUZZER DOES NOT STOP OR REMAINS ON..................................................... 558 TROUBLESHOOTING CODE: [MON-14]................................................................... 560 FRONT WINDSHIELD WIPER DOES NOT WORK......................................................... 560 REAR WINDSHIELD WIPER DOES NOT WORK.......................................................... 562 TROUBLESHOOTING CODE: [MON-15]................................................................... 564 HEADLAMPS (LO AND HIGH BEAM) DOES NOT FUNCTION............................................... 564 20-501 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)................................................. 567 POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM................................................... 568 POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL.......................................... 568 USER CODE MEMORY RETENTION FUNCTION.......................................................... 568 ELECTRICAL SYSTEM CIRCUIT DIAGRAM................................................................ 569 FUSE SYSTEM CHECK................................................................................ 575 FUSE PANEL CONNECTION TABLE.................................................................. 575 INFORMATION CONTAINED IN TESTING PROCEDURES...................................................... 576 CODE: (E-1)...................................................................................... 578 ENGINE WILL NOT CRANK........................................................................ 578 CODE: (E-2)...................................................................................... 581 THE ENGINE DOES NOT SHUT DOWN................................................................ 581 CODE: (E-3)...................................................................................... 583 COLD START PREHEATER DOES NOT WORK PROPERLY.................................................. 583 CODE: (E-4)...................................................................................... 586 PARKING BRAKE DOES NOT FUNCTION PROPERLY..................................................... 586 CODE: (E-5)...................................................................................... 589 EMERGENCY BRAKE SYSTEM DOES NOT FUNCTION..................................................... 589 CODE: (E-6)...................................................................................... 590 BOOM KICK-OUT FUNCTION NOT WORKING PROPERLY.................................................. 590 CODE: (E-7)...................................................................................... 593 BUCKET LEVER FUNCTION NOT WORKING PROPERLY................................................... 593 CODE: (E-8)...................................................................................... 596 FLOAT HOLD FUNCTION NOT WORKING PROPERLY..................................................... 596 CODE: (E-9)...................................................................................... 599 FRONT WINDSHIELD WIPER DOES NOT WORK......................................................... 599 CODE: (E-9)...................................................................................... 603 REAR WINDSHIELD WIPER DOES NOT WORK.......................................................... 603 CODE: (E-10)..................................................................................... 605 THE WINDOW WASHER DOES NOT WORK.............................................................. 605 CODE: (E-11)..................................................................................... 607 HEADLAMPS (LO AND HIGH BEAM) DOES NOT FUNCTION............................................... 607 CODE: (E-11)..................................................................................... 610 HEADLAMPS (LO BEAM) DO NOT FUNCTION.......................................................... 610 CODE: (E-11)..................................................................................... 613 HEADLAMPS (HI BEAM) DO NOT FUNCTION.......................................................... 613 CODE: (E-11)..................................................................................... 616 CLEARANCE LAMPS DO NOT FUNCTION.............................................................. 616 CODE: [E-11]..................................................................................... 619 TURN SIGNALS DO NOT FUNCTION................................................................. 619 CODE: (E-11)..................................................................................... 622 WORK LAMPS DO NOT FUNCTION................................................................... 622 CODE: (E-12)..................................................................................... 625 HORN DOES NOT SOUND.......................................................................... 625 CODE: (E-13)..................................................................................... 627 AIR CONDITIONER SYSTEM DOES NOT WORK......................................................... 627 CODE: (E-13)..................................................................................... 630 AIR DOES NOT FLOW FROM SYSTEM AND CANNOT BE ADJUSTED......................................... 630 CODE: (E-13)..................................................................................... 634 AIR DOES NOT COOL OR TEMPERATURE CANNOT BE ADJUSTED.......................................... 634 CODE: (E-13)..................................................................................... 638 CANNOT SWITCH BETWEEN CIRCULATED AND VENT FUNCTIONS.......................................... 638 CODE: (E-13)..................................................................................... 640 CANNOT SWITCH VENT FUNCTIONS................................................................. 640 20-601 TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE)....................................... 643 METHOD OF USING TROUBLESHOOTING CHART............................................................ 645 FAILURE CODE AND CAUSE TABLE..................................................................... 648 CODE: (H-1)...................................................................................... 651 THE MACHINE DOES NOT START................................................................... 651 CODE: (H-2)...................................................................................... 652 THE TRAVEL SPEED IS SLOW..................................................................... 652 CODE: (H-3)...................................................................................... 653 THE THRUST FORCE IS WEAK..................................................................... 653 CODE: (H-4)...................................................................................... 654 ENGINE STALLS OR ENGINE SPEED DROPS EXCESSIVELY.............................................. 654 CODE: (H-5)...................................................................................... 655 THE GEARS DO NOT CHANGE SPEED RANGE.......................................................... 655 CODE: (H-6)...................................................................................... 656 THE STEERING WHEEL DOES NOT TURN............................................................. 656 CODE: (H-7)...................................................................................... 657 STEERING WHEEL MOVEMENT IS HEAVY............................................................. 657 CODE: (H-8)...................................................................................... 658 STEERING WHEEL SHAKES OR HAS JERKY MOVEMENT.................................................. 658 CODE: (H-9)...................................................................................... 659 BRAKES DO NOT WORK OR WORKS POORLY........................................................... 659 CODE: (H-10)..................................................................................... 660 BRAKES IS NOT RELEASING OR DRAGGED........................................................... 660 CODE: (H-11)..................................................................................... 661 THE PARKING BRAKE IS NOT WORK................................................................ 661 CODE: (H-12)..................................................................................... 662 THE LIFT ARM DOES NOT RISE OR LOWER.......................................................... 662 CODE: (H-13)..................................................................................... 663 LIFT ARM MOVES SLOW OR RISING FORCE IS POOR.................................................. 663 CODE: (H-14)..................................................................................... 664 WHEN RISING LIFT ARM, ARM MOVES SLOWLY AT SPECIFIC HEIGHTS................................... 664 CODE: (H-15)..................................................................................... 664 THE LIFT ARM CYLINDER WILL NOT HOLD DOWN THE BUCKET (THE BUCKET RISES)....................... 664 CODE: (H-16)..................................................................................... 664 HYDRAULIC DRIFT ON THE LIFT ARM OCCURS OFTEN................................................. 664 CODE: (H-17)..................................................................................... 664 THE LIFT ARM WOBBLES DURING OPERATION........................................................ 664 CODE: (H-18)..................................................................................... 665 WHEN THE CONTROL LEVER IS SWITCHED FROM “HOLD” TO “RAISE,” THE LIFT ARM FALLS TEMPORARILY.... 665 CODE: (H-19)..................................................................................... 666 THE BUCKET DOES NOT TILT BACK................................................................ 666 CODE: (H-20)..................................................................................... 667 BUCKET MOVES SLOW OR THE TILTING-BACK FORCE IS INSUFFICIENT.................................. 667 CODE: (H-21)..................................................................................... 668 THE BUCKET OPERATES SLOWLY IN TILTING-BACK................................................... 668 CODE: (H-22)..................................................................................... 668 BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET.................................................. 668 CODE: (H-23)..................................................................................... 668 HYDRAULIC DRIFTS OF THE BUCKET OCCURS OFTEN.................................................. 668 CODE: (H-24)..................................................................................... 668 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVE IS SET TO “HOLD”)...... 668 CODE: (H-25)..................................................................................... 669 WHEN THE CONTROL LEVER IS SWITCHED FROM “HOLD” TO “TILT,” THE BUCKET FALLS TEMPORARILY....... 669 CODE: (H-26)..................................................................................... 669 CONTROL LEVERS FOR THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY.............................. 669 20-701 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)..................................................... 671 METHOD OF USING TROUBLESHOOTING CHARTS........................................................... 672 (S-1) ENGINE STARTING PERFORMANCE IS POOR........................................................ 676 (S-2) ENGINE HAS STARTING PROBLEMS............................................................... 678 ENGINE DOES NOT CRANK........................................................................ 678 ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT OF STACK........................................ 679 SMOKE COMES OUT OF STACK BUT ENGINE DOES NOT START........................................... 680 (S-3) ENGINE DOES NOT RUN SMOOTHLY............................................................... 681 (S-4) ENGINE STOPS DURING OPERATIONS............................................................. 682 (S-5) ENGINE SPEED HUNTS......................................................................... 683 (S-6) ENGINE LACKS POWER......................................................................... 684 (S-7) EXHAUST SMOKE IS BLACK..................................................................... 685 (S-8) OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE...................................... 686 (S-9) OIL BECOMES CONTAMINATED QUICKLY........................................................... 687 (S-10) FUEL CONSUMPTION IS EXCESSIVE............................................................. 688 (S-11) OIL FOUND IN COOLANT, OR COOLANT SPURTS FROM RADIATOR..................................... 689 (S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP....................................................... 690 (S-13) OIL LEVEL RISES (COOLANT OR FUEL FOUND IN OIL)............................................ 691 (S-14) COOLANT TEMPERATURE TOO HIGH (OVERHEATING)................................................ 692 (S-15) ABNORMAL NOISE IS HEARD WHEN ENGINE IS RUNNUNG............................................ 693 (S-16) EXCESSIVE VIBRATION WHEN ENGINE IS RUNNING................................................ 694 20-901 TROUBLESHOOTING AIR CONDITIONING.............................................................. 695 AIR CONDITIONING SYSTEM.......................................................................... 697 ENVIRONMENTAL IMPACT......................................................................... 697 OPERATOR CAB AIR CONDITIONING................................................................ 698 PRINCIPLES OF REFRIGERATION.................................................................. 698 AIR CONDITIONING......................................................................... 698 THE ACT OF COOLING....................................................................... 698 THE REFRIGERATION CYCLE.................................................................. 699 AIR CONDITIONER SYSTEM COMPONENTS............................................................ 699 COMPRESSOR (REFRIGERANT PUMP)............................................................ 699 SERVICE VALVES........................................................................... 700 CONDENSER................................................................................ 700 RECEIVER-DRIER........................................................................... 700 THERMOSTATIC EXPANSION VALVE............................................................. 700 EVAPORATOR............................................................................... 701 ELECTRICAL CIRCUIT........................................................................... 701 THERMOSTAT............................................................................... 702 COMPRESSOR CLUTCH........................................................................ 702 SAFETY SWITCHES.......................................................................... 702 SYSTEM SERVICING............................................................................. 703 R-134A REFRIGERANT CONTAINERS................................................................ 704 SERVICE TOOLS AND EQUIPMENT.................................................................. 704 RECOVERY/RECYCLE STATION................................................................. 704 LEAK DETECTOR............................................................................ 705 SERVICE VALVES........................................................................... 705 VACUUM PUMP.............................................................................. 705 MANIFOLD GAUGE SET....................................................................... 706 INSTALLING MANIFOLD GAUGE SET................................................................ 707 PURGING AIR FROM SERVICE HOSES............................................................... 708 ADDING REFRIGERANT TO THE SYSTEM (WITHOUT A CHARGING STATION)................................ 709 STABILIZING THE AC SYSTEM.................................................................... 709 ADDING REFRIGERANT AND STABILIZING THE SYSTEM (WITH A RECOVERY/RECYCLING STATION)............ 710 RECOVERING AND RECYCLING THE REFRIGERANT..................................................... 710 PERFORMING THE RECOVERY CYCLE............................................................ 710 PERFORMING THE RECYCLING PROCEDURE....................................................... 711 EVACUATING AND CHARGING THE AC SYSTEM.................................................... 711 SYSTEM PERFORMANCE TEST...................................................................... 712 SYSTEM LEAK TESTING.......................................................................... 712 ELECTRONIC LEAK DETECTOR................................................................. 713 TRACER DYES.............................................................................. 713 SOAP AND WATER........................................................................... 713 SYSTEM REPAIR................................................................................ 714 HOSES AND FITTINGS....................................................................... 714 LINES.................................................................................... 714 EXPANSION VALVE.......................................................................... 714 RECEIVER-DRIER........................................................................... 714 THERMOSTAT............................................................................... 714 CLUTCH................................................................................... 715 COMPRESSOR............................................................................... 715 CHECKING COMPRESSOR OIL LEVEL................................................................ 715 EVACUATING THE SYSTEM........................................................................ 716 TROUBLESHOOTING - AIR CONDITIONING SYSTEM.................................................... 717 PRE-DIAGNOSIS CHECKS..................................................................... 717 PREPARING FOR DIAGNOSIS.................................................................. 717 PRELIMINARY STEPS........................................................................ 717 SYSTEM PERFORMANCE TEST.................................................................. 717 DIAGNOSIS OF GAUGE READINGS & SYSTEM PERFORMANCE......................................... 718 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS........................................... 719 DEFECTIVE GROUND ON REFRIGERANT COMPRESSOR............................................... 723 PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM............................................... 724 30 DISASSEMBLY AND ASSEMBLY.......................................................................... 727 HOW TO USE THIS MANUAL........................................................................... 732 REMOVAL AND INSTALLATION OF COMPONANTS....................................................... 732 SPECIAL TOOLS............................................................................ 732 OVERHAUL OF COMPONANTS....................................................................... 733 SPECIAL TOOLS............................................................................ 733 DISASSEMBLY.............................................................................. 733 ASSEMBLY................................................................................. 733 PRECAUTIONS WHEN PERFORMING AN OPERATION......................................................... 734 SPECIAL TOOL LIST................................................................................ 736 SKETCHES OF SPECIAL TOOLS........................................................................ 739 CONNECTOR REPAIR PROCEDURES...................................................................... 745 CONTACT TERMINAL REMOVAL (HD30 TYPE)......................................................... 745 STRIPING INSULATION.......................................................................... 746 CRIMPING CONTACT TERMINAL (HD30 TYPE)........................................................ 747 INSERTION OF CONTACT TERMINAL (HD30 TYPE).................................................... 748 CONTACT TERMINAL REMOVAL (DT TYPE)........................................................... 749 STRIPING INSULATION.......................................................................... 750 CRIMPING CONTACT TERMINAL (DT TYPE).......................................................... 751 INSERTION OF CONTACT TERMINAL (DT TYPE)...................................................... 752 FUEL INJECTION PUMP ASSEMBLY..................................................................... 754 SPECIAL TOOLS................................................................................ 754 REMOVAL...................................................................................... 754 INSTALLATION................................................................................. 758 NOZZLE HOLDER ASSEMBLY........................................................................... 760 SPECIAL TOOLS................................................................................ 760 REMOVAL...................................................................................... 760 INSTALLATION................................................................................. 761 CYLINDER HEAD ASSEMBLY........................................................................... 762 SPECIAL TOOLS................................................................................ 762 REMOVAL...................................................................................... 762 INSTALLATION................................................................................. 769 ENGINE ASSEMBLY.................................................................................. 773 REMOVAL...................................................................................... 773 INSTALLATION................................................................................. 780 RADIATOR ASSEMBLY................................................................................ 782 REMOVAL...................................................................................... 782 INSTALLATION................................................................................. 783 AIR AFTERCOOLER.................................................................................. 784 REMOVAL...................................................................................... 784 INSTALLATION................................................................................. 785 HYDRAULIC OIL COOLER............................................................................. 786 REMOVAL...................................................................................... 786 INSTALLATION................................................................................. 787 COOLING FAN AND FAN MOTOR........................................................................ 788 REMOVAL...................................................................................... 788 INSTALLATION................................................................................. 789 FUEL TANK........................................................................................ 790 REMOVAL...................................................................................... 790 INSTALLATION................................................................................. 791 TRANSFER......................................................................................... 792 REMOVAL...................................................................................... 792 INSTALLATION................................................................................. 795 TRANSFER ASSEMBLY................................................................................ 796 SPECIAL TOOLS................................................................................ 796 DISASSEMBLY.................................................................................. 796 ASSEMBLY..................................................................................... 808 PARKING BRAKE ASSEMBLY........................................................................... 822 REMOVAL...................................................................................... 822 INSTALLATION................................................................................. 823 DISASSEMBLY.................................................................................. 824 SPECIAL TOOLS............................................................................ 824 ASSEMBLY..................................................................................... 827 FRONT AXLE ASSEMBLY.............................................................................. 831 REMOVAL...................................................................................... 831 INSTALLATION................................................................................. 833 REAR AXLE ASSEMBLY............................................................................... 834 REMOVAL...................................................................................... 834 INSTALLATION................................................................................. 837 AXLE HOUSING ASSEMBLY............................................................................ 838 SPECIAL TOOLS................................................................................ 838 DISASSEMBLY.................................................................................. 838 ASSEMBLY..................................................................................... 843 DIFFERENTIAL ASSEMBLY............................................................................ 849 SPECIAL TOOLS................................................................................ 849 DISASSEMBLY.................................................................................. 849 ASSEMBLY..................................................................................... 862 HST PUMP AND 4-GEAR PUMP ASSEMBLY................................................................ 882 REMOVAL...................................................................................... 882 INSTALLATION................................................................................. 885 HST PUMP ASSEMBLY................................................................................ 886 DISASSEMBLY.................................................................................. 886 ASSEMBLY..................................................................................... 898 HST MOTOR 1 ASSEMBLY............................................................................. 920 REMOVAL...................................................................................... 920 INSTALLATION................................................................................. 921 HST MOTOR 2 ASSEMBLY............................................................................. 922 REMOVAL...................................................................................... 922 INSTALLATION................................................................................. 923 HST MOTOR ASSEMBLY............................................................................... 924 DISASSEMBLY.................................................................................. 924 ASSEMBLY..................................................................................... 935 WORK EQUIPMENT CONTROL VALVE ASSEMBLY............................................................ 946 REMOVAL...................................................................................... 946 INSTALLATION................................................................................. 947 TRAVEL DAMPER VALVE ASSEMBLY..................................................................... 948 REMOVAL...................................................................................... 948 INSTALLATION................................................................................. 949 HYDRAULIC TANK................................................................................... 950 REMOVAL...................................................................................... 950 INSTALLATION................................................................................. 951 WORK EQUIPMENT ASSEMBLY (Z-BAR LINKAGE).......................................................... 952 REMOVAL...................................................................................... 952 INSTALLATION................................................................................. 956 BUCKET LINK PIN.......................................................................... 956 BUCKET HINGE PIN......................................................................... 956 BUCKET CYLINDER PIN (ON ROD SIDE)........................................................ 957 LIFT CYLINDER PIN (ON ROD SIDE).......................................................... 957 LIFT ARM PIN (ON FRAME SIDE)............................................................. 958 BUCKET LINK PIN.......................................................................... 958 WORK EQUIPMENT ASSEMBLY (PARELLEL TOOL CARRIER).................................................. 960 BUCKET (TILT) CYLINDER....................................................................... 960 REMOVAL.................................................................................. 960 INSTALLATION............................................................................. 961 BOOM (LIFT) CYLINDER......................................................................... 962 REMOVAL.................................................................................. 962 INSTALLATION............................................................................. 963 BOOM AND PARALLEL TOOL LINKAGE............................................................... 964 REMOVAL...................................................................................... 964 INSTALLATION................................................................................. 972 HYDRAULIC CYLINDER ASSEMBLY...................................................................... 975 SPECIAL TOOLS................................................................................ 975 DISASSEMBLY.................................................................................. 976 ASSEMBLY..................................................................................... 980 OPERATOR'S CAB ASSEMBLY.......................................................................... 985 REMOVAL...................................................................................... 985 INSTALLATION................................................................................. 990 OPERATOR'S CAB GLASS............................................................................. 991 SPECIAL TOOLS................................................................................ 991 REMOVAL...................................................................................... 991 INSTALLATION................................................................................. 992 COATING MATERIALS............................................................................ 999 CENTER HINGE PIN.................................................................................1000 REMOVAL......................................................................................1000 INSTALLATION.................................................................................1006 COUNTERWEIGHT....................................................................................1012 REMOVAL......................................................................................1012 INSTALLATION.................................................................................1013 AIR CONDITIONER UNIT ASSEMBLY....................................................................1014 SPECIAL TOOLS................................................................................1014 REMOVAL......................................................................................1014 INSTALLATION.................................................................................1017 AIR CONDITIONER COMPRESSOR ASSEMBLY..............................................................1018 SPECIAL TOOLS................................................................................1018 REMOVAL......................................................................................1018 INSTALLATION.................................................................................1019 MONITOR PANEL....................................................................................1020 REMOVAL......................................................................................1020 INSTALLATION.................................................................................1024 KOMTRAX TERMINAL ASSEMBLY........................................................................1025 REMOVAL......................................................................................1025 INSTALLATION.................................................................................1026 90 SCHEMATICS AND DIAGRAMS...........................................................................1027 HYDRAULIC CIRCUIT DIAGRAM........................................................................1029 WA250-5L.....................................................................................1029 SHEET 1 OF 2.............................................................................1029 SHEET 2 OF 2.............................................................................1031 WA250PT-5L...................................................................................1033 SHEET 1 OF 2.............................................................................1033 SHEET 2 OF 2.............................................................................1035 ELECTRICAL CIRCUIT DIAGRAM.......................................................................1037 MAIN FLOOR HARNESS...........................................................................1037 SHEET 1 OF 8.............................................................................1037 SHEET 2 OF 8.............................................................................1039 SHEET 3 OF 8.............................................................................1041 SHEET 4 OF 8.............................................................................1043 SHEET 5 OF 8.............................................................................1045 SHEET 6 OF 8.............................................................................1047 SHEET 7 OF 8.............................................................................1049 SHEET 8 OF 8.............................................................................1051 HST HARNESS..................................................................................1053 ENGINE HARNESS AND REAR HARNESS..............................................................1055 CAB HARNESS..................................................................................1057 FRONT HARNESS................................................................................1059 REVERSE FAN WIRING DIAGRAM...................................................................1061
KOMATSU WA250-5L, WA250PT-5L WASTE HANDLER WHEEL LOADER SHOP MANUAL CEBM011604 – PDF DOWNLOAD:
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