Komatsu WA250-5L WA250PT-5L Wheel Loader Waste Handler Shop Manual PDF  

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Komatsu WA250-5L WA250PT-5L Wheel Loader Waste Handler Shop Manual CEBM011605 – PDF DOWNLOAD 

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Komatsu WA250-5L WA250PT-5L Wheel Loader Waste Handler Shop Manual CEBM011605 – PDF DOWNLOAD 

Language : English
Pages : 1027
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu WA250-5L WA250PT-5L Wheel Loader Waste Handler Shop Manual CEBM011605 – PDF DOWNLOAD 

SERIAL NUMBERS
WA250-5L A73001 and UP
WA250PT-5L A79001 and UP

CEBM011605 – WA250-5L/WA250PT-5L 1
CONTENTS 2
01 GENERAL 13
SPECIFICATION 14
WA250-5L/WA250PT-5L DIMENSIONS 14
SYSTEM OPERATING PERAMETERS 16
WEIGHT TABLE 19
FUEL, COOLANT AND LUBRICANTS 21
10 STRUCTURE AND FUNCTION 25
ENGINE AND DRIVE SYSTEM MOUNTING 30
DRIVE SYSTEM DAMPER 31
COOLING SYSTEM 32
REVERSING FAN SYSTEM 33
REVERSING FAN MANIFOLD 34
PROPORTIONAL RELIEF VALVE 35
2-POSITION, 4-WAY SPOOL VALVE 36
FAN CONTROLLER 37
POWER TRAIN 38
POWER TRAIN SYSTEM DIAGRAM 39
DRIVE SHAFT 41
HST HYDRAULIC PIPING DIAGRAM 42
HST PUMP 43
HIGH-PRESSURE RELIEF VALVE 46
LOW-PRESSURE RELIEF VALVE 47
CHARGE PUMP 48
SPEED-RELATED VALVE (DA VALVE) 49
HIGH-PRESSURE CUT-OFF VALVE 50
HST MOTORS 51
HST MOTOR 1 51
HST MOTOR 2 53
EP SERVO VALVE 55
HA SERVO VALVE 56
FORWARD-REVERSE SHUTTLE VALVE 57
TRANSFER 58
INPUT SHAFT PORTION 62
OUTPUT SHAFT PORTION 64
CLUTCH OPERATION 67
TRANSFER OIL COOLER 70
CLUTCH SOLENOID VALVE 71
AXLES 72
FRONT AXLE 72
REAR AXLE 73
DIFFERENTIALS 74
FRONT DIFFERENTIAL 74
REAR DIFFERENTIAL 76
LIMITED-SLIP DIFFERENTIAL 79
FRONT 79
REAR 81
FINAL DRIVE 85
FRONT 85
REAR 87
AXLE MOUNTING AND CENTER HINGE CARIER 90
STEERING PIPING SYSTEM 95
STEERING COLUMN 96
PRIORITY VALVE 97
ORBIT-ROLL VALVE 100
STEERING WHEEL IN NEUTRAL 102
STEERING WHEEL TURNED (TURNING LEFT) 104
CONNECTION BETWEEN HAND PUMP AND SLEEVE 105
2-WAY RESTRICTOR VALVE 107
STEERING CYLINDER 108
EMERGENCY STEERING PIPING 110
EMERGENCY STEERING VALVE 112
BRAKE PIPING 115
BRAKE VALVE 116
INCHING VALVE 121
CHARGE VALVE 122
ACCUMULATOR (FOR BRAKE) 126
SLACK ADJUSTER 128
BRAKE 130
FRONT 130
REAR 132
PARKING BRAKE CONTROL 134
PARKING BRAKE 135
HYDRAULIC PIPING 136
WA250PT-5L 136
WA250PT-5L 138
WORK EQUIPMENT LEVER LINKAGE 140
WA250-5L 140
MULTI-FUNCTION JOYSTICK TYPE 140
JOYSTICK TYPE (IF EQUIPPED) 141
WA250PT-5 142
MULTI-FUNCTION JOYSTICK TYPE 142
JOYSTICK TYPE (IF EQUIPPED) 143
HYDRAULIC TANK 144
BREATHER 145
PREVENTION OF NEGATIVE PRESSURE IN TANK 145
PREVENTION OF RISE OF PRESSURE IN TANK 145
4-GEAR PUMP UNIT 146
ACCUMULATOR (FOR PPC CIRCUIT) 148
LOCK VALVE 148
BY-PASS VALVE 149
WA250-5L 149
WHEN LIFT ARM IS “RAISED” 150
WHEN LIFT ARM IS “LOWERED” 151
WA250PT-5L 152
WHEN BUCKET IS “DUMP” IN FAST MODE (FROM TILT-BACK POSITION TO JUST BEFORE DUMP END) 153
WHEN BUCKET IS “DUMP” IN FAST MODE (FROM JUST BEFORE DUMP END TO DUMP END) 154
QUICK COUPLER SOLENOID VALVE 155
E C S S VALVE (IF EQUIPPED) 156
ACCUMULATOR (FOR E C S S ) (IF EQUIPPED) 158
HYDRAULIC PIPING OF COOLING SYSTEM 159
COOLING FAN MOTOR 160
WORK EQUIPMENT CONTROL VALVE 163
2-SPOOL VALVE 163
3-SPOOL VALVE 167
RELIEF VALVE 170
SAFETY SUCTION VALVE 171
SUCTION VALVE 172
OPERATION OF THE WORK EQUIPMENT CONTROL VALVE 173
NEUTRAL POSITION OF THE LIFT ARM AND BUCKET SPOOLS 173
RAISE POSITION OF THE LIFT ARM SPOOL 174
LOWER POSITION OF THE LIFT ARM SPOOL 175
FLOAT POSITION OF THE LIFT ARM SPOOL 176
ROLL BACK POSITION OF THE BUCKET SPOOL 177
DUMP POSITION OF THE BUCKET SPOOL 178
WORK EQUIPMENT PPC VALVE 179
WHEN IN NEUTRAL 181
WHEN IN FINE CONTROL 182
WHEN LEVER IS OPERATED TO STROKE END 183
WHEN LIFT ARM IS FLOATED 183
WHEN FLOAT STATE OF LIFT ARM IS RESET 183
ATTACHMENT PPC VALVE (IF EQUIPPED) 184
AT THE NEUTRAL POSITION 186
AT THE FINE CONTROL POSITION 186
AT FULL STROKE 187
WORK EQUIPMENT LINKAGE 188
WA250-5L 188
WA250PT-5L 190
BUCKET 192
WA250-5L 192
WA250PT-5L 194
BUCKET POSITIONER, BOOM KICK-OUT, AND DUMP SPEED 196
WA250-5L 196
BUCKET POSITIONER 197
BOOM KICK-OUT 197
OPERATION OF PROXIMITY SWITCH 198
WA250PT-5L 204
BUCKET POSITIONER OR FORK POSITIONER 205
BOOM KICK-OUT 205
DUMP SPEED CONTROL 205
OPERATION OF PROXIMITY SWITCH 206
WORK EQUIPMENT CYLINDER 214
WA250-5L 214
LIFT CYLINDER 214
BUCKET CYLINDER 214
WA250PT-5L 216
LIFT CYLINDER 216
BUCKET CYLINDER 216
COUPLER PLUNGER 216
AIR CONDITIONER PIPING 218
MACHINE MONITORING SYSTEM 219
OUTLINE 219
NORMAL MODE 219
SERVICE MODE 219
SERVICE METER SETTING 220
INDIVIDUAL CIRCUIT DIAGRAMS OF THE MACHINE MONITOR 222
STARTING AND LIGHTING 222
POWER SUPPLY AND NETWORK 224
SENSING 225
HST SAFETY CONTROL 226
AUTOMATIC PREHEATING 227
POWER SUPPLY AND NETWORK 228
MACHINE MONITOR 230
LIST OF ITEMS DISPLAYED ON MONITOR 231
SERVICE MODE FUNCTIONS 235
OPERATING METHOD 237
ITEMS RELATED TO THE FAULT HISTORY OF ELECTRIC SYSTEM 238
ITEMS RELATED TO THE FAULT HISTORY OF MACHINE SYSTEM 241
REAL-TIME MONITOR FUNCTION 243
HOW TO INPUT INTERVAL 247
FUNCTION OF SELECTING OPTIONAL DEVICE 249
ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM) 254
HST CONTROLLER 258
SELECTING FORWARD-REVERSE SELECTOR SWITCH 260
ENGINE STARTING CIRCUIT 262
ENGINE STOP CIRCUIT 264
PREHEATING CIRCUIT (AUTOMATIC PREHEAT SYSTEM) 265
PARKING BRAKE CIRCUIT 266
ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM 269
COUPLER PLUNGER CONTROL SYSTEM 270
SENSORS 271
ENGINE SPEED SENSOR 271
TRAVEL SPEED SENSOR 271
ENGINE OIL PRESSURE SENSOR 272
FUEL LEVEL SENSOR 272
COOLANT AND HST OIL TEMPERATURE SENSOR (FOR MONITOR) 273
COOLANT TEMPERATURE SENSOR (FOR PREHEATING) 273
AXLE OIL TEMPERATURE SENSOR 274
HST OIL PRESSURE SENSOR 274
STEERING AND EMERGENCY STEERING OIL PRESSURE SENSOR (IF EQUIPPED) 275
HST FILTER CLOGGING SENSOR 275
COOLANT LEVEL SENSOR 276
KOMTRAX SYSTEM 277
KOMTRAX TERMINAL SYSTEM 277
KOMTRAX TERMINAL 278
INPUT AND OUTPUT SIGNALS 279
20 TESTING, ADJUSTING AND TROUBLESHOOTING 281
STANDARD VALUE TABLE 283
ENGINE 283
CHASSIS 284
SPECIAL TOOLS 290
ENGINE COMPONENTS 293
MEASURING EXHAUST SMOKE 293
MEASURING EXHAUST TEMPERATURE 293
ADJUSTING VALVE CLEARANCE 293
MEASURING COMPRESSION PRESSURE 293
MEASURING CRANCASE PRESSURE 293
MEASURING ENGINE OIL PRESSURE 293
MEASURING BOOST PRESSURE 293
MEASURING FUEL PRESSURE 293
ADJUSTING ENGINE SPEED SENSOR 293
BLEEDING AIR FROM FUEL SYSTEM 293
MEASURING ENGINE SPEED 294
MEASURING ENGINE SPEED (LOW AND HIGH IDLE) 294
MEASURING HST STALL SPEED 295
MEASURING HYDRAULIC STALL 295
MEASURING FULL STALL SPEED 295
OPERATING FORCE OF ACCELERATOR PEDAL 296
TESTING OPERATING FORCE 296
OPERATING ANGLE OF PEDAL 297
ADJUSTING ENGINE STOP SOLENOID 298
ADJUSTING ENGINE SPEED SENSOR 299
REFRIGERANT COMPRESSOR BELT 300
MEASURING DIRECTIONAL LEVER EFFORT 301
HST OIL PRESSURE 302
MEASURING 302
ADJUSTING 305
MEASURING CLUTCH CONTROL PRESSURE 307
STEERING WHEEL 308
MEASURING STEERING WHEEL END PLAY 308
MEASURING OPERATING FORCE ON STEERING WHEEL 308
MEASURING OPERATING TIME FOR STEERING WHEEL 309
STEERING OIL PRESSURE 310
MEASURING MAIN RELIEF PRESSURE 310
ADJUSTING MAIN RELIEF PRESSURE 310
BLEEDING AIR FROM STEERING CIRCUIT 311
HYDRAULIC FAN 312
MEASURING FAN SPEED 312
MEASURING OIL PRESSURE 312
REVERSING FAN CONTROLLER, IF EQUIPPED 313
LED INDICATORS 313
MEASURING BRAKE PEDAL 314
BRAKE PEDAL LINKAGE 315
MEASURING BRAKE PERFORMANCE 316
ACCUMULATOR CHARGE PRESSURE 317
MEASURING BRAKE OIL PRESSURE 319
MEASURING WEAR OF BRAKE DISC 321
BLEEDING AIR FROM BRAKE CIRCUIT 322
MEASURING PARKING BRAKE PERFORMANCE 323
PARKING BRAKE LINKAGE 324
MEASURING PARKING BRAKE RELEASE PRESSURE 325
WORK EQUIPMENT CONTROL LEVER 326
WORK EQUIPMENT PRESSURE 327
WORK EQUIPMENT PPC OIL PRESSURE 329
TESTING AND ADJUSTING 329
BLEEDING AIR 331
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 332
BUCKET POSITIONER 333
BOOM KICK-OUT 334
TESTING 334
ADJUSTING 334
PROXIMITY SWITCH ACTUATION DISPLAY LAMP 335
PROCEDURE FOR CHECKING DIODE 337
SPECIAL FUNCTIONS OF MACHINE MONITOR 338
FLOW OF MODES AND FUNCTIONS 339
OPERATOR MODE 342
SERVICE MODE 1 342
SERVICE MODE 2 342
CHARACTER DISPLAY 342
OPERATING SWITCHES 342
OPERATOR MODE OPERATION AND DISPLAYS 342
FAILURE CODE TABLE 347
*SEPARATE TABLE: DETAILED PHENOMENA OF PROBLEM CODE (L*) 348
PROCEDURE FOR SWITCHING TO SERVICE MODE 1 AND SCREEN DISPLAY 348
REAL-TIME MONITORING ITEMS 354
PM CLINIC INSPECTION CHART 357
20-101 TROUBLESHOOTING (GENERAL) 359
POINTS TO REMEMBER WHEN TROUBLESHOOTING 360
SEQUENCE OF EVENTS IN TROUBLESHOOTING 362
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 363
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT 363
HANDLING CONTROL BOX 368
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS 369
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT 370
CHECKS BEFORE TROUBLESHOOTING 372
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS 373
PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO 374
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 377
T-ADAPTER TABLE 401
CONNECTOR TYPES AND MOUNTING LOCATIONS 404
CONNECTOR LAYOUT DRAWING 410
20-301 TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE) 415
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM 416
POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL 416
USER CODE MEMORY RETENTION FUNCTION 416
HST CONTROLLER SYSTEM DIAGRAM 417
TROUBLESHOOTING CODE DISPLAY 419
ERROR CODE AND POSSIBLE CAUSE TABLE 419
FUSE SYSTEM CHECK 420
FUSE PANNEL CONNECTION TABLE 420
INFORMATION CONTAINED IN TESTING PROCEDURES 421
CODE KEY TABLE 422
ERROR CODE: [989F00] 423
TRANSMISSION PROTECTION ALERT (00) 423
ERROR CODE: [DHH1KX] 424
HST OIL PRESSURE SIGNAL OUT OF RANGE 424
ERROR CODE: [DLE2LC] 426
ENGINE SPEED SENSOR OUT OF RANGE 426
ERROR CODE: [DW26KZ] 428
MOTOR 2 SOLENOID SYSTEM OPEN OR SHORTED 428
ERROR CODE: [DX19KZ] 432
MOTOR 1 SOLENOID SYSTEM OPEN OR SHORTED 432
ERROR CODE: [DX20KZ] 434
CLUTCH SOLENOID SYSTEM OPEN OR SHORTED 434
TROUBLESHOOTING CODE: [HST-1] 436
DEFECTIVE HST POWER CONTROLLER SOURCE 436
TROUBLESHOOTING CODE: [HST-2] 440
TRAVEL SPEED RANGES DO NOT CHANGE 440
TROUBLESHOOTING CODE: [HST-3] 444
TRAVEL SPEED DOES NOT REGISTER 444
TROUBLESHOOTING CODE: [HST-4] 448
CANNOT CONTROL TRAVEL SPEED WHEN 1ST GEAR IS SELECTED 448
TROUBLESHOOTING CODE: [HST-5] 452
TRACTION CONTROL INNOPERABLE 452
20-402 TROUBLESHOOTING OF HST MONITOR SYSTEM (HST MODE) 455
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM 457
POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL 457
USER CODE MEMORY RETENTION FUNCTION 457
MONITOR SYSTEM CIRCUIT DIAGRAM 458
TROUBLESHOOTING CODE DISPLAY 462
ERROR CODE AND POSSIBLE CAUSE TABLE 462
FUSE SYSTEM CHECK 463
FUSE PANNEL CONNECTION TABLE 463
INFORMATION CONTAINED IN TESTING PROCEDURES 464
CODE KEY TABLE 465
ERROR CODE: [15B0NX] 466
HST OIL FILTER SHOWING CLOGGED CONDITION 466
ERROR CODE: [2G42ZG] 468
LOW ACCUMULATOR OIL PRESSURE INDICATED 468
ERROR CODE: [989F00] 470
TRANSMISSION PROTECTION CAUTION INDICATED 470
ERROR CODE: [989FN1] 471
HST OVERSPEED CONDITION 471
ERROR CODE: [AB00L6] 472
DEFECTIVE BATTERY CHARGING CIRCUIT 472
ERROR CODE: [AB00MA] 474
DEFECTIVE BATTERY CHARGING CIRCUIT 474
ERROR CODE: [B@BAZG] 476
ABNORMAL ENGINE OIL PRESSURE INDICATED 476
ERROR CODE: [B@BCNS] 478
ENGINE COOLANT INDICATING OVERHEAT CONDITION 478
ERROR CODE: [B@BCZK] 480
ABNORMAL COOLANT LEVEL INDICATION 480
ERROR CODE: [B@C7NS] 482
BRAKE COOLING OIL INDICATING OVERHEATING CONDITION 482
ERROR CODE: [B@CRNS] 484
HST OIL SHOWING OVERHEATING CONDITION 484
ERROR CODE: [D5ZHL6] 486
STARTING SWITCH “C” (IGN) INPUT FAILURE INDICATED 486
ERROR CODE: [DAF0KT] 488
CONTROLLER INTERNAL FAILURE) 488
ERROR CODE: [DAJ0KR] 490
HST CONTROLLER COMMUNICATION FAILURE 490
ERROR CODE: [DD15LD] 492
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET 492
ERROR CODE: [DD16LD] 494
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET 494
ERROR CODE: [DD17LD] 496
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET 496
ERROR CODE: [DD18LD] 498
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET 498
ERROR CODE: [DDK3KB] 500
IMPROPER INPUT FOR MULTIPUL SHIFT (FNR) LEVER 500
ERROR CODE: [DDS5L6] 502
DECREASED STEERING OIL PRESSURE 502
ERROR CODE: [DGE2KX] 504
ENGINE COOLANT TEMPERATURE SENSOR OUT OF RANGE 504
ERROR CODE: [DGE3KX] 506
ENGINE COOLANT TEMPERATURE SENSOR OUT OF RANGE 506
ERROR CODE: [DGH1KX] 508
HST OIL SHOWING OVERHEATING CONDITION 508
ERROR CODE: [DGR1KX] 510
BRAKE COOLING OIL INDICATING SHORT CIRCUIT 510
ERROR CODE: [DGR4KX] 512
BRAKE COOLING OIL INDICATING OPEN CIRCUIT 512
ERROR CODE: [DHE4KA] 514
ENGINE OIL PRESSURE INDICATING A SHORT OR OPEN IN THE SYSTEM 514
TROUBLESHOOTING CODE: [MON-1] 516
PARKING BRAKE INDICATOR LAMP DOES NOT WORK 516
TROUBLESHOOTING CODE: [MON-2] 520
BRAKE OIL PRESSURE NOT INDICATING CORRECTLY 520
TROUBLESHOOTING CODE: [MON-3] 522
ENGINE COOLANT SENSOR NOT INDICATING CORRECTLY 522
TROUBLESHOOTING CODE: [MON-4] 524
HST OIL TEMPERATURE NOT INDICATING CORRECTLY 524
TROUBLESHOOTING CODE: [MON-5] 526
FUEL LEVEL GAUGE DOES NOT INDICATE PROPERLY 526
TROUBLESHOOTING CODE: [MON-6] 528
ABNORMAL COOLANT LEVEL INDICATION 528
TROUBLESHOOTING CODE: [MON-7] 530
STEERING OIL PRESSURE NOT READING CORRECTLY 530
TROUBLESHOOTING CODE: [MON-8] 532
EMERGENCY STEERING OIL PRESSURE NOT READING CORRECTLY 532
TROUBLESHOOTING CODE: [MON-9] 534
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY 534
TROUBLESHOOTING CODE: [MON-10] 536
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY 536
TROUBLESHOOTING CODE: [MON-11] 538
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY 538
TROUBLESHOOTING CODE: [MON-12] 540
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY 540
TROUBLESHOOTING CODE: [MON-13] 542
ALARM BUZZER DOES NOT STOP OR REMAINS ON 542
TROUBLESHOOTING CODE: [MON-14] 544
FRONT WINDSHIELD WIPER DOES NOT WORK 544
REAR WINDSHIELD WIPER DOES NOT WORK 546
TROUBLESHOOTING CODE: [MON-15] 548
HEADLAMPS (LO AND HIGH BEAM) DOES NOT FUNCTION 548
20-501 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 551
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM 552
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL 552
USER CODE MEMORY RETENTION FUNCTION 552
ELECTRICAL SYSTEM CIRCUIT DIAGRAM 553
FUSE SYSTEM CHECK 559
FUSE PANEL CONNECTION TABLE 559
INFORMATION CONTAINED IN TESTING PROCEDURES 560
CODE: (E-1) 562
ENGINE WILL NOT CRANK 562
CODE: (E-2) 565
THE ENGINE DOES NOT SHUT DOWN 565
CODE: (E-3) 567
COLD START PREHEATER DOES NOT WORK PROPERLY 567
CODE: (E-4) 570
PARKING BRAKE DOES NOT FUNCTION PROPERLY 570
CODE: (E-5) 573
EMERGENCY BRAKE SYSTEM DOES NOT FUNCTION 573
CODE: (E-6) 574
BOOM KICK-OUT FUNCTION NOT WORKING PROPERLY 574
CODE: (E-7) 577
BUCKET LEVER FUNCTION NOT WORKING PROPERLY 577
CODE: (E-8) 580
FLOAT HOLD FUNCTION NOT WORKING PROPERLY 580
CODE: (E-9) 583
FRONT WINDSHIELD WIPER DOES NOT WORK 583
CODE: (E-9) 587
REAR WINDSHIELD WIPER DOES NOT WORK 587
CODE: (E-10) 589
THE WINDOW WASHER DOES NOT WORK 589
CODE: (E-11) 591
HEADLAMPS (LO AND HIGH BEAM) DOES NOT FUNCTION 591
CODE: (E-11) 594
HEADLAMPS (LO BEAM) DO NOT FUNCTION 594
CODE: (E-11) 597
HEADLAMPS (HI BEAM) DO NOT FUNCTION 597
CODE: (E-11) 600
CLEARANCE LAMPS DO NOT FUNCTION 600
CODE: [E-11] 603
TURN SIGNALS DO NOT FUNCTION 603
CODE: (E-11) 606
WORK LAMPS DO NOT FUNCTION 606
CODE: (E-12) 609
HORN DOES NOT SOUND 609
CODE: (E-13) 611
AIR CONDITIONER SYSTEM DOES NOT WORK 611
CODE: (E-13) 614
AIR DOES NOT FLOW FROM SYSTEM AND CANNOT BE ADJUSTED 614
CODE: (E-13) 618
AIR DOES NOT COOL OR TEMPERATURE CANNOT BE ADJUSTED 618
CODE: (E-13) 622
CANNOT SWITCH BETWEEN CIRCULATED AND VENT FUNCTIONS 622
CODE: (E-13) 624
CANNOT SWITCH VENT FUNCTIONS 624
20-601 TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE) 627
METHOD OF USING TROUBLESHOOTING CHART 629
FAILURE CODE AND CAUSE TABLE 632
CODE: (H-1) 635
THE MACHINE DOES NOT START 635
CODE: (H-2) 636
THE TRAVEL SPEED IS SLOW 636
CODE: (H-3) 637
THE THRUST FORCE IS WEAK 637
CODE: (H-4) 638
ENGINE STALLS OR ENGINE SPEED DROPS EXCESSIVELY 638
CODE: (H-5) 639
THE GEARS DO NOT CHANGE SPEED RANGE 639
CODE: (H-6) 640
THE STEERING WHEEL DOES NOT TURN 640
CODE: (H-7) 641
STEERING WHEEL MOVEMENT IS HEAVY 641
CODE: (H-8) 642
STEERING WHEEL SHAKES OR HAS JERKY MOVEMENT 642
CODE: (H-9) 643
BRAKES DO NOT WORK OR WORKS POORLY 643
CODE: (H-10) 644
BRAKES IS NOT RELEASING OR DRAGGED 644
CODE: (H-11) 645
THE PARKING BRAKE IS NOT WORK 645
CODE: (H-12) 646
THE LIFT ARM DOES NOT RISE OR LOWER 646
CODE: (H-13) 647
LIFT ARM MOVES SLOW OR RISING FORCE IS POOR 647
CODE: (H-14) 648
WHEN RISING LIFT ARM, ARM MOVES SLOWLY AT SPECIFIC HEIGHTS 648
CODE: (H-15) 648
THE LIFT ARM CYLINDER WILL NOT HOLD DOWN THE BUCKET (THE BUCKET RISES) 648
CODE: (H-16) 648
HYDRAULIC DRIFT ON THE LIFT ARM OCCURS OFTEN 648
CODE: (H-17) 648
THE LIFT ARM WOBBLES DURING OPERATION 648
CODE: (H-18) 649
WHEN THE CONTROL LEVER IS SWITCHED FROM “HOLD” TO “RAISE,” THE LIFT ARM FALLS TEMPORARILY 649
CODE: (H-19) 650
THE BUCKET DOES NOT TILT BACK 650
CODE: (H-20) 651
BUCKET MOVES SLOW OR THE TILTING-BACK FORCE IS INSUFFICIENT 651
CODE: (H-21) 652
THE BUCKET OPERATES SLOWLY IN TILTING-BACK 652
CODE: (H-22) 652
BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET 652
CODE: (H-23) 652
HYDRAULIC DRIFTS OF THE BUCKET OCCURS OFTEN 652
CODE: (H-24) 652
THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVE IS SET TO “HOLD”) 652
CODE: (H-25) 653
WHEN THE CONTROL LEVER IS SWITCHED FROM “HOLD” TO “TILT,” THE BUCKET FALLS TEMPORARILY 653
CODE: (H-26) 653
CONTROL LEVERS FOR THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY 653
20-701 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 655
METHOD OF USING TROUBLESHOOTING CHARTS 656
(S-1) ENGINE STARTING PERFORMANCE IS POOR 660
(S-2) ENGINE HAS STARTING PROBLEMS 662
ENGINE DOES NOT CRANK 662
ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT OF STACK 663
SMOKE COMES OUT OF STACK BUT ENGINE DOES NOT START 664
(S-3) ENGINE DOES NOT RUN SMOOTHLY 665
(S-4) ENGINE STOPS DURING OPERATIONS 666
(S-5) ENGINE SPEED HUNTS 667
(S-6) ENGINE LACKS POWER 668
(S-7) EXHAUST SMOKE IS BLACK 669
(S-8) OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE 670
(S-9) OIL BECOMES CONTAMINATED QUICKLY 671
(S-10) FUEL CONSUMPTION IS EXCESSIVE 672
(S-11) OIL FOUND IN COOLANT, OR COOLANT SPURTS FROM RADIATOR 673
(S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP 674
(S-13) OIL LEVEL RISES (COOLANT OR FUEL FOUND IN OIL) 675
(S-14) COOLANT TEMPERATURE TOO HIGH (OVERHEATING) 676
(S-15) ABNORMAL NOISE IS HEARD WHEN ENGINE IS RUNNUNG 677
(S-16) EXCESSIVE VIBRATION WHEN ENGINE IS RUNNING 678
20-901 TROUBLESHOOTING AIR CONDITIONING 679
AIR CONDITIONING SYSTEM 681
ENVIRONMENTAL IMPACT 681
OPERATOR CAB AIR CONDITIONING 682
PRINCIPLES OF REFRIGERATION 682
AIR CONDITIONING 682
THE ACT OF COOLING 682
THE REFRIGERATION CYCLE 683
AIR CONDITIONER SYSTEM COMPONENTS 683
COMPRESSOR (REFRIGERANT PUMP) 683
SERVICE VALVES 684
CONDENSER 684
RECEIVER-DRIER 684
THERMOSTATIC EXPANSION VALVE 684
EVAPORATOR 685
ELECTRICAL CIRCUIT 685
THERMOSTAT 686
COMPRESSOR CLUTCH 686
SAFETY SWITCHES 686
SYSTEM SERVICING 687
R-134A REFRIGERANT CONTAINERS 688
SERVICE TOOLS AND EQUIPMENT 688
RECOVERY/RECYCLE STATION 688
LEAK DETECTOR 689
SERVICE VALVES 689
VACUUM PUMP 689
MANIFOLD GAUGE SET 690
INSTALLING MANIFOLD GAUGE SET 691
PURGING AIR FROM SERVICE HOSES 692
ADDING REFRIGERANT TO THE SYSTEM (WITHOUT A CHARGING STATION) 693
STABILIZING THE AC SYSTEM 693
ADDING REFRIGERANT AND STABILIZING THE SYSTEM (WITH A RECOVERY/RECYCLING STATION) 694
RECOVERING AND RECYCLING THE REFRIGERANT 694
PERFORMING THE RECOVERY CYCLE 694
PERFORMING THE RECYCLING PROCEDURE 695
EVACUATING AND CHARGING THE AC SYSTEM 695
SYSTEM PERFORMANCE TEST 696
SYSTEM LEAK TESTING 696
ELECTRONIC LEAK DETECTOR 697
TRACER DYES 697
SOAP AND WATER 697
SYSTEM REPAIR 698
HOSES AND FITTINGS 698
LINES 698
EXPANSION VALVE 698
RECEIVER-DRIER 698
THERMOSTAT 698
CLUTCH 699
COMPRESSOR 699
CHECKING COMPRESSOR OIL LEVEL 699
EVACUATING THE SYSTEM 700
TROUBLESHOOTING – AIR CONDITIONING SYSTEM 701
PRE-DIAGNOSIS CHECKS 701
PREPARING FOR DIAGNOSIS 701
PRELIMINARY STEPS 701
SYSTEM PERFORMANCE TEST 701
DIAGNOSIS OF GAUGE READINGS & SYSTEM PERFORMANCE 702
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 703
DEFECTIVE GROUND ON REFRIGERANT COMPRESSOR 707
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 708
30 DISASSEMBLY AND ASSEMBLY 711
HOW TO USE THIS MANUAL 716
REMOVAL AND INSTALLATION OF COMPONANTS 716
SPECIAL TOOLS 716
OVERHAUL OF COMPONANTS 717
SPECIAL TOOLS 717
DISASSEMBLY 717
ASSEMBLY 717
PRECAUTIONS WHEN PERFORMING AN OPERATION 718
SPECIAL TOOL LIST 720
SKETCHES OF SPECIAL TOOLS 723
CONNECTOR REPAIR PROCEDURES 729
CONTACT TERMINAL REMOVAL (HD30 TYPE) 729
STRIPING INSULATION 730
CRIMPING CONTACT TERMINAL (HD30 TYPE) 731
INSERTION OF CONTACT TERMINAL (HD30 TYPE) 732
CONTACT TERMINAL REMOVAL (DT TYPE) 733
STRIPING INSULATION 734
CRIMPING CONTACT TERMINAL (DT TYPE) 735
INSERTION OF CONTACT TERMINAL (DT TYPE) 736
FUEL INJECTION PUMP ASSEMBLY 738
SPECIAL TOOLS 738
REMOVAL 738
INSTALLATION 742
NOZZLE HOLDER ASSEMBLY 744
SPECIAL TOOLS 744
REMOVAL 744
INSTALLATION 745
CYLINDER HEAD ASSEMBLY 746
SPECIAL TOOLS 746
REMOVAL 746
INSTALLATION 753
ENGINE ASSEMBLY 757
REMOVAL 757
INSTALLATION 764
RADIATOR ASSEMBLY 766
REMOVAL 766
INSTALLATION 767
AIR AFTERCOOLER 768
REMOVAL 768
INSTALLATION 769
HYDRAULIC OIL COOLER 770
REMOVAL 770
INSTALLATION 771
COOLING FAN AND FAN MOTOR 772
REMOVAL 772
INSTALLATION 773
FUEL TANK 774
REMOVAL 774
INSTALLATION 775
TRANSFER 776
REMOVAL 776
INSTALLATION 779
TRANSFER ASSEMBLY 780
SPECIAL TOOLS 780
DISASSEMBLY 780
ASSEMBLY 792
PARKING BRAKE ASSEMBLY 806
REMOVAL 806
INSTALLATION 807
DISASSEMBLY 808
SPECIAL TOOLS 808
ASSEMBLY 811
FRONT AXLE ASSEMBLY 815
REMOVAL 815
INSTALLATION 817
REAR AXLE ASSEMBLY 818
REMOVAL 818
INSTALLATION 821
AXLE HOUSING ASSEMBLY 822
SPECIAL TOOLS 822
DISASSEMBLY 822
ASSEMBLY 827
DIFFERENTIAL ASSEMBLY 833
SPECIAL TOOLS 833
DISASSEMBLY 833
ASSEMBLY 846
HST PUMP AND 4-GEAR PUMP ASSEMBLY 866
REMOVAL 866
INSTALLATION 869
HST PUMP ASSEMBLY 870
DISASSEMBLY 870
ASSEMBLY 882
HST MOTOR 1 ASSEMBLY 904
REMOVAL 904
INSTALLATION 905
HST MOTOR 2 ASSEMBLY 906
REMOVAL 906
INSTALLATION 907
HST MOTOR ASSEMBLY 908
DISASSEMBLY 908
ASSEMBLY 919
WORK EQUIPMENT CONTROL VALVE ASSEMBLY 930
REMOVAL 930
INSTALLATION 931
TRAVEL DAMPER VALVE ASSEMBLY 932
REMOVAL 932
INSTALLATION 933
HYDRAULIC TANK 934
REMOVAL 934
INSTALLATION 935
WORK EQUIPMENT ASSEMBLY (Z-BAR LINKAGE) 936
REMOVAL 936
INSTALLATION 940
BUCKET LINK PIN 940
BUCKET HINGE PIN 940
BUCKET CYLINDER PIN (ON ROD SIDE) 941
LIFT CYLINDER PIN (ON ROD SIDE) 941
LIFT ARM PIN (ON FRAME SIDE) 942
BUCKET LINK PIN 942
WORK EQUIPMENT ASSEMBLY (PARELLEL TOOL CARRIER) 944
BUCKET (TILT) CYLINDER 944
REMOVAL 944
INSTALLATION 945
BOOM (LIFT) CYLINDER 946
REMOVAL 946
INSTALLATION 947
BOOM AND PARALLEL TOOL LINKAGE 948
REMOVAL 948
INSTALLATION 956
HYDRAULIC CYLINDER ASSEMBLY 959
SPECIAL TOOLS 959
DISASSEMBLY 960
ASSEMBLY 964
OPERATOR’S CAB ASSEMBLY 969
REMOVAL 969
INSTALLATION 974
OPERATOR’S CAB GLASS 975
SPECIAL TOOLS 975
REMOVAL 975
INSTALLATION 976
COATING MATERIALS 983
CENTER HINGE PIN 984
REMOVAL 984
INSTALLATION 990
COUNTERWEIGHT 996
REMOVAL 996
INSTALLATION 997
AIR CONDITIONER UNIT ASSEMBLY 998
SPECIAL TOOLS 998
REMOVAL 998
INSTALLATION 1001
AIR CONDITIONER COMPRESSOR ASSEMBLY 1002
SPECIAL TOOLS 1002
REMOVAL 1002
INSTALLATION 1003
MONITOR PANEL 1004
REMOVAL 1004
INSTALLATION 1008
KOMTRAX TERMINAL ASSEMBLY 1009
REMOVAL 1009
INSTALLATION 1010
90 SCHEMATICS AND DIAGRAMS 1011
HYDRAULIC CIRCUIT DIAGRAM 1012
WA250-5L 1012
SHEET 1 OF 2 1012
SHEET 2 OF 2 1013
WA250PT-5L 1014
SHEET 1 OF 2 1014
SHEET 2 OF 2 1015
ELECTRICAL CIRCUIT DIAGRAM 1016
MAIN FLOOR HARNESS 1016
HST HARNESS 1023
ENGINE HARNESS AND REAR HARNESS 1024
CAB HARNESS 1025
FRONT HARNESS 1026
REVERSE FAN WIRING DIAGRAM 1027

S.V 15/12/24