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Komatsu WA250-6, WA250PZ-6 Wheel Loader Shop Manual SEN03813-03 – PDF DOWNLOAD
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Komatsu WA250-6, WA250PZ-6 Wheel Loader Shop Manual
SERIAL NUMBERS:
- WA250- 75001 and up
- WA250PZ-75001 and up
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Description
Komatsu WA250-6, WA250PZ-6 Wheel Loader Shop Manual SEN03813-03
FILE DETAILS:
Komatsu WA250-6, WA250PZ-6 Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA250-6, WA250PZ-6
Serial Number: 75001 and up
Book Code: SEN03813-03
Language: English
Pages: 1293
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA250-6, WA250PZ-6 Wheel Loader Shop Manual
HOW TO READ THE SHOP MANUAL:
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. FOREWORD:
This section explains the safety and basic information.
01. GENERAL:
This section explains the specifications of the machine.
10. STRUCTURE AND FUNCTION, MAINTENANCE STANDARD:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. TESTING AND ADJUSTING:
Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in
the Chassis volume and Engine volume. In this case, see the Chassis volume.
30. DISASSEMBLY AND ASSEMBLY:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. OTHERS (chassis volume)/Repair and replacement of parts (engine volume):
• Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
• Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu WA250-6, WA250PZ-6 Wheel Loader Shop Manual
COVER ................................................................................................................................ 1 00 Index and foreword................................................................................................................. 0 100 Index......................................................................................................................... 2 Composition of shop manual.................................................................................................... 3 Table of contents............................................................................................................. 5 200 Foreword and general information.............................................................................................. 16 Safety notice................................................................................................................. 17 How to read the shop manual................................................................................................... 22 Explanation of terms for maintenance standard................................................................................. 24 Handling of electric equipment and hydraulic component........................................................................ 26 Handling of connectors newly used for engines................................................................................. 35 How to read electric wire code................................................................................................ 38 Precautions when carrying out operation....................................................................................... 41 Method of disassembling and connecting push-pull type coupler................................................................. 44 Standard tightening torque table.............................................................................................. 47 Conversion table.............................................................................................................. 51 01 Specification...................................................................................................................... 0 100 Specification and technical data.............................................................................................. 58 Specification dimension drawing............................................................................................... 60 Specifications................................................................................................................ 61 Weight table.................................................................................................................. 65 Table of fuel, coolant and lubricants......................................................................................... 67 10 Structure, function and maintenance standard....................................................................................... 0 100 Engine and cooling system..................................................................................................... 70 Engine mount and transfer mount............................................................................................... 71 Damper........................................................................................................................ 72 Cooling system................................................................................................................ 73 Cooling system hydraulic piping diagram....................................................................................... 74 Cooling fan motor............................................................................................................. 76 200 Power train................................................................................................................... 86 Power train................................................................................................................... 88 Power train system diagram.................................................................................................... 89 Drive shaft................................................................................................................... 91 HST hydraulic piping diagram.................................................................................................. 92 HST pump...................................................................................................................... 93 HST motor..................................................................................................................... 101 Transfer...................................................................................................................... 107 Clutch solenoid valve......................................................................................................... 118 Axle.......................................................................................................................... 119 Differential.................................................................................................................. 121 Torque proportioning differential............................................................................................. 126 Limited slip differential..................................................................................................... 129 Final drive................................................................................................................... 133 300 Steering system............................................................................................................... 140 Steering piping diagram....................................................................................................... 142 Steering column............................................................................................................... 143 Priority valve................................................................................................................ 144 Orbit-roll valve.............................................................................................................. 147 2-way restrictor valve........................................................................................................ 155 Cushion valve................................................................................................................. 156 Steering cylinder............................................................................................................. 157 Emergency steering piping diagram............................................................................................. 159 Emergency steering valve...................................................................................................... 160 Steering relief valve......................................................................................................... 163 400 Brake system.................................................................................................................. 166 Brake piping diagram.......................................................................................................... 168 Charge valve.................................................................................................................. 169 Brake valve................................................................................................................... 173 Inching valve................................................................................................................. 177 Accumulator (for brake)....................................................................................................... 178 Slack adjuster................................................................................................................ 179 Brake......................................................................................................................... 181 Parking brake control......................................................................................................... 186 Parking brake................................................................................................................. 187 500 Undercarriage and frame....................................................................................................... 190 Axle mount and center hinge pin............................................................................................... 191 Tires......................................................................................................................... 196 600 Hydraulic system.............................................................................................................. 198 Work equipment hydraulic piping diagram....................................................................................... 199 Work equipment control lever linkage.......................................................................................... 203 Hydraulic tank................................................................................................................ 207 4-gear pump................................................................................................................... 209 Work equipment control valve.................................................................................................. 211 PPC valve..................................................................................................................... 236 Lock valve.................................................................................................................... 251 Accumulator (for PPC circuit)................................................................................................. 252 Bypass valve.................................................................................................................. 253 Quick coupler solenoid valve.................................................................................................. 256 ECSS valve.................................................................................................................... 257 Accumulator (for ECSS)........................................................................................................ 259 700 Work equipment................................................................................................................ 262 Work equipment linkage........................................................................................................ 263 Bucket........................................................................................................................ 267 Bucket positioner and boom kick-out........................................................................................... 271 Work equipment cylinder....................................................................................................... 284 800 Cab and its attachments....................................................................................................... 288 Cab........................................................................................................................... 290 Air conditioner............................................................................................................... 291 910 Electrical system, Part 1..................................................................................................... 304 Machine monitor system........................................................................................................ 305 Machine monitor............................................................................................................... 309 920 Electrical system, Part 2..................................................................................................... 332 Electrical system (HST controller system)..................................................................................... 333 HST controller................................................................................................................ 349 ECSS system................................................................................................................... 351 KOMTRAX system................................................................................................................ 353 Engine starting circuit....................................................................................................... 355 Engine stopping circuit....................................................................................................... 357 Preheating circuit............................................................................................................ 358 Engine output derating function............................................................................................... 359 Automatic warm-up function.................................................................................................... 359 Parking brake circuit......................................................................................................... 360 Coupler plunger control system................................................................................................ 363 Multi-function knob........................................................................................................... 364 Max. traction switch.......................................................................................................... 365 Sensor........................................................................................................................ 366 20 Standard value table............................................................................................................... 0 100 Standard service value table.................................................................................................. 374 Standard service value table.................................................................................................. 375 Standard service value table for chassis...................................................................................... 376 30 Testing and adjusting.............................................................................................................. 0 110 Testing and adjusting, Part 1................................................................................................. 384 Tools for testing, adjusting, and troubleshooting............................................................................. 387 Sketches of special tools..................................................................................................... 392 Measuring engine speed........................................................................................................ 393 Measuring exhaust gas color................................................................................................... 395 Adjusting valve clearance..................................................................................................... 397 Measuring compression pressure................................................................................................ 399 Measuring blow-by pressure.................................................................................................... 402 Measuring engine oil pressure................................................................................................. 403 Measuring intake air (boost) pressure......................................................................................... 404 Handling fuel system equipment................................................................................................ 406 Releasing residual pressure in fuel system.................................................................................... 406 Measuring fuel pressure....................................................................................................... 407 Measuring fuel return rate and leakage........................................................................................ 409 Bleeding air from fuel circuit................................................................................................ 413 Testing leakage in fuel system................................................................................................ 414 Handling reduced cylinder mode operation...................................................................................... 415 Handling no-injection cranking operation...................................................................................... 415 Handling controller voltage circuit........................................................................................... 416 Check of muffler and muffler stack for looseness and damage................................................................... 416 Check of muffler function..................................................................................................... 417 Check of installed condition of cylinder head and manifolds................................................................... 417 Check of engine piping for damage and looseness............................................................................... 418 Testing and adjusting air conditioner compressor belt tension................................................................. 418 Replacing alternator belt..................................................................................................... 419 120 Testing and adjusting, Part 2................................................................................................. 422 Checking operating force of accelerator pedal................................................................................. 424 Checking directional lever.................................................................................................... 425 Testing and adjusting HST oil pressure........................................................................................ 426 Testing clutch control pressure............................................................................................... 430 Testing and adjusting steering wheel.......................................................................................... 431 Testing and adjusting steering oil pressure................................................................................... 433 Bleeding air from steering circuit............................................................................................ 435 Testing hydraulic fan......................................................................................................... 436 Measuring brake pedal......................................................................................................... 438 Testing and adjusting brake pedal linkage..................................................................................... 439 Measuring brake performance................................................................................................... 440 Testing and adjusting accumulator charge pressure............................................................................. 441 Testing wheel brake oil pressure.............................................................................................. 443 Testing wear of brake disc.................................................................................................... 446 Bleeding air from wheel brake circuit......................................................................................... 447 Releasing residual pressure in brake accumulator circuit...................................................................... 448 Testing parking brake performance............................................................................................. 449 Testing and adjusting parking brake control cable............................................................................. 450 Measuring and adjusting work equipment control lever.......................................................................... 451 Testing and adjusting work equipment hydraulic pressure....................................................................... 452 Testing work equipment PPC oil pressure....................................................................................... 453 Bleeding air from hydraulic circuit........................................................................................... 455 Releasing remaining pressure in hydraulic circuit............................................................................. 456 Testing and adjusting bucket positioner....................................................................................... 457 Testing and adjusting of boom kick-out switch................................................................................. 458 Checking proximity switch operation pilot lamp................................................................................ 459 Procedure for testing diodes.................................................................................................. 460 Preparation work for troubleshooting for electric system...................................................................... 462 Starting KOMTRAX terminal operations.......................................................................................... 466 Indicator lamps of KOMTRAX terminal........................................................................................... 470 130 Testing and adjusting, Part 3................................................................................................. 474 Adjusting machine monitor..................................................................................................... 475 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor........................................ 476 Special functions of machine monitor (EMMS)................................................................................... 478 Pm clinic inspection chart.................................................................................................... 532 40 Troubleshooting.................................................................................................................... 0 100 Failure code table and fuse locations......................................................................................... 536 Failure codes table........................................................................................................... 537 Fuse locations................................................................................................................ 543 200 General information on troubleshooting........................................................................................ 548 Points to remember when troubleshooting....................................................................................... 549 Sequence of events in troubleshooting......................................................................................... 550 Testing before troubleshooting................................................................................................ 551 Classification and procedures of troubleshooting.............................................................................. 552 Information contained in troubleshooting table................................................................................ 555 Connection table for connector pin numbers.................................................................................... 557 T- branch box and T- branch adapter table..................................................................................... 593 310 Troubleshooting by failure code (Display of code), Part 1..................................................................... 598 Failure code [2G40GZ] Brake: Oil pressure reduction........................................................................... 599 Failure code [6091NX] HST filter: Clogging.................................................................................... 601 Failure code [989FN1] Travel speed: Overrun alarm............................................................................. 603 Failure code [AB00L6] Alternator R system: Hot short.......................................................................... 605 Failure code [AB00MA] Alternator R system: Ground fault/Disconnection charge/Low charge voltage............................... 607 Failure code [B@BAZG] Engine: Oil pressure reduction.......................................................................... 609 Failure code [B@BCNS] Engine: Overheat........................................................................................ 610 Failure code [B@BCZK] Engine: Low coolant level............................................................................... 611 Failure code [B@C6NS] Front brake: High oil temperature....................................................................... 613 Failure code [B@CRNS] HST: High oil temperature............................................................................... 614 320 Troubleshooting by failure code (Display of code), Part 2..................................................................... 616 Failure code [CA111] Abnormality in engine controller......................................................................... 618 Failure code [CA115] Engine Ne or Bkup speed sensor error..................................................................... 619 Failure code [CA122] Charge pressure sensor high error........................................................................ 621 Failure code [CA123] Charge pressure sensor low error......................................................................... 623 Failure code [CA131] Throttle sensor high error............................................................................... 625 Failure code [CA132] Throttle sensor low error................................................................................ 627 Failure code [CA144] Coolant sensor high error................................................................................ 629 Failure code [CA145] Coolant sensor low error................................................................................. 631 Failure code [CA153] Charge temperature sensor high error..................................................................... 633 Failure code [CA154] Charge temperature sensor low error...................................................................... 635 Failure code [CA155] Derating of speed by abnormally high charge temperature.................................................. 637 Failure code [CA187] Sensor power supply 2 low error.......................................................................... 639 Failure code [CA221] Atmospheric pressure sensor high error................................................................... 641 Failure code [CA222] Atmospheric sensor low error............................................................................. 643 Failure code [CA227] Sensor power supply 2 high error......................................................................... 645 Failure code [CA234] Engine overspeed......................................................................................... 646 Failure code [CA238] Ne speed sensor power supply error....................................................................... 647 Failure code [CA271] IMV (IMA) Short circuit.................................................................................. 648 Failure code [CA272] IMV (IMA) Disconnection.................................................................................. 649 Failure code [CA322] Injector #1 open/short error............................................................................. 651 Failure code [CA323] Injector #5 open/short error............................................................................. 653 Failure code [CA324] Injector #3 open/short error............................................................................. 655 Failure code [CA325] Injector #6 open/short error............................................................................. 657 Failure code [CA331] Injector #2 open/short error............................................................................. 659 Failure code [CA332] Injector #4 open/short error............................................................................. 661 Failure code [CA342] Calibration code inconsistency........................................................................... 663 Failure code [CA351] Injectors drive circuit error............................................................................ 665 Failure code [CA352] Sensor power supply 1 low error.......................................................................... 667 Failure code [CA386] Sensor power supply 1 high error......................................................................... 669 330 Troubleshooting by failure code (Display of code), Part 3..................................................................... 672 Failure code [CA428] Abnormally high level in water sensor.................................................................... 675 Failure code [CA429] Abnormally low level in water sensor..................................................................... 677 Failure code [CA431] Idle validation switch error............................................................................. 679 Failure code [CA432] Idle validation action error............................................................................. 683 Failure code [CA435] Engine oil pressure switch error......................................................................... 687 Failure code [CA441] Battery voltage low error................................................................................ 688 Failure code [CA442] Battery voltage high error............................................................................... 691 Failure code [CA449] Common rail pressure high error 2........................................................................ 693 Failure code [CA451] Common rail pressure sensor high error................................................................... 695 Failure code [CA452] Common rail pressure sensor low error.................................................................... 697 Failure code [CA488] Derating of torque by abnormally high charge temperature................................................. 699 Failure code [CA553] Common rail pressure high error 1........................................................................ 700 Failure code [CA559] Supply pump pressure very low error...................................................................... 701 Failure code [CA689] Engine Ne speed sensor error............................................................................. 703 Failure code [CA731] Engine Bkup speed sensor phase error..................................................................... 705 Failure code [CA757] All continuous data lost error........................................................................... 706 Failure code [CA778] Engine Bkup speed sensor error........................................................................... 709 Failure code [CA1633] KOMNET datalink timeout error........................................................................... 711 Failure code [CA2185] Throttle sensor supply voltage high error............................................................... 715 Failure code [CA2186] Throttle sensor power supply low error.................................................................. 717 Failure code [CA2249] Supply pump pressure very low error 2................................................................... 719 Failure code [CA2311] Abnormality in IMV (IMA) solenoid....................................................................... 721 Failure code [CA2555] Intake heater relay disconnection error................................................................. 723 Failure code [CA2556] Intake heater relay short circuit error................................................................. 725 340 Troubleshooting by failure code (Display of code), Part 4..................................................................... 728 Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short............................................................ 729 Failure code [D192KY] ECSS solenoid relay: Hot short.......................................................................... 731 Failure code [D1B0KA] HST safety relay: Disconnection......................................................................... 733 Failure code [D1B0KB] HST safety relay: Ground fault.......................................................................... 735 Failure code [D1B0KY] HST safety relay: Hot short............................................................................. 737 Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection................................................................ 739 Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection........................................................... 741 Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection........................................................... 743 Failure code [DAJ0KK] HST controller power supply: Low voltage................................................................ 747 Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality............................................................. 749 Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault.............................................. 751 Failure code [DAJ1L6] HST controller main power line: Hot short............................................................... 753 Failure code [DAJ2KK] Controller solenoid power supply: Low voltage........................................................... 755 Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness.............................. 757 Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault............................... 759 Failure code [DAJ5KX] Sensor 5V power supply: Out of output range............................................................. 761 Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals................................. 763 Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection............................................................ 764 Failure code [DAJRMA] HST controller: Disagreement in option selection........................................................ 770 350 Troubleshooting by failure code (Display of code), Part 5..................................................................... 772 Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line................................................. 774 Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality........................................................ 779 Failure code [DD1NLD] Fan reverse switch signal: Abnormality.................................................................. 781 Failure code [DDB6KA] Parking brake switch A: Disconnection/Hot short......................................................... 783 Failure code [DDB6KB] Parking brake switch B: Ground fault.................................................................... 785 Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble.... 787 Failure code [DDB6L0] Parking brake switch A: Ground fault.................................................................... 789 Failure code [DDB6L4] Parking brake switch B: Disconnection/Hot short......................................................... 791 Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault............................................ 793 Failure code [DDD7KY] Travel speed control dial signal: Hot short............................................................. 795 Failure code [DDE5MA] Emergency steering operation switch: Disconnection...................................................... 797 Failure code [DDK3KA] Directional selector switch: Disconnection/Hot short.................................................... 799 Failure code [DDK3KB] Directional selector switch: Ground fault............................................................... 801 Failure code [DDK6KA] FNR lever: Disconnection/Ground fault................................................................... 803 Failure code [DDK6KY] FNR lever: Hot short.................................................................................... 807 Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering)............................................ 809 360 Troubleshooting by failure code (Display of code), Part 6..................................................................... 812 Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault.......................................... 814 Failure code [DF10KB] Travel speed range selector switch: Hot short........................................................... 817 Failure code [DGH1KX] HST oil temperature sensor: Ground fault................................................................ 819 Failure code [DGR2KB] Brake oil temperature sensor: Ground fault.............................................................. 820 Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short................................................... 821 Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault..................................................... 823 Failure code [DHH1KY] HST oil pressure sensor: Hot short...................................................................... 825 Failure code [DHTCL6] HST filter clogging sensor: Functional defect........................................................... 827 Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short.............................................................. 829 Failure code [DLT3KX] Travel speed sensor B: Abnormality...................................................................... 831 Failure code [DLT4KX] Travel speed sensor A: Abnormality...................................................................... 835 Failure code [DLT4LC] Travel speed sensor A & B: Abnormality.................................................................. 837 Failure code [DV00KY] Alarm buzzer: Hot short................................................................................. 839 Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault............................................................ 841 Failure code [DW26KY] Motor 2 solenoid: Hot short............................................................................. 843 Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short................................................................. 845 Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault................................................ 847 370 Troubleshooting by failure code (Display of code), Part 7..................................................................... 850 Failure code [DX16KA] Fan EPC solenoid: Disconnection......................................................................... 851 Failure code [DX16KB] Fan EPC solenoid: Ground fault.......................................................................... 852 Failure code [DX16KY] Fan EPC solenoid: Hot short............................................................................. 853 Failure code [DX19KA] Motor 1 solenoid: Disconnection......................................................................... 855 Failure code [DX19KB] Motor 1 solenoid: Ground fault.......................................................................... 857 Failure code [DX19KY] Motor 1 solenoid: Hot short............................................................................. 859 Failure code [DX20KA] Clutch EPC solenoid: Disconnection...................................................................... 861 Failure code [DX20KB] Clutch EPC solenoid: Ground fault....................................................................... 863 Failure code [DX20KY] Clutch EPC solenoid: Hot short.......................................................................... 865 Failure code [DXH7KB] Reverse solenoid: Ground fault.......................................................................... 867 Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short............................................................... 869 Failure code [DXH8KB] Forward solenoid: Ground fault.......................................................................... 871 Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short............................................................... 873 Failure code [J141N1] Steering pump: Overrun alarm............................................................................ 875 Failure code [M100N1] HST pump: Overrun alarm................................................................................. 875 Failure code [M400N1] Motor 1: Overrun alarm.................................................................................. 876 400 Troubleshooting of electrical system (E-mode)................................................................................. 878 E-1 Engine does not start..................................................................................................... 880 E-2. Preheater does not operate normally...................................................................................... 887 E-3 Defective boom kick-out function and cancellation......................................................................... 891 E-4 Defective bucket positioner function and cancellation..................................................................... 895 E-5 Defective lift arm FLOATING holding function and cancellation............................................................. 899 E-6 Travel direction selection system does not function....................................................................... 903 E-7 Wiper does not operate.................................................................................................... 907 E-8 Windshield washer does not operate........................................................................................ 911 E-9 Headlamp, clearance lamp and tail lamp do not light up or go off.......................................................... 915 E-10 Working lamp does not light up or go off................................................................................. 923 E-11 Turn signal lamp and hazard lamp do not light up or go off............................................................... 928 E-12 Brake lamp does not light or it keeps lighting up........................................................................ 935 E-13 Backup lamp does not light or it keeps lighting up....................................................................... 937 E-14 Backup alarm does not sound or it keeps sounding......................................................................... 940 E-15 Horn does not sound or it keeps sounding................................................................................. 943 E-16 Alarm buzzer does not sound or it keeps sounding......................................................................... 945 E-17 Air conditioner does not operate or stop................................................................................. 947 E-18 The KOMTRAX system does not work properly................................................................................ 950 500 Troubleshooting of hydraulic and mechanical system (H-mode)................................................................... 954 Method of using troubleshooting chart......................................................................................... 956 Failure code and cause table.................................................................................................. 959 H-1 The machine does not start................................................................................................ 961 H-2 The travel speed is slow.................................................................................................. 962 H-3 The traction force is weak................................................................................................ 963 H-4 Engine stalls when traveling or engine speed drops excessively............................................................ 964 H-5 The gear is not shifted................................................................................................... 965 H-6 The steering wheel does not turn.......................................................................................... 966 H-7 The steering wheel is heavy............................................................................................... 967 H-8 Steering wheel shakes or jerks............................................................................................ 968 H-9 Machine deviates naturally to one side when traveling..................................................................... 968 H-10 The brake does not work or does not work well............................................................................ 969 H-11 The brake is not released or is dragged.................................................................................. 970 H-12 The lift arm does not rise or lower...................................................................................... 971 H-13 The lift arm moves slowly or the lift arm rising force is insufficient................................................... 972 H-14 When rising, the lift arm comes to move slowly at specific height........................................................ 973 H-15 The lift arm cylinder cannot hold down the bucket (The bucket............................................................ 973 H-16 Hydraulic drifts of the lift arm occur often............................................................................. 973 H-17 The lift arm wobbles during operation.................................................................................... 973 H-18 When the control lever is switched from "HOLD" to "RAISE," the lift arm falls temporarily................................ 974 H-19 The bucket does not tilt back............................................................................................ 975 H-20 The bucket moves slowly or the tilting-back force is insufficient........................................................ 976 H-21 The bucket comes to operate slowly in the midst of tilting-back.......................................................... 977 H-22 The bucket cylinder cannot hold down the bucket.......................................................................... 977 H-23 Hydraulic drifts of the bucket occur often............................................................................... 977 H-24 The bucket wobbles during travel with load (The work equipment valve is set to "HOLD")................................... 977 H-25 When the control lever is switched from "HOLD" to "TILT," the bucket falls temporarily................................... 978 H-26 The control levers of the lift arm and bucket do not move smoothly and heavy............................................. 978 H-27 The ECSS does not operate and machine pitches and bounces................................................................ 979 H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)................................. 980 600 Troubleshooting of engine (S-mode)............................................................................................ 982 Method of using troubleshooting charts........................................................................................ 983 S-1 Starting performance is poor.............................................................................................. 987 S-2 Engine does not start..................................................................................................... 988 S-3 Engine does not pick up smoothly.......................................................................................... 991 S-4 Engine stops during operations............................................................................................ 992 S-5 Engine does not rotate smoothly........................................................................................... 993 S-6 Engine lacks output (or lacks power)...................................................................................... 994 S-7 Exhaust smoke is black (incomplete combustion)............................................................................ 995 S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................................... 996 S-9 Oil becomes contaminated quickly.......................................................................................... 997 S-10 Fuel consumption is excessive............................................................................................ 998 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).................................................... 999 S-12 Oil pressure drops.......................................................................................................1000 S-13 Oil level rises (Entry of coolant or fuel)...............................................................................1001 S-14 Coolant temperature becomes too high (overheating).......................................................................1002 S-15 Abnormal noise is made...................................................................................................1003 S-16 Vibration is excessive...................................................................................................1004 50 Disassembly and assembly........................................................................................................... 0 100 General information on disassembly and assembly...............................................................................1006 How to read this manual.......................................................................................................1007 Coating materials list........................................................................................................1009 Special tool list.............................................................................................................1012 Sketches of special tools.....................................................................................................1016 200 Engine and cooling system.....................................................................................................1026 Removal and installation of fuel supply pump assembly.........................................................................1027 Removal and installation of fuel injector assembly............................................................................1029 Removal and installation of cylinder head assembly............................................................................1036 Removal and installation of engine hood assembly..............................................................................1049 Removal and installation of radiator..........................................................................................1052 Removal and installation of air aftercooler...................................................................................1055 Removal and installation of hydraulic oil cooler assembly.....................................................................1057 Removal and installation of engine assembly...................................................................................1059 Removal and installation of engine front oil seal assembly....................................................................1065 Removal and installation of engine rear oil seal assembly.....................................................................1068 Removal and installation of cooling fan and fan motor assembly................................................................1071 Removal and installation of fuel tank assembly................................................................................1074 310 Power train, Part 1...........................................................................................................1078 Removal and installation of transfer assembly.................................................................................1079 Disassembly and assembly of transfer assembly.................................................................................1083 Removal and installation of parking brake assembly............................................................................1103 Disassembly and assembly of parking brake assembly............................................................................1105 320 Power train, Part 2...........................................................................................................1112 Removal and installation of front axle assembly...............................................................................1113 Removal and installation of rear axle assembly................................................................................1115 Disassembly and assembly of axle housing assembly.............................................................................1118 Disassembly and assembly of differential assembly.............................................................................1127 400 Undercarriage and frame.......................................................................................................1156 Removal and installation of center hinge pin..................................................................................1157 Removal and installation of counterweight.....................................................................................1167 500 Hydraulic system..............................................................................................................1170 Removal and installation of HST pump and 4-gear pump assembly.................................................................1171 Disassembly and assembly of HST pump assembly.................................................................................1175 Removal and installation of HST motor 1 assembly..............................................................................1202 Removal and installation of HST motor 2 assembly..............................................................................1204 Disassembly and assembly of HST motor assembly................................................................................1206 Removal and installation of work equipment control valve assembly.............................................................1222 Removal and installation of hydraulic tank....................................................................................1224 Disassembly and assembly of hydraulic cylinder assembly.......................................................................1226 600 Work equipment................................................................................................................1234 Removal and installation of work equipment assembly...........................................................................1235 700 Cab and its attachments.......................................................................................................1244 Removal and installation ofoperator's cab and floor frame assembly............................................................1245 Removal and installation of operator's cab glass (Stuck glass)................................................................1250 Removal and installation of air conditioner unit..............................................................................1258 800 Electrical system.............................................................................................................1266 Removal and installation of monitor panel.....................................................................................1267 Removal and installation of engine controller assembly........................................................................1269 Removal and installation of HST controller assembly...........................................................................1270 Removal and installation of KOMTRAX terminal assembly.........................................................................1271 90 Diagrams and drawings.............................................................................................................. 0 100 Hydraulic diagrams and drawings...............................................................................................1274 Hydraulic circuit diagram.....................................................................................................1276 200 Electrical diagrams and drawings..............................................................................................1280 Electrical circuit diagram....................................................................................................1282 Connector list and stereogram.................................................................................................1291
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