Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Komatsu WA250-6 Wheel Loader Shop Manual A76001 and up – PDF DOWNLOAD
Original price was: $37.95.$18.95Current price is: $18.95.
Komatsu WA250-6 Wheel Loader Shop Manual A76001 and up
SERIAL NUMBERS WA250-6 A76001 and up
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Komatsu WA250-6 Wheel Loader Shop Manual A76001 and up
FILE DETAILS:
Komatsu WA250-6 Wheel Loader Shop Manual A76001 and up
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA250-6
Serial Number: A76001 and up
Book Code: CEBM000703
Language: English
Pages: 1368
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA250-6 Wheel Loader Shop Manual A76001 and up
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 judgments. 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, Function, and Maintenance Standard 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. In addition, this section gives the judgment standards when inspecting disassembled parts.
Standard Value Table
This section explains the standard values for a new machine and the judgment 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 checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.
Troubleshooting
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.
Other
This section has the foldout drawings for the machine.
TABLE OF CONTENTS:
Komatsu WA250-6 Wheel Loader Shop Manual A76001 and up
COVER.......................................................................................................................................................... 1 FOREWORD....................................................................................................................................................... 2 CONTENTS................................................................................................................................................... 2 REVISED PAGES.............................................................................................................................................. 3 SAFETY..................................................................................................................................................... 15 Safety Notice.......................................................................................................................................... 15 Important Safety Notice............................................................................................................................ 15 General Precautions................................................................................................................................ 15 Preparations for Work.............................................................................................................................. 16 Precautions During Work............................................................................................................................ 16 GENERAL.................................................................................................................................................... 17 HOW TO READ THE SHOP MANUAL................................................................................................................................ 18 Volumes................................................................................................................................................ 18 Distribution and Updating.............................................................................................................................. 18 Filing Method.......................................................................................................................................... 18 Revised Edition Mark................................................................................................................................... 18 Revisions.............................................................................................................................................. 18 Symbols................................................................................................................................................ 18 HOISTING INSTRUCTIONS...................................................................................................................................... 19 Hoisting............................................................................................................................................... 19 Making Signs........................................................................................................................................... 19 Precautions............................................................................................................................................ 19 Precautions for Sling Work......................................................................................................................... 19 Precautions for Using Mobile Crane................................................................................................................. 20 Precautions for Using Overhead Hoist Crane......................................................................................................... 20 Selecting Wire Ropes................................................................................................................................... 21 AIR CONDITIONER CIRCUITS................................................................................................................................... 22 Precautions for Handling Hoses and Tubes............................................................................................................... 22 Disconnecting Hoses and Tubes...................................................................................................................... 22 Connecting Hoses and Tubes......................................................................................................................... 22 MAINTENANCE STANDARD TERMS................................................................................................................................. 23 HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT.................................................................................................................. 25 Handling Electric Equipment............................................................................................................................ 25 Handling Wiring Harnesses and Connectors........................................................................................................... 25 Main Failures Occurring in Wiring Harness.......................................................................................................... 25 Removing, Installing, and Drying Connectors and Wiring Harnesses................................................................................... 26 Handling Controller................................................................................................................................ 30 Troubleshooting Electric Circuits.................................................................................................................. 30 Handling Hydraulic Equipment........................................................................................................................... 31 Handling Connectors Used for Engines................................................................................................................... 32 Slide Lock Type.................................................................................................................................... 32 Pull Lock Type..................................................................................................................................... 33 Push Lock Type..................................................................................................................................... 33 Turn-housing Type (Round Green Connector).......................................................................................................... 35 PRECAUTIONS FOR OPERATIONS................................................................................................................................. 36 Precautions when Carrying Out Removal Work............................................................................................................. 36 Precautions when Carrying Out Installation Work........................................................................................................ 37 Precautions when Completing the Operation.............................................................................................................. 38 PUSH-PULL COUPLER.......................................................................................................................................... 39 Type 1................................................................................................................................................. 39 Disconnection...................................................................................................................................... 39 Connection......................................................................................................................................... 39 Type 2................................................................................................................................................. 40 Disconnection...................................................................................................................................... 40 Connection......................................................................................................................................... 40 Type 3................................................................................................................................................. 41 Disconnection...................................................................................................................................... 41 Connection......................................................................................................................................... 41 COATING MATERIALS.......................................................................................................................................... 42 STANDARD TIGHTENING TORQUE................................................................................................................................. 44 Standard Tightening Tables............................................................................................................................. 44 For Bolts and Nuts................................................................................................................................. 44 For Split Flange Bolts............................................................................................................................. 45 For O-Ring Boss Piping Joints...................................................................................................................... 45 For O-Ring Boss Plugs.............................................................................................................................. 46 For Hoses (Taper-Seal Type and Face-Seal Type)..................................................................................................... 46 For Face Seal Joints............................................................................................................................... 47 For 102, 107, and 114 Engine Series (Bolts and Nuts)............................................................................................... 47 For 102, 107, and 114 Engine Series (Eye Joints)................................................................................................... 47 For 102, 107, and 114 Engine Series (Taper Screws)................................................................................................. 48 CONVERSION TABLES.......................................................................................................................................... 49 Method of Using the Conversion Table................................................................................................................... 49 01 GENERAL..................................................................................................................................................... 55 SPECIFICATIONS............................................................................................................................................. 56 Dimension Drawing...................................................................................................................................... 56 Specification Tables................................................................................................................................... 58 WEIGHT TABLE............................................................................................................................................... 62 FUEL, COOLANT, AND LUBRICANTS.............................................................................................................................. 64 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD................................................................................................................ 67 ENGINE AND COOLING SYSTEM.................................................................................................................................. 71 Engine and Transmission Mounting....................................................................................................................... 71 Torque Values...................................................................................................................................... 71 Damper................................................................................................................................................. 72 Torque Values...................................................................................................................................... 73 Outline............................................................................................................................................ 73 Cooling System......................................................................................................................................... 74 Specifications..................................................................................................................................... 74 Cooling System Hydraulic Piping Diagram................................................................................................................ 75 Outline............................................................................................................................................ 75 Cooling Fan Motor...................................................................................................................................... 76 Type: LMF16........................................................................................................................................ 76 Torque Values...................................................................................................................................... 77 Specifications..................................................................................................................................... 77 Torque Values...................................................................................................................................... 79 Hydraulic Motor.................................................................................................................................... 80 Function....................................................................................................................................... 80 Principle of Operation......................................................................................................................... 80 Suction Safety Valve............................................................................................................................... 81 Suction Function............................................................................................................................... 81 Operation...................................................................................................................................... 81 Safety Function................................................................................................................................ 82 Function....................................................................................................................................... 82 Operation...................................................................................................................................... 82 Operation of Reversible Valve...................................................................................................................... 83 Flow Control Valve (Continuously Variable Type).................................................................................................... 84 Function....................................................................................................................................... 84 Operation...................................................................................................................................... 84 POWER TRAIN SYSTEM......................................................................................................................................... 85 Drive Line Components.................................................................................................................................. 85 System Diagram......................................................................................................................................... 86 Outline............................................................................................................................................ 87 Drive Shaft............................................................................................................................................ 88 Torque Values...................................................................................................................................... 88 Outline............................................................................................................................................ 88 HST Hydraulic Piping Diagram........................................................................................................................... 89 HST Pump............................................................................................................................................... 90 Specifications..................................................................................................................................... 91 Operation.......................................................................................................................................... 92 Flow of Power.................................................................................................................................. 92 Flow of Oil.................................................................................................................................... 92 High-Pressure Relief Valve......................................................................................................................... 93 Function....................................................................................................................................... 93 Operation...................................................................................................................................... 94 Low-pressure Relief Valve.......................................................................................................................... 95 Function....................................................................................................................................... 95 Operation...................................................................................................................................... 95 HST Charge Pump.................................................................................................................................... 96 Outline........................................................................................................................................ 97 Specifications................................................................................................................................. 97 Function....................................................................................................................................... 97 Speed-Related Valve (DA Valve)..................................................................................................................... 98 Function....................................................................................................................................... 98 Operation...................................................................................................................................... 98 High-Pressure Cutoff Valve......................................................................................................................... 99 Function....................................................................................................................................... 99 Operation...................................................................................................................................... 99 HST Motor.............................................................................................................................................. 100 HST Motor 1........................................................................................................................................ 100 Specifications................................................................................................................................. 101 HST Motor 2........................................................................................................................................ 102 Specifications................................................................................................................................. 103 Principle...................................................................................................................................... 104 Structure...................................................................................................................................... 104 Operation...................................................................................................................................... 104 EP Servo Valve..................................................................................................................................... 105 Function....................................................................................................................................... 105 Operation...................................................................................................................................... 105 HA Servo Valve..................................................................................................................................... 106 Function....................................................................................................................................... 106 Operation...................................................................................................................................... 106 Directional Shuttle Valve.......................................................................................................................... 107 Function....................................................................................................................................... 107 Operation...................................................................................................................................... 107 Transfer............................................................................................................................................... 108 Torque Values...................................................................................................................................... 109 Torque Values...................................................................................................................................... 111 Input Shaft........................................................................................................................................ 112 Output Shaft....................................................................................................................................... 114 Torque Values.................................................................................................................................. 117 Outline............................................................................................................................................ 118 Relation between transfer clutch and transfer clutch pressure at respective speed ranges....................................................... 118 Relationship between accelerator pedal angle and travel speed (A) for starting transfer clutch switching modulation............................ 118 Operation of Clutch................................................................................................................................ 119 Clutch is Engaged (fixed)...................................................................................................................... 119 Clutch is Disengaged (released)................................................................................................................ 119 Power Transmitting Route........................................................................................................................... 120 Low-Speed Mode................................................................................................................................. 120 High-Speed Mode................................................................................................................................ 121 Clutch Solenoid Valve.............................................................................................................................. 122 Operation...................................................................................................................................... 122 DRIVE AXLE SYSTEM.......................................................................................................................................... 124 Front and Rear Axles................................................................................................................................... 124 Front Axle......................................................................................................................................... 124 Torque Values.................................................................................................................................. 125 Rear Axle.......................................................................................................................................... 126 Torque Values.................................................................................................................................. 127 Differential........................................................................................................................................... 128 Front Differential................................................................................................................................. 128 Torque Values.................................................................................................................................. 130 Rear Differential.................................................................................................................................. 132 Torque Values.................................................................................................................................. 133 Outline........................................................................................................................................ 134 While Machine is Traveling Straight............................................................................................................ 134 While Machine is Turning....................................................................................................................... 134 Torque Proportioning Differential...................................................................................................................... 135 Outline............................................................................................................................................ 135 Operation.......................................................................................................................................... 135 Straight Travel (when road resistance under both tires is the same)................................................................................ 135 Travel on Soft Ground (when road resistance under both tires is different)......................................................................... 135 Limited Slip Differential.............................................................................................................................. 136 Torque Values...................................................................................................................................... 136 Operation.......................................................................................................................................... 138 Mechanism of Generation of Braking Torque by Right and Left Side Gears (5)......................................................................... 138 While Machine is Traveling Straight (when the drive forces of the right and left wheels are balanced).............................................. 138 When the drive forces of the right and left wheels are unbalanced.................................................................................. 139 Difference in wheel drive force by type of differentials when either wheel slips................................................................... 139 Torque Proportioning Differential.................................................................................................................. 139 Conventional Differential (not applicable to this machine)......................................................................................... 139 While Machine is Turning........................................................................................................................... 139 Final Drive............................................................................................................................................ 140 Front Final Drive.................................................................................................................................. 140 Torque Values.................................................................................................................................. 140 Rear Final Drive................................................................................................................................... 142 Torque Values.................................................................................................................................. 142 Outline........................................................................................................................................ 143 STEERING SYSTEM............................................................................................................................................ 144 Steering Piping Diagram................................................................................................................................ 144 Steering Column........................................................................................................................................ 145 Torque Values...................................................................................................................................... 145 Priority Valve......................................................................................................................................... 146 Torque Values...................................................................................................................................... 147 Outline............................................................................................................................................ 148 Operation.......................................................................................................................................... 148 When Steering Wheel is at Neutral Position..................................................................................................... 148 When Steering Wheel is Turned Left............................................................................................................. 148 Orbitrol Valve......................................................................................................................................... 150 Torque Values...................................................................................................................................... 150 Outline............................................................................................................................................ 151 Structure.......................................................................................................................................... 151 Operation.......................................................................................................................................... 152 When Steering Wheel is at Neutral Position..................................................................................................... 152 When Steering Wheel is Turned Left............................................................................................................. 154 When Steering Wheel is at Stop Position........................................................................................................ 155 Connection of Hand Pump and Sleeve................................................................................................................. 156 Role of Centering Spring....................................................................................................................... 157 2-Way Restrictor Valve................................................................................................................................. 158 Function........................................................................................................................................... 158 Operation.......................................................................................................................................... 158 Cushion Valve.......................................................................................................................................... 159 Outline............................................................................................................................................ 159 Function........................................................................................................................................... 159 Steering Cylinder...................................................................................................................................... 160 Torque Values...................................................................................................................................... 161 Emergency Steering Piping Diagram...................................................................................................................... 162 Emergency Steering Valve............................................................................................................................... 164 Torque Values...................................................................................................................................... 165 Operation.......................................................................................................................................... 166 When Engine and Steering Pump are Normal....................................................................................................... 166 When Engine or Steering Pump is Abnormal....................................................................................................... 167 Steering Relief Valve.................................................................................................................................. 168 Torque Values...................................................................................................................................... 168 Outline............................................................................................................................................ 168 BRAKE SYSTEM............................................................................................................................................... 169 Brake Piping Diagram................................................................................................................................... 169 Charge Valve........................................................................................................................................... 170 Torque Values...................................................................................................................................... 171 Function........................................................................................................................................... 171 Operation.......................................................................................................................................... 172 When Oil is Not Supplied to Accumulator........................................................................................................ 172 Cutout State............................................................................................................................... 172 When Oil is Supplied to Accumulator............................................................................................................ 172 Cut-in State............................................................................................................................... 172 When Pressure Reaches Cutout Pressure.......................................................................................................... 173 When Oil Pressure from the Pump Goes Beyond the Set Pressure................................................................................... 173 Brake Valve............................................................................................................................................ 174 Outline............................................................................................................................................ 175 Braking Operation...................................................................................................................................... 176 When the Brake Pedal is Pressed Down............................................................................................................... 176 When Brake of One Side is Operated (when the other brake failed)................................................................................... 176 Balancing Operation................................................................................................................................ 177 When Brake Pedal is Released....................................................................................................................... 178 Inching Valve.......................................................................................................................................... 179 Outline............................................................................................................................................ 179 Accumulator (for Brake)................................................................................................................................ 180 Specifications..................................................................................................................................... 180 Function........................................................................................................................................... 180 Slack Adjuster......................................................................................................................................... 182 Function........................................................................................................................................... 183 Operation.......................................................................................................................................... 183 When Brake is Applied.......................................................................................................................... 183 When Brake is Released......................................................................................................................... 183 Brakes................................................................................................................................................. 184 Front Brake........................................................................................................................................ 184 Outline........................................................................................................................................ 185 Rear Brake......................................................................................................................................... 186 Outline........................................................................................................................................ 187 Operation...................................................................................................................................... 187 When Brake is Operated..................................................................................................................... 187 When Brake is Released..................................................................................................................... 187 Parking Brake System................................................................................................................................... 188 Brake Control...................................................................................................................................... 188 Outline........................................................................................................................................ 188 Parking Brake...................................................................................................................................... 189 Torque Values.................................................................................................................................. 189 Outline........................................................................................................................................ 189 UNDERCARRIAGE AND FRAME.................................................................................................................................... 190 Axle Mounting and Center Hinge Pin..................................................................................................................... 190 Torque Values...................................................................................................................................... 191 Outline............................................................................................................................................ 191 Torque Values...................................................................................................................................... 193 Torque Values...................................................................................................................................... 194 Tires.................................................................................................................................................. 196 Radial Tire........................................................................................................................................ 196 Structure...................................................................................................................................... 196 Ground Contact Characteristics................................................................................................................. 196 Deformation Characteristics.................................................................................................................... 196 Bias Tire.......................................................................................................................................... 197 Structure...................................................................................................................................... 197 Ground Contact Characteristics................................................................................................................. 197 Deformation Characteristics.................................................................................................................... 197 HYDRAULIC SYSTEM........................................................................................................................................... 198 Work Equipment Hydraulic Piping Diagram................................................................................................................ 198 Outline............................................................................................................................................ 199 Work Equipment Control Lever Linkage................................................................................................................... 200 Mono-Lever Type.................................................................................................................................... 200 2-Lever Type....................................................................................................................................... 201 Hydraulic Tank......................................................................................................................................... 202 Specifications..................................................................................................................................... 203 Torque Values...................................................................................................................................... 203 Breather........................................................................................................................................... 203 Prevention of Negative Pressure in Tank........................................................................................................ 203 Prevention of Pressure Rise in Tank............................................................................................................ 203 4-Gear Pump............................................................................................................................................ 204 SAR(3)56 + (2)40 + SB(1)12 + 12.................................................................................................................... 204 Outline............................................................................................................................................ 204 Torque Values...................................................................................................................................... 205 Work Equipment Control Valve........................................................................................................................... 206 2-Spool Type....................................................................................................................................... 206 Torque Values.................................................................................................................................. 207 Torque Values.................................................................................................................................. 209 3-Spool Type....................................................................................................................................... 210 Torque Values.................................................................................................................................. 211 Torque Values.................................................................................................................................. 213 Relief Valve....................................................................................................................................... 214 Function....................................................................................................................................... 214 Operation...................................................................................................................................... 214 Safety-Suction Valve............................................................................................................................... 215 Function....................................................................................................................................... 215 Operation...................................................................................................................................... 215 Operation as Safety Valve.................................................................................................................. 215 Operation as Suction Valve................................................................................................................. 216 Suction Valve...................................................................................................................................... 217 Function....................................................................................................................................... 217 Operation...................................................................................................................................... 217 Operation of Work Equipment Control Valve.......................................................................................................... 218 When Lift Arm and Bucket Spool are at the Neutral Position..................................................................................... 218 Operation.................................................................................................................................. 218 When Lift Arm Spool is at Raise Position....................................................................................................... 219 Operation.................................................................................................................................. 219 When Lift Arm Spool is at Lower Position....................................................................................................... 220 Operation.................................................................................................................................. 220 When Lift Arm Spool is at Float Position....................................................................................................... 221 Operation.................................................................................................................................. 221 When Bucket Spool is at Tilt Position.......................................................................................................... 222 Operation.................................................................................................................................. 222 When Bucket Spool is at Dump Position.......................................................................................................... 223 Operation.................................................................................................................................. 223 PPC Valve.............................................................................................................................................. 224 Work Equipment PPC Valve........................................................................................................................... 224 Mono Lever Type................................................................................................................................ 224 Torque Values.................................................................................................................................. 227 Operation...................................................................................................................................... 228 When in Neutral............................................................................................................................ 228 When in Fine Control Mode (neutral Æ fine control)......................................................................................... 229 When in Fine Control Mode (when control lever is returned)................................................................................. 229 When Lever is Operated to Stroke End....................................................................................................... 230 When Lift Arm is Float..................................................................................................................... 230 When Float State of Lift Arm is Reset...................................................................................................... 230 2-Lever Type................................................................................................................................... 232 Torque Values.................................................................................................................................. 235 Operation...................................................................................................................................... 236 When in Neutral............................................................................................................................ 236 When in Fine Control Mode (neutral Æ fine control)......................................................................................... 237 When in Fine Control Mode (when control lever is returned)................................................................................. 237 When Lever is Operated to Stroke End....................................................................................................... 238 When Lift Arm is Float..................................................................................................................... 238 When Float State of Lift Arm is Reset...................................................................................................... 238 Attachment PPC Valve........................................................................................................................... 240 Torque Values.............................................................................................................................. 241 Lock Valve..................................................................................................................................... 242 Outline.................................................................................................................................... 242 Accumulator (for PPC Circuit).................................................................................................................. 243 Outline.................................................................................................................................... 243 Specifications............................................................................................................................. 243 ECSS Valve..................................................................................................................................... 244 Torque Values.............................................................................................................................. 244 Accumulator (for ECSS)......................................................................................................................... 246 Function................................................................................................................................... 246 Specifications............................................................................................................................. 246 Work Equipment................................................................................................................................. 247 Work Equipment Linkage..................................................................................................................... 247 Bucket..................................................................................................................................... 250 Torque Values.......................................................................................................................... 251 Bucket Positioner and Boom Kickout......................................................................................................... 252 Torque Values.......................................................................................................................... 252 Outline................................................................................................................................ 253 Bucket Positioner...................................................................................................................... 253 Boom Kickout (if equipped)............................................................................................................. 253 Operation of Proximity Switch.......................................................................................................... 254 When Bucket is Tilted.............................................................................................................. 254 Function of Proximity Switch....................................................................................................... 256 When Lift Arm is Raised............................................................................................................ 257 Function of Proximity Switch....................................................................................................... 259 Work Equipment Cylinders................................................................................................................... 260 Lift Cylinder.......................................................................................................................... 260 Bucket Cylinder........................................................................................................................ 260 CAB ENVIRONMENT............................................................................................................................................ 262 Cab.................................................................................................................................................... 262 Air Conditioner........................................................................................................................................ 264 Air Conditioner Piping Diagram..................................................................................................................... 264 Specifications................................................................................................................................. 265 Refrigerant Circuit Diagram........................................................................................................................ 266 Table of Tightening Torque for Refrigerant Piping Adapter...................................................................................... 266 Air Conditioner Unit............................................................................................................................... 267 Outline........................................................................................................................................ 268 Cooler......................................................................................................................................... 268 Heater......................................................................................................................................... 268 Functions of Major Components.................................................................................................................. 268 Evaporator..................................................................................................................................... 268 Heater Core.................................................................................................................................... 268 Expansion Valve................................................................................................................................ 268 Blower Controller.............................................................................................................................. 268 Blower Motor Relay............................................................................................................................. 268 Compressor Clutch Relay........................................................................................................................ 268 Air Mix Damper Actuator........................................................................................................................ 269 Evaporator Temperature Sensor.................................................................................................................. 269 Dual Pressure Switch........................................................................................................................... 269 Blower and Intake Unit............................................................................................................................. 270 Functions of Major Components.................................................................................................................. 271 Blower Motor Assembly.......................................................................................................................... 271 Internal/External Air Changeover Damper Actuator............................................................................................... 271 Compressor......................................................................................................................................... 272 Function....................................................................................................................................... 272 Specifications................................................................................................................................. 272 Condenser.......................................................................................................................................... 273 Function....................................................................................................................................... 273 Specifications................................................................................................................................. 273 Receiver........................................................................................................................................... 274 Function....................................................................................................................................... 274 Specifications................................................................................................................................. 274 Air Conditioner Panel.............................................................................................................................. 276 Display Unit................................................................................................................................... 276 Switch Block................................................................................................................................... 276 Outline........................................................................................................................................ 277 Input and Output Signals....................................................................................................................... 277 Function of Abnormality Display in the Control Panel........................................................................................... 278 ELECTRICAL SYSTEM.......................................................................................................................................... 280 Machine Monitor System................................................................................................................................. 280 Outline............................................................................................................................................ 280 Operator Mode...................................................................................................................................... 280 Service Mode....................................................................................................................................... 281 Machine Monitor.................................................................................................................................... 282 Items Displayed on Monitor......................................................................................................................... 283 Machine Monitor Operation Switches..................................................................................................................... 289 Setting Machine Monitor............................................................................................................................ 290 Troubleshooting Function........................................................................................................................... 290 Character Display Function......................................................................................................................... 291 Operator Mode Functions............................................................................................................................ 292 Self-Check Screen (0th layer).................................................................................................................. 292 Normal Screen (1st layer)...................................................................................................................... 292 Failure Code Screen (1st layer)................................................................................................................ 293 Display of Functions Available for the Operator (2nd layer or below)........................................................................... 294 Service Mode Functions............................................................................................................................. 295 Procedure for Switching to Service Mode........................................................................................................ 295 Service Mode Menu.............................................................................................................................. 296 Electrical System Failure History Display Function (ELECTRIC FAULT)............................................................................ 297 Mechanical System Failure History Display Function (MACHINE FAULT)............................................................................. 297 Real-Time Monitoring Function (REAL-TIME MONITOR).............................................................................................. 297 Engine Reduced-Cylinder Function (CYLINDER CUT-OUT)............................................................................................ 297 No Injection Cranking Function (NO INJECTION).................................................................................................. 298 Adjustment Function (TUNING)................................................................................................................... 298 Maintenance Monitoring Function (MAINTENANCE MONITOR).......................................................................................... 298 Operating Information Display Function (OPERATION INFO)........................................................................................ 298 Optional Device Selecting Function (OPTIONAL SELECT)........................................................................................... 299 Machine Serial Number Input Function (MACHINE No. SET)......................................................................................... 299 Model Selection Function (MACHINE)............................................................................................................. 299 Initialize Function (INITIALIZE)............................................................................................................... 299 Input and Output Signals........................................................................................................................... 300 Setting Switches (on circuit board)............................................................................................................ 305 Electrical System (HST Controller System).............................................................................................................. 306 Input and Output Signals Diagram................................................................................................................... 306 HST Controller Gear Shifting Control Function...................................................................................................... 307 Gear Shifting Function......................................................................................................................... 307 Relationship between accelerator pedal angle and travel speed (A) for starting transfer clutch switching modulation............................ 308 Relationship between accelerator pedal angle and travel speed (A) for switching HST motor 2 capacity........................................... 308 Gear Shifting Display Function................................................................................................................. 309 Variable Shift Control System.................................................................................................................. 309 Transfer Clutch Control Function............................................................................................................... 309 Traction Control Function...................................................................................................................... 309 S Mode Function................................................................................................................................ 310 The maximum traction force available when the travel speed range selector switch is set to 1st and the traction control switch is set to ON.... 311 Max. Traction Function......................................................................................................................... 312 HST Controller Protection Function................................................................................................................. 313 HST Motor 1 Overrun Prevention Function 1...................................................................................................... 313 Relationship between accelerator pedal angle and travel speed (A) for starting transfer clutch switching modulation............................ 314 HST Motor 1 Overrun Prevention Function 2...................................................................................................... 314 Travel Speed Control Function.................................................................................................................. 314 Engine Overrun Prevention Function............................................................................................................. 315 Neutralizer Function........................................................................................................................... 315 Economy Operation Pilot Lamp Function.......................................................................................................... 315 Cooling Fan Control Function....................................................................................................................... 316 Input and Output Signals....................................................................................................................... 316 Fan Control.................................................................................................................................... 317 Fan Speed in Accordance with Temperature....................................................................................................... 317 Control at Start of Engine..................................................................................................................... 318 Fan Reverse Rotation Function.................................................................................................................. 319 Fan Manual Reverse Rotation Function........................................................................................................... 319 Overheat Prevention Function................................................................................................................... 319 Fan Speed During Reverse Rotation.............................................................................................................. 319 Fan Automatic Reverse Rotation Function........................................................................................................ 320 Adjustment of the Automatic Fan Switching Cycle to Reverse Rotation and Duration............................................................... 320 System Circuit Diagram............................................................................................................................. 321 HST Controller......................................................................................................................................... 322 Input and Output Signals........................................................................................................................... 323 ECSS System............................................................................................................................................ 324 Input and Output Signals........................................................................................................................... 324 Outline............................................................................................................................................ 324 Setting Method..................................................................................................................................... 324 Operation.......................................................................................................................................... 325 KOMTRAX System......................................................................................................................................... 327 KOMTRAX Terminal................................................................................................................................... 328 Model TC301.................................................................................................................................... 328 Outline........................................................................................................................................ 328 Input and Output Signals....................................................................................................................... 329 Engine Starting Circuit................................................................................................................................ 330 Function........................................................................................................................................... 331 Operation.......................................................................................................................................... 331 Engine Stopping Circuit................................................................................................................................ 332 Operation.......................................................................................................................................... 332 Preheating Circuit..................................................................................................................................... 333 Outline............................................................................................................................................ 333 Operation.......................................................................................................................................... 333 Engine Output Lowering Function........................................................................................................................ 334 Automatic Warm-up Function............................................................................................................................. 334 Parking Brake Circuit.................................................................................................................................. 335 Operation.......................................................................................................................................... 335 When Parking Brake Lever is Set to the Free Position............................................................................................... 336 When Parking Brake Lever is Set to the Mid Position................................................................................................ 336 When Parking Brake Lever is Set to the Lock Position............................................................................................... 336 Max. Traction Switch................................................................................................................................... 337 Function........................................................................................................................................... 337 Multi-Function Knob.................................................................................................................................... 338 Multi-function Mono-Lever Type..................................................................................................................... 338 (If equipped)...................................................................................................................................... 338 Function........................................................................................................................................... 338 Modification of Multi-Function Lever............................................................................................................... 338 Required....................................................................................................................................... 339 Procedure...................................................................................................................................... 339 Sensors................................................................................................................................................ 340 Speed Sensor....................................................................................................................................... 340 Torque Values.................................................................................................................................. 341 Function....................................................................................................................................... 341 HST Oil Temperature Sensor......................................................................................................................... 342 Brake Oil Temperature Sensor....................................................................................................................... 342 Function....................................................................................................................................... 342 HST Oil Pressure Sensor............................................................................................................................ 342 Function....................................................................................................................................... 342 HST Oil FIlter Clogging Sensor..................................................................................................................... 343 Function....................................................................................................................................... 343 Coolant Lever Sensor............................................................................................................................... 343 Function....................................................................................................................................... 343 Fuel Level Sensor.................................................................................................................................. 344 Function....................................................................................................................................... 344 Accelerator Pedal Sensor........................................................................................................................... 345 Torque Values.................................................................................................................................. 345 Function....................................................................................................................................... 345 Accelerator signal............................................................................................................................. 345 Idle Validation Signal......................................................................................................................... 345 Water-in-Fuel Sensor............................................................................................................................... 346 Function....................................................................................................................................... 346 Boom Kick-Out Proximity Switch..................................................................................................................... 346 Bucket Positioner Proximity Switch................................................................................................................. 346 Function....................................................................................................................................... 346 20 STANDARD VALUE TABLES....................................................................................................................................... 347 STANDARD VALUE TABLES...................................................................................................................................... 349 Standard Service Value Table for Engine................................................................................................................ 349 Standard Service Value Table for Chassis............................................................................................................... 350 MACHINE POSTURE............................................................................................................................................ 355 30 TESTING AND ADJUSTING....................................................................................................................................... 357 TOOLS...................................................................................................................................................... 361 Tools for Testing, Adjusting, and Troubleshooting...................................................................................................... 361 ENGINE COMPONENTS.......................................................................................................................................... 366 Engine Speed........................................................................................................................................... 366 Exhaust Gas Color...................................................................................................................................... 368 Using Handy Smoke Checker A1....................................................................................................................... 368 Using Smoke Meter A2............................................................................................................................... 368 Valve Clearance........................................................................................................................................ 370 Compression Pressure................................................................................................................................... 372 Blow-By Pressure....................................................................................................................................... 375 Engine Oil Pressure.................................................................................................................................... 377 Intake Air (Boost) Pressure............................................................................................................................ 378 Handling Cylinder Cut-Out Mode Operation............................................................................................................... 380 Handling No-Injection Cranking Operation............................................................................................................... 380 Handling Controller Voltage Circuit.................................................................................................................... 380 FUEL SYSTEM................................................................................................................................................ 381 Handling Fuel System Equipment......................................................................................................................... 381 Releasing Residual Pressure in Fuel System............................................................................................................. 381 Measuring Fuel Pressure................................................................................................................................ 382 Measuring Fuel Return Rate and Leakage................................................................................................................. 385 Bleeding Air from Fuel Circuit......................................................................................................................... 390 Testing Leakage in Fuel System......................................................................................................................... 391 EXHAUST SYSTEM AND PIPING.................................................................................................................................. 392 Checking Muffler and Muffler Stack for Looseness and Damage............................................................................................ 392 Checking Muffler Function.............................................................................................................................. 392 Checking Installed Condition of Cylinder Head and Manifolds............................................................................................ 392 Checking Engine Piping for Damage and Looseness........................................................................................................ 392 BELTS...................................................................................................................................................... 393 Air Conditioner Compressor Belt........................................................................................................................ 393 Alternator Belt........................................................................................................................................ 394 ACCELERATOR PEDAL.......................................................................................................................................... 395 Testing Operating Effort............................................................................................................................... 395 Testing Operating Angle................................................................................................................................ 396 DIRECTIONAL LEVER.......................................................................................................................................... 397 Checking Operating Effort.............................................................................................................................. 397 Checking Travel........................................................................................................................................ 397 POWER TRAIN OIL PRESSURES.................................................................................................................................. 398 Testing HST Oil Pressure............................................................................................................................... 398 High-Pressure Cutoff Oil Pressure.................................................................................................................. 398 Low-Pressure Relief Pressure....................................................................................................................... 400 Servo Piston Control Pressure (DA Pressure)........................................................................................................ 401 Servo Piston Actuating Pressure.................................................................................................................... 402 Adjusting HST Oil Pressure............................................................................................................................. 403 High-Pressure Cutoff Valve......................................................................................................................... 403 Low-Pressure Relief Valve.......................................................................................................................... 404 DA Valve........................................................................................................................................... 405 Testing Clutch Control Pressure........................................................................................................................ 406 STEERING SYSTEM............................................................................................................................................ 407 Steering Wheel......................................................................................................................................... 407 Measuring Play..................................................................................................................................... 407 Measuring Operating Effort......................................................................................................................... 408 Measuring Operating Time........................................................................................................................... 409 Steering Oil Pressure.................................................................................................................................. 410 Measuring Main Relief Pressure..................................................................................................................... 410 Adjusting Main Relief Pressure..................................................................................................................... 411 Bleeding Air From Steering Circuit..................................................................................................................... 412 HYDRAULIC FAN.............................................................................................................................................. 413 Fan Speed.............................................................................................................................................. 414 Fan Drive Oil Pressure................................................................................................................................. 415 BRAKE SYSTEM............................................................................................................................................... 416 Measuring Brake Pedal.................................................................................................................................. 416 Brake Pedal Linkage.................................................................................................................................... 417 Testing............................................................................................................................................ 417 Adjusting.......................................................................................................................................... 417 Measuring Brake Performance............................................................................................................................ 418 Accumulator Charge Pressure............................................................................................................................ 419 Testing............................................................................................................................................ 419 Adjusting.......................................................................................................................................... 420 Testing Wheel Brake Oil Pressure....................................................................................................................... 421 Testing Wear of Brake Disc............................................................................................................................. 424 Bleeding Air from Wheel Brake Circuit.................................................................................................................. 425 Releasing Residual Pressure in Brake Accumulator Circuit............................................................................................... 426 Testing Parking Brake Performance...................................................................................................................... 426 Parking Brake Limit Switch............................................................................................................................. 427 Testing............................................................................................................................................ 427 Adjusting.......................................................................................................................................... 428 Parking Brake Control Cable............................................................................................................................ 430 Testing............................................................................................................................................ 430 Adjusting.......................................................................................................................................... 430 WORK EQUIPMENT............................................................................................................................................. 431 Control Lever.......................................................................................................................................... 431 Measuring Operating Effort......................................................................................................................... 431 Measuring Travel................................................................................................................................... 431 Hydraulic Pressure..................................................................................................................................... 432 Measuring.......................................................................................................................................... 432 Adjusting.......................................................................................................................................... 433 PPC Oil Pressure....................................................................................................................................... 434 Testing PPC Valve Basic Pressure................................................................................................................... 434 Checking PPC Valve Output Pressure................................................................................................................. 435 Bleeding Air from Hydraulic Circuit.................................................................................................................... 436 From Work Equipment PPC Circuit.................................................................................................................... 436 From Cylinders..................................................................................................................................... 436 Releasing Residual Pressure in Hydraulic Circuit....................................................................................................... 436 Between Hydraulic Cylinder and Control Valve....................................................................................................... 436 In Brake Accumulator Circuit....................................................................................................................... 436 In PPC Accumulator Circuit......................................................................................................................... 436 Bucket Positioner...................................................................................................................................... 437 Testing............................................................................................................................................ 437 Adjusting Clearance................................................................................................................................ 437 Adjusting Installing Position (Stopping Position).................................................................................................. 438 Boom Kickout Switch.................................................................................................................................... 439 Testing............................................................................................................................................ 439 Adjusting.......................................................................................................................................... 439 Checking Proximity Switch Operation Pilot Lamp......................................................................................................... 440 ELECTRICAL SYSTEM TROUBLESHOOTING.......................................................................................................................... 441 Procedure for Testing Diodes........................................................................................................................... 441 Using Digital-Type Circuit Tester.................................................................................................................. 441 Using Analog-Type Circuit Tester................................................................................................................... 442 Preparation Work for Troubleshooting Electric System................................................................................................... 443 Machine Monitor.................................................................................................................................... 443 HST Controller..................................................................................................................................... 444 KOMTRAX Terminal................................................................................................................................... 445 Boost Pressure and Temperature Sensor (BOOST PRESS & IMT).......................................................................................... 445 Supply Pump IMV Solenoid (FUEL REGULATOR).......................................................................................................... 446 Common Rail Pressure Sensor (FUEL RAIL PRESS)...................................................................................................... 446 Engine Coolant Temperature Sensor (COOLANT TEMP)................................................................................................... 447 Ambient Temperature Sensor (AMBAIR PRESSURE)....................................................................................................... 447 Engine Ne Speed Sensor (CRANK SENSOR).............................................................................................................. 447 Engine Bkup Speed Sensor (CAM SENSOR).............................................................................................................. 447 Engine Oil Pressure Switch (OIL PRESSURE SWITCH)................................................................................................... 447 KOMTRAX TERMINAL SYSTEM.................................................................................................................................... 448 Starting KOMTRAX Terminal Operations................................................................................................................... 448 Station Opening Check in Machine Side.............................................................................................................. 448 Application for the Start of Use................................................................................................................... 452 KOMTRAX Terminal Indicator Lamps................................................................................................................... 453 MACHINE MONITOR SYSTEM..................................................................................................................................... 456 Adjusting Machine Monitor.............................................................................................................................. 456 Adjusting Replaced, Reassembled, or Added Sensor, Controller, Etc...................................................................................... 457 Items to Be Set.................................................................................................................................... 457 Adjustment for User’s Needs........................................................................................................................ 457 Special Functions of Machine Monitor (EMSS)............................................................................................................ 458 Normal and Special Functions of Machine Monitor........................................................................................................ 459 Normal Functions: Operator Mode.................................................................................................................... 459 Special Functions: Service Mode.................................................................................................................... 459 Functions and Flow of Service Mode..................................................................................................................... 460 Operator Mode.......................................................................................................................................... 463 Service Meter Display Function..................................................................................................................... 463 Traction Level Selection Function.................................................................................................................. 463 HST Function Selection Function.................................................................................................................... 463 Odometer Display Function.......................................................................................................................... 464 Maintenance Monitoring Function.................................................................................................................... 464 Telephone Number Input Function.................................................................................................................... 464 Language Selection Function........................................................................................................................ 464 Monitor Brightness Adjustment Function............................................................................................................. 465 Travel Speed/Engine Speed Display Selecting Function............................................................................................... 465 Travel Speed/Engine Speed Display/Non-Display Selecting Function................................................................................... 465 Action Code Display Function....................................................................................................................... 466 Failure Code Display Function...................................................................................................................... 467 Service Mode........................................................................................................................................... 468 Switching to Service Mode and Screen Display....................................................................................................... 468 Electrical System Fault History Display Function (ELECTRIC FAULT).................................................................................. 470 Mechanical System Fault History Display Function (MACHINE FAULT)................................................................................... 472 Failure Codes Table................................................................................................................................ 473 Real-Time Monitoring Function (REAL-TIME MONITOR).................................................................................................. 479 Real-Time Monitoring Codes Tables.................................................................................................................. 482 Engine Reduced-Cylinder Function (CYLINDER CUT-OUT)................................................................................................ 495 No-Injection Cranking Function..................................................................................................................... 496 Adjustment Function (TUNING)....................................................................................................................... 497 Maintenance Monitoring Function.................................................................................................................... 501 Operating Information Display Function............................................................................................................. 506 Optional Device Selecting Function................................................................................................................. 509 Machine Serial Number Input Function............................................................................................................... 513 Model Selection Function (MACHINE WA***)........................................................................................................... 514 Initialize Function................................................................................................................................ 515 PM CLINIC INSPECTION TABLES................................................................................................................................ 516 40 TROUBLESHOOTING............................................................................................................................................. 519 POINTS TO REMEMBER WHEN TROUBLESHOOTING.................................................................................................................... 529 SEQUENCE OF EVENTS IN TROUBLESHOOTING...................................................................................................................... 531 PRECAUTIONS FOR MAINTENANCE................................................................................................................................ 532 Precautions when Handling Electrical Equipment......................................................................................................... 532 Handling Electronic Control Unit....................................................................................................................... 537 Points to Remember when Troubleshooting Electrical Circuits............................................................................................ 538 ELECTRIC WIRE CODE......................................................................................................................................... 539 How to Read Electric Wire Code......................................................................................................................... 539 Type, Symbol, and Material......................................................................................................................... 539 Dimensions......................................................................................................................................... 540 Color Codes Table.................................................................................................................................. 541 Types of Circuits and Color Codes.................................................................................................................. 541 HANDLING HYDRAULIC EQUIPMENT............................................................................................................................... 542 CHECKS BEFORE TROUBLESHOOTING.............................................................................................................................. 544 Categories and Method of Using Troubleshooting Charts.................................................................................................. 545 Troubleshooting Individual Electrical Circuits......................................................................................................... 546 Chart Use.......................................................................................................................................... 548 Chart Tips......................................................................................................................................... 548 Troubleshooting Individual Hydraulic Circuits.......................................................................................................... 549 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS................................................................................................................. 551 X-Type Connectors...................................................................................................................................... 551 SWP-Type Connectors.................................................................................................................................... 553 M-Type Connectors...................................................................................................................................... 555 S-Type Connectors...................................................................................................................................... 557 MIC-Type Connectors.................................................................................................................................... 559 AMP040-Type Connectors................................................................................................................................. 561 AMP070-Type Connectors................................................................................................................................. 563 Miscellaneous Types of Connectors...................................................................................................................... 565 HD30 Series Connectors................................................................................................................................. 570 DT Series Connectors................................................................................................................................... 576 DTM Series Connectors.................................................................................................................................. 578 DTHD Series Connectors................................................................................................................................. 578 DTP Series Connectors.................................................................................................................................. 579 DRC26 Series Connectors................................................................................................................................ 580 DRC12, 16 Connectors................................................................................................................................... 582 AMP Connectors for Pump Controller..................................................................................................................... 583 BOSCH Connectors for Engine............................................................................................................................ 585 SUMITOMO Connectors for Engine......................................................................................................................... 586 CANNON Connectors for Engine........................................................................................................................... 587 AMP Connectors for Engine.............................................................................................................................. 588 FRAMATOME Connectors for Engine........................................................................................................................ 589 PACKARD Connectors for Engine.......................................................................................................................... 591 OT Series Connectors for Engine........................................................................................................................ 592 T-BRANCH BOX and T-BRANCH ADAPTER TABLE.................................................................................................................... 593 MODE CHART................................................................................................................................................. 597 INFORMATION CONTAINED IN TESTING PROCEDURES................................................................................................................ 600 TROUBLESHOOTING BY FAILURE CODE............................................................................................................................ 602 Failure Code Table..................................................................................................................................... 602 FUSE BOX AND SLOW-BLOW FUSES............................................................................................................................... 608 Connection Table....................................................................................................................................... 608 Fuse Box: FS1...................................................................................................................................... 608 Fuse Box: FS2...................................................................................................................................... 609 Slow-Blow Fuses.................................................................................................................................... 610 FAILURE CODES.............................................................................................................................................. 612 2G40ZG................................................................................................................................................. 612 Brake: Oil Pressure Reduction...................................................................................................................... 612 6091NX................................................................................................................................................. 614 HST Filter: Clogging............................................................................................................................... 614 989FN1................................................................................................................................................. 615 Travel Speed: Overrun Alarm........................................................................................................................ 615 AB00L6................................................................................................................................................. 616 Alternator R System: Short Circuit................................................................................................................. 616 AB00MA................................................................................................................................................. 618 Alternator R System: Ground Fault/Disconnection/Low Charge Voltage................................................................................. 618 B@BAZG................................................................................................................................................. 620 Engine: Oil Pressure Reduction..................................................................................................................... 620 B@BCNS................................................................................................................................................. 621 Engine: Overheat................................................................................................................................... 621 B@BCZK................................................................................................................................................. 622 Engine: Low Coolant Level.......................................................................................................................... 622 B@C6NS................................................................................................................................................. 624 Front Brake: High Oil Temperature.................................................................................................................. 624 B@CRNS................................................................................................................................................. 625 HST: High Oil Temperature.......................................................................................................................... 625 CA111.................................................................................................................................................. 626 Abnormality in Engine Controller................................................................................................................... 626 CA115.................................................................................................................................................. 627 Engine Ne or Bkup Speed Sensor Error............................................................................................................... 627 CA122.................................................................................................................................................. 628 Charge Pressure Sensor High Error.................................................................................................................. 628 CA123.................................................................................................................................................. 630 Charge Pressure Sensor Low Error................................................................................................................... 630 CA131.................................................................................................................................................. 632 Throttle Sensor High Error......................................................................................................................... 632 CA132.................................................................................................................................................. 634 Throttle Sensor Low Error.......................................................................................................................... 634 CA144.................................................................................................................................................. 636 Coolant Sensor High Error.......................................................................................................................... 636 CA145.................................................................................................................................................. 638 Coolant Sensor Low error........................................................................................................................... 638 CA153.................................................................................................................................................. 640 Charge Temperature Sensor High Error............................................................................................................... 640 CA154.................................................................................................................................................. 642 Charge Temperature Sensor Low Error................................................................................................................ 642 CA155.................................................................................................................................................. 644 Lowering of Speed by Abnormally High Charge Temperature............................................................................................ 644 CA187.................................................................................................................................................. 646 Sensor Power Supply 2 Low Error.................................................................................................................... 646 CA221.................................................................................................................................................. 648 Atmospheric Pressure Sensor High Error............................................................................................................. 648 CA222.................................................................................................................................................. 650 Atmospheric Sensor Low Error....................................................................................................................... 650 CA227.................................................................................................................................................. 652 Sensor Power Supply 2 High Error................................................................................................................... 652 CA234.................................................................................................................................................. 654 Engine Overspeed................................................................................................................................... 654 CA238.................................................................................................................................................. 655 Ne Speed Sensor Power Supply Error................................................................................................................. 655 CA271.................................................................................................................................................. 656 IMV (IMA) Short Circuit............................................................................................................................ 656 CA272.................................................................................................................................................. 658 IMV (IMA) Disconnection............................................................................................................................ 658 CA322.................................................................................................................................................. 660 Injector #1 Open/Short Error....................................................................................................................... 660 CA323.................................................................................................................................................. 662 Injector #5 Open/Short Error....................................................................................................................... 662 CA324.................................................................................................................................................. 664 Injector #3 Open/Short Error....................................................................................................................... 664 CA325.................................................................................................................................................. 666 Injector #6 Open/Short Error....................................................................................................................... 666 CA331.................................................................................................................................................. 668 Injector #2 Open/Short Error....................................................................................................................... 668 CA332.................................................................................................................................................. 670 Injector #4 Open/Short Error....................................................................................................................... 670 CA342.................................................................................................................................................. 672 Calibration Code Inconsistency..................................................................................................................... 672 CA351.................................................................................................................................................. 674 Injectors Drive Circuit Error...................................................................................................................... 674 CA352.................................................................................................................................................. 676 Sensor Power Supply 1 Low Error.................................................................................................................... 676 CA386.................................................................................................................................................. 678 Sensor Power Supply 1 High Error................................................................................................................... 678 CA428.................................................................................................................................................. 680 Abnormally High Level in Water Sensor.............................................................................................................. 680 CA429.................................................................................................................................................. 682 Abnormally Low Level in Water Sensor............................................................................................................... 682 CA431.................................................................................................................................................. 684 Idle Validation Switch Error....................................................................................................................... 684 CA432.................................................................................................................................................. 688 Idle Validation Action Error....................................................................................................................... 688 CA435.................................................................................................................................................. 692 Engine Oil Pressure Switch Error................................................................................................................... 692 CA441.................................................................................................................................................. 694 Battery Voltage Low Error.......................................................................................................................... 694 CA442.................................................................................................................................................. 698 Battery Voltage High Error......................................................................................................................... 698 CA449.................................................................................................................................................. 700 Common Rail Pressure High Error 2.................................................................................................................. 700 CA451.................................................................................................................................................. 702 Common Rail Pressure Sensor High Error............................................................................................................. 702 CA452.................................................................................................................................................. 704 Common Rail Pressure Sensor Low Error.............................................................................................................. 704 CA488.................................................................................................................................................. 706 Lowering of Torque by Abnormally High Charge Temperature........................................................................................... 706 CA553.................................................................................................................................................. 707 Common Rail Pressure High Error 1.................................................................................................................. 707 CA559.................................................................................................................................................. 708 Supply Pump Pressure Very Low Error................................................................................................................ 708 CA689.................................................................................................................................................. 710 Engine Ne Speed Sensor Error....................................................................................................................... 710 CA731.................................................................................................................................................. 712 Engine Bkup Speed Sensor Phase Error............................................................................................................... 712 CA757.................................................................................................................................................. 713 All Continuous Data Lost Error..................................................................................................................... 713 CA778.................................................................................................................................................. 716 Engine Bkup Speed Sensor Error..................................................................................................................... 716 CA1633................................................................................................................................................. 718 KOMNET Datalink Timeout Error...................................................................................................................... 718 CA2185................................................................................................................................................. 722 Throttle Sensor Supply Voltage High Error.......................................................................................................... 722 CA2186................................................................................................................................................. 724 Throttle Sensor Power Supply Low Error............................................................................................................. 724 CA2249................................................................................................................................................. 726 Supply Pump Pressure Very Low Error 2.............................................................................................................. 726 CA2311................................................................................................................................................. 728 Abnormality in IMV (IMA) Solenoid.................................................................................................................. 728 CA2555................................................................................................................................................. 730 Intake Heater Relay Disconnection Error............................................................................................................ 730 CA2556................................................................................................................................................. 732 Intake Heater Relay Short Circuit Error............................................................................................................ 732 D160KY................................................................................................................................................. 734 Backup Alarm/Lamp Relay 1 Circuit: Short Circuit................................................................................................... 734 D192KY................................................................................................................................................. 736 ECSS Solenoid Relay: Short Circuit................................................................................................................. 736 D1B0KA................................................................................................................................................. 738 HST Safety Relay: Disconnection.................................................................................................................... 738 D1B0KB................................................................................................................................................. 740 HST Safety Relay: Ground Fault..................................................................................................................... 740 D1B0KY................................................................................................................................................. 742 HST Safety Relay: Short Circuit.................................................................................................................... 742 D5ZHL6................................................................................................................................................. 744 IGN C System: Ground Fault/Disconnection........................................................................................................... 744 DAF3KK................................................................................................................................................. 746 UNSW Power Supply: Ground Fault/Disconnection...................................................................................................... 746 DAFRKR................................................................................................................................................. 748 Machine Monitor CAN-NET Signal: Disconnection...................................................................................................... 748 DAJ0KK................................................................................................................................................. 750 HST Controller Power Supply: Low Voltage........................................................................................................... 750 DAJ0KT................................................................................................................................................. 752 HST Controller Memory (EEPROM): Abnormality........................................................................................................ 752 DAJ1L4................................................................................................................................................. 754 HST Controller Main Power Line: Disconnection/Ground Fault......................................................................................... 754 DAJ1L6................................................................................................................................................. 756 HST Controller Main Power Line: Short Circuit...................................................................................................... 756 DAJ2KK................................................................................................................................................. 758 Controller Solenoid Power Supply: Low Voltage...................................................................................................... 758 DAJ2L3................................................................................................................................................. 760 HST Controller Load Power Supply Holding Line: Short Circuit in Wiring Harness..................................................................... 760 DAJ2L4................................................................................................................................................. 762 HST Controller Load Power Supply Holding Line: Disconnection/Ground Fault.......................................................................... 762 DAJ5KX................................................................................................................................................. 764 Sensor 5V Power Supply: Out-of-Output Range........................................................................................................ 764 DAJ9KQ................................................................................................................................................. 766 HST Controller Model Selection: Disagreement of Model Selection Signals............................................................................ 766 DAJRKR................................................................................................................................................. 768 HST Controller CAN-NET Signal: Disconnection....................................................................................................... 768 When HST Controller Power Supply Circuit is Defective.............................................................................................. 770 DAJRMA................................................................................................................................................. 773 HST Controller: Disagreement in Option Selection................................................................................................... 773 DB2RKR................................................................................................................................................. 774 Engine Controller CAN-NET: Disconnection in Signal Line............................................................................................ 774 When Engine Controller Power Supply Circuit is Defective........................................................................................... 776 DD1NL4................................................................................................................................................. 778 Fan Automatic Reverse Switch Signal: Abnormality................................................................................................... 778 DD1NLD................................................................................................................................................. 780 Fan Reverse Switch Signal: Abnormality............................................................................................................. 780 DDB6KA................................................................................................................................................. 782 Parking Brake Switch A: Disconnection/Short Circuit................................................................................................ 782 DDB6KB................................................................................................................................................. 784 Parking Brake Switch B: Ground Fault............................................................................................................... 784 DDB6KZ................................................................................................................................................. 786 Parking Brake Switch or Parking Brake Reminder Switch: Trouble..................................................................................... 786 DDB6L0................................................................................................................................................. 788 Parking Brake Switch A: Ground Fault............................................................................................................... 788 DDB6L4................................................................................................................................................. 790 Parking Brake Switch B: Disconnection/Short Circuit................................................................................................ 790 DDD7KY................................................................................................................................................. 792 Travel Speed Control Dial Signal: Short Circuit.................................................................................................... 792 DDE5MA................................................................................................................................................. 794 Emergency Steering Operation Switch: Disconnection................................................................................................. 794 DDK3KA................................................................................................................................................. 796 Directional Selector Switch: Disconnection/Short Circuit........................................................................................... 796 DDK3KB................................................................................................................................................. 798 Directional Selector Switch: Ground Fault.......................................................................................................... 798 DDK6KA................................................................................................................................................. 800 FNR Lever: Disconnection/Ground Fault.............................................................................................................. 800 DDK6KY................................................................................................................................................. 804 FNR Lever: Short Circuit........................................................................................................................... 804 DDS5L6................................................................................................................................................. 806 Steering: Low Oil Pressure (Operation of Emergency Steering)....................................................................................... 806 DF10KA................................................................................................................................................. 808 Travel Speed Range Selector Switch: Disconnection/Ground Fault..................................................................................... 808 DF10KB................................................................................................................................................. 812 Travel Speed Range Selector Switch: Short Circuit.................................................................................................. 812 DGH1KX................................................................................................................................................. 814 HST Oil Temperature Sensor: Ground Fault........................................................................................................... 814 DGR2KB................................................................................................................................................. 816 Brake Oil Temperature Sensor: Ground Fault......................................................................................................... 816 DGR2KZ................................................................................................................................................. 818 Brake Oil Temperature Sensor: Disconnection/Short Circuit.......................................................................................... 818 DHH1KX................................................................................................................................................. 820 HST Oil Pressure Sensor: Disconnection/Ground Fault................................................................................................ 820 DHH1KY................................................................................................................................................. 822 HST Oil Pressure Sensor: Short Circuit............................................................................................................. 822 DHTCL6................................................................................................................................................. 824 HST Filter Clogging Sensor: Functional Defect...................................................................................................... 824 DJF1KA................................................................................................................................................. 826 Fuel Level Sensor: Disconnection/Short Circuit..................................................................................................... 826 DLT3KX................................................................................................................................................. 828 Travel Speed Sensor B: Abnormality................................................................................................................. 828 DLT4KX................................................................................................................................................. 832 Travel Speed Sensor A: Abnormality................................................................................................................. 832 DLT4LC................................................................................................................................................. 834 Travel Speed Sensor A & B: Abnormality............................................................................................................. 834 DV00KY................................................................................................................................................. 836 Alarm Buzzer: Short Circuit........................................................................................................................ 836 DW26KA................................................................................................................................................. 838 Motor 2 Solenoid: Disconnection/Ground Fault....................................................................................................... 838 DW26KY................................................................................................................................................. 840 Motor 2 Solenoid: Short Circuit.................................................................................................................... 840 DW7BKY................................................................................................................................................. 842 Fan Reverse Solenoid Circuit: Short Circuit........................................................................................................ 842 DW7BKZ................................................................................................................................................. 844 Fan Reverse Solenoid Circuit: Disconnection/Ground Fault........................................................................................... 844 DX16KA................................................................................................................................................. 846 Fan EPC Solenoid: Disconnection.................................................................................................................... 846 DX16KB................................................................................................................................................. 848 Fan EPC Solenoid: Ground Fault..................................................................................................................... 848 DX16KY................................................................................................................................................. 850 Fan EPC Solenoid: Short Circuit.................................................................................................................... 850 DX19KA................................................................................................................................................. 852 Motor 1 Solenoid: Disconnection.................................................................................................................... 852 DX19KB................................................................................................................................................. 854 Motor 1 Solenoid: Ground Fault..................................................................................................................... 854 DX19KY................................................................................................................................................. 856 Motor 1 Solenoid: Short Circuit.................................................................................................................... 856 DX20KA................................................................................................................................................. 858 Clutch EPC Solenoid: Disconnection................................................................................................................. 858 DX20KB................................................................................................................................................. 860 Clutch EPC Solenoid: Ground Fault.................................................................................................................. 860 DX20KY................................................................................................................................................. 862 Clutch EPC Solenoid: Short Circuit................................................................................................................. 862 DXH7KB................................................................................................................................................. 864 Reverse Solenoid: Ground Fault..................................................................................................................... 864 DXH7KZ................................................................................................................................................. 866 Reverse Solenoid: Disconnection/Short Circuit...................................................................................................... 866 DXH8KB................................................................................................................................................. 868 Forward Solenoid: Ground Fault..................................................................................................................... 868 DXH8KZ................................................................................................................................................. 870 Forward Solenoid: Disconnection/Short Circuit...................................................................................................... 870 J141N1................................................................................................................................................. 872 Steering Pump: Overrun Alarm....................................................................................................................... 872 M100N1................................................................................................................................................. 873 HST Pump: Overrun Alarm............................................................................................................................ 873 M400N1................................................................................................................................................. 874 Motor 1: Overrun Alarm............................................................................................................................. 874 TROUBLESHOOTING: E-MODE.................................................................................................................................... 876 Troubleshooting Electrical System...................................................................................................................... 876 Information in Troubleshooting Table............................................................................................................... 876 E-1.................................................................................................................................................... 878 Engine Does Not Start.............................................................................................................................. 878 E-2.................................................................................................................................................... 886 Preheater Does Not Operate Normally................................................................................................................ 886 E-3.................................................................................................................................................... 890 Defective Boom Kick-Out Function and Cancellation.................................................................................................. 890 E-4.................................................................................................................................................... 894 Defective Bucket Positioner Function and Cancellation.............................................................................................. 894 E-5.................................................................................................................................................... 898 Defective Lift Arm FLOATING Holding Function and Cancellation...................................................................................... 898 E-6.................................................................................................................................................... 902 Travel Direction Selection System Does Not Function................................................................................................ 902 E-7.................................................................................................................................................... 906 Wiper Does Not Operate............................................................................................................................. 906 E-8.................................................................................................................................................... 910 Windshield Washer Does Not Operate................................................................................................................. 910 E-9.................................................................................................................................................... 913 Headlamp, Clearance Lamp, and Tail Lamp Do Not Light Up or Go Off.................................................................................. 913 E-10................................................................................................................................................... 921 Working Lamp Does Not Light Up or Go Off........................................................................................................... 921 E-11................................................................................................................................................... 926 Turn Signal Lamp and Hazard Lamp Do Not Light Up or Go Off......................................................................................... 926 E-12................................................................................................................................................... 932 Brake Lamp Does Not Light or It Keeps Lighting Up.................................................................................................. 932 E-13................................................................................................................................................... 934 Backup Lamp Does Not Light or It Keeps Lighting Up................................................................................................. 934 E-14................................................................................................................................................... 937 Backup Alarm Does Not Sound or It Keeps Sounding................................................................................................... 937 E-15................................................................................................................................................... 942 Horn Does Not Sound or It Keeps Sounding........................................................................................................... 942 E-16................................................................................................................................................... 944 Alarm Buzzer Does Not Sound or It Keeps Sounding................................................................................................... 944 E-17................................................................................................................................................... 946 Air Conditioner Does Not Operate or Stop........................................................................................................... 946 E-18................................................................................................................................................... 950 The KOMTRAX System Does Not Work Properly.......................................................................................................... 950 Lamp Display Section of KOMTRAX Terminal........................................................................................................... 952 TROUBLESHOOTING: H-MODE.................................................................................................................................... 953 Troubleshooting Hydraulic and Mechanical Systems....................................................................................................... 953 Method of Using Troubleshooting Chart.............................................................................................................. 953 Table of Failure Codes and Causes.................................................................................................................. 956 H-1.................................................................................................................................................... 958 Machine Does Not Start............................................................................................................................. 958 H-2.................................................................................................................................................... 959 Travel Speed Is Slow............................................................................................................................... 959 H-3.................................................................................................................................................... 960 Traction Force Is Weak............................................................................................................................. 960 H-4.................................................................................................................................................... 961 Engine Stalls When Traveling or Engine Speed Drops Excessively..................................................................................... 961 H-5.................................................................................................................................................... 962 Gear is Not Shifted................................................................................................................................ 962 H-6.................................................................................................................................................... 963 Steering Wheel Does Not Turn....................................................................................................................... 963 H-7.................................................................................................................................................... 964 Steering Wheel Is Heavy............................................................................................................................ 964 H-8.................................................................................................................................................... 965 Steering Wheel Shakes or Jerks..................................................................................................................... 965 H-9.................................................................................................................................................... 966 Machine Deviates Naturally to One Side When Traveling.............................................................................................. 966 H-10................................................................................................................................................... 967 Brake Does Not Work or Does Not Work Well.......................................................................................................... 967 H-11................................................................................................................................................... 968 Brake Is Not Released or Is Dragged................................................................................................................ 968 H-12................................................................................................................................................... 969 Lift Arm Does Not Rise or Lower.................................................................................................................... 969 H-13................................................................................................................................................... 970 Lift Arm Moves Slowly or Lift Arm Rising Force Is Insufficient..................................................................................... 970 H-14................................................................................................................................................... 971 When Rising, Lift Arm Starts to Move Slowly at a Specific Height................................................................................... 971 H-15................................................................................................................................................... 971 Lift Arm Cylinder Cannot Hold Down The Bucket (Bucket Rises in the Air)............................................................................ 971 H-16................................................................................................................................................... 971 Hydraulic Drifts of the Lift Arm Occur Often....................................................................................................... 971 H-17................................................................................................................................................... 972 Lift Arm Wobbles During Operation.................................................................................................................. 972 H-18................................................................................................................................................... 972 When Control Lever Is Switched from HOLD to RAISE, Lift Arm Falls Temporarily...................................................................... 972 H-19................................................................................................................................................... 973 Bucket Does Not Tilt Back.......................................................................................................................... 973 H-20................................................................................................................................................... 974 Bucket Moves Slowly or Tilting-Back Force Is Insufficient.......................................................................................... 974 H-21................................................................................................................................................... 975 Bucket Starts to Operate Slowly in the Midst of Tilting-Back....................................................................................... 975 H-22................................................................................................................................................... 975 Bucket Cylinder Cannot Hold Down the Bucket........................................................................................................ 975 H-23................................................................................................................................................... 975 Hydraulic Drifts of the Bucket Occur Often......................................................................................................... 975 H-24................................................................................................................................................... 976 Bucket Wobbles During Travel with Load............................................................................................................. 976 H-25................................................................................................................................................... 976 When Control Lever Is Switched from HOLD to TILT, the Bucket Falls Temporarily..................................................................... 976 H-26................................................................................................................................................... 977 Control Levers of Lift Arm and Bucket Do Not Move Smoothly and Are Heavy........................................................................... 977 H-27................................................................................................................................................... 978 ECSS Does Not Operate and Machine Pitches and Bounces.............................................................................................. 978 H-28................................................................................................................................................... 979 Fan Revolution Is Abnormal......................................................................................................................... 979 ENGINE SYSTEM (S-MODE)..................................................................................................................................... 980 Method Of Using Troubleshooting Charts................................................................................................................. 980 S-1.................................................................................................................................................... 984 Engine Starting Performance Is Poor................................................................................................................ 984 S-2.................................................................................................................................................... 986 Engine Does Not Start.............................................................................................................................. 986 Engine Turns But No Exhaust Smoke Comes Out........................................................................................................ 987 Engine Smoke Comes Out But Engine Does Not Start................................................................................................... 988 S-3.................................................................................................................................................... 990 Engine Does Not Pick Up Smoothly................................................................................................................... 990 S-4.................................................................................................................................................... 992 Engine Stops During Operations..................................................................................................................... 992 S-5.................................................................................................................................................... 994 Engine Does Not Rotate Smoothly.................................................................................................................... 994 S-6.................................................................................................................................................... 996 Engine Lacks Output (or Lacks Power)............................................................................................................... 996 S-7.................................................................................................................................................... 998 Exhaust Smoke is Black (Incomplete Combustion)..................................................................................................... 998 S-8....................................................................................................................................................1000 Oil Consumption is Excessive (or Exhaust Smoke is Blue)............................................................................................1000 S-9....................................................................................................................................................1001 Oil Becomes Contaminated Quickly...................................................................................................................1001 S-10...................................................................................................................................................1002 Fuel Consumption is Excessive......................................................................................................................1002 S-11...................................................................................................................................................1003 Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)..............................................................................1003 S-12...................................................................................................................................................1004 Oil Pressure Drops.................................................................................................................................1004 S-13...................................................................................................................................................1005 Oil Level Rises (Entry of Coolant or Fuel).........................................................................................................1005 S-14...................................................................................................................................................1006 Coolant Temperature Becomes Too High (Overheating).................................................................................................1006 S-15...................................................................................................................................................1008 Abnormal Noise is Made.............................................................................................................................1008 S-16...................................................................................................................................................1010 Vibration is Excessive.............................................................................................................................1010 50 DISASSEMBLY AND ASSEMBLY....................................................................................................................................1013 HOW TO READ THIS MANUAL....................................................................................................................................1017 Removal and Installation of Assemblies.................................................................................................................1017 Disassembly and Assembly of Assemblies.................................................................................................................1019 COATING MATERIALS LIST.....................................................................................................................................1021 SPECIAL TOOLS LIST.........................................................................................................................................1024 SKETCHES OF SPECIAL TOOLS..................................................................................................................................1028 CONNECTOR REPAIR PROCEDURES................................................................................................................................1037 Stripping Insulation...................................................................................................................................1037 Wire Inspection........................................................................................................................................1037 Contact Terminal Removal (HD30 Type)...................................................................................................................1038 Crimping Contact Terminal (HD30 Type)..................................................................................................................1039 Insertion Of Contact Terminal (HD30 Type)..............................................................................................................1040 Contact Terminal Removal (DT Type).....................................................................................................................1041 Crimping Contact Terminal (DT Type)....................................................................................................................1042 Insertion Of Contact Terminal (DT Type)................................................................................................................1043 ENGINE AND COOLING SYSTEM..................................................................................................................................1044 Fuel Supply Pump.......................................................................................................................................1044 Removal............................................................................................................................................1044 Installation.......................................................................................................................................1046 Fuel Injector..........................................................................................................................................1047 Removal............................................................................................................................................1047 Installation.......................................................................................................................................1052 Cylinder Head Assembly.................................................................................................................................1057 Removal............................................................................................................................................1057 Installation.......................................................................................................................................1066 Engine Hood............................................................................................................................................1073 Removal............................................................................................................................................1073 Installation.......................................................................................................................................1076 Radiator...............................................................................................................................................1077 Removal............................................................................................................................................1077 Installation.......................................................................................................................................1080 Air Aftercooler........................................................................................................................................1081 Removal............................................................................................................................................1081 Installation.......................................................................................................................................1082 Hydraulic Oil Cooler...................................................................................................................................1083 Removal............................................................................................................................................1083 Installation.......................................................................................................................................1085 Engine.................................................................................................................................................1086 Removal............................................................................................................................................1086 Installation.......................................................................................................................................1092 Engine Front Oil Seal..................................................................................................................................1094 Removal............................................................................................................................................1094 Installation.......................................................................................................................................1097 Engine Rear Oil Seal...................................................................................................................................1098 Removal............................................................................................................................................1098 Installation.......................................................................................................................................1100 Cooling Fan and Fan Motor..............................................................................................................................1103 Removal............................................................................................................................................1103 Installation.......................................................................................................................................1106 Fuel Tank..............................................................................................................................................1107 Removal............................................................................................................................................1107 Installation.......................................................................................................................................1109 POWER TRAIN................................................................................................................................................1110 Transfer...............................................................................................................................................1110 Removal............................................................................................................................................1110 Installation.......................................................................................................................................1114 Disassembly........................................................................................................................................1116 Assembly...........................................................................................................................................1129 Parking Brake..........................................................................................................................................1144 Removal............................................................................................................................................1144 Installation.......................................................................................................................................1146 Disassembly........................................................................................................................................1147 Assembly...........................................................................................................................................1150 Front Axle.............................................................................................................................................1154 Removal............................................................................................................................................1154 Installation.......................................................................................................................................1156 Rear Axle..............................................................................................................................................1157 Removal............................................................................................................................................1157 Installation.......................................................................................................................................1160 Axle Housing...........................................................................................................................................1161 Disassembly........................................................................................................................................1162 Assembly...........................................................................................................................................1167 Differential...........................................................................................................................................1173 Disassembly........................................................................................................................................1174 Assembly...........................................................................................................................................1187 UNDERCARRIAGE AND FRAME....................................................................................................................................1208 Center Hinge Pin.......................................................................................................................................1208 Removal............................................................................................................................................1208 Installation.......................................................................................................................................1215 Counterweight..........................................................................................................................................1221 Removal............................................................................................................................................1221 Installation.......................................................................................................................................1222 HYDRAULIC SYSTEM...........................................................................................................................................1223 HST Pump and 4-Gear Pump...............................................................................................................................1223 Removal............................................................................................................................................1223 Installation.......................................................................................................................................1226 HST Pump...............................................................................................................................................1228 Disassembly........................................................................................................................................1228 Assembly...........................................................................................................................................1241 HST Motor 1............................................................................................................................................1261 Removal............................................................................................................................................1261 Installation.......................................................................................................................................1263 HST Motor 2............................................................................................................................................1264 Removal............................................................................................................................................1264 Installation.......................................................................................................................................1266 HST Motor..............................................................................................................................................1267 Disassembly........................................................................................................................................1267 Assembly...........................................................................................................................................1279 Work Equipment Control Valve...........................................................................................................................1289 Removal............................................................................................................................................1289 Installation.......................................................................................................................................1291 Hydraulic Tank.........................................................................................................................................1292 Removal............................................................................................................................................1292 Installation.......................................................................................................................................1294 Hydraulic Cylinder.....................................................................................................................................1295 Disassembly........................................................................................................................................1296 Assembly...........................................................................................................................................1299 WORK EQUIPMENT.............................................................................................................................................1303 Work Equipment.........................................................................................................................................1303 Removal............................................................................................................................................1303 Installation.......................................................................................................................................1307 CAB AND ITS ATTACHMENTS....................................................................................................................................1311 Cab and Floor Frame....................................................................................................................................1311 Removal............................................................................................................................................1311 Installation.......................................................................................................................................1316 Cab Glass (Stuck Glass)................................................................................................................................1318 Removal............................................................................................................................................1318 Installation.......................................................................................................................................1319 Air Conditioner Unit...................................................................................................................................1327 Removal............................................................................................................................................1327 Installation.......................................................................................................................................1333 ELECTRICAL SYSTEM..........................................................................................................................................1335 Monitor Panel..........................................................................................................................................1335 Removal............................................................................................................................................1335 Installation.......................................................................................................................................1337 Engine Controller......................................................................................................................................1338 Removal............................................................................................................................................1338 Installation.......................................................................................................................................1339 HST Controller.........................................................................................................................................1340 Removal............................................................................................................................................1340 Installation.......................................................................................................................................1340 KOMTRAX Terminal.......................................................................................................................................1342 Removal............................................................................................................................................1342 Installation.......................................................................................................................................1343 90 DIAGRAMS AND SCHEMATICS.....................................................................................................................................1345 HYDRAULIC SYSTEM...........................................................................................................................................1347 Hydraulic Circuit Diagram..............................................................................................................................1347 ELECTRICAL SYSTEM..........................................................................................................................................1348 Machine Monitor System.................................................................................................................................1348 HST Controller System Circuit Diagram..................................................................................................................1349 HST Controller System (1/2)............................................................................................................................1350 HST Controller System (2/2)............................................................................................................................1351 Machine Monitor System (Lamp Related Items) (1/2)......................................................................................................1352 Machine Monitor System (Lamp Related Items) (2/2)......................................................................................................1353 Machine Monitor System (Other than Lamp Related Items) (1/2)...........................................................................................1354 Machine Monitor System (Other than Lamp Related Items) (2/2)...........................................................................................1355 Engine Controller System (1/2).........................................................................................................................1356 Engine Controller System (2/2).........................................................................................................................1357 Electrical Circuit Diagram (1/9).......................................................................................................................1358 Electrical Circuit Diagram (2/9).......................................................................................................................1359 Electrical Circuit Diagram (3/9).......................................................................................................................1360 Electrical Circuit Diagram (4/9).......................................................................................................................1361 Electrical Circuit Diagram (5/9).......................................................................................................................1362 Electrical Circuit Diagram (6/9).......................................................................................................................1363 Electrical Circuit Diagram (7/9).......................................................................................................................1364 Electrical Circuit Diagram (8/9).......................................................................................................................1365 Electrical Circuit Diagram (9/9).......................................................................................................................1366 Connector List and Sterograms..........................................................................................................................1367 LUBRICATION SYSTEM.........................................................................................................................................1368 Auto-Greasing Circuit Diagram..........................................................................................................................1368
KOMATSU WA250-6 WHEEL LOADER SHOP MANUAL A76001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
