Komatsu WA250-6 Wheel Loader Shop Manual – PDF DOWNLOAD 

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Komatsu WA250-6 Wheel Loader Shop Manual – PDF DOWNLOAD

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Komatsu WA250-6 Wheel Loader Shop Manual – PDF DOWNLOAD 

Language : English
Pages : 1368
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu WA250-6 Wheel Loader Shop Manual – PDF DOWNLOAD 

SERIAL NUMBERS WA250-6 A76001 and up
ENGINE 6D107E-1

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

TABLE OF CONTENTS:

Komatsu WA250-6 Wheel Loader Shop Manual – PDF DOWNLOAD

SERIAL NUMBERS WA250-6 A76001 and up
ENGINE 6D107E-1

 COVER 0
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

S.V 11/12/24