Komatsu Wheel Loader WA200, WA200L, WA250, WA250L, WA250LC Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader WA200, WA200L, WA250, WA250L, WA250LC, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Wheel Loader WA200, WA200L, WA250, WA250L, WA250LC workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
CEBM000703 - Wheel Loader WA250-6 Shop Manual.pdf
CEBM000704 - Wheel Loader WA250-6 Shop Manual.pdf
CEBM001301 - Wheel Loader WA250-3L Shop Manual.pdf
CEBM001801 - Parallel Tool Carrier WA250-3 Shop Manual.pdf
CEBMW18020 - Wheel Loader WA250-1LC Shop Manual.pdf
SEBM005910 - Wheel Loader WA250-3 avance Loader Shop Manual.pdf
SEBM04180110 - Wheel Loader WA200-1, WA250-1 Shop Manual.pdf
SEN06503-05 - Wheel Loader WA200-7 Shop Manual.pdf
SEN06627-03 - Wheel Loader WA200-8 Shop Manual.pdf
TEN00151-00 - Wheel Loader GALEO WA200-5 Operation & Maintenance Manual.pdf
TEN00152-00 - Wheel Loader GALEO WA200L-5 Operation & Maintenance Manual.pdf
TEN00215-00 - Wheel Loader GALEO WA250-5 Operation & Maintenance Manual.pdf
TEN00227-04 - Wheel Loader WA200-6 Operation & Maintenance Manual.pdf
TEN00395-01 - Wheel Loader WA200-5 Operation & Maintenance Manual.pdf
TEN00396-01 - Wheel Loader WA250-5 Operation & Maintenance Manual.pdf
TEN00399-00 - Wheel Loader WA250-6 Operation & Maintenance Manual.pdf
TEN00450-01 - Wheel Loader WA250-6 Operation & Maintenance Manual.pdf
TEN00471-01 - Wheel Loader WA200-6 Operation & Maintenance Manual.pdf
CEAM000502 - Wheel Loader WA250-6 Operation & Maintenance Manual.pdf
CEAM001500 - Wheel Loader WA250-3 Operation & Maintenance Manual.pdf
CEAM002000 - Parallel Tool Carrier Wheel Loader WA250-3 Operation & Maintenance Manual.pdf
SEAM007500 - Wheel Loader WA250-3 Operation & Maintenance Manual.pdf
SEAM021500 - Wheel Loader WA250-3 Operation & Maintenance Manual.pdf
SEAM050500 - Wheel Loader WA250-5 Operation & Maintenance Manual.pdf
SEAM056900T - Wheel Loader GALEO WA250L-5 Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 5,332 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
CEAM000502 - Wheel Loader WA250-6 Operation & Maintenance Manual...3
CEAM000502...3
INTRODUCTION...5
FOREWORD...6
SAFETY INFORMATION...7
APPROVED AND NON-APPROVED USES...8
Approved Functions...8
Non-Approved Functions...8
VISIBILITY STANDARD...9
Visibility in Immediate Area...9
12-M Radius Visibility...9
PRODUCT IDENTIFICATION...10
Machine...10
Service Meter Location...11
Directions of Machine...11
Machine Serial Number/Product Identification Number (PIN)...12
Engine Serial Number, EPA Regulations...12
SERIAL NUMBERS AND DEALER INFORMATION...13
Model: WA250-6...13
TABLE OF CONTENTS...15
SAFETY...27
SAFETY AND WARNING DECALS...28
Location of the Safety Labels...28
Safety Labels...29
GENERAL SAFETY RULES AND PRECAUTIONS...35
General Safety Rules...35
Safety at Job Site...36
Safety Features...36
Clothing and Protective Equipment...36
Keep Machine Clean...37
Fire and Explosion Prevention...37
Fire Caused by Fuel, Oil, Antifreeze, or Window Washer Fluid...37
Fire Caused by Accumulation of Flammable Material...38
Fire Caused by Electrical Wiring...38
Fire Caused by Piping...38
Explosion Caused by Lighting Equipment...38
Action if Fire Occurs...39
Fire Extinguisher and First Aid Kit...39
Mounting and Dismounting...40
Inside Operator’s Compartment...41
Emergency Escape from Operator’s Cab...41
Precautions When Standing Up from Operator’s Seat...42
Leaving Operator’s Compartment...43
Parking the Machine...44
Precautions When Using ROPS...45
Unauthorized Modification...45
Precautions for Attachments and Options...45
Precautions When Cleaning Cab Glass...46
Asbestos Hazard Alert...46
Crush or Pinch-Point Dangers...47
Precautions for Ventilation Exhaust Gas...47
PRECAUTIONS BEFORE STARTING OPERATIONS...48
Pre-Operational Checks...48
Ensure Good Visibility...48
Signs and Signals...48
Precaution for Warning Tag...49
Checks Before Starting Engine, Adjustments...49
Precautions When Starting...50
Precautions in Cold Areas...50
Precautions for Job Site...51
Work Site Hazards...51
Working on Loose or Unstable Ground...51
Prohibited Operations...52
Avoiding Dangerous Situations...52
Working Near High Voltage Cables...54
RULES FOR ROAD TRAVEL...55
Travel Precautions...55
Traveling on Slopes...56
Using the Brakes...57
Traveling in Reverse...57
Operating on Snow or Frozen Surfaces...58
PRECAUTIONS DURING INSPECTION AND MAINTENANCE...59
Warning Tags...59
Workplace Environment...59
Systems Equipped with ECSS...59
Equipment Storage...60
Working Under the Machine...60
Using Drop Lamps...61
Using Proper Tools...61
Keeping the Machine Clean...61
Precautions When Welding...61
Precautions When Using Hammer...62
Noise...62
Stopping Engine During Inspection and Maintenance...63
Running the Machine During Maintenance...65
Rules for Refueling the Machine...66
Cooling System Precautions...66
Window Washer Fluid...66
Battery Information...66
Precautions...66
Hazards...67
Using Booster Cables...68
Starting the Machine with Booster Cables...68
High-Pressure Precautions...69
Precautions for High-Pressure Oil...69
Safe Handling of High-Pressure Hoses...69
Precautions for High-Pressure Fuel...69
High-Temperature Precautions...70
High-Temperature Areas...70
High-Temperature Coolant...70
High-Temperature Oil...70
High Voltage...70
Accumulator and Gas Spring...71
Inflating Tires...71
Storing Tires...71
Using Compressed Air...72
Disposal of Waste Materials...72
Critical Parts...72
Maintenance of Air Conditioner...72
OPERATION...73
GENERAL VIEW...74
General View of Machine...74
General View of Controls and Gauges...75
Machine Monitor...76
EXPLANATION OF COMPONENTS...77
Machine Monitor...77
Types of Warnings...78
Emergency Stop...78
Mistaken Operation...78
Inspection and Maintenance...78
Central Warning Lamp...79
Character Display Portion...80
Service Meter...81
Engine Speed or Travel Speed...81
Action Code Display...81
Failure Code Display...83
Filter, Oil Replacement Time Display...83
Emergency Stop Items...86
Brake Oil Pressure Caution Lamp...87
Engine Oil Pressure Caution Lamp...87
Battery Charge Circuit Caution Lamp...88
Steering Oil Pressure Caution Lamp (if equipped)...88
Caution Items...89
Brake Oil Temperature Caution Lamp...90
Quick Coupler Operation Pilot Lamp (if equipped)...90
Parking Brake Reminder Caution Lamp...91
HST Oil Temperature Caution Lamp...91
Engine Coolant Temperature Caution Lamp...91
Fuel Level Caution Lamp...92
Warning/Limit Functions for Travel Speed...92
Inspection and Maintenance Items...93
Water Separator Caution Lamp...93
Radiator Coolant Level Caution Lamp...94
Engine Oil Level Caution Lamp...94
HST Oil Filter Clogging Caution Lamp...94
Air Cleaner Clogging Caution Lamp...94
Maintenance Caution Lamp...95
Pilot Display Portion...96
Parking Brake Pilot Lamp...97
Cooling Fan Reverse Rotation Pilot Lamp...97
Emergency Steering Pilot Lamp (if equipped)...97
Preheating Pilot Lamp...97
Directional Selector Pilot Lamp...98
Economy Operation Display Lamp...98
S Mode Operation Pilot Lamp...98
Shift Hold Pilot Lamp...98
Traction Control Operation Pilot Light...98
Travel Speed Range Selector Switch Position Pilot Lamp...99
Directional Lever Position Pilot Lamp...99
Turn Signal Pilot Lamp...99
Head Lamp High-Beam Pilot Lamp...99
Meter Display Portion...100
HST Oil Temperature Gauge...100
Engine Coolant Temperature Gauge...101
Speedometer...101
Meter Display Pilot Lamp...101
Fuel Gauge...101
OTHER FUNCTIONS OF MACHINE MONITOR...102
Overall Menu...102
Selecting Traction Level...104
Selecting HST Changing Function...105
Displaying Odometer...106
Resetting Filter, Oil Replacement Time...106
Entering Telephone Number...108
Selecting Language...109
Adjusting Monitor Brightness...111
Switching Travel Speed/Engine Speed Display...113
Switching Travel Speed/Engine Speed Display/Non-Display...114
SWITCHES AND CONTROLS...115
General View...115
Starting Switch...116
Speed Range Selector Switch...116
Variable Shift Control Switch...117
Quick Coupler Attachment Switch (if equipped)...117
Cooling Fan Auto-Reverse Rotation Switch...117
Directional Selector Switch Actuation Switch...121
Traction Control Switch...121
Max. Traction Switch...122
Front Wiper Switch...123
Machine Monitor Mode Selector Switch 1...123
Machine Monitor Mode Selector Switch 2...123
ECSS Switch...124
Horn Button...124
Lamp Switch...125
Turn Signal Lever...125
Dimmer Switch...125
Front Working Lamp Switch...126
Rear Working Lamp Switch...126
Hazard Lamp Switch...126
Rear Wiper Switch...126
Directional Selector Switch...127
Cigarette Lighter...127
Room Lamp Switch...127
Rear Heated Wire Glass Switch...128
CONTROL LEVERS, PEDALS...129
General View...129
Directional Lever...130
Work Equipment Control Lever...130
Work Equipment Lock Lever...131
Accelerator Pedal...131
Brake Pedals...132
Parking Brake Lever...132
SECURITY LOCKS AND SAFETY FEATURES...133
Steering Tilt Lock Lever...133
Frame Lock Bar...133
Caps and Covers with Lock...134
Fuel Tank Filler Port Cap...134
Cover with Lock...135
Backup Alarm...135
MACHINE FEATURES...136
Towing Pin...136
Grease Pump...136
Cab Door...137
Emergency Escape Right Door...137
Left Cab Door, Door Open Lock...139
Left Cab Door, Knob...140
Left Cab Door, Handle...140
Left Cab Sliding Window (Lock Release Knob)...140
Cab Wiper...140
Dust Indicator...141
Storage Box...141
ELECTRICAL...142
Power Outlet...142
Fuses...142
Fuse Capacity and Name of Circuit...143
Slow-Blow Fuse...144
WORK OPERATIONS...145
Walk-Around Check...145
Precautions Before Starting Work Operations...145
Check Before Starting Engine...149
Check Machine Monitor...149
Check Coolant Level, Add Coolant...150
Check Oil Level in Engine Oil Pan, Add Oil...151
Check Water Separator...152
Check Air Cleaner...153
Check Fuel Level, Add Fuel...154
Check Electric Wiring...155
Adjustments...157
Adjusting Seat...157
Adjusting Wrist Rest...158
Adjusting Seat Belt...159
Adjusting Mirrors...160
Final Checks Before Starting Engine...161
Starting Engine...163
Normal Starting...163
Starting in Cold Weather...165
Automatic Warming-Up Operation...166
Operations and Checks After Starting Engine...167
Checks After Starting Engine...167
Breaking in the Machine...168
Normal Operation...168
Stopping Engine...170
Check After Stopping Engine...170
Moving the Machine (Directional, Speed), Stopping the Machine...171
Moving the Machine...171
Changing Direction...174
Using Switch to Change between Forward and Reverse...175
Stopping the Machine...177
Turning...179
Emergency Steering (if equipped)...180
Operation of Work Equipment...181
Work Equipment Lock Lever...181
Lift Arm...181
Bucket...182
Work Possible Using Wheel Loader...183
Digging Operations...183
Loading Piled Soil or Blasted Rock...183
Digging and Loading on Level Ground...185
Leveling Operations...186
Pushing Operations...186
Load-and-Carry Operations...186
Loading Operations...187
Cross-Drive Loading...187
V-Shape Loading...187
Preparations for Loading, Gathering Rocks...188
Approaching Facing...188
Digging...189
Traveling in Reverse After Excavation...191
Approaching Dump Truck...192
Loading Dump Truck...193
Reversing Away From Dump Truck...194
Precautions During Work Operations...195
Piling Up Loads...195
Handling Blasted Rock...195
Loosened Boulders...199
Pit Excavation...199
Cutting Face Operations...199
Switching Between Forward and Reverse...199
Turning When Tires Are Stationary...200
Wheel Brake Does Not Work...200
Permissible Water Depth...200
Lower the Center of Gravity when Turning...200
Driving Up or Down Slopes...200
Driving the Machine...201
Adjusting Work Equipment...202
Adjusting Boom Kickout...202
Adjusting Bucket Positioner...203
Bucket Level Indicator...204
Measuring Dump Angle...205
Measuring Bucket Dump Angle...205
Measuring Coupler Dump Angle...207
Parking the Machine...209
Checks After Completion of Operation...212
Before Stopping Engine...212
After Stopping Engine...212
Locking the Machine...213
HANDLING TIRES...214
Precautions When Handling Tires...214
Tire Pressure...215
Precautions for Using Load-and-Carry Method...216
TRANSPORTATION...217
Transportation Procedure...217
Loading and Unloading Trailers...218
Loading Machine...218
Securing Machine...219
Unloading Machine...221
LIFTING MACHINE...223
Lifting Position...223
Lifting Procedure...224
COLD WEATHER OPERATION...226
Precautions for Low Temperature...226
Fuel and Lubricants...226
Coolant...226
Battery...227
Precautions After Completion of Work...227
After Cold Weather...227
LONG-TERM STORAGE...228
Before Storage...228
During Storage...228
After Storage...228
AUTOMATIC AIR CONDITIONER...229
Control Panel...229
Main Power Switch...230
Fan Switch...230
Air Conditioner Switch...231
Auto Switch...232
Temperature Control Switch...232
FRESH/RECIRC Selector Switch...232
Mode Selector Switch...233
Method of Operation...234
Cooling Operation...234
Heating Operation...234
Drying-Heating and Demisting Operation...235
When Not Using the Air Conditioner Regularly...235
Precautions When Using Air Conditioner...235
Inspection and Maintenance...236
Cool Box...236
KOMTRAX...237
Basic Precautions...237
TROUBLESHOOTING...238
When Machine Runs Out of Fuel...238
Towing the Machine...238
When Engine Can Be Used...239
When Engine Cannot Be Used...239
Emergency Travel Operation...240
If Battery is Discharged...241
Precautions...241
Removal and Installation of Battery...241
Precautions for Charging Battery...242
Starting Engine With Booster Cables...243
Precautions When Connecting or Disconnecting Booster Cable...243
Connecting Booster Cable...243
Starting Engine...244
Disconnecting Booster Cable...244
Lowering Work Equipment When Engine Has Stopped...245
Other Troubleshooting...246
Electrical System...246
Chassis...247
Engine...249
MAINTENANCE...251
GUIDES TO MAINTENANCE...252
Check Service Meter...252
Komatsu Genuine Replacement Parts...252
Komatsu Genuine Oils...252
Always Use Clean Washer Fluid...252
Always Use Clean Oil and Grease...252
Checking for Foreign Materials in Drained Oil and On Filters...252
Fuel Strainer...252
Welding Instructions...253
Do Not Drop Things Inside Machine...253
Dusty Work Sites...253
Avoid Mixing Oil...253
Locking Inspection Covers...253
Bleeding Air from Hydraulic Circuit...253
Precautions When Installing Hydraulic Hoses...254
Checks After Inspection and Maintenance...254
OUTLINES OF SERVICE...255
Handling Oil, Fuel, Coolant, and Performing Oil Clinic...255
Oil...255
Fuel...256
Coolant and Water for Dilution...256
Grease...257
Storing Oil and Fuel...257
Filters...257
Performing KOWA (Komatsu Oil Wear Analysis)...258
KOWA Analysis Items...258
Oil Sampling...258
Outline of Electric System...259
WEAR PARTS...260
Wear Parts List...260
RECOMMENDED FUEL, COOLANT, AND LUBRICANTS...261
Fuel, Coolant, and Lubricant Ambient Temperature Chart...262
Recommended Brands, Other Than Komatsu Genuine Oil...263
Biodiesel Usage...264
Biodiesel Recommendation for Komatsu Engines...264
Biodiesel Terminology...264
Certification and Standards...265
Warranty and Use of Biodiesel Fuel in Komatsu Engines...265
Requirements for Using Biodiesel Fuel in Komatsu Engines...265
Properties of Biodiesel...266
Komatsu Biodiesel Blend Specification for B5 to B20...267
Summary of Recommendations...268
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...269
Torque List...269
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...271
Safety Critical Parts List...272
MAINTENANCE SCHEDULE CHART...273
SERVICE PROCEDURE...275
Initial 10 Hours Service...275
Initial 250 Hours Service...275
Initial 1000 Hours Service...275
When Required...276
Clean, Replace Air Cleaner Element...276
Clean Inside of Cooling System...280
Check Oil Level in Transfer Case, Add Oil...283
Check Axle Oil Level, Add Oil...285
Clean Axle Case Breather...287
Clean Air Conditioner Condenser...288
Check Window Washing Fluid Level, Add Fluid...288
Clean Radiator Fins and Cooler Fins...289
Turn, Replace Bolt-On Cutting Edge...294
Replace Bucket Teeth (if equipped)...295
Check Air Conditioner...298
Replace Slow-Blow Fuse...300
Check Function of Accumulator (ECSS and Brake Damper)...301
Select Tires...302
Check Tire Pressure...303
Clean, Replace Fuel Breather Filter...304
Check Before Starting...306
Every 50 Hours Service...307
Drain Water, Sediment from Fuel Tank...307
Every 100 Hours Service...308
Lubricate Rear Axle Pivot Pin...308
Check Oil Level in Hydraulic Tank, Add Oil...309
Clean Element in Air Conditioner Fresh Air Filter...310
Every 250 Hours Service...311
Check Battery Electrolyte Level...311
Check Parking Brake...312
Check Air Conditioner Compressor Belt Tension, Adjust...313
Check for Loose Wheel Hub Nuts, Tighten...314
Clean Element in Air Conditioner Recirculation Filter...314
Check Function of Brake Accumulator...315
Lubricating...316
Every 500 Hours Service...317
Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge...317
Replace Fuel Prefilter Cartridge...319
Every 1000 Hours Service...321
Change Oil in Transfer Case...321
Clean Transfer Case Breather...322
Replace Fuel Main Filter Cartridge...323
Replace HST Oil Filter Element...325
Lubricating...326
Check Engine Air Intake Piping Clamps for Looseness...326
Check Alternator Drive Belt Tension, Adjust...326
Every 2000 Hours Service...327
Change Oil in Hydraulic Tank, Replace Hydraulic Filter Element...327
Replace Hydraulic Tank Breather Element...329
Replace HST Drain Filter...330
Change Axle Oil...331
Replace Element in Air Conditioner Recirculation Filter, Fresh Air Filter...332
Clean Brake Circuit Strainer...333
Check Brake Disc Wear...334
Check Function of PPC Accumulator...336
Check Alternator...337
Check Engine Valve Clearance, Adjust...337
Check Vibration Damper...337
Every 4000 Hours Service...338
Lubricating...338
Check Water Pump...339
Check Starting Motor...339
Check for Loose Engine High-Pressure Piping Clamps, Hardening of Rubber...339
Check for Missing Fuel Spray Prevention Cap, Hardening of Rubber...340
Every 8000 Hours Service...341
Replace High-Pressure Piping Clamps...341
Replace Fuel Spray Prevention Cap...341
SPECIFICATIONS...343
SPECIFICATIONS...344
OPTIONS, ATTACHMENTS...347
BUCKET AND TIRES...348
AM/FM RADIO CASSETTE STEREO SOUND SYSTEM...349
Sound System Components...351
Power Switch/Volume...351
Auto-Store/Preset Scan Button...351
Bass Control Knob...351
Treble Control Knob...352
Loudness Button...352
Time/Radio Display Selector Button...352
Tape Eject Button...353
Cassette Door...353
Fast-Forward, Rewind Buttons...353
Preset Buttons...353
Metal Tape Button...354
Manual Tuning Buttons...354
Seek Tuning Buttons...354
Band Selector Button...354
Method of Operation...355
Setting Preset Buttons...355
Using Auto-Preset...355
Using Manual Preset...355
Listening to Radio...356
Listening to Cassette Tape...356
Reversing the Tape...357
Precautions When Using...357
Handling Cassette Tape...357
HYDRAULIC QUICK COUPLER...358
Removing Attachment...358
Installing Attachment...360
CEAM001500 - Wheel Loader WA250-3 Operation & Maintenance Manual...363
INTRODUCTION...366
1. FORWARD...367
2. SAFETY INFORMATION...368
3. INTRODUCTION...369
3.1 INTENDED USE...369
3.2 FEATURES...369
3.3 BREAKING IN A NEW MACHINE...369
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...370
4.1 MACHINE SERIAL NO. PLATE POSITION...370
4.2 ENGINE SERIAL NO. PLATE POSITION...370
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...370
5. CONTENTS...371
SAFETY...376
6. GENERAL PRECAUTIONS...377
7. PRECAUTIONS DURING OPERATION...383
7.1 BEFORE STARTING ENGINE...383
7.2 AFTER STARTING ENGINE...386
7.3 TRANSPORTATION...395
7.4 BATTERY...396
7.5 TOWING...399
8. PRECAUTIONS FOR MAINTENANCE...400
8.1 BEFORE CARRYING OUT MAINTENANCE...400
8.2 DURING MAINTENANCE...405
8.3 TIRES...410
9. POSITION FOR ATTACHING SAFETY LABELS...412
9.1 POSITION FOR ATTACHING SAFETY LABELS...412
OPERATION...416
10. GENERAL VIEW...417
10.1 GENERAL VIEW OF MACHINE...417
10.2 GENERAL VIEW OF CONTROLS AND GAUGES...418
11. EXPLANATION OF COMPONENTS...419
11.1 METER, LAMPS...419
11.1.1 WARNING DISPLAYS...421
11.1.2 METER DISPLAY PORTION...425
11.2 SWITCHES...429
11.3 CONTROL LEVERS, PEDAL...434
11.4 STEERING COLUMN TILT LEVER...438
11.5 CAP WITH LOCK...438
11.5.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK...438
11.6 SAFETY BAR...439
11.7 TOWING PIN...439
11.8 GREASE PUMP CLAMP AND RUBBER RING...439
11.9 BACKUP ALARM...440
11.10 FUSE...441
11.10.1 FUSE CAPACITY AND NAME OF CIRCUIT...441
11.11 SLOW BLOW FUSE...442
11.12 STORAGE PLACE FOR THIS MANUAL...443
11.13 AUXILIARY POWER SOURCE...443
11.13.1 FOR MACHINES EQUIPPED WITH ROPS CAB...443
12. CHECK BEFORE STARTING ENGINE...444
12.1 WALK AROUND CHECK...444
12.2 CHECK BEFORE STARTING...447
12.2.1 CHECK COOLANT LEVEL, ADD COOLANT...447
12.2.2 CHECK MONITOR PANEL...447
12.2.3 CHECK FUEL LEVEL, ADD FUEL...448
12.2.4 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...448
12.2.5 CHECK AND REFILL OF OIL IN BRAKE OIL TANK...449
12.2.6 CHECK DUST INDICATOR...449
12.2.7 CHECK ELECTRICAL WIRING...450
12.2.8 DRAIN THE WATER FROM THE FUEL-WATER SEPARATOR...451
12.2.9 CHECK EFFECT OF PARKING BRAKE...451
12.2.10 CHECK EFFECT OF WHEEL BRAKES...452
12.2.11 CHECK SOUND OF HORN AND BACKUP ALARM...452
12.2.12 CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE...452
12.2.13 CHECK ENGINE EXHAUST COLOR AND SOUND...452
12.2.14 CHECK OPERATIONS OF GAUGES...452
12.2.15 CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING...452
12.2.16 CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE...452
12.2.17 CHECK LOCK OF CAB DOOR FOR MACHINES EQUIPPED WITH CAB...452
12.3 ADJUSTMENT BEFORE OPERATION...453
12.3.1 OPERATOR'S SEAT...453
12.3.2 ADJUST SEAT BELT...455
12.3.3 ADJUST REAR VEIW MIRRORS...456
12.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE...457
12.5 STARTING ENGINE...458
12.5.1 NORMAL STARTING PROCEDURES IN COLD AND WARM CONDITIONS...458
12.5.2 STARTING PROCEDURES AFTER EXTENDED SHUTDOWN OR OIL CHANGE...459
12.5.3 STARTING PROCEDURES AFTER CHANGING FUEL FILTERS...459
12.5.4 STARTING PROCEDURES AFTER RUNNING OUT OF FUEL...459
12.6 OPERATIONS AND CHECKS AFTER STARTING ENGINE...460
12.7 MOVING MACHINE OFF...461
12.8 CHANGING GEAR SPEED...463
12.9 CHANGING DIRECTION...463
12.10 TURNING...464
12.11 STOPPING MACHINE...465
12.12 OPERATION OF WORK EQUIPMENT...466
12.13 WORK POSSIBLE USING WHEEL LOADER...467
12.13.1 DIGGING OPERATIONS WITH ROCK PILES...467
12.13.2 DIGGING OPERATIONS ON LEVEL GROUND...468
12.13.3 LEVELING OPERATION...469
12.13.4 PUSHING OPERATIONS...469
12.13.5 LOAD AND CARRY OPERATIONS...469
12.13.6 LOADING OPERATIONS...470
12.14 PRECAUTIONS FOR OPERATION...471
12.14.1 PERMISSIBLE WATER DEPTH...471
12.14.2 IF WHEEL BRAKE DOES NOT WORK...471
12.14.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...471
12.14.4 PRECAUTIONS WHEN DRIVING MACHINE...472
12.15 ADJUSTING WORK EQUIPMENT POSTURE...473
12.15.1 ADJUSTING BOOM KICKOUT...473
12.15.2 ADJUSTING BUCKET POSITIONER...474
12.15.3 BUCKET LEVEL INDICATOR...474
12.16 PARKING MACHINE...475
12.17 CHECKS AFTER COMPLETION OF ENGINE OPERATION...476
12.18 STOPPING ENGINE...476
12.19 CHECKS AFTER STOPPING ENGINE...477
12.20 LOCKING...477
12.21 HANDLING THE TIRES...478
12.21.1 PRECAUTIONS WHEN HANDLING THE TIRES...478
12.21.2 TIRE PRESSURE...478
13. TRANSPORTATION...480
13.1 LOADING, UNLOADING WORK...480
13.2 PRECAUTION FOR LOADING...481
13.3 PRECAUTION FOR LIFTING UP THE VEHICLE...481
13.3.1 THE LOCATION OF DECALS REFERRING TO LIFTING POSITIONS...482
13.3.2 WEIGHT LIST...482
13.3.3 LIFTING PROCEDURE...483
14. COLD WEATHER OPERATIONS...484
14.1 PRECAUTIONS FOR LOW TEMPERATURE...484
14.1.1 FUEL AND LUBRICANTS...484
14.1.2 COOLANT...484
14.1.3 BATTERY...485
14.2 PRECAUTIONS AFTER COMPLETION OF WORK...486
14.3 AFTER COLD WEATHER...486
15. LONG TERM STORAGE...487
15.1 BEFORE STORAGE...487
15.2 DURING STORAGE...487
15.3 AFTER STORAGE...487
16. TROUBLESHOOTING...488
16.1 WHEN MACHINE RUNS OUT OF FUEL...488
16.2 TOWING THE MACHINE...489
16.2.1 WHEN ENGINE CAN BE USED...491
16.2.2 WHEN ENGINE CANNOT BE USED...491
16.3 IF BATTERY IS DISCHARGED...492
16.3.1 REMOVAL AND INSTALLATION OF BATTERY...492
16.3.2 PRECAUTIONS FOR CHARGING BATTERY...493
16.3.3 STARTING ENGINE WITH BOOSTER CABLE...494
16.4 OTHER TROUBLE...496
16.4.1 ELECTRICAL SYSTEM...496
16.4.2 CHASSIS...497
16.4.3 ENGINE...500
MAINTENANCE...502
17. GUIDES TO MAINTENANCE...503
18. OUTLINES OF SERVICE...506
18.1 OUTLINE OF OIL, FUEL, COOLANT...506
18.1.1 OIL...506
18.1.2 FUEL...506
18.1.3 COOLANT...507
18.1.4 GREASE...508
18.1.5 STORING OIL AND FUEL...508
18.1.6 FILTERS...508
18.2 OUTLINE OF ELECTRIC SYSTEM...509
19. WEAR PARTS LIST...510
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...511
20.1 ENGINE OIL SPECIFICATIONS...512
20.2 DIESEL FUEL SPECIFICATIONS...512
20.3 COOLANT SPECIFICATIONS...514
21. STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS...520
21.1 INTRODUCTION OF NECESSARY TOOLS...520
21.2 TORQUE LIST...521
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...522
23. MAINTENANCE SCHEDULE CHART...526
23.1 MAINTENANCE SCHEDULE CHART...526
24. SERVICE PROCEDURES...530
24.1 INITIAL 250 HOURS SERVICE...530
24.1.1 REPLACE FUEL FILTERS...530
24.1.2 REPLACE TRANSMISSION OIL FILTER ELEMENT...530
24.1.3 REPLACE HYDRAULIC TANK FILTER ELEMENT...530
24.2 WHEN REQUIRED...531
24.2.1 CHECK, CLEAN OR REPLACE AIR CLEANER ELEMENT...531
24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL...533
24.2.3 CHECK AXLE OIL LEVEL , ADD OIL...534
24.2.4 CLEAN THE AXLE CASE BREATHER...535
24.2.5 CLEAN RADIATOR FINS...535
24.2.6 REPLACE THE BOLT-ON CUTTING EDGES...536
24.2.7 REPLACE BUCKET TEETH (IF EQUIPPED)...537
24.2.8 CHECK AIR CONDITIONER (IF EQUIPPED)...538
24.2.9 CHECK THE AIR CONDITIONER CONDENSER (IF EQUIPPED)...539
24.2.10 CHECK WINDOW WASHING FLUID...539
24.2.11 ADJUST PARKING BRAKE...540
24.2.12 REPLACE SLOW BLOW FUSE...541
24.2.13 CHECK AIR INTAKE HEATER...541
24.3 CHECK BEFORE STARTING...542
24.4 EVERY 50 HOURS SERVICE...543
24.4.1 CHECK THE TIRE INFLATION PRESSURE...543
24.4.2 DRAIN WATER, SEDIMENT FROM FUEL TANK...543
24.5 EVERY 100 HOURS SERVICE...544
24.5.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...544
24.5.2 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...545
24.5.3 LUBRICATING...546
24.6 EVERY 250 HOURS SERVICE...547
24.6.1 CHANGE OIL IN ENGINE OIL PAN AND REPLACE ENGINE OIL FILTER...547
24.6.2 CHECK FOR LOOSE WHEEL HUB NUTS. TIGHTEN...548
24.6.3 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...548
24.6.4 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...549
24.6.5 CHECK BATTERY ELECTROLYTE LEVEL...550
24.6.6 CHECK AIR INTAKE SYSTEM...550
24.6.7 LUBRICATING...551
24.7 EVERY 500 HOURS SERVICE...552
24.7.1 REPLACE FUEL FILTERS...552
24.7.2 REPLACE TRANSMISSION OIL FILTER ELEMENT...554
24.7.3 LUBRICATE...555
24.8 EVERY 1000 HOURS SERVICE...556
24.8.1 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER...556
24.8.2 CLEAN TRANSMISSION CASE BREATHER...557
24.8.3 LUBRICATE...558
24.8.4 ADJUST ENGINE VALVE LASH CLEARANCE...559
24.8.5 CHECK FAN BELT TENSION...560
24.8.6 CHECK FAN BELT TENSIONER BEARING & FAN HUB BEARING & INSPECT FAN BELT...560
24.9 EVERY 2000 HOURS SERVICE...561
24.9.1 CHANGE OIL IN HYDRAULIC OIL TANK, REPLACE HYDRAULIC FILTER ELEMENT...561
24.9.2 REPLACE HYDRAULIC TANK BREATHER ELEMENT...563
24.9.3 COOLING SYSTEM, REPLACE COOLANT AND FLUSH THE SYSTEM...564
24.9.4 CHANGE AXLE OIL...567
24.9.5 CHECK BRAKE DISC WEAR...568
24.9.6 CHECK ALTERNATOR...568
24.9.7 CHECK STARTER MOTOR...568
24.9.8 CHECK VIBRATION DAMPER...568
24.9.9 REPLACE ELEMENT IN AIR COND. RECIRCULATION AIR FILTER AND FRESH AIR FILTER...568
24.9.10 ADJUST ENGINE VALVE LASH CLEARANCE...569
SPECIFICATIONS...571
25. SPECIFICATIONS...572
OPTIONS, ATTACHMENTS...574
26. AVAILABLE ATTACHMENTS...575
27. SELECTING BUCKETS AND TIRES...576
28. HEATER AND AIR CONDITIONING (IF EQUIPPED)...577
28.1 GENERAL LOCATION AND FUNCTION OF CONTROL PANEL...577
28.2 COOL BOX COMPARTMENT...578
29. HANDLING E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM) (IF EQUIPPED)...579
29.1 STRUCTURE AND FUNCTION OF E.C.S.S...579
29.2 METHOD OF OPERATING E.C.S.S...580
29.3 PRECAUTIONS WHEN OPERATING E.C.S.S...580
29.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR...581
CEAM002000 - Parallel Tool Carrier Wheel Loader WA250-3 Operation & Maintenance Manual...583
COVER...583
INTRODUCTION...586
1. FORWARD...587
2. SAFETY INFORMATION...588
3. INTRODUCTION...589
3.1 INTENDED USE...589
3.2 FEATURES...589
3.3 BREAKING IN A NEW MACHINE...589
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...590
4.1 MACHINE SERIAL NO. PLATE POSITION...590
4.2 ENGINE SERIAL NO. PLATE POSITION...590
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...590
CONTENTS...591
SAFETY...597
6. GENERAL PRECAUTIONS...598
7. PRECAUTIONS DURING OPERATION...604
7.1 BEFORE STARTING ENGINE...604
7.2 AFTER STARTING ENGINE...607
7.3 TRANSPORTATION...616
7.4 BATTERY...617
7.5 TOWING...620
8. PRECAUTIONS FOR MAINTENANCE...621
8.1 BEFORE CARRYING OUT MAINTENANCE...621
8.2 DURING MAINTENANCE...626
8.3 TIRES...631
9. POSITION FOR ATTACHING SAFETY LABELS...633
9.1 POSTION FOR ATTACHING SAFETY LABELS...633
OPERATION...637
10. GENERAL VIEW...638
10.1 GENERAL VIEW OF MACHINE...638
10.2 GENERAL VIEW OF CONTROLS AND GAUGES...639
11. EXPLANANTION OF COMPONENTS...640
11.1 METERS, LAMPS...640
11.1.1 WARNING DISPLAYS...642
11.1.2 METER DISPLAY PORTION...646
11.2 SWITCHES...650
11.3 CONTROL LEVERS, PEDAL...656
11.4 STEERING COLUMN TILT LEVER...660
11.5 CAP WITH LOCK...660
11.5.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK...660
11.6 SAFETY BAR...661
11.7 TOWING PIN...661
11.8 GREASE PUMP CLAMP AND RUBBER RING...661
11.9 BACKUP ALARM...662
11.10 FUSE...663
11.10.1 FUSE CAPACITY AND NAME OF CIRCUIT...663
11.11 SLOW BLOW FUSE...664
11.12 STORAGE PLACE FOR THIS MANUAL...665
11.13 AUXILIARY POWER SOURCE...665
11.13.1 FOR MACHINES EQUIPPED WITH ROPS CAB...665
12. CHECK BEFORE STARTING ENGINE...666
12.1 WALK AROUND CHECK...666
12.2 CHECK BEFORE STARTING...669
12.2.1 CHECK COOLANT LEVEL, ADD COOLANT...669
12.2.2 CHECK MONITOR PANEL...669
12.2.3 CHECK FUEL LEVEL, ADD FUEL...670
12.2.4 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...670
12.2.5 CHECK AND REFILL OF OIL IN BRAKE OIL TANK...671
12.2.6 CHECK DUST INDICATOR...671
12.2.7 CHECK ELECTRICAL WIRING...672
12.2.8 DRAIN THE WATER FROM THE FUEL WATER SEPARATOR...673
12.2.9 CHECK EFFECT OF PARKING BRAKE...673
12.2.10 CHECK EFFECT OF WHEEL BRAKES...674
12.2.11 CHECK SOUND OF HORN AND BACKUP ALARM...674
12.2.12 CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE...674
12.2.13 CHECK ENGINE EXHAUST COLOR AND SOUND...674
12.2.14 CHECK OPERATIONS OF GAUGES...674
12.2.15 CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING...674
12.2.16 CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE...674
12.2.17 CHECK LOCK OF CAB DOOR FOR MACHINES EQUIPPED WITH CAB...674
12.3 ADJUSMENT BEFORE OPERATION...675
12.3.1 OPERATOR'S SEAT...675
12.3.2 ADJUST SEAT BELT...677
12.3.3 ADJUST REAR VIEW MIRRORS...678
12.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE...679
12.5 STARTING ENGINE...680
12.5.1 NORMAL STARTING PROCEDURES IN COLD AND WARM CONDITIONS...680
12.5.2 STARTING PROCEDURES AFTER EXTENDED SHUTDOWN OR OIL CHANGE...681
12.5.3 STARTING PROCEDURES AFTER CHANGING FUEL FILTERS...681
12.5.4 STARTING PROCEDURES AFTER RUNNING OUT OF FUEL...681
12.6 OPERATIONS AND CHECKS AFTER STARTING ENGINE...682
12.7 MOVING MACHINE OFF...683
12.8 CHANGING GEAR SPEED...685
12.9 CHANGING DIRECTION...685
12.10 TURNING...686
12.11 STOPPING MACHINE...687
12.12 OPERATION OF WORK EQUIPMENT (WITH BUCKET TOOL)...688
12.12.1 LIFT ARM OPERATION (LEVER)...688
12.12.2 BUCKET OPERATION (LEVER)...688
12.13 OPERATAION OF WORK EQUIPMENT (WITH FORK TOOL)...689
12.13.1 LIFT ARM OPERATION (LEVER...689
12.13.2 FORK OPERATION (LEVER)...689
12.14 OPERATION OF WORK EQUIPMENT (WITH MULTI-PURPOSE BUCKET TOOL)...690
12.14.1 LIFT ARM OPERATION (LEVER)...690
12.14.2 BUCKET OPERATION (LEVER)...690
12.14.3 AUXILIARY OPERATION (LEVER)...691
12.14.4 POSITION INDICATOR...691
12.15 OPERATION OF WORK EQUIPMENT (WITH MATERIAL HANDLING ARM)...693
12.15.1 LIFT ARM OPERATION (LEVER)...693
12.16 HYDRAULIC QUICK COUPLER...694
12.16.1 COUPLING THE ATTACHEMENT...694
12.16.2 UNCOUPLING FROM THE ATTACHMENT...695
12.16.3 ATTACHMENTS REQUIRING HYDRAULIC POWER...696
12.17 WORK POSSIBLE USING PARALLEL TOOL CARRIER...697
12.17.1 DIGGING OPERATIONS WITH ROCK PILES (GENERAL PURPOSE BUCKET)...697
12.17.2 DIGGING OPERATIONS ON LEVEL GROUND...698
12.17.3 LEVELING OPERATION...699
12.17.4 PUSHING OPERATIONS...699
12.17.5 LOAD AND CARRY OPERATIONS...699
12.17.6 LOADING OPERATIONS...700
12.17.7 MULTI-PURPOSE BUCKET...701
12.17.8 PALLET FORKS...706
12.17.9 MATERIAL HANDLING ARM...709
12.18 PRECAUTIONS FOR OPERATION...710
12.18.1 PERMISSIBLE WATER DEPTH...710
12.18.2 IF WHEEL BRAKE DOES NOT WORK...710
12.18.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...710
12.18.4 PRECAUTIONS WHEN DRIVING MACHINE...711
12.19 ADJUSTING BOOM KICK-OUT POSITIONER...712
12.19.1 ADJUSTING BOOM KICK OUT...712
12.19.2 ADJUSTING BUCKET/FORK POSITIONER...713
12.20 PARKING MACHINE...714
12.21 CHECKS AFTER COMPLETTION OF ENGINE OPERATION...715
12.22 STOPPING ENGINE...715
12.23 CHECKS AFTER STOPPING ENGINE...716
12.24 LOCKING...716
12.25 HANDLING THE TIRES...717
12.25.1 PRECAUTIONS WHEN HANDLING THE TIRES...717
12.25.2 TIRE PRESSURE...717
13. TRANSPORTATION...719
13.1 LOADING, UNLOADING WORK...719
13.2 PRECAUTION FOR LOADING...720
13.3 PRECAUTION FOR LIFTING UP THE VEHICLE...720
13.3.1 THE LOCATION OF DECALS REFERRING TO LIFTING POSITIONS...721
13.3.2 WEIGHT LIST...721
13.3.3 LIFTING PROCEDURE...722
14. COLD WEATHER OPERATIONS...723
14.1 PRECAUTIONS FOR LOW TEMPERATURE...723
14.1.1 FUEL AND LUBRICANTS...723
14.1.2 COOLANT...723
14.1.3 BATTERY...724
14.2 PRECAUTIONS FOR COMPLETION OF WORK...725
14.3 AFTER COLD WEATHER...725
15. LONG TERM STORAGE...726
15.1 BEFORE STORAGE...726
15.2 DURING STORAGE...726
15.3 AFTER STORAGE...726
16. TROUBLESHOOTING...727
16.1 WHEN MACHINE RUNS OUT OF FUEL...727
16.2 TOWING THE MACHINE...728
16.2.1 WHEN ENGINE CAN BE USED...730
16.2.2 WHEN ENGINE CANNOT BE USED...730
16.3 IF BATTERY IS DISCHARGED...731
16.3.1 REMOVAL AND INSTALLATION OF BATTERY...731
16.3.2 PRECAUTION FOR CHARGING BATTERY...732
16.3.3 STARTING ENGINE WITH BOOSTER CABLE...733
16.4 OTHER TROUBLE...735
16.4.1 ELECTRICAL SYSTEM...735
16.4.2 CHASSIS...736
16.4.3 ENGINE...739
MAINTENANCE...741
17. GUIDES TO MAINTENANCE...742
18. OUTLINES OF SERVICE...745
18.1 OUTLINE OF OIL, FUEL, COOLANT...745
18.1.1 OIL...745
18.1.2 FUEL...745
18.1.3 COOLANT...746
18.1.4 GREASE...747
18.1.5 STORING OIL AND FUEL...747
18.1.6 FILTERS...747
18.2 OUTLINE OF ELECTRICAL SYSTEM...748
19. WEAR PARTS LIST...749
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...750
20.1 ENGINE OIL SPECIFICATIONS...751
20.2 DIESEL FUEL SPECIFICATIONS...752
20.3 COOLANT SPECIFICATIONS...753
21. STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS...759
21.1 INTRODUCTION OF NECESSARY TOOLS...759
21.2 TORQUE LIST...760
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...762
23. MAINTENANCE SCHEDULE CHART...766
23.1 MAINTENANCE SCHEDULE CHART...766
24. SERVICE PROCEDURES...770
24.1 INITIAL 250 HOURS SERVICE...770
24.1.1 REPLACE FUEL FILTERS...770
24.1.2 REPLACE TRANSMISSION OIL FILTER ELEMENT...770
24.1.3 REPLACE HYDRAULIC TANK FILTER ELEMENT...770
24.2 WHEN REQUIRED...771
24.2.1 CHECK, CLEAN OR REPLACE AIR CLEANER ELEMENT...771
24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL...773
24.2.3 CHECK AXLE OIL LEVEL, ADD OIL...774
24.2.4 CLEAN THE AXLE CASE BREATHER...775
24.2.5 CLEAN RADIATOR FINS...775
24.2.6 REPLACE THE BOLT-ON CUTTING EDGES...776
24.2.7 REPLACE BUCKET TEETH (IF EQUIPPED)...777
24.2.8 CHECK AIR CONDITIONER (IF EQUIPPED)...778
24.2.9 CHECK THE AIR CONDITIONER CONDENSER (IF EQUIPPED)...779
24.2.10 CHECK WINDOW WASHING FLUID...779
24.2.11 ADJUST PARKING BRAKE...780
24.2.12 REPLACE SLOW BLOW FUSE...781
24.2.13 CHECK AIR INTAKE HEATER...781
24.3 CHECK BEFORE STARTING...782
24.4 EVERY 50 HOURS SERVICE...783
24.4.1 CHECK THE TIRE INFLATION PRESSURE...783
24.4.2 DRAIN WATER, SEDIMENT FROM FUEL TANK...783
24.5 EVERY 100 HOURS OF SERVICE ...784
24.5.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...784
24.5.2 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...785
24.5.3 LUBRICATING...786
24.6 EVERY 250 HOURS SERVICE...787
24.6.1 CHANGE OIL IN ENGINE OIL PAN AND REPLACE ENGINE OIL FILTER...787
24.6.2 CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN...788
24.6.3 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...788
24.6.4 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...789
24.6.5 CHECK BATTERY ELECTROLYTE LEVEL...790
24.6.6 CHECK AIR INTAKE SYSTEM...790
24.6.7 LUBRICATING...791
24.7 EVERY 500 HOURS SERVICE...792
24.7.1 REPLACE FUEL FILTERS...792
24.7.2 REPLACE TRANSMISSION OIL FILTER ELEMENT...794
24.7.3 LUBRICATE...795
24.8 EVERY 1000 HOURS SERVICE...796
24.8.1 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER...796
24.8.2 CLEAN TRANSMISSION CASE BREATHER...797
24.8.3 LUBRICATE...798
24.8.4 ADJUST ENGINE VALVE LASH CLEARANCE...799
24.8.5 CHECK FAN BELT TENSION...800
24.8.6 CHECK FAN BELT TENSIONER BEARING & FAN HUB BEARING & INSPECT FAN BELT...800
24.9 EVERY 2000 HOURS SERVICE...801
24.9.1 CHANGE OIL IN HYDRAULIC OIL TANK, REPLACE HYDRAULIC FILTER ELEMENT...801
24.9.2 REPLACE HYDRAULIC TANK BREATHER ELEMENT...803
24.9.3 COOLING SYSTEM, REPLACE COOLANT AND FLUSH SYSTEM...804
24.9.4 CHANGE AXLE OIL...807
24.9.5 CHECK BRAKE DISC WEAR...808
24.9.6 CHECK ALTERNATOR...808
24.9.7 CHECK STARTER MOTOR...808
24.9.8 CHECK VIBRATION DAMPER...808
24.9.9 REPLACE ELEMENT IN AIR COND. RECIRCULATION AIR FILTER AND FRESH AIR FILTER...808
24.9.10 ADJUST ENGINE VALVE LASH CLEARANCE...809
SPECIFICATIONS...811
25. SPECIFICATIONS...812
OPTIONS, ATTACHMENTS...819
26. AVAILABLE ATTACHMENTS...820
27. SELECTING ATTACHMENTS AND TIRES...821
28. HEATER AND AIR CONDITIONING (IF EQUIPPED)...822
28.1 GENERAL LOCATION AND FUNCTION OF CONTROL PANEL...822
28.2 COOL BOX COMPARTMENT...823
29. HANDLING E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM)(IF EQUIPPED)...824
29.1 STRUCTURE AND FUNCTION OF E.C.S.S...824
29.2 METHOD OF OPERATING E.C.S.S...825
29.3 PRECAUTIONS WHEN OPERATING E.C.S.S...825
29.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR...826
CEBM000703 - Wheel Loader WA250-6 Shop Manual...828
COVER...828
FOREWORD...829
CONTENTS...829
REVISED PAGES...830
SAFETY...842
Safety Notice...842
Important Safety Notice...842
General Precautions...842
Preparations for Work...843
Precautions During Work...843
GENERAL...844
HOW TO READ THE SHOP MANUAL...845
Volumes...845
Distribution and Updating...845
Filing Method...845
Revised Edition Mark...845
Revisions...845
Symbols...845
HOISTING INSTRUCTIONS...846
Hoisting...846
Making Signs...846
Precautions...846
Precautions for Sling Work...846
Precautions for Using Mobile Crane...847
Precautions for Using Overhead Hoist Crane...847
Selecting Wire Ropes...848
AIR CONDITIONER CIRCUITS...849
Precautions for Handling Hoses and Tubes...849
Disconnecting Hoses and Tubes...849
Connecting Hoses and Tubes...849
MAINTENANCE STANDARD TERMS...850
HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT...852
Handling Electric Equipment...852
Handling Wiring Harnesses and Connectors...852
Main Failures Occurring in Wiring Harness...852
Removing, Installing, and Drying Connectors and Wiring Harnesses...853
Handling Controller...857
Troubleshooting Electric Circuits...857
Handling Hydraulic Equipment...858
Handling Connectors Used for Engines...859
Slide Lock Type...859
Pull Lock Type...860
Push Lock Type...860
Turn-housing Type (Round Green Connector)...862
PRECAUTIONS FOR OPERATIONS...863
Precautions when Carrying Out Removal Work...863
Precautions when Carrying Out Installation Work...864
Precautions when Completing the Operation...865
PUSH-PULL COUPLER...866
Type 1...866
Disconnection...866
Connection...866
Type 2...867
Disconnection...867
Connection...867
Type 3...868
Disconnection...868
Connection...868
COATING MATERIALS...869
STANDARD TIGHTENING TORQUE...871
Standard Tightening Tables...871
For Bolts and Nuts...871
For Split Flange Bolts...872
For O-Ring Boss Piping Joints...872
For O-Ring Boss Plugs...873
For Hoses (Taper-Seal Type and Face-Seal Type)...873
For Face Seal Joints...874
For 102, 107, and 114 Engine Series (Bolts and Nuts)...874
For 102, 107, and 114 Engine Series (Eye Joints)...874
For 102, 107, and 114 Engine Series (Taper Screws)...875
CONVERSION TABLES...876
Method of Using the Conversion Table...876
01 GENERAL...882
SPECIFICATIONS...883
Dimension Drawing...883
Specification Tables...885
WEIGHT TABLE...889
FUEL, COOLANT, AND LUBRICANTS...891
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD...894
ENGINE AND COOLING SYSTEM...898
Engine and Transmission Mounting...898
Torque Values...898
Damper...899
Torque Values...900
Outline...900
Cooling System...901
Specifications...901
Cooling System Hydraulic Piping Diagram...902
Outline...902
Cooling Fan Motor...903
Type: LMF16...903
Torque Values...904
Specifications...904
Torque Values...906
Hydraulic Motor...907
Function...907
Principle of Operation...907
Suction Safety Valve...908
Suction Function...908
Operation...908
Safety Function...909
Function...909
Operation...909
Operation of Reversible Valve...910
Flow Control Valve (Continuously Variable Type)...911
Function...911
Operation...911
POWER TRAIN SYSTEM...912
Drive Line Components...912
System Diagram...913
Outline...914
Drive Shaft...915
Torque Values...915
Outline...915
HST Hydraulic Piping Diagram...916
HST Pump...917
Specifications...918
Operation...919
Flow of Power...919
Flow of Oil...919
High-Pressure Relief Valve...920
Function...920
Operation...921
Low-pressure Relief Valve...922
Function...922
Operation...922
HST Charge Pump...923
Outline...924
Specifications...924
Function...924
Speed-Related Valve (DA Valve)...925
Function...925
Operation...925
High-Pressure Cutoff Valve...926
Function...926
Operation...926
HST Motor...927
HST Motor 1...927
Specifications...928
HST Motor 2...929
Specifications...930
Principle...931
Structure...931
Operation...931
EP Servo Valve...932
Function...932
Operation...932
HA Servo Valve...933
Function...933
Operation...933
Directional Shuttle Valve...934
Function...934
Operation...934
Transfer...935
Torque Values...936
Torque Values...938
Input Shaft...939
Output Shaft...941
Torque Values...944
Outline...945
Relation between transfer clutch and transfer clutch pressure at respective speed ranges...945
Relationship between accelerator pedal angle and travel speed (A) for starting transfer clutch switching modulation...945
Operation of Clutch...946
Clutch is Engaged (fixed)...946
Clutch is Disengaged (released)...946
Power Transmitting Route...947
Low-Speed Mode...947
High-Speed Mode...948
Clutch Solenoid Valve...949
Operation...949
DRIVE AXLE SYSTEM...951
Front and Rear Axles...951
Front Axle...951
Torque Values...952
Rear Axle...953
Torque Values...954
Differential...955
Front Differential...955
Torque Values...957
Rear Differential...959
Torque Values...960
Outline...961
While Machine is Traveling Straight...961
While Machine is Turning...961
Torque Proportioning Differential...962
Outline...962
Operation...962
Straight Travel (when road resistance under both tires is the same)...962
Travel on Soft Ground (when road resistance under both tires is different)...962
Limited Slip Differential...963
Torque Values...963
Operation...965
Mechanism of Generation of Braking Torque by Right and Left Side Gears (5)...965
While Machine is Traveling Straight (when the drive forces of the right and left wheels are balanced)...965
When the drive forces of the right and left wheels are unbalanced...966
Difference in wheel drive force by type of differentials when either wheel slips...966
Torque Proportioning Differential...966
Conventional Differential (not applicable to this machine)...966
While Machine is Turning...966
Final Drive...967
Front Final Drive...967
Torque Values...967
Rear Final Drive...969
Torque Values...969
Outline...970
STEERING SYSTEM...971
Steering Piping Diagram...971
Steering Column...972
Torque Values...972
Priority Valve...973
Torque Values...974
Outline...975
Operation...975
When Steering Wheel is at Neutral Position...975
When Steering Wheel is Turned Left...975
Orbitrol Valve...977
Torque Values...977
Outline...978
Structure...978
Operation...979
When Steering Wheel is at Neutral Position...979
When Steering Wheel is Turned Left...981
When Steering Wheel is at Stop Position...982
Connection of Hand Pump and Sleeve...983
Role of Centering Spring...984
2-Way Restrictor Valve...985
Function...985
Operation...985
Cushion Valve...986
Outline...986
Function...986
Steering Cylinder...987
Torque Values...988
Emergency Steering Piping Diagram...989
Emergency Steering Valve...991
Torque Values...992
Operation...993
When Engine and Steering Pump are Normal...993
When Engine or Steering Pump is Abnormal...994
Steering Relief Valve...995
Torque Values...995
Outline...995
BRAKE SYSTEM...996
Brake Piping Diagram...996
Charge Valve...997
Torque Values...998
Function...998
Operation...999
When Oil is Not Supplied to Accumulator...999
Cutout State...999
When Oil is Supplied to Accumulator...999
Cut-in State...999
When Pressure Reaches Cutout Pressure...1000
When Oil Pressure from the Pump Goes Beyond the Set Pressure...1000
Brake Valve...1001
Outline...1002
Braking Operation...1003
When the Brake Pedal is Pressed Down...1003
When Brake of One Side is Operated (when the other brake failed)...1003
Balancing Operation...1004
When Brake Pedal is Released...1005
Inching Valve...1006
Outline...1006
Accumulator (for Brake)...1007
Specifications...1007
Function...1007
Slack Adjuster...1009
Function...1010
Operation...1010
When Brake is Applied...1010
When Brake is Released...1010
Brakes...1011
Front Brake...1011
Outline...1012
Rear Brake...1013
Outline...1014
Operation...1014
When Brake is Operated...1014
When Brake is Released...1014
Parking Brake System...1015
Brake Control...1015
Outline...1015
Parking Brake...1016
Torque Values...1016
Outline...1016
UNDERCARRIAGE AND FRAME...1017
Axle Mounting and Center Hinge Pin...1017
Torque Values...1018
Outline...1018
Torque Values...1020
Torque Values...1021
Tires...1023
Radial Tire...1023
Structure...1023
Ground Contact Characteristics...1023
Deformation Characteristics...1023
Bias Tire...1024
Structure...1024
Ground Contact Characteristics...1024
Deformation Characteristics...1024
HYDRAULIC SYSTEM...1025
Work Equipment Hydraulic Piping Diagram...1025
Outline...1026
Work Equipment Control Lever Linkage...1027
Mono-Lever Type...1027
2-Lever Type...1028
Hydraulic Tank...1029
Specifications...1030
Torque Values...1030
Breather...1030
Prevention of Negative Pressure in Tank...1030
Prevention of Pressure Rise in Tank...1030
4-Gear Pump...1031
SAR(3)56 + (2)40 + SB(1)12 + 12...1031
Outline...1031
Torque Values...1032
Work Equipment Control Valve...1033
2-Spool Type...1033
Torque Values...1034
Torque Values...1036
3-Spool Type...1037
Torque Values...1038
Torque Values...1040
Relief Valve...1041
Function...1041
Operation...1041
Safety-Suction Valve...1042
Function...1042
Operation...1042
Operation as Safety Valve...1042
Operation as Suction Valve...1043
Suction Valve...1044
Function...1044
Operation...1044
Operation of Work Equipment Control Valve...1045
When Lift Arm and Bucket Spool are at the Neutral Position...1045
Operation...1045
When Lift Arm Spool is at Raise Position...1046
Operation...1046
When Lift Arm Spool is at Lower Position...1047
Operation...1047
When Lift Arm Spool is at Float Position...1048
Operation...1048
When Bucket Spool is at Tilt Position...1049
Operation...1049
When Bucket Spool is at Dump Position...1050
Operation...1050
PPC Valve...1051
Work Equipment PPC Valve...1051
Mono Lever Type...1051
Torque Values...1054
Operation...1055
When in Neutral...1055
When in Fine Control Mode (neutral Æ fine control)...1056
When in Fine Control Mode (when control lever is returned)...1056
When Lever is Operated to Stroke End...1057
When Lift Arm is Float...1057
When Float State of Lift Arm is Reset...1057
2-Lever Type...1059
Torque Values...1062
Operation...1063
When in Neutral...1063
When in Fine Control Mode (neutral Æ fine control)...1064
When in Fine Control Mode (when control lever is returned)...1064
When Lever is Operated to Stroke End...1065
When Lift Arm is Float...1065
When Float State of Lift Arm is Reset...1065
Attachment PPC Valve...1067
Torque Values...1068
Lock Valve...1069
Outline...1069
Accumulator (for PPC Circuit)...1070
Outline...1070
Specifications...1070
ECSS Valve...1071
Torque Values...1071
Accumulator (for ECSS)...1073
Function...1073
Specifications...1073
Work Equipment...1074
Work Equipment Linkage...1074
Bucket...1077
Torque Values...1078
Bucket Positioner and Boom Kickout...1079
Torque Values...1079
Outline...1080
Bucket Positioner...1080
Boom Kickout (if equipped)...1080
Operation of Proximity Switch...1081
When Bucket is Tilted...1081
Function of Proximity Switch...1083
When Lift Arm is Raised...1084
Function of Proximity Switch...1086
Work Equipment Cylinders...1087
Lift Cylinder...1087
Bucket Cylinder...1087
CAB ENVIRONMENT...1089
Cab...1089
Air Conditioner...1091
Air Conditioner Piping Diagram...1091
Specifications...1092
Refrigerant Circuit Diagram...1093
Table of Tightening Torque for Refrigerant Piping Adapter...1093
Air Conditioner Unit...1094
Outline...1095
Cooler...1095
Heater...1095
Functions of Major Components...1095
Evaporator...1095
Heater Core...1095
Expansion Valve...1095
Blower Controller...1095
Blower Motor Relay...1095
Compressor Clutch Relay...1095
Air Mix Damper Actuator...1096
Evaporator Temperature Sensor...1096
Dual Pressure Switch...1096
Blower and Intake Unit...1097
Functions of Major Components...1098
Blower Motor Assembly...1098
Internal/External Air Changeover Damper Actuator...1098
Compressor...1099
Function...1099
Specifications...1099
Condenser...1100
Function...1100
Specifications...1100
Receiver...1101
Function...1101
Specifications...1101
Air Conditioner Panel...1103
Display Unit...1103
Switch Block...1103
Outline...1104
Input and Output Signals...1104
Function of Abnormality Display in the Control Panel...1105
ELECTRICAL SYSTEM...1107
Machine Monitor System...1107
Outline...1107
Operator Mode...1107
Service Mode...1108
Machine Monitor...1109
Items Displayed on Monitor...1110
Machine Monitor Operation Switches...1116
Setting Machine Monitor...1117
Troubleshooting Function...1117
Character Display Function...1118
Operator Mode Functions...1119
Self-Check Screen (0th layer)...1119
Normal Screen (1st layer)...1119
Failure Code Screen (1st layer)...1120
Display of Functions Available for the Operator (2nd layer or below)...1121
Service Mode Functions...1122
Procedure for Switching to Service Mode...1122
Service Mode Menu...1123
Electrical System Failure History Display Function (ELECTRIC FAULT)...1124
Mechanical System Failure History Display Function (MACHINE FAULT)...1124
Real-Time Monitoring Function (REAL-TIME MONITOR)...1124
Engine Reduced-Cylinder Function (CYLINDER CUT-OUT)...1124
No Injection Cranking Function (NO INJECTION)...1125
Adjustment Function (TUNING)...1125
Maintenance Monitoring Function (MAINTENANCE MONITOR)...1125
Operating Information Display Function (OPERATION INFO)...1125
Optional Device Selecting Function (OPTIONAL SELECT)...1126
Machine Serial Number Input Function (MACHINE No. SET)...1126
Model Selection Function (MACHINE)...1126
Initialize Function (INITIALIZE)...1126
Input and Output Signals...1127
Setting Switches (on circuit board)...1132
Electrical System (HST Controller System)...1133
Input and Output Signals Diagram...1133
HST Controller Gear Shifting Control Function...1134
Gear Shifting Function...1134
Relationship between accelerator pedal angle and travel speed (A) for starting transfer clutch switching modulation...1135
Relationship between accelerator pedal angle and travel speed (A) for switching HST motor 2 capacity...1135
Gear Shifting Display Function...1136
Variable Shift Control System...1136
Transfer Clutch Control Function...1136
Traction Control Function...1136
S Mode Function...1137
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...1138
Max. Traction Function...1139
HST Controller Protection Function...1140
HST Motor 1 Overrun Prevention Function 1...1140
Relationship between accelerator pedal angle and travel speed (A) for starting transfer clutch switching modulation...1141
HST Motor 1 Overrun Prevention Function 2...1141
Travel Speed Control Function...1141
Engine Overrun Prevention Function...1142
Neutralizer Function...1142
Economy Operation Pilot Lamp Function...1142
Cooling Fan Control Function...1143
Input and Output Signals...1143
Fan Control...1144
Fan Speed in Accordance with Temperature...1144
Control at Start of Engine...1145
Fan Reverse Rotation Function...1146
Fan Manual Reverse Rotation Function...1146
Overheat Prevention Function...1146
Fan Speed During Reverse Rotation...1146
Fan Automatic Reverse Rotation Function...1147
Adjustment of the Automatic Fan Switching Cycle to Reverse Rotation and Duration...1147
System Circuit Diagram...1148
HST Controller...1149
Input and Output Signals...1150
ECSS System...1151
Input and Output Signals...1151
Outline...1151
Setting Method...1151
Operation...1152
KOMTRAX System...1154
KOMTRAX Terminal...1155
Model TC301...1155
Outline...1155
Input and Output Signals...1156
Engine Starting Circuit...1157
Function...1158
Operation...1158
Engine Stopping Circuit...1159
Operation...1159
Preheating Circuit...1160
Outline...1160
Operation...1160
Engine Output Lowering Function...1161
Automatic Warm-up Function...1161
Parking Brake Circuit...1162
Operation...1162
When Parking Brake Lever is Set to the Free Position...1163
When Parking Brake Lever is Set to the Mid Position...1163
When Parking Brake Lever is Set to the Lock Position...1163
Max. Traction Switch...1164
Function...1164
Multi-Function Knob...1165
Multi-function Mono-Lever Type...1165
(If equipped)...1165
Function...1165
Modification of Multi-Function Lever...1165
Required...1166
Procedure...1166
Sensors...1167
Speed Sensor...1167
Torque Values...1168
Function...1168
HST Oil Temperature Sensor...1169
Brake Oil Temperature Sensor...1169
Function...1169
HST Oil Pressure Sensor...1169
Function...1169
HST Oil FIlter Clogging Sensor...1170
Function...1170
Coolant Lever Sensor...1170
Function...1170
Fuel Level Sensor...1171
Function...1171
Accelerator Pedal Sensor...1172
Torque Values...1172
Function...1172
Accelerator signal...1172
Idle Validation Signal...1172
Water-in-Fuel Sensor...1173
Function...1173
Boom Kick-Out Proximity Switch...1173
Bucket Positioner Proximity Switch...1173
Function...1173
20 STANDARD VALUE TABLES...1174
STANDARD VALUE TABLES...1176
Standard Service Value Table for Engine...1176
Standard Service Value Table for Chassis...1177
MACHINE POSTURE...1182
30 TESTING AND ADJUSTING...1184
TOOLS...1188
Tools for Testing, Adjusting, and Troubleshooting...1188
ENGINE COMPONENTS...1193
Engine Speed...1193
Exhaust Gas Color...1195
Using Handy Smoke Checker A1...1195
Using Smoke Meter A2...1195
Valve Clearance...1197
Compression Pressure...1199
Blow-By Pressure...1202
Engine Oil Pressure...1204
Intake Air (Boost) Pressure...1205
Handling Cylinder Cut-Out Mode Operation...1207
Handling No-Injection Cranking Operation...1207
Handling Controller Voltage Circuit...1207
FUEL SYSTEM...1208
Handling Fuel System Equipment...1208
Releasing Residual Pressure in Fuel System...1208
Measuring Fuel Pressure...1209
Measuring Fuel Return Rate and Leakage...1212
Bleeding Air from Fuel Circuit...1217
Testing Leakage in Fuel System...1218
EXHAUST SYSTEM AND PIPING...1219
Checking Muffler and Muffler Stack for Looseness and Damage...1219
Checking Muffler Function...1219
Checking Installed Condition of Cylinder Head and Manifolds...1219
Checking Engine Piping for Damage and Looseness...1219
BELTS...1220
Air Conditioner Compressor Belt...1220
Alternator Belt...1221
ACCELERATOR PEDAL...1222
Testing Operating Effort...1222
Testing Operating Angle...1223
DIRECTIONAL LEVER...1224
Checking Operating Effort...1224
Checking Travel...1224
POWER TRAIN OIL PRESSURES...1225
Testing HST Oil Pressure...1225
High-Pressure Cutoff Oil Pressure...1225
Low-Pressure Relief Pressure...1227
Servo Piston Control Pressure (DA Pressure)...1228
Servo Piston Actuating Pressure...1229
Adjusting HST Oil Pressure...1230
High-Pressure Cutoff Valve...1230
Low-Pressure Relief Valve...1231
DA Valve...1232
Testing Clutch Control Pressure...1233
STEERING SYSTEM...1234
Steering Wheel...1234
Measuring Play...1234
Measuring Operating Effort...1235
Measuring Operating Time...1236
Steering Oil Pressure...1237
Measuring Main Relief Pressure...1237
Adjusting Main Relief Pressure...1238
Bleeding Air From Steering Circuit...1239
HYDRAULIC FAN...1240
Fan Speed...1241
Fan Drive Oil Pressure...1242
BRAKE SYSTEM...1243
Measuring Brake Pedal...1243
Brake Pedal Linkage...1244
Testing...1244
Adjusting...1244
Measuring Brake Performance...1245
Accumulator Charge Pressure...1246
Testing...1246
Adjusting...1247
Testing Wheel Brake Oil Pressure...1248
Testing Wear of Brake Disc...1251
Bleeding Air from Wheel Brake Circuit...1252
Releasing Residual Pressure in Brake Accumulator Circuit...1253
Testing Parking Brake Performance...1253
Parking Brake Limit Switch...1254
Testing...1254
Adjusting...1255
Parking Brake Control Cable...1257
Testing...1257
Adjusting...1257
WORK EQUIPMENT...1258
Control Lever...1258
Measuring Operating Effort...1258
Measuring Travel...1258
Hydraulic Pressure...1259
Measuring...1259
Adjusting...1260
PPC Oil Pressure...1261
Testing PPC Valve Basic Pressure...1261
Checking PPC Valve Output Pressure...1262
Bleeding Air from Hydraulic Circuit...1263
From Work Equipment PPC Circuit...1263
From Cylinders...1263
Releasing Residual Pressure in Hydraulic Circuit...1263
Between Hydraulic Cylinder and Control Valve...1263
In Brake Accumulator Circuit...1263
In PPC Accumulator Circuit...1263
Bucket Positioner...1264
Testing...1264
Adjusting Clearance...1264
Adjusting Installing Position (Stopping Position)...1265
Boom Kickout Switch...1266
Testing...1266
Adjusting...1266
Checking Proximity Switch Operation Pilot Lamp...1267
ELECTRICAL SYSTEM TROUBLESHOOTING...1268
Procedure for Testing Diodes...1268
Using Digital-Type Circuit Tester...1268
Using Analog-Type Circuit Tester...1269
Preparation Work for Troubleshooting Electric System...1270
Machine Monitor...1270
HST Controller...1271
KOMTRAX Terminal...1272
Boost Pressure and Temperature Sensor (BOOST PRESS & IMT)...1272
Supply Pump IMV Solenoid (FUEL REGULATOR)...1273
Common Rail Pressure Sensor (FUEL RAIL PRESS)...1273
Engine Coolant Temperature Sensor (COOLANT TEMP)...1274
Ambient Temperature Sensor (AMBAIR PRESSURE)...1274
Engine Ne Speed Sensor (CRANK SENSOR)...1274
Engine Bkup Speed Sensor (CAM SENSOR)...1274
Engine Oil Pressure Switch (OIL PRESSURE SWITCH)...1274
KOMTRAX TERMINAL SYSTEM...1275
Starting KOMTRAX Terminal Operations...1275
Station Opening Check in Machine Side...1275
Application for the Start of Use...1279
KOMTRAX Terminal Indicator Lamps...1280
MACHINE MONITOR SYSTEM...1283
Adjusting Machine Monitor...1283
Adjusting Replaced, Reassembled, or Added Sensor, Controller, Etc...1284
Items to Be Set...1284
Adjustment for User’s Needs...1284
Special Functions of Machine Monitor (EMSS)...1285
Normal and Special Functions of Machine Monitor...1286
Normal Functions: Operator Mode...1286
Special Functions: Service Mode...1286
Functions and Flow of Service Mode...1287
Operator Mode...1290
Service Meter Display Function...1290
Traction Level Selection Function...1290
HST Function Selection Function...1290
Odometer Display Function...1291
Maintenance Monitoring Function...1291
Telephone Number Input Function...1291
Language Selection Function...1291
Monitor Brightness Adjustment Function...1292
Travel Speed/Engine Speed Display Selecting Function...1292
Travel Speed/Engine Speed Display/Non-Display Selecting Function...1292
Action Code Display Function...1293
Failure Code Display Function...1294
Service Mode...1295
Switching to Service Mode and Screen Display...1295
Electrical System Fault History Display Function (ELECTRIC FAULT)...1297
Mechanical System Fault History Display Function (MACHINE FAULT)...1299
Failure Codes Table...1300
Real-Time Monitoring Function (REAL-TIME MONITOR)...1306
Real-Time Monitoring Codes Tables...1309
Engine Reduced-Cylinder Function (CYLINDER CUT-OUT)...1322
No-Injection Cranking Function...1323
Adjustment Function (TUNING)...1324
Maintenance Monitoring Function...1328
Operating Information Display Function...1333
Optional Device Selecting Function...1336
Machine Serial Number Input Function...1340
Model Selection Function (MACHINE WA***)...1341
Initialize Function...1342
PM CLINIC INSPECTION TABLES...1343
40 TROUBLESHOOTING...1346
POINTS TO REMEMBER WHEN TROUBLESHOOTING...1356
SEQUENCE OF EVENTS IN TROUBLESHOOTING...1358
PRECAUTIONS FOR MAINTENANCE...1359
Precautions when Handling Electrical Equipment...1359
Handling Electronic Control Unit...1364
Points to Remember when Troubleshooting Electrical Circuits...1365
ELECTRIC WIRE CODE...1366
How to Read Electric Wire Code...1366
Type, Symbol, and Material...1366
Dimensions...1367
Color Codes Table...1368
Types of Circuits and Color Codes...1368
HANDLING HYDRAULIC EQUIPMENT...1369
CHECKS BEFORE TROUBLESHOOTING...1371
Categories and Method of Using Troubleshooting Charts...1372
Troubleshooting Individual Electrical Circuits...1373
Chart Use...1375
Chart Tips...1375
Troubleshooting Individual Hydraulic Circuits...1376
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...1378
X-Type Connectors...1378
SWP-Type Connectors...1380
M-Type Connectors...1382
S-Type Connectors...1384
MIC-Type Connectors...1386
AMP040-Type Connectors...1388
AMP070-Type Connectors...1390
Miscellaneous Types of Connectors...1392
HD30 Series Connectors...1397
DT Series Connectors...1403
DTM Series Connectors...1405
DTHD Series Connectors...1405
DTP Series Connectors...1406
DRC26 Series Connectors...1407
DRC12, 16 Connectors...1409
AMP Connectors for Pump Controller...1410
BOSCH Connectors for Engine...1412
SUMITOMO Connectors for Engine...1413
CANNON Connectors for Engine...1414
AMP Connectors for Engine...1415
FRAMATOME Connectors for Engine...1416
PACKARD Connectors for Engine...1418
OT Series Connectors for Engine...1419
T-BRANCH BOX and T-BRANCH ADAPTER TABLE...1420
MODE CHART...1424
INFORMATION CONTAINED IN TESTING PROCEDURES...1427
TROUBLESHOOTING BY FAILURE CODE...1429
Failure Code Table...1429
FUSE BOX AND SLOW-BLOW FUSES...1435
Connection Table...1435
Fuse Box: FS1...1435
Fuse Box: FS2...1436
Slow-Blow Fuses...1437
FAILURE CODES...1439
2G40ZG...1439
Brake: Oil Pressure Reduction...1439
6091NX...1441
HST Filter: Clogging...1441
989FN1...1442
Travel Speed: Overrun Alarm...1442
AB00L6...1443
Alternator R System: Short Circuit...1443
AB00MA...1445
Alternator R System: Ground Fault/Disconnection/Low Charge Voltage...1445
B@BAZG...1447
Engine: Oil Pressure Reduction...1447
B@BCNS...1448
Engine: Overheat...1448
B@BCZK...1449
Engine: Low Coolant Level...1449
B@C6NS...1451
Front Brake: High Oil Temperature...1451
B@CRNS...1452
HST: High Oil Temperature...1452
CA111...1453
Abnormality in Engine Controller...1453
CA115...1454
Engine Ne or Bkup Speed Sensor Error...1454
CA122...1455
Charge Pressure Sensor High Error...1455
CA123...1457
Charge Pressure Sensor Low Error...1457
CA131...1459
Throttle Sensor High Error...1459
CA132...1461
Throttle Sensor Low Error...1461
CA144...1463
Coolant Sensor High Error...1463
CA145...1465
Coolant Sensor Low error...1465
CA153...1467
Charge Temperature Sensor High Error...1467
CA154...1469
Charge Temperature Sensor Low Error...1469
CA155...1471
Lowering of Speed by Abnormally High Charge Temperature...1471
CA187...1473
Sensor Power Supply 2 Low Error...1473
CA221...1475
Atmospheric Pressure Sensor High Error...1475
CA222...1477
Atmospheric Sensor Low Error...1477
CA227...1479
Sensor Power Supply 2 High Error...1479
CA234...1481
Engine Overspeed...1481
CA238...1482
Ne Speed Sensor Power Supply Error...1482
CA271...1483
IMV (IMA) Short Circuit...1483
CA272...1485
IMV (IMA) Disconnection...1485
CA322...1487
Injector #1 Open/Short Error...1487
CA323...1489
Injector #5 Open/Short Error...1489
CA324...1491
Injector #3 Open/Short Error...1491
CA325...1493
Injector #6 Open/Short Error...1493
CA331...1495
Injector #2 Open/Short Error...1495
CA332...1497
Injector #4 Open/Short Error...1497
CA342...1499
Calibration Code Inconsistency...1499
CA351...1501
Injectors Drive Circuit Error...1501
CA352...1503
Sensor Power Supply 1 Low Error...1503
CA386...1505
Sensor Power Supply 1 High Error...1505
CA428...1507
Abnormally High Level in Water Sensor...1507
CA429...1509
Abnormally Low Level in Water Sensor...1509
CA431...1511
Idle Validation Switch Error...1511
CA432...1515
Idle Validation Action Error...1515
CA435...1519
Engine Oil Pressure Switch Error...1519
CA441...1521
Battery Voltage Low Error...1521
CA442...1525
Battery Voltage High Error...1525
CA449...1527
Common Rail Pressure High Error 2...1527
CA451...1529
Common Rail Pressure Sensor High Error...1529
CA452...1531
Common Rail Pressure Sensor Low Error...1531
CA488...1533
Lowering of Torque by Abnormally High Charge Temperature...1533
CA553...1534
Common Rail Pressure High Error 1...1534
CA559...1535
Supply Pump Pressure Very Low Error...1535
CA689...1537
Engine Ne Speed Sensor Error...1537
CA731...1539
Engine Bkup Speed Sensor Phase Error...1539
CA757...1540
All Continuous Data Lost Error...1540
CA778...1543
Engine Bkup Speed Sensor Error...1543
CA1633...1545
KOMNET Datalink Timeout Error...1545
CA2185...1549
Throttle Sensor Supply Voltage High Error...1549
CA2186...1551
Throttle Sensor Power Supply Low Error...1551
CA2249...1553
Supply Pump Pressure Very Low Error 2...1553
CA2311...1555
Abnormality in IMV (IMA) Solenoid...1555
CA2555...1557
Intake Heater Relay Disconnection Error...1557
CA2556...1559
Intake Heater Relay Short Circuit Error...1559
D160KY...1561
Backup Alarm/Lamp Relay 1 Circuit: Short Circuit...1561
D192KY...1563
ECSS Solenoid Relay: Short Circuit...1563
D1B0KA...1565
HST Safety Relay: Disconnection...1565
D1B0KB...1567
HST Safety Relay: Ground Fault...1567
D1B0KY...1569
HST Safety Relay: Short Circuit...1569
D5ZHL6...1571
IGN C System: Ground Fault/Disconnection...1571
DAF3KK...1573
UNSW Power Supply: Ground Fault/Disconnection...1573
DAFRKR...1575
Machine Monitor CAN-NET Signal: Disconnection...1575
DAJ0KK...1577
HST Controller Power Supply: Low Voltage...1577
DAJ0KT...1579
HST Controller Memory (EEPROM): Abnormality...1579
DAJ1L4...1581
HST Controller Main Power Line: Disconnection/Ground Fault...1581
DAJ1L6...1583
HST Controller Main Power Line: Short Circuit...1583
DAJ2KK...1585
Controller Solenoid Power Supply: Low Voltage...1585
DAJ2L3...1587
HST Controller Load Power Supply Holding Line: Short Circuit in Wiring Harness...1587
DAJ2L4...1589
HST Controller Load Power Supply Holding Line: Disconnection/Ground Fault...1589
DAJ5KX...1591
Sensor 5V Power Supply: Out-of-Output Range...1591
DAJ9KQ...1593
HST Controller Model Selection: Disagreement of Model Selection Signals...1593
DAJRKR...1595
HST Controller CAN-NET Signal: Disconnection...1595
When HST Controller Power Supply Circuit is Defective...1597
DAJRMA...1600
HST Controller: Disagreement in Option Selection...1600
DB2RKR...1601
Engine Controller CAN-NET: Disconnection in Signal Line...1601
When Engine Controller Power Supply Circuit is Defective...1603
DD1NL4...1605
Fan Automatic Reverse Switch Signal: Abnormality...1605
DD1NLD...1607
Fan Reverse Switch Signal: Abnormality...1607
DDB6KA...1609
Parking Brake Switch A: Disconnection/Short Circuit...1609
DDB6KB...1611
Parking Brake Switch B: Ground Fault...1611
DDB6KZ...1613
Parking Brake Switch or Parking Brake Reminder Switch: Trouble...1613
DDB6L0...1615
Parking Brake Switch A: Ground Fault...1615
DDB6L4...1617
Parking Brake Switch B: Disconnection/Short Circuit...1617
DDD7KY...1619
Travel Speed Control Dial Signal: Short Circuit...1619
DDE5MA...1621
Emergency Steering Operation Switch: Disconnection...1621
DDK3KA...1623
Directional Selector Switch: Disconnection/Short Circuit...1623
DDK3KB...1625
Directional Selector Switch: Ground Fault...1625
DDK6KA...1627
FNR Lever: Disconnection/Ground Fault...1627
DDK6KY...1631
FNR Lever: Short Circuit...1631
DDS5L6...1633
Steering: Low Oil Pressure (Operation of Emergency Steering)...1633
DF10KA...1635
Travel Speed Range Selector Switch: Disconnection/Ground Fault...1635
DF10KB...1639
Travel Speed Range Selector Switch: Short Circuit...1639
DGH1KX...1641
HST Oil Temperature Sensor: Ground Fault...1641
DGR2KB...1643
Brake Oil Temperature Sensor: Ground Fault...1643
DGR2KZ...1645
Brake Oil Temperature Sensor: Disconnection/Short Circuit...1645
DHH1KX...1647
HST Oil Pressure Sensor: Disconnection/Ground Fault...1647
DHH1KY...1649
HST Oil Pressure Sensor: Short Circuit...1649
DHTCL6...1651
HST Filter Clogging Sensor: Functional Defect...1651
DJF1KA...1653
Fuel Level Sensor: Disconnection/Short Circuit...1653
DLT3KX...1655
Travel Speed Sensor B: Abnormality...1655
DLT4KX...1659
Travel Speed Sensor A: Abnormality...1659
DLT4LC...1661
Travel Speed Sensor A & B: Abnormality...1661
DV00KY...1663
Alarm Buzzer: Short Circuit...1663
DW26KA...1665
Motor 2 Solenoid: Disconnection/Ground Fault...1665
DW26KY...1667
Motor 2 Solenoid: Short Circuit...1667
DW7BKY...1669
Fan Reverse Solenoid Circuit: Short Circuit...1669
DW7BKZ...1671
Fan Reverse Solenoid Circuit: Disconnection/Ground Fault...1671
DX16KA...1673
Fan EPC Solenoid: Disconnection...1673
DX16KB...1675
Fan EPC Solenoid: Ground Fault...1675
DX16KY...1677
Fan EPC Solenoid: Short Circuit...1677
DX19KA...1679
Motor 1 Solenoid: Disconnection...1679
DX19KB...1681
Motor 1 Solenoid: Ground Fault...1681
DX19KY...1683
Motor 1 Solenoid: Short Circuit...1683
DX20KA...1685
Clutch EPC Solenoid: Disconnection...1685
DX20KB...1687
Clutch EPC Solenoid: Ground Fault...1687
DX20KY...1689
Clutch EPC Solenoid: Short Circuit...1689
DXH7KB...1691
Reverse Solenoid: Ground Fault...1691
DXH7KZ...1693
Reverse Solenoid: Disconnection/Short Circuit...1693
DXH8KB...1695
Forward Solenoid: Ground Fault...1695
DXH8KZ...1697
Forward Solenoid: Disconnection/Short Circuit...1697
J141N1...1699
Steering Pump: Overrun Alarm...1699
M100N1...1700
HST Pump: Overrun Alarm...1700
M400N1...1701
Motor 1: Overrun Alarm...1701
TROUBLESHOOTING: E-MODE...1703
Troubleshooting Electrical System...1703
Information in Troubleshooting Table...1703
E-1...1705
Engine Does Not Start...1705
E-2...1713
Preheater Does Not Operate Normally...1713
E-3...1717
Defective Boom Kick-Out Function and Cancellation...1717
E-4...1721
Defective Bucket Positioner Function and Cancellation...1721
E-5...1725
Defective Lift Arm FLOATING Holding Function and Cancellation...1725
E-6...1729
Travel Direction Selection System Does Not Function...1729
E-7...1733
Wiper Does Not Operate...1733
E-8...1737
Windshield Washer Does Not Operate...1737
E-9...1740
Headlamp, Clearance Lamp, and Tail Lamp Do Not Light Up or Go Off...1740
E-10...1748
Working Lamp Does Not Light Up or Go Off...1748
E-11...1753
Turn Signal Lamp and Hazard Lamp Do Not Light Up or Go Off...1753
E-12...1759
Brake Lamp Does Not Light or It Keeps Lighting Up...1759
E-13...1761
Backup Lamp Does Not Light or It Keeps Lighting Up...1761
E-14...1764
Backup Alarm Does Not Sound or It Keeps Sounding...1764
E-15...1769
Horn Does Not Sound or It Keeps Sounding...1769
E-16...1771
Alarm Buzzer Does Not Sound or It Keeps Sounding...1771
E-17...1773
Air Conditioner Does Not Operate or Stop...1773
E-18...1777
The KOMTRAX System Does Not Work Properly...1777
Lamp Display Section of KOMTRAX Terminal...1779
TROUBLESHOOTING: H-MODE...1780
Troubleshooting Hydraulic and Mechanical Systems...1780
Method of Using Troubleshooting Chart...1780
Table of Failure Codes and Causes...1783
H-1...1785
Machine Does Not Start...1785
H-2...1786
Travel Speed Is Slow...1786
H-3...1787
Traction Force Is Weak...1787
H-4...1788
Engine Stalls When Traveling or Engine Speed Drops Excessively...1788
H-5...1789
Gear is Not Shifted...1789
H-6...1790
Steering Wheel Does Not Turn...1790
H-7...1791
Steering Wheel Is Heavy...1791
H-8...1792
Steering Wheel Shakes or Jerks...1792
H-9...1793
Machine Deviates Naturally to One Side When Traveling...1793
H-10...1794
Brake Does Not Work or Does Not Work Well...1794
H-11...1795
Brake Is Not Released or Is Dragged...1795
H-12...1796
Lift Arm Does Not Rise or Lower...1796
H-13...1797
Lift Arm Moves Slowly or Lift Arm Rising Force Is Insufficient...1797
H-14...1798
When Rising, Lift Arm Starts to Move Slowly at a Specific Height...1798
H-15...1798
Lift Arm Cylinder Cannot Hold Down The Bucket (Bucket Rises in the Air)...1798
H-16...1798
Hydraulic Drifts of the Lift Arm Occur Often...1798
H-17...1799
Lift Arm Wobbles During Operation...1799
H-18...1799
When Control Lever Is Switched from HOLD to RAISE, Lift Arm Falls Temporarily...1799
H-19...1800
Bucket Does Not Tilt Back...1800
H-20...1801
Bucket Moves Slowly or Tilting-Back Force Is Insufficient...1801
H-21...1802
Bucket Starts to Operate Slowly in the Midst of Tilting-Back...1802
H-22...1802
Bucket Cylinder Cannot Hold Down the Bucket...1802
H-23...1802
Hydraulic Drifts of the Bucket Occur Often...1802
H-24...1803
Bucket Wobbles During Travel with Load...1803
H-25...1803
When Control Lever Is Switched from HOLD to TILT, the Bucket Falls Temporarily...1803
H-26...1804
Control Levers of Lift Arm and Bucket Do Not Move Smoothly and Are Heavy...1804
H-27...1805
ECSS Does Not Operate and Machine Pitches and Bounces...1805
H-28...1806
Fan Revolution Is Abnormal...1806
ENGINE SYSTEM (S-MODE)...1807
Method Of Using Troubleshooting Charts...1807
S-1...1811
Engine Starting Performance Is Poor...1811
S-2...1813
Engine Does Not Start...1813
Engine Turns But No Exhaust Smoke Comes Out...1814
Engine Smoke Comes Out But Engine Does Not Start...1815
S-3...1817
Engine Does Not Pick Up Smoothly...1817
S-4...1819
Engine Stops During Operations...1819
S-5...1821
Engine Does Not Rotate Smoothly...1821
S-6...1823
Engine Lacks Output (or Lacks Power)...1823
S-7...1825
Exhaust Smoke is Black (Incomplete Combustion)...1825
S-8...1827
Oil Consumption is Excessive (or Exhaust Smoke is Blue)...1827
S-9...1828
Oil Becomes Contaminated Quickly...1828
S-10...1829
Fuel Consumption is Excessive...1829
S-11...1830
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)...1830
S-12...1831
Oil Pressure Drops...1831
S-13...1832
Oil Level Rises (Entry of Coolant or Fuel)...1832
S-14...1833
Coolant Temperature Becomes Too High (Overheating)...1833
S-15...1835
Abnormal Noise is Made...1835
S-16...1837
Vibration is Excessive...1837
50 DISASSEMBLY AND ASSEMBLY...1840
HOW TO READ THIS MANUAL...1844
Removal and Installation of Assemblies...1844
Disassembly and Assembly of Assemblies...1846
COATING MATERIALS LIST...1848
SPECIAL TOOLS LIST...1851
SKETCHES OF SPECIAL TOOLS...1855
CONNECTOR REPAIR PROCEDURES...1864
Stripping Insulation...1864
Wire Inspection...1864
Contact Terminal Removal (HD30 Type)...1865
Crimping Contact Terminal (HD30 Type)...1866
Insertion Of Contact Terminal (HD30 Type)...1867
Contact Terminal Removal (DT Type)...1868
Crimping Contact Terminal (DT Type)...1869
Insertion Of Contact Terminal (DT Type)...1870
ENGINE AND COOLING SYSTEM...1871
Fuel Supply Pump...1871
Removal...1871
Installation...1873
Fuel Injector...1874
Removal...1874
Installation...1879
Cylinder Head Assembly...1884
Removal...1884
Installation...1893
Engine Hood...1900
Removal...1900
Installation...1903
Radiator...1904
Removal...1904
Installation...1907
Air Aftercooler...1908
Removal...1908
Installation...1909
Hydraulic Oil Cooler...1910
Removal...1910
Installation...1912
Engine...1913
Removal...1913
Installation...1919
Engine Front Oil Seal...1921
Removal...1921
Installation...1924
Engine Rear Oil Seal...1925
Removal...1925
Installation...1927
Cooling Fan and Fan Motor...1930
Removal...1930
Installation...1933
Fuel Tank...1934
Removal...1934
Installation...1936
POWER TRAIN...1937
Transfer...1937
Removal...1937
Installation...1941
Disassembly...1943
Assembly...1956
Parking Brake...1971
Removal...1971
Installation...1973
Disassembly...1974
Assembly...1977
Front Axle...1981
Removal...1981
Installation...1983
Rear Axle...1984
Removal...1984
Installation...1987
Axle Housing...1988
Disassembly...1989
Assembly...1994
Differential...2000
Disassembly...2001
Assembly...2014
UNDERCARRIAGE AND FRAME...2035
Center Hinge Pin...2035
Removal...2035
Installation...2042
Counterweight...2048
Removal...2048
Installation...2049
HYDRAULIC SYSTEM...2050
HST Pump and 4-Gear Pump...2050
Removal...2050
Installation...2053
HST Pump...2055
Disassembly...2055
Assembly...2068
HST Motor 1...2088
Removal...2088
Installation...2090
HST Motor 2...2091
Removal...2091
Installation...2093
HST Motor...2094
Disassembly...2094
Assembly...2106
Work Equipment Control Valve...2116
Removal...2116
Installation...2118
Hydraulic Tank...2119
Removal...2119
Installation...2121
Hydraulic Cylinder...2122
Disassembly...2123
Assembly...2126
WORK EQUIPMENT...2130
Work Equipment...2130
Removal...2130
Installation...2134
CAB AND ITS ATTACHMENTS...2138
Cab and Floor Frame...2138
Removal...2138
Installation...2143
Cab Glass (Stuck Glass)...2145
Removal...2145
Installation...2146
Air Conditioner Unit...2154
Removal...2154
Installation...2160
ELECTRICAL SYSTEM...2162
Monitor Panel...2162
Removal...2162
Installation...2164
Engine Controller...2165
Removal...2165
Installation...2166
HST Controller...2167
Removal...2167
Installation...2167
KOMTRAX Terminal...2169
Removal...2169
Installation...2170
90 DIAGRAMS AND SCHEMATICS...2172
HYDRAULIC SYSTEM...2174
Hydraulic Circuit Diagram...2174
ELECTRICAL SYSTEM...2175
Machine Monitor System...2175
HST Controller System Circuit Diagram...2176
HST Controller System (1/2)...2177
HST Controller System (2/2)...2178
Machine Monitor System (Lamp Related Items) (1/2)...2179
Machine Monitor System (Lamp Related Items) (2/2)...2180
Machine Monitor System (Other than Lamp Related Items) (1/2)...2181
Machine Monitor System (Other than Lamp Related Items) (2/2)...2182
Engine Controller System (1/2)...2183
Engine Controller System (2/2)...2184
Electrical Circuit Diagram (1/9)...2185
Electrical Circuit Diagram (2/9)...2186
Electrical Circuit Diagram (3/9)...2187
Electrical Circuit Diagram (4/9)...2188
Electrical Circuit Diagram (5/9)...2189
Electrical Circuit Diagram (6/9)...2190
Electrical Circuit Diagram (7/9)...2191
Electrical Circuit Diagram (8/9)...2192
Electrical Circuit Diagram (9/9)...2193
Connector List and Sterograms...2194
LUBRICATION SYSTEM...2195
Auto-Greasing Circuit Diagram...2195
CEBM000704 - Wheel Loader WA250-6 Shop Manual...2196
COVER...0
CONTENTS...2197
REVISED PAGES...2198
SAFETY...2210
Safety Notice...2210
Important Safety Notice...2210
General Precautions...2210
Preparations for Work...2211
Precautions During Work...2211
GENERAL...2212
HOW TO READ THE SHOP MANUAL...2213
Volumes...2213
Distribution and Updating...2213
Filing Method...2213
Revised Edition Mark...2213
Revisions...2213
Symbols...2213
HOISTING INSTRUCTIONS...2214
Hoisting...2214
Making Signs...2214
Precautions...2214
Precautions for Sling Work...2214
Precautions for Using Mobile Crane...2215
Precautions for Using Overhead Hoist Crane...2215
Selecting Wire Ropes...2216
AIR CONDITIONER CIRCUITS...2217
Precautions for Handling Hoses and Tubes...2217
Disconnecting Hoses and Tubes...2217
Connecting Hoses and Tubes...2217
MAINTENANCE STANDARD TERMS...2218
HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT...2220
Handling Electric Equipment...2220
Handling Wiring Harnesses and Connectors...2220
Main Failures Occurring in Wiring Harness...2220
Removing, Installing, and Drying Connectors and Wiring Harnesses...2221
Handling Controller...2225
Troubleshooting Electric Circuits...2225
Handling Hydraulic Equipment...2226
Handling Connectors Used for Engines...2227
Slide Lock Type...2227
Pull Lock Type...2228
Push Lock Type...2228
Turn-housing Type (Round Green Connector)...2230
PRECAUTIONS FOR OPERATIONS...2231
Precautions when Carrying Out Removal Work...2231
Precautions when Carrying Out Installation Work...2232
Precautions when Completing the Operation...2233
PUSH-PULL COUPLER...2234
Type 1...2234
Disconnection...2234
Connection...2234
Type 2...2235
Disconnection...2235
Connection...2235
Type 3...2236
Disconnection...2236
Connection...2236
COATING MATERIALS...2237
STANDARD TIGHTENING TORQUE...2239
Standard Tightening Tables...2239
For Bolts and Nuts...2239
For Split Flange Bolts...2240
For O-Ring Boss Piping Joints...2240
For O-Ring Boss Plugs...2241
For Hoses (Taper-Seal Type and Face-Seal Type)...2241
For Face Seal Joints...2242
For 102, 107, and 114 Engine Series (Bolts and Nuts)...2242
For 102, 107, and 114 Engine Series (Eye Joints)...2242
For 102, 107, and 114 Engine Series (Taper Screws)...2243
CONVERSION TABLES...2244
Method of Using the Conversion Table...2244
01 GENERAL...2250
SPECIFICATIONS...2251
Dimension Drawing...2251
Specification Tables...2253
WEIGHT TABLE...2257
FUEL, COOLANT, AND LUBRICANTS...2259
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD...2262
ENGINE AND COOLING SYSTEM...2266
Engine and Transmission Mounting...2266
Torque Values...2266
Damper...2267
Torque Values...2268
Outline...2268
Cooling System...2269
Specifications...2269
Cooling System Hydraulic Piping Diagram...2270
Outline...2270
Cooling Fan Motor...2271
Type: LMF16...2271
Torque Values...2272
Specifications...2272
Torque Values...2274
Hydraulic Motor...2275
Function...2275
Principle of Operation...2275
Suction Safety Valve...2276
Suction Function...2276
Operation...2276
Safety Function...2277
Function...2277
Operation...2277
Operation of Reversible Valve...2278
Flow Control Valve (Continuously Variable Type)...2279
Function...2279
Operation...2279
POWER TRAIN SYSTEM...2280
Drive Line Components...2280
System Diagram...2281
Outline...2282
Drive Shaft...2283
Torque Values...2283
Outline...2283
HST Hydraulic Piping Diagram...2284
HST Pump...2285
Specifications...2286
Operation...2287
Flow of Power...2287
Flow of Oil...2287
High-Pressure Relief Valve...2288
Function...2288
Operation...2289
Low-pressure Relief Valve...2290
Function...2290
Operation...2290
HST Charge Pump...2291
Outline...2292
Specifications...2292
Function...2292
Speed-Related Valve (DA Valve)...2293
Function...2293
Operation...2293
High-Pressure Cutoff Valve...2294
Function...2294
Operation...2294
HST Motor...2295
HST Motor 1...2295
Specifications...2296
HST Motor 2...2297
Specifications...2298
Principle...2299
Structure...2299
Operation...2299
EP Servo Valve...2300
Function...2300
Operation...2300
HA Servo Valve...2301
Function...2301
Operation...2301
Directional Shuttle Valve...2302
Function...2302
Operation...2302
Transfer...2303
Torque Values...2304
Torque Values...2306
Input Shaft...2307
Output Shaft...2309
Torque Values...2312
Outline...2313
Relation between transfer clutch and transfer clutch pressure at respective speed ranges...2313
Relationship between accelerator pedal angle and travel speed (A) for starting transfer clutch switching modulation...2313
Operation of Clutch...2314
Clutch is Engaged (fixed)...2314
Clutch is Disengaged (released)...2314
Power Transmitting Route...2315
Low-Speed Mode...2315
High-Speed Mode...2316
Clutch Solenoid Valve...2317
Operation...2317
DRIVE AXLE SYSTEM...2319
Front and Rear Axles...2319
Front Axle...2319
Torque Values...2320
Rear Axle...2321
Torque Values...2322
Differential...2323
Front Differential...2323
Torque Values...2325
Rear Differential...2327
Torque Values...2328
Outline...2329
While Machine is Traveling Straight...2329
While Machine is Turning...2329
Torque Proportioning Differential...2330
Outline...2330
Operation...2330
Straight Travel (when road resistance under both tires is the same)...2330
Travel on Soft Ground (when road resistance under both tires is different)...2330
Limited Slip Differential...2331
Torque Values...2331
Operation...2333
Mechanism of Generation of Braking Torque by Right and Left Side Gears (5)...2333
While Machine is Traveling Straight (when the drive forces of the right and left wheels are balanced)...2333
When the drive forces of the right and left wheels are unbalanced...2334
Difference in wheel drive force by type of differentials when either wheel slips...2334
Torque Proportioning Differential...2334
Conventional Differential (not applicable to this machine)...2334
While Machine is Turning...2334
Final Drive...2335
Front Final Drive...2335
Torque Values...2335
Rear Final Drive...2337
Torque Values...2337
Outline...2338
STEERING SYSTEM...2339
Steering Piping Diagram...2339
Steering Column...2340
Torque Values...2340
Priority Valve...2341
Torque Values...2342
Outline...2343
Operation...2343
When Steering Wheel is at Neutral Position...2343
When Steering Wheel is Turned Left...2343
Orbitrol Valve...2345
Torque Values...2345
Outline...2346
Structure...2346
Operation...2347
When Steering Wheel is at Neutral Position...2347
When Steering Wheel is Turned Left...2349
When Steering Wheel is at Stop Position...2350
Connection of Hand Pump and Sleeve...2351
Role of Centering Spring...2352
2-Way Restrictor Valve...2353
Function...2353
Operation...2353
Cushion Valve...2354
Outline...2354
Function...2354
Steering Cylinder...2355
Torque Values...2356
Emergency Steering Piping Diagram...2357
Emergency Steering Valve...2359
Torque Values...2360
Operation...2361
When Engine and Steering Pump are Normal...2361
When Engine or Steering Pump is Abnormal...2362
Steering Relief Valve...2363
Torque Values...2363
Outline...2363
BRAKE SYSTEM...2364
Brake Piping Diagram...2364
Charge Valve...2365
Torque Values...2366
Function...2366
Operation...2367
When Oil is Not Supplied to Accumulator...2367
Cutout State...2367
When Oil is Supplied to Accumulator...2367
Cut-in State...2367
When Pressure Reaches Cutout Pressure...2368
When Oil Pressure from the Pump Goes Beyond the Set Pressure...2368
Brake Valve...2369
Outline...2370
Braking Operation...2371
When the Brake Pedal is Pressed Down...2371
When Brake of One Side is Operated (when the other brake failed)...2371
Balancing Operation...2372
When Brake Pedal is Released...2373
Inching Valve...2374
Outline...2374
Accumulator (for Brake)...2375
Specifications...2375
Function...2375
Slack Adjuster...2377
Function...2378
Operation...2378
When Brake is Applied...2378
When Brake is Released...2378
Brakes...2379
Front Brake...2379
Outline...2380
Rear Brake...2381
Outline...2382
Operation...2382
When Brake is Operated...2382
When Brake is Released...2382
Parking Brake System...2383
Brake Control...2383
Outline...2383
Parking Brake...2384
Torque Values...2384
Outline...2384
UNDERCARRIAGE AND FRAME...2385
Axle Mounting and Center Hinge Pin...2385
Torque Values...2386
Outline...2386
Torque Values...2388
Torque Values...2389
Tires...2391
Radial Tire...2391
Structure...2391
Ground Contact Characteristics...2391
Deformation Characteristics...2391
Bias Tire...2392
Structure...2392
Ground Contact Characteristics...2392
Deformation Characteristics...2392
HYDRAULIC SYSTEM...2393
Work Equipment Hydraulic Piping Diagram...2393
Outline...2394
Work Equipment Control Lever Linkage...2395
Mono-Lever Type...2395
2-Lever Type...2396
Hydraulic Tank...2397
Specifications...2398
Torque Values...2398
Breather...2398
Prevention of Negative Pressure in Tank...2398
Prevention of Pressure Rise in Tank...2398
4-Gear Pump...2399
SAR(3)56 + (2)40 + SB(1)12 + 12...2399
Outline...2399
Torque Values...2400
Work Equipment Control Valve...2401
2-Spool Type...2401
Torque Values...2402
Torque Values...2404
3-Spool Type...2405
Torque Values...2406
Torque Values...2408
Relief Valve...2409
Function...2409
Operation...2409
Safety-Suction Valve...2410
Function...2410
Operation...2410
Operation as Safety Valve...2410
Operation as Suction Valve...2411
Suction Valve...2412
Function...2412
Operation...2412
Operation of Work Equipment Control Valve...2413
When Lift Arm and Bucket Spool are at the Neutral Position...2413
Operation...2413
When Lift Arm Spool is at Raise Position...2414
Operation...2414
When Lift Arm Spool is at Lower Position...2415
Operation...2415
When Lift Arm Spool is at Float Position...2416
Operation...2416
When Bucket Spool is at Tilt Position...2417
Operation...2417
When Bucket Spool is at Dump Position...2418
Operation...2418
PPC Valve...2419
Work Equipment PPC Valve...2419
Mono Lever Type...2419
Torque Values...2422
Operation...2423
When in Neutral...2423
When in Fine Control Mode (neutral Æ fine control)...2424
When in Fine Control Mode (when control lever is returned)...2424
When Lever is Operated to Stroke End...2425
When Lift Arm is Float...2425
When Float State of Lift Arm is Reset...2425
2-Lever Type...2427
Torque Values...2430
Operation...2431
When in Neutral...2431
When in Fine Control Mode (neutral Æ fine control)...2432
When in Fine Control Mode (when control lever is returned)...2432
When Lever is Operated to Stroke End...2433
When Lift Arm is Float...2433
When Float State of Lift Arm is Reset...2433
Attachment PPC Valve...2435
Torque Values...2436
Lock Valve...2437
Outline...2437
Accumulator (for PPC Circuit)...2438
Outline...2438
Specifications...2438
ECSS Valve...2439
Torque Values...2439
Accumulator (for ECSS)...2441
Function...2441
Specifications...2441
Work Equipment...2442
Work Equipment Linkage...2442
Bucket...2445
Torque Values...2446
Bucket Positioner and Boom Kickout...2447
Torque Values...2447
Outline...2448
Bucket Positioner...2448
Boom Kickout (if equipped)...2448
Operation of Proximity Switch...2449
When Bucket is Tilted...2449
Function of Proximity Switch...2451
When Lift Arm is Raised...2452
Function of Proximity Switch...2454
Work Equipment Cylinders...2455
Lift Cylinder...2455
Bucket Cylinder...2455
CAB ENVIRONMENT...2457
Cab...2457
Air Conditioner...2459
Air Conditioner Piping Diagram...2459
Specifications...2460
Refrigerant Circuit Diagram...2461
Table of Tightening Torque for Refrigerant Piping Adapter...2461
Air Conditioner Unit...2462
Outline...2463
Cooler...2463
Heater...2463
Functions of Major Components...2463
Evaporator...2463
Heater Core...2463
Expansion Valve...2463
Blower Controller...2463
Blower Motor Relay...2463
Compressor Clutch Relay...2463
Air Mix Damper Actuator...2464
Evaporator Temperature Sensor...2464
Dual Pressure Switch...2464
Blower and Intake Unit...2465
Functions of Major Components...2466
Blower Motor Assembly...2466
Internal/External Air Changeover Damper Actuator...2466
Compressor...2467
Function...2467
Specifications...2467
Condenser...2468
Function...2468
Specifications...2468
Receiver...2469
Function...2469
Specifications...2469
Air Conditioner Panel...2471
Display Unit...2471
Switch Block...2471
Outline...2472
Input and Output Signals...2472
Function of Abnormality Display in the Control Panel...2473
ELECTRICAL SYSTEM...2475
Machine Monitor System...2475
Outline...2475
Operator Mode...2475
Service Mode...2476
Machine Monitor...2477
Items Displayed on Monitor...2478
Machine Monitor Operation Switches...2484
Setting Machine Monitor...2485
Troubleshooting Function...2485
Character Display Function...2486
Operator Mode Functions...2487
Self-Check Screen (0th layer)...2487
Normal Screen (1st layer)...2487
Failure Code Screen (1st layer)...2488
Display of Functions Available for the Operator (2nd layer or below)...2489
Service Mode Functions...2490
Procedure for Switching to Service Mode...2490
Service Mode Menu...2491
Electrical System Failure History Display Function (ELECTRIC FAULT)...2492
Mechanical System Failure History Display Function (MACHINE FAULT)...2492
Real-Time Monitoring Function (REAL-TIME MONITOR)...2492
Engine Reduced-Cylinder Function (CYLINDER CUT-OUT)...2492
No Injection Cranking Function (NO INJECTION)...2493
Adjustment Function (TUNING)...2493
Maintenance Monitoring Function (MAINTENANCE MONITOR)...2493
Operating Information Display Function (OPERATION INFO)...2493
Optional Device Selecting Function (OPTIONAL SELECT)...2494
Machine Serial Number Input Function (MACHINE No. SET)...2494
Model Selection Function (MACHINE)...2494
Initialize Function (INITIALIZE)...2494
Input and Output Signals...2495
Setting Switches (on circuit board)...2500
Electrical System (HST Controller System)...2501
Input and Output Signals Diagram...2501
HST Controller Gear Shifting Control Function...2502
Gear Shifting Function...2502
Relationship between accelerator pedal angle and travel speed (A) for starting transfer clutch switching modulation...2503
Relationship between accelerator pedal angle and travel speed (A) for switching HST motor 2 capacity...2503
Gear Shifting Display Function...2504
Variable Shift Control System...2504
Transfer Clutch Control Function...2504
Traction Control Function...2504
S Mode Function...2505
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...2506
Max. Traction Function...2507
HST Controller Protection Function...2508
HST Motor 1 Overrun Prevention Function 1...2508
Relationship between accelerator pedal angle and travel speed (A) for starting transfer clutch switching modulation...2509
HST Motor 1 Overrun Prevention Function 2...2509
Travel Speed Control Function...2509
Engine Overrun Prevention Function...2510
Neutralizer Function...2510
Economy Operation Pilot Lamp Function...2510
Cooling Fan Control Function...2511
Input and Output Signals...2511
Fan Control...2512
Fan Speed in Accordance with Temperature...2512
Control at Start of Engine...2513
Fan Reverse Rotation Function...2514
Fan Manual Reverse Rotation Function...2514
Overheat Prevention Function...2514
Fan Speed During Reverse Rotation...2514
Fan Automatic Reverse Rotation Function...2515
Adjustment of the Automatic Fan Switching Cycle to Reverse Rotation and Duration...2515
System Circuit Diagram...2516
HST Controller...2517
Input and Output Signals...2518
ECSS System...2519
Input and Output Signals...2519
Outline...2519
Setting Method...2519
Operation...2520
KOMTRAX System...2522
KOMTRAX Terminal...2523
Model TC301...2523
Outline...2523
Input and Output Signals...2524
Engine Starting Circuit...2525
Function...2526
Operation...2526
Engine Stopping Circuit...2527
Operation...2527
Preheating Circuit...2528
Outline...2528
Operation...2528
Engine Output Lowering Function...2529
Automatic Warm-up Function...2529
Parking Brake Circuit...2530
Operation...2530
When Parking Brake Lever is Set to the Free Position...2531
When Parking Brake Lever is Set to the Mid Position...2531
When Parking Brake Lever is Set to the Lock Position...2531
Max. Traction Switch...2532
Function...2532
Multi-Function Knob...2533
Multi-function Mono-Lever Type...2533
(If equipped)...2533
Function...2533
Modification of Multi-Function Lever...2533
Required...2534
Procedure...2534
Sensors...2535
Speed Sensor...2535
Torque Values...2536
Function...2536
HST Oil Temperature Sensor...2537
Brake Oil Temperature Sensor...2537
Function...2537
HST Oil Pressure Sensor...2537
Function...2537
HST Oil FIlter Clogging Sensor...2538
Function...2538
Coolant Lever Sensor...2538
Function...2538
Fuel Level Sensor...2539
Function...2539
Accelerator Pedal Sensor...2540
Torque Values...2540
Function...2540
Accelerator signal...2540
Idle Validation Signal...2540
Water-in-Fuel Sensor...2541
Function...2541
Boom Kick-Out Proximity Switch...2541
Bucket Positioner Proximity Switch...2541
Function...2541
20 STANDARD VALUE TABLES...2542
STANDARD VALUE TABLES...2544
Standard Service Value Table for Engine...2544
Standard Service Value Table for Chassis...2545
MACHINE POSTURE...2550
30 TESTING AND ADJUSTING...2552
TOOLS...2556
Tools for Testing, Adjusting, and Troubleshooting...2556
ENGINE COMPONENTS...2561
Engine Speed...2561
Exhaust Gas Color...2563
Using Handy Smoke Checker A1...2563
Using Smoke Meter A2...2563
Valve Clearance...2565
Compression Pressure...2567
Blow-By Pressure...2570
Engine Oil Pressure...2572
Intake Air (Boost) Pressure...2573
Handling Cylinder Cut-Out Mode Operation...2575
Handling No-Injection Cranking Operation...2575
Handling Controller Voltage Circuit...2575
FUEL SYSTEM...2576
Handling Fuel System Equipment...2576
Releasing Residual Pressure in Fuel System...2576
Measuring Fuel Pressure...2577
Measuring Fuel Return Rate and Leakage...2580
Bleeding Air from Fuel Circuit...2585
Testing Leakage in Fuel System...2586
EXHAUST SYSTEM AND PIPING...2587
Checking Muffler and Muffler Stack for Looseness and Damage...2587
Checking Muffler Function...2587
Checking Installed Condition of Cylinder Head and Manifolds...2587
Checking Engine Piping for Damage and Looseness...2587
BELTS...2588
Air Conditioner Compressor Belt...2588
Alternator Belt...2589
ACCELERATOR PEDAL...2590
Testing Operating Effort...2590
Testing Operating Angle...2591
DIRECTIONAL LEVER...2592
Checking Operating Effort...2592
Checking Travel...2592
POWER TRAIN OIL PRESSURES...2593
Testing HST Oil Pressure...2593
High-Pressure Cutoff Oil Pressure...2593
Low-Pressure Relief Pressure...2595
Servo Piston Control Pressure (DA Pressure)...2596
Servo Piston Actuating Pressure...2597
Adjusting HST Oil Pressure...2598
High-Pressure Cutoff Valve...2598
Low-Pressure Relief Valve...2599
DA Valve...2600
Testing Clutch Control Pressure...2601
STEERING SYSTEM...2602
Steering Wheel...2602
Measuring Play...2602
Measuring Operating Effort...2603
Measuring Operating Time...2604
Steering Oil Pressure...2605
Measuring Main Relief Pressure...2605
Adjusting Main Relief Pressure...2606
Bleeding Air From Steering Circuit...2607
HYDRAULIC FAN...2608
Fan Speed...2609
Fan Drive Oil Pressure...2610
BRAKE SYSTEM...2611
Measuring Brake Pedal...2611
Brake Pedal Linkage...2612
Testing...2612
Adjusting...2612
Measuring Brake Performance...2613
Accumulator Charge Pressure...2614
Testing...2614
Adjusting...2615
Testing Wheel Brake Oil Pressure...2616
Testing Wear of Brake Disc...2619
Bleeding Air from Wheel Brake Circuit...2620
Releasing Residual Pressure in Brake Accumulator Circuit...2621
Testing Parking Brake Performance...2621
Parking Brake Limit Switch...2622
Testing...2622
Adjusting...2623
Parking Brake Control Cable...2625
Testing...2625
Adjusting...2625
WORK EQUIPMENT...2626
Control Lever...2626
Measuring Operating Effort...2626
Measuring Travel...2626
Hydraulic Pressure...2627
Measuring...2627
Adjusting...2628
PPC Oil Pressure...2629
Testing PPC Valve Basic Pressure...2629
Checking PPC Valve Output Pressure...2630
Bleeding Air from Hydraulic Circuit...2631
From Work Equipment PPC Circuit...2631
From Cylinders...2631
Releasing Residual Pressure in Hydraulic Circuit...2631
Between Hydraulic Cylinder and Control Valve...2631
In Brake Accumulator Circuit...2631
In PPC Accumulator Circuit...2631
Bucket Positioner...2632
Testing...2632
Adjusting Clearance...2632
Adjusting Installing Position (Stopping Position)...2633
Boom Kickout Switch...2634
Testing...2634
Adjusting...2634
Checking Proximity Switch Operation Pilot Lamp...2635
ELECTRICAL SYSTEM TROUBLESHOOTING...2636
Procedure for Testing Diodes...2636
Using Digital-Type Circuit Tester...2636
Using Analog-Type Circuit Tester...2637
Preparation Work for Troubleshooting Electric System...2638
Machine Monitor...2638
HST Controller...2639
KOMTRAX Terminal...2640
Boost Pressure and Temperature Sensor (BOOST PRESS & IMT)...2640
Supply Pump IMV Solenoid (FUEL REGULATOR)...2641
Common Rail Pressure Sensor (FUEL RAIL PRESS)...2641
Engine Coolant Temperature Sensor (COOLANT TEMP)...2642
Ambient Temperature Sensor (AMBAIR PRESSURE)...2642
Engine Ne Speed Sensor (CRANK SENSOR)...2642
Engine Bkup Speed Sensor (CAM SENSOR)...2642
Engine Oil Pressure Switch (OIL PRESSURE SWITCH)...2642
KOMTRAX TERMINAL SYSTEM...2643
Starting KOMTRAX Terminal Operations...2643
Station Opening Check in Machine Side...2643
Application for the Start of Use...2647
KOMTRAX Terminal Indicator Lamps...2648
MACHINE MONITOR SYSTEM...2651
Adjusting Machine Monitor...2651
Adjusting Replaced, Reassembled, or Added Sensor, Controller, Etc...2652
Items to Be Set...2652
Adjustment for User’s Needs...2652
Special Functions of Machine Monitor (EMSS)...2653
Normal and Special Functions of Machine Monitor...2654
Normal Functions: Operator Mode...2654
Special Functions: Service Mode...2654
Functions and Flow of Service Mode...2655
Operator Mode...2658
Service Meter Display Function...2658
Traction Level Selection Function...2658
HST Function Selection Function...2658
Odometer Display Function...2659
Maintenance Monitoring Function...2659
Telephone Number Input Function...2659
Language Selection Function...2659
Monitor Brightness Adjustment Function...2660
Travel Speed/Engine Speed Display Selecting Function...2660
Travel Speed/Engine Speed Display/Non-Display Selecting Function...2660
Action Code Display Function...2661
Failure Code Display Function...2662
Service Mode...2663
Switching to Service Mode and Screen Display...2663
Electrical System Fault History Display Function (ELECTRIC FAULT)...2665
Mechanical System Fault History Display Function (MACHINE FAULT)...2667
Failure Codes Table...2668
Real-Time Monitoring Function (REAL-TIME MONITOR)...2674
Real-Time Monitoring Codes Tables...2677
Engine Reduced-Cylinder Function (CYLINDER CUT-OUT)...2690
No-Injection Cranking Function...2691
Adjustment Function (TUNING)...2692
Maintenance Monitoring Function...2696
Operating Information Display Function...2701
Optional Device Selecting Function...2704
Machine Serial Number Input Function...2708
Model Selection Function (MACHINE WA***)...2709
Initialize Function...2710
PM CLINIC INSPECTION TABLES...2711
40 TROUBLESHOOTING...2714
POINTS TO REMEMBER WHEN TROUBLESHOOTING...2724
SEQUENCE OF EVENTS IN TROUBLESHOOTING...2726
PRECAUTIONS FOR MAINTENANCE...2727
Precautions when Handling Electrical Equipment...2727
Handling Electronic Control Unit...2732
Points to Remember when Troubleshooting Electrical Circuits...2733
ELECTRIC WIRE CODE...2734
How to Read Electric Wire Code...2734
Type, Symbol, and Material...2734
Dimensions...2735
Color Codes Table...2736
Types of Circuits and Color Codes...2736
HANDLING HYDRAULIC EQUIPMENT...2737
CHECKS BEFORE TROUBLESHOOTING...2739
Categories and Method of Using Troubleshooting Charts...2740
Troubleshooting Individual Electrical Circuits...2741
Chart Use...2743
Chart Tips...2743
Troubleshooting Individual Hydraulic Circuits...2744
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...2746
X-Type Connectors...2746
SWP-Type Connectors...2748
M-Type Connectors...2750
S-Type Connectors...2752
MIC-Type Connectors...2754
AMP040-Type Connectors...2756
AMP070-Type Connectors...2758
Miscellaneous Types of Connectors...2760
HD30 Series Connectors...2765
DT Series Connectors...2771
DTM Series Connectors...2773
DTHD Series Connectors...2773
DTP Series Connectors...2774
DRC26 Series Connectors...2775
DRC12, 16 Connectors...2777
AMP Connectors for Pump Controller...2778
BOSCH Connectors for Engine...2780
SUMITOMO Connectors for Engine...2781
CANNON Connectors for Engine...2782
AMP Connectors for Engine...2783
FRAMATOME Connectors for Engine...2784
PACKARD Connectors for Engine...2786
OT Series Connectors for Engine...2787
T-BRANCH BOX and T-BRANCH ADAPTER TABLE...2788
MODE CHART...2792
INFORMATION CONTAINED IN TESTING PROCEDURES...2795
TROUBLESHOOTING BY FAILURE CODE...2797
Failure Code Table...2797
FUSE BOX AND SLOW-BLOW FUSES...2803
Connection Table...2803
Fuse Box: FS1...2803
Fuse Box: FS2...2804
Slow-Blow Fuses...2805
FAILURE CODES...2807
2G40ZG...2807
Brake: Oil Pressure Reduction...2807
6091NX...2809
HST Filter: Clogging...2809
989FN1...2810
Travel Speed: Overrun Alarm...2810
AB00L6...2811
Alternator R System: Short Circuit...2811
AB00MA...2813
Alternator R System: Ground Fault/Disconnection/Low Charge Voltage...2813
B@BAZG...2815
Engine: Oil Pressure Reduction...2815
B@BCNS...2816
Engine: Overheat...2816
B@BCZK...2817
Engine: Low Coolant Level...2817
B@C6NS...2819
Front Brake: High Oil Temperature...2819
B@CRNS...2820
HST: High Oil Temperature...2820
CA111...2821
Abnormality in Engine Controller...2821
CA115...2822
Engine Ne or Bkup Speed Sensor Error...2822
CA122...2823
Charge Pressure Sensor High Error...2823
CA123...2825
Charge Pressure Sensor Low Error...2825
CA131...2827
Throttle Sensor High Error...2827
CA132...2829
Throttle Sensor Low Error...2829
CA144...2831
Coolant Sensor High Error...2831
CA145...2833
Coolant Sensor Low error...2833
CA153...2835
Charge Temperature Sensor High Error...2835
CA154...2837
Charge Temperature Sensor Low Error...2837
CA155...2839
Lowering of Speed by Abnormally High Charge Temperature...2839
CA187...2841
Sensor Power Supply 2 Low Error...2841
CA221...2843
Atmospheric Pressure Sensor High Error...2843
CA222...2845
Atmospheric Sensor Low Error...2845
CA227...2847
Sensor Power Supply 2 High Error...2847
CA234...2849
Engine Overspeed...2849
CA238...2850
Ne Speed Sensor Power Supply Error...2850
CA271...2851
IMV (IMA) Short Circuit...2851
CA272...2853
IMV (IMA) Disconnection...2853
CA322...2855
Injector #1 Open/Short Error...2855
CA323...2857
Injector #5 Open/Short Error...2857
CA324...2859
Injector #3 Open/Short Error...2859
CA325...2861
Injector #6 Open/Short Error...2861
CA331...2863
Injector #2 Open/Short Error...2863
CA332...2865
Injector #4 Open/Short Error...2865
CA342...2867
Calibration Code Inconsistency...2867
CA351...2869
Injectors Drive Circuit Error...2869
CA352...2871
Sensor Power Supply 1 Low Error...2871
CA386...2873
Sensor Power Supply 1 High Error...2873
CA428...2875
Abnormally High Level in Water Sensor...2875
CA429...2877
Abnormally Low Level in Water Sensor...2877
CA431...2879
Idle Validation Switch Error...2879
CA432...2883
Idle Validation Action Error...2883
CA435...2887
Engine Oil Pressure Switch Error...2887
CA441...2889
Battery Voltage Low Error...2889
CA442...2893
Battery Voltage High Error...2893
CA449...2895
Common Rail Pressure High Error 2...2895
CA451...2897
Common Rail Pressure Sensor High Error...2897
CA452...2899
Common Rail Pressure Sensor Low Error...2899
CA488...2901
Lowering of Torque by Abnormally High Charge Temperature...2901
CA553...2902
Common Rail Pressure High Error 1...2902
CA559...2903
Supply Pump Pressure Very Low Error...2903
CA689...2905
Engine Ne Speed Sensor Error...2905
CA731...2907
Engine Bkup Speed Sensor Phase Error...2907
CA757...2908
All Continuous Data Lost Error...2908
CA778...2911
Engine Bkup Speed Sensor Error...2911
CA1633...2913
KOMNET Datalink Timeout Error...2913
CA2185...2917
Throttle Sensor Supply Voltage High Error...2917
CA2186...2919
Throttle Sensor Power Supply Low Error...2919
CA2249...2921
Supply Pump Pressure Very Low Error 2...2921
CA2311...2923
Abnormality in IMV (IMA) Solenoid...2923
CA2555...2925
Intake Heater Relay Disconnection Error...2925
CA2556...2927
Intake Heater Relay Short Circuit Error...2927
D160KY...2929
Backup Alarm/Lamp Relay 1 Circuit: Short Circuit...2929
D192KY...2931
ECSS Solenoid Relay: Short Circuit...2931
D1B0KA...2933
HST Safety Relay: Disconnection...2933
D1B0KB...2935
HST Safety Relay: Ground Fault...2935
D1B0KY...2937
HST Safety Relay: Short Circuit...2937
D5ZHL6...2939
IGN C System: Ground Fault/Disconnection...2939
DAF3KK...2941
UNSW Power Supply: Ground Fault/Disconnection...2941
DAFRKR...2943
Machine Monitor CAN-NET Signal: Disconnection...2943
DAJ0KK...2945
HST Controller Power Supply: Low Voltage...2945
DAJ0KT...2947
HST Controller Memory (EEPROM): Abnormality...2947
DAJ1L4...2949
HST Controller Main Power Line: Disconnection/Ground Fault...2949
DAJ1L6...2951
HST Controller Main Power Line: Short Circuit...2951
DAJ2KK...2953
Controller Solenoid Power Supply: Low Voltage...2953
DAJ2L3...2955
HST Controller Load Power Supply Holding Line: Short Circuit in Wiring Harness...2955
DAJ2L4...2957
HST Controller Load Power Supply Holding Line: Disconnection/Ground Fault...2957
DAJ5KX...2959
Sensor 5V Power Supply: Out-of-Output Range...2959
DAJ9KQ...2961
HST Controller Model Selection: Disagreement of Model Selection Signals...2961
DAJRKR...2963
HST Controller CAN-NET Signal: Disconnection...2963
When HST Controller Power Supply Circuit is Defective...2965
DAJRMA...2968
HST Controller: Disagreement in Option Selection...2968
DB2RKR...2969
Engine Controller CAN-NET: Disconnection in Signal Line...2969
When Engine Controller Power Supply Circuit is Defective...2971
DD1NL4...2973
Fan Automatic Reverse Switch Signal: Abnormality...2973
DD1NLD...2975
Fan Reverse Switch Signal: Abnormality...2975
DDB6KA...2977
Parking Brake Switch A: Disconnection/Short Circuit...2977
DDB6KB...2979
Parking Brake Switch B: Ground Fault...2979
DDB6KZ...2981
Parking Brake Switch or Parking Brake Reminder Switch: Trouble...2981
DDB6L0...2983
Parking Brake Switch A: Ground Fault...2983
DDB6L4...2985
Parking Brake Switch B: Disconnection/Short Circuit...2985
DDD7KY...2987
Travel Speed Control Dial Signal: Short Circuit...2987
DDE5MA...2989
Emergency Steering Operation Switch: Disconnection...2989
DDK3KA...2991
Directional Selector Switch: Disconnection/Short Circuit...2991
DDK3KB...2993
Directional Selector Switch: Ground Fault...2993
DDK6KA...2995
FNR Lever: Disconnection/Ground Fault...2995
DDK6KY...2999
FNR Lever: Short Circuit...2999
DDS5L6...3001
Steering: Low Oil Pressure (Operation of Emergency Steering)...3001
DF10KA...3003
Travel Speed Range Selector Switch: Disconnection/Ground Fault...3003
DF10KB...3007
Travel Speed Range Selector Switch: Short Circuit...3007
DGH1KX...3009
HST Oil Temperature Sensor: Ground Fault...3009
DGR2KB...3011
Brake Oil Temperature Sensor: Ground Fault...3011
DGR2KZ...3013
Brake Oil Temperature Sensor: Disconnection/Short Circuit...3013
DHH1KX...3015
HST Oil Pressure Sensor: Disconnection/Ground Fault...3015
DHH1KY...3017
HST Oil Pressure Sensor: Short Circuit...3017
DHTCL6...3019
HST Filter Clogging Sensor: Functional Defect...3019
DJF1KA...3021
Fuel Level Sensor: Disconnection/Short Circuit...3021
DLT3KX...3023
Travel Speed Sensor B: Abnormality...3023
DLT4KX...3027
Travel Speed Sensor A: Abnormality...3027
DLT4LC...3029
Travel Speed Sensor A & B: Abnormality...3029
DV00KY...3031
Alarm Buzzer: Short Circuit...3031
DW26KA...3033
Motor 2 Solenoid: Disconnection/Ground Fault...3033
DW26KY...3035
Motor 2 Solenoid: Short Circuit...3035
DW7BKY...3037
Fan Reverse Solenoid Circuit: Short Circuit...3037
DW7BKZ...3039
Fan Reverse Solenoid Circuit: Disconnection/Ground Fault...3039
DX16KA...3041
Fan EPC Solenoid: Disconnection...3041
DX16KB...3043
Fan EPC Solenoid: Ground Fault...3043
DX16KY...3045
Fan EPC Solenoid: Short Circuit...3045
DX19KA...3047
Motor 1 Solenoid: Disconnection...3047
DX19KB...3049
Motor 1 Solenoid: Ground Fault...3049
DX19KY...3051
Motor 1 Solenoid: Short Circuit...3051
DX20KA...3053
Clutch EPC Solenoid: Disconnection...3053
DX20KB...3055
Clutch EPC Solenoid: Ground Fault...3055
DX20KY...3057
Clutch EPC Solenoid: Short Circuit...3057
DXH7KB...3059
Reverse Solenoid: Ground Fault...3059
DXH7KZ...3061
Reverse Solenoid: Disconnection/Short Circuit...3061
DXH8KB...3063
Forward Solenoid: Ground Fault...3063
DXH8KZ...3065
Forward Solenoid: Disconnection/Short Circuit...3065
J141N1...3067
Steering Pump: Overrun Alarm...3067
M100N1...3068
HST Pump: Overrun Alarm...3068
M400N1...3069
Motor 1: Overrun Alarm...3069
TROUBLESHOOTING: E-MODE...3071
Troubleshooting Electrical System...3071
Information in Troubleshooting Table...3071
E-1...3073
Engine Does Not Start...3073
E-2...3081
Preheater Does Not Operate Normally...3081
E-3...3085
Defective Boom Kick-Out Function and Cancellation...3085
E-4...3089
Defective Bucket Positioner Function and Cancellation...3089
E-5...3093
Defective Lift Arm FLOATING Holding Function and Cancellation...3093
E-6...3097
Travel Direction Selection System Does Not Function...3097
E-7...3101
Wiper Does Not Operate...3101
E-8...3105
Windshield Washer Does Not Operate...3105
E-9...3108
Headlamp, Clearance Lamp, and Tail Lamp Do Not Light Up or Go Off...3108
E-10...3116
Working Lamp Does Not Light Up or Go Off...3116
E-11...3121
Turn Signal Lamp and Hazard Lamp Do Not Light Up or Go Off...3121
E-12...3127
Brake Lamp Does Not Light or It Keeps Lighting Up...3127
E-13...3129
Backup Lamp Does Not Light or It Keeps Lighting Up...3129
E-14...3132
Backup Alarm Does Not Sound or It Keeps Sounding...3132
E-15...3137
Horn Does Not Sound or It Keeps Sounding...3137
E-16...3139
Alarm Buzzer Does Not Sound or It Keeps Sounding...3139
E-17...3141
Air Conditioner Does Not Operate or Stop...3141
E-18...3145
The KOMTRAX System Does Not Work Properly...3145
Lamp Display Section of KOMTRAX Terminal...3147
TROUBLESHOOTING: H-MODE...3148
Troubleshooting Hydraulic and Mechanical Systems...3148
Method of Using Troubleshooting Chart...3148
Table of Failure Codes and Causes...3151
H-1...3153
Machine Does Not Start...3153
H-2...3154
Travel Speed Is Slow...3154
H-3...3155
Traction Force Is Weak...3155
H-4...3156
Engine Stalls When Traveling or Engine Speed Drops Excessively...3156
H-5...3157
Gear is Not Shifted...3157
H-6...3158
Steering Wheel Does Not Turn...3158
H-7...3159
Steering Wheel Is Heavy...3159
H-8...3160
Steering Wheel Shakes or Jerks...3160
H-9...3161
Machine Deviates Naturally to One Side When Traveling...3161
H-10...3162
Brake Does Not Work or Does Not Work Well...3162
H-11...3163
Brake Is Not Released or Is Dragged...3163
H-12...3164
Lift Arm Does Not Rise or Lower...3164
H-13...3165
Lift Arm Moves Slowly or Lift Arm Rising Force Is Insufficient...3165
H-14...3166
When Rising, Lift Arm Starts to Move Slowly at a Specific Height...3166
H-15...3166
Lift Arm Cylinder Cannot Hold Down The Bucket (Bucket Rises in the Air)...3166
H-16...3166
Hydraulic Drifts of the Lift Arm Occur Often...3166
H-17...3167
Lift Arm Wobbles During Operation...3167
H-18...3167
When Control Lever Is Switched from HOLD to RAISE, Lift Arm Falls Temporarily...3167
H-19...3168
Bucket Does Not Tilt Back...3168
H-20...3169
Bucket Moves Slowly or Tilting-Back Force Is Insufficient...3169
H-21...3170
Bucket Starts to Operate Slowly in the Midst of Tilting-Back...3170
H-22...3170
Bucket Cylinder Cannot Hold Down the Bucket...3170
H-23...3170
Hydraulic Drifts of the Bucket Occur Often...3170
H-24...3171
Bucket Wobbles During Travel with Load...3171
H-25...3171
When Control Lever Is Switched from HOLD to TILT, the Bucket Falls Temporarily...3171
H-26...3172
Control Levers of Lift Arm and Bucket Do Not Move Smoothly and Are Heavy...3172
H-27...3173
ECSS Does Not Operate and Machine Pitches and Bounces...3173
H-28...3174
Fan Revolution Is Abnormal...3174
ENGINE SYSTEM (S-MODE)...3175
Method Of Using Troubleshooting Charts...3175
S-1...3179
Engine Starting Performance Is Poor...3179
S-2...3181
Engine Does Not Start...3181
Engine Turns But No Exhaust Smoke Comes Out...3182
Engine Smoke Comes Out But Engine Does Not Start...3183
S-3...3185
Engine Does Not Pick Up Smoothly...3185
S-4...3187
Engine Stops During Operations...3187
S-5...3189
Engine Does Not Rotate Smoothly...3189
S-6...3191
Engine Lacks Output (or Lacks Power)...3191
S-7...3193
Exhaust Smoke is Black (Incomplete Combustion)...3193
S-8...3195
Oil Consumption is Excessive (or Exhaust Smoke is Blue)...3195
S-9...3196
Oil Becomes Contaminated Quickly...3196
S-10...3197
Fuel Consumption is Excessive...3197
S-11...3198
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)...3198
S-12...3199
Oil Pressure Drops...3199
S-13...3200
Oil Level Rises (Entry of Coolant or Fuel)...3200
S-14...3201
Coolant Temperature Becomes Too High (Overheating)...3201
S-15...3203
Abnormal Noise is Made...3203
S-16...3205
Vibration is Excessive...3205
50 DISASSEMBLY AND ASSEMBLY...3208
HOW TO READ THIS MANUAL...3212
Removal and Installation of Assemblies...3212
Disassembly and Assembly of Assemblies...3214
COATING MATERIALS LIST...3216
SPECIAL TOOLS LIST...3219
SKETCHES OF SPECIAL TOOLS...3223
CONNECTOR REPAIR PROCEDURES...3232
Stripping Insulation...3232
Wire Inspection...3232
Contact Terminal Removal (HD30 Type)...3233
Crimping Contact Terminal (HD30 Type)...3234
Insertion Of Contact Terminal (HD30 Type)...3235
Contact Terminal Removal (DT Type)...3236
Crimping Contact Terminal (DT Type)...3237
Insertion Of Contact Terminal (DT Type)...3238
ENGINE AND COOLING SYSTEM...3239
Fuel Supply Pump...3239
Removal...3239
Installation...3241
Fuel Injector...3242
Removal...3242
Installation...3247
Cylinder Head Assembly...3252
Removal...3252
Installation...3261
Engine Hood...3268
Removal...3268
Installation...3271
Radiator...3272
Removal...3272
Installation...3275
Air Aftercooler...3276
Removal...3276
Installation...3277
Hydraulic Oil Cooler...3278
Removal...3278
Installation...3280
Engine...3281
Removal...3281
Installation...3287
Engine Front Oil Seal...3289
Removal...3289
Installation...3292
Engine Rear Oil Seal...3293
Removal...3293
Installation...3295
Cooling Fan and Fan Motor...3298
Removal...3298
Installation...3301
Fuel Tank...3302
Removal...3302
Installation...3304
POWER TRAIN...3305
Transfer...3305
Removal...3305
Installation...3309
Disassembly...3311
Assembly...3324
Parking Brake...3339
Removal...3339
Installation...3341
Disassembly...3342
Assembly...3345
Front Axle...3349
Removal...3349
Installation...3351
Rear Axle...3352
Removal...3352
Installation...3355
Axle Housing...3356
Disassembly...3357
Assembly...3362
Differential...3368
Disassembly...3369
Assembly...3382
UNDERCARRIAGE AND FRAME...3403
Center Hinge Pin...3403
Removal...3403
Installation...3410
Counterweight...3416
Removal...3416
Installation...3417
HYDRAULIC SYSTEM...3418
HST Pump and 4-Gear Pump...3418
Removal...3418
Installation...3421
HST Pump...3423
Disassembly...3423
Assembly...3436
HST Motor 1...3456
Removal...3456
Installation...3458
HST Motor 2...3459
Removal...3459
Installation...3461
HST Motor...3462
Disassembly...3462
Assembly...3474
Work Equipment Control Valve...3484
Removal...3484
Installation...3486
Hydraulic Tank...3487
Removal...3487
Installation...3489
Hydraulic Cylinder...3490
Disassembly...3491
Assembly...3494
WORK EQUIPMENT...3498
Work Equipment...3498
Removal...3498
Installation...3502
CAB AND ITS ATTACHMENTS...3506
Cab and Floor Frame...3506
Removal...3506
Installation...3511
Cab Glass (Stuck Glass)...3513
Removal...3513
Installation...3514
Air Conditioner Unit...3522
Removal...3522
Installation...3528
ELECTRICAL SYSTEM...3530
Monitor Panel...3530
Removal...3530
Installation...3532
Engine Controller...3533
Removal...3533
Installation...3534
HST Controller...3535
Removal...3535
Installation...3535
KOMTRAX Terminal...3537
Removal...3537
Installation...3538
90 DIAGRAMS AND SCHEMATICS...3540
HYDRAULIC SYSTEM...3542
Hydraulic Circuit Diagram...3542
ELECTRICAL SYSTEM...3543
Machine Monitor System...3543
HST Controller System Circuit Diagram...3544
HST Controller System (1/2)...3545
HST Controller System (2/2)...3546
Machine Monitor System (Lamp Related Items) (1/2)...3547
Machine Monitor System (Lamp Related Items) (2/2)...3548
Machine Monitor System (Other than Lamp Related Items) (1/2)...3549
Machine Monitor System (Other than Lamp Related Items) (2/2)...3550
Engine Controller System (1/2)...3551
Engine Controller System (2/2)...3552
Electrical Circuit Diagram (1/9)...3553
Electrical Circuit Diagram (2/9)...3554
Electrical Circuit Diagram (3/9)...3555
Electrical Circuit Diagram (4/9)...3556
Electrical Circuit Diagram (5/9)...3557
Electrical Circuit Diagram (6/9)...3558
Electrical Circuit Diagram (7/9)...3559
Electrical Circuit Diagram (8/9)...3560
Electrical Circuit Diagram (9/9)...3561
Connector List and Sterograms...3562
LUBRICATION SYSTEM...3563
Auto-Greasing Circuit Diagram...3563
CEBM001301 - Wheel Loader WA250-3L Shop Manual...3564
CEBM001801 - Parallel Tool Carrier WA250-3 Shop Manual...4217
CEBMW18020 - Wheel Loader WA250-1LC Shop Manual...4933
CONTENTS...4937
10 ENGINE...4951
12 TESTING AND ADJUSTING...4951
STANDARD VALUE TABLE...4953
ENGINE ON TEST BENCH...4953
ENGINE ON CHASSIS...4954
TOOL LIST...4954
VALVE CLEARANCE...4955
FUEL INJECTION TIMING...4955
ENGINE OIL PRESSURE...4956
ENGINE OIL TEMPERATURE...4957
BLOW-BY PRESSURE...4958
EXHAUST GAS COLOR...4959
ACCELERATOR PEDAL...4960
OPERATING FORCE...4960
OPERATING ANGLE...4961
13 DISASSEMBLY AND ASSEMBLY...4963
NOZZLE HOLDER ASSEMBLY...4964
REMOVAL...4964
INSTALLATION...4964
CYLINDER HEAD ASSEMBLY...4965
REMOVAL...4965
INSTALLATION...4966
RADIATOR...4967
REMOVAL...4967
INSTALLATION...4969
ENGINE...4971
REMOVAL...4971
INSTALLATION...4976
FUEL TANK...4980
REMOVAL...4980
INSTALLATION...4981
20 POWER TRAIN...4984
21 STRUCTURE AND FUNCTION...4984
GENERAL...4986
HYDRAULIC CIRCUIT FOR POWER TRAIN...4988
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN...4989
TORQUE CONVERTER AND TRANSMISSION PIPING...4990
TORQUE CONVERTER CHARGING PUMP...4991
SPECIFICATIONS...4991
OUTLINE...4991
TORQUE CONVERTER...4992
SPECIFICATIONS...4992
OUTLINE...4993
TORQUE CONVERTER OIL FILTER...4994
TORQUE CONVERTER OIL COOLER AND RADIATOR...4995
TORQUEFLOW TRANSMISSION...4996
CLUTCH PACK...4998
FORWARD AND REVERSE CLUTCH...4998
1ST AND 3RD CLUTCH...4998
2ND AND 4TH CLUTCH...4999
OPERATION OF CLUTCH...5000
FORWARD 1ST...5001
FORWARD 2ND...5002
FORWARD 3RD...5003
FORWARD 4TH...5004
REVERSE 1ST...5005
TRANSMISSION CONTROL VALVE...5006
TRANSMISSION SOLENOID VALVE...5007
UPPER VALVE...5008
LOWER VALVE...5009
TORQUE CONVERTER OUTLET VALVE...5010
PILOT REDUCING VALVE...5011
TRANSMISSION SOLENOID VALVE...5012
PRIORITY AND MAIN REGULATOR VALVE ...5013
MAIN REGULATOR VALVE...5014
MODULATING RELIEF VALVE...5015
ACCUMULATOR VALVE...5015
QUICK RETURN VALVE...5015
EMERGENCY MANUAL SPOOL...5019
FORWARD 1ST...5020
DIRECTIONAL SPOOL...5021
FILL VALVE...5022
PILOT OIL FILTER...5024
DRIVE SHAFT...5025
AXLE...5026
FRONT...5026
REAR...5027
DIFFERENTIAL...5028
FRONT...5028
REAR...5029
TORQUE PROPORTIONING...5030
FINAL DRIVE...5032
AXLE MOUNT...5033
TIRE AND WHEEL...5035
22 TESTING AND ADJUSTING...5036
STANDARD VALUE TABLE...5037
ENGINE STALL SPEED...5038
OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION...5040
SHIFT LEVER...5043
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL...5044
TIRE AND WHEEL...5046
TROUBLESHOOTING...5047
PREVENTING RECURRENCE OF TROUBLE...5048
METHOD OF READING TROUBLESHOOTING TABLE...5049
CHECKS BEFORE TROUBLESHOOTING...5051
METHOD OF LOCATING MAIN PROBLEM POINTS WHEN TROUBLESHOOTING TRANSMISSION SYSTEM...5052
TROUBLESHOOTING TABLE...5053
TORQUE CONVERTER AND TRANSMISSION...5053
1. Machine does not move off...5053
2. Machine speed is low, thrust is weak, grade-ability falls off...5055
3. Large shock when moving off or changing gear...5057
4. Large time lag when moving off or changing gear...5058
5. Oil temperature in torque converter is high...5059
23 DISASSEMBLY AND ASSEMBLY...5060
TORQUE CONVERTER CHARGING PUMP...5062
REMOVAL...5062
INSTALLATION...5062
TRANSMISSION, TORQUE CONVERTER...5063
REMOVAL...5063
INSTALLATION...5070
TORQUE CONVERTER...5077
DISASSEMBLY...5077
ASSEMBLY...5080
TRANSMISSION...5083
DISASSEMBLY...5083
ASSEMBLY...5090
CLUTCH PACK...5102
DISASSEMBLY...5102
FORWARD-REVERSE CLUTCH PACK...5102
1ST -3RD SPEED CLUTCH PACK...5105
2ND-4TH SPEED CLUTCH PACK...5107
ASSEMBLY...5109
FORWARD-REVERSE CLUTCH PACK...5109
1ST-3RD SPEED CLUTCH PACK...5114
2ND-4TH SPEED CLUTCH PACK...5118
TRANSMISSION CONTROL VALVE...5122
REMOVAL...5122
INSTALLATION...5123
TRANSMISSION SOLENOID VALVE...5129
DISASSEMBLY...5129
ASSEMBLY...5129
DRIVE SHAFT...5130
DISASSEMBLY...5130
ASSEMBLY...5132
FRONT AXLE...5134
REMOVAL...5134
INSTALLATION...5136
REAR AXLE...5138
REMOVAL...5138
INSTALLATION...5142
DIFFERENTIAL...5147
DISASSEMBLY...5147
ASSEMBLY...5151
AXLE HOUSING...5161
DISASSEMBLY...5161
ASSEMBLY...5165
24 MAINTENANCE STANDARD...5172
ENGINE AND TRANSMISSION MOUNT...5173
TORQUE CONVERTER CHARGING PUMP...5174
TORQUE CONVERTER...5175
TRANSMlSSlON...5177
TRANSMISSION CLUTCH...5181
UPPER VALVE...5185
LOWER VALVE...5187
SOLENOID VALVE...5188
AXLE...5189
DIFFERENTIAL...5193
FINAL DRIVE...5195
DRIVE SHAFT...5196
AXLE MOUNT...5197
40 STEERING SYSTEM...5199
41 STRUCTURE AND FUNCTION...5199
STEERING PIPING...5200
HYDRAULIC CIRCUIT FOR STEERING...5201
HYDRAULIC CIRCUIT DIAGRAM FOR STEERING...5202
TWO-WAY RESTRICTOR VALVE...5203
STEERING VALVE...5204
CONNECTION OF HAND PUMP AND SLEEVE...5210
PRIORITY VALVE...5212
STEERING COLUMN...5215
STEERING CYLINDER...5216
CENTER HINGE PIN...5217
42 TESTING AND ADJUSTING...5219
STANDARD VALUE TABLE...5220
TOOL LIST...5220
STEERING WHEEL PLAY...5221
OPERATING FORCE OF STEERING WHEEL...5222
OPERATING TIME OF STEERING WHEEL...5223
STEERING OIL PRESSURE...5224
TROUBLESHOOTING...5227
TROUBLESHOOTING TABLE...5228
1. Steering wheel does not turn...5228
2. Steering wheel is sluggish...5229
3. Steering wheel moves unsteadily or is subjected to large shock...5230
4. Machine tends to turn naturally in one particular direction when traveling...5230
5. Left and right turning radii are different...5230
43 DISASSEMBLY AND ASSEMBLY...5231
STEERING VALVE...5232
REMOVAL...5232
INSTALLATION...5234
DISASSEMBLY...5236
ASSEMBLY...5238
PRIORITY VALVE...5240
REMOVAL...5240
INSTALLATION...5242
STEERING CYLINDER...5244
REMOVAL...5244
INSTALLATION...5245
DISASSEMBLY...5246
ASSEMBLY...5248
CENTER HINGE PIN REMOVAL...5251
REMOVAL...5251
INSTALLATION...5256
44 MAINTENANCE STANDARD...5261
HYDRAULIC AND STEERING PUMP...5262
STEERING CYLINDER MOUNT...5263
CENTER HINGE PIN...5264
STEERING COLUMN AND GEAR BOX...5266
PRIORITY VALVE...5267
50 BRAKE AND AIR SYSTEM...5270
51 STRUCTURE AND FUNCTION...5270
BRAKE PIPING...5271
POWER MASTER CYLINDER...5272
BRAKE...5276
PARKING BRAKE CONTROL...5278
PARKING BRAKE...5279
OPERATION OF PARKING BRAKE...5280
BRAKE CALIPER...5281
52 TESTING AND ADJUSTING...5282
STANDARD VALUE TABLE...5283
TOOL LIST...5284
MEASURING BRAKE PEDAL...5285
BRAKE PEDAL LINKAGE...5286
BRAKE PERFORMANCE...5288
BRAKE PISTON LEAKAGE...5289
BRAKE DISC WEAR...5290
AIR BLEEDING FROM BRAKE CIRCUIT...5291
PARKING BRAKE PERFORMANCE...5292
PARKING BRAKE...5293
CHECKING...5293
ADJUSTING...5294
MEASURING CLEARANCE...5295
TROUBLESHOOTING...5296
TROUBLESHOOTING TABLES...5297
1. Brake is ineffective or not very effective...5297
2. Brake cannot be released or drags...5298
53 DISASSEMBLY AND ASSEMBLY...5300
POWER MASTER CYLINDER...5301
REMOVAL...5301
INSTALLATION...5302
DISASSEMBLY...5303
ASSEMBLY...5306
PARKING BRAKE...5311
REMOVAL...5311
lNSTALLATION...5313
PARKING BRAKE PAD...5315
REMOVAL...5315
INSTALLATION...5315
54 MAINTENANCE STANDARD...5316
POWER MASTER CYLINDER...5317
BRAKE...5318
PARKING BRAKE...5319
60 WORK EQUIPMENT SYSTEM...5321
61 STRUCTURE AND FUNCTION...5321
HYDRAULIC PIPING...5322
HYDRAULIC CIRCUIT...5323
HYDRAULIC CIRCUIT DIAGRAM...5324
WORK EQUIPMENT LEVER LINKAGE...5325
BUCKET LINKAGE...5326
BUCKET POSITIONER AND BOOM KICK-OUT...5328
HYDRAULIC TANK...5330
OIL FILTER BYPASS VALVE...5331
BREATHER...5331
HYDRAULIC AND STEERING PUMPS...5332
MAIN CONTROL VALVE...5333
RELIEF VALVE...5335
SAFElY VALVE W/SUCTION VALVE...5336
As a safety valve...5336
As a suction valve...5337
SUCTION VALVE...5337
LIFT AND DUMP SPOOLS AT "NEUTRAL POSITION"...5338
LIFT SPOOL AT "RAISE POSITION"...5339
LIFT SPOOL AT "LOWER POSITION"...5340
LIFT SPOOL AT "FLOAT POSITION"...5341
DUMP SPOOL AT "TILT BACK POSITION"...5342
DUMP SPOOL AT DUMP "POSITION"...5343
HYDRAULIC CYLINDER...5344
62 TESTING AND ADJUSTING...5345
STANDARD VALUE TABLE...5347
DUMP AND LIFT CONTROL LEVERS...5348
HYDRAULIC PRESSURE...5351
LIFT ARM AND BUCKET...5353
HYDRAULIC DRIFT OF LIFT ARM AND BUCKET...5354
BUCKET POSITIONER...5355
BOOM KICK-OUT...5356
TROUBLESHOOTING...5358
TROUBLESHOOTING TABLES...5359
1. Lift arm does not rise...5359
2. Lift arm moves slowly or does not have sufficient lifting power...5360
3. Lift arm movement becomes slow after it reaches a certain height...5361
4. Bucket cannot be held down with lift arm cylinder...5361
5. Lift arm has large hydraulic drift...5361
6. Lift arm movement is unsteady during work...5361
7. Lift arm descends momentarily when control lever is shifted from "Hold to Raise"...5361
8. Bucket does not tilt back...5362
9. Bucket moves slowly or has insufficient tilt back power...5363
10. Bucket movement becomes slow during tilt back...5364
11. Bucket cannot be held down by the bucket cylinder...5364
12. Bucket has large hydraulic drift...5364
13. Bucket moves unsteadily when machine travels under load. (Main control valve in "Hold")...5364
14. Bucket dumps momentarily when control lever is shifted from "Hold to Tilt back."...5364
15. Control levers of lift arm and dump move stiffly and sluggishly...5365
63 DISASSEMBLY AND ASSEMBLY...5367
HYDRAULIC TANK...5369
REMOVAL...5369
INSTALLATION...5371
HYDRAULIC FILTER...5373
REMOVAL...5373
INSTALLATION...5373
HYDRAULIC, STEERING PUMP...5374
REMOVAL...5374
INSTALLATION...5375
MAIN CONTROL VALVE...5376
REMOVAL...5376
INSTALLATION...5378
DISASSEMBLY...5381
ASSEMBLY...5381
DUMP CYLINDER...5382
REMOVAL...5382
INSTALLATION...5384
DISASSEMBLY...5385
ASSEMBLY...5387
LIFT CYLINDER...5389
REMOVAL...5389
INSTALLATION...5390
DISASSEMBLY...5391
ASSEMBLY...5393
WORK EQUIPMENT...5395
REMOVAL...5395
INSTALLATION...5398
COUNTERWEIGHT...5401
REMOVAL...5401
INSTALLATION...5401
64 STRUCTURE AND FUNCTION...5403
HYDRAULIC AND STEERING PUMP...5404
MAIN CONTROL VALVE...5406
DUMP CYLINDER...5408
LIFT CYLINDER...5409
BUCKET LINKAGE...5410
BUCKET POSITIONER AND BOOM KICK-OUT...5413
BUCKET...5414
80 ELECTRIC AND ELECTRONIC SYSTEM...5416
81 STRUCTURE AND FUNCTION...5416
ELECTRICAL WIRING CIRCUIT DlAGRAMS...5417
ENGINE STARTING CIRCUIT...5418
ENGINE STOP CIRCUIT...5420
COMBINATION SWITCH...5421
ELECTRICAL TRANSMISSION CONTROL...5422
TRANSMISSION CUT-OFF SELECTOR SWITCH...5423
NEUTRALIZER RELAY...5424
ELECTRONIC VEHICLE MONITORING SYSTEM (RIMS)...5425
MONITOR PANEL...5426
INDICATION ON MONITOR PANEL...5427
WIRING HARNESS...5429
SENSORS...5430
ENGINE OIL LEVEL SENSOR...5431
COOLANT LEVEL SENSOR...5431
BRAKE OIL LEVEL SENSOR...5432
FUEL GAUGE SENSOR...5433
COOLANT TEMPERATURE SENSOR...5434
TORQUE CONVERTER OIL TEMPERATURE SENSOR...5434
ENGINE OIL PRESSURE SENSOR...5435
ROTATIONAL SPEED SENSOR...5435
PROXIMITY SWITCH...5436
82 TESTING AND ADJUSTING...5440
ADJUSTING SPEEDOMETER MODULE...5443
TROUBLESHOOTING...5444
ELECTRICAL CIRCUIT SYSTEM...5446
1. ENGINE STARTING CIRCUIT SYSTEM...5446
2. ENGINE STOP CIRCUIT SYSTEM...5447
3. TRANSMISSION CONTROL AND PARKING BRAKE SYSTEM...5448
CONNECTION TABLE FOR CONNECTOR PIN NUMBER CONNECT1...5449
PRECAUTION WHEN HANDLING CONNECTOR...5454
METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART...5456
ELECTRICAL SCHEMATIC...5459
CHECKS BEFORE TROUBLESHOOTING...5460
TROUBLESHOOTING CHARTS FOR ELECTRIC SYSTEM...5462
POSITION OF CONNECTORS...5463
E-1 ENGINE DOES NOT START...5468
E-2 ENGINE DOES NOT STOP...5469
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING...5469
E-4 TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED. (TRANSMISSION CUT-OFF NORMAL)...5470
E-5 MACHINE MOVES IN REVERSE BUT NOT IN FORWARD...5470
E-6 MACHINE MOVES NEITHER IN FORWARD NOR REVERSE...5471
E-7 MACHINE MOVES IN FORWARD BUT NOT IN REVERSE...5473
E-8 MACHINE MOVES FORWARD EVEN WHEN...5473
E-9 MACHINE MOVES IN REVERSE EVEN WHEN TRANSMISSION CONTROL LEVERS ARE IN NEUTRAL...5474
E-10 MACHINE ALWAYS TRAVELS IN 2ND...5474
E-11 TRANSMISSION DOES NOT CHANGE GEAR (But F-R changeable)...5475
E-12 TRANSMISSION CANNOT BE CUT-OFF EVEN WHEN L.H. BRAKE PEDAL IS DEPRESSED WITH...5476
E-13 TRANSMISSION DOES NOT RETURN TO NEUTRAL...5477
TROUBLESHOOTING CHARTS FOR ELECTRONIC VEHICLE MONITORING SYSTEM...5480
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS) SCHEMATIC...5481
POSITION OF CONNECTORS...5482
M-1 EVEN WHEN ENGINE IS STOPPED, (BRAKE OIL LEVEL) FLASHES...5488
M-2 EVEN WHEN ENGINE IS STOPPED, (ENGINE OIL LEVEL) FLASHES...5488
M-3 EVEN WHEN ENGINE IS STOPPED, (COOLANT LEVEL) FLASHES...5489
M-4 (BATTERY CHARGE) FLASHES WHEN ENGINE IS RUNNING...5489
M-5 (FUEL LEVEL) FLASHES...5490
M-6 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, (BRAKE OIL LEVEL)...5490
M-7 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, (ENGINE OIL PRESSURE)...5490
M-8 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, (COOLANT LEVEL) ...5491
M-9 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, (BRAKE SERVO PRESSURE)...5491
M-10 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, (COOLANT TEMPERATURE)...5491
M-11 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, (TORQUE CONVERTER OIL TEMPERATURE)...5492
M-12 (PARKING BRAKE) LIGHTS UP OR DOES NOT LIGHT UP...5492
M-13 (WORKING LAMP) LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP...5493
M-14 NOT USED...5494
M-15 (FAILURE IN MAIN STEERING) LIGHTS UP OR DOES NOT LIGHT UP (IF EQUIPPED)...5494
M-16 (EMERGENCY STEERING NORMAL) LIGHTS UP OR DOES NOT LIGHT UP (IF EQUIPPED)...5495
M-17 (TRANSMISSION CUT-OFF) LIGHTS UP OR DOES NOT LIGHT UP...5496
M-18 TURN SIGNAL LAMPS, HIGH BEAM LIGHT UP OR DO NOT LIGHT UP...5497
M-19 SPEEDOMETER DISPLAY DOES NOT WORK...5499
M-20 SERVICEMETER DOES NOT WORK NORMALLY...5500
M-21 ALL OR PART OF MONITOR PANEL DOES NOT WORK...5501
M-22 EVEN WHEN ENGINE IS STOPPED, (BATTERY CHARGE) FLASHES, OR (ENGINE OIL PRESSURE) FLASHES...5502
M-23 NO LAMPS ON MONITOR LIGHT UP (IMMEDIATELY AFTER TURNING STARTING SWITCH TO ON, ENGINE STOPPED)...5502
M-24 CENTRAL WARNING LAMP DOES NOT GO OUT...5503
M-25 CENTRAL WARNING BUZZER DOES NOT STOP...5503
M-26 NONE OF PANEL LAMPS ON MACHINE MONITOR LIGHT UP...5504
M-27 SOME OF PANEL LAMPS ON MACHINE MONITOR DO NOT LIGHT UP...5506
M-28 EMERGENCY ITEM IS FLASHING, BUT ALARM BUZZER DOES NOT SOUND...5507
M-29 EMERGENCY ITEM OR NON-EMERGENCY ITEM IS FLASHING, BUT WARNING LAMP DOES NOT FLASH...5507
M-30 ABNORMALITY IN (FUEL GAUGE)...5508
M-31 ABNORMALITY IN (COOLANT TEMPERATURE GAUGE)...5509
M-32 ABNORMALITY IN (TORQUE CONVERTER OIL TEMPERATURE GAUGE)...5510
TABLE OF MONITOR REFERENCE VALUES...5511
83 DISASSEMBLY AND ASSEMBLY...5516
ELECTRONIC VECHICLE MONITOR SYSTEM (EVMS)...5517
REMOVAL...5517
INSTALLATION...5518
90 OTHER...5521
91 STRUCTURE AND FUNCTION...5521
CAB...5522
AIR CONDITIONER...5524
PIPING, ENGINE TO HEATER CORE...5524
PIPING, CONDENSER AND COMPRESSOR...5525
ELECTRICAL DIAGRAM...5526
AIR CONDITIONER UNIT...5527
HEATING...5527
COOLING...5527
AIR CONDITIONER COMPRESSOR...5528
AIR CONDITIONER CONDENSER...5528
AIR CONDITIONER DRY RESERVOIR...5529
93 DISASSEMBLY AND ASSEMBLY...5531
CAB...5532
REMOVAL...5532
INSTALLATION...5533
AIR CONDITIONER UNIT...5534
REMOVAL...5534
INSTALLATION...5536
CONDENSER (AIR CONDITIONER)...5538
REMOVAL...5538
INSTALLATION...5538
DRY RECEIVER (AIR CONDITIONER)...5539
REMOVAL...5539
INSTALLATION...5539
COMPRESSOR (AIR CONDITIONER)...5540
REMOVAL...5540
INSTALLATION...5540
97 GEAR PUMP...5541
GENERAL...5542
PRINCIPLE OF OPERATION...5543
PRESSURE LOADED TYPE GEAR PUMP...5546
FIXED SIDE PLATE TYPE GEAR PUMP...5548
SA SERIES...5549
STRUCTURE...5549
TESTING AND ADJUSTING...5553
DISASSEMBLY...5556
ASSEMBLY...5560
MAINTENANCE STANDARD...5565
99 METRIC CONVERSIONS...5567
SEAM007500 - Wheel Loader WA250-3 Operation & Maintenance Manual...5581
1. FOREWORD...5582
2. SAFETY INFORMATION...5583
3. INTRODUCTION...5584
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...5585
5. CONTENTS...5586
SAFETY...5590
6. GENERAL PRECAUTIONS ...5591
7. PRECAUTIONS DURING OPERATION ...5596
7.1 BEFORE STARTING ENGINE ...5596
7.2 OPERATING MACHINE ...5598
7.3 TRANSPORTATION ...5602
7.4 BATTERY ...5603
7.5 TOWING ...5604
8. PRECAUTIONS FOR MAINTENANCE ...5605
8.1 BEFORE CARRYING OUT MAINTENANCE ...5605
8.2 DURING MAINTENANCE ...5608
8.3 TIRES ...5612
9. POSITION FOR ATTACHING SAFETY LABELS ...5614
OPERATION...5618
10. GENERAL VIEW ...5619
10.1 GENERAL VIEW OF MACHINE ...5619
10.2 GENERAL VIEW OF CONTROLS AND GAUGES ...5620
11. EXPLANATION OF COMPONENTS ...5621
11.1 MACHINE MONITOR ...5621
11.2 SWITCHES ...5631
11.3 CONTROL LEVERS, PEDALS ...5636
11.4 STEERING COLUMN TILT LEVER ...5640
11.5 CAP WITH LOCK ...5640
11.6 SAFETY BAR ...5641
11.7 TOWING PIN ...5641
11.8 GREASE PUMP CLAMP AND RUBBER RING ...5641
11.9 BACKUP ALARM...5642
11.10 FUSE ...5643
11.11 SLOW-BLOW FUSE ...5644
12. OPERATION ...5645
12.1 CHECK BEFORE STARTING ENGINE ...5645
12.2 STARTING ENGINE ...5660
12.3 OPERATIONS AND CHECKS AFTER -- STARTING ENGINE ...5661
12.4 MOVING MACHINE OFF ...5662
12.5 CHANGING GEAR SPEED ...5664
12.6 CHANGING DIRECTION ...5664
12.7 TURNING...5665
12.8 STOPPING MACHINE...5666
12.9 OPERATION OF WORK EQUIPMENT ...5667
12.10 WORK POSSIBLE USING WHEEL LOADER ...5668
12.11 PRECAUTIONS FOR OPERATION 12.11.1 PERMISSIBLE WATER DEPTH Axle ...5672
12.12 ADJUSTING WORK EQUIPMENT POSTURE ...5674
12.13 PARKING MACHINE FIR ...5676
12.14 CHECKS AFTER COMPLETION OF OPERATION ...5677
12.15 STOPPING ENGINE ...5677
12.16 CHECK AFTER STOPPING ENGINE ...5678
12.17 LOCKING ...5678
12.18 HANDLING THE TIRES PRECAUTIONS WHEN HANDLING TIRES 1218.1 ...5679
13. TRANSPORTATION ...5681
13.1 LOADING, UNLOADING WORK ...5681
13.2 PRECAUTIONS FOR LOADING ...5682
13.3 PRECAUTIONS FOR TRANSPORTATION ...5682
14. COLD WEATHER OPERATION ...5683
14.1 PRECAUTIONS FOR LOW TEMPERATURE ...5683
14.2 PERCAUTIONS AFTER COMPLETION OF ...5685
14.3 AFTER COLD WEATHER ...5685
15. LONG-TERM STORAGE ...5686
15.1 BEFORE STORAGE ...5686
15.2 DURING STORAGE ...5686
15.3 AFTER STORAGE ...5686
16. TROUBLESHOOTING ...5687
16.1 WHEN MACHINE RUNS OUT OF FUEL ...5687
16.2 TOWING THE MACHINE ...5688
16.3 IF BATTERY IS DISCHARGED ...5691
16.4 OTHER TROUBLE ...5695
MAINTENANCE...5701
17. GUIDES TO MAINTENANCE ...5702
18. OUTLINES OF SERVICE ...5705
18.1 OUTLINE OF OIL, FUEL, COOLANT ...5705
18.2 OUTLINE OF ELECTRIC SYSTEM ...5708
19. WEAR PARTS LIST ...5709
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE ...5710
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND BOLTS...5714
21.1 INTRODUCTION OF NECESSARY TOOLS ...5714
21.2 TORQUE LIST...5715
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ...5716
23. MAINTENANCE SCHEDULE CHART ...5720
23.1 MAINTENANCE SCHEDULE CHART ...5720
24. SERVICE PROCEDURE ...5724
24.1 INITIAL 250 HOURS SERVICE ...5724
24.2 WHEN REQUIRED ...5725
24.3 CHECK BEFORE STARTING ...5740
24.4 EVERY 50 HOURS SERVICE ...5746
24.5 EVERY 100 HOURS SERVICE ...5747
24.6 EVERY 250 HOURS SERVICE ...5749
24.7 EVERY 500 HOURS SERVICE ...5756
24.8 EVERY 1000 HOURS SERVICE ...5760
24.9 EVERY 2000 HOURS SERVICE ...5764
24.10 EVERY 4000 HOURS SERVICE ...5769
SPECIFICATIONS...5770
25. SPECIFICATIONS ...5771
OPTIONS, ATTACHMENTS...5773
26. OPTIONAL PARTS AND ATTACHMENTS ...5774
27. SELECTING BUCKETS AND TIRES ...5775
28. CAR RADIO ...5776
28.1 EXPLANATION OF COMPONENTS ...5776
28.2 METHOD OF USE ...5778
28.3 PRECAUTIONS WHEN USING RADIO ...5779
29. AIR CONDITIONER ...5780
29.1 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL ...5780
29.2 METHOD OF OPERATION ...5782
29.3 COOL BOX ...5782
30. HANDLING E.C.S.S. (Electronic Controlled Suspension System) ...5783
30.1 STRUCTURE AND FUNCTION OF E.C.S.S. ...5783
30.2 METHOD OF OPERATING E.C.S.S. ...5784
30.3 PRECAUTIONS WHEN OPERATING E.C.S.S. ...5784
30.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR ...5785
SEAM021500 - Wheel Loader WA250-3 Operation & Maintenance Manual...5787
INTRODUCTION...5788
1. FORWARD...5789
2. SAFETY INFORMATION...5790
3. INTRODUCTION...5791
3.1 INTENDED USE...5791
3.2 FEATURES...5791
3.3 BREAKING IN A NEW MACHINE...5791
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRlBUTOR...5792
4.1 MACHINE SERIAL NO. PLATE POSITION...5792
4.2 ENGINE SERIAL NO. PLATE POSITION...5792
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...5792
5. CONTENTS...5793
SAFETY...5798
6. GENERAL PRECAUTIONS...5799
7. PRECAUTIONS DURING OPERATION...5805
7.1 BEFORE STARTING ENGINE...5805
7.2 AFTER STARTING ENGINE...5808
7.3 TRANSPORTATION...5817
7.4 BATTERY...5818
7.5 TOWNG...5821
8. PRECAUTIONS FOR MAINTENANCE...5822
8.1 BEFORE CARRYING OUT MAINTENANCE...5822
8.2 DURING MAINTENANCE...5827
8.3 TIRES...5832
9. POSITION FOR ATTACHING SAFETY LABELS...5834
9.1 POSITION FOR ATTACHING SAFETY LABELS...5834
OPERATION...5838
10. GENERAL VIEW...5839
10.1 GENERAL VIEW OF MACHINE...5839
10.2 GENERAL VIEW OF CONTROLS AND GAUGES...5840
11. EXPLANATION OF COMPONENTS...5841
11.1 METER, LAMPS...5841
11.1.1 WARNING DISPLAYS...5843
11.1.2 METER DISPLAY PORTION...5847
11.2 SWITCHES...5851
11.3 CONTROL LEVERS, PEDAL...5856
11.4 STEERING COLUMN TILT LEVER...5860
11.5 CAP WITH LOCK...5860
11.5.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK...5860
11.6 SAFETY BAR...5861
11.7 TOWING PIN...5861
11.8 GREASE PUMP CLAMP AND RUBBER RING...5861
11.9 BACKUP ALARM...5862
11.10 FUSE...5863
11.10.1 FUSE CAPACITY AND NAME OF CIRCUIT...5863
11.11 SLOW BLOW FUSE...5864
11.12 STORAGE PLACE FOR THIS MANUAL...5865
11.13 AUXILIARY POWER SOURCE...5865
11.13.1 FOR MACHINES EQUIPPED WITH ROPS CAB...5865
12. CHECK BEFORE STARTING ENGINE...5866
12.1 WALK AROUND CHECK...5866
12.2 CHECK BEFORE STARTING...5869
12.2.1 CHECK COOLANT LEVEL, ADD COOLANT...5869
12.2.2 CHECK MONITOR PANEL...5869
12.2.3 CHECK FUEL LNEL, ADD FUEL...5870
12.2.4 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...5870
12.2.5 CHECK AND REFILL OF OIL IN BRAKE OIL TANK...5871
12.2.6 CHECK DUST INDICATOR...5871
12.2.7 CHECK ELECTRICAL WIRING...5872
12.2.8 DRAIN THE WATER FROM THE FUEL-WATER SEPARATOR...5873
12.9.9 CHECK EFFECT OF PARKING BRAKE...5873
12.2.10 CHECK EFFECT OF WHEEL BRAKES...5874
12.2.11 CHECK SOUND OF HORN AND BACKUP ALARM...5874
12.2.12 CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE...5874
12.2.13 CHECK ENGINE EXHAUST COLOR AND SOUND...5874
12.2.14 CHECK OPERATIONS OF GAUGES...5874
12.2.15 CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING...5874
12.2.16 CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE...5874
12.2.17 CHECK LOCK OF CAB DOOR FOR MACHINES EQUIPPED WITH CAB...5874
12.3 ADJUSTMENT BEFORE OPERATION...5875
12.3.1 OPERATORS SEAT A...5875
12.3.2 ADJUST SEAT BELT...5877
12.3.3 ADJUST REAR VEIW MIRRORS...5878
12.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE...5879
12.5 STARTING ENGINE...5880
12.5.1 NORMAL STARTING PROCEDURES IN COLD AND WARM CONDITIONS...5880
12.5.2 STARTING PROCEDURES AFTER EXTENDED SHUTDOWN OR OIL CHANGE...5881
12.5.3 STARTING PROCEDURES AFTER CHANGING FUEL FILTERS...5881
12.5.4 STARTING PROCEDURES AFTER RUNNING OUT OF FUEL...5881
12.6 OPERATIONS AND CHECKS AFTER STARTING ENGINE...5882
12.7 MOVING MACHINE OFF...5883
12.8 CHANGING GEAR SPEED...5885
12.9 CHANGING DIRECTION...5885
12.10 TURNING...5886
12.11 STOPPING MACHINE...5887
12.12 OPERATION OF WORK EQUIPMENT...5888
12.13 WORK POSSIBLE USING WHEEL LOADER...5889
12.13.1 DIGGING OPERATIONS WITH ROCK PILES...5889
12.13.2 DIGGING OPERATIONS ON LEVEL GROUND...5890
12.13.3 LEVELING OPERATION...5891
12.13.3 LEVELING OPERATION...5891
12.13.4 PUSHING OPERATIONS...5891
12.13.5 LOAD AND CARRY OPERATIONS...5891
12.13.6 LOADING OPERATIONS...5892
12.14 PRECAUTIONS FOR OPERATION...5893
12.14.1 PERMISSIBLE WATER DEPTH...5893
12.14.2 IF WHEEL BRAKE DOES NOT WORK...5893
12.14.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...5893
12.14.4 PRECAUTIONS WHEN DRIVING MACHINE...5894
12.15 ADJUSTING WORK EQUIPMENT POSTURE...5895
12.151 ADJUSTING BOOM KICKOUT...5895
12.15.2 ADJUSTING BUCKET POSITIONER...5896
12.15.3 BUCKET LEVEL INDICATOR...5896
12.16 PARKING MACHINE...5897
12.17 CHECKS AFTER COMPLETION OF ENGINE OPERATION...5898
12.18 STOPPING ENGINE...5898
12.19 CHECKS AFTER STOPPING ENGINE...5899
12.20 LOCKING...5899
12.21 HANDLING THE TIRES...5900
12.21.1 PRECAUTIONS WHEN HANDLING THE TIRES...5900
12.21.2 TIRE PRESSURE...5900
13. TRANSPORTATION...5902
13.1 LOADING, UNLOADING WORK...5902
13.2 PRECAUTION FOR LOADING...5903
13.3 PRECAUTION FOR LIFTING UP THE VEHICLE...5903
13.3.1 THE LOCATION OF DECALS REFERRING TO LIFTING POSITIONS...5904
13.3.2 WEIGHT LIST...5904
13.3.3 LIFTING PROCEDURE...5905
14. COLD WEATHER OPERATIONS...5906
14.1 PRECAUTIONS FOR LOW TEMPERATURE...5906
14.1.1 FUEL AND LUBRICANTS...5906
14.1.2 COOLANT...5906
14.1.3 BATTERY...5907
14.2 PRECAUTIONS AFTER COMPLETION OF WORK...5908
14.3 AFTER COLD WEATHER...5908
15. LONG TERM STORAGE...5909
15.1 BEFORE STORAGE...5909
15.2 DURING STORAGE...5909
15.3 AFTER STORAGE...5909
16. TROUBLESHOOTING...5910
16.1 WHEN MACHINE RUNS OUT OF FUEL...5910
16.2 TOWING THE MACHINE...5911
16.2.1 WHEN ENGINE CAN BE USED...5913
16.2.2 WHEN ENGINE CANNOT BE USED...5913
16.3 IF BATTERY IS DISCHARGED...5914
16.3.1 REMOVAL AND INSTALLATION OF BATTERY...5914
16.3.2 PRECAUTIONS FOR CHARGING BATTERY...5915
16.3.3 STARTING ENGINE WITH BOOSTER CABLE...5916
16.4 OTHER TROUBLE...5918
16.4.1 ELECTRICAL SYSTEM...5918
16.4.2 CHASSIS...5919
16.4.3 ENGINE...5922
MAINTENANCE...5924
17. GUIDES TO MAINTENANCE...5925
18. OUTLINES OF SERVICE...5928
18.1 OUTLINE OF OIL, FUEL, COOLANT...5928
18.1.1 OIL...5928
18.1.2 FUEL...5929
18.1.3 COOLANT...5929
18.1.4 GREASE...5930
18.1.5 STORING OIL AND FUEL...5930
18.2.6 FILTERS...5930
18.2 OUTLINE OF ELECTRIC SYSTEM...5931
19. WEAR PARTS LIST...5932
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...5933
20.1 ENGINE OIL SPECIFICATIONS...5934
20.2 DIESEL FUEL SPECIFICATIONS...5935
20.3 COOLANT SPECIFICATIONS...5936
21. STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS...5942
21.1 INTRODUCTION OF NECESSARY TOOLS...5942
21.2 TORQUE LIST...5943
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...5944
23. MAINTENANCE SCHEDULE CHART...5948
23.1 MAINTENANCE SCHEDULE CHART...5948
24. SERVICE PROCEDURES...5952
24.1 INITIAL 250 HOURS SERVICE...5952
24.1.1 REPLACE FUEL FILTERS...5952
24.1.2 REPLACE TRANSMISSION OIL FILTER ELEMENT...5952
24.1.3 REPLACE HYDRAULIC TANK FILTER ELEMENT...5952
24.2 WHEN REQUIRED...5953
24.2.1 CHECK, CLEAN OR REPLACE AIR CLEANER ELEMENT...5953
24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL...5955
24.2.3 CHECK AXLE OIL LEVEL, ADD OIL...5956
24.2.4 CLEAN THE AXLE CASE BREATHER...5957
24.2.5 CLEAN RADIATOR FINS...5957
24.2.6 REPLACE THE BOLT-ON CUTTING EDGES...5958
24.2.7 REPLACE BUCKET TEETH (IF EQUIPPED)...5959
24.2.8 CHECK AIR CONDITIONER (IF EQUIPPED)...5960
24.2.9 CHECK THE AIR CONDITIONER CONDENSER (IF EQUIPPED)...5961
24.2.10 CHECK WINDOW WASHING FLUID...5961
24.2.11 ADJUST PARKING BRAKE...5962
24.2.12 REPLACE SLOW BLOW FUSE...5963
24.2.13 CHECK AIR INTAKE HEATER...5963
24.3 CHECK BEFORE STARTING...5964
24.4 EVERY 50 HOURS SERVICE...5965
24.4.1 CHECK THE TIRE INFLATION PRESSURE...5965
24.4.2 DRAIN WATER, SEDIMENT FROM FUEL TANK...5965
24.5 EVERY 100 HOURS SERVICE...5966
24.5.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...5966
24.5.2 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...5967
24.5.3 LUBRICATING...5968
24.6 EVERY 250 HOURS SERVICE...5969
24.6.1 CHANGE OIL IN ENGINE OIL PAN AND REPLACE ENGINE OIL FILTER...5969
24.6.2 CHECK FOR LOOSE WHEEL HUB NUTS. TIGHTEN...5970
24.6.3 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...5970
24.6.4 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...5971
24.6.5 CHECK BATTERY ELECTROLYTE LEVEL...5972
24.6.6 CHECK AIR INTAKE SYSTEM...5972
24.6.7 LUBRICATING...5973
24.7 EVERY 500 HOURS SERVICE...5974
24.7.1 REPLACE FUEL FILTERS...5974
24.7.2 REPLACE TRANSMISSION OIL FILTER ELEMENT...5976
24.7.3 LUBRICATE...5977
24.8 EVERY 1000 HOURS SERVICE...5978
24.8.1 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER...5978
24.8.2 CLEAN TRANSMISSION CASE BREATHER...5979
24.8.3 LUBRICATE...5980
24.8.4 ADJUST ENGINE VALVE LASH CLEARANCE...5981
24.8.5 CHECK FAN BELT TENSION...5982
24.8.6 CHECK FAN BELT TENSIONER BEARING 8 FAN HUB BEARING 8 INSPECT FAN BELT...5982
24.9 EVERY 2000 HOURS SERVICE...5983
24.9.1 CHANGE OIL IN HYDRAULIC OIL TANK, REPLACE HYDRAULIC FILTER ELEMENT...5983
24.9.2 REPLACE HYDRAULIC TANK BREATHER ELEMENT...5985
24.9.3 COOLING SYSTEM, REPLACE COOLANT AND FLUSH THE SYSTEM...5986
24.9.4 CHANGE AXLE OIL...5989
24.9.5 CHECK BRAKE DISC WEAR...5990
24.9.6 CHECK ALTERNATOR...5990
24.9.7 CHECK STARTER MOTOR...5990
24.9.8 CHECK VIBRATION DAMPER...5990
24.9.9 REPLACE ELEMENT IN AIR COND. RECIRCULATION AIR FILTER AND FRESH AIR FILTER...5990
24.9.10 ADJUST ENGINE VALVE LASH CLEARANCE...5991
SPECIFICATIONS...5993
25. SPECIFICATIONS...5994
OPTIONS, ATTACHMENTS...5996
26. AVAILABLE ATTACHMENTS...5997
27. SELECTING BUCKETS AND TIRES...5998
28. HEATER AND AIR CONDITIONING (IF EQUIPPED)...5999
28.1 GENERAL LOCATION AND FUNCTION OF CONTROL PANEL...5999
28.2 COOL BOX COMPARTMENT...6000
29. HANDLING E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM) (IF EQUIPPED)...6001
29.1 STRUCTURE AND FUNCTION OF E.C.S.S...6001
29.2 METHOD OF OPERATING E.C.S.S...6002
29.3 PRECAUTIONS WHEN OPERATING E.C.S.S...6002
29.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR...6003
SEAM050500 - Wheel Loader WA250-5 Operation & Maintenance Manual...6005
COVER...6005
FOREWARD...6006
FOREWARD...6007
SAFETY INFORMATION...6010
INTRODUCTION...6012
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...6012
NECESSARY INFORMATION...6013
MACHINE SERIAL NO. PLATE AND POSITION...6013
ENGINE SERIAL NO. PLATE AND POSITION...6013
POSITION OF SERVICE METER...6014
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...6014
CONTENTS...6015
SAFETY...6018
SAFETY...6019
SAFETY LABELS...6022
LOCATION OF SAFETY LABELS...6022
SAFETY LABELS...6023
GENERAL PRECAUTIONS...6028
SAFETY RULES...6028
IF ABNORMALITIES ARE FOUND...6028
CLOTHING AND PERSONAL PROTECTIVE ITEMS...6028
FIRE EXTINGUISHER AND FIRST AID KIT...6028
SAFETY FEATURES...6028
KEEP MACHINE CLEAN...6029
INSIDE OPERATOR'S COMPARTMENT...6029
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT...6029
HANDRAILS AND STEPS...6030
MOUNTING AND DISMOUNTING...6031
NO PEOPLE ON ATTACHMENTS...6031
DO NOT GET CAUGHT IN ARTICULATED PORTION...6031
PREVENTION OF BURNS...6031
FIRE PREVENTION...6032
ACTION IF FIRE OCCURS...6033
WINDOW WASHER FLUID...6033
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTION STRUCTURE)...6033
PRECAUTIONS FOR ATTACHMENTS...6033
UNAUTHORIZED MODIFICATION...6033
SAFETY AT WORKSITE...6034
WORKING ON LOOSE GROUND...6034
DO NOT GO CLOSE TO HIGH VOLTAGE CABLES...6034
ENSURE GOOD VISIBILITY...6035
PRECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS...6035
CHECKING SIGNALMAN'S SIGNALS AND SIGNS...6035
EMERGENCY EXIT FROM OPERATOR'S CAB...6035
ASBESTOS DUST HAZARD PREVENTION...6036
PRECAUTIONS FOR OPERATION...6037
BEFORE STARTING ENGINE...6037
CHECKS BEFORE STARTING...6037
PRECAUTIONS WHEN STARTING...6038
PRECAUTIONS IN COLD AREAS...6038
OPERATION...6039
CHECKS BEFORE OPERATION...6039
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE...6039
PRECAUTIONS WHEN TRAVELING...6040
TRAVELING ON SLOPES...6041
PROHIBITED OPERATIONS...6042
PRECAUTIONS WHEN OPERATING...6042
METHODS OF USING BRAKE...6043
OPERATE CAREFULLY ON SNOW...6043
PARKING MACHINE...6044
TRANSPORTATION...6045
LOADING AND UNLOADING...6045
SHIPPING...6045
BATTERY...6046
BATTERY HAZARD PREVENTION...6046
STARTING WITH BOOSTER CABLES...6047
TOWING...6048
WHEN TOWING...6048
PRECAUTIONS FOR MAINTENANCE...6049
WARNING TAG...6049
KEEP WORK PLACE CLEAN AND TIDY...6049
APPOINT LEADER WHEN WORKING WITH OTHERS...6049
MAINTENANCE WITH ENGINE RUNNING...6050
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNIING...6051
INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF...6051
PROPER TOOLS...6052
ACCUMULATOR...6052
PERSONNEL...6052
ATTACHMENTS...6052
WORK UNDER THE MACHINE...6053
NOISE...6053
PRECAUTIONS WHEN USING HAMMER...6053
REPAIR WELDING...6053
REMOVING BATTERY TERMINAL...6053
PRECAUTIONS WITH HIGH PRESSURE OIL...6054
HANDLING HIGH PRESSURE HOSES...6054
WASTE MATERIALS...6054
MAINTENANCE OF AIR CONDITIONER...6054
COMPRESSED AIR...6055
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...6055
PRECAUTIONS WITH TIRES...6056
HANDLING TIRES...6056
PRECAUTIONS WHEN STORING TIRES...6056
OPERATION...6058
GENERAL VIEW...6059
GENERAL VIEW OF MACHINE...6059
GENERAL VIEW OF CONTROLS AND GAUGES...6060
EXPLANATION OF COMPONENTS...6062
MACHINE MONITOR...6062
SWITCHES...6088
CONTROL LEVERS, PEDALS...6096
STEERING TILT LOCK LEVER...6100
CAP AND COVER WITH LOCK...6100
SAFETY BAR...6101
TOWING PIN...6102
GREASE PUMP...6102
CAB DOOR INNER LOCK...6102
CAB DOOR OPEN LOCK...6103
CAB WINDOW OPEN LOCK CANCEL KNOB...6103
FUSE...6103
SLOW BLOW FUSE...6105
POWER OUTLET...6105
AIR CONDITIONER...6106
HANDLING CAB WIPER...6111
OPERATION...6112
CHECK BEFORE STARTING ENGINE, ADJUST...6112
STARTING ENGINE...6127
OPERATIONS AND CHECKS AFTER STARTING ENGINE...6129
STOPPING ENGINE...6131
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...6132
TURNING...6137
OPERATION OF WORK EQUIPMENT...6139
WORK POSSIBLE USING WHEEL LOADER...6141
PRECAUTIONS FOR OPERATION...6146
ADJUSTING WORK EQUIPMENT POSTURE...6148
PARKING MACHINE...6150
CHECK AFTER STOPPING ENGINE...6152
CHECKS AFTER COMPLETION OF OPERATION...6152
LOCKING...6152
HANDLING THE TIRES...6153
TRANSPORTATION...6155
TRANSPORTATION PROCEDURE...6155
LOADING, UNLOADING WORK WITH TRAILERS...6155
LIFTING MACHINE...6157
COLD WEATHER OPERATION...6160
PRECAUTIONS FOR LOW TEMPERATURE...6160
PRECAUTIONS AFTER COMPLETION OF WORK...6161
AFTER COLD WEATHER...6162
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...6162
LONG TERM STORAGE...6163
BEFORE STORAGE...6163
DURING STORAGE...6163
AFTER STORAGE...6163
TROUBLESHOOTING...6164
WHEN MACHINE RUNS OUT OF FUEL...6164
TOWING THE MACHINE...6164
IF BATTERY IS DISCHARGED...6166
OTHER TROUBLE...6169
MAINTENANCE...6174
GUIDES TO MAINTENANCE...6175
OUTLINES OF SERVICE...6177
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...6177
OUTLINE OF ELECTRIC SYSTEM...6179
WEAR PARTS...6180
WEAR PARTS LIST...6180
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...6181
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS...6181
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...6185
TORQUE LIST...6185
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...6186
MAINTENANCE SCHEDULE CHART...6187
MAINTENANCE SCHEDULE CHART...6187
SERVICE PROCEDURE...6189
INITIAL 250 HOURS SERVICE...6189
REPLACE HST OIL FILTER ELEMENT...6220
REPLACE HYDRAULIC FILTER ELEMENT...6222
WHEN REQUIRED...6190
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT...6190
CLEAN INSIDE OF COOLING SYSTEM...6193
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL...6196
CHECK AXLE OIL, ADD OIL...6197
CLEAN AXLE CASE BREATHER...6198
CLEAN AIR CONDITIONER CONDENSER...6198
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID...6199
CLEAN RADIATOR FINS, COOLER FINS...6199
CLEAN TRANSFER OIL COOLER FINS...6200
CHECK ELECTRICAL INTAKE AIR HEATER...6200
REPLACE BOLT ON CUTTING EDGE...6200
REPLACE BUCKET TEETH...6201
CHECK AIR CONDITIONER...6202
REPLACE SLOW BLOW FUSE...6203
SELECTION AND INSPECTION OF TIRES...6204
CHECK BEFORE STARTING...6206
EVERY 50 HOURS SERVICE...6207
DRAIN WATER FROM FUEL TANK...6207
EVERY 100 HOURS SERVICE...6208
LUBRICATE REAR AXLE PIVOT PIN...6208
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...6208
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...6209
EVERY 250 HOURS SERVICE...6210
CHECK BATTERY ELECTROLYTE LEVEL...6210
CHECK PARKING BRAKE...6212
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...6212
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN...6213
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...6214
LUBRICATING...6215
EVERY 500 HOURS SERVICE...6216
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...6216
REPLACE FUEL FILTER CARTRIDGE...6217
EVERY 1000 HOURS SERVICE...6218
CHANGE OIL IN TRANSFER CASE...6218
CLEAN TRANSFER CASE BREATHER...6219
REPLACE HST OIL FILTER ELEMENT...6220
LUBRICATING...6221
CHECK TIGHTENING PARTS OF TURBOCHARGER...6221
CHECK PLAY OF TURBOCHARGER ROTOR...6221
CHECK FAN BELT TENSION, REPLACE...6221
EVERY 2000 HOURS SERVICE...6222
CHANGE IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...6222
REPLACE HYDRAULIC TANK BREATHER ELEMENT...6223
CHANGE AXLE OIL...6224
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER...6224
CHECK ALTERNATOR, STARTING MOTOR...6224
CHECK ENGINE VALVE CLEARANCE, ADJUST...6225
CHECK BRAKE DISC WEAR...6225
CLEAN AND CHECK TURBOCHARGER...6225
CHECK ACCUMULATOR GAS PRESSURE...6225
CHECK VIBRATION DAMPER...6226
EVERY 4000 HOURS SERVICE...6227
LUBRICATING...6227
CHECK WATER PUMP...6227
SPECIFICATIONS...6228
SPECIFICATIONS...6229
ATTACHMENTS, OPTIONS...6230
SELECTING BUCKET AND TIRES...6231
AM/FM RADIO-CASSETTE STEREO...6232
EXPLANATION OF COMPONENTS...6232
METHOD OF OPERATION...6237
PRECAUTIONS FOR USE...6239
INDEX...6240
SEAM056900T - Wheel Loader GALEO WA250L-5 Operation & Maintenance Manual...6244
COVER...6244
FOREWORD...6245
FOREWORD...6246
SAFETY INFORMATION...6249
INTRODUCTION...6251
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...6251
NECESSARY INFORMATION...6252
MACHINE SERIAL NO. PLATE AND POSITION...6252
ENGINE SERIAL NO. PLATE AND POSITION...6252
POSITION OF SERVICE METER...6253
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...6253
CONTENTS...6254
SAFETY...6257
SAFETY...6258
SAFETY LABELS...6261
LOCATION OF SAFETY LABELS...6261
SAFETY LABELS...6262
GENERAL PRECAUTIONS...6267
SAFETY RULES...6267
IF ABNORMALITIES ARE FOUND...6267
CLOTHING AND PERSONAL PROTECTIVE ITEMS...6267
FIRE EXTINGUISHER AND FIRST AID KIT...6267
SAFETY FEATURES...6267
KEEP MACHINE CLEAN...6268
INSIDE OPERATOR'S COMPARTMENT...6268
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT...6268
HANDRAILS AND STEPS...6269
MOUNTING AND DISMOUNTING...6270
NO PEOPLE ON ATTACHMENTS...6270
DO NOT GET CAUGHT IN ARTICULATED PORTION...6270
PREVENTION OF BURNS...6270
FIRE PREVENTION...6271
ACTION IF FIRE OCCURS...6272
WINDOW WASHER LIQUID...6272
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)...6272
PRECAUTIONS FOR ATTACHMENTS...6272
UNAUTHORIZED MODIFICATION...6272
SAFETY AT WORKSITE...6273
WORKING ON LOOSE GROUND...6273
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...6273
ENSURE GOOD VISIBILITY...6274
BE CAREFUL ABOUT ASBESTOS DUST...6274
CHECKING SIGNALMAN'S SIGNALS AND SIGNS...6274
EMERGENCY EXIT FROM OPERATOR'S CAB...6274
VENTILATION FOR ENCLOSED AREAS...6275
PRECAUTIONS FOR OPERATION...6276
STARTING ENGINE...6276
CHECKS BEFORE STARTING ENGINE...6276
PRECAUTIONS WHEN STARTING...6277
PRECAUTIONS IN COLD AREAS...6277
OPERATION...6278
CHECKS BEFORE OPERATION...6278
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE...6278
PRECAUTIONS WHEN TRAVELING...6279
TRAVELING ON SLOPES...6280
PROHIBITED OPERATIONS...6281
PRECAUTIONS WHEN OPERATING...6281
METHODS OF USING BRAKE...6282
OPERATE CAREFULLY ON SNOW...6282
PARKING MACHINE...6283
TRANSPORTATION...6284
LOADING AND UNLOADING...6284
SHIPPING...6284
BATTERY...6285
BATTERY HAZARD PREVENTION...6285
STARTING WITH BOOSTER CABLES...6286
TOWING...6287
WHEN TOWING...6287
PRECAUTIONS FOR MAINTENANCE...6288
WARNING TAG...6288
KEEP WORK PLACE CLEAN AND TIDY...6288
APPOINT LEADER WHEN WORKING WITH OTHERS...6288
MAINTENANCE WITH ENGINE RUNNING...6289
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...6290
INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF...6290
PROPER TOOLS...6291
ACCUMULATOR...6291
PERSONNEL...6291
ATTACHMENTS...6291
WORK UNDER THE MACHINE...6292
NOISE...6292
PRECAUTIONS WHEN USING HAMMER...6292
REPAIR WELDING...6292
REMOVING BATTERY TERMINAL...6292
PRECAUTIONS WITH HIGH-PRESSURE OIL...6293
HANDLING HIGH-PRESSURE HOSES...6293
WASTE MATERIALS...6293
MAINTENANCE OF AIR CONDITIONER...6293
COMPRESSED AIR...6294
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...6294
PRECAUTIONS WITH TIRES...6295
HANDLING TIRES...6295
PRECAUTIONS WHEN STORING TIRE...6295
OPERATION...6296
GENERAL VIEW...6297
GENERAL VIEW OF MACHINE...6297
GENERAL VIEW OF CONTROLS AND GAUGES...6298
EXPLANATION OF COMPONENTS...6300
MACHINE MONITOR...6300
SWITCHES...6326
CONTROL LEVERS, PEDALS...6335
STEERING TILT LOCK LEVER...6339
CAP AND COVER WITH LOCK...6339
SAFETY BAR...6340
TOWING PIN...6341
GREASE PUMP...6341
CAB DOOR INNER LOCK...6341
CAB DOOR OPEN LOCK...6342
CAB WINDOW OPEN LOCK CANCEL KNOB...6342
FUSE...6342
SLOW BLOW FUSE...6344
POWER OUTLET...6344
STORAGE BOX...6344
AM/FM RADIO-CASSETTE STEREO...6345
AIR CONDITIONER...6353
HANDLING CAB WIPER...6358
OPERATION...6359
CHECK BEFORE STARTING ENGINE, ADJUST...6359
STARTING ENGINE...6374
OPERATIONS AND CHECKS AFTER STARTING ENGINE...6376
STOPPING ENGINE...6378
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...6379
TURNING...6384
OPERATION OF WORK EQUIPMENT...6386
WORK POSSIBLE USING WHEEL LOADER...6388
PRECAUTIONS FOR OPERATION...6393
ADJUSTING WORK EQUIPMENT POSTURE...6395
PARKING MACHINE...6397
CHECK AFTER STOPPING ENGINE...6399
CHECKS AFTER COMPLETION OF OPERATION...6399
LOCKING...6399
HANDLING THE TIRES...6400
TRANSPORTATION...6402
TRANSPORTATION PROCEDURE...6402
LOADING, UNLOADING WORK WITH TRAILERS...6402
LIFTING MACHINE...6404
COLD WEATHER OPERATION...6407
PRECAUTIONS FOR LOW TEMPERATURE...6407
PRECAUTIONS AFTER COMPLETION OF WORK...6408
AFTER COLD WEATHER...6409
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...6409
LONG-TERM STORAGE...6410
BEFORE STORAGE...6410
DURING STORAGE...6410
AFTER STORAGE...6410
TROUBLESHOOTING...6411
WHEN MACHINE RUNS OUT OF FUEL...6411
TOWING THE MACHINE...6411
IF BATTERY IS DISCHARGED...6413
OTHER TROUBLE...6416
MAINTENANCE...6421
GUIDES TO MAINTENANCE...6422
OUTLINES OF SERVICE...6424
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...6424
OUTLINE OF ELECTRIC SYSTEM...6426
WEAR PARTS...6427
WEAR PARTS LIST...6427
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...6428
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS...6428
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...6433
TORQUE LIST...6433
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...6434
MAINTENANCE SCHEDULE CHART...6435
MAINTENANCE SCHEDULE CHART...6435
SERVICE PROCEDURE...6437
INITIAL 250 HOURS SERVICE...6437
WHEN REQUIRED...6438
CHECK,CLEAN,OR REPLACE AIR CLEANER ELEMENT...6438
CLEAN INSIDE OF COOLING SYSTEM...6441
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL...6444
CHECK AXLE OIL LEVEL, ADD OIL...6445
CHEAN AXLE CASE BREATHER...6446
CLEAN AIR CONDITIONER CONDENSER...6447
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID...6447
CLEAN RADIATOR FINS AND COOLER FINS...6448
CLEAN TRANSFER OIL COOLER FINS...6449
CHECK ELECTRICAL INTAKE AIR HEATER...6449
REPLACE BOLT ON CUTTING EDGE...6449
REPLACE BUCKET TEETH...6450
CHECK AIR CONDITIONER...6451
REPLACE SLOW BLOW FUSE...6452
SELECTION AND INSPECTION OF TIRES...6453
CHECK BEFORE STARTING...6455
EVERY 50 HOURS SERVICE...6456
DRAIN WATER, SEDIMENT FROM FUEL TANK...6456
EVERY 100 HOURS SERVICE...6457
LUBRICATE REAR AXLE PIVOT PIN...6457
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...6457
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...6458
EVERY 250 HOURS SERVICE...6459
CHECK BATTERY ELECTROLYTE LEVEL...6459
CHECK PARKING BRAKE...6461
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...6461
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN...6462
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...6463
LUBRICATING...6464
EVERY 500 HOURS SERVICE...6465
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...6465
REPLACE FUEL FILTER CARTRIDGE...6466
CLEAN WATER SEPARATOR STRAINER...6467
EVERY 1000 HOURS SERVICE...6468
CHANGE OIL IN TRANSFER CASE...6468
CLEAN TRANSFER CASE BREATHER...6469
REPLACE HST OIL FILTER ELEMENT...6470
LUBRICATING...6471
CHECK TIGHTENING PARTS OF TURBOCHARGER...6471
CHECK PLAY OF TURBOCHARGER ROTOR...6471
CHECK ALTERNATOR BELT TENSION, REPLACE...6471
EVERY 2000 HOURS SERVICE...6472
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...6472
REPLACE HYDRAULIC TANK BREATHER ELEMENT...6473
CHANGE AXLE OIL...6474
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER...6474
CHECK ALTERNATOR, STARTING MOTOR...6474
CHECK ENGINE VALVE CLEARANCE, ADJUST...6475
CHECK BRAKE DISC WEAR...6475
CLEAN AND CHECK TURBOCHARGER...6475
CHECK ACCUMULATOR GAS PRESSURE...6475
CHECK VIBRATION DAMPER...6476
EVERY 4000 HOURS SERVICE...6477
LUBRICATING...6477
CHECK WATER PUMP...6477
SPECIFICATIONS...6478
SPECIFICATIONS...6479
ATTACHMENTS, OPTIONS...6480
SELECTING BUCKET AND TIRES...6481
INDEX...6482
SEBM005910 - Wheel Loader WA250-3 avance Loader Shop Manual...6485
COVER...6485
CONTENTS...6486
01 GENERAL...6513
GENERAL ASSENBLY DRAWING...6514
SPECIFICATIONS...6516
WEIGHT TABLE...6519
LIST OF LUBRICANT AND WATER...6521
10 STRUCTURE AND FUNCTION...6523
POWER TRAIN...6524
PATH OF POWER TRANSMISSOM...6525
TORQUE CONVERTER, TRANSMISSION PIPING...6527
TORQUE CONVERTER,TRANSMISSION HYDRAULIC SISTEM DIAGRAM...6528
TORQUE CONVERTER,TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM...6529
TORQUE CONVERTER...6530
TORQUE CONVERTER OIL FILTER...6532
TRANSMISSION...6533
TRANSMISSION CONTROL VALVE...6544
DRIVE SHAFT...6565
AXLE...6566
FINAL DRIVE...6572
AXLE MOUNT...6573
CENTER HINGE PIN...6575
STEERING PIPING...6576
STEERING COLUMN...6577
PRIORITY VALVE...6578
STEERING VALVE (ORBIT-ROLL)...6581
2-WAY RESTRICTOR VALVE...6589
BRAKE PIPING...6590
POWER MASTER CYLINDER...6591
BRAKE...6595
PARKING BRAKE CONTROL...6597
HYDRAULIC PIPING...6599
STEERING, HYDRAULIC PUMP HYDRAULIC SYSTEM DIAGRAM...6601
STEERING,HYDRAULIC PUMP CIRCUIT DIAGRAM...6602
WORK EQUIPMENT CONTROL LEVER LINKAGE...6603
HYDRAULIC TANK...6604
WORK EQUIPMENT LINKAGE...6620
BUCKT...6622
BUKKET POSITIONER AND BOOM KICKOUT...6623
CAB...6627
MACHINE MOINTOR SISTEM...6628
MAIN MONITOR...6629
MAINTENANCE MONITOR DISPLAY FUNCTION...6634
SENSORS AND SWITCHES...6636
ENGINE STARTING CIRCUIT...6641
ENGINE STOP CIRCUIT...6643
PREHEATING CIRCUIT...6645
STARTING AID...6647
ELECTRICAL TRANSMISSION CONTROL...6648
COMBINATION SWITCH...6649
TRANSMISSION CUT-OFF FUNCTION...6650
PARKING BRAKE NEUTRALIZER RELAY FUNCTION...6652
KICK-DOWN SWITCH...6653
KICK-DOWN ELECTRIC CIRCUIT DIAGRAM...6654
TRANSMISSION AUTO SHIFT CONTRCL SYSTEM (IF EQUIPPED)...6659
20 TESTING AND ADJUSTING...6667
STANDARD VALUE TABLE FOR ENGINE...6668
STANDARD VALUE TABLE FOR CHASSIS...6670
STANDARD VALUE TABLE FOR ELECTRICAL PARTS...6673
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...6675
ADJUSTING VALUE CLEARANCE...6677
MEASURING COMPRESSION PRESSURE...6679
TESTING AND ADJUSTING FUEL INGECTION TIMING...6680
MEASURING EXHAUST COLOR...6682
MEASURING BLOW-BY PRESSURE...6683
TESTING AND ADJUSTING FAN BELT TENSION...6685
MEASURING ENGINE SPEED...6686
METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE...6688
ADJUSTING ENGINE STOP SOLENOID...6690
MEASURING ENGINE OIL PRESSURE...6691
MEASURING INTAKE AIR PRESSURE (BOSST PRESSURE)...6692
MEASURING EXHAUST GAS TEMPERATURE...6693
MEASURING ACCELERATOR PEDAL...6694
MEASURING SHIFT LEVER...6696
MEASURING STALL SPEED...6697
MEASURING TORQUE CONVERTER,TRANSMISSION OIL PRESSURE...6699
METHOD OF OPERATING EMERGENCY MANUAL SPOOL...6701
TESTING AND ADJUSTING STEERING WHEEL...6703
MEASURING STEERING OIL PRESSURE...6706
MEASURING BRAKE PEDAL...6708
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE...6709
MEASURING BRAKE PERFORMANCE...6711
MEASURING BRAKE OIL PRESSURE...6712
MEASURING WEAR OF BRAKE DISC...6713
BLEEDING AIR FROM BRAKE SISTEM...6714
MEASURING PARKING BRAKE PERFORMANCE...6715
TESTING AND ADJUSTING PARKING BRAKE LINKAGE...6716
TESTING PARKING BRAKE PISTON STROKE...6717
MEASURING WEAR OF PARKING BRAKE DISC...6718
MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER...6719
MEASURING STROKE F WORK EQUIPMENT VALVE SPOOL...6722
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE...6723
MEASURING WORK EQUIPMENT...6725
TESTING AND ADJUSTING BUCKET POSITIONER...6727
TESTING AND ADJUSTING BOOM KICK-OUT...6728
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)...6730
CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR...6731
TROUBLESHOOTING...6732
POINTS TO REMEMBER WHEN TROUBLESHOOTING...6733
SEQUENCE OF EVENTS IN TROUBLESHOOTING...6734
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...6735
HANDLING CONNECTORS...6742
CHECKS BEOORE TROUBLESHOOTING...6743
JUDGEMENT OF POWER TRAIN...6744
METHOD OF USING TROUBLESHOOTING CHARTS...6745
CONNECTOR TYPES AND MOUNTING LOCATIONS...6753
CONNECTOR PIN ARRANGEMENT DIAGRAM...6754
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...6757
TROUBLESHOOTING OF ENGINE (S6D95L) SYSTEM (SMODE)[SERIAL NO.53001-52999]...6765
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...6766
S-2 ENGINE DOES NOT START ...6767
(1) ENGINE DOES NOT TURN...6767
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)...6768
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED...6769
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...6770
S-4 ENGINE STOPS DURING OPERATIONS...6771
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...6772
S-6 ENGINE LACKS OUTPUT (NO POWER)...6773
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)...6774
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)...6775
S-9 OIL BECOMES CONTAMINATED QUICKLY...6776
S-10 FUEL CONSUMPTION IS EXCESSIVE...6777
S-11 OIL IS COLLING WATER, OR WATER SPURTS BACKS, OR WATER LEVEL GOSE DOWN...6778
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)...6779
S-13 OIL LEVEL RISES...6780
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...6781
S-15 ABNORMAL NOISE IS MADE...6782
S-16 VIBRATION IS EXCESSIVE...6783
TROULESHOOTING OF ENGINE (S6D102E) SYSTEM (S MODE) [SERIAL NO.53001 AND UP]...6784
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...6785
S-2 ENGINE DOES NOT START...6786
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...6789
S-4 ENGINE STOPS DURING OPERATIONS...6790
S-5 ENGINE DOSE NOT ROTATE SMOOTHLY (HUNTING)...6791
S-6 ENGINE LACKS OUTPUT (NO POWER)...6792
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)...6793
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)...6794
S-9 OIL BECOMES CONTAMINATED QUICKLY...6795
S-10 FUEL CONSUMPTION IS EXCESSIVE...6796
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN...6797
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)...6798
S-13 OIL LEVEL RISES...6799
S-14 WATER TEMPERATURE BECOME TOO HIGH (OVERHEATING)...6800
S-15 ABNORMAL NOISE IS MADE...6801
S-16 VIBRATION IS EXCESSIVE...6802
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (T MODE)...6803
POWEER TRAIN ...6804
T-1 MACHINE DOES NOT START...6804
T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES...6806
T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR...6808
T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR...6809
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH...6810
STEERING SYSTEM...6811
T-6 STEERING WHEEL DOES NOT TURN...6811
T-7 STEERING IS HEAVY...6812
T-8 STEERING WHEEL SHAKES OR THERE EXCESSIVE SHOCK...6813
T-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING...6813
BRAKE SYSTEM...6814
T-10 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR...6814
T-11 BRAKE IS NOT RELEASED, BRAKE DRAGS...6815
WORK EQUIPMENT...6816
T-12 BOOM DOES NOT RISE...6816
T-13 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER...6817
T-14 WHEN MOON IS RAISED IT MOVES SLOWLY AT A CERTAIN HEIGHT...6818
T-15 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS)...6818
T-16 EXCESSIVE HYDRAULIC DRIFT OF BOOM...6818
T-17 BOOM SHAKES DURING OPERATION...6819
T-18 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FORM HOLD TO RAISE...6819
T-19 BUCKET DOES NOT TILT BACK...6820
T-20 BUCKET MOVEMENT IS SLOW OR TILT-LACKS POWER...6821
T-21 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION...6822
T-22 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER...6822
T-23 EXCESSIVE HYDRAULIC DRIFT OF BUCKET...6822
T-24 BUCKET SHAKETS DURING LOADING OPERATION (MAIN CONTROL VALVE AT HOLD)...6823
T-25 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT...6823
T-26 BOOM, BUCKET CONTROL LEVERS ARE HEAVE OR NOT MOVE SMOOTHLY...6824
TROUBLESHOOTING OF ELECTRICAL SYSTEM FOR ENGINE, TRANMISSION (E MODE)...6825
E-1 ENGINE DOES NOT START...6826
(a) STARTING MOTOR DOES NOT TURN...6826
1) CHECK STARTING CIRCUIT...6826
2) CHECK BETWEEN BATTERY RELAY AND STARTING SWITCH...6827
(b) STARTING MOTOR TURNS...6828
E-2 ENGINE DOES NOT STOP...6834
E-3 ENGIN STOPS WHEN MACHINE IS TRAVELLING...6835
E-4 TRAMISSION IS NOT SET TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (TRANSMISSION CUT-OFF IS NORMAL)...6836
E-5 TRAMISSION DOES NOT WORK NORMALLY...6837
(a) PROBLEM IN PARKING BRAKE, TRANSMISSION CUT-OFF SWITCH, NEUTRALIZER RELAY CIRCUIT...6838
(b) DEFECTIVE CONTINUITY IN FORWARD SOLENOID CIRCUITY...6840
(c) DEFECTIVE CONTINUITY IN REVERSE SOLENOID CIRCUIT...6842
(d) CONTACT IS DIRECTIONAL CIRCUIT...6844
1) FORWARD IS CONTINUOUS...6844
2) REVERSE IS CONTINUOUS...6846
(e) PROBLEM WITH SPEED SOLENOID OR ALWAYS STAYS IN 2ND...6848
(f) CONTACT IN SPEED CIRCULT...6850
1) BATTERY VOITAGE FORMED IN 1ST (SPEED) SOLENOID)...6850
2) BATTERY VOLTAGE FORMED IN 3RD (H-L) SOLENOLD...6852
E-6 KICK-DOWN SWITCH DOES NOT WORK (USUAL F1-F4 SHIFTS NORMALLY)...6854
E-7 KICK-DOWN IS ACTUATED ONLY WHEN KICK-DOWN SWITCH IS ON (SELF-HOLD FUNCTION OF KICK-DOWN SWITCH RETAY DOES NOT WORK)...6856
E-8 KICK-DOWN IS NOT CANCELED...6857
(a) KICK-DOWN IS NOT CANCELED WHEN DIRECTIONAL LEVER IS MOVED FROM FORWARD TO NEUTRAL OR REVERSE...6857
(b) KICK-DOWN IS NOT CANCELED WHEN SPEED LEVER IS MOVED FROM 2ND TO OTHER SPEED RANGE...6858
E-9 KICK-DOWN SWITCH IS WRONGLY ACTUATED WHEN TRAVELING IN F2...6860
E-10 PREHEATING IS NOT CARRIED OUT...6861
E-11 PREHEATING REMAINS ACTUATED...6866
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)...6871
TROUBLE DATE DISPLY...6873
TABLE OF ACTION CODES AND FAILURE CODES...6874
M-1 MAIN MONITOR DOES NOT WORK...6875
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP...6876
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY...6877
M-4 ABNORMALITY IN SHIFT INDICATOR...6878
(a) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT F...6878
(b) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT R...6878
(c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS E WHEN DIRECTIONAL LEVER IS AT F...6878
(d) DOES NOT DISPLAY N EVEN DIRECTIONAL LEVER IS AT N AND DISPLAYS E WHEN DIRECTIONAL LEVER IS AT R...6879
(e) DOES NOT PLAY 1ST, 4TH...6879
(f) DOES NOT DISPLAY 3RD, 4TH...6879
(e-1) DOES NOT DISPLAY 1ST, 4TH...6880
(f-1) DOES NOT DISPLAY 3RD, 4TH...6880
(g) DOES NOT DISPLAY 2ND, 3RD...6881
(h) DOES NOT DISPLAY 1ST, 2ND...6881
M-5 HIGH BEAM DOES NOT LIGHT UP...6882
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP...6883
(a) L.H. TURN SIGNAL DOES NOT LIAGT UP...6883
(b) R.N. TURN SINGNAL DOES NOT LIGHT UP...6883
M-7 ABNORMALITY IN PARKING DISPLAY...6884
(a) PARKING LAMP DOES NOT LIGHT UP...6884
(b) PARKING LAMP STAYS LIGHTED UP...6884
M-8 ABNORMALITY IN PREHEATING SYSTEM...6885
(a) DOES NOT CARRY OUT PREHEATING...6885
(b) ONLY MONITOR DISPLAY DOES NOT LIGHT UP...6886
(c) ALWAYS CARRIES OUT PREHEATING FOR 1 MINUTE...6886
(d) PREHEATING STAYS ON...6886
(e) PREHEATING TIME BECOMES SHORTER, OR IS UNSTABLE...6887
M-9 NIGHT LIGHTING DOES NOT LIGHT UP...6893
M-10 ABNORMALITY IN FRONT WORKING LAMP...6894
(a) NEITHER MONITOR DISPLAY NOR FRONT WORKING LIGHT UP...6894
(b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP...6894
(c) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP...6894
M-11 ABNORMALITY IN REAR WORKING LAMP...6895
(a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP...6895
(b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP...6895
(c) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP...6895
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF...6897
(a) WHEN MONITOR SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY IS NOT GIVEN...6897
(b) MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION STAYS ON...6897
(c) MONITOR DISPLAY LIGHTS UP BUT CUT-OFF FUNCTION IS NOT ACTUATED...6898
(a) WHEN MONITOR SWITCH IS PRESSED,SUT-OFF FUNCTION AND DISPLAY DO NOT CHANGE...6899
(b) DISPLAY ON MONITOR GOES OFF BUT-OFF FUNCTION OPERATES IF PEDAL IS PRESSED...6899
(c) IF DISPLAY OF MONITOR IS TURNED OFF, SUT-OFF FUNCTION ALWAYS OPERATES...6899
(d) CUT-OFF FUNCTION OPERATES, REGARDLESS OF DISPLAY ON MOMITOR...6899
(e) DISPLAY ON MONITOR LIGHTS UP BUT CUT-OFF FUNCTION DOES NOT OPERATE...6900
M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING...6901
(a) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS(INTERMITTENTLY) EVEN WHEN DIRECTIONAL LEVER IS AT N, AND CAUTION LAMP FLASHES...6901
(b) WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVEL IS AT POSITION OTHER THEN N...6901
M-14 WHEN PARKING BRAKE DRAGGING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED...6902
(a) ACTUATED CONTINUOUSLY...6902
(b) NOT ACTUATED...6902
M-15 ABNOMALITY IN BUZZER...6903
(a) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS TURNED ON (DURING SELF-CHECK)...6903
(b) BUZZER ALWAYS SOUNDS...6903
M-16 CONDITION OF MONITOR OF SWITCHES IS NOT STORED IN MEMORY...6904
M-17 ABNORMALITY IN FAILURE DISPLAY MODE...6905
(a) DOES NOT ENTER FAILURE DISPLAY MODE...6905
(b) TIME FOR TIME ELAPSED SINCE FAILURE ON FAILURE DISPLAY MODE NOT ADVANCE...6905
TROUBLESHING OF MAINTENANCE MONITOR SYSTEM(K MODE)...6906
K-1 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS,MAINTENANCE MONITOR DOES NOT WORK...6907
(a)ALL LUMPS ON MAINTENANCE MONITIOR DO NOT LIGHT UP FOR 3 SECONDS...6907
(b)SOME LAMPS DO NOT LIGHT UP...6908
K-2 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT...6908
K-3 WHEN ENGINE IS STARTING IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON(WITHIN 3 SECONDS),ALL LAMPS ON MAINTENANCE MONITOR DO NOT GO OUT...6909
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED),CHECK ITEMS FLASH...6910
(a) ENGINE OIL LEVEL DISPLAY FLASHES...6910
(b) ENGINE WATER LEVEL DISPLAY FLASHES...6911
(c) BRAKE OIL LEVEL DISPLAY FLASHES...6912
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED),CAUTION ITEMS FLASH...6913
(a) ENGINE OIL PRESSURE DISPLAY FLASHES...6913
(b)BATTERY CHARGE LEVEL DISPLAY FLASHES...6914
K-6 CAUTION ITEMS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUND...6915
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT ALARM BUZZER SOUNDS...6916
K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP,CAUTION LAMP)DOES NOT LIGHT UP...6917
(a)CHECK LAMP...6917
(b)CAUTION LAMP...6917
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT WARNING LAMP (CHECK LAMP) LIGHTS UP...6918
(a) CHECK LAMP...6918
(b) CAUTION LAMP...6918
K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTEANCE MONITOR DOESNOT LIGHT UP)...6919
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAYS LIGHTED UP...6920
K-12 SERVICE METER DOES NOT WORK...6921
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED...6921
K-14 ABNORMALITY IN GAUGE ITEMS...6922
(a) ABNORMALITY IN FUEL GAUGE ...6922
(b) ABNORMALITY IN ENGINE WATER TEMPURATURE GAUGE...6923
(c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE...6924
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE)...6925
1. FUNCTION...6926
2. NOTE ON TROUBLESHOOTING...6926
3. FAILURE CODES LIST...6926
4. TABLE OF FAILURE MODES AND CAUSES...6927
5. SYSTEM DIAGRAM RELATED TO TRANSMISSION CONTROLLER...6928
A-1. FAILURE CODE [12] F SOLENOID SIGNAL SYSTEM...6930
A-2. FAILURE CODE [13] R SOLENOID SIGNAL SYSTEM...6930
A-3. FAILURE CODE [14] ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM...6931
A-4. FAILURE CODE [16] ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM...6932
A-5. FAILURE CODE [20] ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM...6933
A-6. FAILURE CODE [21] ABNORMALITY IN GEARSHIFT LEVER SIGNAL SYSTEM...6934
A-7. FAILURE CODE [22] ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM...6935
A-8. FAILURE CODE [23] ABNORMALITY IN SPEED SIGNAL...6936
A-9. HOLDING SWITCH SYSTEM...6937
A-10. KICK-DOWN SWITCH SYSTEM...6937
A-11. TRANSMISSION CUT-OFF SIGNAL SYSTEM...6938
A-12. NEUTRALIZER RELAY SIGNAL SYSTEM...6939
A-13. ALARM BUZZER SIGNAL SYSTEM...6940
A-14. NETWORK SIGNAL SYSTEM...6941
A-15. CONTROLLER POWER SUPPLY SYSTEM...6942
30 DISASSEMBLY AND ASSEMBLY...6943
METHOD OF USING MANUAL...6945
PRECAUTIONS WHEN CARRYING OUT OPERATION...6946
SPECIAL TOOL LIST...6948
STARTING MOTOR...6950
REMOVAL AND INSTALLATION...6950
ALTERNATOR...6951
REMOVAL AND INSTALLATION...6951
ENGINE OIL COOLER ...6953
REMOVAL AND INSTALLATION...6953
FUEL OF INJECTION PUMP...6955
REMOVAL...6955
INSTALLATION...6956
WATER PUMP...6962
REMOVAL AND INSTALLATION...6962
TURBOCHARGER...6964
REMOVAL AND INSTALLATION...6964
NOZZLE HOLDER ...6966
REMOVAL AND INSTALLATION...6966
THERMOSTAT...6969
REMOVAL AND INSTALLATION...6969
CYLINDER HEAD...6971
REMOVAL...6971
INSTALLATION...6973
RADIATOR ...6983
REMOVAL...6983
INSTALLATION...6986
RADIATOR, HYDRAULIC COOLER ...6987
REMOVAL...6987
INSTALLATION...6988
ENGINE...6989
REMOVAL ...6989
INSTALLATION...6992
TORQUE CONVERTER CHARGING PUMP...6997
REMOVAL AND INSTALLATION...6997
TORQUE CONVERTER, TRANSMISSION...6998
REMOVAL...6998
INSTALLATION...7007
TORQUE CONVERTER...7009
DISASSEMBLY...7009
ASSEMBLY...7011
TRANSMISSION ...7013
DISASSEMBLY...7013
ASSEMBLY ...7022
CLUTCH PACK ...7035
DISASSEMBLY...7035
ASSEMBLY ...7041
PARKING BRAKE...7053
DISASSEMBLY...7053
ASSEMBLY ...7055
TRANSMISSION CONTROL VLVE...7058
REMOVAL ...7058
INSTALLATION...7059
DISASSEMBLY...7060
ASSEMBLY ...7062
TRANSMISSION SOLENOID VALVE...7064
DISASSEMBLY AND ASSEMBLY...7064
ACCUMULATOR VALVE...7065
DISASSEMBLY AND ASSEMBLY...7065
DRIVE SHAFT...7067
DISASSEMBLY...7067
ASSEMBLY...7069
FRONT AXLE...7071
REMOVAL...7071
INSTALLATION...7073
REAR AXLE...7074
REMOVAL...7074
ASSEMBLY...7078
DIFFERENTIAL...7081
DISASSEMBLY...7081
ASSEMBLY...7085
AXLE HOUSING...7094
DISASSEMBLY...7094
ASSEMBLY...7099
CENTER HINGE PIN...7105
REMOVAL...7105
INSTALLATION...7112
STEERING VALVE...7115
REMOVAL ...7115
INSTALLATION ...7117
DISASSEMBLY ...7118
ASEMBLY...7121
PRIORITY...7126
REMOVAL ...7126
INSTALLATION...7127
STEERING CYLINDER...7128
REMOVAL AND INSTALLATION...7128
POWER MASTER CYLINDER ...7129
REMOVAL ...7129
INSTALLATION...7130
DISASSEMBLY ...7131
ASSEMBLY ...7134
PARKING BRAKE DISC...7139
REMOVAL...7139
INSTALLATION...7140
HYDRAULIC TANK ...7141
REMOVAL...7141
INSTALLATION...7142
HYDRAULIC FILTER ...7143
REMOVAL AND INSTALLATION...7143
WORK EQUIPMENT, STEERING PUMP ...7144
REMOVAL AND INSTALLATION...7144
MAIN CONTROL VALVE ...7145
REMOVAL ...7145
INSTALLATION...7146
DISASSEMBLY AND ASSEMBLY ...7147
BUCKET CYLINDER...7149
REMOVAL...7149
INSTALLATION...7150
BOOM CYLINDER...7151
REMOVAL...7151
INSTALLATION...7152
HYDRAULIC CYLINDER...7153
DISASSEMBLY...7153
ASSEMBLY ...7155
WORK EQUIPMENT...7157
REMOVAL...7157
INSTALLATION...7160
COUNTERWEIGHT...7162
REMOVAL AND INSTALLATION...7162
FUEL TANK...7163
REMOVAL ...7163
INSTALLATION...7164
CAB ...7165
REMOVAL...7165
INSTALLATION...7166
MAIN MONITOR...7167
REMOVAL...7167
INSTALLATION...7168
MAINTENANCE MONITOR...7169
REMOVAL AND INSTALLATION...7169
AIR CONDITIONER UNIT...7170
REMOVAL...7170
INSTALLATION...7175
AIR CONDITIONER CONDENSER...7176
REMOVAL...7176
INSTALLATION...7177
DPY RECEIVER...7178
REMOVAL AND INSTALLATION...7178
AIR CONDITIONER COMPRESSOR ...7179
REMOVAL AND INSTALLATION...7179
40 MAINTENANCE STANDARD...7180
TRANSMISSION, ENGINE MOUNT...7181
TORQUE CONVERTER...7183
TRANSMISSION...7184
TRANSMISSION CONTROL VALVE...7190
ACCUMULATOR VALVE...7194
DRIVE SHAFT...7195
DIFFERENTIAL...7196
FINAL DRIVE...7200
AXLE MOUNT...7202
CENTER HINGE PIN...7204
STEERING COLUMN ...7206
PRIORITY VALVE...7207
MASTER CYLINDER...7208
BRAKE...7209
PARKING BRAKE...7210
MAIN CONTROL VALVE...7211
HYDRAULIC CYLINDER...7215
STEERING CYLINDER MOUNT...7216
WORK EQUIPMENT LINKAGE...7217
BUCKET...7219
BUCKET POSITIONER AND BOOM KICK-OUT...7220
90 OTHERS...7221
ELECTRICAL CIRCUIT DIAGRAM (1/2) (SERIAL NO. : 50001-53000)...7222
ELECTRICAL CIRCUIT DIAGRAM (2/2) (SERIAL NO. : 50001-53000)...7223
ELECTRICAL CIRCUIT DIAGRAM (1/2) (SERIAL NO. : 53001 AND UP )...7224
ELECTRICAL CIRCUIT DIAGRAM (2/2) (SERIAL NO. : 53001 AND UP)...7225
ELECTRICAL CIRCUIT DIAGRAM (1/2) FOR AUTO SHIFT CONTROL SPEC. (SERIAL NO. : 53001 AND UP)...7226
ELECTRICAL CIRCUIT DIAGRAM (2/2) FOR AUTO SHIFT CONTROL SPEC. (SERIAL NO. : 53001 AND UP)...7227
SEBM04180110 - Wheel Loader WA200-1, WA250-1 Shop Manual...7228
COVER...7228
CONTENTS...7229
10 ...7244
11 STRUCTURE AND FUNCTION...7244
ENGINE MOUNT...7245
RADIATOR AND COOLER...7246
RADIATOR AND COOLER...7247
ENGINE CONTROL...7249
12 TESTING AND ADJUSTING...7250
TABLE OF JUDGEMENT STANDARD...7251
TESTING AND ADJUSTING TOOL LIST...7256
ADJUSTING VALVE CLEARANCE...7257
MEASURING COMPRESSION PRESSURE...7258
TESTING AND ADJUSTING FUEL INJECTION TIMING...7259
MEASURING ENGINE OIL PRESSURE AND TEMPERATURE...7261
MEASURING BLOW-BY PRESSURE...7262
TESTING AND ADJUSTING FAN BELT TENSION...7263
MEASURING EXHAUST GAS COLOR...7264
ADJUSTING FUEL CUT SOLENOID...7265
MEASURING OPERATING FORCE AND OPERATING ANGLE OF ACCELERATOR PEDAL...7266
13 DISASSEMBLY AND ASSEMBLY...7272
STARTING MOTOR...7273
REMOVAL OF STARTING MOTOR ASSEMBLY...7273
INSTALLATION OF STARTING MOTOR ASSEMBLY...7273
ALTERNATOR...7274
REMOVAL OF ALTERNATOR ASSEMBLY...7274
INSTALLATION OF ALTERNATOR ASSEMBLY...7274
ENGINE OIL COOLER...7275
REMOVAL OF ENGINE OIL COOLER ASSEMBLY...7275
INSTALLATION OF ENGINE OIL COOLER ASSEMBLY...7275
FUEL INJUCTION PUMP...7276
REMOVAL OF FUEL INJUCTION PUMP ASSEMBLY...7276
INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY...7276
WATER PUMP...7277
REMOVAL OF WATER PUMP ASSEMBLY...7277
INSTALLATION OF WATER PUMP ASSEMBLY...7277
NOZZLE HOLDER...7278
REMOVAL OF NOZZLE HOLDER ASSEMBLY...7278
INSTALLATION OF NOZZLE HOLDER ASSEMBLY...7278
CYLINDER HEAD...7279
REMOVAL OF CYLINDER HEAD ASSEMBLY...7279
INSTALLATION OF CYLINDER HEAD ASSEMBLY...7284
RADIATOR...7290
REMOVAL OF RADIATOR...7290
INSTALLATION OF RADIATOR...7292
ENGINE...7294
REMOVAL OF ENGINE...7294
INSTALLATION OF ENGINE...7299
FUEL TANK...7303
REMOVAL OF FUEL TANK ASSEMBLY...7303
INSTALLATION OF FUEL TANK ASSEMBLY...7304
20 POWER TRAIN...7306
21 STRUCTURE AND FUNCTION...7306
GENERAL...7307
HYDRAULIC CIRCUIT FOR POWER TRAIN...7309
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN...7310
TORQUE CONVERTER AND TRANSMISSION PIPING...7317
TORQUE CONVERTER CHARGING PUMP...7320
TORQUE CONVERTER...7321
TORQUE CONVERTER OIL FILTER...7323
TORQUE CONVERTER OIL COOLER AND RADIATOR...7326
TORQUE CONVERTER REGULATOR VALVE...7327
TORQFLOW TRANSMISSION...7333
CLUTCH PACK...7339
TRANSMISSION CONTROL VALVE...7347
UPPER VALVE...7349
LOVER VALVE...7350
PILOT REDUCING VALVE...7351
TRANSMISSION SOLENOID VALVE...7352
PRIORITY VALVE, RELIEF VALVE...7353
MODULATING RELIEF VALVE...7354
MODULATING RELIEF VALVE, ACCUMULATOR VALVE AND QUICK RETURN VALVE...7355
EMERGENCY MANUAL SPOOL...7359
SPEED SPOOL...7362
TRANSMISSION CONTROL VALVE...7363
(WA200-1 SERIAL NO. 20001 AND UP, WA250-1 WAITH ELECTRICAL CONTROL TRANSMISSION TYPE)...7363
TRANSMISSION SOLENOID VALVE...7364
UPPER VALVE...7365
LOWER VALVE...7366
TORQUE CONVERTER OUTLET VALVE...7367
PILOT REDUCING VALVE...7368
TRANSMISSION SOLENOID VALVE...7369
PRIORITY AND MAIN REGULATOR VALVE...7370
MAIN REGULATOR VALVE...7371
MODULATING RELIEF VALVE, ACCUMULATOR VALVE, QUICK RETURN VALVE...7372
EMERGENCY MANUAL SPOOL...7376
DIRECTIONAL SPOOL...7378
FILL VALVE...7379
TRANSMISSION CONTROL VALVE...7381
(WA250-1 WITH MECHANICAL CONTROL TRANSMISSION TYPE)...7381
SELECTOR VALVE...7382
UPPER VALVE...7383
LOWER VALVE...7384
PILOT REDUCING VALVE...7385
PRIORITY AND MAIN REGULATOR VALVE...7386
MAIN REGULATOR VALVE...7387
MODULATING RELIEF VALVE, ACCUMULATOR VALVE AND QUICK RETURN VALVE...7388
DIRECTIONAL VALVE...7392
PILOT OIL FILTER...7395
DRIVE SHAFT...7396
AXLE...7397
DIFFERENTIAL...7399
FINAL DRIVE...7403
AXLE MOUNT ...7405
TIRE AND WHEEL...7407
22 TESTING AND ADJUSTIOG...7408
STANDARD VALUE TABLE...7409
TOOL LIST FOR TESTING AND ADJUSTING...7410
MEASURING ENGINE STALL SPEED...7411
MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION...7413
MEASURING SHIFT LEVER...7417
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL...7418
TIRE AND WHEEL...7420
TROUBLESHOOTING...7422
23 DISASSEMBLY AND ASSEMBLY...7436
TORQUE CONVERTER CHARGING PUMP...7437
REMOVAL OF TORQUE CONVERTER CHARGING PUMP...7437
INSTALLATION OF TORQUE CONVERTER CHARGING PUMP...7437
TORQUE CONVERTER, TRANSMISSION...7438
REMOVAL OF TORQUE CONVERTER, TRANSMISSION...7438
INSTALLATION OF TORQUE CONVERTER, TRANSMISSION...7446
TORQUE CONVERTER...7454
DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY...7454
ASSEMBLY OF TORQUE CONVERTER ASSEMBLY...7457
TRANSMISSION...7460
DISASSEMBLY OF TRANSMISSION...7460
ASSEMBLY OF TRANSMISSION...7467
CLUTCH PACK...7478
DISASSEMBLY OF CLUTCH PACK...7478
ASSEMBLY OF CLUTCH PACK...7486
TRANSMISSION CONTROL VALVE...7499
REMOVAL OF TRANSMISSION CONTROL VALVE...7499
INSTALLATION OF TRANSMISSION CONTROL VALVE...7500
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CONTROL VALVE...7504
TRANSMISSION SOLENOID VALVE...7510
DISASSEMBLY AND ASSEMBLY TRANSMISSION SOLENOID VALVE...7510
SELECTOR VALVE...7511
DISASSEMBLY AND ASSEMBLY SELECTOR VALVE...7511
DRIVE SHAFT...7514
DISASSEMBLY OF DRIVE SHAFT...7514
ASSEMBLY OF DRIVE SHAFT...7516
FRONT AXLE...7518
REMOVAL OF FRONT AXLE...7518
INSTALLATION OF FRONT AXLE...7520
REAR AXLE...7522
REMOVAL OF REAR AXLE...7522
INSTALLATION OF REAR AXLE...7526
DIFFERENTIAL...7531
DISASSEMBLY OF DIFFERENTIAL...7531
ASSEMBLY OF DIFFERENTIAL...7535
AXLE HOUSING...7545
DISASSEMBLY OF AXLE HOUSING...7545
ASSEMBLY OF AXLE HOUSING...7551
24 MAINTENANCE STANDARD...7558
TRANSMISSION AND ENGINE MOUNT...7559
TORQUE CONVERTER CHARGING PUMP...7560
TORQUE CONVERTER...7561
TORQUE CONVERTER REGULATOR VALVE...7562
TRANSMISSION...7563
TRANSMISSION CLUTCH ASSEMBLY...7571
TRANSMISSION CONTROL VALVE...7573
UPPER VALVE...7573
LOWER VALVE...7577
SOLENOID VALVE...7579
AXLE...7583
DIFFERENTIAL...7587
FINAL DRIVE...7589
DRIVE SHAFT...7590
AXLE MOUNT...7591
40 STEERING SYSTEM...7592
41 STRUCTURE AND FUNCTION...7592
GENERAL...7593
HYDRAULIC CIRCUIT FOR STEERING...7595
HYDRAULIC CIRCUIT DIAGRAM FOR STEERING...7596
OPERATIONS OF STEERING VALVE...7597
STEERING VALVE...7599
STEERING RELIEF VALVE...7601
SAFETY VALVE (WITH SUCTION VALVE)...7602
OPERATION OF DEMAND VALVE...7603
TWO-WAY RESTRICTOR VALVE...7605
HYDRAULIC CIRCUIT FOR STEERING...7606
STTERING VALVE...7607
STEERING COLUMN AND GEAR BOX...7618
STEERING LINKAGE ...7621
STEERING CYLINDER...7622
CENTER HINGE PIN...7623
42 TESTING AND ADJUSTING...7624
STANDARD VALUE TABLE...7625
TOOL LIST FOR TESTING AND ADJUSTING...7625
MEASURING STEERING WHEEL PLAY...7626
MEASURING OPERATING FORCE OF STEERING WHEEL...7627
OPERATING TIME OF STEERING WHEEL...7628
TESTING STEERING LINKAGE...7629
ADJUSTING STEERING LINKAGE...7630
STEERING OIL PRESSURE...7631
TROUBLESHOOTING...7634
43 DISASSEMBLY AND ASSEMBLY...7642
STEERING GEAR BOX...7643
REMOVAL OF STEERING GEAR BOX...7643
INSTALLATION OF STEERING GEAR BOX...7644
DISASSEMBLY OF STEERING GEAR BOX ...7645
ASSEMBLY OF STEERING GEAR BOX...7646
STEERING VALVE...7648
REMOVAL OF STEERING VALVE...7648
INSTALLATION OF STEERING VALVE...7650
DISASSEMBLY AND ASSEMBLY OF STEERING VALVE...7656
PRIORITY VALVE...7658
REMOVAL OF PRIORITY VALVE...7658
INSTALLATION OF PRIORITY VALVE...7660
STEERING CYLINDER...7662
REMOVAL OF STEERING CYLINDER...7662
INSTALLATION OF STEERING CYLINDER...7663
DISASSEMBLY OF STEERING CYLINDER ASSEMBLY...7664
ASSEMBLY OF STERING CYLINDER ASSEMBLY...7666
CENTER HINGE PIN...7669
REMOVAL OF CENTER HINGE PIN...7669
INSTALLATION OF CENTER HINGE PIN...7674
44 MAINTENANCE STANDARD...7680
STEERING VALVE...7681
STTEERING CYLINDER MOUNT...7683
STEERING CYLINDER ...7684
CENTER HINGE PIN...7685
STEERING LINKAGE ...7687
STEERING COLUMN AND GEAR BOX...7688
50 BRAKE AND AIR SYSTEM...7692
51 STRUCTURE AND FUNCTION...7692
GENERAL...7693
POWER MASTER CYLINDER...7695
BRAKE...7699
PARKING BRAKE...7701
OPERATION OF PARKING BRAKE...7702
BRAKE CALIPER...7703
52 TESTING AND ADJUSTING...7704
STANDARD VALUE TABLE...7705
TOOL LIST FOR TESTING AND ADJUSTING...7706
MEASURING BRAKE PEDAL...7707
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE...7708
CHECKING BRAKE PERFORMANCE...7710
CHECKING BRAKE PISTON LEAKAGE...7711
MEASURING WEAR OF BRAKE DISC...7712
AIR BLEEDING FROM BRAKE CIRCUIT...7713
CHECKING PARKING BRAKE PERFORMANCE...7714
CHECKING AND ADJUSTING PARKING BRAKE...7715
MEASURING CLEARANCE OF PARKING BRAKE...7717
TROUBLESHOOTING...7718
53 DISASSEMBLY AND ASSEMBLY...7722
POWER MASTER CYLINDER...7723
REMOVAL OF POWER MASTER CYLINDER...7723
INSTALLATION OF POWER MASTER CYLINDER...7724
DISASSEMBLY OF POWER MASTER CYLINDER...7725
ASSEMBLY OF POWER MASTER CYLINDER...7728
PARKING BRAKE...7733
REMOVAL OF PARKING BRAKE...7733
INSTALLATION OF PARKING BRAKE...7735
PARKING BRAKE PAD...7737
REMOVAL OF PARKING BRAKE PAD...7737
INSTALLATION OF PARKING BRAKE PAD...7737
54 MAINTENANCE STANDARD...7738
POWER MASTER CYLINDER...7739
BRAKE...7740
PARKING BRAKE...7741
60 WORK EQUIPMENT SYSTEM...7742
61 STRUCTURE AND FUNCTION...7742
GENERAL...7743
HYDRAULIC CIRCUIT...7745
HYDRAULIC CIRCUIT DIAGRAM...7746
WORK EQUIPMENT LEVER LINKAGE...7753
BUCKET LINKAGE...7755
BUCKET POSITIONER AND BOOM KICK-OUT...7757
HYDRAULIC TANK...7759
OIL FILTER BYPASS VALVE...7762
BREATHER...7762
HYDRAULIC AND STEERING PUMPS...7763
MAIN CONTROL VALVE...7765
RELIEF VALVE...7767
SAFETY VALVE...7768
SUCTION VALVE...7769
HYDRAULIC CYLINDER...7776
62 TESTING AND ADJUSTING...7778
STANDARD VALUE TABLE...7779
TOOL LIST FOR TESTING AND ADJUSTING ...7780
MEASURING DUMP AND LIFT CONTROL LEVERS...7781
ADJUSTING DUMP AND LIFT CONTROL LEVERS...7782
MEASURING HYDRAULIC PRESSURE...7783
MEASURING LIFT ARM AND BUCKET...7785
MEASURING HYDRAULIC DRIFT OF LIFT ARM AND BUCKET...7786
ADJUSTING BUCKET POSITIONER...7787
ADJUSTING BOOM KICK-OUT...7788
TROUBLESHOOTING...7790
63 DISASSEMBLY AND ASSEMBLY...7798
HYDRAULIC TANK...7799
REMOVAL OF HYDRAULIC TANK...7799
INSTALLATION OF HYDRAULIC TANK...7801
HYDRAULIC FILTER...7803
REMOVAL OF HYDRAULIC FILTER...7803
INSTALLATION OF HYDRAULIC FILTER...7803
HYDRAULIC, STEERING PUMP...7804
REMOVAL OF HYDRAULIC, STEERING PUMP...7804
INSTALLATION OF HYDRAULIC, STEERING PUMP...7805
MAIN CONTROL VALVE...7806
REMOVAL OF MAINCONTROL VALVE...7806
INSTALLATION OF MAIN CONTROL VALVE...7808
DISASSEMBLY AND ASSEMBLY OF MAIN CONTROL VALVE...7810
DUMP CYLINDER...7812
REMOVAL OF DUMP CYLINDER...7812
INSTALLATION OF DUMP CYLINDER...7814
LIFT CYLINDER...7815
REMOVAL OF LIFT CYLINDER...7815
INSTALLATION OF LIFT CYLINDER...7816
DUMP CYLINDER...7817
DISASSEMBLY OF DUMP CYLINDER(FOR WA200)...7817
ASSEMBLY OF DUMP CYLINDER (FOR WA200...7819
LIFT CYLINDER...7825
DISASSEMBLY OF LIFT CYLINDER...7825
ASSEMBLY OF LIFT CYLINDER...7827
WORK EQUIPMENT...7830
REMOVAL OF WORK EQUIPMENT...7830
INSTALLATION OF WORK EQUIPPMENT...7833
COUNTERWEIGHT...7836
REMOVAL OF COUNTERWEIGHT...7836
INSTALLATION OF COUNTERWEIGHT...7836
64 MAINTENANCE STANDARD...7838
MAIN CONTROL VALVE...7839
DUMP CYLINDER...7841
LIFT CYLINDER...7842
DUCKET LINKAGE...7843
DUCKET LINKAGE...7847
BUCKET...7848
HYDRAULIC AND STEERING PUMP...7849
80 ELECTRICAL AND ELECTRONIC SYSTEM...7850
81 STRUCTURE AND FUNCTION...7850
ELECTRICAL CIRCUIT DIAGRAM...7851
ENGINE STOP CIRCUIT...7855
PREHATING CIRCUIT...7856
PREHEATING AND AFTER-HEATING WITH HEATER SWITCH...7856
PREHEATING WITH STARTING SWITCH...7857
COMBINATION SWITCH...7858
ELECTRICAL TRANSMISSION CONTROL...7859
TRANSMISSION CUT-OFF SELECTOR SWITCH...7860
NEUTRALIZER RELAY...7861
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS...7862
MONITOR PANEL...7863
INDICATION ON MONITOR PANEL...7865
CONTROLLER...7867
SENSOR...7868
PROXIMITY SWITCH...7875
82 TESTING AND ADJUSTING...7880
ADJUSTING SPEEDOMETER MODULE...7881
TROUBLESHOOTING...7884
83 DISASSEMBLY AND ASSEMBLY...8026
REMOVAL OF MACHINE MONITOR...8027
INSTALLATION OF MACHINE MONITOR...8027
90 OTHERS...8028
91 STRUCTURE AND FUNCTION...8028
CAB...8029
AIR CONDITIONER ...8030
AIR CONDITIONER PIPING...8030
AIR CONDITIONER WIRING DIAGRAM...8031
AIR CONDITIONER ELECTRIC CIRCUIT...8031
AIR CONDITIONER UNIT...8032
AIR CONDITIONER COMPESSOR...8033
AIR CONDITIONER CONDENSOR...8033
AIR CONDITIONER DRY RESERVOIR...8034
93 DISASSEMBLY AND ASSEMBLY...8036
CAB...8037
REMOVAL OF CAB...8037
INSTALLATION OF CAB...8038
AIR CONDITIONER UNIT...8039
REMOVAL OF AIR CONDITIONER UNIT...8039
INSTALLATION OF AIR CONDITIONER UNIT...8041
CONDENSER FOR AIR CONDITIONER...8043
REMOVAL OF CONDENSER FOR AIR CONDITIONER...8043
INSTALLATION OF CONDENSER FOR AIR CONDITIONER...8043
DRY RECEIVER...8044
REMOVAL OF DRY RECEIVER (IF EQUIPPED)...8044
INSTALLATION OF DRY RECEIVER...8044
COMPRESSOR FOR AIR CONDITIONER...8045
REMOVAL OF COMPRESSOR FOR AIR CONDITIONER...8045
INSTALLATION OF COMPRESSOR FOR AIR CONDITIONER...8045
97 GEARPUMP...8046
GENERAL...8047
PRINCIPLE OF OPERATION...8048
PRESSURE LOADED TYPE GEAR PUMP...8051
FIXED SIDE PLATE TYPE GEAR PUMP...8053
SEN06503-05 - Wheel Loader WA200-7 Shop Manual...8072
Cover...8072
00 Index and foreword...8074
Index and foreword...8075
Index...8075
Foreword, safety and general information...8087
Important safety notice...8087
How to read the shop manual...8094
Explanation of terms for maintenance standard...8096
Handling equipment of fuel system devices...8098
Handling of intake system parts...8099
Handling of hydraulic equipment...8100
Method of disconnecting and connecting of push-pull type coupler...8102
Handling of electrical equipment...8105
How to read electric wire code...8113
Precautions when performing operation...8116
Practical use of KOMTRAX...8121
Standard tightening torque table...8122
List of Abbreviation...8128
Conversion table...8132
01 Specifications...8138
Specifications...8141
Specification dimension drawing...8141
Specifications...8143
Weight table...8151
Table of fuel, coolant, and lubricants...8155
10 Structure and function...8158
Engine and cooling system...8161
VFT...8161
EGR system piping drawing...8165
EGR system circuit diagram...8167
EGR valve...8169
EGR cooler...8171
KCCV layout drawing...8173
KCCV ventilator...8176
KDOC muffler...8180
Damper...8182
Cooling system...8183
Cooling system hydraulic piping diagram...8184
Cooling fan motor...8185
Power train...8194
Power train...8194
Power train system diagram...8195
Drive shaft...8197
HST hydraulic piping diagram...8198
HST pump...8199
HST motor...8207
Transfer...8213
Clutch solenoid valve...8219
Axle...8220
Differential...8222
Torque proportioning differential...8225
Limited slip differential...8226
Final drive...8229
Steering system...8232
Steering piping diagram...8232
Orbitrol valve...8233
Steering column...8241
Priority valve...8242
Emergency steering valve...8245
Brake system...8248
Brake piping diagram...8248
Brake valve...8249
Charge valve...8253
Accumulator (for brake)...8257
Slack adjuster...8258
Brake...8260
Parking brake control...8263
Parking brake...8264
Parking brake cylinder...8265
Parking brake solenoid valve...8266
Inching valve...8268
Undercarriage and frame...8269
Axle mount and center hinge pin...8269
Hydraulic system...8271
Hydraulic component layout...8271
Work equipment control lever linkage...8273
Hydraulic tank...8274
Accumulator (for PPC circuit)...8276
Work equipment control valve...8277
PPC valve...8290
Attachment EPC valve...8296
Work equipment lock solenoid valve...8297
ECSS valve...8298
Accumulator (for ECSS)...8300
2-way restrictor valve...8301
Cushion valve...8302
Accumulator (for oil cooler circuit)...8303
Quadruple gear pump...8304
Quick coupler solenoid valve...8305
Work equipment...8306
Work equipment linkage...8306
Bucket...8308
Bucket positioner and boom kick-out...8309
Cab and its attachments...8315
Cab...8315
Electrical system...8316
Machine monitor system...8316
Machine monitor...8321
Electrical system (HST controller system)...8343
System component parts...8359
HST controller...8365
ECSS...8369
KOMTRAX system...8371
Engine starting circuit...8374
Engine stopping circuit...8376
Preheating system...8377
Automatic preheating system...8378
Manual preheating system...8378
Engine output limit function...8379
Automatic warm-up function...8379
Parking brake control system...8380
Multi-function mono-lever...8384
Sensor...8386
20 Standard value table...8402
Standard value table...8404
Standard value table for engine...8404
Standard value table for machine...8406
30 Testing and adjusting...8414
Related information on testing and adjusting...8417
Tools for testing and adjusting...8417
Engine and cooling system...8420
Testing and adjusting engine speed...8420
Testing exhaust gas temperature...8422
Testing exhaust gas color...8423
Testing and adjusting valve clearance...8425
Testing compression pressure...8427
Testing blowby pressure...8430
Testing engine oil pressure...8431
Testing boost pressure...8432
Handling equipment of fuel system devices...8434
Releasing remaining pressure from fuel system...8434
Testing fuel pressure...8435
Testing fuel discharge, return and leakage...8440
Bleeding air from fuel system...8445
Testing fuel circuit for leakage...8447
Handling cylinder cutout mode operation...8448
Handling no-injection cranking operation...8448
Testing KDPF and muffler stack for looseness and damage...8449
Testing KDOC function...8449
Testing installed condition of cylinder heads and manifolds...8450
Testing engine piping for damage and looseness...8450
Testing and adjusting air conditioner compressor belt tension...8451
Replacing alternator belt...8452
Power train...8453
Testing oil leakage from axle final drive...8453
Testing drive shaft for looseness, backlash, and damage...8454
Testing accelerator pedal...8455
Testing and adjusting HST oil pressure...8457
Testing transfer clutch control pressure...8462
Steering system...8463
Testing directional lever...8463
Testing and adjusting steering wheel...8464
Testing work equipment control lever...8466
Testing and adjusting steering circuit oil pressure...8467
Bleeding air from steering circuit...8469
Brake system...8470
Testing brake pedal...8470
Testing and adjusting brake pedal and linkage...8471
Testing braking performance...8472
Testing and adjusting accumulator charge pressure...8473
Testing wheel brake oil pressure...8475
Testing lowering of wheel brake pressure...8476
Testing wear of wheel brake disc...8479
Bleeding air from wheel brake circuit...8480
Releasing remaining pressure in brake accumulator circuit...8481
Testing parking brake performance...8482
Testing parking brake release pressure...8483
Method of releasing parking brake manually...8484
Hydraulic system...8485
Testing and adjusting cooling fan speed...8485
Testing cooling fan pump circuit oil pressure...8486
Testing work equipment PPC oil pressure...8487
Testing and adjusting work equipment oil pressure...8488
Bleeding air from each part...8489
Releasing remaining pressure in hydraulic circuit...8490
Work equipment...8491
Testing and adjusting bucket positioner...8491
Testing and adjusting boom kick-out switch...8492
Checking the proximity switch working pilot lamp...8493
Electrical system...8494
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor...8494
Special functions of machine monitor...8496
KOMTRAX terminal start-up procedure...8550
Lamp indication of KOMTRAX terminal...8553
Handling voltage circuit of controller...8557
Test diodes...8558
Pm Clinic...8559
Pm Clinic service...8559
40 Troubleshooting...8562
Related information on troubleshooting...8569
Points to remember when performing troubleshooting...8569
How to proceed in troubleshooting...8571
Checks before troubleshooting...8573
Check procedure before troubleshooting...8575
Preparation for troubleshooting of electrical system...8593
Classification and procedures of troubleshooting...8598
Symptom and troubleshooting No...8602
Information described in troubleshooting table...8604
Procedure for troubleshooting of open circuit in wiring harness of pressure sensor system...8606
Connector list and layout...8609
Connection table of connector by No. of pins...8622
T-box and T-adapter list...8659
Fuse location table...8663
Failure code list...8666
Troubleshooting by failure code (Display of code)...8674
Failure code [2F00MB] Malfunction of Parking Brake...8674
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front)...8676
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear)...8678
Failure code [6091NX] HST Filter Clogging...8680
Failure code [7RHYKA] Open Circuit of Fan Motor EPC Solenoid Output...8682
Failure code [7RHYKB] Ground Fault of Fan Motor EPC Solenoid Output...8684
Failure code [7RHYKY] Hot Short of Fan Motor EPC Solenoid Output...8686
Failure code [989FN1] Travel Speed Overrun Alarm...8688
Failure code [AB00L6] Discharge of Alternator R Terminal...8689
Failure code [AB00MA] Ground Fault or Open Circuit of Battery Relay Status Signal Line, or Insufficient Battery Charging...8691
Failure code [B@BAZG] Engine Oil Pressure Low...8693
Failure code [B@BCNS] Engine Water Overheat...8694
Failure code [B@BCZK] Engine Coolant Level Low...8695
Failure code [B@C6NS] Front Brake Oil Temperature Overheat (This Alarm)...8697
Failure code [B@CRNS] HST Oil Temperature Overheat...8698
Failure code [CA115] Eng Ne and Bkup Speed Sens Error...8699
Failure code [CA122] Charge Air Pressure Sensor High Error...8700
Failure code [CA123] Charge Air Pressure Sensor Low Error...8702
Failure code [CA131] Throttle Sensor High Error...8704
Failure code [CA132] Throttle Sensor Low Error...8706
Failure code [CA144] Coolant Temperature Sensor High Error...8708
Failure code [CA145] Coolant Temperature Sensor Low Error...8710
Failure code [CA153] Charge Air Temperature Sensor High Error...8712
Failure code [CA154] Chg Air Temp Sensor Low Error...8714
Failure code [CA187] Sensor 2 Supply Voltage Low Error...8716
Failure code [CA221] Ambient Pressure Sensor High Error...8718
Failure code [CA222] Ambient Pressure Sensor Low Error...8720
Failure code [CA227] Sensor 2 Supply Voltage High Error...8722
Failure code [CA234] Engine Overspeed...8723
Failure code [CA238] Ne Speed Sensor Supply Volt Error...8724
Failure code [CA239] Ne Speed Sens Supply Volt High Error...8725
Failure code [CA271] IMV/PCV1 Short Error...8726
Failure code [CA272] IMV/PCV1 Open Error...8728
Failure code [CA322] Injector #1 (L#1) Open/Short Error...8730
Failure code [CA324] Injector #3 (L#3) Open/Short Error...8732
Failure code [CA331] Injector #2 (L#2) Open/Short Error...8734
Failure code [CA332] Injector #4 (L#4) Open/Short Error...8736
Failure code [CA343] Engine Controller Internal Failure...8738
Failure code [CA351] Injectors Drive Circuit Error...8739
Failure code [CA352] Sensor 1 Supply Voltage Low Error...8740
Failure code [CA356] Mass Air Flow Sensor High Error...8742
Failure code [CA357] Mass Air Flow Sensor Low Error...8744
Failure code [CA386] Sensor 1 Supply Voltage High Error...8746
Failure code [CA428] Water in Fuel Sensor High Error...8747
Failure code [CA429] Water in Fuel Sensor Low Error...8749
Failure code [CA431] Idle Validation Sw Error...8751
Failure code [CA432] Idle Validation Process Error...8754
Failure code [CA435] Engine Oil Pressure Sw Error...8756
Failure code [CA441] Battery Voltage Low Error...8757
Failure code [CA442] Battery Voltage High Error...8759
Failure code [CA449] Rail Press Very High Error...8760
Failure code [CA451] Common Rail Pressure Sensor High Error...8761
Failure code [CA452] Common Rail Pressure Sensor Low Error...8763
Failure code [CA466] KVGT Motor Driver Position Error...8765
Failure code [CA488] Chg Air Temp High Torque Derate...8767
Failure code [CA515] Rail Pressure Sensor Sup Volt High Error...8768
Failure code [CA516] Rail Pressure Sensor Sup Volt Low Error...8770
Failure code [CA553] Common Rail Pressure High Error 1...8772
Failure code [CA555] Crankcase Press High Error 1...8773
Failure code [CA556] Crankcase Press High Error 2...8774
Failure code [CA559] Rail Press Low Error 1...8775
Failure code [CA689] Engine Ne Speed Sensor Error...8778
Failure code [CA691] Intake Air Temp Sens High Error...8780
Failure code [CA692] Intake Air Temp Sens Low Error...8782
Failure code [CA697] ECM Internal Temperature Sensor High Error...8784
Failure code [CA698] EMC Internal Temperature Sensor Low Error...8785
Failure code [CA731] Engine Bkup Speed Sensor Phase Error...8786
Failure code [CA778] Engine Bkup Speed Sensor Error...8788
Failure code [CA1117] Persistent Data Lost Error...8793
Failure code [CA1695] Sensor 5 Supply Voltage High Error...8794
Failure code [CA1696] Sensor 5 Supply Voltage Low Error...8795
Failure code [CA1843] Crankcase Press Sens High Error...8796
Failure code [CA1844] Crankcase Press Sens Low Error...8798
Failure code [CA1896] EGR Valve Stuck Error...8800
Failure code [CA1942] Crankcase Press Sens In-Range Error...8801
Failure code [CA1961] EGR Motor Driver IC Over Temp Error...8802
Failure code [CA2185] Throttle Sensor Supply Voltage High Error...8803
Failure code [CA2186] Throttle Sensor Supply Voltage Low Error...8805
Failure code [CA2249] Rail Press Low Error 2...8807
Failure code [CA2272] EGR Valve Position Sensor Low Error...8808
Failure code [CA2311] IMV Solenoid Error...8810
Failure code [CA2349] EGR Valve Solenoid Open Circuit Error...8811
Failure code [CA2353] EGR Valve Solenoid Short Circuit Error...8813
Failure code [CA2357] EGR Valve Servo Error...8815
Failure code [CA2373] Exhaust Manifold Pressure Sensor High Error...8816
Failure code [CA2374] Exhaust Manifold Pressure Sensor Low Error...8818
Failure code [CA2375] EGR Orifice Temperature Sensor High Error...8820
Failure code [CA2376] EGR Orifice Temperature Sensor Low Error...8822
Failure code [CA2554] Exhaust Manifold Pressure Sensor In-Range Error...8824
Failure code [CA2555] Grid Heater Relay Voltage Low Error...8825
Failure code [CA2556] Grid Heater Relay Voltage High Error...8827
Failure code [CA2961] EGR Orifice Temperature High Error 1...8829
Failure code [CA2973] Charge Air Pressure Sensor In-Range Error...8830
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error...8831
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error...8833
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error...8835
Failure code [CA3741] Common Rail Pressure Valve Trip Error...8837
Failure code [CA3918] KVGT Stuck Error...8838
Failure code [CA3919] KVGT Motor Driver IC Over Temperature Error...8839
Failure code [CA3921] KVGT Servo Error 2...8840
Failure code [CA3922] KVGT Motor Driver Open Error...8841
Failure code [CA3923] KVGT Motor Driver Short Error...8843
Failure code [D110L4] Disconnection or Short to Ground of Battery Relay Signal Line...8845
Failure code [D160KA] Disconnection of Backup Lamp Relay Output...8847
Failure code [D160KB] Ground Fault of Backup Lamp Relay Output...8849
Failure code [D160KY] Hot Short of Backup Lamp Relay Output...8851
Failure code [D191KA] Disconnection of Neutral Output Relay...8853
Failure code [D191KB] Ground Fault of Neutral Output Relay...8855
Failure code [D191KY] Hot Short of Neutral Output Relay...8857
Failure code [D192KA] Disconnection of ECSS Solenoid Relay...8859
Failure code [D192KB] Ground Fault of ECSS Solenoid Relay...8861
Failure code [D192KY] Hot Short of ECSS Solenoid Relay...8863
Failure code [D1B0KA] Disconnection of HST Safety Relay...8865
Failure code [D1B0KB] Ground Fault of HST Safety Relay...8867
Failure code [D1B0KY] Hot Short of HST Safety Relay...8869
Failure code [D1B0MC] Malfunction of HST Safety Relay...8871
Failure code [D1E6KA] Disconnection of Parking Brake Relay...8872
Failure code [D1E6KB] Ground Fault of Parking Brake Relay...8874
Failure code [D1E6KY] Hot Short of Parking Brake Relay...8876
Failure code [D5ZHKA] Failure of Key SW C Signal...8878
Failure code [D5ZHKB] Key SW C Signal Hot Short Circuit...8880
Failure code [D5ZHL6] Disconnection of Key SW C...8882
Failure code [DAF3KK] Controller Power Source Low (MON)...8884
Failure code [DAF5KP] 5 V Sensor Power Supply: Ground Fault...8886
Failure code [DAF6KP] 24 V Sensor Power Supply: Ground Fault...8888
Failure code [DAFRKR] Machine Monitor CAN2 Communication Error (Machine Monitor)...8890
Failure code [DAJ0KK] Controller Power Source Low (HST)...8891
Failure code [DAJ0KT] Abnormality of Non-volatile Memory (HST)...8894
Failure code [DAJ0MC] HST Controller Malfunction...8895
Failure code [DAJ1KA] Disconnection of Key SW ACC (HST)...8896
Failure code [DAJ2KK] Solenoid Power Source Low (HST)...8898
Failure code [DAJ4KB] Ground Fault of Solenoid Self-Holding Relay (HST)...8901
Failure code [DAJ4KZ] Failure of Solenoid Self-Holding Relay (HST)...8903
Failure code [DAJ5KX] Failure of 5 V Power Source 0 (HST)...8905
Failure code [DAJ6KX] Failure of 5 V Power Source 1 (HST)...8907
Failure code [DAJ9KQ] Inconsistency of Model Selection (HST)...8909
Failure code [DAJLKA] Operating Lamp Open Circuit (HST)...8910
Failure code [DAJLKB] Operating Lamp Short Circuit (HST)...8912
Failure code [DAJQKR] CAN2 Disconnection (HST)...8914
Failure code [DAJRMA] Inconsistency of Option Selection (HST)...8915
Failure code [DB2QKR] CAN2 Disconnection (Engine Controller)...8916
Failure code [DB2RKR] CAN1 Disconnection (Engine Controller)...8920
Failure code [DBE6KX] 24V Output Power Supply System Failure...8923
Failure code [DD1NL4] Fan Auto Reverse Switch Signal Error...8925
Failure code [DD1NLD] Fan Reverse Switch Signal: Abnormal...8927
Failure code [DDB6L4] Parking Brake Signal Malfunction...8929
Failure code [DDD7KA] Failure of Variable Speed Control...8931
Failure code [DDD7KY] Hot Short of Variable Speed Control...8933
Failure code [DDE5MA] Disconnection of Steering Oil Pressure Switch (Emergency Steering Control Switch)...8935
Failure code [DDK3KA] FNR SW Input Signal Disconnection...8937
Failure code [DDK3KB] FNR SW Input Signal Short Circuit...8939
Failure code [DDK6KA] FNR Lever Input Signal Disconnection...8941
Failure code [DDK6KY] FNR Lever Input Signal Disconnection (Hot Short)...8943
Failure code [DDNRLD] Ground Fault of Work Equipment Lock Switch...8945
Failure code [DDS5L6] Low Steering Oil Pressure (Emergency Steering Control)...8947
Failure code [DF10KA] Disconnection of Speed Range Input Switch...8949
Failure code [DF10KB] Disconnection of Speed Range Selector Switch (Hot Short)...8954
Failure code [DGH1KX] HST Oil Temperature Sensor Short to Ground...8959
Failure code [DGR2KB] Ground Fault of Brake Oil Temperature Sensor...8961
Failure code [DGR2KZ] Failure of Brake Oil Temperature Sensor...8963
Failure code [DHH1KX] Failure of HST Oil Pressure Sensor...8965
Failure code [DHH1KY] Hot Short of HST Oil Pressure Sensor...8967
Failure code [DHPCKX] Failure of Boom Pressure Sensor (Bottom)...8969
Failure code [DHPDKX] Failure of Boom Pressure Sensor (Head)...8971
Failure code [DHTCL6] HST Oil Filter Clogging Detection Failure...8973
Failure code [DJF1KA] Disconnection or Hot Short Circuit of Fuel Level Sensor...8975
Failure code [DK5DKA] Failure of 3rd Lever Potentiometer Sensor (Main)...8977
Failure code [DK5DKY] Hot Short of 3rd Lever Potentiometer Sensor (Main)...8980
Failure code [DK5DL8] 3rd Lever Potentiometer Sensor (Main & Sub) Disagree...8982
Failure code [DK5EKA] Failure of 3rd Lever Potentiometer Sensor (Sub)...8985
Failure code [DK5EKY] Hot Short of 3rd Lever Potentiometer Sensor (Sub)...8988
Failure code [DKA0KX] Failure of Boom Angle Sensor...8990
Failure code [DLM3KA] Failure of Cooling Fan Speed Sensor...8992
Failure code [DLM3LC] Ground Fault of Cooling Fan Speed Sensor...8994
Failure code [DLT3KX] Vehicle Speed Sensor Circuit Failure (B)...8995
Failure code [DLT4KX] Vehicle Speed Sensor Circuit Failure (A)...8997
Failure code [DLT4L0] Vehicle Speed Sensor Failure (A & B)...8999
Failure code [DLT4LC] Vehicle Speed Sensor Failure (A or B)...9002
Failure code [DT22KB] Ground Fault of Work Equip. Lock Indicator...9004
Failure code [DV00KY] Hot Short of Alarm Buzzer...9006
Failure code [DW26KA] Open Circuit of Motor 2 Solenoid...9008
Failure code [DW26KB] Ground Fault of Motor 2 Solenoid...9010
Failure code [DW26KY] Hot Short of Motor 2 Solenoid...9012
Failure code [DW44KA] Open Circuit of Directional Pressure Selection Solenoid...9014
Failure code [DW44KB] Ground Fault of Directional Pressure Selection Solenoid...9016
Failure code [DW44KY] Hot Short of Directional Pressure Selection Solenoid...9018
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid...9020
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid...9022
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid...9024
Failure code [DX19KA] Disconnection of Motor 1 Solenoid...9026
Failure code [DX19KB] Ground Fault of Motor 1 Solenoid...9029
Failure code [DX19KY] Hot Short of Motor 1 Solenoid...9031
Failure code [DX20KA] Disconnection of Clutch EPC Solenoid...9033
Failure code [DX20KB] Ground Fault of Clutch EPC Solenoid...9036
Failure code [DX20KY] Hot Short of Clutch EPC Solenoid...9038
Failure code [DXH7KA] Disconnection of Reverse Solenoid...9040
Failure code [DXH7KB] Ground Fault of Reverse Solenoid...9042
Failure code [DXH7KY] Hot Short of Reverse Solenoid...9044
Failure code [DXH8KA] Disconnection of Forward Solenoid...9045
Failure code [DXH8KB] Ground Fault of Forward Solenoid...9047
Failure code [DXH8KY] Hot Short of Forward Solenoid...9049
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT)...9050
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT)...9052
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT)...9054
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET)...9055
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET)...9057
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET)...9059
Failure code [H2K0KA] Failure of Quick Coupler Lock Signal...9060
Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal...9063
Failure code [J141N1] Steering Pump Over Run...9065
Failure code [LA00L3] Failure of Fan Reverse...9066
Failure code [M100N1] HST Pump Over Run...9067
Failure code [M400N1] HST Motor 1 Over Run...9068
Troubleshooting of electrical system (E-mode)...9069
E-1 Engine does not start...9069
E-2 Manual preheating system does not work...9074
E-3 Automatic preheating system does not work...9077
E-4 While preheating is working, preheating monitor does not light up...9079
E-5 When starting switch is turned to ON position, nothing is displayed on machine monitor...9081
E-6 Travel speed is slow...9084
E-7 ECSS does not operate...9086
E-8 ECSS remains being operated...9089
E-9 Boom kick-out does not work or is not reset...9092
E-10 Bucket positioner does not work or is not reset...9095
E-11 Boom FLOAT holding does not work or is not reset...9098
E-12 Directional selection does not work normally...9101
E-13 Fan does not rotate in reverse...9112
E-14 Fan remains in reverse rotation mode...9115
E-15 Wipers do not operate...9117
E-16 Window washer does not operate...9122
E-17 Headlamp, clearance lamp, tail lamp or license-plate lamp does not light up or does not go out...9125
E-18 Working lamp does not light up or does not go out...9134
E-19 Turn signal and hazard lamp do not light up or do not go out...9139
E-20 Stop lamp does not light up or remains lighting up...9146
E-21 Backup lamp does not light up or remains lighting up...9149
E-22 Backup alarm does not sound or does not stop sounding...9152
E-23 Horn does not sound or does not stop sounding...9154
E-24 Alarm buzzer does not sound or does not stop sounding...9157
E-25 KOMTRAX system does not operate normally...9159
E-26 Fuel gauge does not indicate correct level...9161
E-27 Seat belt caution lamp indication is incorrect...9163
Troubleshooting for hydraulic and mechanical system (H-mode)...9164
Information described in troubleshooting table (H-mode)...9164
System chart of hydraulic and mechanical systems...9165
Failure mode and cause table...9167
H-1 Machine travels neither forward nor in reverse...9173
H-2 Machine does not travel forward (normally travels in reverse)...9175
H-3 Machine does not travel in reverse (normally travels forward)...9176
H-4 Both forward and reverse travel speeds are low...9177
H-5 Forward travel speed is low (normal when traveling in reverse)...9179
H-6 Reverse travel speed is low (normal when traveling forward)...9180
H-7 Machine lacks power when traveling both forward and in reverse...9181
H-8 Machine lacks power when traveling forward (normal when traveling in reverse)...9183
H-9 Machine lacks power when traveling in reverse (normal when traveling forward)...9184
H-10 Engine stalls during travel or engine speed drops significantly...9185
H-11 Machine does not turn...9186
H-12 Steering wheel is heavy to turn...9188
H-13 Machine sways or large shocks are made while machine turns...9189
H-14 Machine turns to either side unintentionally during traveling...9190
H-15 Brake does not work or it is weak...9191
H-16 Brake is not released or drags...9192
H-17 Parking brake does not work or it is weak...9193
H-18 Parking brake is not released or drags...9194
H-19 Boom does not rise...9195
H-20 Boom moves slow or lacks lifting force...9196
H-21 Boom rising speed lowers at certain height...9197
H-22 Lift cylinder cannot hold down bucket (bucket rises off ground)...9198
H-23 Hydraulic drift of boom is large...9199
H-24 Boom wobbles during operation...9203
H-25 Bucket does not tilt back...9204
H-26 Bucket moves slow or lacks tilting back force...9205
H-27 Bucket speed lowers in tilt-back motion...9206
H-28 Bucket cylinder cannot hold down bucket (bucket rises off ground)...9207
H-29 Hydraulic drift of bucket is large...9208
H-30 Loaded bucket wobbles during travel (with work equipment valve at "HOLD")...9209
H-31 Boom and bucket control levers do not move smoothly and are heavy to move...9210
H-32 Engine speed lowers remarkably or engine stalls while work equipment is operated...9211
H-33 Large shock is made when work equipment starts and stops...9212
H-34 When certain work equipment is relieved hydraulically, other work equipment moves...9213
H-35 ECSS does not operate and machine pitches and bounds...9214
H-36 Fan speed is abnormal (too high or low, or fan does not rotate)...9215
H-37 Unusual noise is heard from around fan...9217
Troubleshooting of engine (S-mode)...9218
Information mentioned in troubleshooting table (S mode)...9218
S-1 Engine does not crank when starting switch is turned to START position...9219
S-2 Engine cranks but no exhaust smoke comes out...9220
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start)...9221
S-4 Engine startability is poor...9222
S-5 Engine does not pick up smoothly...9224
S-6 Engine stops during operation...9226
S-7 Engine runs rough or is unstable...9227
S-8 Engine lacks power...9228
S-9 Exhaust smoke is black...9230
S-10 Engine oil consumption is excessive...9232
S-11 Oil becomes contaminated quickly...9233
S-12 Fuel consumption is excessive...9234
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...9235
S-14 Oil pressure drops...9236
S-15 Fuel mixes into engine oil...9237
S-16 Water mixes into engine oil (milky)...9238
S-17 Coolant temperature rises too high (overheating)...9239
S-18 Unusual noise is heard...9240
S-19 Vibration is excessive...9241
S-20 Air cannot be bled from fuel circuit...9242
50 Disassembly and assembly...9244
General information on disassembly and assembly...9247
How to read this manual...9247
Coating materials list...9249
Special tool list...9253
Sketches of special tools...9257
Engine and cooling system...9267
Removal and installation of fuel supply pump assembly...9267
Removal and installation of fuel injector assembly...9271
Removal and installation of engine hood assembly...9279
Removal and installation of cylinder head assembly...9282
Removal and installation of radiator assembly...9293
Removal and installation of air aftercooler assembly...9296
Removal and installation of hydraulic oil cooler assembly...9298
Removal and installation of engine assembly...9300
Removal and installation of belt for alternator and air conditioner compressor...9305
Removal and installation of engine front oil seal assembly...9307
Removal and installation of engine rear oil seal assembly...9311
Removal and installation of cooling fan and fan motor assembly...9315
Removal and installation of fuel tank assembly...9318
Removal and installation of KCCV ventilator assembly...9320
Removal and installation of KDOC muffler...9321
Removal and installation of EGR cooler assembly...9322
Removal and installation of EGR valve assembly...9324
Power train...9326
Removal and installation of transfer assembly...9326
Disassembly and assembly of transfer assembly...9330
Removal and installation of parking brake assembly...9353
Removal and installation of parking brake cylinder assembly...9355
Disassembly and assembly of parking brake assembly...9356
Removal and installation of front axle assembly...9362
Removal and installation of rear axle assembly...9364
Disassembly and assembly of axle housing assembly...9367
Disassembly and assembly of differential assembly...9376
Undercarriage and frame...9401
Removal and installation of center hinge pin...9401
Removal and installation of counterweight assembly...9410
Hydraulic system...9413
Removal and installation of HST pump and quadruple type gear pump assembly...9413
Removal and installation of HST motor 1 assembly...9417
Removal and installation of HST motor 2 assembly...9419
Removal and installation of work equipment control valve assembly...9422
Removal and installation of ECSS (Electronically Controlled Suspension System) valve assembly...9424
Removal and installation of hydraulic tank assembly...9426
Disassembly and assembly of hydraulic cylinder assembly...9428
Work equipment...9432
Removal and installation of work equipment assembly...9432
Cab and its attachments...9438
Removal and installation of operator's cab and floor frame assembly...9438
Removal and installation of operator's cab glass (adhered glass)...9443
Disassembly and assembly of operator's seat...9451
Removal and installation of air conditioner unit assembly...9461
Removal and installation of air conditioner compressor assembly...9467
Electrical system...9469
Removal and installation of machine monitor...9469
Removal and installation of engine controller assembly...9471
Removal and installation of HST controller assembly...9473
Removal and installation of KOMTRAX terminal assembly...9474
60 Maintenance standard...9476
Engine and cooling system...9478
Engine mount and transfer mount...9478
Damper...9479
Cooling system...9480
Cooling fan motor...9481
Power train...9483
Drive shaft...9483
Transfer...9484
Axle...9492
Differential...9494
Limited slip differential...9498
Final drive...9500
Steering system...9503
Orbitrol valve...9503
Steering cylinder...9504
Steering column...9506
Priority valve...9507
Emergency steering valve...9508
Brake system...9509
Charge valve...9509
Slack adjuster...9511
Brake...9512
Parking brake...9514
Undercarriage and frame...9515
Axle mount and center hinge pin...9515
Hydraulic system...9519
Hydraulic tank...9519
Work equipment control valve...9520
PPC valve...9526
ECSS valve...9529
Quadruple gear pump...9530
Work equipment...9532
Work equipment linkage...9532
Bucket...9534
Bucket positioner and boom kick-out...9535
Work equipment cylinder...9536
80 Appendix...9538
Air conditioner...9540
Precautions for refrigerant...9540
Air conditioner component...9541
Configuration and function of refrigeration cycle...9543
Outline of refrigeration cycle...9544
Air conditioner unit...9546
Functions of main components in air conditioner unit...9547
Blower and intake unit...9548
Compressor...9549
Condenser...9550
Receiver drier...9551
Air conditioner control panel...9552
Procedure for troubleshooting...9553
Circuit diagram and arrangement of connector pins...9555
System diagram...9557
Details of air conditioner unit...9559
Parts and connectors layout...9560
Inspection by self-diagnosis function (displays diagnosis on the control panel)...9562
Testing temperature control system...9563
Testing FRESH/RECIRC air changeover...9564
Testing evaporator temperature sensor...9566
Testing relays...9567
Troubleshooting chart 1...9568
Troubleshooting chart 2...9570
Information described in troubleshooting table...9573
Troubleshooting for power supply system (Air conditioner does not operate)...9574
Troubleshooting for compressor and refrigerant system (Air is not cooled)...9578
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)...9581
Troubleshooting for temperature control...9584
Troubleshooting for FRESH/RECIRC air changeover...9587
Connection of service tool...9589
Troubleshooting by gauge pressure...9591
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit...9594
Handling of compressor oil...9596
90 Diagrams and drawings...9600
Hydraulic diagrams and drawings...9602
Symbols used in hydraulic circuit diagrams...9602
Hydraulic circuit diagram...9604
Electrical diagrams and drawings...9605
Symbols used in electric circuit diagrams...9605
Electrical circuit diagram...9609
Index...9624
SEN06627-03 - Wheel Loader WA200-8 Shop Manual...9634
COVER...9634
00 INDEX AND FOREWORD...9636
INDEX...9637
ABBREVIATION LIST...9654
FOREWORD, SAFETY, BASIC INFORMATION...9660
HOW TO READ THE SHOP MANUAL...9660
SAFETY NOTICE FOR OPERATION...9662
PRECAUTIONS TO PREVENT FIRE...9670
ACTIONS IF FIRE OCCURS...9672
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS...9673
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS...9674
PRECAUTIONS FOR DEF...9675
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING...9675
PRECAUTIONS FOR ADDING...9675
PRECAUTIONS FOR STORING...9675
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE...9675
THE OTHER PRECAUTIONS...9675
STORE AdBlue/DEF...9676
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT...9677
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS...9680
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT...9687
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT...9689
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT...9690
PRACTICAL USE OF KOMTRAX...9691
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER...9692
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER...9692
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER...9693
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER...9694
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS...9696
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR...9700
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR...9701
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL...9703
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH...9704
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE...9706
HOW TO READ ELECTRICAL WIRE CODE...9707
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD...9711
STANDARD TIGHTENING TORQUE TABLE...9714
CONVERSION TABLE...9721
01 SPECIFICATIONS...9726
CONTENTS...9727
ABBREVIATION LIST...9728
SPECIFICATIONS...9734
SPECIFICATION DRAWING...9734
SPECIFICATION DRAWING: WA200-8...9734
SPECIFICATIONS...9736
SPECIFICATIONS: WA200-8...9736
WEIGHT TABLE...9742
WEIGHT TABLE: WA200-8...9742
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA)...9744
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...9744
FUEL, COOLANT, LUBRICANTS (FOR EUROPEAN UNION)...9746
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...9746
10 STRUCTURE AND FUNCTION...9748
CONTENTS...9749
ABBREVIATION LIST...9753
UREA SCR SYSTEM...9759
LAYOUT DRAWING OF UREA SCR SYSTEM...9759
UREA SCR SYSTEM DIAGRAM...9761
FUNCTION OF UREA SCR SYSTEM...9762
FUNCTION OF AdBlue/DEF SYSTEM...9762
INDUCEMENT STRATEGY...9765
COMPONENT PARTS OF UREA SCR SYSTEM...9779
AdBlue/DEF MIXING TUBE...9779
SCR ASSEMBLY...9780
AdBlue/DEF TANK...9782
AdBlue/DEF PUMP...9784
AdBlue/DEF INJECTOR...9785
AdBlue/DEF HOSE...9786
AdBlue/DEF TANK HEATING VALVE...9787
BOOT-UP SYSTEM...9788
LAYOUT DRAWING OF BOOT-UP SYSTEM...9788
SYSTEM OPERATING LAMP SYSTEM...9790
SYSTEM OPERATING LAMP SYSTEM DIAGRAM...9790
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM...9790
BATTERY DISCONNECT SWITCH...9791
FUNCTION OF BATTERY DISCONNECT SWITCH...9791
PREHEATING SYSTEM...9792
PREHEATING SYSTEM DIAGRAM...9792
FUNCTION OF AUTOMATIC PREHEATING SYSTEM...9792
OPERATION OF AUTOMATIC PREHEATING SYSTEM...9792
FUNCTION OF MANUAL PREHEATING SYSTEM...9793
OPERATION OF MANUAL PREHEATING SYSTEM...9793
ENGINE SYSTEM...9794
LAYOUT DRAWING OF ENGINE SYSTEM...9794
FUNCTION OF ENGINE SYSTEM...9795
ENGINE CONTROL SYSTEM...9796
ENGINE CONTROL SYSTEM DIAGRAM...9796
FUNCTION OF ENGINE CONTROL SYSTEM...9798
OPERATION OF ENGINE CONTROL SYSTEM...9801
AUTOMATIC IDLE STOP SYSTEM...9803
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM...9803
COMPONENT PARTS OF ENGINE SYSTEM...9804
DAMPER...9804
VGT...9805
EGR SYSTEM...9808
EGR VALVE...9810
EGR COOLER...9812
KCCV SYSTEM...9814
KCCV VENTILATOR...9816
KDOC...9818
COOLING SYSTEM...9821
LAYOUT DRAWING OF COOLING SYSTEM...9821
SPECIFICATIONS OF COOLING SYSTEM...9822
COOLING FAN CONTROL SYSTEM...9823
COOLING FAN CONTROL SYSTEM DIAGRAM...9823
FUNCTION OF COOLING FAN CONTROL SYSTEM...9823
COMPONENT PARTS OF COOLING SYSTEM...9828
COOLING FAN MOTOR...9828
HYDRAULIC OIL COOLER BYPASS VALVE...9838
CONTROL SYSTEM...9839
LAYOUT DRAWING OF CONTROL SYSTEM...9839
MACHINE MONITOR SYSTEM...9841
MACHINE MONITOR SYSTEM DIAGRAM...9841
FUNCTION OF MACHINE MONITOR SYSTEM...9841
REARVIEW MONITOR SYSTEM...9843
REARVIEW MONITOR SYSTEM DIAGRAM...9843
FUNCTION OF REARVIEW MONITOR SYSTEM...9843
KOMTRAX SYSTEM...9844
KOMTRAX SYSTEM DIAGRAM...9844
FUNCTION OF KOMTRAX SYSTEM...9844
COMPONENT PARTS OF CONTROL SYSTEM...9845
MACHINE MONITOR...9845
SWITCH PANEL...9862
REARVIEW MONITOR...9863
REARVIEW CAMERA...9865
KOMTRAX TERMINAL...9866
MONITOR CONTROLLER...9868
HST CONTROLLER...9873
CAN TERMINATING RESISTOR...9877
ENGINE CONTROLLER...9878
ACCELERATOR PEDAL...9885
HYDRAULIC SYSTEM...9887
LAYOUT DRAWING OF HYDRAULIC SYSTEM...9887
COMPONENT PARTS OF HYDRAULIC SYSTEM...9888
HYDRAULIC TANK...9888
HYDRAULIC OIL FILTER...9890
STEERING, WORK EQUIPMENT, BRAKE AND COOLING FAN, AND TRANSFER LUBRICATION PUMP...9891
CONTROL VALVE...9893
POWER TRAIN SYSTEM...9914
LAYOUT DRAWING OF POWER TRAIN SYSTEM...9914
OPERATION OF POWER TRAIN SYSTEM...9916
DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION...9917
HST CONTROL SYSTEM...9919
HST CONTROL SYSTEM DIAGRAM...9919
ENGINE OVERRUN PREVENTION FUNCTION...9920
NEUTRALIZER FUNCTION...9920
SECONDARY HST TRAVEL FUNCTION...9920
HST CHARGE SYSTEM...9921
SYSTEM DIAGRAM OF HST CHARGE SYSTEM...9921
FUNCTION OF HST CHARGE SYSTEM...9921
HST PUMP CONTROL SYSTEM...9922
SYSTEM DIAGRAM OF HST PUMP CONTROL SYSTEM...9922
DIRECTIONAL SELECTION FUNCTION...9922
INCHING CONTROL FUNCTION...9922
TRAVEL SPEED ADJUSTMENT FUNCTION (AT LOW SPEED)...9923
HST CONTROLLER GEAR SHIFT CONTROL FUNCTION...9924
GEAR SHIFT FUNCTION...9924
GEAR SHIFT DISPLAY FUNCTION...9926
TRAVEL SPEED ADJUSTMENT FUNCTION...9926
TRANSFER CLUTCH CONTROL FUNCTION...9927
HST SYSTEM PROTECTION FUNCTION...9928
DIRECTION PROTECTION FUNCTION...9928
HST MOTOR 1 OVERRUN PREVENTION FUNCTION 1...9928
HST MOTOR 1 OVERRUN PREVENTION FUNCTION 2...9929
TRAVEL SPEED LIMITATION FUNCTION...9929
KOMATSU TRACTION CONTROL SYSTEM (KTCS)...9930
KOMATSU TRACTION CONTROL SYSTEM (KTCS) DIAGRAM...9930
FUNCTION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS)...9930
COMPONENT PARTS OF POWER TRAIN SYSTEM...9934
DRIVE SHAFT...9934
HST PUMP...9936
HST CHARGE PUMP...9944
HST MOTOR...9946
TRANSFER...9955
AXLE...9963
TORQUE PROPORTIONING DIFFERENTIAL...9965
LIMITED SLIP DIFFERENTIAL...9969
FINAL DRIVE...9973
COMBINATION SWITCH...9975
WORK EQUIPMENT SYSTEM...9979
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM...9979
WORK EQUIPMENT CONTROL SYSTEM...9981
WORK EQUIPMENT LEVER OPERATION FUNCTION...9981
WORK EQUIPMENT LOCK SYSTEM...9982
WORK EQUIPMENT LOCK SYSTEM DIAGRAM...9982
FUNCTION OF WORK EQUIPMENT LOCK SYSTEM...9982
BUCKET POSITIONER SYSTEM...9984
BUCKET POSITIONER SYSTEM DIAGRAM...9984
FUNCTION OF BUCKET POSITIONER SYSTEM...9984
OPERATION OF BUCKET POSITIONER SYSTEM...9985
BOOM KICK-OUT SYSTEM...9987
SYSTEM DRAWING OF BOOM KICK-OUT SYSTEM...9987
FUNCTION OF BOOM KICK-OUT SYSTEM...9987
OPERATION OF BOOM KICK-OUT SYSTEM...9988
ECSS...9990
ECSS DIAGRAM...9990
FUNCTION OF ECSS...9990
OPERATION OF ECSS...9990
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM...9992
WORK EQUIPMENT LOCK SOLENOID VALVE...9992
ATTACHMENT EPC SOLENOID VALVE...9993
PILOT CIRCUIT ACCUMULATOR...9994
ECSS CIRCUIT ACCUMULATOR...9995
MULTIFUNCTION MONO-LEVER...9996
MULTIFUNCTION MONO-LEVER PPC VALVE...9998
QUICK COUPLER SOLENOID VALVE...10003
STEERING SYSTEM...10004
LAYOUT DRAWING OF STEERING SYSTEM...10004
STEERING COLUMN...10005
STRUCTURE OF STEERING COLUMN...10005
COMPONENT PARTS OF STEERING SYSTEM...10006
PRIORITY VALVE...10006
ORBITROL VALVE...10009
CUSHION VALVE...10016
2-WAY RESTRICTOR VALVE...10018
SECONDARY STEERING VALVE...10019
BRAKE SYSTEM...10022
LAYOUT DRAWING OF BRAKE SYSTEM...10022
PARKING BRAKE CONTROL SYSTEM...10024
PARKING BRAKE CONTROL SYSTEM DIAGRAM...10024
OPERATION OF PARKING BRAKE CONTROL SYSTEM...10024
COMPONENT PARTS OF BRAKE SYSTEM...10027
BRAKE CIRCUIT ACCUMULATOR CHARGE VALVE...10027
PARKING BRAKE SOLENOID VALVE...10031
BRAKE CIRCUIT ACCUMULATOR...10033
BRAKE VALVE...10035
SLACK ADJUSTER...10039
BRAKE...10041
PARKING BRAKE...10044
PARKING BRAKE CYLINDER...10045
UNDERCARRIAGE AND FRAME...10046
FRAME, AXLE MOUNT AND CENTER HINGE PIN...10046
STRUCTURE OF FRAME, AXLE MOUNT AND CENTER HINGE PIN...10046
FUNCTION OF FRAME, AXLE MOUNT AND CENTER HINGE PIN...10047
TIRE...10049
FEATURES OF RADIAL TIRE WHEN COMPARED WITH BIAS TIRE...10049
STRUCTURE OF RADIAL TIRE...10049
FUNCTION OF RADIAL TIRE...10049
STRUCTURE OF BIAS TIRE...10050
FUNCTION OF BIAS TIRE...10050
WORK EQUIPMENT...10051
STRUCTURE OF WORK EQUIPMENT...10051
STRUCTURE OF BUCKET...10052
CAB AND ITS ATTACHMENTS...10053
ROPS CAB...10053
STRUCTURE OF ROPS CAB...10053
FUNCTION OF ROPS CAB...10053
CAB MOUNT...10054
STRUCTURE OF CAB MOUNT...10054
FUNCTION OF CAB MOUNT...10054
20 STANDARD VALUE TABLE...10056
CONTENTS...10057
ABBREVIATION LIST...10058
STANDARD VALUE TABLE FOR ENGINE...10064
STANDARD VALUE TABLE FOR ENGINE: WA200-8...10064
STANDARD VALUE TABLE FOR MACHINE...10069
STANDARD VALUE TABLE FOR MACHINE: WA200-8...10069
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE...10081
30 TESTING AND ADJUSTING...10084
CONTENTS...10085
ABBREVIATION LIST...10088
RELATED INFORMATION ON TESTING AND ADJUSTING...10094
TOOLS FOR TESTING AND ADJUSTING...10094
ENGINE AND COOLING SYSTEM...10102
TEST ENGINE SPEED...10102
METHOD FOR TESTING ENGINE SPEED...10102
TEST BOOST PRESSURE...10105
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR...10105
METHOD FOR TESTING BOOST PRESSURE BY TESTING TOOL...10106
TEST EXHAUST GAS COLOR...10108
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER...10108
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER...10109
TEST AND ADJUST VALVE CLEARANCE...10111
METHOD FOR TESTING VALVE CLEARANCE...10111
METHOD FOR ADJUSTING VALVE CLEARANCE...10112
TEST COMPRESSION PRESSURE...10114
METHOD FOR TESTING COMPRESSION PRESSURE...10114
TEST BLOWBY PRESSURE...10119
METHOD FOR TESTING BLOWBY PRESSURE...10119
TEST ENGINE OIL PRESSURE...10122
METHOD FOR TESTING ENGINE OIL PRESSURE...10122
TEST FUEL PRESSURE...10124
METHOD FOR TESTING FUEL PRESSURE...10125
TEST FUEL DISCHARGE, RETURN AND LEAKAGE...10129
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE...10130
BLEED AIR FROM FUEL SYSTEM...10135
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM...10135
TEST FUEL CIRCUIT FOR LEAKAGE...10137
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE...10137
HANDLE CYLINDER CUT-OUT MODE OPERATION...10139
HANDLE NO-INJECTION CRANKING OPERATION...10140
TEST KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE...10141
METHOD FOR TESTING KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE...10141
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS...10142
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS...10142
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS...10143
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS...10143
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION...10144
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT...10144
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT...10144
TEST ALTERNATOR BELT...10146
METHOD FOR TESTING ALTERNATOR BELT...10146
TEST AUTOMATIC TENSIONER...10148
METHOD FOR TESTING AUTOMATIC TENSIONER...10148
TEST SCR RELATED FUNCTIONS...10151
TEST AdBlue/DEF PUMP RAISED PRESSURE...10155
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR...10158
TEST AdBlue/DEF LINE HEATER RELAY 1...10164
TEST AdBlue/DEF LINE HEATER RELAY 2...10168
TEST AdBlue/DEF PUMP HEATER RELAY...10172
TEST AdBlue/DEF TANK HEATER VALVE...10176
TEST SCR NOx REMOVAL EFFICIENCY...10180
CLEAN AdBlue/DEF TANK...10183
METHOD FOR CLEANING AdBlue/DEF TANK...10183
POWER TRAIN...10188
TEST AND ADJUST HST OIL PRESSURE...10188
METHOD FOR TESTING HST OIL PRESSURE...10188
METHOD FOR ADJUSTING HST OIL PRESSURE...10191
TEST THE CONTROL PRESSURE OF TRANSFER CLUTCH...10193
METHOD FOR TESTING THE CONTROL PRESSURE OF TRANSFER CLUTCH...10193
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE...10195
METHOD FOR TESTING DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE...10195
STEERING SYSTEM...10196
TEST STEERING WHEEL...10196
METHOD FOR TESTING STEERING WHEEL...10196
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE...10198
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE...10198
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE...10199
BLEED AIR FROM STEERING CYLINDER CIRCUIT...10201
METHOD FOR BLEEDING AIR FROM STEERING CYLINDER CIRCUIT...10201
BRAKE SYSTEM...10202
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT...10202
METHOD FOR RELEASING REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT...10202
TEST WHEEL BRAKE OIL PRESSURE...10203
METHOD FOR TESTING WHEEL BRAKE OIL PRESSURE...10203
TEST AND ADJUST BRAKE ACCUMULATOR CHARGE PRESSURE...10205
METHOD FOR TESTING BRAKE ACCUMULATOR CHARGE PRESSURE...10205
METHOD FOR ADJUSTING BRAKE ACCUMULATOR CHARGE PRESSURE...10206
BLEED AIR FROM BRAKE CIRCUIT...10207
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT...10207
TEST BRAKING PERFORMANCE...10208
METHOD FOR TESTING BRAKING PERFORMANCE...10208
TEST BRAKE PEDAL...10209
METHOD FOR TESTING BRAKE PEDAL...10209
TEST AND ADJUST BRAKE PEDAL AND LINKAGE...10210
METHOD FOR TESTING BRAKE PEDAL AND LINKAGE...10210
METHOD FOR ADJUSTING BRAKE PEDAL AND LINKAGE...10210
TEST LOWERING OF WHEEL BRAKE PRESSURE...10211
METHOD FOR TESTING LOWERING OF WHEEL BRAKE PRESSURE...10212
TEST WEAR OF WHEEL BRAKE DISC...10214
METHOD FOR TESTING WEAR OF WHEEL BRAKE DISC...10214
TEST PARKING BRAKE OIL PRESSURE...10216
METHOD FOR TESTING PARKING BRAKE OIL PRESSURE...10216
TEST PARKING BRAKE PERFORMANCE...10218
METHOD FOR TESTING PARKING BRAKE PERFORMANCE...10218
RELEASE PARKING BRAKE MANUALLY...10219
METHOD FOR RELEASING PARKING BRAKE MANUALLY...10219
HYDRAULIC SYSTEM...10220
RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT...10220
METHOD FOR RELEASING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT...10220
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE...10222
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURE...10222
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURE...10223
TEST WORK EQUIPMENT PPC OIL PRESSURE...10225
METHOD FOR TESTING WORK EQUIPMENT PPC OIL PRESSURE...10225
BLEED AIR FROM WORK EQUIPMENT PPC CIRCUIT...10227
METHOD FOR BLEEDING REMAINING PRESSURE FROM WORK EQUIPMENT PPC CIRCUIT...10227
TEST COOLING FAN SPEED...10228
METHOD FOR TESTING COOLING FAN SPEED...10228
TEST COOLING FAN CIRCUIT OIL PRESSURE...10229
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE...10229
BLEED AIR FROM COOLING FAN CIRCUIT...10231
METHOD FOR BLEEDING AIR FROM COOLING FAN CIRCUIT...10231
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GAS...10233
METHOD FOR TESTING ECSS ACCUMULATOR NITROGEN GAS PRESSURE...10233
METHOD FOR CHARGING ECSS ACCUMULATOR WITH NITROGEN GAS...10235
WORK EQUIPMENT...10238
TEST AND ADJUST BUCKET POSITIONER...10238
METHOD FOR TESTING BUCKET POSITIONER...10238
METHOD FOR ADJUSTING BUCKET POSITIONER...10238
CAB AND ITS ATTACHMENTS...10240
TEST DIRECTIONAL LEVER...10240
METHOD FOR TESTING DIRECTIONAL LEVER...10240
TEST MULTIFUNCTION MONO-LEVER...10241
METHOD FOR TESTING MULTIFUNCTION MONO-LEVER...10241
TEST ACCELERATOR PEDAL...10243
METHOD FOR TESTING ACCELERATOR PEDAL...10243
ELECTRICAL SYSTEM...10245
SET AND ADJUST EACH EQUIPMENT...10245
SET AND OPERATE MACHINE MONITOR...10247
OPERATOR MODE...10251
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN...10251
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN...10251
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)...10252
CHECKING FUNCTION OF SERVICE METER AND ODOMETER...10253
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD...10253
SERVICE MODE...10257
METHOD FOR OPERATING SERVICE MODE...10257
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION...10259
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION...10265
ABNORMALITY RECORD MENU...10277
METHOD FOR CONFIRMING MAINTENANCE RECORD...10282
METHOD FOR OPERATING MAINTENANCE MODE SETTING...10284
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING...10289
DEFAULT MENU...10291
DIAGNOSTIC TESTS MENU...10305
ADJUSTMENT MENU...10313
METHOD FOR PERFORMING NO-INJECTION CRANKING...10333
KOMTRAX SETTINGS MENU...10335
METHOD FOR DISPLAYING SERVICE MESSAGE...10337
METHOD FOR STARTING UP KOMTRAX TERMINAL...10339
ADJUST REARVIEW CAMERA ANGLE...10344
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE...10344
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER...10346
HANDLE BATTERY DISCONNECT SWITCH...10347
TEST DIODES...10348
METHOD FOR TESTING DIODE USING DIGITAL TESTER...10348
METHOD FOR TESTING DIODE USING ANALOG TESTER...10348
Pm CLINIC...10349
Pm CLINIC SERVICE...10349
Pm CLINIC CHECK SHEET: WA200-8...10351
40 TROUBLESHOOTING...10360
CONTENTS...10361
ABBREVIATION LIST...10371
RELATED INFORMATION ON TROUBLESHOOTING...10377
GENERAL TROUBLESHOOTING POINTS...10377
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM...10378
SEQUENCE OF EVENTS IN TROUBLESHOOTING...10390
CHECKS BEFORE TROUBLESHOOTING...10392
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING...10394
WALK-AROUND CHECK...10394
TESTING IN ACCORDANCE WITH TESTING PROCEDURE...10396
CHECK FUEL LEVEL AND TYPE...10396
FUEL - CHECK FOR FOREIGN MATERIAL...10396
CHECK AdBule/DEF LEVEL AND TYPE...10397
CHECK FUEL PREFILTER...10397
CHECK MAIN FILTER...10399
OIL PAN - CHECK ENGINE OIL LEVEL AND TYPE...10401
CHECK COOLANT LEVEL (RESERVOIR TANK)...10402
CHECK CLOGGING OF AIR CLEANER...10403
OUTER ELEMENT - CLEAN...10404
REPLACE ELEMENT...10406
CHECK HYDRAULIC OIL LEVEL...10408
CHECK HYDRAULIC FILTER...10410
CHECK THE OIL LEVEL IN THE TRANSFER CASE...10411
CHECK OIL LEVEL IN FRONT AXLE CASE...10412
CHECK OIL LEVEL IN REAR AXLE CASE...10413
BLEED AIR FROM FUEL SYSTEM...10414
BLEED AIR FROM HYDRAULIC SYSTEM...10414
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod...10414
ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION...10421
PROCEDURE FOR TESTING AND TROUBLESHOOTING...10429
SYMPTOM AND TROUBLESHOOTING NUMBERS...10431
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE...10435
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM...10437
CONNECTORS LIST AND LAYOUT...10440
CONNECTOR CONTACT IDENTIFICATION...10457
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE...10496
FUSE LOCATION TABLE...10502
PRECAUTIONS FOR REPLACING KDOC...10506
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR...10507
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT...10509
FAILURE CODES TABLE...10515
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)...10533
FAILURE CODE [2F00MA]...10533
FAILURE CODE [2F00MB]...10536
FAILURE CODE [2G42ZG]...10538
FAILURE CODE [2G43ZG]...10540
FAILURE CODE [6091NX]...10542
FAILURE CODE [7RHYKA]...10544
FAILURE CODE [7RHYKB]...10546
FAILURE CODE [7RHYKY]...10548
FAILURE CODE [879AKA]...10550
FAILURE CODE [879AKB]...10552
FAILURE CODE [879BKA]...10554
FAILURE CODE [879BKB]...10556
FAILURE CODE [879CKA]...10558
FAILURE CODE [879CKB]...10560
FAILURE CODE [879DKZ]...10562
FAILURE CODE [879EMC]...10564
FAILURE CODE [879FMC]...10565
FAILURE CODE [989FN1]...10566
FAILURE CODE [989L00]...10567
FAILURE CODE [989M00]...10568
FAILURE CODE [989N00]...10569
FAILURE CODE [A1U0N3]...10570
FAILURE CODE [A1U0N4]...10572
FAILURE CODE [AB00KE]...10574
FAILURE CODE [AB00KY]...10576
FAILURE CODE [AQ10MB]...10578
FAILURE CODE [AQ10N3]...10580
FAILURE CODE [AS00R2]...10582
FAILURE CODE [AS00R3]...10583
FAILURE CODE [AS00R4]...10584
FAILURE CODE [AS00R5]...10585
FAILURE CODE [AS00R6]...10586
FAILURE CODE [AS00ZK]...10587
FAILURE CODE [AS10KM]...10588
FAILURE CODE [AS10NR]...10589
FAILURE CODE [AS10NT]...10590
FAILURE CODE [B@BAZG]...10591
FAILURE CODE [B@BCNS]...10592
FAILURE CODE [B@BCZK]...10593
FAILURE CODE [B@C6NS]...10595
FAILURE CODE [B@CRNS]...10597
FAILURE CODE [CA115]...10598
FAILURE CODE [CA122]...10599
FAILURE CODE [CA123]...10601
FAILURE CODE [CA131]...10603
FAILURE CODE [CA132]...10605
FAILURE CODE [CA144]...10608
FAILURE CODE [CA145]...10610
FAILURE CODE [CA153]...10612
FAILURE CODE [CA154]...10614
FAILURE CODE [CA187]...10616
FAILURE CODE [CA221]...10618
FAILURE CODE [CA222]...10620
FAILURE CODE [CA227]...10622
FAILURE CODE [CA234]...10624
FAILURE CODE [CA238]...10625
FAILURE CODE [CA239]...10626
FAILURE CODE [CA249]...10627
FAILURE CODE [CA256]...10629
FAILURE CODE [CA271]...10631
FAILURE CODE [CA272]...10633
FAILURE CODE [CA295]...10635
FAILURE CODE [CA322]...10636
FAILURE CODE [CA324]...10638
FAILURE CODE [CA331]...10640
FAILURE CODE [CA332]...10642
FAILURE CODE [CA343]...10644
FAILURE CODE [CA351]...10645
FAILURE CODE [CA352]...10646
FAILURE CODE [CA356]...10648
FAILURE CODE [CA357]...10650
FAILURE CODE [CA386]...10652
FAILURE CODE [CA428]...10653
FAILURE CODE [CA429]...10655
FAILURE CODE [CA431]...10657
FAILURE CODE [CA432]...10660
FAILURE CODE [CA435]...10664
FAILURE CODE [CA441]...10666
FAILURE CODE [CA442]...10668
FAILURE CODE [CA451]...10669
FAILURE CODE [CA452]...10671
FAILURE CODE [CA488]...10673
FAILURE CODE [CA515]...10674
FAILURE CODE [CA516]...10676
FAILURE CODE [CA553]...10678
FAILURE CODE [CA555]...10679
FAILURE CODE [CA556]...10680
FAILURE CODE [CA559]...10681
FAILURE CODE [CA595]...10684
FAILURE CODE [CA687]...10686
FAILURE CODE [CA689]...10688
FAILURE CODE [CA691]...10691
FAILURE CODE [CA692]...10693
FAILURE CODE [CA697]...10695
FAILURE CODE [CA698]...10696
FAILURE CODE [CA731]...10697
FAILURE CODE [CA778]...10699
FAILURE CODE [CA1117]...10703
FAILURE CODE [CA1664]...10705
FAILURE CODE [CA1669]...10707
FAILURE CODE [CA1673]...10708
FAILURE CODE [CA1677]...10709
FAILURE CODE [CA1678]...10710
FAILURE CODE [CA1682]...10711
FAILURE CODE [CA1683]...10715
FAILURE CODE [CA1684]...10717
FAILURE CODE [CA1686]...10719
FAILURE CODE [CA1691]...10720
FAILURE CODE [CA1694]...10722
FAILURE CODE [CA1695]...10724
FAILURE CODE [CA1696]...10725
FAILURE CODE [CA1712]...10728
FAILURE CODE [CA1713]...10731
FAILURE CODE [CA1714]...10733
FAILURE CODE [CA1715]...10734
FAILURE CODE [CA1776]...10735
FAILURE CODE [CA1777]...10738
FAILURE CODE [CA1843]...10741
FAILURE CODE [CA1844]...10743
FAILURE CODE [CA1885]...10746
FAILURE CODE [CA1887]...10748
FAILURE CODE [CA1896]...10750
FAILURE CODE [CA1898]...10751
FAILURE CODE [CA1938]...10753
FAILURE CODE [CA1942]...10755
FAILURE CODE [CA1961]...10756
FAILURE CODE [CA1962]...10757
FAILURE CODE [CA2185]...10758
FAILURE CODE [CA2186]...10760
FAILURE CODE [CA2198]...10762
FAILURE CODE [CA2272]...10763
FAILURE CODE [CA2288]...10765
FAILURE CODE [CA2311]...10766
FAILURE CODE [CA2349]...10767
FAILURE CODE [CA2353]...10769
FAILURE CODE [CA2357]...10771
FAILURE CODE [CA2373]...10772
FAILURE CODE [CA2374]...10774
FAILURE CODE [CA2375]...10776
FAILURE CODE [CA2376]...10778
FAILURE CODE [CA2387]...10781
FAILURE CODE [CA2554]...10782
FAILURE CODE [CA2555]...10783
FAILURE CODE [CA2556]...10785
FAILURE CODE [CA2634]...10787
FAILURE CODE [CA2635]...10789
FAILURE CODE [CA2636]...10790
FAILURE CODE [CA2637]...10792
FAILURE CODE [CA2771]...10794
FAILURE CODE [CA2961]...10798
FAILURE CODE [CA2973]...10799
FAILURE CODE [CA2976]...10800
FAILURE CODE [CA3142]...10802
FAILURE CODE [CA3143]...10803
FAILURE CODE [CA3144]...10804
FAILURE CODE [CA3146]...10807
FAILURE CODE [CA3147]...10808
FAILURE CODE [CA3148]...10809
FAILURE CODE [CA3151]...10812
FAILURE CODE [CA3165]...10820
FAILURE CODE [CA3228]...10822
FAILURE CODE [CA3229]...10824
FAILURE CODE [CA3231]...10826
FAILURE CODE [CA3232]...10828
FAILURE CODE [CA3235]...10832
FAILURE CODE [CA3239]...10834
FAILURE CODE [CA3241]...10837
FAILURE CODE [CA3242]...10840
FAILURE CODE [CA3251]...10843
FAILURE CODE [CA3313]...10845
FAILURE CODE [CA3314]...10846
FAILURE CODE [CA3315]...10847
FAILURE CODE [CA3419]...10849
FAILURE CODE [CA3421]...10851
FAILURE CODE [CA3497]...10853
FAILURE CODE [CA3498]...10854
FAILURE CODE [CA3545]...10855
FAILURE CODE [CA3547]...10857
FAILURE CODE [CA3558]...10858
FAILURE CODE [CA3559]...10860
FAILURE CODE [CA3562]...10862
FAILURE CODE [CA3563]...10864
FAILURE CODE [CA3567]...10867
FAILURE CODE [CA3568]...10871
FAILURE CODE [CA3571]...10877
FAILURE CODE [CA3572]...10879
FAILURE CODE [CA3574]...10881
FAILURE CODE [CA3575]...10884
FAILURE CODE [CA3577]...10886
FAILURE CODE [CA3578]...10888
FAILURE CODE [CA3582]...10890
FAILURE CODE [CA3583]...10897
FAILURE CODE [CA3596]...10899
FAILURE CODE [CA3649]...10902
FAILURE CODE [CA3681]...10904
FAILURE CODE [CA3682]...10909
FAILURE CODE [CA3713]...10914
FAILURE CODE [CA3717]...10917
FAILURE CODE [CA3718]...10918
FAILURE CODE [CA3724]...10919
FAILURE CODE [CA3725]...10920
FAILURE CODE [CA3741]...10923
FAILURE CODE [CA3748]...10924
FAILURE CODE [CA3755]...10926
FAILURE CODE [CA3866]...10928
FAILURE CODE [CA3868]...10931
FAILURE CODE [CA4152]...10935
FAILURE CODE [CA4155]...10939
FAILURE CODE [CA4156]...10942
FAILURE CODE [CA4157]...10945
FAILURE CODE [CA4159]...10947
FAILURE CODE [CA4164]...10948
FAILURE CODE [CA4165]...10950
FAILURE CODE [CA4166]...10952
FAILURE CODE [CA4168]...10953
FAILURE CODE [CA4169]...10956
FAILURE CODE [CA4171]...10958
FAILURE CODE [CA4249]...10960
FAILURE CODE [CA4251]...10962
FAILURE CODE [CA4261]...10964
FAILURE CODE [CA4277]...10967
FAILURE CODE [CA4459]...10970
FAILURE CODE [CA4461]...10972
FAILURE CODE [CA4533]...10975
FAILURE CODE [CA4534]...10976
FAILURE CODE [CA4731]...10977
FAILURE CODE [CA4732]...10978
FAILURE CODE [CA4739]...10979
FAILURE CODE [CA4768]...10980
FAILURE CODE [CA4769]...10982
FAILURE CODE [CA4842]...10985
FAILURE CODE [CA4952]...10988
FAILURE CODE [CA5115]...10990
FAILURE CODE [CA5179]...10993
FAILURE CODE [CA5181]...10995
FAILURE CODE [CA5387]...10997
FAILURE CODE [CA5388]...10999
FAILURE CODE [CA5389]...11002
FAILURE CODE [CA5391]...11004
FAILURE CODE [CA5392]...11008
FAILURE CODE [CA5393]...11010
FAILURE CODE [CA5394]...11013
FAILURE CODE [CA5395]...11016
FAILURE CODE [CA5396]...11019
FAILURE CODE [CA5631]...11020
FAILURE CODE [CA5632]...11022
FAILURE CODE [CA5938]...11023
FAILURE CODE [D110L4]...11025
FAILURE CODE [D160KA]...11027
FAILURE CODE [D160KY]...11029
FAILURE CODE [D191KA]...11030
FAILURE CODE [D191KB]...11032
FAILURE CODE [D191KY]...11034
FAILURE CODE [D192KA]...11035
FAILURE CODE [D192KB]...11036
FAILURE CODE [D192KY]...11037
FAILURE CODE [D19JKZ]...11038
FAILURE CODE [D1B0KA]...11040
FAILURE CODE [D1B0KB]...11042
FAILURE CODE [D1B0KY]...11044
FAILURE CODE [D1B0MC]...11046
FAILURE CODE [D1E6KA]...11048
FAILURE CODE [D1E6KB]...11050
FAILURE CODE [D1E6KY]...11052
FAILURE CODE [D5ZHKA]...11054
FAILURE CODE [D5ZHKB]...11056
FAILURE CODE [D5ZHL6]...11058
FAILURE CODE [D811MC]...11060
FAILURE CODE [D862KA]...11061
FAILURE CODE [D8ALKA]...11062
FAILURE CODE [D8ALKB]...11064
FAILURE CODE [D8AQK4]...11066
FAILURE CODE [D8AQKR]...11070
FAILURE CODE [DAF0KT]...11074
FAILURE CODE [DAF0MB]...11075
FAILURE CODE [DAF0MC]...11076
FAILURE CODE [DAF3KK]...11077
FAILURE CODE [DAF8KB]...11079
FAILURE CODE [DAFDKB]...11081
FAILURE CODE [DAFGMC]...11083
FAILURE CODE [DAFLKA]...11084
FAILURE CODE [DAFLKB]...11086
FAILURE CODE [DAFQKR]...11088
FAILURE CODE [DAJ0KK]...11093
FAILURE CODE [DAJ0KT]...11096
FAILURE CODE [DAJ0MC]...11097
FAILURE CODE [DAJ1KA]...11098
FAILURE CODE [DAJ2KK]...11100
FAILURE CODE [DAJ4KB]...11103
FAILURE CODE [DAJ4KZ]...11105
FAILURE CODE [DAJ5KX]...11107
FAILURE CODE [DAJ6KX]...11109
FAILURE CODE [DAJ9KQ]...11111
FAILURE CODE [DAJLKA]...11112
FAILURE CODE [DAJLKB]...11114
FAILURE CODE [DAJQKR]...11116
FAILURE CODE [DAJRKR]...11121
FAILURE CODE [DAJRMA]...11126
FAILURE CODE [DAZ9KQ]...11127
FAILURE CODE [DAZQKR]...11128
FAILURE CODE [DB2QKR]...11132
FAILURE CODE [DB2RKR]...11138
FAILURE CODE [DDAAL6]...11143
FAILURE CODE [DDB6L4]...11145
FAILURE CODE [DDD7KA]...11147
FAILURE CODE [DDD7KY]...11149
FAILURE CODE [DDE5MA]...11151
FAILURE CODE [DDE7KA]...11153
FAILURE CODE [DDE7KB]...11155
FAILURE CODE [DDK3KA]...11157
FAILURE CODE [DDK3KB]...11160
FAILURE CODE [DDK6KA]...11163
FAILURE CODE [DDK6KB]...11166
FAILURE CODE [DDNRLD]...11169
FAILURE CODE [DDS5L6]...11171
FAILURE CODE [DF10KA]...11173
FAILURE CODE [DF10KB]...11176
FAILURE CODE [DGH1KX]...11179
FAILURE CODE [DGR2KB]...11181
FAILURE CODE [DGR2KZ]...11183
FAILURE CODE [DHH1KX]...11185
FAILURE CODE [DHH1KY]...11187
FAILURE CODE [DHTCL6]...11189
FAILURE CODE [DJF1KA]...11191
FAILURE CODE [DK55KA]...11192
FAILURE CODE [DK55KY]...11195
FAILURE CODE [DK55L5]...11198
FAILURE CODE [DK5DKA]...11199
FAILURE CODE [DK5DKY]...11202
FAILURE CODE [DK5DL8]...11205
FAILURE CODE [DK5EKA]...11209
FAILURE CODE [DK5EKY]...11212
FAILURE CODE [DLM3KA]...11215
FAILURE CODE [DLM3LC]...11216
FAILURE CODE [DLT3KX]...11218
FAILURE CODE [DLT4KX]...11220
FAILURE CODE [DLT4L0]...11222
FAILURE CODE [DLT4LC]...11223
FAILURE CODE [DPQ1KR]...11225
FAILURE CODE [DPQ2KR]...11228
FAILURE CODE [DPQ3KR]...11231
FAILURE CODE [DSJ0KR]...11235
FAILURE CODE [DT22KB]...11240
FAILURE CODE [DV00KB]...11242
FAILURE CODE [DW26KA]...11243
FAILURE CODE [DW26KB]...11245
FAILURE CODE [DW26KY]...11247
FAILURE CODE [DW44KA]...11249
FAILURE CODE [DW44KB]...11251
FAILURE CODE [DW44KY]...11253
FAILURE CODE [DWM1KA]...11254
FAILURE CODE [DWM1KB]...11255
FAILURE CODE [DWM1KY]...11257
FAILURE CODE [DWN6KA]...11258
FAILURE CODE [DWN6KB]...11260
FAILURE CODE [DWN6KY]...11261
FAILURE CODE [DWN7KA]...11262
FAILURE CODE [DWN7KB]...11264
FAILURE CODE [DWN7KY]...11265
FAILURE CODE [DWN8KA]...11266
FAILURE CODE [DWN8KB]...11268
FAILURE CODE [DWN8KY]...11269
FAILURE CODE [DWPBKA]...11270
FAILURE CODE [DWPBKB]...11272
FAILURE CODE [DWPBKY]...11274
FAILURE CODE [DX19KA]...11276
FAILURE CODE [DX19KB]...11279
FAILURE CODE [DX19KY]...11281
FAILURE CODE [DX20KA]...11283
FAILURE CODE [DX20KB]...11285
FAILURE CODE [DX20KY]...11287
FAILURE CODE [DXH7KA]...11289
FAILURE CODE [DXH7KB]...11291
FAILURE CODE [DXH7KY]...11293
FAILURE CODE [DXH8KA]...11295
FAILURE CODE [DXH8KB]...11297
FAILURE CODE [DXH8KY]...11299
FAILURE CODE [DXHJKA]...11301
FAILURE CODE [DXHJKB]...11303
FAILURE CODE [DXHJKY]...11305
FAILURE CODE [DXHKKA]...11307
FAILURE CODE [DXHKKB]...11309
FAILURE CODE [DXHKKY]...11311
FAILURE CODE [H2K0KA]...11313
FAILURE CODE [H2K0KY]...11315
FAILURE CODE [J141N1]...11317
FAILURE CODE [LA00L3]...11318
FAILURE CODE [M100N1]...11319
FAILURE CODE [M400N1]...11320
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...11321
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)...11321
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK...11327
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK...11330
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP...11333
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING...11335
E-6 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING...11338
E-7 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS)...11340
E-8 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY...11342
E-9 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL...11344
E-10 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL...11347
E-11 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL...11351
E-12 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY...11353
E-13 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION...11356
E-14 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL...11359
E-15 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY...11362
E-16 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS...11363
E-17 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY...11366
E-18 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED...11371
E-19 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL...11375
E-20 RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP...11377
E-21 PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT WHEN THE PARKING BRAKE IS SET TO ON (PARKING) POSITION...11378
E-22 WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP...11382
E-23 WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP...11383
E-24 INDICATION OF HST OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR HST OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP...11384
E-25 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL...11385
E-26 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL...11387
E-27 ALARM BUZZER DOES NOT SOUND...11388
E-28 ALARM BUZZER DOES NOT STOP SOUNDING...11389
E-29 WHEN THE SECONDARY HST TRAVEL SWITCH IS OPERATED, IT DOES NOT WORK OR WHEN THE SECONDARY HST PUMP DRIVE SWITCH IS NOT OPERATED, IT WORKS...11390
E-30 SETTING DOES NOT CHANGE WHILE OPERATING THE TRACTION CONTROL SWITCH...11393
E-31 THE BUCKET POSITIONER DOES NOT WORK OR CANNOT BE RELEASED...11395
E-32 THE BOOM KICK-OUT DOES NOT WORK OR CANNOT BE RELEASED...11398
E-33 BRAKE DOES NOT WORK WHEN PARKING BRAKE IS APPLIED OR BRAKE DRAGS WHILE TRAVELING WHEN PARKING BRAKE IS RELEASED...11400
E-34 DIRECTIONAL SELECTOR (FNR) SWITCH MODE IS NOT SELECTED OR NOT RELEASED...11403
E-35 TRACKTION LEVEL DOES NOT DISPLAY MAX WHEN MAX. TRACTION SWITCH IS TURNED ON...11405
E-36 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED...11407
E-37 HORN DOES NOT SOUND...11409
E-38 HORN DOES NOT STOP SOUNDING...11412
E-39 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS...11414
E-40 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT...11416
E-41 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT...11420
E-42 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT...11424
E-43 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT...11426
E-44 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT...11428
E-45 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT...11433
E-46 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT...11437
E-47 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT...11440
E-48 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT...11443
E-49 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED...11447
E-50 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT...11451
E-51 BACKUP BUZZER DOES NOT SOUND OR CONTINUES TO SOUND...11455
E-52 FRONT WIPER DOES NOT OPERATE...11457
E-53 REAR WIPER DOES NOT OPERATE...11461
E-54 WINDOW WASHER DOES NOT OPERATE...11464
E-55 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY...11467
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)...11468
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)...11468
FAILURE MODE AND CAUSE TABLE...11469
H-1 MACHINE CAN TRAVEL NEITHER FORWARD NOR REVERSE...11483
H-2 MACHINE CAN NOT TRAVEL FORWARD (MACHINE TRAVELS REVERSE NORMALLY)...11485
H-3 MACHINE CAN NOT TRAVEL REVERSE (MACHINE TRAVELS FORWARD NORMALLY)...11486
H-4 TRAVEL SPEED OF FORWARD TRAVEL AND REVERSE TRAVEL IS SLOW, OR POWER IS LOW...11487
H-5 FORWARD TRAVEL SPEED IS SLOW OR POWER IS LOW (MACHINE TRAVELS REVERSE NORMALLY)...11490
H-6 REVERSE TRAVEL SPEED IS SLOW OR POWER IS LOW (MACHINE TRAVELS FORWARD NORMALLY)...11492
H-7 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS...11493
H-8 MACHINE DOES NOT TURN...11495
H-9 STEERING WHEEL IS HEAVY TO OPERATE...11496
H-10 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS...11497
H-11 MACHINE UNINTENTIONALLY TURNS TO ONE SIDE WHEN MACHINE TRAVELS...11498
H-12 WHEEL BRAKES DO NOT WORK OR ARE WEAK...11499
H-13 WHEEL BRAKES ARE NOT RELEASED OR DRAG...11501
H-14 PARKING BRAKE DOES NOT WORK OR IT IS WEAK...11502
H-15 PARKING BRAKE IS NOT RELEASED OR DRAGS...11503
H-16 BOOM DOES NOT RISE...11505
H-17 BOOM MOVES SLOW OR BOOM LACKS LIFTING FORCE...11507
H-18 RISING BOOM SLOWS DOWN AT CERTAIN HEIGHT...11509
H-19 LIFT CYLINDERS DO NOT SERVE TO HOLD BUCKET ON GROUND...11510
H-20 HYDRAULIC DRIFT OF BOOM IS LARGE...11512
H-21 BOOM MOVES UP AND DOWN DURING OPERATION...11513
H-22 BUCKET DOES NOT TILT BACK...11514
H-23 BUCKET MOVES SLOW OR LACKS TILT-BACK FORCE...11516
H-24 BUCKET DECELERATES DURING TILT-BACK OPERATION...11518
H-25 BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND...11519
H-26 HYDRAULIC DRIFT OF BUCKET IS LARGE...11521
H-27 BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD (WORK EQUIPMENT VALVE IN HOLD)...11522
H-28 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE...11523
H-29 WHEN OPERATING WORK EQUIPMENT ENGINE SPEED DROPS LARGELY OR ENGINE STOPS...11524
H-30 LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS TO MOVE AND STOPS...11525
H-31 WHEN CERTAIN WORK EQUIPMENT STALLS HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES...11527
H-32 E.C.S.S. (TRAVEL DAMPER) DOES NOT WORK AND MACHINE PITCHES AND BOUNCES...11528
H-33 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)...11529
H-34 UNUSUAL NOISE IS HEARD FROM AROUND FAN...11531
TROUBLESHOOTING OF ENGINE (S-MODE)...11532
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)...11532
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION...11533
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT...11534
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)...11535
S-4 ENGINE STARTABILITY IS POOR...11537
S-5 ENGINE DOES NOT PICK UP SMOOTHLY...11539
S-6 ENGINE STOPS DURING OPERATION...11541
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE...11543
S-8 ENGINE LACKS POWER...11544
S-9 EXHAUST SMOKE IS BLACK...11546
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE...11548
S-11 OIL BECOMES CONTAMINATED QUICKLY...11549
S-12 FUEL CONSUMPTION IS EXCESSIVE...11550
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)...11551
S-14 OIL PRESSURE DROPS...11552
S-15 FUEL MIXES INTO ENGINE OIL...11554
S-16 WATER MIXES INTO ENGINE OIL (MILKY)...11555
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)...11556
S-18 UNUSUAL NOISE IS HEARD...11557
S-19 VIBRATION IS EXCESSIVE...11558
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT...11559
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY...11560
S-22 ACTIVE REGENERATION TAKES TIME...11561
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION...11562
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE...11563
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)...11565
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)...11566
50 DISASSEMBLY AND ASSEMBLY...11568
CONTENTS...11569
ABBREVIATION LIST...11573
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY...11579
HOW TO READ THIS MANUAL...11579
COATING MATERIALS LIST...11581
SPECIAL TOOLS LIST...11585
SKETCHES OF SPECIAL TOOLS...11606
ENGINE AND COOLING SYSTEM...11615
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY...11615
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY...11616
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY...11622
REMOVE AND INSTALL INJECTOR ASSEMBLY...11628
METHOD FOR REMOVING INJECTOR ASSEMBLY...11628
METHOD FOR INSTALLING INJECTOR ASSEMBLY...11639
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY...11651
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY...11652
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY...11671
REMOVE AND INSTALL EGR VALVE ASSEMBLY...11698
METHOD FOR REMOVING EGR VALVE ASSEMBLY...11698
METHOD FOR INSTALLING EGR VALVE ASSEMBLY...11701
REMOVE AND INSTALL EGR COOLER ASSEMBLY...11705
METHOD FOR REMOVING EGR COOLER ASSEMBLY...11705
METHOD FOR INSTALLING EGR COOLER ASSEMBLY...11712
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY...11720
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY...11720
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY...11722
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT...11724
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT...11724
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT...11726
REMOVE AND INSTALL ALTERNATOR BELT...11728
METHOD FOR REMOVING ALTERNATOR BELT...11728
METHOD FOR INSTALLING ALTERNATOR BELT...11733
REMOVE AND INSTALL ALTERNATOR ASSEMBLY...11737
METHOD FOR REMOVING ALTERNATOR ASSEMBLY...11737
METHOD FOR INSTALLING ALTERNATOR ASSEMBLY...11739
REMOVE AND INSTALL AUTOMATIC TENSIONER...11741
METHOD FOR REMOVING AUTOMATIC TENSIONER...11741
METHOD FOR INSTALLING AUTOMATIC TENSIONER...11746
REMOVE AND INSTALL RADIATOR ASSEMBLY...11751
METHOD FOR REMOVING RADIATOR ASSEMBLY...11751
METHOD FOR INSTALLING RADIATOR ASSEMBLY...11757
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY...11764
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY...11764
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY...11768
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY...11773
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY...11773
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY...11775
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY...11777
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY...11777
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY...11779
REMOVE AND INSTALL ENGINE ASSEMBLY...11782
METHOD FOR REMOVING ENGINE ASSEMBLY...11783
METHOD FOR INSTALLING ENGINE ASSEMBLY...11801
REMOVE AND INSTALL ENGINE FRONT OIL SEAL...11821
METHOD FOR REMOVING ENGINE FRONT OIL SEAL...11821
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL...11826
REMOVE AND INSTALL ENGINE REAR OIL SEAL...11833
METHOD FOR REMOVING ENGINE REAR OIL SEAL...11834
METHOD FOR INSTALLING ENGINE REAR OIL SEAL...11836
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY...11840
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY...11840
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY...11852
REMOVE AND INSTALL KDOC ASSEMBLY...11864
METHOD FOR REMOVING KDOC ASSEMBLY...11864
METHOD FOR INSTALLING KDOC ASSEMBLY...11871
REMOVE AND INSTALL KDOC AND SCR ASSEMBLY...11881
METHOD FOR REMOVING KDOC AND SCR ASSEMBLY...11882
METHOD FOR INSTALLING KDOC AND SCR ASSEMBLY...11894
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY...11905
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY...11905
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY...11909
REMOVE AND INSTALL FUEL TANK ASSEMBLY...11915
METHOD FOR REMOVING FUEL TANK ASSEMBLY...11915
METHOD FOR INSTALLING FUEL TANK ASSEMBLY...11919
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY...11924
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY...11925
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY...11932
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...11940
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...11940
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...11942
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR...11945
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR...11945
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR...11946
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER...11953
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER...11953
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER...11954
REMOVE AND INSTALL SCR ASSEMBLY...11955
METHOD FOR REMOVING SCR ASSEMBLY...11955
METHOD FOR INSTALLING SCR ASSEMBLY...11964
REMOVE AND INSTALL KCCV ASSEMBLY...11976
METHOD FOR REMOVING KCCV ASSEMBLY...11976
METHOD FOR INSTALLING KCCV ASSEMBLY...11977
REMOVE AND INSTALL VGT ASSEMBLY...11980
METHOD FOR REMOVING VGT ASSEMBLY...11980
METHOD FOR INSTALLING VGT ASSEMBLY...11995
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE...12011
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE...12011
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE...12017
REMOVE AND INSTALL AdBlue/DEF INJECTOR...12024
METHOD FOR REMOVING AdBlue/DEF INJECTOR...12024
METHOD FOR INSTALLING AdBlue/DEF INJECTOR...12027
REMOVE AND INSTALL AdBlue/DEF PUMP...12030
METHOD FOR REMOVING AdBlue/DEF PUMP...12030
METHOD FOR INSTALLING AdBlue/DEF PUMP...12034
REMOVE AND INSTALL AdBlue/DEF HOSE...12039
METHOD FOR REMOVING AdBlue/DEF HOSE...12039
METHOD FOR INSTALLING AdBlue/DEF HOSE...12049
REMOVE AND INSTALL AIR CLEANER ASSEMBLY...12060
METHOD FOR REMOVING AIR CLEANER ASSEMBLY...12060
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY...12064
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY...12068
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY...12069
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY...12072
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY...12075
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY...12075
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY...12077
POWER TRAIN...12079
REMOVE AND INSTALL HST PUMP ASSEMBLY, STEERING, WORK EQUIPMENT, BRAKE AND COOLING FAN, AND TRANSFER LUBRICATION PUMP ASSEMBLY...12079
METHOD FOR REMOVING HST PUMP ASSEMBLY, STEERING, WORK EQUIPMENT, BRAKE AND COOLING FAN, AND TRANSFER LUBRICATION PUMP ASSEMBLY...12080
METHOD FOR INSTALLING HST PUMP ASSEMBLY, STEERING, WORK EQUIPMENT, BRAKE AND COOLING FAN, AND TRANSFER LUBRICATION PUMP ASSEMBLY...12084
REMOVE AND INSTALL HST MOTOR1 ASSEMBLY...12088
METHOD FOR REMOVING HST MOTOR1 ASSEMBLY...12088
METHOD FOR INSTALLING HST MOTOR1 ASSEMBLY...12090
REMOVE AND INSTALL HST MOTOR2 ASSEMBLY...12093
METHOD FOR REMOVING HST MOTOR2 ASSEMBLY...12093
METHOD FOR INSTALLING HST MOTOR2 ASSEMBLY...12095
REMOVE AND INSTALL TRANSFER ASSEMBLY...12097
METHOD FOR REMOVING TRANSFER ASSEMBLY...12098
METHOD FOR INSTALLING TRANSFER ASSEMBLY...12105
DISASSEMBLE AND ASSEMBLE TRANSFER ASSEMBLY...12112
METHOD FOR DISASSEMBLING TRANSFER ASSEMBLY...12113
METHOD FOR ASSEMBLING TRANSFER ASSEMBLY...12128
REMOVE AND INSTALL FRONT AXLE ASSEMBLY...12147
METHOD FOR REMOVING FRONT AXLE ASSEMBLY...12147
METHOD FOR INSTALLING FRONT AXLE ASSEMBLY...12149
REMOVE AND INSTALL REAR AXLE ASSEMBLY...12151
METHOD FOR REMOVING REAR AXLE ASSEMBLY...12151
METHOD FOR INSTALLING REAR AXLE ASSEMBLY...12153
DISASSEMBLE AND ASSEMBLE AXLE HOUSING ASSEMBLY...12156
METHOD FOR DISASSEMBLING AXLE HOUSING ASSEMBLY...12157
METHOD FOR ASSEMBLING AXLE HOUSING ASSEMBLY...12161
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY...12169
METHOD FOR DISASSEMBLING DIFFERENTIAL ASSEMBLY...12170
METHOD FOR ASSEMBLING DIFFERENTIAL ASSEMBLY...12184
UNDERCARRIAGE AND FRAME...12206
REMOVE AND INSTALL CENTER HINGE PIN...12206
METHOD FOR REMOVING CENTER HINGE PIN...12207
METHOD FOR INSTALLING CENTER HINGE PIN...12215
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY...12227
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY...12227
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY...12241
HYDRAULIC SYSTEM...12252
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY...12252
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY...12253
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY...12259
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY...12265
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY...12265
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY...12270
DISASSEMBLE AND ASSEMBLE HYDRAULIC CYLINDER ASSEMBLY...12275
METHOD FOR DISASSEMBLING HYDRAULIC CYLINDER ASSEMBLY...12276
METHOD FOR ASSEMBLING HYDRAULIC CYLINDER ASSEMBLY...12279
WORK EQUIPMENT...12286
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY...12286
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY...12287
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY...12291
CAB AND ITS ATTACHMENTS...12302
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY...12302
METHOD FOR REMOVING OPERATOR'S CAB ASSEMBLY...12303
METHOD FOR INSTALLING OPERATOR'S CAB ASSEMBLY...12315
REMOVE AND INSTALL OPERATOR'S CAB GLASS (ADHERED GLASS)...12328
METHOD FOR REMOVING OPERATOR'S CAB GLASS (ADHERED GLASS)...12328
METHOD FOR INSTALLING OPERATOR'S CAB GLASS (ADHERED GLASS)...12329
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY...12338
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY...12338
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY...12344
REMOVE AND INSTALL OPERATOR'S SEAT ASSEMBLY...12351
METHOD FOR REMOVING OPERATOR'S SEAT ASSEMBLY...12351
METHOD FOR INSTALLING OPERATOR'S SEAT ASSEMBLY...12351
REMOVE AND INSTALL SEAT BELT...12353
METHOD FOR REMOVING SEAT BELT...12353
METHOD FOR INSTALLING SEAT BELT...12353
ELECTRICAL SYSTEM...12355
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY...12355
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY...12355
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY...12359
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY...12364
METHOD FOR REMOVING HST CONTROLLER ASSEMBLY...12364
METHOD FOR INSTALLING HST CONTROLLER ASSEMBLY...12366
REMOVE AND INSTALL AIR CONDITIONER CONTROLLER ASSEMBLY...12368
METHOD FOR REMOVING AIR CONDITIONER CONTROLLER ASSEMBLY...12368
METHOD FOR INSTALLING AIR CONDITIONER CONTROLLER ASSEMBLY...12369
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY...12371
METHOD FOR REMOVING MONITOR CONTROLLER ASSEMBLY...12371
METHOD FOR INSTALLING MONITOR CONTROLLER ASSEMBLY...12374
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY...12376
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY...12376
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY...12379
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR...12382
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR...12382
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR...12383
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR...12385
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR...12385
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR...12386
REMOVE AND INSTALL SCR TEMPERATURE SENSOR...12388
METHOD FOR REMOVING SCR TEMPERATURE SENSOR...12388
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR...12391
REMOVE AND INSTALL SCR OUTLET NOx SENSOR...12395
METHOD FOR REMOVING SCR OUTLET NOx SENSOR...12395
METHOD FOR INSTALLING SCR OUTLET NOx SENSOR...12398
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY...12402
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY...12402
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY...12403
60 MAINTENANCE STANDARD...12404
CONTENTS...12405
ABBREVIATION LIST...12406
ENGINE AND COOLING SYSTEM...12412
MAINTENANCE STANDARD OF ENGINE MOUNT...12412
MAINTENANCE STANDARD OF DAMPER...12413
MAINTENANCE STANDARD OF COOLING FAN MOTOR...12414
POWER TRAIN...12418
MAINTENANCE STANDARD OF DRIVE SHAFT...12418
MAINTENANCE STANDARD OF TRANSFER...12419
MAINTENANCE STANDARD OF TRANSFER MOUNT...12428
MAINTENANCE STANDARD OF FRONT AXLE...12429
MAINTENANCE STANDARD OF REAR AXLE...12430
MAINTENANCE STANDARD OF FRONT TORQUE PROPORTIONING DIFFERENTIAL...12431
MAINTENANCE STANDARD OF REAR TORQUE PROPORTIONING DIFFERENTIAL...12433
MAINTENANCE STANDARD OF LIMITED SLIP DIFFERENTIAL...12435
MAINTENANCE STANDARD OF FRONT FINAL DRIVE...12437
MAINTENANCE STANDARD OF REAR FINAL DRIVE...12439
STEERING SYSTEM...12441
MAINTENANCE STANDARD OF STEERING COLUMN...12441
MAINTENANCE STANDARD OF PRIORITY VALVE...12442
MAINTENANCE STANDARD OF STEERING CYLINDER...12443
MAINTENANCE STANDARD OF SECONDARY STEERING VALVE...12445
BRAKE SYSTEM...12446
MAINTENANCE STANDARD OF BRAKE CIRCUIT ACCUMULATOR CHARGE VALVE...12446
MAINTENANCE STANDARD OF SLACK ADJUSTER...12447
MAINTENANCE STANDARD OF FRONT BRAKE...12448
MAINTENANCE STANDARD OF REAR BRAKE...12449
MAINTENANCE STANDARD OF PARKING BRAKE...12450
UNDERCARRIAGE AND FRAME...12451
MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN...12451
HYDRAULIC SYSTEM...12456
MAINTENANCE STANDARD OF HYDRAULIC TANK...12456
MAINTENANCE STANDARD OF STEERING, WORK EQUIPMENT, BRAKE AND COOLING FAN, AND TRANSFER LUBRICATION PUMP...12457
MAINTENANCE STANDARD OF CONTROL VALVE...12459
MAINTENANCE STANDARD OF MULTIFUNCTION MONO-LEVER PPC VALVE...12462
MAINTENANCE STANDARD OF ATTACHMENT EPC SOLENOID VALVE...12464
WORK EQUIPMENT...12465
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE...12465
MAINTENANCE STANDARD OF BUCKET...12468
MAINTENANCE STANDARD OF LIFT CYLINDER...12469
MAINTENANCE STANDARD OF BUCKET CYLINDER...12470
MAINTENANCE STANDARD OF COUPLER PLUNGER...12471
CAB AND ITS ATTACHMENTS...12472
MAINTENANCE STANDARD OF CAB MOUNT...12472
80 APPENDIX...12474
CONTENTS...12475
ABBREVIATION LIST...12477
AIR CONDITIONER SYSTEM...12483
PRECAUTIONS FOR REFRIGERANT...12483
AIR CONDITIONER COMPONENT...12484
SPECIFICATIONS OF AIR CONDITIONER...12486
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE...12487
OUTLINE OF REFRIGERATION CYCLE...12488
COMPONENT PARTS OF AIR CONDITIONER SYSTEM...12490
AIR CONDITIONER UNIT...12490
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT...12490
FUNCTION OF AIR CONDITIONER UNIT...12491
COMPONENT PARTS OF AIR CONDITIONER UNIT...12492
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT...12492
FUNCTION OF INSIDE AIR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT...12492
FUNCTION OF BLOWER AMPLIFIER AS AIR CONDITIONER UNIT COMPONENT...12493
FUNCTION OF BLOWER OFF RELAY AS AIR CONDITIONER UNIT COMPONENT...12493
FUNCTION OF COMPRESSOR CLUTCH RELAY AS AIR CONDITIONER UNIT COMPONENT...12493
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT...12493
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT...12493
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT...12493
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...12494
FUNCTION OF DUAL PRESSURE SWITCH...12494
AIR CONDITIONER CONTROLLER...12495
STRUCTURE OF AIR CONDITIONER CONTROLLER...12495
COMPRESSOR...12496
STRUCTURE OF COMPRESSOR...12496
SPECIFICATIONS OF COMPRESSOR...12496
FUNCTION OF COMPRESSOR...12496
CONDENSER...12497
STRUCTURE OF CONDENSER...12497
SPECIFICATIONS OF CONDENSER...12497
FUNCTION OF CONDENSER...12497
RECEIVER DRIER...12498
STRUCTURE OF RECEIVER DRIER...12498
SPECIFICATIONS OF RECEIVER DRIER...12498
FUNCTION OF RECEIVER DRIER...12498
SENSORS FOR AIR CONDITIONER SYSTEM...12499
FUNCTION OF SUNLIGHT SENSOR...12499
FUNCTION OF AMBIENT TEMPERATURE SENSOR...12499
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER...12500
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER...12502
AIR CONDITIONER SYSTEM DIAGRAM...12505
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER...12506
FUNCTION OF AIR CONDITIONER CONTROLLER...12507
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS...12508
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION...12514
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR...12515
CHECK TEMPERATURE CONTROL FUNCTION...12516
METHOD FOR CHECKING TEMPERATURE CONTROL FUNCTION...12516
TEST VENT (MODE) CHANGEOVER...12518
METHOD FOR TESTING VENT (MODE) CHANGEOVER...12518
TESTING FRESH/RECIRC AIR CHANGEOVER...12520
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER...12520
TEST EVAPORATOR TEMPERATURE SENSOR...12522
TEST RELAYS...12524
METHOD FOR TESTING RELAYS...12524
AIR CONDITIONER TROUBLESHOOTING CHART 1...12526
AIR CONDITIONER TROUBLESHOOTING CHART 2...12527
FAILURE CODE [879AKA]...12530
FAILURE CODE [879AKB]...12532
FAILURE CODE [879BKA]...12534
FAILURE CODE [879BKB]...12536
FAILURE CODE [879CKA]...12538
FAILURE CODE [879CKB]...12540
FAILURE CODE [879DKZ]...12542
FAILURE CODE [879EMC]...12544
FAILURE CODE [879FMC]...12545
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)...12546
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)...12549
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)...12552
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER...12556
TROUBLESHOOTING USING GAUGE PRESSURE...12558
CONNECTION OF SERVICE TOOL...12561
METHOD FOR CONNECTING SERVICE TOOL...12562
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS...12563
HANDLE COMPRESSOR OIL...12565
90 CIRCUIT DIAGRAMS...12568
CONTENTS...12569
ABBREVIATION LIST...12570
HYDRAULIC CIRCUIT DIAGRAM...12576
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM...12576
HYDRAULIC CIRCUIT DIAGRAM...12580
ELECTRICAL CIRCUIT DIAGRAM...12581
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM...12581
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/10)...12585
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/10)...12586
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/10)...12587
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/10)...12588
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/10)...12589
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/10)...12590
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/10)...12591
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (8/10)...12592
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (9/10)...12593
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (10/10)...12594
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (1/9)...12595
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (2/9)...12596
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (3/9)...12597
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (4/9)...12598
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (5/9)...12599
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (6/9)...12600
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (7/9)...12601
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (8/9)...12602
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (9/9)...12603
INDEX...12604
TEN00151-00 - Wheel Loader GALEO WA200-5 Operation & Maintenance Manual...12622
COVER...12622
FOREWORD...12623
FOREWORD...12624
SAFETY INFORMATION...12627
INTRODUCTION...12629
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...12629
NECESSARY INFORMATION...12630
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...12630
ENGINE SERIAL NO. PLATE...12630
POSITION OF SERVICE METER...12631
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...12631
CONTENTS...12632
SAFETY...12635
SAFETY...12636
SAFETY LABELS...12639
LOCATION OF SAFETY LABELS...12639
SAFETY LABELS...12640
GENERAL PRECAUTIONS...12645
SAFETY RULES...12645
IF ABNORMALITIES ARE FOUND...12645
CLOTHING AND PERSONAL PROTECTIVE ITEMS...12645
FIRE EXTINGUISHER AND FIRST AID KIT...12645
SAFETY FEATURES...12645
KEEP MACHINE CLEAN...12646
INSIDE OPERATOR'S COMPARTMENT...12646
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT...12646
HANDRAILS AND STEPS...12647
MOUNTING AND DISMOUNTING...12648
NO PEOPLE ON ATTACHMENTS...12648
DO NOT GET CAUGHT IN ARTICULATED PORTION...12648
PREVENTION OF BURNS...12648
FIRE PREVENTION...12649
ACTION IF FIRE OCCURS...12650
WINDOW WASHER LIQUID...12650
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)...12650
PRECAUTIONS FOR ATTACHMENTS, OPTIONS...12650
UNAUTHORIZED MODIFICATION...12650
SAFETY AT WORKSITE...12651
WORKING ON LOOSE GROUND...12651
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...12651
ENSURE GOOD VISIBILITY...12652
VENTILATION FOR ENCLOSED AREAS...12652
CHECKING SIGNALMAN'S SIGNALS AND SIGNS...12652
EMERGENCY EXIT FROM OPERATOR'S CAB...12652
BE CAREFUL ABOUT ASBESTOS DUST...12653
PRECAUTIONS FOR OPERATION...12654
STARTING ENGINE...12654
CHECKS BEFORE STARTING ENGINE...12654
PRECAUTIONS WHEN STARTING...12654
PRECAUTIONS IN COLD AREAS...12655
OPERATION...12656
CHECKS BEFORE OPERATION...12656
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE...12656
PRECAUTIONS WHEN TRAVELING...12657
TRAVELING ON SLOPES...12658
PROHIBITED OPERATIONS...12659
PRECAUTIONS WHEN OPERATING...12659
METHODS OF USING BRAKE...12660
OPERATE CAREFULLY ON SNOW...12660
PARKING MACHINE...12661
TRANSPORTATION...12662
LOADING AND UNLOADING...12662
SHIPPING...12662
BATTERY...12663
BATTERY HAZARD PREVENTION...12663
STARTING WITH BOOSTER CABLES...12664
TOWING...12665
WHEN TOWING...12665
PRECAUTIONS FOR MAINTENANCE...12666
WARNING TAG...12666
KEEP WORK PLACE CLEAN AND TIDY...12666
APPOINT LEADER WHEN WORKING WITH OTHERS...12666
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...12667
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...12668
INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF...12668
PROPER TOOLS...12669
ACCUMULATOR...12669
PERSONNEL...12669
ATTACHMENTS...12669
WORK UNDER THE MACHINE...12670
NOISE...12670
PRECAUTIONS WHEN USING HAMMER...12670
REPAIR WELDING...12670
REMOVING BATTERY TERMINAL...12670
PRECAUTIONS WITH HIGH-PRESSURE OIL...12671
HANDLING HIGH-PRESSURE HOSES...12671
WASTE MATERIALS...12671
MAINTENANCE OF AIR CONDITIONER...12671
COMPRESSED AIR...12672
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...12672
PRECAUTIONS WITH TIRES...12673
HANDLING TIRES...12673
PRECAUTIONS WHEN STORING TIRES...12673
OPERATION...12674
GENERAL VIEW...12675
GENERAL VIEW OF MACHINE...12675
GENERAL VIEW OF CONTROLS AND GAUGES...12676
EXPLANATION OF COMPONENTS...12678
MACHINE MONITOR...12678
SWITCHES...12704
CONTROL LEVERS, PEDALS...12711
STEERING TILT LOCK LEVER...12715
CAP AND COVER WITH LOCK...12715
FRAME LOCK BAR...12716
TOWING PIN...12717
GREASE PUMP...12717
CAB DOOR INNER LOCK...12717
CAB DOOR OPEN LOCK...12718
CAB WINDOW OPEN LOCK CANCEL KNOB...12718
FUSE...12718
SLOW BLOW FUSE...12720
POWER OUTLET...12720
STORAGE BOX...12720
AM/FM RADIO...12721
AM/FM RADIO-CASSETTE STEREO...12727
AIR CONDITIONER...12735
HANDLING CAB WIPER...12740
OPERATION...12741
CHECK BEFORE STARTING ENGINE, ADJUST...12741
STARTING ENGINE...12757
OPERATIONS AND CHECKS AFTER STARTING ENGINE...12759
STOPPING ENGINE...12761
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...12762
TURNING...12766
OPERATION OF WORK EQUIPMENT...12768
WORK POSSIBLE USING WHEEL LOADER...12770
PRECAUTIONS FOR OPERATION...12775
ADJUSTING WORK EQUIPMENT POSTURE...12777
PARKING MACHINE...12779
CHECKS AFTER COMPLETION OF OPERATION...12781
LOCKING...12781
HANDLING THE TIRES...12782
TRANSPORTATION...12784
TRANSPORTATION PROCEDURE...12784
LOADING, UNLOADING WORK WITH TRAILERS...12784
LIFTING MACHINE...12788
COLD WEATHER OPERATION...12790
PRECAUTIONS FOR LOW TEMPERATURE...12790
PRECAUTIONS AFTER COMPLETION OF WORK...12791
AFTER COLD WEATHER...12791
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...12792
LONG-TERM STORAGE...12793
BEFORE STORAGE...12793
DURING STORAGE...12793
AFTER STORAGE...12793
TROUBLESHOOTING...12794
WHEN MACHINE RUNS OUT OF FUEL...12794
METHOD OF TOWING MACHINE...12794
IF BATTERY IS DISCHARGED...12796
OTHER TROUBLE...12799
MAINTENANCE...12804
GUIDES TO MAINTENANCE...12805
OUTLINES OF SERVICE...12807
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...12807
OUTLINE OF ELECTRIC SYSTEM...12810
WEAR PARTS...12811
WEAR PARTS LIST...12811
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...12812
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...12813
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN ...12814
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...12815
TORQUE LIST...12815
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...12816
MAINTENANCE SCHEDULE CHART...12817
MAINTENANCE SCHEDULE CHART...12817
SERVICE PROCEDURE...12819
INITIAL 250 HOURS SERVICE...12819
WHEN REQUIRED...12820
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT...12820
CLEAN INSIDE OF COOLING SYSTEM...12823
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL...12826
CHECK AXLE OIL LEVEL, ADD OIL...12827
CLEAN AXLE CASE BREATHER...12828
CLEAN AIR CONDITIONER CONDENSER...12829
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID...12829
CLEAN RADIATOR FINS AND COOLER FINS...12830
CHECK ELECTRICAL INTAKE AIR HEATER...12830
TURN, REPLACE BOLT-ON CUTTING EDGE...12831
REPLACE BUCKET TEETH...12832
CHECK AIR CONDITIONER...12834
REPLACE SLOW BLOW FUSE...12835
CHECKING FUNCTION OF ACCUMULATOR...12836
SELECTION AND INSPECTION OF TIRES...12837
CHECK BEFORE STARTING...12839
EVERY 50 HOURS SERVICE...12840
DRAIN WATER, SEDIMENT FROM FUEL TANK...12840
EVERY 100 HOURS SERVICE...12841
LUBRICATE REAR AXLE PIVOT PIN...12841
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...12841
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...12842
EVERY 250 HOURS SERVICE...12843
CHECK BATTERY ELECTROLYTE LEVEL...12843
CHECK PARKING BRAKE...12845
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...12845
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN...12846
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...12847
CHECKING FUNCTION OF ACCUMULATOR...12847
LUBRICATING...12848
EVERY 500 HOURS SERVICE...12849
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...12849
REPLACE FUEL FILTER CARTRIDGE...12850
REPLACEMENT OF FILTER CARTRIDGE FOR POOR-QUALITY FUEL...12851
CLEAN WATER SEPARATOR STRAINER...12852
EVERY 1000 HOURS SERVICE...12853
CHANGE OIL IN TRANSFER CASE...12853
CLEAN TRANSFER CASE BREATHER...12854
REPLACE HST OIL FILTER ELEMENT...12855
REPLACE CORROSION RESISTOR CARTRIDGE...12856
LUBRICATING...12856
CHECK TIGHTENING PARTS OF TURBOCHARGER...12856
CHECK PLAY OF TURBOCHARGER ROTOR...12856
CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT...12857
EVERY 2000 HOURS SERVICE...12858
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...12858
REPLACE HYDRAULIC TANK BREATHER ELEMENT...12859
CHANGE AXLE OIL...12860
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER...12860
CLEAN BRAKE CIRCUIT STRAINER...12861
CHECK BRAKE DISC WEAR...12862
CHECKING FUNCTION OF ACCUMULATOR...12863
CHECK ALTERNATOR, STARTING MOTOR...12863
CHECK ENGINE VALVE CLEARANCE, ADJUST...12863
CLEAN AND CHECK TURBOCHARGER...12863
CHECK VIBRATION DAMPER...12863
EVERY 4000 HOURS SERVICE...12864
LUBRICATING...12864
CHECK WATER PUMP...12864
SPECIFICATIONS...12865
SPECIFICATIONS...12866
ATTACHMENTS, OPTIONS...12868
SELECTING BUCKET AND TIRES...12869
HANDLING BATTERY DISCONNECTOR SWITCH...12870
EXPLANATION OF COMPONENTS...12870
HANDLING...12870
INDEX...12871
TEN00152-00 - Wheel Loader GALEO WA200L-5 Operation & Maintenance Manual...12874
COVER...12874
FOREWORD...12875
FOREWORD...12876
SAFETY INFORMATION...12879
INTRODUCTION...12881
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...12881
NECESSARY INFORMATION...12882
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...12882
ENGINE SERIAL NO. PLATE...12882
POSITION OF SERVICE METER...12883
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...12883
CONTENTS...12884
SAFETY...12887
SAFETY...12888
SAFETY LABELS...12891
LOCATION OF SAFETY LABELS...12891
SAFETY LABELS...12892
GENERAL PRECAUTIONS...12897
SAFETY RULES...12897
IF ABNORMALITIES ARE FOUND...12897
CLOTHING AND PERSONAL PROTECTIVE ITEMS...12897
FIRE EXTINGUISHER AND FIRST AID KIT...12897
SAFETY FEATURES...12897
KEEP MACHINE CLEAN...12898
INSIDE OPERATOR'S COMPARTMENT...12898
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT...12898
HANDRAILS AND STEPS...12899
MOUNTING AND DISMOUNTING...12900
NO PEOPLE ON ATTACHMENTS...12900
DO NOT GET CAUGHT IN ARTICULATED PORTION...12900
PREVENTION OF BURNS...12900
FIRE PREVENTION...12901
ACTION IF FIRE OCCURS...12902
WINDOW WASHER LIQUID...12902
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)...12902
PRECAUTIONS FOR ATTACHMENTS, OPTIONS...12902
UNAUTHORIZED MODIFICATION...12902
SAFETY AT WORKSITE...12903
WORKING ON LOOSE GROUND...12903
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...12903
ENSURE GOOD VISIBILITY...12904
VENTILATION FOR ENCLOSED AREAS...12904
CHECKING SIGNALMAN'S SIGNALS AND SIGNS...12904
EMERGENCY EXIT FROM OPERATOR'S CAB...12904
BE CAREFUL ABOUT ASBESTOS DUST...12905
PRECAUTIONS FOR OPERATION...12906
STARTING ENGINE...12906
CHECKS BEFORE STARTING ENGINE...12906
PRECAUTIONS WHEN STARTING...12906
PRECAUTIONS IN COLD AREAS...12907
OPERATION...12908
CHECKS BEFORE OPERATION...12908
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE...12908
PRECAUTIONS WHEN TRAVELING...12909
TRAVELING ON SLOPES...12910
PROHIBITED OPERATIONS...12911
PRECAUTIONS WHEN OPERATING...12911
METHODS OF USING BRAKE...12912
OPERATE CAREFULLY ON SNOW...12912
PARKING MACHINE...12913
TRANSPORTATION...12914
LOADING AND UNLOADING...12914
SHIPPING...12914
BATTERY...12915
BATTERY HAZARD PREVENTION...12915
STARTING WITH BOOSTER CABLES...12916
TOWING...12917
WHEN TOWING...12917
PRECAUTIONS FOR MAINTENANCE...12918
WARNING TAG...12918
KEEP WORK PLACE CLEAN AND TIDY...12918
APPOINT LEADER WHEN WORKING WITH OTHERS...12918
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...12919
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...12920
INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF...12920
PROPER TOOLS...12921
ACCUMULATOR...12921
PERSONNEL...12921
ATTACHMENTS...12921
WORK UNDER THE MACHINE...12922
NOISE...12922
PRECAUTIONS WHEN USING HAMMER...12922
REPAIR WELDING...12922
REMOVING BATTERY TERMINAL...12922
PRECAUTIONS WITH HIGH-PRESSURE OIL...12923
HANDLING HIGH-PRESSURE HOSES...12923
WASTE MATERIALS...12923
MAINTENANCE OF AIR CONDITIONER...12923
COMPRESSED AIR...12924
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...12924
PRECAUTIONS WITH TIRES...12925
HANDLING TIRES...12925
PRECAUTIONS WHEN STORING TIRES...12925
OPERATION...12926
GENERAL VIEW...12927
GENERAL VIEW OF MACHINE...12927
GENERAL VIEW OF CONTROLS AND GAUGES...12928
EXPLANATION OF COMPONENTS...12930
MACHINE MONITOR...12930
SWITCHES...12956
CONTROL LEVERS, PEDALS...12965
STEERING TILT LOCK LEVER...12969
CAP AND COVER WITH LOCK...12969
FRAME LOCK BAR...12970
TOWING PIN...12971
GREASE PUMP...12971
CAB DOOR INNER LOCK...12971
CAB DOOR OPEN LOCK...12972
CAB WINDOW OPEN LOCK CANCEL KNOB...12972
FUSE...12972
SLOW BLOW FUSE...12974
POWER OUTLET...12974
STORAGE BOX...12974
AM/FM RADIO-CASSETTE STEREO...12975
AIR CONDITIONER...12983
HANDLING CAB WIPER...12988
OPERATION...12989
CHECK BEFORE STARTING ENGINE, ADJUST...12989
STARTING ENGINE...13004
OPERATIONS AND CHECKS AFTER STARTING ENGINE...13006
STOPPING ENGINE...13008
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...13009
TURNING...13014
OPERATION OF WORK EQUIPMENT...13016
WORK POSSIBLE USING WHEEL LOADER...13018
PRECAUTIONS FOR OPERATION...13023
ADJUSTING WORK EQUIPMENT POSTURE...13025
PARKING MACHINE...13027
CHECKS AFTER COMPLETION OF OPERATION...13029
LOCKING...13029
HANDLING THE TIRES...13030
TRANSPORTATION...13032
TRANSPORTATION PROCEDURE...13032
LOADING, UNLOADING WORK WITH TRAILERS...13032
LIFTING MACHINE...13036
COLD WEATHER OPERATION...13038
PRECAUTIONS FOR LOW TEMPERATURE...13038
PRECAUTIONS AFTER COMPLETION OF WORK...13039
AFTER COLD WEATHER...13039
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...13040
LONG-TERM STORAGE...13041
BEFORE STORAGE...13041
DURING STORAGE...13041
AFTER STORAGE...13041
TROUBLESHOOTING...13042
WHEN MACHINE RUNS OUT OF FUEL...13042
METHOD OF TOWING MACHINE...13042
IF BATTERY IS DISCHARGED...13044
OTHER TROUBLE...13047
MAINTENANCE...13052
GUIDES TO MAINTENANCE...13053
OUTLINES OF SERVICE...13055
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...13055
OUTLINE OF ELECTRIC SYSTEM...13058
WEAR PARTS...13059
WEAR PARTS LIST...13059
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...13060
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...13061
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN ...13062
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...13063
TORQUE LIST...13063
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...13064
MAINTENANCE SCHEDULE CHART...13065
MAINTENANCE SCHEDULE CHART...13065
SERVICE PROCEDURE...13067
INITIAL 250 HOURS SERVICE...13067
WHEN REQUIRED...13068
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT...13068
CLEAN INSIDE OF COOLING SYSTEM...13071
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL...13074
CHECK AXLE OIL LEVEL, ADD OIL...13075
CLEAN AXLE CASE BREATHER...13076
CLEAN AIR CONDITIONER CONDENSER...13077
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID...13077
CLEAN RADIATOR FINS AND COOLER FINS...13078
CHECK ELECTRICAL INTAKE AIR HEATER...13078
TURN, REPLACE BOLT-ON CUTTING EDGE...13079
REPLACE BUCKET TEETH...13080
CHECK AIR CONDITIONER...13082
REPLACE SLOW BLOW FUSE...13083
CHECKING FUNCTION OF ACCUMULATOR...13084
SELECTION AND INSPECTION OF TIRES...13085
CHECK BEFORE STARTING...13087
EVERY 50 HOURS SERVICE...13088
DRAIN WATER, SEDIMENT FROM FUEL TANK...13088
EVERY 100 HOURS SERVICE...13089
LUBRICATE REAR AXLE PIVOT PIN...13089
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...13089
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...13090
EVERY 250 HOURS SERVICE...13091
CHECK BATTERY ELECTROLYTE LEVEL...13091
CHECK PARKING BRAKE...13093
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...13093
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN...13094
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...13095
CHECKING FUNCTION OF ACCUMULATOR...13095
LUBRICATING...13096
EVERY 500 HOURS SERVICE...13097
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...13097
REPLACE FUEL FILTER CARTRIDGE...13098
CLEAN WATER SEPARATOR STRAINER...13099
EVERY 1000 HOURS SERVICE...13100
CHANGE OIL IN TRANSFER CASE...13100
CLEAN TRANSFER CASE BREATHER...13101
REPLACE HST OIL FILTER ELEMENT...13102
LUBRICATING...13103
CHECK TIGHTENING PARTS OF TURBOCHARGER...13103
CHECK PLAY OF TURBOCHARGER ROTOR...13103
CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT...13103
EVERY 2000 HOURS SERVICE...13104
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...13104
REPLACE HYDRAULIC TANK BREATHER ELEMENT...13105
CHANGE AXLE OIL...13106
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER...13106
CLEAN BRAKE CIRCUIT STRAINER...13107
CHECK BRAKE DISC WEAR...13108
CHECKING FUNCTION OF ACCUMULATOR...13109
CHECK ALTERNATOR, STARTING MOTOR...13109
CHECK ENGINE VALVE CLEARANCE, ADJUST...13109
CLEAN AND CHECK TURBOCHARGER...13109
CHECK VIBRATION DAMPER...13109
EVERY 4000 HOURS SERVICE...13110
LUBRICATING...13110
CHECK WATER PUMP...13110
SPECIFICATIONS...13111
SPECIFICATIONS...13112
ATTACHMENTS, OPTIONS...13114
SELECTING BUCKET AND TIRES...13115
INDEX...13116
TEN00215-00 - Wheel Loader GALEO WA250-5 Operation & Maintenance Manual...13119
COVER...13119
FOREWORD...13120
FOREWORD...13121
SAFETY INFORMATION...13124
INTRODUCTION...13126
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...13126
NECESSARY INFORMATION...13127
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...13127
ENGINE SERIAL NO. PLATE...13127
POSITION OF SERVICE METER...13128
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...13128
CONTENTS...13129
SAFETY...13132
SAFETY...13133
SAFETY LABELS...13136
LOCATION OF SAFETY LABELS...13136
SAFETY LABELS...13137
GENERAL PRECAUTIONS...13142
SAFETY RULES...13142
IF ABNORMALITIES ARE FOUND...13142
CLOTHING AND PERSONAL PROTECTIVE ITEMS...13142
FIRE EXTINGUISHER AND FIRST AID KIT...13142
SAFETY FEATURES...13142
KEEP MACHINE CLEAN...13143
INSIDE OPERATOR'S COMPARTMENT...13143
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT...13143
HANDRAILS AND STEPS...13144
MOUNTING AND DISMOUNTING...13145
NO PEOPLE ON ATTACHMENTS...13145
DO NOT GET CAUGHT IN ARTICULATED PORTION...13145
PREVENTION OF BURNS...13145
FIRE PREVENTION...13146
ACTION IF FIRE OCCURS...13147
WINDOW WASHER LIQUID...13147
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)...13147
PRECAUTIONS FOR ATTACHMENTS, OPTIONS...13147
UNAUTHORIZED MODIFICATION...13147
SAFETY AT WORKSITE...13148
WORKING ON LOOSE GROUND...13148
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...13148
ENSURE GOOD VISIBILITY...13149
VENTILATION FOR ENCLOSED AREAS...13149
CHECKING SIGNALMAN'S SIGNALS AND SIGNS...13149
EMERGENCY EXIT FROM OPERATOR'S CAB...13149
BE CAREFUL ABOUT ASBESTOS DUST...13150
PRECAUTIONS FOR OPERATION...13151
STARTING ENGINE...13151
CHECKS BEFORE STARTING ENGINE...13151
PRECAUTIONS WHEN STARTING...13151
PRECAUTIONS IN COLD AREAS...13152
OPERATION...13153
CHECKS BEFORE OPERATION...13153
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE...13153
PRECAUTIONS WHEN TRAVELING...13154
TRAVELING ON SLOPES...13155
PROHIBITED OPERATIONS...13156
PRECAUTIONS WHEN OPERATING...13156
METHODS OF USING BRAKE...13157
OPERATE CAREFULLY ON SNOW...13157
PARKING MACHINE...13158
TRANSPORTATION...13159
LOADING AND UNLOADING...13159
SHIPPING...13159
BATTERY...13160
BATTERY HAZARD PREVENTION...13160
STARTING WITH BOOSTER CABLES...13161
TOWING...13162
WHEN TOWING...13162
PRECAUTIONS FOR MAINTENANCE...13163
WARNING TAG...13163
KEEP WORK PLACE CLEAN AND TIDY...13163
APPOINT LEADER WHEN WORKING WITH OTHERS...13163
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...13164
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...13165
INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF...13165
PROPER TOOLS...13166
ACCUMULATOR...13166
PERSONNEL...13166
ATTACHMENTS...13166
WORK UNDER THE MACHINE...13167
NOISE...13167
PRECAUTIONS WHEN USING HAMMER...13167
REPAIR WELDING...13167
REMOVING BATTERY TERMINAL...13167
PRECAUTIONS WITH HIGH-PRESSURE OIL...13168
HANDLING HIGH-PRESSURE HOSES...13168
WASTE MATERIALS...13168
MAINTENANCE OF AIR CONDITIONER...13168
COMPRESSED AIR...13169
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...13169
PRECAUTIONS WITH TIRES...13170
HANDLING TIRES...13170
PRECAUTIONS WHEN STORING TIRES...13170
OPERATION...13172
GENERAL VIEW...13173
GENERAL VIEW OF MACHINE...13173
GENERAL VIEW OF CONTROLS AND GAUGES...13174
EXPLANATION OF COMPONENTS...13176
MACHINE MONITOR...13176
SWITCHES...13202
CONTROL LEVERS, PEDALS...13209
STEERING TILT LOCK LEVER...13213
CAP AND COVER WITH LOCK...13213
FRAME LOCK BAR...13214
TOWING PIN...13215
GREASE PUMP...13215
CAB DOOR INNER LOCK...13215
CAB DOOR OPEN LOCK...13216
CAB WINDOW OPEN LOCK CANCEL KNOB...13216
FUSE...13216
SLOW BLOW FUSE...13218
POWER OUTLET...13218
STORAGE BOX...13218
AM/FM RADIO...13219
AM/FM RADIO-CASSETTE STEREO...13225
AIR CONDITIONER...13233
HANDLING CAB WIPER...13238
HANDLING MACHINES EQUIPPED WITH KOMTRAX...13239
OPERATION...13240
CHECK BEFORE STARTING ENGINE, ADJUST...13240
STARTING ENGINE...13255
OPERATIONS AND CHECKS AFTER STARTING ENGINE...13257
STOPPING ENGINE...13259
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...13260
TURNING...13264
OPERATION OF WORK EQUIPMENT...13266
WORK POSSIBLE USING WHEEL LOADER...13268
PRECAUTIONS FOR OPERATION...13273
ADJUSTING WORK EQUIPMENT POSTURE...13275
PARKING MACHINE...13277
CHECKS AFTER COMPLETION OF OPERATION...13279
LOCKING...13279
HANDLING THE TIRES...13280
TRANSPORTATION...13282
TRANSPORTATION PROCEDURE...13282
LOADING, UNLOADING WORK WITH TRAILERS...13282
LIFTING MACHINE...13286
COLD WEATHER OPERATION...13288
PRECAUTIONS FOR LOW TEMPERATURE...13288
PRECAUTIONS AFTER COMPLETION OF WORK...13289
AFTER COLD WEATHER...13289
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...13290
LONG-TERM STORAGE...13291
BEFORE STORAGE...13291
DURING STORAGE...13291
AFTER STORAGE...13291
TROUBLESHOOTING...13292
WHEN MACHINE RUNS OUT OF FUEL...13292
METHOD OF TOWING MACHINE...13292
IF BATTERY IS DISCHARGED...13294
OTHER TROUBLE...13297
MAINTENANCE...13302
GUIDES TO MAINTENANCE...13303
OUTLINES OF SERVICE...13305
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...13305
OUTLINE OF ELECTRIC SYSTEM...13308
WEAR PARTS...13309
WEAR PARTS LIST...13309
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...13310
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...13311
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...13312
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...13313
TORQUE LIST...13313
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...13314
MAINTENANCE SCHEDULE CHART...13315
MAINTENANCE SCHEDULE CHART...13315
SERVICE PROCEDURE...13317
INITIAL 250 HOURS SERVICE...13317
WHEN REQUIRED...13318
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT...13318
CLEAN INSIDE OF COOLING SYSTEM...13321
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL...13324
CHECK AXLE OIL LEVEL, ADD OIL...13326
CLEAN AXLE CASE BREATHER...13327
CLEAN AIR CONDITIONER CONDENSER...13328
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID...13328
CLEAN RADIATOR FINS AND COOLER FINS...13329
CHECK ELECTRICAL INTAKE AIR HEATER...13329
TURN, REPLACE BOLT-ON CUTTING EDGE...13330
REPLACE BUCKET TEETH...13331
CHECK AIR CONDITIONER...13333
REPLACE SLOW BLOW FUSE...13334
CHECKING FUNCTION OF ACCUMULATOR...13335
SELECTION AND INSPECTION OF TIRES...13336
CHECK BEFORE STARTING...13338
EVERY 50 HOURS SERVICE...13339
DRAIN WATER, SEDIMENT FROM FUEL TANK...13339
EVERY 100 HOURS SERVICE...13340
LUBRICATE REAR AXLE PIVOT PIN...13340
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...13340
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...13341
EVERY 250 HOURS SERVICE...13342
CHECK BATTERY ELECTROLYTE LEVEL...13342
CHECK PARKING BRAKE...13344
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...13344
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN...13345
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...13346
CHECKING FUNCTION OF ACCUMULATOR...13346
LUBRICATING...13347
EVERY 500 HOURS SERVICE...13348
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...13348
REPLACE FUEL FILTER CARTRIDGE...13349
REPLACEMENT OF FILTER CARTRIDGE FOR POOR-QUALITY FUEL...13350
CLEAN WATER SEPARATOR STRAINER...13351
EVERY 1000 HOURS SERVICE...13352
CHANGE OIL IN TRANSFER CASE...13352
CLEAN TRANSFER CASE BREATHER...13353
REPLACE HST OIL FILTER ELEMENT...13354
REPLACE CORROSION RESISTOR CARTRIDGE...13355
LUBRICATING...13355
CHECK TIGHTENING PARTS OF TURBOCHARGER...13355
CHECK PLAY OF TURBOCHARGER ROTOR...13355
CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT...13356
EVERY 2000 HOURS SERVICE...13357
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...13357
REPLACE HYDRAULIC TANK BREATHER ELEMENT...13358
CHANGE AXLE OIL...13359
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER...13359
CLEAN BRAKE CIRCUIT STRAINER...13360
CHECK BRAKE DISC WEAR...13361
CHECKING FUNCTION OF ACCUMULATOR...13362
CHECK ALTERNATOR, STARTING MOTOR...13362
CHECK ENGINE VALVE CLEARANCE, ADJUST...13362
CLEAN AND CHECK TURBOCHARGER...13362
CHECK VIBRATION DAMPER...13362
EVERY 4000 HOURS SERVICE...13363
LUBRICATING...13363
CHECK WATER PUMP...13363
SPECIFICATIONS...13364
SPECIFICATIONS...13365
ATTACHMENTS, OPTIONS...13366
SELECTING BUCKET AND TIRES...13367
INDEX...13368
TEN00227-04 - Wheel Loader WA200-6 Operation & Maintenance Manual...13372
COVER...13372
FOREWORD...13373
BEFORE READING THIS MANUAL...13374
SAFETY INFORMATION...13375
INTRODUCTION...13376
USE OF MACHINE...13376
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...13376
VISIBILITY FROM OPERATOR'S SEAT...13376
NECESSARY INFORMATION...13377
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...13377
EPA REGULATIONS, ENGINE NUMBER PLATE...13377
POSITION OF SERVICE METER...13378
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...13378
CONTENTS...13379
SAFETY...13383
SAFETY...13384
SAFETY LABELS...13387
LOCATION OF SAFETY LABELS...13387
SAFETY LABELS...13388
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE...13394
PRECAUTIONS BEFORE STARTING OPERATION...13394
PREPARATIONS FOR SAFE OPERATION...13394
FIRE PREVENTION...13396
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE...13397
DO NOT GET CAUGHT IN ARTICULATING PORTION...13400
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES...13400
UNAUTHORIZED MODIFICATION...13400
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS...13400
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING...13401
PRECAUTIONS FOR OPERATION...13402
PRECAUTIONS FOR JOBSITE...13402
STARTING ENGINE...13404
OPERATION...13406
TRANSPORTATION...13413
TOWING...13414
PRECAUTIONS FOR MAINTENANCE...13415
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE...13415
PRECAUTIONS FOR INSPECTION AND MAINTENANCE...13420
TIRES...13425
OPERATION...13427
GENERAL VIEW...13428
GENERAL VIEW OF MACHINE...13428
GENERAL VIEW OF CONTROLS AND GAUGES...13429
EXPLANATION OF COMPONENTS...13431
MACHINE MONITOR...13431
SWITCHES...13468
CONTROL LEVERS, PEDALS...13482
STEERING TILT LOCK LEVER...13487
CAP AND COVER WITH LOCK...13487
FRAME LOCK BAR...13488
TOWING PIN...13489
GREASE PUMP...13489
OPENING, CLOSING CAB DOORS, WINDOWS...13490
FUSE...13494
SLOW BLOW FUSE...13496
POWER OUTLET...13497
STORAGE BOX...13497
AM/FM RADIO-CASSETTE STEREO...13498
AIR CONDITIONER...13506
HANDLING CAB WIPER...13513
OPERATION...13514
CHECK BEFORE STARTING ENGINE, ADJUST...13514
STARTING ENGINE...13532
CHECKS AFTER STARTING ENGINE...13536
OPERATIONS AND CHECKS AFTER STARTING ENGINE...13537
STOPPING ENGINE...13540
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...13541
TURNING...13547
OPERATION OF WORK EQUIPMENT...13549
WORK POSSIBLE USING WHEEL LOADER...13551
PRECAUTIONS FOR OPERATION...13557
ADJUSTING WORK EQUIPMENT POSTURE...13559
PARKING MACHINE...13561
CHECKS AFTER COMPLETION OF OPERATION...13563
LOCKING...13563
HANDLING THE TIRES...13564
TRANSPORTATION...13566
TRANSPORTATION PROCEDURE...13566
LOADING, UNLOADING WORK WITH TRAILERS...13566
LIFTING MACHINE...13570
COLD WEATHER OPERATION...13572
PRECAUTIONS FOR LOW TEMPERATURE...13572
PRECAUTIONS AFTER COMPLETION OF WORK...13573
AFTER COLD WEATHER...13573
LONG-TERM STORAGE...13574
BEFORE STORAGE...13574
DURING STORAGE...13574
AFTER STORAGE...13574
TROUBLESHOOTING...13575
WHEN MACHINE RUNS OUT OF FUEL...13575
METHOD OF TOWING MACHINE...13575
IF BATTERY IS DISCHARGED...13577
OTHER TROUBLE...13580
MAINTENANCE...13585
GUIDES TO MAINTENANCE...13586
OUTLINES OF SERVICE...13588
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...13588
OUTLINE OF ELECTRIC SYSTEM...13592
WEAR PARTS...13593
WEAR PARTS LIST...13593
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...13594
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...13595
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...13596
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...13597
TORQUE LIST...13597
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...13598
MAINTENANCE SCHEDULE CHART...13599
MAINTENANCE SCHEDULE CHART...13599
SERVICE PROCEDURE...13601
INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE)...13601
INITIAL 250 HOURS SERVICE...13601
INITIAL 1000 HOURS SERVICE...13601
WHEN REQUIRED...13602
CHECK BEFORE STARTING...13629
EVERY 50 HOURS SERVICE...13630
EVERY 100 HOURS SERVICE...13631
EVERY 250 HOURS SERVICE...13634
EVERY 500 HOURS SERVICE...13640
EVERY 1000 HOURS SERVICE...13644
EVERY 2000 HOURS SERVICE...13650
EVERY 4000 HOURS SERVICE...13657
EVERY 8000 HOURS SERVICE...13659
SPECIFICATIONS...13661
SPECIFICATIONS...13662
ATTACHMENTS, OPTIONS...13665
SELECTING BUCKET AND TIRES...13666
HANDLING HYDRAULIC QUICK COUPLER...13667
REMOVING ATTACHMENT...13667
INSTALLING ATTACHMENT...13669
METHOD OF USING 2 LEVERS...13671
EXPLANATION OF COMPONENTS...13671
HANDLING MACHINES EQUIPPED WITH KOMTRAX...13673
BASIC PRECAUTIONS...13673
INDEX...13675
TEN00395-01 - Wheel Loader WA200-5 Operation & Maintenance Manual...13679
COVER...13679
FOREWORD...13680
FOREWORD...13681
SAFETY INFORMATION...13682
INTRODUCTION...13684
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...13684
NECESSARY INFORMATION...13685
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...13685
ENGINE SERIAL NO. PLATE...13685
POSITION OF SERVICE METER...13686
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...13686
CONTENTS...13687
SAFETY...13690
SAFETY...13691
SAFETY LABELS...13694
LOCATION OF SAFETY LABELS...13694
SAFETY LABELS...13695
GENERAL PRECAUTIONS...13700
PRECAUTIONS FOR OPERATION...13709
STARTING ENGINE...13709
OPERATION...13711
TRANSPORTATION...13717
BATTERY...13718
TOWING...13720
PRECAUTIONS FOR MAINTENANCE...13721
PRECAUTIONS WITH TIRES...13728
OPERATION...13730
GENERAL VIEW...13731
GENERAL VIEW OF MACHINE...13731
GENERAL VIEW OF CONTROLS AND GAUGES...13732
EXPLANATION OF COMPONENTS...13734
MACHINE MONITOR...13734
SWITCHES...13760
CONTROL LEVERS, PEDALS...13767
CAP AND COVER WITH LOCK...13771
FRAME LOCK BAR...13772
TOWING PIN...13773
GREASE PUMP...13773
CAB DOOR INNER LOCK...13773
CAB DOOR OPEN LOCK...13774
CAB WINDOW OPEN LOCK CANCEL KNOB...13774
FUSE...13774
SLOW BLOW FUSE...13776
POWER OUTLET...13776
STORAGE BOX...13776
AM/FM RADIO...13777
AM/FM RADIO-CASSETTE STEREO...13783
AIR CONDITIONER...13791
HANDLING CAB WIPER...13796
HANDLING MACHINES EQUIPPED WITH KOMTRAX...13797
OPERATION...13798
CHECK BEFORE STARTING ENGINE, ADJUST...13798
STARTING ENGINE...13814
OPERATIONS AND CHECKS AFTER STARTING ENGINE...13816
STOPPING ENGINE...13818
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...13819
TURNING...13823
OPERATION OF WORK EQUIPMENT...13825
WORK POSSIBLE USING WHEEL LOADER...13827
PRECAUTIONS FOR OPERATION...13832
ADJUSTING WORK EQUIPMENT POSTURE...13834
PARKING MACHINE...13836
CHECKS AFTER COMPLETION OF OPERATION...13838
LOCKING...13838
HANDLING THE TIRES...13839
TRANSPORTATION...13841
TRANSPORTATION PROCEDURE...13841
LOADING, UNLOADING WORK WITH TRAILERS...13841
LIFTING MACHINE...13845
COLD WEATHER OPERATION...13847
PRECAUTIONS FOR LOW TEMPERATURE...13847
PRECAUTIONS AFTER COMPLETION OF WORK...13848
AFTER COLD WEATHER...13848
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...13849
LONG-TERM STORAGE...13850
BEFORE STORAGE...13850
DURING STORAGE...13850
AFTER STORAGE...13850
TROUBLESHOOTING...13851
WHEN MACHINE RUNS OUT OF FUEL...13851
METHOD OF TOWING MACHINE...13851
IF BATTERY IS DISCHARGED...13853
OTHER TROUBLE...13856
MAINTENANCE...13862
GUIDES TO MAINTENANCE...13863
OUTLINES OF SERVICE...13865
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...13865
OUTLINE OF ELECTRIC SYSTEM...13868
WEAR PARTS...13869
WEAR PARTS LIST...13869
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...13870
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...13871
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...13872
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...13873
TORQUE LIST...13873
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...13874
MAINTENANCE SCHEDULE CHART...13875
MAINTENANCE SCHEDULE CHART...13875
SERVICE PROCEDURE...13877
INITIAL 250 HOURS SERVICE...13877
WHEN REQUIRED...13878
CHECK BEFORE STARTING...13898
EVERY 50 HOURS SERVICE...13899
EVERY 100 HOURS SERVICE...13900
EVERY 250 HOURS SERVICE...13902
EVERY 500 HOURS SERVICE...13908
EVERY 1000 HOURS SERVICE...13912
EVERY 2000 HOURS SERVICE...13916
EVERY 4000 HOURS SERVICE...13923
SPECIFICATIONS...13924
SPECIFICATIONS...13925
ATTACHMENTS, OPTIONS...13928
SELECTING BUCKET AND TIRES...13929
HANDLING BATTERY DISCONNECTOR SWITCH...13930
EXPLANATION OF COMPONENTS...13930
HANDLING...13930
INDEX...13932
TEN00396-01 - Wheel Loader WA250-5 Operation & Maintenance Manual...13936
COVER...13936
FOREWORD...13937
FOREWORD...13938
SAFETY INFORMATION...13939
INTRODUCTION...13941
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...13941
NECESSARY INFORMATION...13942
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...13942
ENGINE SERIAL NO. PLATE...13942
POSITION OF SERVICE METER...13943
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...13943
CONTENTS...13944
SAFETY...13947
SAFETY...13948
SAFETY LABELS...13951
LOCATION OF SAFETY LABELS...13951
SAFETY LABELS...13952
GENERAL PRECAUTIONS...13957
PRECAUTIONS FOR OPERATION...13966
STARTING ENGINE...13966
OPERATION...13968
TRANSPORTATION...13974
BATTERY...13975
TOWING...13977
PRECAUTIONS FOR MAINTENANCE...13978
PRECAUTIONS WITH TIRES...13985
OPERATION...13987
GENERAL VIEW...13988
GENERAL VIEW OF MACHINE...13988
GENERAL VIEW OF CONTROLS AND GAUGES...13989
EXPLANATION OF COMPONENTS...13991
MACHINE MONITOR...13991
SWITCHES...14017
CONTROL LEVERS, PEDALS...14024
STEERING TILT LOCK LEVER...14028
CAP AND COVER WITH LOCK...14028
FRAME LOCK BAR...14029
TOWING PIN...14030
GREASE PUMP...14030
CAB DOOR INNER LOCK...14030
CAB DOOR OPEN LOCK...14031
CAB WINDOW OPEN LOCK CANCEL KNOB...14031
FUSE...14031
SLOW BLOW FUSE...14033
POWER OUTLET...14033
STORAGE BOX...14033
AM/FM RADIO...14034
AM/FM RADIO-CASSETTE STEREO...14040
AIR CONDITIONER...14048
HANDLING CAB WIPER...14053
HANDLING MACHINES EQUIPPED WITH KOMTRAX...14054
OPERATION...14055
CHECK BEFORE STARTING ENGINE, ADJUST...14055
STARTING ENGINE...14070
OPERATIONS AND CHECKS AFTER STARTING ENGINE...14072
STOPPING ENGINE...14074
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...14075
TURNING...14079
OPERATION OF WORK EQUIPMENT...14081
WORK POSSIBLE USING WHEEL LOADER...14083
PRECAUTIONS FOR OPERATION...14088
ADJUSTING WORK EQUIPMENT POSTURE...14090
PARKING MACHINE...14092
CHECKS AFTER COMPLETION OF OPERATION...14094
LOCKING...14094
HANDLING THE TIRES...14095
TRANSPORTATION...14097
TRANSPORTATION PROCEDURE...14097
LOADING, UNLOADING WORK WITH TRAILERS...14097
LIFTING MACHINE...14101
COLD WEATHER OPERATION...14103
PRECAUTIONS FOR LOW TEMPERATURE...14103
PRECAUTIONS AFTER COMPLETION OF WORK...14104
AFTER COLD WEATHER...14104
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...14105
LONG-TERM STORAGE...14106
BEFORE STORAGE...14106
DURING STORAGE...14106
AFTER STORAGE...14106
TROUBLESHOOTING...14107
WHEN MACHINE RUNS OUT OF FUEL...14107
METHOD OF TOWING MACHINE...14107
IF BATTERY IS DISCHARGED...14109
OTHER TROUBLE...14112
MAINTENANCE...14117
GUIDES TO MAINTENANCE...14118
OUTLINES OF SERVICE...14120
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...14120
OUTLINE OF ELECTRIC SYSTEM...14123
WEAR PARTS...14124
WEAR PARTS LIST...14124
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...14125
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...14126
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...14127
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...14128
TORQUE LIST...14128
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...14129
MAINTENANCE SCHEDULE CHART...14130
MAINTENANCE SCHEDULE CHART...14130
SERVICE PROCEDURE...14132
INITIAL 250 HOURS SERVICE...14132
WHEN REQUIRED...14133
CHECK BEFORE STARTING...14153
EVERY 50 HOURS SERVICE...14154
EVERY 100 HOURS SERVICE...14155
EVERY 250 HOURS SERVICE...14157
EVERY 500 HOURS SERVICE...14163
EVERY 1000 HOURS SERVICE...14167
EVERY 2000 HOURS SERVICE...14171
EVERY 4000 HOURS SERVICE...14177
SPECIFICATIONS...14179
SPECIFICATIONS...14180
ATTACHMENTS, OPTIONS...14181
SELECTING BUCKET AND TIRES...14182
INDEX...14183
TEN00399-00 - Wheel Loader WA250-6 Operation & Maintenance Manual...14187
COVER...14187
FOREWORD...14188
BEFORE READING THIS MANUAL...14189
SAFETY INFORMATION...14190
INTRODUCTION...14191
USE OF MACHINE...14191
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...14191
VISIBILITY FROM OPERATOR'S SEAT...14191
NECESSARY INFORMATION...14192
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...14192
EPA REGULATIONS, ENGINE NUMBER PLATE...14192
POSITION OF SERVICE METER...14193
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...14193
CONTENTS...14194
SAFETY...14198
SAFETY...14199
SAFETY LABELS...14202
LOCATION OF SAFETY LABELS...14202
SAFETY LABELS...14203
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE...14209
PRECAUTIONS BEFORE STARTING OPERATION...14209
PREPARATIONS FOR SAFE OPERATION...14209
FIRE PREVENTION...14211
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE...14212
DO NOT GET CAUGHT IN ARTICULATING PORTION...14215
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES...14215
UNAUTHORIZED MODIFICATION...14215
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS...14215
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING...14216
PRECAUTIONS FOR OPERATION...14217
PRECAUTIONS FOR JOBSITE...14217
STARTING ENGINE...14219
OPERATION...14221
TRANSPORTATION...14228
TOWING...14229
PRECAUTIONS FOR MAINTENANCE...14230
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE...14230
PRECAUTIONS FOR INSPECTION AND MAINTENANCE...14235
TIRES...14240
OPERATION...14242
GENERAL VIEW...14243
GENERAL VIEW OF MACHINE...14243
GENERAL VIEW OF CONTROLS AND GAUGES...14244
EXPLANATION OF COMPONENTS...14246
MACHINE MONITOR...14246
SWITCHES...14282
CONTROL LEVERS, PEDALS...14298
STEERING TILT LOCK LEVER...14303
CAP AND COVER WITH LOCK...14303
FRAME LOCK BAR...14304
TOWING PIN...14305
GREASE PUMP...14305
OPENING, CLOSING CAB DOORS, WINDOWS...14306
FUSE...14310
SLOW BLOW FUSE...14312
POWER OUTLET...14313
STORAGE BOX...14313
AM/FM RADIO-CASSETTE STEREO...14314
AIR CONDITIONER...14322
HANDLING CAB WIPER...14329
OPERATION...14330
CHECK BEFORE STARTING ENGINE, ADJUST...14330
STARTING ENGINE...14348
CHECKS AFTER STARTING ENGINE...14352
OPERATIONS AND CHECKS AFTER STARTING ENGINE...14353
STOPPING ENGINE...14356
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...14357
TURNING...14361
OPERATION OF WORK EQUIPMENT...14363
WORK POSSIBLE USING WHEEL LOADER...14365
PRECAUTIONS FOR OPERATION...14370
ADJUSTING WORK EQUIPMENT POSTURE...14372
PARKING MACHINE...14374
CHECKS AFTER COMPLETION OF OPERATION...14376
LOCKING...14376
HANDLING THE TIRES...14377
TRANSPORTATION...14379
TRANSPORTATION PROCEDURE...14379
LOADING, UNLOADING WORK WITH TRAILERS...14379
LIFTING MACHINE...14383
COLD WEATHER OPERATION...14385
PRECAUTIONS FOR LOW TEMPERATURE...14385
PRECAUTIONS AFTER COMPLETION OF WORK...14386
AFTER COLD WEATHER...14386
LONG-TERM STORAGE...14387
BEFORE STORAGE...14387
DURING STORAGE...14387
AFTER STORAGE...14387
TROUBLESHOOTING...14388
WHEN MACHINE RUNS OUT OF FUEL...14388
METHOD OF TOWING MACHINE...14388
IF BATTERY IS DISCHARGED...14390
OTHER TROUBLE...14393
MAINTENANCE...14398
GUIDES TO MAINTENANCE...14399
OUTLINES OF SERVICE...14401
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...14401
OUTLINE OF ELECTRIC SYSTEM...14404
WEAR PARTS...14405
WEAR PARTS LIST...14405
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...14406
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...14407
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...14408
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...14409
TORQUE LIST...14409
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...14410
MAINTENANCE SCHEDULE CHART...14411
MAINTENANCE SCHEDULE CHART...14411
SERVICE PROCEDURE...14413
INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE)...14413
INITIAL 250 HOURS SERVICE...14413
INITIAL 1000 HOURS SERVICE...14413
WHEN REQUIRED...14414
CHECK BEFORE STARTING...14441
EVERY 50 HOURS SERVICE...14442
EVERY 100 HOURS SERVICE...14443
EVERY 250 HOURS SERVICE...14446
EVERY 500 HOURS SERVICE...14452
EVERY 1000 HOURS SERVICE...14456
EVERY 2000 HOURS SERVICE...14462
EVERY 4000 HOURS SERVICE...14469
EVERY 8000 HOURS SERVICE...14471
SPECIFICATIONS...14472
SPECIFICATIONS...14473
ATTACHMENTS, OPTIONS...14476
SELECTING BUCKET AND TIRES...14477
HANDLING HYDRAULIC QUICK COUPLER...14478
REMOVING ATTACHMENT...14478
INSTALLING ATTACHMENT...14480
METHOD OF USING 2 LEVERS...14482
EXPLANATION OF COMPONENTS...14482
HANDLING MACHINES EQUIPPED WITH KOMTRAX...14484
BASIC PRECAUTIONS...14484
INDEX...14486
TEN00450-01 - Wheel Loader WA250-6 Operation & Maintenance Manual...14490
COVER...14490
FOREWORD...14491
BEFORE READING THIS MANUAL...14492
SAFETY INFORMATION...14493
INTRODUCTION...14494
USE OF MACHINE...14494
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...14494
VISIBILITY FROM OPERATOR'S SEAT...14494
NECESSARY INFORMATION...14495
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...14495
EPA REGULATIONS, ENGINE NUMBER PLATE...14495
POSITION OF SERVICE METER...14496
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...14496
CONTENTS...14497
SAFETY...14501
SAFETY...14502
SAFETY LABELS...14505
LOCATION OF SAFETY LABELS...14505
SAFETY LABELS...14506
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE...14512
PRECAUTIONS BEFORE STARTING OPERATION...14512
PREPARATIONS FOR SAFE OPERATION...14512
FIRE PREVENTION...14514
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE...14515
DO NOT GET CAUGHT IN ARTICULATING PORTION...14518
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES...14518
UNAUTHORIZED MODIFICATION...14518
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS...14518
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING...14519
PRECAUTIONS FOR OPERATION...14520
PRECAUTIONS FOR JOBSITE...14520
STARTING ENGINE...14522
OPERATION...14524
TRANSPORTATION...14531
TOWING...14532
PRECAUTIONS FOR MAINTENANCE...14533
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE...14533
PRECAUTIONS FOR INSPECTION AND MAINTENANCE...14538
TIRES...14543
OPERATION...14545
GENERAL VIEW...14546
GENERAL VIEW OF MACHINE...14546
GENERAL VIEW OF CONTROLS AND GAUGES...14547
EXPLANATION OF COMPONENTS...14549
MACHINE MONITOR...14549
SWITCHES...14586
CONTROL LEVERS, PEDALS...14600
STEERING TILT LOCK LEVER...14605
CAP AND COVER WITH LOCK...14605
FRAME LOCK BAR...14606
TOWING PIN...14607
GREASE PUMP...14607
OPENING, CLOSING CAB DOORS, WINDOWS...14608
FUSE...14612
SLOW BLOW FUSE...14614
POWER OUTLET...14615
STORAGE BOX...14615
AM/FM RADIO-CASSETTE STEREO...14616
AIR CONDITIONER...14624
HANDLING CAB WIPER...14631
OPERATION...14632
CHECK BEFORE STARTING ENGINE, ADJUST...14632
STARTING ENGINE...14651
CHECKS AFTER STARTING ENGINE...14655
OPERATIONS AND CHECKS AFTER STARTING ENGINE...14656
STOPPING ENGINE...14659
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...14660
TURNING...14666
OPERATION OF WORK EQUIPMENT...14668
WORK POSSIBLE USING WHEEL LOADER...14670
PRECAUTIONS FOR OPERATION...14675
ADJUSTING WORK EQUIPMENT POSTURE...14677
PARKING MACHINE...14679
CHECKS AFTER COMPLETION OF OPERATION...14681
LOCKING...14681
HANDLING THE TIRES...14682
TRANSPORTATION...14684
TRANSPORTATION PROCEDURE...14684
LOADING, UNLOADING WORK WITH TRAILERS...14684
LIFTING MACHINE...14688
COLD WEATHER OPERATION...14690
PRECAUTIONS FOR LOW TEMPERATURE...14690
PRECAUTIONS AFTER COMPLETION OF WORK...14691
AFTER COLD WEATHER...14691
LONG-TERM STORAGE...14692
BEFORE STORAGE...14692
DURING STORAGE...14692
AFTER STORAGE...14692
TROUBLESHOOTING...14693
WHEN MACHINE RUNS OUT OF FUEL...14693
METHOD OF TOWING MACHINE...14693
IF BATTERY IS DISCHARGED...14695
OTHER TROUBLE...14698
MAINTENANCE...14703
GUIDES TO MAINTENANCE...14704
OUTLINES OF SERVICE...14706
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...14706
OUTLINE OF ELECTRIC SYSTEM...14709
WEAR PARTS...14710
WEAR PARTS LIST...14710
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...14711
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...14712
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...14713
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...14714
TORQUE LIST...14714
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...14715
MAINTENANCE SCHEDULE CHART...14716
MAINTENANCE SCHEDULE CHART...14716
SERVICE PROCEDURE...14718
INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE)...14718
INITIAL 250 HOURS SERVICE...14718
INITIAL 1000 HOURS SERVICE...14718
WHEN REQUIRED...14719
CHECK BEFORE STARTING...14746
EVERY 50 HOURS SERVICE...14747
EVERY 100 HOURS SERVICE...14748
EVERY 250 HOURS SERVICE...14751
EVERY 500 HOURS SERVICE...14757
EVERY 1000 HOURS SERVICE...14761
EVERY 2000 HOURS SERVICE...14767
EVERY 4000 HOURS SERVICE...14774
EVERY 8000 HOURS SERVICE...14776
SPECIFICATIONS...14777
SPECIFICATIONS...14778
ATTACHMENTS, OPTIONS...14781
SELECTING BUCKET AND TIRES...14782
HANDLING HYDRAULIC QUICK COUPLER...14783
REMOVING ATTACHMENT...14783
INSTALLING ATTACHMENT...14785
METHOD OF USING 2 LEVERS...14787
EXPLANATION OF COMPONENTS...14787
HANDLING MACHINES EQUIPPED WITH KOMTRAX...14789
BASIC PRECAUTIONS...14789
INDEX...14791
TEN00471-01 - Wheel Loader WA200-6 Operation & Maintenance Manual...14795
COVER...14795
FOREWORD...14796
BEFORE READING THIS MANUAL...14797
SAFETY INFORMATION...14798
INTRODUCTION...14799
USE OF MACHINE...14799
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...14799
VISIBILITY FROM OPERATOR'S SEAT...14799
NECESSARY INFORMATION...14800
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...14800
EPA REGULATIONS, ENGINE NUMBER PLATE...14800
POSITION OF SERVICE METER...14801
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...14801
CONTENTS...14802
SAFETY...14806
SAFETY...14807
SAFETY LABELS...14810
LOCATION OF SAFETY LABELS...14810
SAFETY LABELS...14811
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE...14817
PRECAUTIONS BEFORE STARTING OPERATION...14817
PREPARATIONS FOR SAFE OPERATION...14817
FIRE PREVENTION...14819
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE...14820
DO NOT GET CAUGHT IN ARTICULATING PORTION...14823
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES...14823
UNAUTHORIZED MODIFICATION...14823
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS...14823
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING...14824
PRECAUTIONS FOR OPERATION...14825
PRECAUTIONS FOR JOBSITE...14825
STARTING ENGINE...14827
OPERATION...14829
TRANSPORTATION...14836
TOWING...14837
PRECAUTIONS FOR MAINTENANCE...14838
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE...14838
PRECAUTIONS FOR INSPECTION AND MAINTENANCE...14843
TIRES...14848
OPERATION...14850
GENERAL VIEW...14851
GENERAL VIEW OF MACHINE...14851
GENERAL VIEW OF CONTROLS AND GAUGES...14852
EXPLANATION OF COMPONENTS...14854
MACHINE MONITOR...14854
SWITCHES...14891
CONTROL LEVERS, PEDALS...14905
STEERING TILT LOCK LEVER...14910
CAP AND COVER WITH LOCK...14910
FRAME LOCK BAR...14911
TOWING PIN...14912
GREASE PUMP...14912
OPENING, CLOSING CAB DOORS, WINDOWS...14913
FUSE...14917
SLOW BLOW FUSE...14919
POWER OUTLET...14920
STORAGE BOX...14920
AM/FM RADIO-CASSETTE STEREO...14921
AIR CONDITIONER...14929
HANDLING CAB WIPER...14936
OPERATION...14937
CHECK BEFORE STARTING ENGINE, ADJUST...14937
STARTING ENGINE...14955
CHECKS AFTER STARTING ENGINE...14959
OPERATIONS AND CHECKS AFTER STARTING ENGINE...14960
STOPPING ENGINE...14963
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...14964
TURNING...14970
OPERATION OF WORK EQUIPMENT...14972
WORK POSSIBLE USING WHEEL LOADER...14974
PRECAUTIONS FOR OPERATION...14980
ADJUSTING WORK EQUIPMENT POSTURE...14982
PARKING MACHINE...14984
CHECKS AFTER COMPLETION OF OPERATION...14986
LOCKING...14986
HANDLING THE TIRES...14987
TRANSPORTATION...14989
TRANSPORTATION PROCEDURE...14989
LOADING, UNLOADING WORK WITH TRAILERS...14989
LIFTING MACHINE...14993
COLD WEATHER OPERATION...14995
PRECAUTIONS FOR LOW TEMPERATURE...14995
PRECAUTIONS AFTER COMPLETION OF WORK...14996
AFTER COLD WEATHER...14996
LONG-TERM STORAGE...14997
BEFORE STORAGE...14997
DURING STORAGE...14997
AFTER STORAGE...14997
TROUBLESHOOTING...14998
WHEN MACHINE RUNS OUT OF FUEL...14998
METHOD OF TOWING MACHINE...14998
IF BATTERY IS DISCHARGED...15000
OTHER TROUBLE...15003
MAINTENANCE...15008
GUIDES TO MAINTENANCE...15009
OUTLINES OF SERVICE...15011
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...15011
OUTLINE OF ELECTRIC SYSTEM...15014
WEAR PARTS...15015
WEAR PARTS LIST...15015
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...15016
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...15017
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...15018
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...15019
TORQUE LIST...15019
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...15020
MAINTENANCE SCHEDULE CHART...15021
MAINTENANCE SCHEDULE CHART...15021
SERVICE PROCEDURE...15023
INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE)...15023
INITIAL 250 HOURS SERVICE...15023
INITIAL 1000 HOURS SERVICE...15023
WHEN REQUIRED...15024
CHECK BEFORE STARTING...15051
EVERY 50 HOURS SERVICE...15052
EVERY 100 HOURS SERVICE...15053
EVERY 250 HOURS SERVICE...15056
EVERY 500 HOURS SERVICE...15062
EVERY 1000 HOURS SERVICE...15066
EVERY 2000 HOURS SERVICE...15072
EVERY 4000 HOURS SERVICE...15079
EVERY 8000 HOURS SERVICE...15081
SPECIFICATIONS...15082
SPECIFICATIONS...15083
ATTACHMENTS, OPTIONS...15086
SELECTING BUCKET AND TIRES...15087
HANDLING HYDRAULIC QUICK COUPLER...15088
REMOVING ATTACHMENT...15088
INSTALLING ATTACHMENT...15090
METHOD OF USING 2 LEVERS...15092
EXPLANATION OF COMPONENTS...15092
HANDLING MACHINES EQUIPPED WITH KOMTRAX...15094
BASIC PRECAUTIONS...15094
INDEX...15096
bonus_material...15100
Achsen&Bremsen_WA200_WA250_320-5.ppt...15101
Arbeitshydraulik_WA200_250-5.ppt...15125
Bedienung_WA200_250_320-5.ppt...15153
Elektrik_WA200_250_320-5.ppt...15171
Fahrantrieb_WA200_250-5.ppt...15186
Komatsu Wheel Loader WA200, WA200L, WA250, WA250L, WA250LC Repair Service Manual
