Komatsu Wheel Loaders WA250, WA250L, WA250MC, WA250H, WA250PT, WA250PTL, WA250PTH, WA250PTMC Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loaders WA250, WA250L, WA250MC, WA250H, WA250PT, WA250PTL, WA250PTH, WA250PTMC, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Wheel Loaders WA250, WA250-5L, WA250-3MC, WA250-5H, WA250PT, WA250PT-5L, WA250PT-5H, WA250PT-3MC 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.
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PRODUCT DETAILS:
Total Pages: 6,113 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
CEAM005801 - Wheel Loader WA250-3MC avance plus Operation & Maintenance Manual...3
COVER...3
INTRODUCTION...9
FORWARD...10
SAFETY INFORMATION...11
INTRODUCTION...12
INTENDED USE...12
FEATURES...12
BREAKING IN A NEW MACHINE...12
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...13
MACHINE SERIAL NO. PLATE POSITION...13
ENGINE SERIAL NO. PLATE POSITION...13
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...13
CONTENTS...14
SAFETY...23
GENERAL PRECAUTIONS...24
SAFETY RULES...24
SAFETY FEATURES...24
UNAUTHORIZED MODIFICATION...24
CLOTHING AND PERSONAL PROTECTIVE ITEMS...25
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT...25
MOUNTING AND DISMOUNTING...26
FIRE PREVENTION FOR FUEL AND OIL...26
PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES...27
ASBESTOS DUST HAZARD PREVENTION...27
CRUSHING OR CUTTING PREVENTION...27
FIRE EXTINGUISHER AND FIRST AID KIT...28
PRECAUTIONS WHEN USING ROPS...28
PRECAUTIONS FOR ATTACHMENTS...28
PRECAUTION WHEN HANDLING ACCUMULATOR...29
PRECAUTIONS DURING OPERATION...30
BEFORE STARTING ENGINE...30
SAFETY AT WORKSITE...30
FIRE PREVENTION...30
WALK AROUND CHECK...30
IN OPERATOR'S CAB...31
VENTILATION FOR ENCLOSED AREAS...31
PRECAUTIONS FOR MIRRORS, WINDOWS, AND LIGHTS...31
WHEN STARTING ENGINE...32
AFTER STARTING ENGINE...33
CHECKS AFTER STARTING ENGINE...33
PRECAUTIONS WHEN STARTING OFF...33
CHECK WHEN CHANGING DIRECTION...34
PRECAUTIONS WHEN TRAVELING...35
TRAVELING ON SLOPES...36
PROHIBITED OPERATIONS...36
PRECAUTIONS WHEN TRAVELING...37
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...38
ENSURE GOOD VISIBILITY...39
OPERATE CAREFULLY ON SNOW...39
DO NOT HIT WORK EQUIPMENT...39
WHEN USING THE BRAKE...39
WHEN MAKING A DOWNHILL TRAVEL...39
WORKING ON LOOSE GROUND...40
PARKING THE MACHINE...40
PRECAUTIONS IN COLD AREAS...41
TRANSPORTATION...42
LOADING AND UNLOADING...42
SHIPPING...42
BATTERY...43
BATTERY HAZARD PREVENTION...43
STARTING WITH BOOSTER CABLES...44
CHARGING BATTERY...45
TOWING...46
WHEN TOWING...46
PRECAUTIONS FOR MAINTENANCE...47
BEFORE CARRYING OUT MAINTENANCE...47
NOTIFICATION OF FAILURE...47
WARNING TAGS...47
CLEAN BEFORE INSPECTION AND MAINTENANCE...47
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE...48
WORK EQUIPMENT SUPPORT...48
PROPER TOOLS...49
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...49
USE OF LIGHTING...49
KEEP WORK PLACE CLEAN AND TIDY...49
APPOINT A LEADER WHEN WORKING WITH OTHERS...50
RADIATOR WATER LEVEL...50
PREVENTION OF FIRE...50
TURN E.C.S.S. SWITCH OFF...50
DURING MAINTENANCE...51
PERSONNEL...51
ATTACHMENTS...51
WORK UNDER THE MACHINE...51
DO NOT DROP TOOLS OR PARTS INSIDE MACHINE...51
PRECAUTIONS WHEN USING HAMMER...52
REPAIR WELDING...52
PRECAUTIONS WITH BATTERY...52
WHEN ABNORMALITY IS LOCATED...52
RULES TO FOLLOW WHEN ADDING FUEL OR OIL...52
ROTATING FAN AND BLADE...53
HANDLING HIGH-PRESSURE HOSES...53
PRECAUTION HIGH PRESSURE OIL...53
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE OR HIGH PRESSURE...53
TIRE MAINTENANCE...54
CHECKS AFTER INSPECTION AND MAINTENANCE...54
WASTE MATERIALS...54
WHEN PERFORMING MAINTENANCE WITH THE CHASSIS RAISED...54
TIRES...55
HANDLING TIRES...55
STORING TIRES AFTER REMOVAL...56
POSITION FOR ATTACHING SAFETY LABELS...57
POSITION FOR ATTACHING SAFETY LABELS...57
OPERATION...63
GENERAL VIEW...64
GENERAL VIEW OF MACHINE...64
GENERAL VIEW OF CONTROLS AND GAUGES...65
EXPLANATION OF COMPONENTS...66
METER, LAMPS...66
ALARM DISPLAY PORTIONS (B, E)...66
METER DISPLAY PORTION (A, C, D)...67
OPTION DISPLAY PORTION (F)...67
TESTING ACTUATION OF MACHINE MONITOR SYSTEM...67
WARNING DISPLAYS...68
METER DISPLAY PORTION...72
SWITCHES...76
CONTROL LEVERS, PEDAL...82
STEERING COLUMN TILT LEVER...89
CAP WITH LOCK...89
METHOD OF OPENING AND CLOSING CAP WITH LOCK...89
SAFETY BAR...90
TOWING PIN...90
GREASE PUMP CLAMP AND RUBBER RING...90
BACKUP ALARM...91
FUSE...91
FUSE CAPACITY AND NAME OF CIRCUIT...91
SLOW BLOW FUSE...92
STORAGE FOR THIS MANUAL...93
AUXILIARY POWER SOURCE...93
FOR MACHINES EQUIPPED WITH ROPS CAB...93
CHECK BEFORE STARTING ENGINE...94
WALK AROUND CHECK...94
CHECK BEFORE STARTING...97
CHECK COOLANT LEVEL, ADD COOLANT...97
CHECK MONITOR PANEL...97
CHECK FUEL LEVEL, ADD FUEL...97
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...98
CHECK AND REFILL OF OIL IN BRAKE OIL TANK...99
CHECK DUST INDICATOR...99
CHECK ELECTRICAL WIRING...99
DRAIN THE WATER FROM THE FUEL-WATER SEPARATOR...100
FUEL SEDIMENT STRAINER...100
INSPECTION OF TIRES...101
INSPECTION OF RIMS...101
TIRE PRESSURE...101
CHECK EFFECT OF PARKING BRAKE...103
CHECK EFFECT OF WHEEL BRAKES...103
CHECK SOUND OF HORN AND BACKUP ALARM...103
CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE...103
CHECK ENGINE EXHAUST COLOR AND SOUND...103
CHECK OPERATIONS OF GAUGES...103
CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING...103
CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE...103
CHECK LOCK OF CAB DOOR FOR MACHINES EQUIPPED WITH CAB...103
OPERATOR'S SEAT ADJUSTMENT...104
OPERATOR'S AIR RIDE SUSPENSION SEAT...105
SEAT BELT ADJUSTMENT...106
REAR VEIW MIRRORS ADJUSTMENT...106
BEFORE STARTING ENGINE OPERATIONS AND CHECKS...107
STARTING ENGINE...109
NORMAL STARTING PROCEDURES IN COLD AND WARM CONDITIONS...109
STARTING PROCEDURES AFTER EXTENDED SHUTDOWN OR OIL CHANGE...111
STARTING PROCEDURES AFTER CHANGING FUEL FILTERS...111
STARTING PROCEDURES AFTER RUNNING OUT OF FUEL...111
AFTER STARTING ENGINE OPERATIONS AND CHECKS...112
MOVING MACHINE...113
CHANGING GEAR SPEED...116
CHANGING DIRECTION...116
AUTO-SHIFT TRANSMISSION...117
TURNING...117
STOPPING MACHINE...118
OPERATION OF WORK EQUIPMENT...120
LIFT ARM OPERATION (LEVER)...120
BUCKET OPERATION (LEVER)...120
WORK POSSIBLE USING WHEEL LOADER...122
DIGGING OPERATIONS WITH ROCK PILES...122
DIGGING OPERATIONS ON LEVEL GROUND...123
LEVELING OPERATION...124
PUSHING OPERATIONS...124
LOAD AND CARRY OPERATIONS...124
LOADING OPERATIONS...125
PRECAUTIONS FOR OPERATION...126
PERMISSIBLE WATER DEPTH...126
IF WHEEL BRAKE DOES NOT WORK...126
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...126
PRECAUTIONS WHEN DRIVING MACHINE...127
ADJUSTING WORK EQUIPMENT POSTURE...128
ADJUSTING BOOM KICKOUT...128
ADJUSTING BUCKET POSITIONER...128
BUCKET LEVEL INDICATOR...129
PARKING MACHINE...130
CHECKS AFTER COMPLETION OF OPERATION...132
STOPPING ENGINE...132
CHECKS AFTER STOPPING ENGINE...132
LOCKING...133
TRANSPORTATION...134
LOADING, UNLOADING WORK...134
PRECAUTION FOR LOADING...134
PRECAUTION FOR LIFTING UP THE VEHICLE...135
DECALS FOR LIFTING POINTS...136
WEIGHT LIST...136
LIFTING PROCEDURE...137
COLD WEATHER OPERATIONS...138
PRECAUTIONS FOR LOW TEMPERATURE...138
FUEL AND LUBRICANTS...138
COOLANT...138
BATTERY...139
PRECAUTIONS AFTER COMPLETION OF WORK...139
AFTER COLD WEATHER...139
LONG TERM STORAGE...140
BEFORE STORAGE...140
DURING STORAGE...140
AFTER STORAGE...140
TROUBLESHOOTING...141
WHEN MACHINE RUNS OUT OF FUEL...141
TOWING THE MACHINE...141
WHEN ENGINE CAN BE USED...142
WHEN ENGINE CANNOT BE USED...142
IF BATTERY IS DISCHARGED...143
REMOVAL AND INSTALLATION OF BATTERY...144
PRECAUTIONS FOR CHARGING BATTERY...144
STARTING ENGINE WITH BOOSTER CABLE...145
OTHER TROUBLE...147
ELECTRICAL SYSTEM...147
CHASSIS...148
ENGINE...150
MAINTENANCE...153
GUIDES TO MAINTENANCE...154
OUTLINES OF SERVICE...156
OUTLINE OF OIL, FUEL, COOLANT...156
OIL...156
FUEL...157
COOLANT...157
GREASE...157
STORING OIL AND FUEL...158
FILTERS...158
FUEL INJECTION PUMP...158
OUTLINE OF ELECTRIC SYSTEM...158
WEAR PARTS LIST...159
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...160
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS...160
ENGINE OIL SPECIFICATIONS...161
NORMAL OPERATION...161
ARCTIC OPERATION...162
DIESEL FUEL SPECIFICATIONS...162
COOLANT SPECIFICATIONS...163
GENERAL...163
WATER...163
ANTIFREEZE...163
INHIBITORS/CONDITIONERS...164
MAINTENANCE OF COOLING SYSTEM INHIBITORS...165
COOLANT TESTING FOR CONDITIONER CONCENTRATION...165
REPLENISHING COOLANT CONDITIONER...165
DCA4 UNIT MAINTENANCE GUIDE...166
COOLING SYSTEM TEST KIT...168
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS...169
INTRODUCTION OF NECESSARY TOOLS...169
TORQUE LIST...170
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...172
SAFETY CRITICAL PARTS...173
MAINTENANCE SCHEDULE CHART...176
MAINTENANCE SCHEDULE CHART...176
SERVICE PROCEDURES...179
INITIAL 250 HOURS SERVICE...179
REPLACE FUEL FILTERS...179
REPLACE TRANSMISSION OIL FILTER ELEMENT...179
REPLACE HYDRAULIC TANK FILTER ELEMENT...179
WHEN REQUIRED...180
CHECK, CLEAN OR REPLACE AIR CLEANER ELEMENT...180
CHECK TRANSMISSION OIL LEVEL, ADD OIL...182
CHECK AXLE OIL LEVEL, ADD OIL...183
CLEAN THE AXLE CASE BREATHER...184
CLEAN RADIATOR FINS...184
REPLACE THE BOLT-ON CUTTING EDGES...185
REPLACE BUCKET TEETH (IF EQUIPPED)...186
CHECK AIR CONDITIONER (IF EQUIPPED)...187
CHECK THE AIR CONDITIONER CONDENSER (IF EQUIPPED)...188
CHECK WINDOW WASHING FLUID...188
ADJUST PARKING BRAKE...189
REPLACE SLOW BLOW FUSE...190
CHECK INTAKE HEATER...190
DRAIN WATER FROM FUEL-WATER SEPARATOR...100
DRAIN SEDIMENT FROM THE FUEL-SEDIMENT STRAINER...100
CHECK BEFORE STARTING...191
CHECK COOLANT LEVEL, ADD COOLANT...97
CHECK FUEL LEVEL, ADD FUEL...97
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...98
CHECK AND REFILL OIL IN BRAKE OIL TANK...99
CHECK DUST INDICATOR...99
CHECK ELECTRIC WIRING...99
CHECK EFFECT OF PARKING BRAKE...103
CHECK EFFECT OF WHEEL BRAKES...103
CHECK SOUND OF HORN AND BACKUP ALARM...103
CHECK FLASHING OF LAMPS, CHECK FOR DIRT OR DAMAGE...103
CHECK ENGINE EXHAUST COLOR AND SOUND...103
CHECK OPERATION OF GAUGES...103
CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING...103
CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE...103
CHECK LOCK OF CAB DOOR (MACHINE EQUIPPED WITH CAB)...103
EVERY 50 HOURS SERVICE...191
CHECK THE TIRE INFLATION PRESSURE...191
DRAIN WATER, SEDIMENT FROM FUEL TANK...191
EVERY 100 HOURS SERVICE...192
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...192
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...193
LUBRICATING...193
REAR AXLE PIVOT PIN (2 PLACES)...193
EVERY 250 HOURS SERVICE...194
CHANGE OIL IN ENGINE OIL PAN AND REPLACE ENGINE OIL FILTER...194
CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN...195
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...196
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...197
CHECK BATTERY ELECTROLYTE LEVEL...198
CHECK AIR INTAKE SYSTEM...198
LUBRICATING...199
DUMP CYLINDER PIN (2 PLACES)...199
BUCKET PIN (2 PLACES)...199
BUCKET LINK PIN (2 PLACES)...199
LIFT CYLINDER PIN (4 PLACES)...199
LIFT ARM PIVOT PIN (2 PLACES)...199
BELLCRANK PIN (1 PLACE)...199
STEERING CYLINDER PIN (4 PLACES)...199
EVERY 500 HOURS SERVICE...200
REPLACE FUEL FILTERS...200
REPLACE TRANSMISSION OIL FILTER ELEMENT...202
LUBRICATE THE FOLLOWING:...203
CENTER DRIVE SHAFT SPLINE...178
EVERY 1000 HOURS SERVICE...204
CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER...204
CLEAN TRANSMISSION CASE BREATHER...205
LUBRICATE...205
CENTER HINGE PIN (2 PLACES)...205
FRONT DRIVE SHAFT (2 PLACES)...205
DRIVE SHAFT CENTER SUPPORT (1 PLACE)...206
CENTER DRIVE SHAFT (2 PLACES)...206
REAR DRIVE SHAFT (2 PLACES)...206
ADJUST ENGINE VALVE LASH CLEARANCE...206
CHECK FAN BELT TENSION...207
CHECK FAN BELT TENSIONER BEARING & FAN HUB BEARING & INSPECT FAN BELT...207
EVERY 2000 HOURS SERVICE...209
CHANGE OIL IN HYDRAULIC OIL TANK, REPLACE HYDRAULIC FILTER ELEMENT...209
REPLACE HYDRAULIC TANK BREATHER ELEMENT...211
COOLING SYSTEM, REPLACE COOLANT AND FLUSH THE SYSTEM...211
RADIATOR CAP GENERAL INFORMATION...212
CHANGE AXLE OIL...214
CHECK BRAKE DISC WEAR...214
CHECK ALTERNATOR...214
CHECK STARTER MOTOR...214
CHECK VIBRATION DAMPER...215
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AND FRESH AIR FILTER...215
ADJUST ENGINE VALVE LASH CLEARANCE...216
CLEAN PPC CIRCUIT STRAINER...218
CHECK ACCUMULATOR GAS PRESSURE...218
SPECIFICATIONS...219
SPECIFICATIONS...220
WA250-3MC...220
OPTIONS, ATTACHMENTS...223
AVAILABLE ATTACHMENTS...224
BUCKETS AND TIRES SELECTION...225
AIR CONDITIONING...226
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL...226
FAN SWITCH...226
AIR CONDITIONER SWITCH...226
MODE SELECTOR SWITCH...227
FRESH/RECIRC SELECTOR SWITCH...227
TEMPERATURE CONTROL SWITCH...227
METHOD OF OPERATION...228
WHEN NOT USING THE AIR CONDITIONER REGU LARLY...228
COOL BOX...228
HANDLING ECSS (Electronic Controlled Suspension System)...229
STRUCTURE AND FUNCTION OF ECSS...229
METHOD OF OPERATING ECSS...230
PRECAUTIONS WHEN OPERATING ECSS SWITCH...230
ACCUMULATOR PRECAUTIONS...231
RADIO...232
OPERATING CONTROLS...232
OPERATION...233
SETTING THE CLOCK...235
REMOTE CONTROL UNIT...235
BATTERY REPLACEMENT...236
PRECAUTIONS WHEN USING...236
CEAM007401 - Wheel Loader WA250PT-3MC avance plus Operation & Maintenance Manual...239
COVER...239
INTRODUCTION...245
FOREWORD...246
SAFETY INFORMATION...247
INTRODUCTION...248
INTENDED USE...248
FEATURES...248
BREAKING IN A NEW MACHINE...248
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...249
MACHINE SERIAL NO. PLATE POSITION...249
ENGINE SERIAL NO. PLATE POSITION...249
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...249
CONTENTS...250
SAFETY...259
GENERAL PRECAUTIONS...260
SAFETY RULES...260
SAFETY FEATURES...260
UNAUTHORIZED MODIFICATION...260
CLOTHING AND PERSONAL PROTECTIVE ITEMS...261
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT...261
MOUNTING AND DISMOUNTING...262
FIRE PREVENTION FOR FUEL AND OIL...262
PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES...263
ASBESTOS DUST HAZARD PREVENTION...263
CRUSHING OR CUTTING PREVENTION...263
FIRE EXTINGUISHER AND FIRST AID KIT...264
PRECAUTIONS WHEN USING ROPS...264
PRECAUTIONS FOR ATTACHMENTS...264
PRECAUTION WHEN HANDLING ACCUMULATOR...265
PRECAUTIONS DURING OPERATION...266
BEFORE STARTING ENGINE...266
SAFETY AT WORKSITE...266
FIRE PREVENTION...266
WALK AROUND CHECK...266
IN OPERATOR'S CAB...267
VENTILATION FOR ENCLOSED AREAS...267
PRECAUTIONS FOR MIRRORS, WINDOWS, AND LIGHTS...267
WHEN STARTING ENGINE...268
AFTER STARTING ENGINE...269
CHECKS AFTER STARTING ENGINE...269
PRECAUTIONS WHEN STARTING OFF...269
CHECK WHEN CHANGING DIRECTION...270
PRECAUTIONS WHEN TRAVELING...271
TRAVELING ON SLOPES...272
PROHIBITED OPERATIONS...272
PRECAUTIONS WHEN TRAVELING...273
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...274
ENSURE GOOD VISIBILITY...275
OPERATE CAREFULLY ON SNOW...275
DO NOT HIT WORK EQUIPMENT...275
WHEN USING THE BRAKE...275
WHEN MAKING A DOWNHILL TRAVEL...275
WORKING ON LOOSE GROUND...276
PARKING THE MACHINE...276
PRECAUTIONS IN COLD AREAS...277
TRANSPORTATION...278
LOADING AND UNLOADING...278
SHIPPING...278
BATTERY...279
BATTERY HAZARD PREVENTION...279
STARTING WITH BOOSTER CABLES...280
CHARGING BATTERY...281
TOWING...282
WHEN TOWING...282
PRECAUTIONS FOR MAINTENANCE...283
BEFORE CARRYING OUT MAINTENANCE...283
NOTIFICATION OF FAILURE...283
WARNING TAGS...283
CLEAN BEFORE INSPECTION AND MAINTENANCE...283
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE...284
WORK EQUIPMENT SUPPORT...284
PROPER TOOLS...285
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...285
USE OF LIGHTING...285
KEEP WORK PLACE CLEAN AND TIDY...285
APPOINT A LEADER WHEN WORKING WITH OTHERS...286
RADIATOR WATER LEVEL...286
PREVENTION OF FIRE...286
TURN E.C.S.S. SWITCH OFF...286
DURING MAINTENANCE...287
PERSONNEL...287
ATTACHMENTS...287
WORK UNDER THE MACHINE...287
DO NOT DROP TOOLS OR PARTS INSIDE MACHINE...287
PRECAUTIONS WHEN USING HAMMER...288
REPAIR WELDING...288
PRECAUTIONS WITH BATTERY...288
WHEN ABNORMALITY IS LOCATED...288
RULES TO FOLLOW WHEN ADDING FUEL OR OIL...288
ROTATING FAN AND BLADE...289
HANDLING HIGH-PRESSURE HOSES...289
PRECAUTION HIGH PRESSURE OIL...289
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE OR HIGH PRESSURE...289
TIRE MAINTENANCE...290
CHECKS AFTER INSPECTION AND MAINTENANCE...290
WASTE MATERIALS...290
WHEN PERFORMING MAINTENANCE WITH THE CHASSIS RAISED...290
TIRES...291
HANDLING TIRES...291
STORING TIRES AFTER REMOVAL...292
POSITION FOR ATTACHING SAFETY LABELS...293
POSITION FOR ATTACHING SAFETY LABELS...293
OPERATION...299
GENERAL VIEW...300
GENERAL VIEW OF MACHINE...300
GENERAL VIEW OF CONTROLS AND GAUGES...301
EXPLANATION OF COMPONENTS...302
METER, LAMPS...302
ALARM DISPLAY PORTIONS (B, E)...302
METER DISPLAY PORTION (A, C, D)...303
OPTION DISPLAY PORTION (F)...303
TESTING ACTUATION OF MACHINE MONITOR SYSTEM...303
WARNING DISPLAYS...304
METER DISPLAY PORTION...307
SWITCHES...311
CONTROL LEVERS, PEDAL...318
STEERING COLUMN TILT LEVER...325
CAP WITH LOCK...325
METHOD OF OPENING AND CLOSING CAP WITH LOCK...325
SAFETY BAR...326
TOWING PIN...326
GREASE PUMP CLAMP AND RUBBER RING...326
BACKUP ALARM...327
FUSE...327
FUSE CAPACITY AND NAME OF CIRCUIT...327
SLOW BLOW FUSE...328
STORAGE FOR THIS MANUAL...329
AUXILIARY POWER SOURCE...329
FOR MACHINES EQUIPPED WITH ROPS CAB...329
CHECK BEFORE STARTING...330
WALK AROUND CHECK...330
CHECK BEFORE STARTING...333
CHECK COOLANT LEVEL, ADD COOLANT...333
CHECK MONITOR PANEL...333
CHECK FUEL LEVEL, ADD FUEL...333
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...334
CHECK AND REFILL OF OIL IN BRAKE OIL TANK...335
CHECK DUST INDICATOR...335
CHECK ELECTRICAL WIRING...335
DRAIN THE WATER FROM THE FUEL-WATER SEPARATOR...336
FUEL SEDIMENT STRAINER...336
INSPECTION OF TIRES...337
INSPECTION OF RIMS...337
TIRE PRESSURE...337
CHECK EFFECT OF PARKING BRAKE...339
CHECK EFFECT OF WHEEL BRAKES...339
CHECK SOUND OF HORN AND BACKUP ALARM...339
CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE...339
CHECK ENGINE EXHAUST COLOR AND SOUND...339
CHECK OPERATIONS OF GAUGES...339
CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING...339
CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE...339
CHECK LOCK OF CAB DOOR FOR MACHINES EQUIPPED WITH CAB...339
OPERATOR'S SEAT ADJUSTMENT...340
OPERATOR'S AIR RIDE SUSPENSION SEAT...341
SEAT BELT ADJUSTMENT...342
REAR VEIW MIRRORS ADJUSTMENT...342
BEFORE STARTING ENGINE OPERATIONS AND CHECKS...343
STARTING ENGINE...345
NORMAL STARTING PROCEDURES IN COLD AND WARM CONDITIONS...345
STARTING PROCEDURES AFTER EXTENDED SHUTDOWN OR OIL CHANGE...347
STARTING PROCEDURES AFTER CHANGING FUEL FILTERS...347
STARTING PROCEDURES AFTER RUNNING OUT OF FUEL...347
AFTER STARTING ENGINE OPERATIONS AND CHECKS...348
MOVING MACHINE...349
CHANGING GEAR SPEED...352
CHANGING DIRECTION...352
AUTO-SHIFT TRANSMISSION...353
TURNING...353
OPERATION OF WORK EQUIPMENT (WITH BUCKET TOOL)...354
LIFT ARM OPERATION (LEVER)...354
BUCKET OPERATION (LEVER)...354
OPERATION OF WORK EQUIPMENT (WITH FORK TOOL)...356
LIFT ARM OPERATION (LEVER)...356
FORK OPERATION (LEVER)...356
OPERATION OF WORK EQUIPMENT (WITH MULTI-PURPOSE BUCKET)...358
LIFT ARM OPERATION (LEVER)...358
BUCKET OPERATION (LEVER)...358
AUXILIARY OPERATION (LEVER)...359
OPEN (A)...359
HOLD (B)...359
CLOSE (C)...360
POSITION INDICATOR...360
OPERATION OF WORK EQUIPMENT (WITH MATERIAL HANDLING ARM)...362
LIFT ARM OPERATION (LEVER)...362
HYDRAULIC QUICK COUPLER...363
COUPLING THE ATTACHMENT...363
UNCOUPLING FROM THE ATTACHMENT...364
WORK POSSIBLE USING WHEEL LOADER...366
DIGGING OPERATIONS WITH ROCK PILES...366
DIGGING OPERATIONS ON LEVEL GROUND...367
LEVELING OPERATION...368
PUSHING OPERATIONS...368
LOAD AND CARRY OPERATIONS...368
LOADING OPERATIONS...369
MULTI-PURPOSE BUCKET...370
IN SCRAPER POSITION...370
DIGGING, CLEARING AND LEVELING...371
IMPROPER USE OF THE MULTI-PURPOSE BUCKET...373
PALLET FORKS...375
GENERAL...375
LOADING...375
TRANSPORTING...376
UNLOADING...377
MATERIAL HANDLING ARM...378
PRECAUTIONS FOR OPERATION...379
PERMISSIBLE WATER DEPTH...379
IF WHEEL BRAKE DOES NOT WORK...379
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...379
PRECAUTIONS WHEN DRIVING MACHINE...380
ADJUSTING WORK EQUIPMENT POSTURE...381
ADJUSTING BOOM KICKOUT POSITIONER...381
ADJUSTING BUCKET / FORK POSITIONER...382
STOPPING AND PARKING MACHINE...384
CHECKS AFTER COMPLETION OF OPERATION...386
STOPPING ENGINE...386
CHECKS AFTER STOPPING ENGINE...386
LOCKING...387
TRANSPORTATION...388
LOADING, UNLOADING WORK...388
PRECAUTION FOR LOADING...388
PRECAUTION FOR LIFTING UP THE VEHICLE...389
DECALS FOR LIFTING POINTS...390
WEIGHT LIST...390
LIFTING PROCEDURE...391
COLD WEATHER OPERATIONS...392
PRECAUTIONS FOR LOW TEMPERATURE...392
FUEL AND LUBRICANTS...392
COOLANT...392
BATTERY...393
PRECAUTIONS AFTER COMPLETION OF WORK...393
AFTER COLD WEATHER...393
LONG TERM STORAGE...394
BEFORE STORAGE...394
DURING STORAGE...394
AFTER STORAGE...394
TROUBLESHOOTING...395
WHEN MACHINE RUNS OUT OF FUEL...395
TOWING THE MACHINE...395
WHEN ENGINE CAN BE USED...396
WHEN ENGINE CANNOT BE USED...396
IF BATTERY IS DISCHARGED...397
REMOVAL AND INSTALLATION OF BATTERY...398
PRECAUTIONS FOR CHARGING BATTERY...398
STARTING ENGINE WITH BOOSTER CABLE...399
OTHER TROUBLE...401
ELECTRICAL SYSTEM...401
CHASSIS...402
ENGINE...404
MAINTENANCE...407
GUIDES TO MAINTENANCE...408
OUTLINES OF SERVICE...410
OUTLINE OF OIL, FUEL, COOLANT...410
OIL...410
FUEL...411
COOLANT...411
GREASE...411
STORING OIL AND FUEL...412
FILTERS...412
FUEL INJECTION PUMP...412
OUTLINE OF ELECTRIC SYSTEM...412
WEAR PARTS LIST...413
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...414
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS...414
ENGINE OIL SPECIFICATIONS...415
NORMAL OPERATION...415
ARCTIC OPERATION...416
DIESEL FUEL SPECIFICATIONS...416
COOLANT SPECIFICATIONS...417
GENERAL...417
WATER...417
ANTIFREEZE...417
INHIBITORS/CONDITIONERS...418
MAINTENANCE OF COOLING SYSTEM INHIBITORS...419
COOLANT TESTING FOR CONDITIONER CONCENTRATION...419
REPLENISHING COOLANT CONDITIONER...419
DCA4 UNIT MAINTENANCE GUIDE...420
COOLING SYSTEM TEST KIT...422
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS...423
INTRODUCTION OF NECESSARY TOOLS...423
TORQUE LIST...424
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...426
SAFETY CRITICAL PARTS...427
MAINTENANCE SCHEDULE CHART...430
MAINTENANCE SCHEDULE CHART...430
SERVICE PROCEDURES...433
INITIAL 250 HOURS SERVICE...433
REPLACE FUEL FILTERS...433
REPLACE TRANSMISSION OIL FILTER ELEMENT...433
REPLACE HYDRAULIC TANK FILTER ELEMENT...433
WHEN REQUIRED...434
CHECK, CLEAN OR REPLACE AIR CLEANER ELEMENT...434
CHECK TRANSMISSION OIL LEVEL, ADD OIL...436
CHECK AXLE OIL LEVEL, ADD OIL...437
CLEAN THE AXLE CASE BREATHER...438
CLEAN RADIATOR FINS...438
REPLACE THE BOLT-ON CUTTING EDGES...439
REPLACE BUCKET TEETH (IF EQUIPPED)...440
CHECK AIR CONDITIONER (IF EQUIPPED)...441
CHECK THE AIR CONDITIONER CONDENSER (IF EQUIPPED)...442
CHECK WINDOW WASHING FLUID...442
ADJUST PARKING BRAKE...443
REPLACE SLOW BLOW FUSE...444
CHECK AIR INTAKE HEATER...444
DRAIN WATER FROM THE FUEL-WATER SEPARATOR...336
DRAIN SEDIMENT FROM THE FUEL-SEDIMENT STRAINER...336
CHECK BEFORE STARTING...445
CHECK COOLANT LEVEL, ADD COOLANT...333
CHECK FUEL LEVEL, ADD FUEL...333
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...334
CHECK AND REFILL OIL IN BRAKE OIL TANK...335
CHECK DUST INDICATOR...335
CHECK ELECTRIC WIRING...335
DRAIN WATER FROM FUEL WATER SEPARATOR...336
INSPECTION OF TIRES...337
CHECK EFFECT OF PARKING BRAKE...339
CHECK EFFECT OF WHEEL BRAKES...339
CHECK SOUND OF HORN AND BACKUP ALARM...339
CHECK FLASHING OF LAMPS, CHECK FOR DIRT OR DAMAGE...339
CHECK ENGINE EXHAUST COLOR AND SOUND...339
CHECK OPERATION OF GAUGES...339
CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING...339
CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE...339
CHECK LOCK OF CAB DOOR (MACHINE EQUIPPED WITH CAB)...339
EVERY 50 HOURS SERVICE...445
CHECK THE TIRE INFLATION PRESSURE...445
DRAIN WATER, SEDIMENT FROM FUEL TANK...445
EVERY 100 HOURS SERVICE...446
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...446
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...447
LUBRICATING...447
REAR AXLE PIVOT PIN (2 PLACES)...447
BUCKET/FORK LINK PIN (2 PLACES)...448
BUCKET/FORK HINGE PIN (2 PLACES)...448
EVERY 250 HOURS SERVICE...449
CHANGE OIL IN ENGINE OIL PAN AND REPLACE ENGINE OIL FILTER...449
CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN...450
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...451
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...452
CHECK BATTERY ELECTROLYTE LEVEL...453
CHECK AIR INTAKE SYSTEM...453
LUBRICATING...454
TILT CYLINDER PIN (4 PLACES)...454
LOADER LINK PIN (10 PLACES)...454
LIFT CYLINDER PIN (4 PLACES)...454
LIFT ARM PIVOT PIN (2 PLACES)...454
STEERING CYLINDER PIN (4 PLACES)...454
EVERY 500 HOURS SERVICE...455
REPLACE FUEL FILTERS...455
REPLACE TRANSMISSION OIL FILTER ELEMENT...457
LUBRICATE THE FOLLOWING...458
CENTER DRIVE SHAFT SPLINE (1 PLACE)...458
EVERY 1000 HOURS SERVICE...459
CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER...459
CLEAN TRANSMISSION CASE BREATHER...460
LUBRICATE...460
CENTER HINGE PIN (2 PLACES)...460
FRONT DRIVE SHAFT (2 PLACES)...460
DRIVE SHAFT CENTER SUPPORT (1 PLACE)...461
CENTER DRIVE SHAFT (2 PLACES)...461
REAR DRIVE SHAFT (2 PLACES)...461
ADJUST ENGINE VALVE LASH CLEARANCE...461
CHECK FAN BELT TENSION...462
CHECK FAN BELT TENSIONER BEARING & FAN HUB BEARING & INSPECT FAN BELT...462
EVERY 2000 HOURS SERVICE...464
CHANGE OIL IN HYDRAULIC OIL TANK, REPLACE HYDRAULIC FILTER ELEMENT...464
REPLACE HYDRAULIC TANK BREATHER ELEMENT...466
COOLING SYSTEM, REPLACE COOLANT AND FLUSH THE SYSTEM...466
RADIATOR CAP GENERAL INFORMATION...467
CHANGE AXLE OIL...469
CHECK BRAKE DISC WEAR...469
CHECK ALTERNATOR...469
CHECK STARTER MOTOR...469
CHECK VIBRATION DAMPER...470
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AND FRESH AIR FILTER...470
ADJUST ENGINE VALVE LASH CLEARANCE...471
CLEAN PPC CIRCUIT STRAINER...473
CHECK ACCUMULATOR GAS PRESSURE...473
SPECIFICATIONS...475
sPECIFICATIONS...476
wa250pt-3 (with bucket attachment)...476
wa250pt-3 (with fork attachment...478
WA250PT-3 (WITH MATERIAL HANDLING ARM)...480
OPTIONS, ATTACHMENTS...483
AVAILABLE ATTACHMENTS...484
BUCKETS AND TIRES SELECTION...485
AIR CONDITIONING...486
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL...486
FAN SWITCH...486
AIR CONDITIONER SWITCH...486
MODE SELECTOR SWITCH...487
FRESH/RECIRC SELECTOR SWITCH...487
TEMPERATURE CONTROL SWITCH...487
METHOD OF OPERATION...488
WHEN NOT USING THE AIR CONDITIONER REGU LARLY...488
COOL BOX...488
HANDLING ECSS (Electronic Controlled Suspension System)...489
STRUCTURE AND FUNCTION OF ECSS...489
METHOD OF OPERATING ECSS...490
PRECAUTIONS WHEN OPERATING ECSS SWITCH...490
ACCUMULATOR PRECAUTIONS...491
RADIO...492
OPERATING CONTROLS...492
OPERATION...493
SETTING THE CLOCK...495
REMOTE CONTROL UNIT...495
BATTERY REPLACEMENT...496
PRECAUTIONS WHEN USING...496
CEAM011300 - Wheel Loader GALEO WA250-5L Operation & Maintenance Manual...499
COVER...499
INTRODUCTION...505
FOREWORD...506
SAFETY INFORMATION...507
INTRODUCTION...508
DIRECTIONS OF MACHINE...508
NECESSARY INFORMATION...509
MACHINE SERIAL NO. PLATE...509
ENGINE SERIAL NO. PLATE AND POSITION...509
SERVICE METER POSITION...510
ENTER SERIAL NO. AND DISTRIBUTOR...510
TABLE OF CONTENTS...511
SAFETY...521
SAFETY LABELS...522
LOCATION OF SAFETY LABELS...522
SAFETY LABELS...523
GENERAL PRECAUTIONS...529
SAFETY RULES...529
IF ABNORMALITIES ARE FOUND...529
CLOTHING AND PERSONAL PROTECTIVE ITEMS...529
FIRE EXTINGUISHER AND FIRST AID KIT...529
SAFETY FEATURES...529
KEEP THE MACHINE CLEAN...530
INSIDE OPERATOR'S COMPARTMENT...530
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT...530
HANDRAILS AND STEPS...531
MOUNTING AND DISMOUNTING...532
NO PEOPLE ON ATTACHMENTS...532
DO NOT GET CAUGHT IN ARTICULATED PORTION...532
BURN PREVENTION...532
HOT COOLANT...532
HOT OIL...532
FIRE PREVENTION...533
ACTION IF FIRE OCCURS...534
WINDOW WASHER LIQUID...534
PRECAUTIONS WHEN USING ROPS...534
PRECAUTIONS FOR ATTACHMENTS...534
UNAUTHORIZED MODIFICATION...534
SAFETY AT WORK SITE...535
WORKING ON LOOSE GROUND...535
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...535
ENSURE GOOD VISIBILITY...536
BE CAREFUL ABOUT EXHAUST FUMES...536
CHECKING SIGNALMAN'S SIGNALS AND SIGNS...536
EMERGENCY EXIT FROM OPERATOR'S CAB...536
ASBESTOS DUST HAZARD...537
PRECAUTIONS WHEN STARTING...537
PRECAUTIONS IN COLD AREAS...537
PRECAUTIONS FOR OPERATION...538
BEFORE STARTING ENGINE...538
CHECKS BEFORE STARTING ENGINE...538
CHECKS BEFORE OPERATION...539
PRECAUTIONS BEFORE MOVING FORWARD OR BACK...539
PRECAUTIONS WHEN TRAVELING...540
TRAVELING ON SLOPES...541
PROHIBITED OPERATIONS...542
PRECAUTIONS WHEN OPERATING...542
METHODS OF USING BRAKE...543
OPERATE CAREFULLY ON SNOW...543
PARKING MACHINE...544
TRANSPORTATION...545
LOADING AND UNLOADING...545
SHIPPING...545
BATTERY...546
BATTERY HAZARD PREVENTION...546
STARTING WITH BOOSTER CABLES...547
TOWING...548
WHEN TOWING...548
PRECAUTIONS FOR MAINTENANCE...549
WARNING TAG...549
KEEP WORK PLACE CLEAN AND TIDY...549
APPOINT LEADER WHEN WORKING WITH OTHERS...549
MAINTENANCE WITH ENGINE RUNNING...550
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...551
INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF...551
PROPER TOOLS...552
ACCUMULATOR...552
PERSONNEL...552
ATTACHMENTS...552
WORK UNDER THE MACHINE...553
NOISE...553
PRECAUTIONS WHEN USING HAMMER...553
REPAIR WELDING...553
REMOVING BATTERY TERMINAL...554
PRECAUTIONS WITH HIGH-PRESSURE OIL...554
HANDLING HIGH-PRESSURE HOSES...554
WASTE MATERIALS...554
MAINTENANCE OF AIR CONDITIONER...554
COMPRESSED AIR...555
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...555
PRECAUTIONS WITH TIRES...556
HANDLING TIRES...556
PRECAUTIONS WHEN STORING TIRES...556
OPERATION...557
GENERAL VIEW...558
WA250-5L...558
CONTROLS AND GAUGES...559
MACHINE MONITOR...560
EXPLANATION OF COMPONENTS...561
MACHINE MONITOR...561
MONITOR SYSTEM...562
TESTING ACTUATION OF MACHINE MONITOR SYSTEM...562
TYPES OF WARNING...563
EMERGENCY STOP...563
CAUTION...563
MISTAKEN OPERATION...563
INSPECTION AND MAINTENANCE...563
CENTRAL WARNING LAMP...563
CHARACTER DISPLAY PORTION...564
SERVICE METER...564
ACTION CODE DISPLAY...565
FAILURE CODE DISPLAY...566
FILTER, OIL REPLACEMENT TIME DISPLAY...567
EMERGENCY STOP ITEM...569
BRAKE OIL PRESSURE CAUTION LAMP...569
ENGINE OIL PRESSURE CAUTION LAMP...570
BATTERY CHARGE CIRCUIT CAUTION LAMP...570
STEERING OIL PRESSURE CAUTION LAMP - RED...570
CAUTION ITEMS...571
AXLE OIL TEMPERATURE CAUTION LAMP...571
PARKING BRAKE REMINDER CAUTION LAMP...572
HST OIL TEMPERATURE CAUTION LAMP...572
ENGINE COOLING WATER TEMPERATURE CAUTION LAMP...572
FUEL LEVEL CAUTION LAMP...573
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED...573
TRAVEL SPEED LIMIT FUNCTION...573
INSPECTION AND MAINTENANCE ITEM...574
RADIATOR COOLANT LEVEL CAUTION LAMP...574
MAINTENANCE CAUTION LAMP...575
HST OIL FILTER CLOG CAUTION LAMP...575
PILOT DISPLAY PORTION...576
PARKING BRAKE PILOT LAMP...576
PREHEATING PILOT LAMP...576
EMERGENCY STEERING PILOT LAMP- GREEN...577
DIRECTIONAL LEVER POSITION PILOT LAMP...577
PILOT LAMP FOR SPEED RANGE SELECTOR SWITCH POSITION...577
TURN SIGNAL PILOT LAMP...577
HEAD LAMP HIGH BEAM PILOT LAMP...578
METER DISPLAY PORTION...579
HST OIL TEMPERATURE GAUGE...579
ENGINE COOLANT TEMPERATURE GAUGE...579
FUEL GAUGE...580
SPEEDOMETER...580
METER DISPLAY PILOT LAMP...580
OTHER FUNCTIONS OF MACHINE MONITOR...581
METHOD OF DISPLAYING ODOMETER...581
RESET METHOD FOR FILTER, OIL REPLACEMENT TIME...581
METHOD FOR SELECTING LANGUAGE...582
METHOD OF SELECTING HST CHANGING FUNCTION...583
SWITCHES...584
STARTING SWITCH...584
SPEED RANGE SELECTOR SWITCH...585
VARIABLE SHIFT CONTROL SWITCH...585
DIRECTIONAL SELECTOR SWITCH...585
DIRECTIONAL SELECTOR SWITCH ACTUATION SWITCH...586
E.C.S.S. SWITCH...586
LAMP SWITCH...587
TURN SIGNAL LEVER...587
DIMMER SWITCH...587
HORN BUTTON...587
HAZARD LAMP SWITCH...588
FRONT WORKING LAMP SWITCH...588
REAR WORKING LAMP SWITCH...589
MONITOR PANEL MODE SELECTOR SWITCH 1...589
MONITOR PANEL MODE SELECTOR SWITCH 2...589
FRONT WIPER SWITCH...590
REAR WIPER SWITCH...590
CIGARETTE LIGHTER...590
ROOM LAMP SWITCH...590
REAR WINDOW DEFROSTER SWITCH...591
CONTROL LEVERS, PEDALS...592
DIRECTIONAL LEVER...592
SAFETY LOCK LEVER (FOR WORK EQUIPMENT LEVER)...593
WORK EQUIPMENT LEVER...593
BRAKE PEDAL...594
ACCELERATOR PEDAL...594
PARKING BRAKE LEVER...595
STEERING TILT LOCK LEVER...595
CAP AND COVER WITH LOCK...596
METHOD OF OPENING AND CLOSING CAP WITH LOCK...596
METHOD OF OPENING AND CLOSING COVER WITH LOCK...596
SAFETY BAR...597
TOWING PIN...597
GREASE PUMP...598
CAB DOOR INNER LOCK...598
CAB DOOR OPEN LOCK...598
CAB WINDOW OPEN LOCK CANCEL KNOB...599
FUSE...599
FUSE CAPACITY AND NAME OF CIRCUIT...599
SLOW BLOW FUSE...600
AUXILIARY POWER...601
AIR CONDITIONER...602
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL...602
FAN SWITCH...602
AIR CONDITIONER SWITCH...602
MODE SELECTOR SWITCH...603
FRESH/RECIRC SELECTOR SWITCH...603
TEMPERATURE CONTROL SWITCH...604
METHOD OF OPERATION...604
WHEN NOT USING THE AIR CONDITIONER REGULARLY...605
COOL BOX...605
PRECAUTIONS WHEN USING...605
PRECAUTIONS WHEN USING THE COOLING...605
HANDLING CAB WIPER...606
PREVENTING WIPER ARM BRACKET DAMAGE...606
OPERATION...607
CHECK BEFORE STARTING ENGINE, ADJUST...607
WALK-AROUND CHECK...607
CHECK BEFORE STARTING...610
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...610
CHECK WATER SEPARATOR...611
CHECK DUST INDICATOR...611
CHECK COOLANT LEVEL, ADD COOLANT...612
CHECK INFLATION PRESSURE OF TIRES...612
CHECK ELECTRIC WIRING...613
CHECK MONITOR PANEL...613
CHECK FUEL LEVEL, ADD FUEL...614
CHECK PARKING BRAKE...615
CHECK BRAKE PEDAL...615
ADJUSTMENT...615
SEAT ADJUSTMENT...615
ADJUST SEAT BELT...617
ADJUST LEVER STAND...617
ADJUST REAR VIEW MIRROR...618
OPERATIONS AND CHECKS BEFORE STARTING ENGINE...618
STARTING ENGINE...620
OPERATIONS AND CHECKS AFTER STARTING ENGINE...621
BREAKING-IN THE MACHINE...622
NORMAL OPERATION...622
STOPPING ENGINE...624
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...625
MOVING THE MACHINE...625
CHANGING DIRECTION...627
CHANGING BETWEEN FORWARD AND REVERSE...627
STOPPING THE MACHINE...629
TURNING...630
EMERGENCY STEERING...630
OPERATION OF WORK EQUIPMENT...631
LIFT ARM OPERATION...631
BUCKET OPERATION...632
WORK POSSIBLE USING WHEEL LOADER...633
DIGGING OPERATIONS...633
LOADING PILED SOIL...633
DIGGING AND LOADING ON LEVEL GROUND...634
LEVELING OPERATIONS...635
PUSHING OPERATION...635
LOAD AND CARRY OPERATIONS...635
LOADING OPERATIONS...636
CROSS DRIVE LOADING...636
V-SHAPE LOADING...637
PRECAUTIONS WHEN PILING UP LOADS...637
PRECAUTIONS FOR OPERATION...637
PERMISSIBLE WATER DEPTH...637
IF WHEEL BRAKE DOES NOT WORK...637
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...638
LOWER THE CENTER OF GRAVITY WHEN TURNING...638
BRAKING ON DOWNHILL SLOPE...638
IF ENGINE STOPS...638
PRECAUTIONS WHEN DRIVING MACHINE...638
ADJUSTING WORK EQUIPMENT POSTURE...639
ADJUSTING BOOM KICKOUT...639
ADJUSTING BUCKET POSITIONER...640
BUCKET LEVEL INDICATOR...640
PARKING MACHINE...641
CHECK AFTER STOPPING ENGINE...642
CHECKS AFTER COMPLETION OF OPERATION...642
LOCKING...643
HANDLING THE TIRES...643
PRECAUTIONS WHEN HANDLING TIRES...643
TIRE PRESSURE...644
PRECAUTIONS FOR USING LOAD AND CARRY METHOD...644
TRANSPORTATION...645
TRANSPORTATION PROCEDURE...645
LOADING, UNLOADING WORK WITH TRAILERS...645
LOADING...645
SECURING MACHINE...646
UNLOADING...646
LIFTING MACHINE...647
LOCATION OF LIFTING POSITION MARK...648
WEIGHT TABLE...648
LIFTING PROCEDURE...649
COLD WEATHER OPERATION...650
PRECAUTIONS FOR LOW TEMPERATURE...650
FUEL AND LUBRICANTS...650
COOLANT...650
BATTERY...651
PRECAUTIONS AFTER COMPLETION OF WORK...651
AFTER COLD WEATHER...651
STEERING HYDRAULIC CIRCUIT WARM UP...652
LONG TERM STORAGE...652
BEFORE STORAGE...652
DURING STORAGE...652
AFTER STORAGE...652
TROUBLESHOOTING...653
WHEN MACHINE RUNS OUT OF FUEL...653
TOWING THE MACHINE...653
WHEN ENGINE CAN BE USED...654
WHEN ENGINE CANNOT BE USED...654
IF BATTERY IS DISCHARGED...654
REMOVAL AND INSTALLATION OF BATTERY...654
PRECAUTIONS FOR CHARGING BATTERY...655
STARTING ENGINE WITH BOOSTER CABLE...655
OTHER TROUBLE...657
ELECTRICAL SYSTEM...657
CHASSIS...658
ENGINE...660
MAINTENANCE...663
GUIDES TO MAINTENANCE...664
CHECK SERVICE METER...664
KOMATSU GENUINE REPLACEMENT PARTS...664
KOMATSU GENUINE OILS...664
ALWAYS USE CLEAN WASHER FLUID...664
ALWAYS USE CLEAN OIL AND GREASE...664
CHECKING FOR FOREIGN MATERIALS IN DRAINED OIL AND ON FILTERS...664
FUEL STRAINER...664
WELDING INSTRUCTIONS...664
DO NOT DROP THINGS INSIDE MACHINE...664
DUSTY WORK SITES...665
AVOID MIXING OIL...665
LOCKING INSPECTION COVERS...665
BLEEDING AIR FROM HYDRAULIC CIRCUIT...665
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES...665
CHECKS AFTER INSPECTION AND MAINTENANCE...665
OUTLINES OF SERVICE...666
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...666
OIL...666
FUEL...666
COOLANT...666
GREASE...667
KOWA (Komatsu Oil Wear Analysis)...667
STORING OIL AND FUEL...668
FILTERS...668
OUTLINE OF ELECTRIC SYSTEM...668
WEAR PARTS...669
WEAR PARTS LIST...669
FLUID USE ACCORDING TO AMBIENT TEMPERATURE...670
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS...670
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...674
TORQUE LIST...674
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...675
MAINTENANCE SCHEDULE CHART...676
MAINTENANCE SCHEDULE CHART...676
SERVICE PROCEDURE...678
INITIAL 250 HOURS SERVICE...678
REPLACE HST OIL FILTER ELEMENT...705
REPLACE HYDRAULIC TANK FILTER ELEMENT...707
WHEN REQUIRED...678
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT...678
CLEAN INSIDE OF COOLING SYSTEM...681
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL...684
CHECK AXLE OIL LEVEL, ADD OIL...685
CLEAN AXLE CASE BREATHER...686
CLEAN AIR CONDITIONER CONDENSER...686
WINDOW WASHING FLUID LEVEL...686
CLEAN RADIATOR FINS AND COOLER FINS...687
CHECK ELECTRICAL INTAKE AIR HEATER...687
REPLACE BOLT-ON CUTTING EDGE...688
REPLACE BUCKET TEETH...689
CHECK AIR CONDITIONER...690
REPLACE SLOW BLOW FUSE...691
SELECTION AND INSPECTION OF TIRES...692
CHECK BEFORE STARTING...693
EVERY 50 HOURS SERVICE...694
DRAIN WATER, SEDIMENT FROM FUEL TANK...694
EVERY 100 HOURS SERVICE...694
LUBRICATE REAR AXLE PIVOT PIN...694
CLEAN AIR CONDITIONER FRESH AIR FILTER ELEMENT...694
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...695
EVERY 250 HOURS SERVICE...696
CHECK BATTERY ELECTROLYTE LEVEL...696
CHECK PARKING BRAKE...698
AIR CONDITIONER COMPRESSOR BELT TENSION...698
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN...699
AIR CONDITIONER RECIRCULATION FILTER...699
LUBRICATING...700
EVERY 500 HOURS SERVICE...701
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...701
REPLACE FUEL FILTER CARTRIDGE...702
EVERY 1000 HOURS SERVICE...703
CHANGE OIL IN TRANSFER CASE...703
CLEAN TRANSFER CASE BREATHER...704
REPLACE HST OIL FILTER ELEMENT...705
LUBRICATING...706
CHECK TIGHTENING PARTS OF TURBOCHARGER...706
CHECK PLAY OF TURBOCHARGER ROTOR...706
CHECK FAN BELT TENSION, REPLACE...706
EVERY 2000 HOURS SERVICE...707
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...707
REPLACE HYDRAULIC TANK BREATHER ELEMENT...708
CHANGE AXLE OIL...709
REPLACE AIR CONDITIONER RECIRCULATION AIR FILTER AND FRESH AIR FILTER ELEMENTS...709
CHECK ALTERNATOR, STARTING MOTOR...709
CHECK ENGINE VALVE CLEARANCE, ADJUST...709
CHECK BRAKE DISC WEAR...710
CLEAN AND CHECK TURBOCHARGER...710
CHECK ACCUMULATOR GAS PRESSURE...710
CHECK VIBRATION DAMPER...710
EVERY 4000 HOURS SERVICE...711
LUBRICATING...711
CHECK WATER PUMP...711
SPECIFICATIONS...713
SPECIFICATIONS...714
WA250-5L WITH BOLT-ON CUTTING EDGE...714
OPTIONS, ATTACHMENTS...717
BUCKETS AND TIRES SELECTION...718
AM/FM RADIO-CASSETTE STEREO...719
COMPONENTS...719
POWER SWITCH/VOLUME...720
AUTO-STORE/PRESET SCAN BUTTON...720
BASS CONTROL KNOB...720
TREBLE CONTROL KNOB...721
LOUDNESS BUTTON...721
TIME/RADIO DISPLAY SELECTOR BUTTON...721
TAPE EJECT BUTTON...722
CASSETTE DOOR...722
FAST FORWARD, REWIND BUTTONS...722
PRESET BUTTONS...722
METAL TAPE BUTTON...723
MANUAL TUNING BUTTONS...723
SEEK TUNING BUTTONS...723
BAND SELECTOR BUTTON...723
METHOD OF OPERATION...724
METHOD OF SETTING PRESET BUTTONS...724
METHOD OF AUTO-MEMORY...724
LISTENING TO RADIO...725
LISTENING TO CASSETTE TAPE...725
REVERSING TAPE...726
PRECAUTIONS FOR USE...726
CEAM011401 - Wheel Loader WA250PT-5L Operation & Maintenance Manual...729
COVER...729
INTRODUCTION...731
FOREWORD...732
SAFETY INFORMATION...733
INTRODUCTION...734
DIRECTIONS OF MACHINE...734
NECESSARY INFORMATION...735
MACHINE SERIAL NO. PLATE...735
ENGINE SERIAL NO. PLATE AND POSITION...735
SERVICE METER POSITION...736
ENTER SERIAL NO. AND DISTRIBUTOR...736
TABLE OF CONTENTS...737
SAFETY...747
SAFETY AND WARNING DECALS...748
LOCATION OF THE SAFETY DECALS...748
DESCRIPTION OF SAFETY LABELS...749
SAFETY LABELS...749
GENERAL SAFETY RULES AND PRECAUTIONS...757
GENERAL SAFETY RULES...757
UNAUTHORIZED MODIFICATIONS...758
GENERAL SAFETY AT JOB SITE...758
WORKING ON LOOSE GROUND...758
SAFETY FEATURES...759
PERSONAL PROTECTIVE EQUIPMENT...759
FIRE AND EXPLOSION PREVENTION...760
FIRE CAUSED BY FUEL OR OIL...760
FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL...760
FIRE COMING FROM ELECTRIC WIRING...761
FIRE COMING FROM HYDRAULIC LINE...761
WINDSHIELD WASHER FLUID...761
ACTION IF FIRE OCCURS...761
FIRE EXTINGUISHER AND FIRST AID KIT...761
MOUNTING AND DISMOUNTING...762
INSIDE OPERATOR’S COMPARTMENT...763
PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT...763
PRECAUTIONS WHEN USING ROPS...763
EMERGENCY ESCAPE FROM OPERATOR'S CAB...763
LEAVING OPERATOR’S COMPARTMENT...764
KEEP OPERATOR'S COMPARTMENT CLEAN...764
DUST HAZARD PRECAUTIONS...765
ASBESTOS HAZARD ALERT...765
CRUSH OR PINCH POINT DANGERS...765
PRECAUTIONS BEFORE STARTING OPERATIONS...766
PRE-OPERATIONAL CHECKS...766
STARTING YOUR WORK OPERATIONS...766
WORK SITE HAZARDS...767
AVOIDING DANGEROUS SITUATIONS...767
WORKING CLEARANCES...768
RULES FOR ROAD TRAVEL...770
TRAVELING IN REVERSE...770
TRAVELING ON ICY OR SNOW-COVERED SURFACES...770
WORKING ON LOOSE OR UNSTABLE GROUND...770
TRAVEL ON SLOPES...771
PARKING THE MACHINE...772
PRECAUTIONS DURING MAINTENANCE OPERATIONS...773
WARNING TAGS...773
EQUIPMENT STORAGE...773
WORKING UNDER THE MACHINE...774
USING DROP LAMPS...774
KEEPING THE MACHINE CLEAN...775
RUNNING THE MACHINE DURING MAINTENANCE...775
RULES FOR REFUELING THE MACHINE...776
COOLING SYSTEM PRECAUTIONS...776
BATTERY PRECAUTIONS...777
STARTING THE MACHINE...777
HIGH-PRESSURE HOSES...778
SAFETY HANDLING HIGH-PRESSURE HOSES...778
PRECAUTION FOR HIGH FUEL PRESSURE...778
HIGH TEMPERATURES AREAS...778
DISPOSAL OF WASTE MATERIALS...779
INFLATING TIRES...779
DISPOSAL OF WASTE MATERIALS...779
ACCUMULATOR...780
CRITICAL PARTS...780
HIGH VOLTAGE...780
OPERATION...781
GENERAL VIEW...782
WA250PT-5L...782
CONTROLS AND GAUGES...783
MACHINE MONITOR...784
EXPLANATION OF COMPONENTS...785
MACHINE MONITOR...785
MONITOR SYSTEM...786
TESTING ACTUATION OF MACHINE MONITOR SYSTEM...786
TYPES OF WARNING...787
EMERGENCY STOP...787
CAUTION...787
MISTAKEN OPERATION...787
INSPECTION AND MAINTENANCE...787
CENTRAL WARNING LAMP...787
CHARACTER DISPLAY PORTION...788
SERVICE METER...788
ACTION CODE DISPLAY...789
FAILURE CODE DISPLAY...790
FILTER, OIL REPLACEMENT TIME DISPLAY...791
EMERGENCY STOP ITEM...793
BRAKE OIL PRESSURE CAUTION LAMP...793
ENGINE OIL PRESSURE CAUTION LAMP...794
BATTERY CHARGE CIRCUIT CAUTION LAMP...794
STEERING OIL PRESSURE CAUTION LAMP - RED...794
CAUTION ITEMS...795
AXLE OIL TEMPERATURE CAUTION LAMP...795
PARKING BRAKE REMINDER CAUTION LAMP...796
HST OIL TEMPERATURE CAUTION LAMP...796
ENGINE COOLING WATER TEMPERATURE CAUTION LAMP...796
FUEL LEVEL CAUTION LAMP...797
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED...797
TRAVEL SPEED LIMIT FUNCTION...797
INSPECTION AND MAINTENANCE ITEM...798
RADIATOR COOLANT LEVEL CAUTION LAMP...798
MAINTENANCE CAUTION LAMP...799
HST OIL FILTER CLOG CAUTION LAMP...799
PILOT DISPLAY PORTION...800
PARKING BRAKE PILOT LAMP...800
PREHEATING PILOT LAMP...800
EMERGENCY STEERING PILOT LAMP - GREEN...801
DIRECTIONAL LEVER POSITION PILOT LAMP...801
PILOT LAMP FOR SPEED RANGE SELECTOR SWITCH POSITION...801
TURN SIGNAL PILOT LAMP...801
HEAD LAMP HIGH BEAM PILOT LAMP...802
METER DISPLAY PORTION...803
HST OIL TEMPERATURE GAUGE...803
ENGINE COOLANT TEMPERATURE GAUGE...803
FUEL GAUGE...804
SPEEDOMETER...804
METER DISPLAY PILOT LAMP...804
OTHER FUNCTIONS OF MACHINE MONITOR...805
METHOD OF DISPLAYING ODOMETER...805
RESET METHOD FOR FILTER, OIL REPLACEMENT TIME...805
METHOD FOR SELECTING LANGUAGE...806
METHOD OF SELECTING HST CHANGING FUNCTION...807
SWITCHES...808
STARTING SWITCH...808
SPEED RANGE SELECTOR SWITCH...809
VARIABLE SHIFT CONTROL SWITCH...809
DIRECTIONAL SELECTOR SWITCH...809
DIRECTIONAL SELECTOR SWITCH ACTUATION SWITCH...810
E.C.S.S. SWITCH...810
LAMP SWITCH...811
TURN SIGNAL LEVER...811
DIMMER SWITCH...811
HORN BUTTON...811
HAZARD LAMP SWITCH...812
FRONT WORKING LAMP SWITCH...812
REAR WORKING LAMP SWITCH...813
MONITOR PANEL MODE SELECTOR SWITCH 1...813
MONITOR PANEL MODE SELECTOR SWITCH 2...813
FRONT WIPER SWITCH...814
REAR WIPER SWITCH...814
CIGARETTE LIGHTER...814
ROOM LAMP SWITCH...814
REAR WINDOW DEFROSTER SWITCH...815
FAN REVERSE SWITCH...815
CONTROL LEVERS, PEDALS...816
DIRECTIONAL LEVER...816
SAFETY LOCK LEVER (FOR WORK EQUIPMENT LEVER)...817
WORK EQUIPMENT LEVER...817
BRAKE PEDAL...818
ACCELERATOR PEDAL...818
PARKING BRAKE LEVER...819
STEERING TILT LOCK LEVER...819
CAP AND COVER WITH LOCK...820
METHOD OF OPENING AND CLOSING CAP WITH LOCK...820
METHOD OF OPENING AND CLOSING COVER WITH LOCK...820
SAFETY BAR...821
TOWING PIN...821
GREASE PUMP...822
CAB DOOR INNER LOCK...822
CAB DOOR OPEN LOCK...822
CAB WINDOW OPEN LOCK CANCEL KNOB...823
FUSE...823
FUSE CAPACITY AND NAME OF CIRCUIT...823
SLOW-BLOW FUSE...824
AUXILIARY POWER...825
STORAGE BOX...825
AIR CONDITIONER...826
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL...826
FAN SWITCH...826
AIR CONDITIONER SWITCH...826
MODE SELECTOR SWITCH...827
FRESH/RECIRC SELECTOR SWITCH...827
TEMPERATURE CONTROL SWITCH...828
METHOD OF OPERATION...828
WHEN NOT USING THE AIR CONDITIONER REGULARLY...829
COOL BOX...829
PRECAUTIONS WHEN USING THE COOLING...829
HANDLING CAB WIPER...830
PREVENTING WIPER ARM BRACKET DAMAGE...830
OPERATION...831
CHECK BEFORE STARTING ENGINE, ADJUST...831
WALK-AROUND CHECK...831
CHECK BEFORE STARTING...834
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...834
CHECK WATER SEPARATOR...835
CHECK DUST INDICATOR...835
CHECK COOLANT LEVEL, ADD COOLANT...836
CHECK INFLATION PRESSURE OF TIRES...836
CHECK ELECTRIC WIRING...837
CHECK MONITOR PANEL...837
CHECK FUEL LEVEL, ADD FUEL...838
CHECK PARKING BRAKE...839
CHECK BRAKE PEDAL...839
ADJUSTMENT...839
ADJUST SEAT...839
ADJUST SEAT BELT...841
ADJUST LEVER STAND...841
ADJUST REAR VIEW MIRROR...842
OPERATIONS AND CHECKS BEFORE STARTING ENGINE...842
STARTING ENGINE...844
OPERATIONS AND CHECKS AFTER STARTING ENGINE...846
BREAKING IN THE MACHINE...846
NORMAL OPERATION...846
STOPPING ENGINE...848
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...849
MOVING THE MACHINE...849
CHANGING DIRECTION...851
CHANGING BETWEEN FORWARD AND REVERSE...852
STOPPING THE MACHINE...853
TURNING...854
EMERGENCY STEERING...855
OPERATION OF WORK EQUIPMENT...855
LIFT ARM OPERATION...856
BUCKET OPERATION...856
HANDLING HYDRAULIC QUICK COUPLER...857
REMOVING THE ATTACHMENT...857
INSTALLING THE ATTACHMENT...858
WORK POSSIBLE USING WHEEL LOADER...860
DIGGING OPERATIONS...860
LOADING PILED SOIL...860
DIGGING AND LOADING ON LEVEL GROUND...861
LEVELING OPERATIONS...862
PUSHING OPERATIONS...862
LOAD AND CARRY OPERATIONS...863
LOADING OPERATIONS...863
CROSS-DRIVE LOADING...864
V-SHAPE LOADING...864
PRECAUTIONS WHEN PILING UP LOADS...864
PRECAUTIONS FOR OPERATION...865
PERMISSIBLE WATER DEPTH...865
IF WHEEL BRAKE DOES NOT WORK...865
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...865
LOWER THE CENTER OF GRAVITY WHEN TURNING...865
BRAKING ON DOWNHILL SLOPE...865
IF ENGINE STOPS...865
PRECAUTIONS WHEN DRIVING MACHINE...865
ADJUSTING WORK EQUIPMENT POSTURE...866
ADJUSTING BOOM KICKOUT...866
ADJUSTING BUCKET POSITIONER...867
ADJUSTING FORK POSITIONER...868
BUCKET LEVEL INDICATOR...869
PARKING MACHINE...870
CHECK AFTER STOPPING ENGINE...871
CHECKS AFTER COMPLETION OF OPERATION...871
LOCKING...872
HANDLING THE TIRES...872
PRECAUTIONS WHEN HANDLING TIRES...872
TIRE PRESSURE...873
PRECAUTIONS FOR USING LOAD AND CARRY METHOD...873
TRANSPORTATION...874
TRANSPORTATION PROCEDURE...874
LOADING, UNLOADING WORK WITH TRAILERS...874
LOADING...874
SECURING MACHINE...875
UNLOADING...875
LIFTING MACHINE...876
LOCATION OF LIFTING POSITION MARK...877
WEIGHT TABLE...877
LIFTING PROCEDURE...878
COLD WEATHER OPERATION...879
PRECAUTIONS FOR LOW TEMPERATURE...879
FUEL AND LUBRICANTS...879
COOLANT...879
BATTERY...880
PRECAUTIONS AFTER COMPLETION OF WORK...880
AFTER COLD WEATHER...880
STEERING HYDRAULIC CIRCUIT WARM-UP...881
LONG-TERM STORAGE...881
BEFORE STORAGE...881
DURING STORAGE...881
AFTER STORAGE...882
TROUBLESHOOTING...883
WHEN MACHINE RUNS OUT OF FUEL...883
TOWING THE MACHINE...883
WHEN ENGINE CAN BE USED...884
WHEN ENGINE CANNOT BE USED...884
IF BATTERY IS DISCHARGED...884
REMOVAL AND INSTALLATION OF BATTERY...885
PRECAUTIONS FOR CHARGING BATTERY...885
STARTING ENGINE WITH BOOSTER CABLE...886
OTHER TROUBLE...888
ELECTRICAL SYSTEM...888
CHASSIS...889
ENGINE...891
MAINTENANCE...893
GUIDES TO MAINTENANCE...894
CHECK SERVICE METER...894
KOMATSU GENUINE REPLACEMENT PARTS...894
KOMATSU GENUINE OILS...894
ALWAYS USE CLEAN WASHER FLUID...894
ALWAYS USE CLEAN OIL AND GREASE...894
CHECKING FOR FOREIGN MATERIALS IN DRAINED OIL AND ON FILTERS...894
FUEL STRAINER...894
WELDING INSTRUCTIONS...894
DO NOT DROP THINGS INSIDE MACHINE...894
DUSTY WORK SITES...895
AVOID MIXING OIL...895
LOCKING INSPECTION COVERS...895
BLEEDING AIR FROM HYDRAULIC CIRCUIT...895
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES...895
CHECKS AFTER INSPECTION AND MAINTENANCE...895
OUTLINES OF SERVICE...896
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...896
OIL...896
FUEL...896
COOLANT...896
GREASE...897
KOWA (Komatsu Oil Wear Analysis)...897
STORING OIL AND FUEL...898
FILTERS...898
OUTLINE OF ELECTRIC SYSTEM...898
WEAR PARTS...899
WEAR PARTS LIST...899
FLUID USE ACCORDING TO AMBIENT TEMPERATURE...900
PROPER SELECTION OF FUEL, COOLANT, AND LUBRICANTS...900
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...904
TORQUE LIST...904
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...905
MAINTENANCE SCHEDULE CHART...906
SERVICE PROCEDURE...908
INITIAL 250 HOURS SERVICE...908
WHEN REQUIRED...908
CLEANING THE MACHINE...908
AIR CLEANER ELEMENT...910
CLEAN INSIDE OF COOLING SYSTEM...913
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL...916
CHECK AXLE OIL LEVEL, ADD OIL...917
CLEAN AXLE CASE BREATHER...918
CLEAN AIR CONDITIONER CONDENSER...918
WASHING METHOD...918
WINDOW WASHING FLUID LEVEL...919
CLEAN RADIATOR FINS AND COOLER FINS...919
CLEAN TRANSFER OIL COOLER FINS...920
CHECK ELECTRICAL INTAKE AIR HEATER...920
REPLACE BOLT-ON CUTTING EDGE...920
REPLACE BUCKET TEETH...921
CHECK AIR CONDITIONER...922
REPLACE SLOW-BLOW FUSE...923
SELECTION AND INSPECTION OF TIRES...924
CHECK BEFORE STARTING...926
EVERY 50 HOURS SERVICE...926
DRAIN WATER, SEDIMENT FROM FUEL TANK...926
EVERY 100 HOURS SERVICE...926
LUBRICATE REAR AXLE PIVOT PIN...926
CLEAN AIR CONDITIONER FRESH AIR FILTER ELEMENT...927
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...928
EVERY 250 HOURS SERVICE...929
CHECK BATTERY ELECTROLYTE LEVEL...929
CHECK PARKING BRAKE...931
AIR CONDITIONER COMPRESSOR BELT TENSION...931
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN...932
AIR CONDITIONER RECIRCULATION FILTER...932
LUBRICATING...933
EVERY 500 HOURS SERVICE...934
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...934
REPLACE FUEL FILTER CARTRIDGE...935
EVERY 1000 HOURS SERVICE...936
CHANGE OIL IN TRANSFER CASE...936
CLEAN TRANSFER CASE BREATHER...937
REPLACE HST OIL FILTER ELEMENT...938
LUBRICATING...939
CHECK TIGHTENING PARTS OF TURBOCHARGER...939
CHECK PLAY OF TURBOCHARGER ROTOR...939
CHECK FAN BELT TENSION, REPLACE...939
EVERY 2000 HOURS SERVICE...940
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...940
REPLACE HYDRAULIC TANK BREATHER ELEMENT...941
CHANGE AXLE OIL...942
REPLACE AIR CONDITIONER RECIRCULATION AIR FILTER AND FRESH AIR FILTER ELEMENTS...942
CHECK ALTERNATOR, STARTING MOTOR...942
CHECK ENGINE VALVE CLEARANCE, ADJUST...942
CHECK BRAKE DISC WEAR...943
CLEAN AND CHECK TURBOCHARGER...943
CHECK ACCUMULATOR GAS PRESSURE...943
CHECK VIBRATION DAMPER...943
EVERY 4000 HOURS SERVICE...944
LUBRICATING...944
CHECK WATER PUMP...944
SPECIFICATIONS...947
SPECIFICATIONS...948
WA250PT-5L WITH BOLT-ON CUTTING EDGE...948
OPTIONS, ATTACHMENTS...951
BUCKETS AND TIRES SELECTION...952
WASTE HANDLER ENGINE COOLING FAN CONTROL SYSTEM...953
FAN SYSTEM OPERATION...953
DIRECTION PUSH BUTTON SWITCH...954
CONTROL BOX...954
CLEANING RADIATOR AND COOLER FINS...955
ROTATING THE FAN IN REVERSE...955
AM/FM RADIO-CASSETTE...956
GENERAL VIEW OF AM/FM RADIO-CASSETTE...956
POWER SWITCH/VOLUME...957
AUTO-STORE/PRESET SCAN BUTTON...957
BASS CONTROL KNOB...957
TREBLE CONTROL KNOB...958
LOUDNESS BUTTON...958
TIME/RADIO DISPLAY SELECTOR BUTTON...958
TAPE EJECT BUTTON...959
CASSETTE DOOR...959
FAST FORWARD, REWIND BUTTONS...959
PRESET BUTTONS...959
METAL TAPE BUTTON...960
MANUAL TUNING BUTTONS...960
SEEK TUNING BUTTONS...960
BAND SELECTOR BUTTON...960
USING RADIO FEATURE...961
METHOD OF SETTING PRESET BUTTONS...961
METHOD OF AUTO-MEMORY...961
LISTENING TO RADIO...962
LISTENING TO CASSETTE TAPE...962
REVERSING TAPE...963
PRECAUTIONS FOR USE...963
HANDLING FORK TOOL...964
EXPLANATION OF COMPONENTS...964
WORK EQUIPMENT LEVER...964
FORKLIFT OPERATION...965
LOADING OPERATION...965
LOADING...965
TRANSPORTING...966
UNLOADING...966
CEAM013101 - Wheel Loader WA200PT-5L Operation & Maintenance Manual...969
COVER...969
INTRODUCTION...971
FOREWORD...972
SAFETY INFORMATION...973
INTRODUCTION...974
DIRECTIONS OF MACHINE...974
NECESSARY INFORMATION...975
MACHINE SERIAL NO. PLATE...975
ENGINE SERIAL NO. PLATE AND POSITION...975
SERVICE METER POSITION...976
ENTER SERIAL NO. AND DISTRIBUTOR...976
TABLE OF CONTENTS...977
SAFETY...987
SAFETY AND WARNING DECALS...988
LOCATION OF THE SAFETY DECALS...988
DESCRIPTION OF SAFETY LABELS...989
SAFETY LABELS...989
GENERAL SAFETY RULES AND PRECAUTIONS...997
GENERAL SAFETY RULES...997
UNAUTHORIZED MODIFICATIONS...998
GENERAL SAFETY AT JOB SITE...998
WORKING ON LOOSE GROUND...998
SAFETY FEATURES...999
PERSONAL PROTECTIVE EQUIPMENT...999
FIRE AND EXPLOSION PREVENTION...1000
FIRE CAUSED BY FUEL OR OIL...1000
FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL...1000
FIRE COMING FROM ELECTRIC WIRING...1001
FIRE COMING FROM HYDRAULIC LINE...1001
WINDSHIELD WASHER FLUID...1001
ACTION IF FIRE OCCURS...1001
FIRE EXTINGUISHER AND FIRST AID KIT...1001
MOUNTING AND DISMOUNTING...1002
INSIDE OPERATOR’S COMPARTMENT...1003
PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT...1003
PRECAUTIONS WHEN USING ROPS...1003
EMERGENCY ESCAPE FROM OPERATOR'S CAB...1003
LEAVING OPERATOR’S COMPARTMENT...1004
KEEP OPERATOR'S COMPARTMENT CLEAN...1004
DUST HAZARD PRECAUTIONS...1005
ASBESTOS HAZARD ALERT...1005
CRUSH OR PINCH POINT DANGERS...1005
PRECAUTIONS BEFORE STARTING OPERATIONS...1006
PRE-OPERATIONAL CHECKS...1006
STARTING YOUR WORK OPERATIONS...1006
WORK SITE HAZARDS...1007
AVOIDING DANGEROUS SITUATIONS...1007
WORKING CLEARANCES...1008
RULES FOR ROAD TRAVEL...1010
TRAVELING IN REVERSE...1010
TRAVELING ON ICY OR SNOW-COVERED SURFACES...1010
WORKING ON LOOSE OR UNSTABLE GROUND...1010
TRAVEL ON SLOPES...1011
PARKING THE MACHINE...1012
PRECAUTIONS DURING MAINTENANCE OPERATIONS...1013
WARNING TAGS...1013
EQUIPMENT STORAGE...1013
WORKING UNDER THE MACHINE...1014
USING DROP LAMPS...1014
KEEPING THE MACHINE CLEAN...1015
RUNNING THE MACHINE DURING MAINTENANCE...1015
RULES FOR REFUELING THE MACHINE...1016
COOLING SYSTEM PRECAUTIONS...1016
BATTERY PRECAUTIONS...1017
STARTING THE MACHINE...1017
HIGH-PRESSURE HOSES...1018
SAFETY HANDLING HIGH-PRESSURE HOSES...1018
PRECAUTION FOR HIGH FUEL PRESSURE...1018
HIGH TEMPERATURES AREAS...1018
DISPOSAL OF WASTE MATERIALS...1019
INFLATING TIRES...1019
DISPOSAL OF WASTE MATERIALS...1019
ACCUMULATOR...1020
CRITICAL PARTS...1020
HIGH VOLTAGE...1020
OPERATION...1021
GENERAL VIEW...1022
GENERAL VIEW OF MACHINE...1022
CONTROLS AND GAUGES...1023
MACHINE MONITOR...1024
EXPLANATION OF COMPONENTS...1025
MONITOR SYSTEM...1026
TESTING ACTUATION OF MACHINE MONITOR SYSTEM...1026
TYPES OF WARNING...1027
EMERGENCY STOP...1027
CAUTION...1027
MISTAKEN OPERATION...1027
INSPECTION AND MAINTENANCE...1027
CENTRAL WARNING LAMP...1027
CHARACTER DISPLAY PORTION...1028
SERVICE METER...1028
ACTION CODE DISPLAY...1029
FAILURE CODE DISPLAY...1030
FILTER, OIL REPLACEMENT TIME DISPLAY...1031
EMERGENCY STOP ITEMS...1033
BRAKE OIL PRESSURE CAUTION LAMP...1033
ENGINE OIL PRESSURE CAUTION LAMP...1034
BATTERY CHARGE CIRCUIT CAUTION LAMP...1034
STEERING OIL PRESSURE CAUTION LAMP - RED...1034
CAUTION ITEMS...1035
AXLE OIL TEMPERATURE CAUTION LAMP...1035
PARKING BRAKE REMINDER CAUTION LAMP...1036
HST OIL TEMPERATURE CAUTION LAMP...1036
ENGINE COOLING WATER TEMPERATURE CAUTION LAMP...1036
FUEL LEVEL CAUTION LAMP...1037
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED...1037
TRAVEL SPEED LIMIT FUNCTION...1037
INSPECTION AND MAINTENANCE ITEMS...1038
RADIATOR COOLANT LEVEL CAUTION LAMP...1038
MAINTENANCE CAUTION LAMP...1039
HST OIL FILTER CLOG CAUTION LAMP...1039
PILOT DISPLAY PORTION...1040
PARKING BRAKE PILOT LAMP...1040
PREHEATING PILOT LAMP...1040
EMERGENCY STEERING PILOT LAMP - GREEN...1041
DIRECTIONAL LEVER POSITION PILOT LAMP...1041
PILOT LAMP FOR SPEED RANGE SELECTOR SWITCH POSITION...1041
TURN SIGNAL PILOT LAMP...1042
HEAD LAMP HIGH BEAM PILOT LAMP...1042
METER DISPLAY PORTION...1043
HST OIL TEMPERATURE GAUGE...1043
ENGINE COOLANT TEMPERATURE GAUGE...1043
FUEL GAUGE...1044
SPEEDOMETER...1044
METER DISPLAY PILOT LAMP...1044
OTHER FUNCTIONS OF MACHINE MONITOR...1045
METHOD OF DISPLAYING ODOMETER...1045
RESET METHOD FOR FILTER, OIL REPLACEMENT TIME...1045
METHOD FOR SELECTING LANGUAGE...1046
METHOD OF SELECTING HST CHANGING FUNCTION...1047
SWITCHES...1048
STARTING SWITCH...1048
SPEED RANGE SELECTOR SWITCH...1049
VARIABLE SHIFT CONTROL SWITCH...1049
DIRECTIONAL SELECTOR SWITCH...1049
DIRECTIONAL SELECTOR SWITCH ACTUATION SWITCH...1050
E.C.S.S. SWITCH...1050
LAMP SWITCH...1051
TURN SIGNAL LEVER...1051
DIMMER SWITCH...1051
HORN BUTTON...1051
HAZARD LAMP SWITCH...1052
FRONT WORKING LAMP SWITCH...1052
REAR WORKING LAMP SWITCH...1053
MONITOR PANEL MODE SELECTOR SWITCH 1...1053
MONITOR PANEL MODE SELECTOR SWITCH 2...1053
FRONT WIPER SWITCH...1054
REAR WIPER SWITCH...1054
CIGARETTE LIGHTER...1054
ROOM LAMP SWITCH...1054
REAR WINDOW DEFROSTER SWITCH...1055
FAN REVERSE SWITCH...1055
CONTROL LEVERS, PEDALS...1056
DIRECTIONAL LEVER...1056
SAFETY LOCK LEVER (FOR WORK EQUIPMENT LEVER)...1057
WORK EQUIPMENT LEVER...1057
BRAKE PEDAL...1058
ACCELERATOR PEDAL...1058
PARKING BRAKE LEVER...1059
STEERING TILT LOCK LEVER...1059
CAP AND COVER WITH LOCK...1060
METHOD OF OPENING AND CLOSING CAP WITH LOCK...1060
METHOD OF OPENING AND CLOSING COVER WITH LOCK...1060
SAFETY BAR...1061
TOWING PIN...1061
GREASE PUMP...1062
CAB DOOR INNER LOCK...1062
CAB DOOR OPEN LOCK...1062
CAB WINDOW OPEN LOCK CANCEL KNOB...1063
FUSE...1063
FUSE CAPACITY AND NAME OF CIRCUIT...1063
SLOW-BLOW FUSE...1064
AUXILIARY POWER...1065
STORAGE BOX...1065
AM/FM RADIO-CASSETTE...1066
GENERAL VIEW OF AM/FM RADIO-CASSETTE...1066
POWER SWITCH/VOLUME...1067
AUTO-STORE/PRESET SCAN BUTTON...1067
BASS CONTROL KNOB...1067
TREBLE CONTROL KNOB...1068
LOUDNESS BUTTON...1068
TIME/RADIO DISPLAY SELECTOR BUTTON...1068
TAPE EJECT BUTTON...1069
CASSETTE DOOR...1069
FAST FORWARD, REWIND BUTTONS...1069
PRESET BUTTONS...1069
METAL TAPE BUTTON...1070
MANUAL TUNING BUTTONS...1070
SEEK TUNING BUTTONS...1070
BAND SELECTOR BUTTON...1070
METHOD OF SETTING PRESET BUTTONS...1071
METHOD OF AUTO PRESET...1071
METHOD OF MANUAL PRESET...1071
LISTENING TO RADIO...1072
LISTENING TO CASSETTE TAPE...1072
REVERSING TAPE...1073
OPERATING HINTS...1073
AIR CONDITIONER...1074
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL...1074
FAN SWITCH...1074
AIR CONDITIONER SWITCH...1074
MODE SELECTOR SWITCH...1075
FRESH/RECIRC SELECTOR SWITCH...1075
TEMPERATURE CONTROL SWITCH...1076
METHOD OF OPERATION...1076
WHEN NOT USING THE AIR CONDITIONER REGULARLY...1077
COOL BOX...1077
PRECAUTIONS...1077
WHEN USING THE COOLING...1077
PREVENTING WIPER ARM BRACKET DAMAGE...1078
OPERATION...1079
CHECK BEFORE STARTING ENGINE, ADJUST...1079
WALK-AROUND CHECK...1079
CHECK BEFORE STARTING...1082
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...1082
CHECK WATER SEPARATOR...1083
CHECK DUST INDICATOR...1083
CHECK COOLANT LEVEL, ADD COOLANT...1084
CHECK INFLATION PRESSURE OF TIRES...1084
CHECK ELECTRIC WIRING...1085
CHECK MONITOR PANEL...1085
CHECK FUEL LEVEL, ADD FUEL...1086
CHECK PARKING BRAKE...1087
CHECK BRAKE PEDAL...1087
ADJUSTMENT...1087
SEAT ADJUSTMENT...1087
ADJUST SEAT BELT...1089
ADJUST LEVER STAND...1089
ADJUST REAR VIEW MIRROR...1090
OPERATIONS AND CHECKS BEFORE STARTING ENGINE...1091
STARTING ENGINE...1093
OPERATIONS AND CHECKS AFTER STARTING ENGINE...1095
BREAKING IN THE MACHINE...1095
NORMAL OPERATION...1095
STOPPING ENGINE...1097
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...1098
MOVING THE MACHINE...1098
CHANGING DIRECTION...1100
CHANGING BETWEEN FORWARD AND REVERSE...1100
STOPPING THE MACHINE...1102
TURNING...1103
EMERGENCY STEERING...1104
OPERATION OF WORK EQUIPMENT...1105
LIFT ARM OPERATION...1105
BUCKET OPERATION...1106
WORK POSSIBLE USING WHEEL LOADER...1107
DIGGING OPERATIONS...1107
LOADING PILED SOIL...1107
DIGGING AND LOADING ON LEVEL GROUND...1108
LEVELING OPERATIONS...1109
PUSHING OPERATIONS...1109
LOAD AND CARRY OPERATIONS...1109
LOADING OPERATIONS...1110
CROSS-DRIVE LOADING...1110
V-SHAPE LOADING...1111
PRECAUTIONS WHEN PILING UP LOADS...1111
PRECAUTIONS FOR OPERATION...1111
PERMISSIBLE WATER DEPTH...1111
IF WHEEL BRAKE DOES NOT WORK...1111
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...1112
LOWER THE CENTER OF GRAVITY WHEN TURNING...1112
BRAKING ON DOWNHILL SLOPE...1112
IF ENGINE STOPS...1112
PRECAUTIONS WHEN DRIVING MACHINE...1112
ADJUSTING WORK EQUIPMENT POSTURE...1113
ADJUSTING BOOM KICKOUT...1113
ADJUSTING BUCKET POSITIONER...1114
BUCKET LEVEL INDICATOR...1114
PARKING MACHINE...1115
CHECK AFTER STOPPING ENGINE...1116
CHECKS AFTER COMPLETION OF OPERATION...1117
LOCKING...1117
HANDLING THE TIRES...1118
PRECAUTIONS WHEN HANDLING TIRES...1118
TIRE PRESSURE...1118
PRECAUTIONS FOR USING LOAD AND CARRY METHOD...1119
TRANSPORTATION...1120
TRANSPORTATION PROCEDURE...1120
LOADING, UNLOADING WORK WITH TRAILERS...1120
LOADING...1120
SECURING MACHINE...1121
UNLOADING...1121
LIFTING MACHINE...1122
LOCATION OF LIFTING POSITION MARKS...1123
WEIGHT TABLE...1123
LIFTING PROCEDURE...1124
COLD WEATHER OPERATION...1125
PRECAUTIONS FOR LOW TEMPERATURE...1125
FUEL AND LUBRICANTS...1125
COOLANT...1125
BATTERY...1126
PRECAUTIONS AFTER COMPLETION OF WORK...1126
AFTER COLD WEATHER...1126
STEERING HYDRAULIC CIRCUIT WARM UP...1127
LONG TERM STORAGE...1127
BEFORE STORAGE...1127
DURING STORAGE...1127
AFTER STORAGE...1128
TROUBLESHOOTING...1129
WHEN MACHINE RUNS OUT OF FUEL...1129
TOWING THE MACHINE...1129
WHEN ENGINE CAN BE USED...1130
WHEN ENGINE CANNOT BE USED...1130
IF BATTERY IS DISCHARGED...1130
REMOVAL AND INSTALLATION OF BATTERY...1131
PRECAUTIONS FOR CHARGING BATTERY...1131
STARTING ENGINE WITH BOOSTER CABLE...1132
STARTING ENGINE...1133
OTHER TROUBLE...1134
ELECTRICAL SYSTEM...1134
CHASSIS...1135
ENGINE...1137
MAINTENANCE...1141
GUIDES TO MAINTENANCE...1142
CHECK SERVICE METER...1142
KOMATSU GENUINE REPLACEMENT PARTS...1142
KOMATSU GENUINE OILS...1142
ALWAYS USE CLEAN WASHER FLUID...1142
ALWAYS USE CLEAN OIL AND GREASE...1142
CHECKING FOR FOREIGN MATERIALS IN DRAINED OIL AND ON FILTERS...1142
FUEL STRAINER...1142
WELDING INSTRUCTIONS...1142
DO NOT DROP THINGS INSIDE MACHINE...1142
DUSTY WORK SITES...1143
AVOID MIXING OIL...1143
LOCKING INSPECTION COVERS...1143
BLEEDING AIR FROM HYDRAULIC CIRCUIT...1143
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES...1143
CHECKS AFTER INSPECTION AND MAINTENANCE...1143
OUTLINES OF SERVICE...1144
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...1144
OIL...1144
FUEL...1144
COOLANT...1144
GREASE...1145
KOWA (Komatsu Oil Wear Analysis)...1145
STORING OIL AND FUEL...1146
FILTERS...1146
OUTLINE OF ELECTRIC SYSTEM...1146
WEAR PARTS...1147
WEAR PARTS LIST...1147
FLUID USE ACCORDING TO AMBIENT TEMPERATURE...1148
PROPER SELECTION OF FUEL, COOLANT, AND LUBRICANTS...1148
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...1152
TORQUE LIST...1152
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...1153
MAINTENANCE SCHEDULE CHART...1154
SERVICE PROCEDURE...1156
INITIAL 250 HOURS SERVICE...1156
WHEN REQUIRED...1156
CLEANING THE MACHINE...1156
AIR CLEANER ELEMENT...1158
CLEAN INSIDE OF COOLING SYSTEM...1161
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL...1164
CHECK AXLE OIL LEVEL, ADD OIL...1165
CLEAN AXLE CASE BREATHER...1166
CLEAN AIR CONDITIONER CONDENSER...1166
WASHING METHOD...1166
WINDOW WASHING FLUID LEVEL...1167
CLEAN RADIATOR FINS AND COOLER FINS...1167
CHECK ELECTRICAL INTAKE AIR HEATER...1167
REPLACE BOLT-ON CUTTING EDGE...1168
REPLACE BUCKET TEETH...1169
CHECK AIR CONDITIONER...1170
REPLACE SLOW-BLOW FUSE...1171
SELECTION AND INSPECTION OF TIRES...1172
CHECK BEFORE STARTING...1174
EVERY 50 HOURS SERVICE...1174
DRAIN WATER, SEDIMENT FROM FUEL TANK...1174
EVERY 100 HOURS SERVICE...1174
LUBRICATE REAR AXLE PIVOT PIN...1174
CLEAN AIR CONDITIONER FRESH AIR FILTER ELEMENT...1175
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...1176
EVERY 250 HOURS SERVICE...1177
CHECK BATTERY ELECTROLYTE LEVEL...1177
CHECK PARKING BRAKE...1179
AIR CONDITIONER COMPRESSOR BELT TENSION...1179
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN...1180
AIR CONDITIONER RECIRCULATION FILTER...1180
LUBRICATING...1181
EVERY 500 HOURS SERVICE...1182
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...1182
REPLACE FUEL FILTER CARTRIDGE...1183
CLEAN WATER SEPARATOR STRAINER...1184
EVERY 1000 HOURS SERVICE...1185
CHANGE OIL IN TRANSFER CASE...1185
CLEAN TRANSFER CASE BREATHER...1186
REPLACE HST OIL FILTER ELEMENT...1187
LUBRICATING...1188
CHECK TIGHTENING PARTS OF TURBOCHARGER...1188
CHECK PLAY OF TURBOCHARGER ROTOR...1188
CHECK FAN BELT TENSION, REPLACE...1188
EVERY 2000 HOURS SERVICE...1189
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...1189
REPLACE HYDRAULIC TANK BREATHER ELEMENT...1190
CHANGE AXLE OIL...1191
REPLACE AIR CONDITIONER RECIRCULATION AIR FILTER AND FRESH AIR FILTER ELEMENTS...1191
CLEAN BRAKE CIRCUIT STRAINER...1192
CHECK ALTERNATOR, STARTING MOTOR...1192
CHECK ENGINE VALVE CLEARANCE, ADJUST...1192
CHECK BRAKE DISC WEAR...1193
CLEAN AND CHECK TURBOCHARGER...1194
CHECK ACCUMULATOR GAS PRESSURE...1194
CHECK VIBRATION DAMPER...1194
EVERY 4000 HOURS SERVICE...1195
LUBRICATING...1195
CHECK WATER PUMP...1195
SPECIFICATIONS...1197
SPECIFICATIONS...1198
WA200-5L WITH BOLT-ON CUTTING EDGE...1198
OPTIONS, ATTACHMENTS...1201
BUCKETS AND TIRES SELECTION...1202
WASTE HANDLER ENGINE COOLING FAN CONTROL SYSTEM...1203
FAN SYSTEM OPERATION...1203
DIRECTION PUSH BUTTON SWITCH...1204
CONTROL BOX...1204
CLEANING RADIATOR AND COOLER FINS...1205
ROTATING THE FAN IN REVERSE...1205
CEAMW18021 - Wheel Loader WA250-1LC Operation & Maintenance Manual...1207
FOREWORD...1211
INTRODUCTION...1212
SAFETY INFORMATION...1212
BREAKING IN THE NEW MACHINE...1213
MACHINE AND ENGINE SERIAL NUMBERS...1214
QUICK REFERENCE INFORMATION...1215
CONTENTS...1216
SAFETY PRECAUTIONS -- SECTION 1...1225
GENERAL PRECAUTIONS...1226
PERSONNEL PRECAUTIONS...1226
MACHINE PRECAUTIONS...1226
OPERATION...1227
BEFORE STARTING...1227
START-UP...1228
GENERAL OPERATING PRECAUTIONS...1228
DRIVING THE MACHINE...1229
OPERATING THE ATTACHMENTS...1230
PULLING/TOWING...1230
SHUTDOWN...1231
MAINTENANCE...1231
GENERAL MACHINE PRECAUTIONS...1231
GENERAL WORK PRECAUTIONS...1232
ATTACHMENTS...1233
BRAKES...1233
CAB/ROPS...1233
COOLING...1233
ELECTRICAL...1234
ENGINE...1234
FUEL SYSTEM...1235
HYDRAULICS...1235
TIRES AND RIMS...1235
TURBOCHARGER...1235
VITON SEALS...1236
SAFETY PRODUCT GRAPHICS AND LOCATIONS...1237
BEFORE CARRYING OUT MAINTENANCE...1249
OPERATION -- SECTION 2...1251
GENERAL VIEW...1252
INSTRUMENTS AND CONTROLS...1253
MONITOR PANEL...1253
CHECK MONITOR LAMP GROUP...1253
CAUTION MONITOR LAMP GROUP...1253
METER GROUP...1254
WARNING LAMP...1254
SYSTEM CHECK...1254
CHECK MONITOR LAMP GROUP...1255
Brake Oil Level Monitor...1255
Engine Oil Level Monitor...1256
Coolant Level Monitor...1256
CAUTION MONITOR LAMP GROUP...1257
Battery charge monitor...1257
Fuel level monitor...1258
Brake oil level monitor...1259
Engine oil pressure monitor ...1259
Coolant level monitor ...1259
Brake servo pressure monitor ...1259
Coolant temperature monitor ...1260
Torque converter oil temperature monitor ...1260
Ground driven steering monitor - if equipped ...1260
METER GROUP...1261
Parking brake pilot lamp ...1261
Pilot lamp for working lamp ...1262
Transmission cut-off selector pilot lamp ...1262
Ground driven steering pilot lamp...1262
Engine cooling water temperature gauge ...1262
Torque converter oil temperature gauge ...1263
Fuel gauge...1263
Turn signal pilot lamp ...1263
High beam pilot lamp...1263
Speedometer...1264
Service meter...1264
SWITCHES ...1265
WORKING LAMP SWITCH ...1265
STARTING SWITCH ...1266
HAZARD LAMP SWITCH...1266
HORN BUTTON...1266
LAMP SWITCHES ...1267
Lamp switch ...1267
Turn signal lever ...1267
Dimmer switch ...1267
TRANSMISSION CUT-OFFSELECTOR SWITCH ...1268
ETHER START SWITCH ...1268
FRONT WIPER SWITCH ...1269
REAR WIPER SWITCH...1269
WINDOW WASHER SWITCH...1270
FRONT FLOOD LIGHT SWITCH...1270
ACCESSARY SWITCH...1270
ROOM LAMP SWITCH...1270
ROOM LAMP SWITCH...1270
CIGARETTE LIGHTER ...1271
LEVERS AND PEDALS...1272
DIRECTIONAL LEVER...1272
SPEED CONTROL LEVER ...1273
SPEED CONTROL LEVER STOPPER...1273
STEERING COLUMN TILT LEVER ...1273
ACCELERATOR PEDAL...1274
BRAKE PEDALS...1274
Right brake pedal...1274
Left brake pedal...1274
LIFT ARM CONTROL LEVER ...1275
BUCKET CONTROL LEVER ...1275
WORK EQUIPMENT CONTROL LEVERS LOCK...1276
PARKING BRAKE LEVER...1276
WORK EQUIPMENT CONTROL LEVER...1277
MON-LEVER TYPE...1277
CAB DOOR HOLD OPEN LOCK - IF EQUIPPED ...1278
AIR CLEANER SERVICE INDICATOR ...1278
FRAME LOCKING BAR ...1278
ENGINE SIDE DOOR LOCK...1279
MAIN CIRCUIT BREAKER...1279
CIGARETTE LIGHTER...1279
FUSE BOXES...1280
OPERATOR'S SEAT...1282
RIGID TYPE...1282
FORWARD-BACKWARD ADJUSTMENT ...1282
SEAT HEIGHT ADJUSTMENT...1282
BACKREST ADJUSTMENT...1282
BUCKET TYPE SEAT (OPT)...1282
FORWARD-BACKWARD ADJUSTMENT ...1283
SEAT ANGLE ADJUSTMENT ...1282
SEAT CUSHION ADJUSTMENT...1282
BACKREST ADJUSTMENT...1282
SEAT HEIGHT ADJUSTMENT...1282
SEARS SEAT...1283
FORWARD-BACKWARD ADJUSTMENT...1283
SEAT ANGLE ADJUSTMENT ...1283
WEIGHT ADJUSTMENT...1283
BACKREST TILT ADJUSTMENT...1283
HEIGHT ADJUSTMENT...1283
KAB SEAT...1284
WEIGHT ADJUSTMENT...1284
HEIGHT ADJUSTMENT...1284
BACKREST ANGLE ADJUSTMENT...1284
FORE AND AFT ADJUSTMENT...1284
HEADREST ADJUSTMENT (IF EQUIPPED)...1284
RIGHT SIDE ARMREST...1285
SEAT BELT...1286
DRAWBAR PIN...1287
CAB HEATER AND DEFROSTER...1288
CONTROL PANEL ...1288
FAN SPEED SWITCH ...1288
FOOT / DEFROSTER SELECT LEVER (2) ...1288
AIR INTAKE SELECTOR LEVER...1288
CONTROL PANEL...1289
FAN SPEED SWITCH ...1289
TEMPERATURE CONTROL LEVER...1289
AIR INTAKE SELECTOR LEVER ...1289
METHOD OF OPERATION ...1290
CAB HEATER, DEFROSTER AND AIR CONDITIONER - IF EQUIPPED...1291
CONTROL PANEL...1291
FAN SPEED SWITCH...1291
AIR CONDITIONER SWITCH...1291
TEMPERATURE CONTROL LEVER...1291
AIR INTAKE SELECTOR LEVER...1291
METHOD OF OPERATION...1292
PRECAUTIONS FOR USING AIR CONDITIONER...1293
HANDLING AIR CONDITIONER IN SEASON...1293
HANDLING AIR CONDITIONER IN OFF-SEASONS...1293
LOCKING FILLER CAPS...1294
FUEL TANK FILLER CAP...1294
HYDRAULIC TANK FILLER CAP ...1295
CHECK BEFORE STARTING...1296
WALK-AROUND CHECK ...1296
CHECK MONITOR PANEL ...1296
CHECK AND REFILL COOLANT ...1297
CHECK AIR CLEANER SERVICE INDICATOR ...1297
CHECK OIL LEVEL AND REFILL IN ENGINE OIL PAN ...1298
CHECK FUEL LEVEL AND REFILL FUEL ...1298
CHECK AND REFILL OIL IN BRAKE OIL TANK...1299
DRAIN THE WATER FROM THE FUEL-WATER SEPARATOR...1299
ADDITIONAL CHECKS...1300
CHECK ELECTRICAL WIRING...1300
OPERATING YOUR MACHINE...1301
BEFORE STARTING THE ENGINE ...1301
STARTING ENGINE ...1302
SPECIAL STARTING ...1303
COLD WEATHER STARTING...1303
COLD WEATHER WARM-UP PROCEDURE ...1305
CHECKS AFTER STARTING ...1306
MOVING MACHINE OFF ...1306
SHIFTING GEAR...1308
SHIFTING BETWEEN FORWARD AND REVERSE...1308
STEERING MACHINE...1309
TO STOP THE MACHINE...1310
TO STOP THE ENGINE ...1311
OPERATIONS AFTER STOPPING ENGINE...1311
OPERATIONAL PRECAUTIONS...1312
WORKING IN DUSTY LOCATIONS ...1312
MAXIMUM DEPTH OF WATER ...1312
IF WHEEL BRAKE DOES NOT WORK ...1313
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES ...1313
LOWER THE CENTER OF GRAVITY WHEN TURNING...1313
BRAKING ON DOWNHILL SLOPES...1313
IF ENGINE STOPS...1313
POSSIBLE WORK USING LOADER ...1314
EXCAVATION ...1314
LEVELING...1316
LOAD AND CARRY OPERATIONS ...1317
LOADING ...1317
Cross Drive Loading ...1317
V-Shape Loading ...1317
PARKING MACHINE ...1318
ADJUSTMENT OF WORK EQUIPMENT ...1319
ADJUSTING BOOM KICKOUT ...1319
ADJUSTING BUCKET POSITIONER ...1320
BUCKET LEVEL INDICATOR ...1320
HANDLING TIRES...1321
PRECAUTIONS WHEN HANDLING TIRES ...1321
PRECAUTIONS WHEN DRIVING MACHINE ...1321
TIRE PRESSURE ...1321
TOWING ...1323
TOWING THE MACHINE ...1323
WHEN ENGINE CAN BE USED ...1323
WHEN ENGINE CANNOT BE USED...1323
TRANSPORTATION ...1323
COLD WEATHER OPERATION...1324
PREPARATION FOR LOW TEMPERATURE ...1324
FUEL AND LUBRICANTS ...1324
COOLANT...1324
BATTERY ...1324
CAUTIONS AFTER COMPLETION OF WORK ...1324
AFTER COLD WEATHER ...1325
LONG TERM STORAGE...1325
BEFORE STORAGE ...1325
DURING STORAGE...1325
AFTER STORAGE ...1325
HANDLING OF BATTERY...1326
PRECAUTIONS FOR CHARGING BATTERY ...1326
REMOVAL AND INSTALLATION OF BATTERY...1326
STARTING ENGINE WITH BOOSTER CABLES...1326
BEFORE CONNECTING BOOSTER CABLES ...1326
CONNECTING BOOSTER CABLES ...1327
STARTING ENGINE ...1327
DISCONNECTING BOOSTER CABLES ...1327
TROUBLESHOOTING...1328
ELECTRICAL SYSTEM ...1328
ENGINE ...1329
CHASSIS ...1330
TRANSMISSION ...1330
DRIVE AXLES...1330
WHEEL BRAKES...1330
PARKING BRAKE ...1330
STEERING ...1330
EQUIPMENT HYDRAULIC SYSTEM...1330
MAINTENANCE -- SECTION 3...1331
PERIODIC MAINTENANCE...1332
MAINTENANCE GUIDELINES...1332
OUTLINES OF SERVICE...1333
LUBRICATION WHEN SHIPPED ...1333
RELATING TO ENGINE ...1334
ENGINE OIL ...1334
COOLANT...1334
DIESEL FUEL...1334
RELATING TO HYDRAULIC SYSTEM ...1334
RELATING TO ELECTRICAL SYSTEM ...1334
RELATING TO LUBRICATION ...1335
BLEEDING AIR ...1335
BLEEDING AIR FROM HYDRAULIC TANK ...1335
BLEEDING AIR FROM THE WHEEL BRAKE HYDRAULIC CIRCUIT ...1336
BLEEDING AIR FROM FUEL SYSTEM ...1337
WEAR PARTS REPLACEMENT...1339
PERIODICAL PART REPLACEMENT...1339
LUBRICANTS, FUEL AND COOLANT ...1340
PROPER SELECTION TABLE ...1340
ENGINE OIL...1341
Normal Operation...1341
Arctic Operation...1341
AXLE OIL...1342
GREASE...1342
DIESEL FUEL...1342
COOLANT ...1342
SCHEDULED MAINTENANCE GUIDE ...1349
OIL FILLER AND LEVEL GAUGE POSITIONS ...1353
INITIAL 250 HOURS SERVICE ONLY...1355
TRANSMISSION OIL FILTER ...1355
WHEN REQUIRED...1207
COOLANT ADDITIVE CONCENTRATION - DCA4 ...1355
AIR CLEANER ELEMENT ...1355
CHECKING ...1355
CLEANING OR REPLACING OUTER ELEMENT ...1356
REPLACING INNER ELEMENT ...1356
CLEANING OUTER ELEMENT...1357
TRANSMISSION OIL ...1358
RADIATOR CORE ...1358
WINDSHIELD WASHER TANKS ...1359
DRIVE AXLE OIL ...1359
DRIVE AXLE HOUSING BREATHERS ...1360
LUBRICATING ...1361
BUCKET BOLT-ON CUlTING EDGE - IF EQUIPPED ...1363
BUCKET TEETH - IF EQUIPPED ...1363
BUCKET IS EQUIPPED WITH BOLT-ON TEETH ...1363
BUCKET IS EQUIPPED WITH WELDED ON OR REPLACEABLE TIP TEETH...1364
PARKING BRAKE ...1365
INSPECTION...1365
ADJUSTMENT...1365
LENGTH OF LEVER ...1366
AIR CONDITIONER CONDENSER - IF EQUIPPED ...1366
AIR CONDITIONER REFRIGERANT CHARGE - IF EQUIPPED ...1367
STEERING ...1368
HYDRAULIC SYSTEM ...1368
SERVICE METER ...1368
CHECK BEFORE STARTING...1369
EVERY 50 HOURS SERVICE...1369
FUEL TANK ...1369
TIRES ...1369
EVERY 100 HOURS SERVICE ...1369
HYDRAULIC TANK ...1369
LUBRICATING ...1370
CAB AIR FILTER - IF EQUIPPED ...1371
AIR CONDITIONER FILTER - IF EQUIPPED ...1371
EVERY 250 HOURS SERVICE ...1372
LUBRICATING ...1372
WHEEL HUB BOLTS ...1374
ENGINE OIL PAN AND FILTER ...1374
BATTERY ELECTROLYTE ...1375
AIR INTAKE SYSTEM ...1376
AIR CONDITIONER COMPRESSOR DRIVE BELT - IF EQUIPPED ...1376
EVERY 500 HOURS SERVICE ...1377
LUBRICATING ...1377
FUEL FILTERS ...1378
GENERAL...1378
REPLACEMENT...1378
TRANSMISSION OIL FILTER ...1380
ANTIFREEZE CONCENTRATION ...1380
AIR DRYER - IF EQUIPPED ...1380
EVERY 1000 HOURS SERVICE...1381
LUBRICATING...1381
TRANSMISSION CASE BREATHER ...1383
TRANSMISSION OIL AND STRAINER ...1383
ENGINE VALVES...1384
DRIVE BELT ...1387
DRIVE BELT, TENSIONER BEARING AND FAN HUB ...1387
EVERY 2000 HOURS SERVICE ...1388
DRIVE AXLES ...1388
HYDRAULIC TANK BREATHER ...1390
HYDRAULIC TANK AND FILTER ...1391
BRAKE DISC ...1392
VIBRATION DAMPER ...1392
COOLING SYSTEM ...1393
AIR CONDITIONER FILTER ...1395
SPECIFICATIONS -- SECTION 4...1397
GENERAL SPECIFICATIONS...1398
STANDARD TIGHTENING TORQUES ...1403
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS ...1403
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS ...1403
TIGHTENING TORQUE FOR NUTS OF FLARED Fll-l-INGS ...1404
UNIT CONVERSIONS...1405
AREA...1406
DENSITY (Mass Density) ...1406
FORCE...1407
FORCE PER LENGTH...1407
HEAT...1407
LENGTH...1408
MASS (WEIGHT)...1408
POWER...1409
PRESSURE...1409
TEMPERATURE...1409
TEMPERATURE INTERVAL OR TOLERANCE...1410
VOLUME...1410
TORQUE...1411
VELOCITY...1411
CEBM004602 - Wheel Loader WA250-3MC avance plus Shop Manual...1414
COVER...1414
CONTENTS...1415
00 FORWARD...1426
01 GENERAL...1442
DIMENSIONAL DRAWING...1443
GENERAL SPECIFICATIONS...1444
WEIGHT TABLE...1447
FUEL, COOLANT AND LUBRICANTS...1448
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS...1448
ENGINE OIL SPECIFICATIONS...1449
NORMAL OPERATION...1449
ARCTIC OPERATION...1449
DIESEL FUEL SPECIFICATIONS...1450
COOLANT SPECIFICATIONS...1450
GENERAL...1450
WATER...1450
ANTIFREEZE...1451
INHIBITORS/CONDITIONERS...1451
10 STRUCTURE AND FUNCTION...1456
POWER TRAIN...1460
PATH OF POWER TRANSMISSION...1461
TORQUE CONVERTER, TRANSMISSION PIPING...1464
HYDRAULIC SYSTEM DIAGRAM...1465
HYDRAULIC CIRCUIT DIAGRAM...1466
TORQUE CONVERTER...1467
TORQUE CONVERTER OIL FILTER...1469
TRANSMISSION...1470
CLUTCH...1473
FORWARD, REVERSE CLUTCH...1473
1ST, 3RD CLUTCH...1474
2ND, 4TH CLUTCH...1474
FORWARD 1ST...1476
FORWARD 2ND...1477
FORWARD 3RD...1478
FORWARD 4TH...1479
REVERSE 1ST...1480
TRANSMISSION CONTROL VALVE...1481
UPPER VALVE...1482
LOWER VALVE...1483
TRANSMISSION SOLENOID VALVE...1484
TORQUE CONVERTER OUTLET PORT VALVE...1485
PILOT REDUCING VALVE...1486
TRANSMISSION SOLENOID VALVE...1487
PRIORITY VALVE...1488
MAIN REGULATOR VALVE...1489
QUICK RETURN VALVE...1490
MODULATION FILL VALVE...1494
DIRECTIONAL SELECTOR SPOOL...1496
EMERGENCY MANUAL SPOOL...1497
OPERATION OF FORWARD 1ST...1499
ACCUMULATOR VALVE...1501
DRIVE SHAFT...1503
AXLE...1504
FRONT AXLE...1504
REAR AXLE...1505
AXLE MOUNT...1507
DIFFERENTIAL...1509
FRONT DIFFERENTIAL...1509
REAR DIFFERENTIAL...1510
TORQUE-PROPORTIONING DIFFERENTIAL...1512
FINAL DRIVE...1513
CENTER HINGE PIN...1514
STEERING PIPING...1515
STEERING COLUMN...1516
PRIORITY VALVE...1517
STEERING VALVE (ORBITAL)...1520
CONNECTION BETWEEN HAND PUMP AND SLEEVE...1527
2-WAY RESTRICTOR VALVE...1529
BRAKE...1530
BRAKE PIPING...1530
POWER MASTER CYLINDER...1531
BRAKE OFF...1532
OIL PRESSURE STARTING TO RISE...1532
PRESSURE RISING...1533
RELIEF VALVE...1533
ONE BRAKE LINE ACTUATED...1534
BRAKE...1535
PARKING BRAKE...1537
PARKING BRAKE CONTROL...1537
PARKING BRAKE...1538
HYDRAULIC SYSTEM...1539
STEERING AND HYDRAULIC PUMP...1539
HYDRAULIC PIPING...1540
HYDRAULIC SYSTEM DIAGRAM...1541
HYDRAULIC CIRCUIT DIAGRAM...1543
WORK EQUIPMENT LEVER LINKAGE...1545
HYDRAULIC TANK...1546
OIL FILTER BYPASS VALVE...1547
BREATHER...1548
PPC VALVE...1550
OPERATION OF PPC VALVE...1551
PPC RELIEF VALVE...1554
ACCUMULATOR FOR PPC VALVE...1555
MAIN CONTROL VALVE...1557
2-SPOOL VALVE...1557
3-SPOOL VALVE...1559
RELIEF VALVE...1561
SAFETY VALVE (WITH SUCTION)...1562
SUCTION VALVE...1563
MAIN CONTROL VALVE OPERATION...1564
BOOM AND BUCKET SPOOLS AT NEUTRAL POSITION...1564
BOOM SPOOL AT RAISE POSITION...1565
BOOM SPOOL AT LOWER POSITION...1566
BOOM SPOOL AT FLOAT POSITION...1567
BUCKET SPOOL AT TILT BACK POSITION...1568
BUCKET SPOOL AT DUMP POSITION...1569
WORK EQUIPMENT...1571
WORK EQUIPMENT LINKAGE...1571
BUCKET...1573
BUCKET POSITIONER AND BOOM KICK-OUT...1574
BUCKET POSITIONER...1575
BOOM KICK-OUT...1575
PROXIMITY SWITCHES...1577
ROPS CAB...1579
AIR CONDITIONER PIPING...1580
MACHINE MONITOR SYSTEM...1581
MAIN MONITOR...1582
MAIN MONITOR DISPLAY FUNCTION...1583
PREHEATING OUTPUT FUNCTION...1585
TROUBLE DATA DISPLAY MODE...1586
MAINTENANCE MONITOR...1587
MAINTENANCE MONITOR DISPLAY FUNCTION...1587
TRANSMISSION AUTO-SHIFT CONTROL SYSTEM...1591
SHIFT CONTROL SYSTEM FUNCTION...1592
INPUT SIGNALS...1592
OUTPUT SIGNALS...1593
SHIFT CHARACTERISTICS...1594
SAFETY FUNCTION...1598
TROUBLESHOOTING...1598
MODEL (ENGINE) SELECT SIGNAL...1598
TRANSMISSION CONTROLLER...1599
CONNECTOR SIGNALS...1599
LED DISPLAY...1600
ECSS...1601
ECSS HYDRAULIC AND ELECTRICAL DIAGRAM...1602
SENSORS AND SWITCHES...1603
BRAKE OIL LEVEL SENSOR...1603
RADIATOR WATER LEVEL...1604
ENGINE OIL LEVEL SENSOR...1604
FUEL LEVEL SENSOR...1605
ENGINE WATER TEMPERATURE SENSOR...1606
TORQUE CONVERTER OIL TEMPERATURE SENSOR...1606
ENGINE SPEED SENSOR...1607
ENGINE OIL PRESSURE SENSOR...1607
ENGINE...1608
ENGINE STARTING CIRCUIT...1608
ENGINE STOP CIRCUIT...1609
AUTOMATIC PREHEATING CIRCUIT...1610
RIBBON HEATER...1612
Q.H.S. WATER TEMPERATURE SENSOR...1612
HEATER RELAY...1612
ELECTRICAL TRANSMISSION CONTROL...1613
COMBINATION SWITCH...1614
TRANSMISSION CUT-OFF FUNCTION...1615
PARKING BRAKE NEUTRALIZER RELAY FUNCTION...1617
KICK-DOWN SWITCH, HOLD SWITCH...1618
KICK-DOWN SWITCH...1618
KICK-DOWN ELECTRIC CIRCUIT DIAGRAM...1619
KICK-DOWN SWITCH OPERATED...1620
CANCELING ACTUATION OF KICK-DOWN SWITCH (CASE I)...1621
CANCELLING ACTUATION OF KICK-DOWN SWITCH (CASE II)...1622
CANCELLING ACTUATION OF KICK-DOWN SWITCH (CASE III)...1623
ELECTRICAL WIRING DIAGRAM...1624
ELECTRICAL WIRING DIAGRAM (1/6)...1624
ELECTRICAL WIRING DIAGRAM (2/6)...1626
ELECTRICAL WIRING DIAGRAM (3/6)...1628
ELECTRICAL WIRING DIAGRAM (4/6)...1630
ELECTRICAL WIRING DIAGRAM (5/6)...1632
ELECTRICAL WIRING DIAGRAM (6/6)...1634
20 TESTING, ADJUSTING AND TROUBLESHOOTING...1636
STANDARD VALUE TABLE...1640
ENGINE TABLE - IN CHASSIS...1640
CHASSIS TABLE...1641
SERVICE TOOLS TABLE...1649
ENGINE...1651
ADJUSTING ENGINE STOP MOTOR CABLE...1651
ADJUSTING ENGINE STOP SOLENOID...1651
MEASURING AND ADJUSTING VALVE CLEARANCE...1651
MEASURING BLOW-BY PRESSURE...1651
MEASURING COMPRESSION PRESSURE...1651
MEASURING COOLANT TEMPERATURE...1651
MEASURING ENGINE LUBRICATING OIL PRESSURE...1651
MEASURING ENGINE SPEEDS...1651
MEASURING EXHAUST COLOR...1651
MEASURING EXHAUST GAS TEMPERATURE...1651
MEASURING FUEL FILTER INLET RESTRICTION...1651
TEST AND ADJUSTING FAN BELT TENSION...1651
TEST AND ADJUSTING FUEL INJECTION TIMING...1651
ACCELERATOR PEDAL...1652
OPERATING FORCE...1652
OPERATING ANGLE...1653
SHIFT LEVER...1654
OPERATING FORCE...1654
TRAVEL...1654
STALL SPEEDS...1655
TORQUE CONVERTER STALL SPEED...1655
HYDRAULIC STALL SPEED...1656
FULL STALL SPEED...1656
TORQUE CONVERTER...1657
TRANSMISSION OIL PRESSURE...1657
EMERGENCY MANUAL SPOOL...1659
OPERATION...1659
STEERING WHEEL...1661
PLAY...1661
OPERATING FORCE...1661
OPERATING TIME...1662
STEERING OIL PRESSURE...1663
METHOD OF MEASURING MAIN RELIEF PRESSURE...1663
METHOD OF ADJUSTING MAIN RELIEF PRESSURE...1664
BRAKE...1665
BRAKE PEDAL...1665
OPERATING EFFORT...1665
TRAVEL...1665
BRAKE PEDAL LINKAGE...1666
TESTING...1666
ADJUSTING...1666
BRAKE PERFORMANCE...1668
BRAKE OIL PRESSURE...1669
BRAKE DISC WEAR...1670
BLEEDING AIR...1671
PARKING BRAKE...1672
PARKING BRAKE PERFORMANCE...1672
PARKING BRAKE LINKAGE...1673
PARKING BRAKE PISTON STROKE...1674
PARKING BRAKE DISC WEAR...1675
WORK EQUIPMENT...1676
WORK EQUIPMENT CONTROL LEVER...1676
PPC VALVE...1677
MEASURING PRESSURE...1677
WORK EQUIPMENT HYDRAULIC PRESSURE...1679
WORK EQUIPMENT MEASUREMENT...1681
WORK EQUIPMENT - HYDRAULIC DRIFT...1682
BUCKET POSITIONER...1683
BOOM KICK-OUT...1684
MAIN MONITOR...1686
FUEL LEVEL SENSOR...1688
CHECKING FOR ABNORMALITY...1688
TROUBLESHOOTING GENERAL...1690
POINTS TO REMEMBER WHEN TROUBLESHOOTING...1692
SEQUENCE OF EVENTS IN TROUBLESHOOTING...1694
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...1695
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT...1695
HANDLING CONTROL BOX...1700
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT...1701
CHECKS BEFORE TROUBLESHOOTING...1703
JUDGEMENT OF POWER TRAIN...1704
PRECAUTIONS WHEN TROUBLESHOOTING...1705
SAFETY...1705
METHODS FOR TROUBLESHOOTING...1705
PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING...1707
PREVENTING RECURRENCE OF TROUBLE...1708
HYDRAULIC EQUIPMENT...1708
OIL CHECKS...1708
CLEANING FRAGMENTS OF DAMAGED PARTS...1708
METHOD OF USING TROUBLESHOOTING CHARTS...1709
CATEGORY OF TROUBLESHOOTING CODE NUMBER...1709
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE...1709
METHOD OF USING MATRIX TROUBLESHOOTING TABLES...1711
METHOD OF USING ENGINE RELATED CHARTS...1713
TROUBLESHOOTING ELECTRICAL CONNECTORS...1718
CONNECTOR TYPES...1720
CONNECTOR PIN ARRANGEMENT...1721
DIAGRAM (1/2)...1721
DIAGRAM (2/2)...1722
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...1723
ELECTRICAL CIRCUIT DIAGRAMS...1731
ENGINE START, STOP SYSTEM...1731
PREHEATING SYSTEM...1732
TRANSMISSION CONTROL, PARKING BRAKE SYSTEM...1734
MACHINE MONITOR SYSTEM (1 of 2)...1736
MACHINE MONITOR SYSTEM (2 of 2)...1738
TROUBLESHOOTING SYSTEMS OF:...1740
TROUBLESHOOTING OF TRANSMISSION CONGTROLLER SYSTEM (A-MODE)...1740
OUTLINE...1741
FUNCTION...1741
TROUBLESHOOTING...1741
FAILURE CODE TABLE...1741
TABLE OF TROUBLESHOOTING MODES AND CAUSES...1742
ELECTRICAL CIRCUIT DIAGRAM...1743
A-1 TROUBLESHOOTING CODE [12]...1745
F SOLENOID SIGNAL SYSTEM...1745
A-2 TROUBLESHOOTING CODE [13]...1746
R SOLENOID SIGNAL SYSTEM...1746
A-3 TROUBLESHOOTING CODE [14]...1747
ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM...1747
A-4 TROUBLESHOOTING CODE [16]...1748
ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM...1748
A-5 TROUBLESHOOTING CODE [20]...1749
ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM...1749
A-6 TROUBLESHOOTING CODE [21]...1750
ABNORMALITY IN SPEED LEVER SIGNAL SYSTEM...1750
A-7 TROUBLESHOOTING CODE [22]...1751
ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM...1751
A-8 TROUBLESHOOTING CODE [23]...1752
ABNORMALITY IN ENGINE SPEED SIGNAL SYSTEM...1752
A-9 HOLD SWITCH SIGNAL SYSTEM...1753
A-10 KICK-DOWN SWITCH SYSTEM...1754
A-11 TRANSMISSION CUT-OUT SIGNAL SYSTEM...1755
A-12 NEUTRALIZER RELAY SIGNAL SYSTEM...1756
A-13 BUZZER SIGNAL SYSTEM...1757
A-14 NETWORK SIGNAL SYSTEM...1758
A-15 CONTROLLER POWER SOURCE SYSTEM...1759
TROUBLESHOOTING ELECTRICALLY CONTROLLED SUSPENSION SYSTEM D MODE - (ECSS)...1760
ECSS-ELECTRICAL/HYDRAULIC SCHEMATIC...1761
ECSS-WORKING CHART...1761
ECSS CIRCUIT - REMAINING PRESSURE REMOVAL...1762
INSPECTION/ADJUSTMENT...1762
TROUBLESHOOTING OF ELECTRICAL (E-MODE)...1764
E-1 ENGINE DOES NOT START...1765
(A) STARTING MOTOR DOES NOT TURN WHEN STARTING SWITCH IS TURNED TO START...1765
(B) CHECK FUEL SHUT-OFF SOLENOID...1767
E-2 ENGINE DOES NOT STOP...1768
E-4 TRANSMISSION IS NOT SET TO NEUTRAL...1769
WHEN PARKING BRAKE IS APPLIED (TRANSMISSION CUT-OFF IS NORMAL)...1769
E-10 PREHEATING IS NOT CARRIED OUT...1771
E-11 PREHEATING REMAINS ACTUATED...1773
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K-MODE)...1776
K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS,...1778
A. ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS...1778
B. SOME LAMPS DO NOT LIGHT UP ...1779
K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP, BUT BO NOT GO OUT...1779
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), ALL LAMPS...1780
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) CHECK ITEMS FLASH...1781
A. ENGINE OIL LEVEL DISPLAY FLASHES...1781
B. ENGINE WATER LEVEL DISPLAY FLASHES...1782
C. BRAKE OIL LEVEL DISPLAY FLASHES...1783
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH...1784
A. ENGINE OIL PRESSURE DISPLAY FLASHES...1784
B. BATTERY CHARGE LEVEL DISPLAY FLASHES...1785
K-6 CAUTION ITEMS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUND...1786
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT ALARM BUZZER SOUNDS...1787
K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DO NOT LIGHT UP...1788
A. CHECK LAMP...1788
B. CAUTION LAMP...1788
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DO NOT LIGHT UP...1789
A. CHECK LAMP...1789
B. CAUTION LAMP...1789
K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE MONITOR...1790
K-11 NIGHT LIGHTING IS ON EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAYS ON...1791
K-12 SERVICE METER DOES NOT WORK...1792
K-13 SERVICE METER IS RUNNING WITH ENGINE STOPPED...1793
K-14 ABNORMALITY IN GAUGE ITEMS...1794
A. ABNORMALITY IN FUEL GAUGE...1794
B. ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE...1795
C. ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE...1796
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M-MODE)...1798
TROUBLE DATA DISPLAY...1800
TABLE OF ACTION CODES AND FAILURES CODES...1801
ACTION CODE TABLE...1801
FAILURE CODE CHART...1801
M-1 MAIN MONITOR DOES NOT WORK...1802
M-2 WHEN STARTING SWITCH IS TURNED ON ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIT...1803
M-3 SPEEDOMETER DISPLAYS DOES WORK PROPERLY...1804
M-4 ABNORMALITY IN SHIFT INDICATOR...1805
A. STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT F...1805
B. STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT R...1805
C. DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N DISPLAYS E WHEN DIRECTIONAL LEVER IS AT F...1805
D. DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N DISPLAYS E WHEN DIRECTIONAL LEVER IS AT R...1806
E. DOES NOT DISPLAY 1ST, 4TH...1806
F. DOES NOT DISPLAY 3RD, 4TH...1806
G. DOES NOT DISPLAY 2ND, 3RD...1807
H. DOES NOT DISPLAY 1ST, 2ND...1807
M-5 HIGH BEAM DOES NOT LIGHT UP...1808
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP...1809
A. L.H. TURN SIGNAL DOES NOT LIGHT UP...1809
B. R.H. TURN SIGNAL DOES NOT LIGHT UP...1809
M-7 ABNORMALITY IN PARKING DISPLAY...1810
A. PARKING LAMP DOES NOT LIGHT UP...1810
B. PARKING LAMP STAYS ON...1810
M-8 ABNORMALITY IN PREHEATING SYSTEM...1811
A. DOES NOT CARRY OUT PREHEATING...1811
B. ONLY MONITOR DISPALY DOES NOT LIGHT UP...1812
C. ALWAYAS CARRIES OUT PREHEATING FOR 1 MINUTE...1812
D. PREHEATING STAYS ON...1812
E. PREHEATING TIME BECOMES SHORTER OR IS UNSTABLE...1813
M-9 NIGHT LIGHTING DOES NOT LIGHT UP...1815
M-10 ABNORMALITY IN FRONT WORKING LAMP...1816
A. NEITHER MONITOR DISPLAY, NOR FRONT WORKING LAMP LIGHT UP ...1816
B. WORKING LAMP LIGHTS UP, BUT MONITOR DISPLAY DOES NOT LIGHT UP...1816
C. MONITOR LIGHTS UP, BUT WORKING LAMP DOES NOT LIGHT UP...1816
M-11 ABNORMALITY IN REAR WORKING LAMP...1817
A. NEITHER MONITOR DISPLAY, NOR REAR WORKING LAMP LIGHT UP ...1817
B. WORKING LAMP LIGHTS UP, BUT MONITOR DISPLAY DOES NOT LIGHT UP...1817
C. MONITOR LIGHTS UP, BUT WORKING LAMP DOES NOT LIGHT UP...1817
M-12 ABNORMALITY IN TRNASMISSION CUT-OFF...1819
A. WHEN MONITOR SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT NOT SWITCHED AND DISPALY IS NOT GIVEN...1819
B. MONITOR DISPLAY GOES OUT, BUT CUT-OFF FUNCTION STAYS ON...1819
C. MONITOR DISPLAY LIGHTS UP, BUT CUT-OFF FUNCTION IS NOT ACTUATED...1820
M-13 ABNORMALITY IN PARKING DRAGGING WARNING...1821
A. WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) EVEN WHEN DIRECTIONAL LEVER IS AT N AND CAUTION LAMP FLASHES...1821
B. WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT ...1821
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, ...1823
A. ACTUATED CONTINUOUSLY...1823
B. NOT ACTUATED...1823
M-15 ABNORMALITY IN BUZZER...1824
A. BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS TURNED ON (DURING SELF-CHECK)...1824
B. BUZZER ALWAYS SOUNDS...1824
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY...1825
M-17 ABNORMALITY IN FALIURE DISPLAY MODE...1826
A. DOES NOT ENTER FAILURE DISPLAY MODE...1826
B. TIME FOR TIME ELAPSED SINCE FAILURE ON FAILURE DISPLAY MODE DOES NOT ADVANCE...1826
TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE)...1827
S1 STARTING PERFORMANCE IS POOR...1829
S2 ENGINE DOES NOT START...1830
(1) ENGINE DOES NOT TURN...1830
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT...1831
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START...1832
S-3 ENGINE DOES NOT PICK UP SMOOTHLY...1833
S-4 ENGINE STOPS DURING OPERATIONS...1834
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...1835
S-6 ENGINE LACKS OUTPUT (NO POWER)...1836
S-7 EXHAUST GAS IS BLACK...1837
S-8 OIL CONSUMPTION IS EXCESSIVE...1838
S-9 OIL BECOMES CONTAMINATED QUICKLY...1839
S-10 FUEL CONSUMPTION IS EXCESSIVE...1840
S-11 OIL IN COOLING WATER...1841
S-12 OIL PRESSURE LAMP LIGHTS UP...1842
S-13 OIL LEVEL RISES...1843
S-14 WATER TEMPERATURE BECOMES TOO HIGH...1844
S-15 ABNORMAL NOISE IS MADE...1845
S-16 VIBRATION IS EXCESSIVE...1846
TROUBLESHOOTING OF HYDRAULIC & MECHANICAL SYSTEMS (T-MODE)...1847
POWER TRAIN...1849
T-1 MACHINE DOES NOT START...1849
T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES...1850
T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR...1852
T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR...1853
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH...1854
STEERING SYSTEM...1855
T-6 STEEERING WHEEL DOES NOT TURN...1855
T-7 STEERING IS HEAVY...1856
T-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK...1857
T-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING...1857
BRAKE SYSTEM...1858
T-10 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR...1858
T-11 BRAKE IS NOT RELEASED, BRAKE DRAGS...1859
WORK EQUIPMENT...1860
T-12 BOOM DOES NOT RISE...1860
T-13 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER...1861
T-14 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT...1862
T-15 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS)...1862
T-16 EXCESSIVE HYDRAULIC DRIFT OF BOOM...1862
T-17 BOOM SHAKES DURING OPERATION...1863
T-18 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE...1863
T-19 BUCKET DOES NOT TILT BACK...1864
T-20 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER...1865
T-21 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION...1866
T-22 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER...1866
T-23 EXCESSIVE HYDRAULIC DRIFT OF BUCKET...1866
T-24 BUCKET SHAKES DURING LOADING PERATION...1867
T-25 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT...1867
T-26 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY...1868
TESTING, ADJUSTING AND TROUBLESHOOTING AIR CONDITIONER...1869
SERVICE TOOLS...1871
GAUGE MANIFOLD...1871
STRUCTURE AND HANDLING OF GAUGE MANIFOLD...1872
CHARGING HOSES...1874
GAS LEAK DETECTOR...1875
HALIDE TORCH LEAK DETECTOR...1875
ELECTRIC LEAK TESTER...1877
VALVE FOR SERVICE CANS...1879
MAINTENANCE PROCEDURE...1880
PRECAUTIONS WHEN REMOVING OR INSTALLING PIPING...1880
PROHIBITED WORK...1880
OTHER PRECAUTIONS...1880
BLEEDING AIR FROM REFRIGERATION CIRCUIT...1882
PURPOSE...1882
CONNECTING GAUGE MANIFOLD...1882
EVACUATION...1883
AIR-TIGHTNESS CHECK...1883
GAS-LEAK CHECK...1884
EVACUATION (REPEATING)...1884
CHARGING THE REFRIGERATION CIRCUIT WITH REFRIGERANT...1885
CHARGING FROM THE HIGH-PRESSURE SIDE...1885
CHARGING FROM THE LOW PRESSURE SIDE...1886
WHEN THE AMBIENT TEMPERATURE IS LOW...1887
WHEN THE AMBIENT TEMPERATURE IS HIGH...1887
REPLACING SERVICE CANS...1888
CHECKING THE AMOUNT OF REFRIGERANT...1888
REMOVAL OF GAUGE MANIFOLD...1890
DISCHARGING THE REFRIGERANT...1890
DAILY CHECKS...1891
CHECK REFRIGERANT LEVEL...1891
CLEANING THE CONDENSER...1891
CHECKING THE V-BELT...1891
CHECKING OIL LEVEL...1892
PROCEDURE FOR CHECKING...1892
PROCEDURE FOR CHECKING OIL LEVEL...1892
ADDING AND REMOVING OIL...1893
ADDING OIL BY EVACUATION...1893
TROUBLESHOOTING...1894
VISUAL AND ACOUSTICAL CHECKS...1894
DEFECTIVE COOLING...1895
30 DISASSEMBLY AND ASSEMBLY...1907
METHOD OF USING MANUAL...1911
PRECAUTIONS DURING OPERATION...1912
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK...1912
PRECAUTIONS WHEN CARRYING OUT INTSTALLATION WORK...1913
PRECAUTIONS WHEN COMPLETING THE OPERATIONS...1914
OTHER PRECAUTIONS...1914
SPECIAL TOOL LIST...1915
ENGINE...1918
ALTERNATOR...1918
CYLINDER HEAD...1918
ENGINE OIL COOLER...1918
FUEL INJECTION PUMP...1918
NOZZLE HOLDER...1918
STARTING MOTOR...1918
THERMOSTAT...1918
TURBOCHARGER...1918
WATER PUMP...1918
COVERS, LADDER AND ENGINE HOOD...1919
REMOVAL...1919
INSTALLATION...1922
RADIATOR, HYDRAULIC COOLER...1923
REMOVAL...1923
INSTALLATION...1924
MUFFER AND AIR CLEANER...1925
REMOVAL...1925
INSTALLATION...1925
ENGINE...1926
REMOVAL...1926
INSTALLATION...1929
TORQUE COVERTER CHARGING PUMP...1930
REMOVAL...1930
INSTALLATION...1930
TORQUE COVERTER TRANSMISSION...1931
REMOVAL...1931
INSTALLATION...1940
TORQUE COVERTER...1942
DISASSEMBLY...1942
ASSEMBLY...1944
TRANSMISSION...1946
DISASSEMBLY...1946
ASSEMBLY...1955
CLUTCH PACK...1968
DISASSEMBLY...1968
DISASSEMBLY OF FR CLUTCH PACK...1968
DISASSEMBLY OF 1ST AND 3RD CLUTCH PACK...1970
DISASSEMBLY OF 2ND AND 4TH CLUTCH PACK...1972
ASSEMBLY...1974
ASSEMBLY OF FORWARD, REVERSE CLUTCH PACK...1974
ASSEMBLY OF 1ST AND 3RD CLUTCH PACK...1978
ASSEMBLY OF 2ND AND 4TH CLUTCH PACK...1982
PARKING BRAKE...1986
DISASSEMBLY...1986
ASSEMBLY...1988
TRANSMISSION CONTROL VALVE...1991
REMOVAL...1991
INSTALLATION...1993
DISASSEMBLY...1994
ASSEMBLY...1996
TRANSMISSION SOLENIOD VALVE...1999
DISASSEMBLY...1999
ASSEMBLY...2000
ACCUMULATOR VALVE...2001
DISASSEMBLY...2001
ASSEMBLY...2002
DRIVE SHAFT...2003
DISASSEMBLY...2003
ASSEMBLY...2005
FRONT AXLE...2007
REMOVAL...2007
INSTALLATION...2009
REAR AXLE...2010
REMOVAL...2010
INSTALLATION...2014
DIFFERENTIAL...2017
DISASSEMBLY...2017
ASSEMBLY...2021
AXLE HOUSING...2030
DISASSEMBLY...2003
ASSEMBLY...2035
CENTER HINGE PIN...2041
REMOVAL...2041
INSTALLATION...2048
STEERING VALVE...2052
REMOVAL...2052
INSTALLATION...2054
DISASSEMBLY...2055
DISASSEMBLY OF ROTOR...2055
ASSEMBLY...2058
ASSEMBLY OF CONTROL SIDE...2058
ASSEMBLY OF ROTOR...2060
PRIORITY VALVE...2063
REMOVAL...2063
INSTALLATION...2064
STEERING CYLINDER...2065
REMOVAL...2065
INSTALLATION...2066
POWER MASTER CYLINDER...2067
REMOVAL...2067
INSTALLATION...2068
DISASSEMBLY...2069
ASSEMBLY...2072
PARKING BRAKE DISC...2077
REMOVAL...2077
INSTALLATION...2078
HYDRAULIC TANK...2079
REMOVAL...2079
INSTALLATION...2080
HYDRAULIC FILTER...2081
REMOVAL...2081
INSTALLATION...2081
WORK EQUIPMENT...2082
REMOVAL...2082
INSTALLATION...2083
MAIN CONTROL VALVE...2084
REMOVAL...2084
INSTALLATION...2085
DISASSEMBLY...2087
ASSEMBLY...2089
HYDRAULIC LINES...2090
PPC VALVE TO MAIN CONTROL VALVE...2090
PPC VALVE...2092
REMOVAL...2092
INSTALLATION...2093
CYLINDER...2094
BUCKET CYLINDER...2094
REMOVAL...2094
INSTALLATION...2095
BOOM CYLINDER...2096
REMOVAL...2096
INSTALLATION...2097
HYDRAULIC CYLINDER...2098
DISASSEMBLY...2098
ASSEMBLY...2100
WORK EQUIPMENT...2103
REMOVAL...2103
INSTALLATION...2106
ECSS SYSTEM...2108
ECSS CIRCUIT - REMAINING PRESSURE REMOVAL...2108
ECSS SOLENOID VALVE...2109
REMOVAL...2109
INSTALLATION...2109
ECSS CONTROL VALVE...2110
REMOVAL...2110
INSTALLATION...2110
COUNTERWEIGHT...2111
REMOVAL...2111
INSTALLATION...2111
FUEL TANK...2112
REMOVAL...2112
INSTALLATION...2113
CAB (ROPS)...2114
REMOVAL...2114
INSTALLATION...2115
MONITOR...2116
MAIN MONITOR...2116
REMOVAL...2116
INSTALLATION...2117
MAINTENANCE MONITOR...2118
REMOVAL...2118
INSTALLATION...2118
AIR CONDITIONER...2119
AIR CONDITIONER UNIT...2119
REMOVAL...2119
INSTALLATION...2124
CONDENSER...2125
REMOVAL...2125
INSTALLATION...2126
DRY RECIEVER...2127
REMOVAL...2127
INSTALLATION...2128
COMPRESSOR...2129
REMOVAL...2129
INSTALLATION...2130
40 MAINTENANCE STANDARD...2180
TRANSMISSION, ENGINE MOUNT...2181
TORQUE CONVERTER CHARGING PUMP...2183
SAL (2) 32 + SAL (2) 25...2183
TORQUE CONVERTER...2185
TRANSMISSION...2188
FORWARD, REVERSE CLUTCH...2195
1ST, 3RD CLUTCH...2197
2nd, 4th CLUTCH...2199
TRANSMISSION CONTROL VALVE...2201
UPPER VALVE...2201
LOWER VALVE...2205
SOLENOID VALVE...2207
ACCUMULATOR VALVE...2209
DRIVE SHAFTS...2211
DIFFERENTIAL...2213
FINAL DRIVE...2219
AXLE MOUNT...2221
CENTER HINGE PIN...2223
STEERING COLUMN...2225
PRIORITY VALVE...2227
MASTER CYLINDER...2229
BRAKE...2231
PARKING BRAKE...2233
HYDRAULIC PUMP...2234
MAIN CONTROL VALVE...2235
2-SPOOL VALVE...2235
3-SPOOL VALVE...2239
PPC VALVE...2243
HYDRAULIC CYLINDER...2245
STEERING CYLINDER MOUNT...2247
WORK EQUIPMENT LINKAGE...2249
BUCKET...2253
BUCKET POSITIONER AND KICK-OUT...2255
90 OTHERS...2256
ELECTRICAL WIRING DIAGRAM (1/6)...2258
ELECTRICAL WIRING DIAGRAM (2/6)...2260
ELECTRICAL WIRING DIAGRAM (3/6)...2262
ELECTRICAL WIRING DIAGRAM (4/6)...2264
ELECTRICAL WIRING DIAGRAM (5/6)...2266
ELECTRICAL WIRING DIAGRAM (6/6)...2268
TRANSMISSION CONTROL, PARKING BRAKE SYSTEM...2270
MACHINE MONITOR SYSTEM (1 OF 2)...2272
MACHINE MONITOR SYSTEM (2 OF 2)...2274
CEBM004702 - Parallel Tool Carrier WA250PT-3MC avance plus Shop Manual...2278
COVER...2278
CONTENTS...2279
00 FORWARD...2290
SAFETY...2290
SAFETY NOTICE...2290
IMPORTANT SAFETY NOTICE...2290
GENERAL PRECAUTIONS...2290
PREPARATIONS FOR WORK...2290
PRECAUTIONS DURING WORK...2290
GENERAL...2292
HOW TO READ THE SHOP MANUAL...2293
VOLUMES...2293
DISTRIBUTION AND UPDATING...2293
FILING METHOD...2293
REVISED EDITION MARK...2293
REVISIONS...2293
SYMBOLS...2293
HOISTING INSTRUCTIONS...2294
HOISTING...2294
WIRE ROPES...2294
COATING MATERIALS...2295
STANDARD TIGHTENING TORQUE...2297
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS...2297
TIGHTENING TORQUE OF HOSE NUTS...2298
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS...2298
TIGHTENING TORQUE FOR FLARED NUTS...2298
ELECTRIC WIRE CODE...2299
CLASSIFICATION BY THICKNESS...2299
CLASSIFICATION BY COLOR AND CODE...2299
CONVERSION TABLES...2300
METHOD OF USING THE CONVERSION TABLE...2300
01 GENERAL...2306
SPECIFICATION DRAWING...2307
WA250PT-3 (WITH BUCKET ATTACHMENT)...2307
WA250PT-3 (WITH FORK ATTACHMENT)...2309
SPECIFICATIONS...2311
WA250PT-3 (MATERIAL HANDLING ARM)...2313
WEIGHT TABLE...2315
FUEL, COOLANT AND LUBRICANTS...2316
ENGINE OIL SPECIFICATIONS...2317
NORMAL OPERATION...2317
ARCTIC OPERATION...2317
DRIVE TRAIN, BRAKE AND HYDRAULIC SYSTEM OIL SPECIFICATIONS...2318
FINAL DRIVE OIL SPECIFICATIONS...2318
DRIVE AXLE OIL SPECIFICATIONS...2318
DIESEL FUEL SPECIFICATIONS...2318
COOLANT SPECIFICATIONS...2319
SUPPLEMENTAL COOLANT ADDITIVES...2321
COOLING SYSTEM TEST KIT...2325
10 STRUCTURE AND FUNCTION...2326
POWER TRAIN...2330
PATH OF POWER TRANSMISSION...2331
TORQUE CONVERTER AND TRANSMISSION PIPING...2333
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM...2334
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM...2335
TORQUE CONVERTER...2336
TORQUE CONVERTER OIL FILTER...2338
TRANSMISSION...2340
CLUTCH...2343
FORWARD, REVERSE CLUTCH...2343
1ST, 3RD CLUTCH...2344
2ND, 4TH CLUTCH...2344
OPERATION OF CLUTCH...2345
FORWARD 1ST...2346
FORWARD 2ND...2347
FORWARD 3RD...2348
FORWARD 4TH...2349
REVERSE 1ST...2350
TRANSMISSION CONTROL VALVE...2352
UPPER VALVE...2353
LOWER VALVE...2354
TRANSMISSION SOLENOID VALVE...2355
TORQUE CONVERTER OUTLET PORT VALVE...2356
PILOT REDUCING VALVE...2357
TRANSMISSION SOLENOID VALVE...2358
PRIORITY VALVE...2359
MAIN REGULATOR VALVE...2360
QUICK RETURN VALVE...2361
MODULATION FILL VALVE...2365
DIRECTIONAL SELECTOR SPOOL...2367
EMERGENCY MANUAL SPOOL...2368
DRIVE SHAFT...2373
AXLE...2374
FRONT AXLE...2374
FRONT DIFFERENTIAL...2375
REAR AXLE...2376
REAR DIFFERENTIAL...2377
TORQUE PROPORTIONING DIFFERENTIAL...2379
FINAL DRIVE...2380
AXLE MOUNT...2381
FRONT AXLE...2382
REAR AXLE...2382
CENTER HINGE PIN...2383
STEERING PIPING...2384
STEERING COLUMN...2385
PRIORITY VALVE...2386
STEERING VALVE (ORBITAL)...2389
CONNECTION BETWEEN HAND PUMP AND SLEEVE...2395
2-WAY RESTRICTOR VALVE...2397
BRAKE PIPING...2398
POWER MASTER CYLINDER...2399
BRAKE OFF...2400
OIL PRESSURE STARTING TO RISE...2400
PRESSURE RISING...2401
RELIEF VALVE...2401
ONE BRAKE LINE ACTUATED...2402
BRAKE...2403
OPERATION...2404
PARKING BRAKE CONTROL...2405
PARKING BRAKE...2406
HYDRAULIC PIPING...2407
STEERING, HYDRAULIC PUMP HYDRAULIC SYSTEM DIAGRAM...2409
WORK EQUIPMENT LEVER LINKAGE...2411
HYDRAULIC TANK...2412
OIL FILTER BYPASS VALVE...2413
BREATHER...2414
PPC VALVE...2415
OPERATION OF PPC VALVE...2417
FUNCTION OF PPC VALVE...2418
PPC RELIEF VALVE...2420
ACCUMULATOR (FOR PPC VALVE)...2421
MAIN CONTROL VALVE...2422
3-SPOOL VALVE...2422
RELIEF VALVE...2424
SAFETY VALVE (WITH SUCTION)...2425
SUCTION VALVE...2426
BOOM AND BUCKET SPOOL AT "NEUTRAL" POSITION...2427
BOOM SPOOL AT "RAISE" POSITION...2428
BOOM SPOOL AT "LOWER" POSITION...2429
BOOM SPOOL AT "FLOAT" POSITION...2430
BUCKET SPOOL AT "TILT BACK" POSITION...2431
BUCKET SPOOL AT "DUMP" POSITION - SLOW SPEED DUMP...2432
BUCKET SPOOL AT "DUMP" POSITION - FAST SPEED DUMP...2433
COUPLER PLUNGERS EXTENDED, COUPLER ATTACHED...2434
COUPLER PLUNGERS RETRACTED, COUPLER REMOVAL...2435
WORK EQUIPMENT LINKAGE...2436
BUCKET...2438
BUCKET POSITIONER AND BOOM KICK-OUT...2439
BUCKET OR FORK POSITIONER...2440
BOOM KICK-OUT...2440
PROXIMITY SWITCH...2442
OPERATION OF THE PROXIMITY SWITCH...2444
ROPS CAB...2445
AIR CONDITIONER...2446
AIR CONDITIONER PIPING...2446
MACHINE MONITOR SYSTEM...2447
MAIN MONITOR...2448
MAIN MONITOR DISPLAY FUNCTION...2449
PREHEATING OUTPUT FUNCTION...2451
MAINTENANCE MONITOR DISPLAY FUNCTION...2453
TRANSMISSION AUTO-SHIFT CONTROL SYSTEM...2456
SYSTEM...2456
SHIFT CONTROL SYSTEM FUNCTION...2457
INPUT SIGNALS...2457
OUTPUT SIGNALS...2457
SHIFT CHARACTERISTICS...2458
SAFETY FUNCTION...2461
TROUBLESHOOTING...2462
MODEL (ENGINE) SELECT SIGNAL...2462
TRANSMISSION CONTROLLER...2463
LED DISPLAY...2464
SENSORS AND SWITCHES...2465
BRAKE OIL LEVEL SENSOR...2465
RADIATOR WATER LEVEL...2466
ENGINE OIL LEVEL SENSOR...2466
FUEL LEVEL SENSOR...2467
ENGINE COOLANT TEMPERATURE SENSOR...2468
ENGINE SPEED SENSOR...2469
ENGINE OIL PRESSURE SENSOR...2469
ELECTRICAL WIRING DIAGRAM (1/7)...2470
ELECTRICAL WIRING DIAGRAM (2/7)...2472
ELECTRICAL WIRING DIAGRAM (3/7)...2474
ELECTRICAL WIRING DIAGRAM (4/7)...2476
ELECTRICAL WIRING DIAGRAM (5/7)...2478
ELECTRICAL WIRING DIAGRAM (6/7)...2480
ELECTRICAL WIRING DIAGRAM (7/7)...2482
ENGINE STARTING CIRCUIT...2484
ENGINE STOP CIRCUIT...2485
AUTOMATIC PREHEATING CIRCUIT...2486
RIBBON HEATER...2488
Q.H.S. WATER TEMPERATURE SENSOR...2488
HEATER RELAY...2488
ELECTRICAL TRANSMISSION CONTROL...2489
COMBINATION SWITCH...2490
TRANSMISSION CUT-OFF FUNCTION...2491
PARKING BRAKE NEUTRALIZER RELAY FUNCTION...2493
KICK DOWN, HOLD SWITCH...2494
KICK-DOWN SWITCH...2494
HOLD SWITCH...2494
KICK DOWN ELECTRIC CIRCUIT DIAGRAM...2495
DUMP SPEED SWITCH...2500
QUICK COUPLER SWITCH...2501
20 TESTING, ADJUSTING AND TROUBLESHOOTING...2502
STANDARD VALUE TABLE...2506
ENGINE TABLE - IN CHASSIS...2506
CHASSIS TABLE...2507
ELECTRICAL PARTS TABLE...2512
SERVICE TOOLS TABLE...2515
ENGINE...2517
ADJUSTING ENGINE STOP MOTOR CABLE...2517
ADJUSTING ENGINE STOP SOLENOID...2517
MEASURING AND ADJUSTING VALVE CLEARANCE...2517
MEASURING BLOW-BY PRESSURE...2517
MEASURING COMPRESSION PRESSURE...2517
MEASURING COOLANT TEMPERATURE...2517
MEASURING ENGINE LUBRICATING OIL PRESSURE...2517
MEASURING ENGINE SPEEDS...2517
MEASURING EXHAUST COLOR...2517
MEASURING EXHAUST GAS TEMPERATURE...2517
MEASURING FUEL FILTER INLET RESTRICTION...2517
TEST AND ADJUSTING FAN BELT TENSION...2517
TEST AND ADJUSTING FUEL INJECTION TIMING...2517
ACCELERATOR PEDAL...2518
OPERATING FORCE...2518
OPERATING ANGLE...2519
SHIFT LEVER...2520
OPERATING FORCE...2520
TRAVEL...2520
STALL SPEEDS...2521
TORQUE CONVERTER STALL SPEED...2521
HYDRAULIC STALL SPEED...2522
FULL STALL SPEED...2522
TORQUE CONVERTER...2523
TRANSMISSION OIL PRESSURE...2523
EMERGENCY MANUAL SPOOL...2525
OPERATION...2525
STEERING WHEEL...2527
PLAY...2527
OPERATING FORCE...2527
OPERATING TIME...2528
STEERING OIL PRESSURE...2529
METHOD OF MEASURING MAIN RELIEF PRESSURE...2529
METHOD OF ADJUSTING MAIN RELIEF PRESSURE...2530
BRAKE...2531
BRAKE PEDAL...2531
OPERATING EFFORT...2531
TRAVEL...2531
BRAKE PEDAL LINKAGE...2532
TESTING...2532
ADJUSTING...2532
BRAKE PERFORMANCE...2534
BRAKE OIL PRESSURE...2535
BRAKE DISC WEAR...2536
BLEEDING AIR...2537
PARKING BRAKE...2538
PARKING BRAKE PERFORMANCE...2538
PARKING BRAKE LINKAGE...2539
PARKING BRAKE PISTON STROKE...2540
PARKING BRAKE DISC WEAR...2541
WORK EQUIPMENT...2542
WORK EQUIPMENT CONTROL LEVER...2542
PPC VALVE...2543
MEASURING PRESSURE...2543
HYDRAULIC PRESSURE...2545
MEASUREMENT...2548
HYDRAULIC DRIFT...2549
BOOM KICK-OUT...2550
BUCKET / FORK POSITIONER...2551
MAIN MONITOR...2553
FUEL LEVEL SENSOR...2555
CHECKING FOR ABNORMALITY...2555
TROUBLESHOOTING GENERAL...2556
POINTS TO REMEMBER WHEN TROUBLESHOOTING...2558
SEQUENCE OF EVENTS IN TROUBLESHOOTING...2560
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...2561
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT...2561
HANDLING CONTROL BOX...2566
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT...2567
CHECKS BEFORE TROUBLESHOOTING...2569
JUDGEMENT OF POWER TRAIN...2570
PRECAUTIONS WHEN TROUBLESHOOTING...2571
SAFETY...2571
METHODS FOR TROUBLESHOOTING...2571
PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING...2573
PREVENTING RECURRENCE OF TROUBLE...2574
HYDRAULIC EQUIPMENT...2574
OIL CHECKS...2574
CLEANING FRAGMENTS OF DAMAGED PARTS...2574
METHOD OF USING TROUBLESHOOTING CHARTS...2575
CATEGORY OF TROUBLESHOOTING CODE NUMBER...2575
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE...2575
METHOD OF USING MATRIX TROUBLESHOOTING TABLES...2577
METHOD OF USING ENGINE RELATED CHARTS...2579
TROUBLESHOOTING ELECTRICAL CONNECTORS...2584
CONNECTOR TYPES...2585
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...2588
ELECTRICAL CIRCUIT DIAGRAMS...2596
ENGINE START, STOP SYSTEM...2596
PREHEATING SYSTEM...2597
TRANSMISSION CONTROL, PARKING BRAKE SYSTEM...2598
MACHINE MONITOR SYSTEM (1/2)...2600
TROUBLESHOOTING SYSTEMS OF A MODE - TRANSMISSION CONTROLLER SYSTEM...2606
OUTLINE...2607
FUNCTION...2607
TROUBLESHOOTING...2607
FAILURE CODE TABLE...2607
TABLE OF TROUBLESHOOTING MODES AND CAUSES...2608
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLER SYSTEM...2609
A-1 TROUBLESHOOTING CODE [12]...2611
F SOLENOID SIGNAL SYSTEM...2611
A-2 TROUBLESHOOTING CODE [13]...2612
R SOLENOID SIGNAL SYSTEM...2612
A-3 TROUBLESHOOTING CODE [14]...2613
ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM...2613
A-4 TROUBLESHOOTING CODE [16]...2614
ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM...2614
A-5 TROUBLESHOOTING CODE [20]...2615
ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM...2615
A-6 TROUBLESHOOTING CODE [21]...2616
ABNORMALITY IN SPEED LEVER SIGNAL SYSTEM...2616
A-7 TROUBLESHOOTING CODE [22]...2617
ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM...2617
A-8 TROUBLESHOOTING CODE [23]...2618
ABNORMALITY IN ENGINE SPEED SIGNAL SYSTEM...2618
A-9 HOLD SWITCH SIGNAL SYSTEM...2619
A-10 KICK-DOWN SWITCH SYSTEM...2620
A-11 TRANSMISSION CUT-OUT SIGNAL SYSTEM...2621
A-12 NEUTRALIZER RELAY SIGNAL SYSTEM...2622
A-13 BUZZER SIGNAL SYSTEM...2623
A-14 NETWORK SIGNAL SYSTEM...2624
A-15 CONTROLLER POWER SOURCE SYSTEM...2625
TROUBLESHOOTING ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM D MODE - (ECSS)...2626
ECSS - ELECTRICAL/HYDRAULIC SCHEMATIC...2627
ECSS - WORKING CHART...2627
ECSS CIRCUIT - REMAINING PRESSURE REMOVAL ...2628
INSPECTION/ADJUSTMENT...2628
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...2630
E-1 ENGINE DOES NOT START...2631
A. STARTING MOTOR DOES NOT TURN WHEN STARTING SWITCYH IS TURNED TO START...2631
B. CHECK FUEL SHUT-OFF SOLENOID...2633
E-2 ENGINE DOES NOT STOP...2634
E-4 TRANSMISSION IS NOT SET UP TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (TRANSMISION CUT-OFF IS NORMAL)...2635
E-10 PREHEATING IS NOT CARRIED OUT...2637
E-11 PREHEATING REMAINS ACTUATED...2639
E-12 ABNORMALITY IN QUICK COUPLER SYSTEM...2641
E-13 ABNORMALITY IN TILT CYLINDER OPERATION...2642
A. ONLY SLOW DUMP SPEED IS AVAILABLE...2642
B. DUMP SPEED IS ERRATIC OR ONLY FAST DUMP SPEED IS AVAILABLE ...2643
C. TILT BACK IS NOT AVAILABLE...2644
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K-MODE)...2646
K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DO...2648
A. ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS...2648
B. SOME LAMPS DO NOT LIGHT UP...2649
K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP, BUT DO NOT GO OUT...2649
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECS), ALL LAMPS ON MAINTENANCE MONITOR D...2650
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) CHECK ITEMS FLASH...2651
A. ENGINE OIL LEVEL DISPLAY FLASHES...2651
B. ENGINE WATER LEVEL DISPLAY FLASHES...2652
C. BRAKE OIL LEVEL DISPLAY FLASHES...2653
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH ...2654
A. ENGINE OIL PRESSURE DISPLAY FLASHES...2654
B. BATTERY CHARGE LEVEL DISPLAY FLASHES...2655
K-6 CAUTION ITEMS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUND...2656
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT ALARM BUZZER SOUNDS...2657
K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DO NOT LIGHT UP...2658
A. CHECK LAMP...2658
B. CAUTION LAMP...2658
K-9 THERE IS NOT ABNORMALITY IN MAINTENANCE DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) LIGHTS UP...2659
A. CHECK LAMP...2659
B. CAUTION LAMP...2659
K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENACE MONITOR DOES NOT LIGHT UP)...2660
K-11 NIGHT LIGHING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAY LIT UP...2661
K-12 SERVICE METER DOES NOT WORK...2662
K-13 SERVICE METER IS RUNNING WITH ENGINE STOPPED...2663
K-14 ABNORMALITY IN GAUGE ITEMS...2664
A. ABNORMALITY IN FUEL GAUGE...2664
B. ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE...2665
C. ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE...2666
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M-MODE)...2668
TROUBLE DATA DISPLAY...2670
TABLE OF ACTION CODES AND FAILURE CODES...2671
ACTION CODE TABLE...2671
FAILURE CODE CHART...2671
M-1 MAIN MONITOR DOES NOT WORK...2672
M-2 WHEN STARING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIT...2673
M-3 SPEEDOMETER DISPLAYS DOES NOT WORK PROPERLY...2674
M-4 ABNORMALITY IN SHIFT INDICATOR...2675
A. STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT F...2675
B. STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT R...2675
C. DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS E WHEN DIRECTIONAL LEVER I...2675
D. DOES NOT DISPLAY N EVEN DIRECTIONAL LEVER IS AT N AND DISPLAYS E WHEN DIRECTIONAL LEVER IS AT R...2676
E. DOES NOT DISPLAY 1ST, 4TH...2676
F. DOES NOT DISPLAY 3RD, 4TH...2676
G. DOES NOT DISPLAY 2ND, 3RD...2677
H. DOES NOT DISPLAY 1ST, 2ND...2677
M-5 HIGH BEAM DOES NOT LIGHT UP...2678
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP...2679
A. L.H. TURN SIGNAL DOES NOT LIGHT UP...2679
B. R.H. TURN SIGNAL DOES NOT LIGHT UP...2679
M-7 ABNORMALITY IN PARKING DISPLAY...2680
A. PARKING LAMP DOES NOT LIGHT UP...2680
B. PARKING LAMP STAYS ON...2680
M-8 ABNORMALITY IN PREHEATING SYSTEM...2681
A. DOES NOT CARRY OUT PREHEATING...2681
1. MONITOR DISPLAY ALSO DOES NOT LIGHT UP...2681
2. ONLY MONITOR DISPLAY LIGHTS UP...2681
B. ONLY MONITOR DISPLAY DOES NOT LIGHT UP...2682
C. ALWAYS CARRIES OUT PREHEATING FOR 1 MINUTE...2682
D. PREHEATING STAYS ON...2682
E. PREHEATING TIME BECOMES SHORTER OR IS UNSTABLE...2683
M-9 NIGHT LIGHTING DOES NOT LIGHT UP...2685
M-10 ABNORMALITY IN FRONT WORKING LAMP...2686
A. NEITHER MONITOR DISPLAY, NOR FRONT WORKING LAMP LIGHT UP...2686
B. WORKING LAMP LIGHTS UP, BUT MONITOR DISPLAY DOES NOT LIGHT UP...2686
C. MONITOR LIGHTS UP, BUT WORKING LAMP DOES NOT LIGHT UP...2686
M-11 ABNORMALITY IN REAR WORKING LAMP...2687
A. NEITHER MONITOR DISPLAY, NOR rear WORKING LAMP LIGHT UP...2687
B. WORKING LAMP LIGHTS UP, BUT MONITOR DISPLAY DOES NOT LIGHT UP...2687
C. MONITOR LIGHTS UP, BUT WORKING LAMP DOES NOT LIGHT UP...2687
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF...2689
A. WHEN MONITOR SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY IS NOT GIVEN...2689
B. MONITOR DISPLAY GOES OUT, BUT CUT-OFF FUNCTION STAYS ON...2689
C. MONITOR DISPLAY LIGHTS UP, BUT CUT-OFF FUNCTION IS NOT ACTUATED...2690
M-13 ABNORMALITY IN PARKING DRAGGING WARNING...2691
A. WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) EVEN WHEN DIRECTIONAL LEVER IS A...2691
B. WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN W...2691
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOU...2692
A. ACTUATED CONTINUOUSLY...2692
B. NOT ACTUATED...2692
M-15 ABNORMALITY IN BUZZER...2693
A. BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS TURNED ON (DURING SELF-CHECK)...2693
B. BUZZER ALWAYS SOUNDS...2693
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY...2694
M-17 ABNORMALITY IN FAILURE DISPLAY MODE...2695
A. DOES NOT ENTER FAILURE DISPLAY MODE...2695
B. TIME FOR TIME ELAPSED SINCE FAILURE ON FAILURE DISPLAY MODE DOES NOT ADVANCE...2695
TROUBLESHOOTING SYSTEMS OF (S MODE)...2696
S1 STARTING PERFORMANCE IS POOR...2698
S2 ENGINE DOES NOT START...2699
(1) ENGINE DOES NOT TURN...2699
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT...2700
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START...2701
S-3 ENGINE DOES NOT PICK UP SMOOTHLY...2702
S-4 ENGINE STOPS DURING OPERATIONS...2703
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...2704
S-6 ENGINE LACKS OUTPUT (NO POWER)...2705
S-7 EXHAUST GAS IS BLACK...2706
S-8 OIL CONSUMPTION IS EXCESSIVE...2707
S-9 OIL BECOMES CONTAMINATED QUICKLY...2708
S-10 FUEL CONSUMPTION IS EXCESSIVE...2709
S-11 OIL IN COOLING WATER...2710
S-12 OIL PRESSURE LAMP LIGHTS UP...2711
S-13 OIL LEVEL RISES...2712
S-14 WATER TEMPERATURE BECOMES TOO HIGH...2713
S-15 ABNORMAL NOISE IS MADE...2714
S-16 VIBRATION IS EXCESSIVE...2737
TROUBLESHOOTING OF HYDRAULIC & MECHANICAL SYSTEM (T-MODE)...2715
POWER TRAIN...2717
T-1 MACHINE DOES NOT START...2717
T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES...2718
T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR...2720
T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR...2721
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH...2722
STEERING SYSTEM...2723
T-6 STEERING WHEEL DOES NOT TURN...2723
T-7 STEERING IS HEAVY...2724
T-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK...2725
T-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING...2725
BRAKE SYSTEM...2726
T-10 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR...2726
T-11 BRAKE IS NOT RELEASED, BRAKE DRAGS...2727
WORK EQUIPMENT...2728
T-12 BOOM DOES NOT RISE...2728
T-13 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER...2729
T-14 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT...2730
T-15 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS)...2730
T-16 EXCESSIVE HYDRAULIC DRIFT OF BOOM...2730
T-17 BOOM SHAKES DURING OPERATION...2731
T-18 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE...2731
T-19 BUCKET DOES NOT TILT BACK...2732
T-20 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER...2733
T-21 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION...2734
T-22 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER...2734
T-23 EXCESSIVE HYDRAULIC DRIFT OF BUCKET...2734
T-24 BUCKET SHAKES DURING LOADING OPERATION...2735
T-25 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT...2735
T-26 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY...2736
TROUBLESHOOTING SYSTEMS OF AIR CONDITIONER...2738
SERVICE TOOLS...2740
GAUGE MANIFOLD...2740
STRUCTURE AND HANDLING OF GAUGE MANIFOLD...2741
CHARGING HOSES...2743
GAS LEAK DETECTOR...2744
HALIDE TORCH LEAK DETECTOR...2744
ELECTRIC LEAK TESTER...2746
VALVE FOR SERVICE CANS...2748
MAINTENANCE PROCEDURE...2749
PRECAUTIONS WHEN REMOVING OR INSTALLING PIPING...2749
PROHIBITED WORK...2749
OTHER PRECAUTIONS...2749
BLEEDING AIR FROM REFRIGERATION CIRCUIT...2751
PURPOSE...2751
CONNECTING GAUGE MANIFOLD...2751
EVACUATION...2752
AIR-TIGHTNESS CHECK...2752
GAS-LEAK CHECK...2753
EVACUATION (REPEATING)...2753
CHARGING THE REFRIGERATION CIRCUIT WITH REFRIGERANT...2754
CHARGING FROM THE HIGH-PRESSURE SIDE...2754
CHARGING FROM THE LOW PRESSURE SIDE...2755
WHEN THE AMBIENT TEMPERATURE IS LOW...2756
WHEN THE AMBIENT TEMPERATURE IS HIGH...2756
REPLACING SERVICE CANS...2757
CHECKING THE AMOUNT OF REFRIGERANT...2757
REMOVAL OF GAUGE MANIFOLD...2759
DISCHARGING THE REFRIGERANT...2759
DAILY CHECKS...2760
CHECK REFRIGERANT LEVEL...2760
CLEANING THE CONDENSER...2760
CHECKING THE V-BELT...2760
CHECKING OIL LEVEL...2761
PROCEDURE FOR CHECKING...2761
PROCEDURE FOR CHECKING OIL LEVEL...2761
ADDING AND REMOVING OIL...2762
ADDING OIL BY EVACUATION...2762
TROUBLESHOOTING...2763
VISUAL AND ACOUSTICAL CHECKS...2763
DEFECTIVE COOLING...2764
TROUBLESHOOTING TABLE...2766
DEFECTIVE HEATING...2768
TROUBLESHOOTING USING GAUGE MANIFOLD...2769
PREPARATIONS BEFORE MEASURING...2769
INSUFFICIENT REFRIGERANT...2769
EXCESSIVE REFRIGERANT OR INSUFFICIENT COOLING OF CONDENSER...2770
AIR INSIDE REFRIGERATION SYSTEM...2771
MOISTURE IN REFRIGERATING SYSTEM...2772
REFRIGERANT DOES NOT CIRCULATE...2773
FAILURE OF EXPANSION VALVE (OPEN TO FAR), DEFECTIVE MOUNTING OF HEAT SENSING TUBE...2774
DEFECTIVE COMPRESSION BY COMPRESSOR...2775
30 DISASSEMBLY AND ASSEMBLY...2776
METHOD OF USING MANUAL...2780
PRECAUTIONS DURING OPERATION...2781
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK...2781
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK...2782
SPECIAL TOOL LIST...2784
ENGINE...2787
ALTERNATOR ASSEMBLY...2787
CYLINDER HEAD ASSEMBLY...2787
ENGINE OIL COOLER ASSEMBLY...2787
FUEL INJECTION PUMP ASSEMBLY...2787
NOZZLE HOLDER ASSEMBLY...2787
STARTING MOTOR ASSEMBLY...2787
THERMOSTAT ASSEMBLY...2787
TURBOCHARGER ASSEMBLY...2787
WATER PUMP ASSEMBLY...2787
COVERS, LADDER AND ENGINE HOOD...2788
REMOVAL...2788
INSTALLATION...2791
RADIATOR, HYDRAULIC COOLER ASSEMBLY...2792
REMOVAL...2792
MUFFER AND AIR CLEANER...2794
ENGINE ASSEMBLY...0
REMOVAL...2795
INSTALLATION...2798
TORQUE CONVERTER CHARGING PUMP...2799
REMOVAL...2799
INSTALLATION...2799
TORQUE CONVERTER, TRANSMISSION...2800
TORQUE CONVERTER...2811
DISASSEMBLY...2811
ASSEMBLY...2813
TRANSMISSION...2815
DISASSEMBLY...2815
ASSEMBLY...2824
CLUTCH PACK...2837
DISASSEMBLY...2837
DISASSEMBLY OF FR CLUTCH PACK...2837
DISASSEMBLY OF 1ST AND 3RD CLUTCH PACK...2839
ASSEMBLY...0
ASSEMBLY OF FORWARD, REVERSE CLUTCH PACK...2843
ASSEMBLY OF 1ST AND 3RD CLUTCH PACK...2847
PARKING BRAKE...2855
DISASSEMBLY...2855
ASSEMBLY...2857
TRANSMISSION CONTROL VALVE...2860
REMOVAL...2860
INSTALLATION...2862
DISASSEMBLY...2863
TRANSMISSION SOLENOID VALVE...2868
DISASSEMBLY...2868
ASSEMBLY...2869
ACCUMULATOR VALVE...0
DISASSEMBLY...2870
DRIVE SHAFT...2872
FRONT AXLE...2876
REAR AXLE...0
REMOVAL...2879
DIFFERENTIAL...2886
DISASSEMBLY...2886
ASSEMBLY...2890
AXLE HOUSING...2899
DISASSEMBLY...2899
ASSEMBLY...2904
CENTER HINGE PIN...2910
40 MAINTENANCE STANDARD...3010
TRANSMISSION, ENGINE MOUNT...3012
TORQUE CONVERTER CHARGING PUMP...3013
TORQUE CONVERTER...3014
TRANSMISSION...3016
FORWARD, REVERSE CLUTCH...3021
1ST, 3RD CLUTCH...3022
2nd, 4th CLUTCH...3023
TRANSMISSION CONTROL VALVE...3025
UPPER VALVE...3025
LOWER VALVE...3027
SOLENOID VALVE...3028
ACCUMULATOR VALVE...3029
DRIVE SHAFT...3030
DIFFERENTIAL...3031
DIFFERENTIAL...3033
FINAL DRIVE...3035
AXLE MOUNT...3037
CENTER HINGE PIN...3039
STEERING COLUMN...3041
PRIORITY VALVE...3042
MASTER CYLINDER...3043
BRAKE...3044
PARKING BRAKE...3045
HYDRAULIC PUMP...3046
MAIN CONTROL VALVE...3047
PILOT SOLENOID VALVE...3049
PPC VALVE...3050
HYDRAULIC CYLINDER...3051
90 OTHERS...3052
OPERATION OF THE PROXIMITY SWITCH...3054
ELECTRICAL WIRING DIAGRAM (1/7)...3056
ELECTRICAL WIRING DIAGRAM (2/7)...3058
ELECTRICAL WIRING DIAGRAM (3/7)...3060
ELECTRICAL WIRING DIAGRAM (4/7)...3062
ELECTRICAL WIRING DIAGRAM (5/7)...3064
ELECTRICAL WIRING DIAGRAM (6/7)...3066
ELETRICAL WIRING DIAGRAM (7/7)...3068
TRANSMISSION CONTROL, PARKING BRAKE SYSTEM...3070
MACHINE MONITOR SYSTEM (1/2)...3072
MACHINE MONITOR SYSTEM (2/2)...3074
CEBM011605 - Wheel Loader - Waste Handler WA250-5L, WA250PT-5L Shop Manual...3078
CEBM011605 - WA250-5L/WA250PT-5L...3078
CONTENTS...3079
01 GENERAL...3090
SPECIFICATION...3091
WA250-5L/WA250PT-5L DIMENSIONS...3091
SYSTEM OPERATING PERAMETERS...3093
WEIGHT TABLE...3096
FUEL, COOLANT AND LUBRICANTS...3098
10 STRUCTURE AND FUNCTION...3102
ENGINE AND DRIVE SYSTEM MOUNTING...3107
DRIVE SYSTEM DAMPER...3108
COOLING SYSTEM...3109
REVERSING FAN SYSTEM...3110
REVERSING FAN MANIFOLD...3111
PROPORTIONAL RELIEF VALVE...3112
2-POSITION, 4-WAY SPOOL VALVE...3113
FAN CONTROLLER...3114
POWER TRAIN...3115
POWER TRAIN SYSTEM DIAGRAM...3116
DRIVE SHAFT...3118
HST HYDRAULIC PIPING DIAGRAM...3119
HST PUMP...3120
HIGH-PRESSURE RELIEF VALVE...3123
LOW-PRESSURE RELIEF VALVE...3124
CHARGE PUMP...3125
SPEED-RELATED VALVE (DA VALVE)...3126
HIGH-PRESSURE CUT-OFF VALVE...3127
HST MOTORS...3128
HST MOTOR 1...3128
HST MOTOR 2...3130
EP SERVO VALVE...3132
HA SERVO VALVE...3133
FORWARD-REVERSE SHUTTLE VALVE...3134
TRANSFER...3135
INPUT SHAFT PORTION...3139
OUTPUT SHAFT PORTION...3141
CLUTCH OPERATION...3144
TRANSFER OIL COOLER...3147
CLUTCH SOLENOID VALVE...3148
AXLES...3149
FRONT AXLE...3149
REAR AXLE...3150
DIFFERENTIALS...3151
FRONT DIFFERENTIAL...3151
REAR DIFFERENTIAL...3153
LIMITED-SLIP DIFFERENTIAL...3156
FRONT...3156
REAR...3158
FINAL DRIVE...3162
FRONT...3162
REAR...3164
AXLE MOUNTING AND CENTER HINGE CARIER...3167
STEERING PIPING SYSTEM...3172
STEERING COLUMN...3173
PRIORITY VALVE...3174
ORBIT-ROLL VALVE...3177
STEERING WHEEL IN NEUTRAL...3179
STEERING WHEEL TURNED (TURNING LEFT)...3181
CONNECTION BETWEEN HAND PUMP AND SLEEVE...3182
2-WAY RESTRICTOR VALVE...3184
STEERING CYLINDER...3185
EMERGENCY STEERING PIPING...3187
EMERGENCY STEERING VALVE...3189
BRAKE PIPING...3192
BRAKE VALVE...3193
INCHING VALVE...3198
CHARGE VALVE...3199
ACCUMULATOR (FOR BRAKE)...3203
SLACK ADJUSTER...3205
BRAKE...3207
FRONT...3207
REAR...3209
PARKING BRAKE CONTROL...3211
PARKING BRAKE...3212
HYDRAULIC PIPING...3213
WA250PT-5L...3213
WA250PT-5L...3215
WORK EQUIPMENT LEVER LINKAGE...3217
WA250-5L...3217
MULTI-FUNCTION JOYSTICK TYPE...3217
JOYSTICK TYPE (IF EQUIPPED)...3218
WA250PT-5...3219
MULTI-FUNCTION JOYSTICK TYPE...3219
JOYSTICK TYPE (IF EQUIPPED)...3220
HYDRAULIC TANK...3221
BREATHER...3222
PREVENTION OF NEGATIVE PRESSURE IN TANK...3222
PREVENTION OF RISE OF PRESSURE IN TANK...3222
4-GEAR PUMP UNIT...3223
ACCUMULATOR (FOR PPC CIRCUIT)...3225
LOCK VALVE...3225
BY-PASS VALVE...3226
WA250-5L...3226
WHEN LIFT ARM IS "RAISED"...3227
WHEN LIFT ARM IS "LOWERED"...3228
WA250PT-5L...3229
WHEN BUCKET IS "DUMP" IN FAST MODE (FROM TILT-BACK POSITION TO JUST BEFORE DUMP END)...3230
WHEN BUCKET IS "DUMP" IN FAST MODE (FROM JUST BEFORE DUMP END TO DUMP END)...3231
QUICK COUPLER SOLENOID VALVE...3232
E.C.S.S. VALVE (IF EQUIPPED)...3233
ACCUMULATOR (FOR E.C.S.S.) (IF EQUIPPED)...3235
HYDRAULIC PIPING OF COOLING SYSTEM...3236
COOLING FAN MOTOR...3237
WORK EQUIPMENT CONTROL VALVE...3240
2-SPOOL VALVE...3240
3-SPOOL VALVE...3244
RELIEF VALVE...3247
SAFETY SUCTION VALVE...3248
SUCTION VALVE...3249
OPERATION OF THE WORK EQUIPMENT CONTROL VALVE...3250
NEUTRAL POSITION OF THE LIFT ARM AND BUCKET SPOOLS...3250
RAISE POSITION OF THE LIFT ARM SPOOL...3251
LOWER POSITION OF THE LIFT ARM SPOOL...3252
FLOAT POSITION OF THE LIFT ARM SPOOL...3253
ROLL BACK POSITION OF THE BUCKET SPOOL...3254
DUMP POSITION OF THE BUCKET SPOOL...3255
WORK EQUIPMENT PPC VALVE...3256
WHEN IN NEUTRAL...3258
WHEN IN FINE CONTROL...3259
WHEN LEVER IS OPERATED TO STROKE END...3260
WHEN LIFT ARM IS FLOATED...3260
WHEN FLOAT STATE OF LIFT ARM IS RESET...3260
ATTACHMENT PPC VALVE (IF EQUIPPED)...3261
AT THE NEUTRAL POSITION...3263
AT THE FINE CONTROL POSITION...3263
AT FULL STROKE...3264
WORK EQUIPMENT LINKAGE...3265
WA250-5L...3265
WA250PT-5L...3267
BUCKET...3269
WA250-5L...3269
WA250PT-5L...3271
BUCKET POSITIONER, BOOM KICK-OUT, AND DUMP SPEED...3273
WA250-5L...3273
BUCKET POSITIONER...3274
BOOM KICK-OUT...3274
OPERATION OF PROXIMITY SWITCH...3275
WA250PT-5L...3281
BUCKET POSITIONER OR FORK POSITIONER...3282
BOOM KICK-OUT...3282
DUMP SPEED CONTROL...3282
OPERATION OF PROXIMITY SWITCH...3283
WORK EQUIPMENT CYLINDER...3291
WA250-5L...3291
LIFT CYLINDER...3291
BUCKET CYLINDER...3291
WA250PT-5L...3293
LIFT CYLINDER...3293
BUCKET CYLINDER...3293
COUPLER PLUNGER...3293
AIR CONDITIONER PIPING...3295
MACHINE MONITORING SYSTEM...3296
OUTLINE...3296
NORMAL MODE...3296
SERVICE MODE...3296
SERVICE METER SETTING...3297
INDIVIDUAL CIRCUIT DIAGRAMS OF THE MACHINE MONITOR...3299
STARTING AND LIGHTING...3299
POWER SUPPLY AND NETWORK...3301
SENSING...3302
HST SAFETY CONTROL...3303
AUTOMATIC PREHEATING...3304
POWER SUPPLY AND NETWORK...3305
MACHINE MONITOR...3307
LIST OF ITEMS DISPLAYED ON MONITOR...3308
SERVICE MODE FUNCTIONS...3312
OPERATING METHOD...3314
ITEMS RELATED TO THE FAULT HISTORY OF ELECTRIC SYSTEM...3315
ITEMS RELATED TO THE FAULT HISTORY OF MACHINE SYSTEM...3318
REAL-TIME MONITOR FUNCTION...3320
HOW TO INPUT INTERVAL...3324
FUNCTION OF SELECTING OPTIONAL DEVICE...3326
ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)...3331
HST CONTROLLER...3335
SELECTING FORWARD-REVERSE SELECTOR SWITCH...3337
ENGINE STARTING CIRCUIT...3339
ENGINE STOP CIRCUIT...3341
PREHEATING CIRCUIT (AUTOMATIC PREHEAT SYSTEM)...3342
PARKING BRAKE CIRCUIT...3343
ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM...3346
COUPLER PLUNGER CONTROL SYSTEM...3347
SENSORS...3348
ENGINE SPEED SENSOR...3348
TRAVEL SPEED SENSOR...3348
ENGINE OIL PRESSURE SENSOR...3349
FUEL LEVEL SENSOR...3349
COOLANT AND HST OIL TEMPERATURE SENSOR (FOR MONITOR)...3350
COOLANT TEMPERATURE SENSOR (FOR PREHEATING)...3350
AXLE OIL TEMPERATURE SENSOR...3351
HST OIL PRESSURE SENSOR...3351
STEERING AND EMERGENCY STEERING OIL PRESSURE SENSOR (IF EQUIPPED)...3352
HST FILTER CLOGGING SENSOR...3352
COOLANT LEVEL SENSOR...3353
KOMTRAX SYSTEM...3354
KOMTRAX TERMINAL SYSTEM...3354
KOMTRAX TERMINAL...3355
INPUT AND OUTPUT SIGNALS...3356
20 TESTING, ADJUSTING AND TROUBLESHOOTING...3358
STANDARD VALUE TABLE...3360
ENGINE...3360
CHASSIS...3361
SPECIAL TOOLS...3367
ENGINE COMPONENTS...3370
MEASURING EXHAUST SMOKE...3370
MEASURING EXHAUST TEMPERATURE...3370
ADJUSTING VALVE CLEARANCE...3370
MEASURING COMPRESSION PRESSURE...3370
MEASURING CRANCASE PRESSURE...3370
MEASURING ENGINE OIL PRESSURE...3370
MEASURING BOOST PRESSURE...3370
MEASURING FUEL PRESSURE...3370
ADJUSTING ENGINE SPEED SENSOR...3370
BLEEDING AIR FROM FUEL SYSTEM...3370
MEASURING ENGINE SPEED...3371
MEASURING ENGINE SPEED (LOW AND HIGH IDLE)...3371
MEASURING HST STALL SPEED...3372
MEASURING HYDRAULIC STALL...3372
MEASURING FULL STALL SPEED...3372
OPERATING FORCE OF ACCELERATOR PEDAL...3373
TESTING OPERATING FORCE...3373
OPERATING ANGLE OF PEDAL...3374
ADJUSTING ENGINE STOP SOLENOID...3375
ADJUSTING ENGINE SPEED SENSOR...3376
REFRIGERANT COMPRESSOR BELT...3377
MEASURING DIRECTIONAL LEVER EFFORT...3378
HST OIL PRESSURE...3379
MEASURING...3379
ADJUSTING...3382
MEASURING CLUTCH CONTROL PRESSURE...3384
STEERING WHEEL...3385
MEASURING STEERING WHEEL END PLAY...3385
MEASURING OPERATING FORCE ON STEERING WHEEL...3385
MEASURING OPERATING TIME FOR STEERING WHEEL...3386
STEERING OIL PRESSURE...3387
MEASURING MAIN RELIEF PRESSURE...3387
ADJUSTING MAIN RELIEF PRESSURE...3387
BLEEDING AIR FROM STEERING CIRCUIT...3388
HYDRAULIC FAN...3389
MEASURING FAN SPEED...3389
MEASURING OIL PRESSURE...3389
REVERSING FAN CONTROLLER, IF EQUIPPED...3390
LED INDICATORS...3390
MEASURING BRAKE PEDAL...3391
BRAKE PEDAL LINKAGE...3392
MEASURING BRAKE PERFORMANCE...3393
ACCUMULATOR CHARGE PRESSURE...3394
MEASURING BRAKE OIL PRESSURE...3396
MEASURING WEAR OF BRAKE DISC...3398
BLEEDING AIR FROM BRAKE CIRCUIT...3399
MEASURING PARKING BRAKE PERFORMANCE...3400
PARKING BRAKE LINKAGE...3401
MEASURING PARKING BRAKE RELEASE PRESSURE...3402
WORK EQUIPMENT CONTROL LEVER...3403
WORK EQUIPMENT PRESSURE...3404
WORK EQUIPMENT PPC OIL PRESSURE...3406
TESTING AND ADJUSTING...3406
BLEEDING AIR...3408
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...3409
BUCKET POSITIONER...3410
BOOM KICK-OUT...3411
TESTING...3411
ADJUSTING...3411
PROXIMITY SWITCH ACTUATION DISPLAY LAMP...3412
PROCEDURE FOR CHECKING DIODE...3414
SPECIAL FUNCTIONS OF MACHINE MONITOR...3415
FLOW OF MODES AND FUNCTIONS...3416
OPERATOR MODE...3419
SERVICE MODE 1...3419
SERVICE MODE 2...3419
CHARACTER DISPLAY...3419
OPERATING SWITCHES...3419
OPERATOR MODE OPERATION AND DISPLAYS...3419
FAILURE CODE TABLE...3424
*SEPARATE TABLE: DETAILED PHENOMENA OF PROBLEM CODE (L*)...3425
PROCEDURE FOR SWITCHING TO SERVICE MODE 1 AND SCREEN DISPLAY...3425
REAL-TIME MONITORING ITEMS...3431
PM CLINIC INSPECTION CHART...3434
20-101 TROUBLESHOOTING (GENERAL)...3436
POINTS TO REMEMBER WHEN TROUBLESHOOTING...3437
SEQUENCE OF EVENTS IN TROUBLESHOOTING...3439
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...3440
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT...3440
HANDLING CONTROL BOX...3445
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS...3446
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT...3447
CHECKS BEFORE TROUBLESHOOTING...3449
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS...3450
PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO...3451
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...3454
T-ADAPTER TABLE...3478
CONNECTOR TYPES AND MOUNTING LOCATIONS...3481
CONNECTOR LAYOUT DRAWING...3487
20-301 TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)...3492
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM...3493
POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL...3493
USER CODE MEMORY RETENTION FUNCTION...3493
HST CONTROLLER SYSTEM DIAGRAM...3494
TROUBLESHOOTING CODE DISPLAY...3496
ERROR CODE AND POSSIBLE CAUSE TABLE...3496
FUSE SYSTEM CHECK...3497
FUSE PANNEL CONNECTION TABLE...3497
INFORMATION CONTAINED IN TESTING PROCEDURES...3498
CODE KEY TABLE...3499
ERROR CODE: [989F00]...3500
TRANSMISSION PROTECTION ALERT (00)...3500
ERROR CODE: [DHH1KX]...3501
HST OIL PRESSURE SIGNAL OUT OF RANGE...3501
ERROR CODE: [DLE2LC]...3503
ENGINE SPEED SENSOR OUT OF RANGE...3503
ERROR CODE: [DW26KZ]...3505
MOTOR 2 SOLENOID SYSTEM OPEN OR SHORTED...3505
ERROR CODE: [DX19KZ]...3509
MOTOR 1 SOLENOID SYSTEM OPEN OR SHORTED...3509
ERROR CODE: [DX20KZ]...3511
CLUTCH SOLENOID SYSTEM OPEN OR SHORTED...3511
TROUBLESHOOTING CODE: [HST-1]...3513
DEFECTIVE HST POWER CONTROLLER SOURCE...3513
TROUBLESHOOTING CODE: [HST-2]...3517
TRAVEL SPEED RANGES DO NOT CHANGE...3517
TROUBLESHOOTING CODE: [HST-3]...3521
TRAVEL SPEED DOES NOT REGISTER...3521
TROUBLESHOOTING CODE: [HST-4]...3525
CANNOT CONTROL TRAVEL SPEED WHEN 1ST. GEAR IS SELECTED...3525
TROUBLESHOOTING CODE: [HST-5]...3529
TRACTION CONTROL INNOPERABLE...3529
20-402 TROUBLESHOOTING OF HST MONITOR SYSTEM (HST MODE)...3532
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM...3534
POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL...3534
USER CODE MEMORY RETENTION FUNCTION...3534
MONITOR SYSTEM CIRCUIT DIAGRAM...3535
TROUBLESHOOTING CODE DISPLAY...3539
ERROR CODE AND POSSIBLE CAUSE TABLE...3539
FUSE SYSTEM CHECK...3540
FUSE PANNEL CONNECTION TABLE...3540
INFORMATION CONTAINED IN TESTING PROCEDURES...3541
CODE KEY TABLE...3542
ERROR CODE: [15B0NX]...3543
HST OIL FILTER SHOWING CLOGGED CONDITION...3543
ERROR CODE: [2G42ZG]...3545
LOW ACCUMULATOR OIL PRESSURE INDICATED...3545
ERROR CODE: [989F00]...3547
TRANSMISSION PROTECTION CAUTION INDICATED...3547
ERROR CODE: [989FN1]...3548
HST OVERSPEED CONDITION...3548
ERROR CODE: [AB00L6]...3549
DEFECTIVE BATTERY CHARGING CIRCUIT...3549
ERROR CODE: [AB00MA]...3551
DEFECTIVE BATTERY CHARGING CIRCUIT...3551
ERROR CODE: [B@BAZG]...3553
ABNORMAL ENGINE OIL PRESSURE INDICATED...3553
ERROR CODE: [B@BCNS]...3555
ENGINE COOLANT INDICATING OVERHEAT CONDITION...3555
ERROR CODE: [B@BCZK]...3557
ABNORMAL COOLANT LEVEL INDICATION...3557
ERROR CODE: [B@C7NS]...3559
BRAKE COOLING OIL INDICATING OVERHEATING CONDITION...3559
ERROR CODE: [B@CRNS]...3561
HST OIL SHOWING OVERHEATING CONDITION...3561
ERROR CODE: [D5ZHL6]...3563
STARTING SWITCH "C" (IGN) INPUT FAILURE INDICATED...3563
ERROR CODE: [DAF0KT]...3565
CONTROLLER INTERNAL FAILURE)...3565
ERROR CODE: [DAJ0KR]...3567
HST CONTROLLER COMMUNICATION FAILURE...3567
ERROR CODE: [DD15LD]...3569
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET...3569
ERROR CODE: [DD16LD]...3571
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET...3571
ERROR CODE: [DD17LD]...3573
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET...3573
ERROR CODE: [DD18LD]...3575
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET...3575
ERROR CODE: [DDK3KB]...3577
IMPROPER INPUT FOR MULTIPUL SHIFT (FNR) LEVER...3577
ERROR CODE: [DDS5L6]...3579
DECREASED STEERING OIL PRESSURE...3579
ERROR CODE: [DGE2KX]...3581
ENGINE COOLANT TEMPERATURE SENSOR OUT OF RANGE...3581
ERROR CODE: [DGE3KX]...3583
ENGINE COOLANT TEMPERATURE SENSOR OUT OF RANGE...3583
ERROR CODE: [DGH1KX]...3585
HST OIL SHOWING OVERHEATING CONDITION...3585
ERROR CODE: [DGR1KX]...3587
BRAKE COOLING OIL INDICATING SHORT CIRCUIT...3587
ERROR CODE: [DGR4KX]...3589
BRAKE COOLING OIL INDICATING OPEN CIRCUIT...3589
ERROR CODE: [DHE4KA]...3591
ENGINE OIL PRESSURE INDICATING A SHORT OR OPEN IN THE SYSTEM...3591
TROUBLESHOOTING CODE: [MON-1]...3593
PARKING BRAKE INDICATOR LAMP DOES NOT WORK...3593
TROUBLESHOOTING CODE: [MON-2]...3597
BRAKE OIL PRESSURE NOT INDICATING CORRECTLY...3597
TROUBLESHOOTING CODE: [MON-3]...3599
ENGINE COOLANT SENSOR NOT INDICATING CORRECTLY...3599
TROUBLESHOOTING CODE: [MON-4]...3601
HST OIL TEMPERATURE NOT INDICATING CORRECTLY...3601
TROUBLESHOOTING CODE: [MON-5]...3603
FUEL LEVEL GAUGE DOES NOT INDICATE PROPERLY...3603
TROUBLESHOOTING CODE: [MON-6]...3605
ABNORMAL COOLANT LEVEL INDICATION...3605
TROUBLESHOOTING CODE: [MON-7]...3607
STEERING OIL PRESSURE NOT READING CORRECTLY...3607
TROUBLESHOOTING CODE: [MON-8]...3609
EMERGENCY STEERING OIL PRESSURE NOT READING CORRECTLY...3609
TROUBLESHOOTING CODE: [MON-9]...3611
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY...3611
TROUBLESHOOTING CODE: [MON-10]...3613
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY...3613
TROUBLESHOOTING CODE: [MON-11]...3615
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY...3615
TROUBLESHOOTING CODE: [MON-12]...3617
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY...3617
TROUBLESHOOTING CODE: [MON-13]...3619
ALARM BUZZER DOES NOT STOP OR REMAINS ON...3619
TROUBLESHOOTING CODE: [MON-14]...3621
FRONT WINDSHIELD WIPER DOES NOT WORK...3621
REAR WINDSHIELD WIPER DOES NOT WORK...3623
TROUBLESHOOTING CODE: [MON-15]...3625
HEADLAMPS (LO AND HIGH BEAM) DOES NOT FUNCTION...3625
20-501 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...3628
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM...3629
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL...3629
USER CODE MEMORY RETENTION FUNCTION...3629
ELECTRICAL SYSTEM CIRCUIT DIAGRAM...3630
FUSE SYSTEM CHECK...3636
FUSE PANEL CONNECTION TABLE...3636
INFORMATION CONTAINED IN TESTING PROCEDURES...3637
CODE: (E-1)...3639
ENGINE WILL NOT CRANK...3639
CODE: (E-2)...3642
THE ENGINE DOES NOT SHUT DOWN...3642
CODE: (E-3)...3644
COLD START PREHEATER DOES NOT WORK PROPERLY...3644
CODE: (E-4)...3647
PARKING BRAKE DOES NOT FUNCTION PROPERLY...3647
CODE: (E-5)...3650
EMERGENCY BRAKE SYSTEM DOES NOT FUNCTION...3650
CODE: (E-6)...3651
BOOM KICK-OUT FUNCTION NOT WORKING PROPERLY...3651
CODE: (E-7)...3654
BUCKET LEVER FUNCTION NOT WORKING PROPERLY...3654
CODE: (E-8)...3657
FLOAT HOLD FUNCTION NOT WORKING PROPERLY...3657
CODE: (E-9)...3660
FRONT WINDSHIELD WIPER DOES NOT WORK...3660
CODE: (E-9)...3664
REAR WINDSHIELD WIPER DOES NOT WORK...3664
CODE: (E-10)...3666
THE WINDOW WASHER DOES NOT WORK...3666
CODE: (E-11)...3668
HEADLAMPS (LO AND HIGH BEAM) DOES NOT FUNCTION...3668
CODE: (E-11)...3671
HEADLAMPS (LO BEAM) DO NOT FUNCTION...3671
CODE: (E-11)...3674
HEADLAMPS (HI BEAM) DO NOT FUNCTION...3674
CODE: (E-11)...3677
CLEARANCE LAMPS DO NOT FUNCTION...3677
CODE: [E-11]...3680
TURN SIGNALS DO NOT FUNCTION...3680
CODE: (E-11)...3683
WORK LAMPS DO NOT FUNCTION...3683
CODE: (E-12)...3686
HORN DOES NOT SOUND...3686
CODE: (E-13)...3688
AIR CONDITIONER SYSTEM DOES NOT WORK...3688
CODE: (E-13)...3691
AIR DOES NOT FLOW FROM SYSTEM AND CANNOT BE ADJUSTED...3691
CODE: (E-13)...3695
AIR DOES NOT COOL OR TEMPERATURE CANNOT BE ADJUSTED...3695
CODE: (E-13)...3699
CANNOT SWITCH BETWEEN CIRCULATED AND VENT FUNCTIONS...3699
CODE: (E-13)...3701
CANNOT SWITCH VENT FUNCTIONS...3701
20-601 TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE)...3704
METHOD OF USING TROUBLESHOOTING CHART...3706
FAILURE CODE AND CAUSE TABLE...3709
CODE: (H-1)...3712
THE MACHINE DOES NOT START...3712
CODE: (H-2)...3713
THE TRAVEL SPEED IS SLOW...3713
CODE: (H-3)...3714
THE THRUST FORCE IS WEAK...3714
CODE: (H-4)...3715
ENGINE STALLS OR ENGINE SPEED DROPS EXCESSIVELY...3715
CODE: (H-5)...3716
THE GEARS DO NOT CHANGE SPEED RANGE...3716
CODE: (H-6)...3717
THE STEERING WHEEL DOES NOT TURN...3717
CODE: (H-7)...3718
STEERING WHEEL MOVEMENT IS HEAVY...3718
CODE: (H-8)...3719
STEERING WHEEL SHAKES OR HAS JERKY MOVEMENT...3719
CODE: (H-9)...3720
BRAKES DO NOT WORK OR WORKS POORLY...3720
CODE: (H-10)...3721
BRAKES IS NOT RELEASING OR DRAGGED...3721
CODE: (H-11)...3722
THE PARKING BRAKE IS NOT WORK...3722
CODE: (H-12)...3723
THE LIFT ARM DOES NOT RISE OR LOWER...3723
CODE: (H-13)...3724
LIFT ARM MOVES SLOW OR RISING FORCE IS POOR...3724
CODE: (H-14)...3725
WHEN RISING LIFT ARM, ARM MOVES SLOWLY AT SPECIFIC HEIGHTS...3725
CODE: (H-15)...3725
THE LIFT ARM CYLINDER WILL NOT HOLD DOWN THE BUCKET (THE BUCKET RISES)...3725
CODE: (H-16)...3725
HYDRAULIC DRIFT ON THE LIFT ARM OCCURS OFTEN...3725
CODE: (H-17)...3725
THE LIFT ARM WOBBLES DURING OPERATION...3725
CODE: (H-18)...3726
WHEN THE CONTROL LEVER IS SWITCHED FROM “HOLD” TO “RAISE,” THE LIFT ARM FALLS TEMPORARILY...3726
CODE: (H-19)...3727
THE BUCKET DOES NOT TILT BACK...3727
CODE: (H-20)...3728
BUCKET MOVES SLOW OR THE TILTING-BACK FORCE IS INSUFFICIENT...3728
CODE: (H-21)...3729
THE BUCKET OPERATES SLOWLY IN TILTING-BACK...3729
CODE: (H-22)...3729
BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET...3729
CODE: (H-23)...3729
HYDRAULIC DRIFTS OF THE BUCKET OCCURS OFTEN...3729
CODE: (H-24)...3729
THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVE IS SET TO “HOLD”)...3729
CODE: (H-25)...3730
WHEN THE CONTROL LEVER IS SWITCHED FROM “HOLD” TO “TILT,” THE BUCKET FALLS TEMPORARILY...3730
CODE: (H-26)...3730
CONTROL LEVERS FOR THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY...3730
20-701 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)...3732
METHOD OF USING TROUBLESHOOTING CHARTS...3733
(S-1) ENGINE STARTING PERFORMANCE IS POOR...3737
(S-2) ENGINE HAS STARTING PROBLEMS...3739
ENGINE DOES NOT CRANK...3739
ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT OF STACK...3740
SMOKE COMES OUT OF STACK BUT ENGINE DOES NOT START...3741
(S-3) ENGINE DOES NOT RUN SMOOTHLY...3742
(S-4) ENGINE STOPS DURING OPERATIONS...3743
(S-5) ENGINE SPEED HUNTS...3744
(S-6) ENGINE LACKS POWER...3745
(S-7) EXHAUST SMOKE IS BLACK...3746
(S-8) OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE...3747
(S-9) OIL BECOMES CONTAMINATED QUICKLY...3748
(S-10) FUEL CONSUMPTION IS EXCESSIVE...3749
(S-11) OIL FOUND IN COOLANT, OR COOLANT SPURTS FROM RADIATOR...3750
(S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP...3751
(S-13) OIL LEVEL RISES (COOLANT OR FUEL FOUND IN OIL)...3752
(S-14) COOLANT TEMPERATURE TOO HIGH (OVERHEATING)...3753
(S-15) ABNORMAL NOISE IS HEARD WHEN ENGINE IS RUNNUNG...3754
(S-16) EXCESSIVE VIBRATION WHEN ENGINE IS RUNNING...3755
20-901 TROUBLESHOOTING AIR CONDITIONING...3756
AIR CONDITIONING SYSTEM...3758
ENVIRONMENTAL IMPACT...3758
OPERATOR CAB AIR CONDITIONING...3759
PRINCIPLES OF REFRIGERATION...3759
AIR CONDITIONING...3759
THE ACT OF COOLING...3759
THE REFRIGERATION CYCLE...3760
AIR CONDITIONER SYSTEM COMPONENTS...3760
COMPRESSOR (REFRIGERANT PUMP)...3760
SERVICE VALVES...3761
CONDENSER...3761
RECEIVER-DRIER...3761
THERMOSTATIC EXPANSION VALVE...3761
EVAPORATOR...3762
ELECTRICAL CIRCUIT...3762
THERMOSTAT...3763
COMPRESSOR CLUTCH...3763
SAFETY SWITCHES...3763
SYSTEM SERVICING...3764
R-134A REFRIGERANT CONTAINERS...3765
SERVICE TOOLS AND EQUIPMENT...3765
RECOVERY/RECYCLE STATION...3765
LEAK DETECTOR...3766
SERVICE VALVES...3766
VACUUM PUMP...3766
MANIFOLD GAUGE SET...3767
INSTALLING MANIFOLD GAUGE SET...3768
PURGING AIR FROM SERVICE HOSES...3769
ADDING REFRIGERANT TO THE SYSTEM (WITHOUT A CHARGING STATION)...3770
STABILIZING THE AC SYSTEM...3770
ADDING REFRIGERANT AND STABILIZING THE SYSTEM (WITH A RECOVERY/RECYCLING STATION)...3771
RECOVERING AND RECYCLING THE REFRIGERANT...3771
PERFORMING THE RECOVERY CYCLE...3771
PERFORMING THE RECYCLING PROCEDURE...3772
EVACUATING AND CHARGING THE AC SYSTEM...3772
SYSTEM PERFORMANCE TEST...3773
SYSTEM LEAK TESTING...3773
ELECTRONIC LEAK DETECTOR...3774
TRACER DYES...3774
SOAP AND WATER...3774
SYSTEM REPAIR...3775
HOSES AND FITTINGS...3775
LINES...3775
EXPANSION VALVE...3775
RECEIVER-DRIER...3775
THERMOSTAT...3775
CLUTCH...3776
COMPRESSOR...3776
CHECKING COMPRESSOR OIL LEVEL...3776
EVACUATING THE SYSTEM...3777
TROUBLESHOOTING - AIR CONDITIONING SYSTEM...3778
PRE-DIAGNOSIS CHECKS...3778
PREPARING FOR DIAGNOSIS...3778
PRELIMINARY STEPS...3778
SYSTEM PERFORMANCE TEST...3778
DIAGNOSIS OF GAUGE READINGS & SYSTEM PERFORMANCE...3779
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS...3780
DEFECTIVE GROUND ON REFRIGERANT COMPRESSOR...3784
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM...3785
30 DISASSEMBLY AND ASSEMBLY...3788
HOW TO USE THIS MANUAL...3793
REMOVAL AND INSTALLATION OF COMPONANTS...3793
SPECIAL TOOLS...3793
OVERHAUL OF COMPONANTS...3794
SPECIAL TOOLS...3794
DISASSEMBLY...3794
ASSEMBLY...3794
PRECAUTIONS WHEN PERFORMING AN OPERATION...3795
SPECIAL TOOL LIST...3797
SKETCHES OF SPECIAL TOOLS...3800
CONNECTOR REPAIR PROCEDURES...3806
CONTACT TERMINAL REMOVAL (HD30 TYPE)...3806
STRIPING INSULATION...3807
CRIMPING CONTACT TERMINAL (HD30 TYPE)...3808
INSERTION OF CONTACT TERMINAL (HD30 TYPE)...3809
CONTACT TERMINAL REMOVAL (DT TYPE)...3810
STRIPING INSULATION...3811
CRIMPING CONTACT TERMINAL (DT TYPE)...3812
INSERTION OF CONTACT TERMINAL (DT TYPE)...3813
FUEL INJECTION PUMP ASSEMBLY...3815
SPECIAL TOOLS...3815
REMOVAL...3815
INSTALLATION...3819
NOZZLE HOLDER ASSEMBLY...3821
SPECIAL TOOLS...3821
REMOVAL...3821
INSTALLATION...3822
CYLINDER HEAD ASSEMBLY...3823
SPECIAL TOOLS...3823
REMOVAL...3823
INSTALLATION...3830
ENGINE ASSEMBLY...3834
REMOVAL...3834
INSTALLATION...3841
RADIATOR ASSEMBLY...3843
REMOVAL...3843
INSTALLATION...3844
AIR AFTERCOOLER...3845
REMOVAL...3845
INSTALLATION...3846
HYDRAULIC OIL COOLER...3847
REMOVAL...3847
INSTALLATION...3848
COOLING FAN AND FAN MOTOR...3849
REMOVAL...3849
INSTALLATION...3850
FUEL TANK...3851
REMOVAL...3851
INSTALLATION...3852
TRANSFER...3853
REMOVAL...3853
INSTALLATION...3856
TRANSFER ASSEMBLY...3857
SPECIAL TOOLS...3857
DISASSEMBLY...3857
ASSEMBLY...3869
PARKING BRAKE ASSEMBLY...3883
REMOVAL...3883
INSTALLATION...3884
DISASSEMBLY...3885
SPECIAL TOOLS...3885
ASSEMBLY...3888
FRONT AXLE ASSEMBLY...3892
REMOVAL...3892
INSTALLATION...3894
REAR AXLE ASSEMBLY...3895
REMOVAL...3895
INSTALLATION...3898
AXLE HOUSING ASSEMBLY...3899
SPECIAL TOOLS...3899
DISASSEMBLY...3899
ASSEMBLY...3904
DIFFERENTIAL ASSEMBLY...3910
SPECIAL TOOLS...3910
DISASSEMBLY...3910
ASSEMBLY...3923
HST PUMP AND 4-GEAR PUMP ASSEMBLY...3943
REMOVAL...3943
INSTALLATION...3946
HST PUMP ASSEMBLY...3947
DISASSEMBLY...3947
ASSEMBLY...3959
HST MOTOR 1 ASSEMBLY...3981
REMOVAL...3981
INSTALLATION...3982
HST MOTOR 2 ASSEMBLY...3983
REMOVAL...3983
INSTALLATION...3984
HST MOTOR ASSEMBLY...3985
DISASSEMBLY...3985
ASSEMBLY...3996
WORK EQUIPMENT CONTROL VALVE ASSEMBLY...4007
REMOVAL...4007
INSTALLATION...4008
TRAVEL DAMPER VALVE ASSEMBLY...4009
REMOVAL...4009
INSTALLATION...4010
HYDRAULIC TANK...4011
REMOVAL...4011
INSTALLATION...4012
WORK EQUIPMENT ASSEMBLY (Z-BAR LINKAGE)...4013
REMOVAL...4013
INSTALLATION...4017
BUCKET LINK PIN...4017
BUCKET HINGE PIN...4017
BUCKET CYLINDER PIN (ON ROD SIDE)...4018
LIFT CYLINDER PIN (ON ROD SIDE)...4018
LIFT ARM PIN (ON FRAME SIDE)...4019
BUCKET LINK PIN...4019
WORK EQUIPMENT ASSEMBLY (PARELLEL TOOL CARRIER)...4021
BUCKET (TILT) CYLINDER...4021
REMOVAL...4021
INSTALLATION...4022
BOOM (LIFT) CYLINDER...4023
REMOVAL...4023
INSTALLATION...4024
BOOM AND PARALLEL TOOL LINKAGE...4025
REMOVAL...4025
INSTALLATION...4033
HYDRAULIC CYLINDER ASSEMBLY...4036
SPECIAL TOOLS...4036
DISASSEMBLY...4037
ASSEMBLY...4041
OPERATOR'S CAB ASSEMBLY...4046
REMOVAL...4046
INSTALLATION...4051
OPERATOR'S CAB GLASS...4052
SPECIAL TOOLS...4052
REMOVAL...4052
INSTALLATION...4053
COATING MATERIALS...4060
CENTER HINGE PIN...4061
REMOVAL...4061
INSTALLATION...4067
COUNTERWEIGHT...4073
REMOVAL...4073
INSTALLATION...4074
AIR CONDITIONER UNIT ASSEMBLY...4075
SPECIAL TOOLS...4075
REMOVAL...4075
INSTALLATION...4078
AIR CONDITIONER COMPRESSOR ASSEMBLY...4079
SPECIAL TOOLS...4079
REMOVAL...4079
INSTALLATION...4080
MONITOR PANEL...4081
REMOVAL...4081
INSTALLATION...4085
KOMTRAX TERMINAL ASSEMBLY...4086
REMOVAL...4086
INSTALLATION...4087
90 SCHEMATICS AND DIAGRAMS...4088
HYDRAULIC CIRCUIT DIAGRAM...4089
WA250-5L...4089
SHEET 1 OF 2...4089
SHEET 2 OF 2...4090
WA250PT-5L...4091
SHEET 1 OF 2...4091
SHEET 2 OF 2...4092
ELECTRICAL CIRCUIT DIAGRAM...4093
MAIN FLOOR HARNESS...4093
HST HARNESS...4100
ENGINE HARNESS AND REAR HARNESS...4101
CAB HARNESS...4102
FRONT HARNESS...4103
REVERSE FAN WIRING DIAGRAM...4104
SEAM007503 - Wheel Loader WA250-3A Operation & Maintenance Manual...4105
COVER...4105
1. FOREWORD...4106
2. SAFETY INFORMATION...4109
3. INTRODUCTION...4110
3.1 INTENDED USE...4110
3.2 FEATURES...4110
3.3 BREAKING IN THE MACHINE...4110
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...4111
4.1 MACHINE SERIAL NO. PLATE POSITION...4111
4.2 ENGINE SERIAL NO. PLATE POSITION...4111
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...4111
CONTENTS...4112
SAFETY...4116
6. GENERAL PRECAUTIONS...4117
7. PRECAUTIONS DURING OPERATION...4122
7.1 BEFORE STARTING ENGINE...4122
7.2 AFTER STARTING ENGINE...4124
7.3 TRANSPORTATION...4132
7.4 BATTERY...4133
7.5 TOWING...4135
8. PRECAUTIONS FOR MAINTENANCE...4136
8.1 BEFORE CARRYING OUT MAINTENANCE...4136
8.2 DURING MAINTENANCE...4141
8.3 TIRES...4147
9. POSITION FOR ATTACHING SAFETY LABELS...4149
OPERATION...4154
10. GENERAL VIEW...4155
10.1 GENERAL VIEW OF MACHINE...4155
10.2 GENERAL VIEW OF CONTROLS AND GAUGES...4156
11. EXPLANATION OF COMPONENTS...4157
11.1 MACHINE MONITOR...4157
11.2 SWITCHES...4167
11.3 CONTROL LEVERS, PEDALS...4172
11.4 STEERING COLUMN TILT LEVER...4176
11.5 CAP WITH LOCK...4176
11.6 SAFETY BAR...4177
11.7 TOWING PIN...4177
11.8 GREASE PUMP CLAMP AND RUBBER RING...4177
11.9 BACKUP ALARM...4178
11.10 FUSE...4179
11.11 SLOW BLOW FUSE...4180
11.12 MANUAL POCKET...4180
11.13 POWER SUPPLY SOCKET...4180
12. OPERATION...4181
12.1 CHECK BEFORE STARTING ENGINE...4181
12.2 STARTING ENGINE...4198
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE...4200
12.4 MOVING MACHINE OFF...4201
12.5 CHANGING GEAR SPEED...4203
12.6 CHANGING DIRECTION...4203
12.7 TURNING...4204
12.8 STOPPING MACHINE...4205
12.9 OPERATION OF WORK EQUIPMENT...4206
12.10 WORK POSSIBLE USING WHEEL LOADER...4207
12.11 PRECAUTIONS FOR OPERATION...4211
12.12 ADJUSTING WORK EQUIPMENT POSTURE...4213
12.13 PARKING MACHINE...4215
12.14 CHECKS AFTER COMPLETION OF OPERATION...4216
12.15 STOPPING ENGINE...4216
12.16 CHECK AFTER STOPPING ENGINE...4217
12.17 LOCKING...4217
12.18 HANDLING THE TIRES...4218
13. TRANSPORTATION...4220
13.1 LOADING, UNLOADING WORK...4220
13.2 PRECAUTIONS FOR LOADING...4221
13.3 LIFTING MACHINE...4221
13.4 PRECAUTIONS FOR TRANSPORTATION...4224
14. COLD WEATHER OPERATION...4225
14.1 PRECAUTIONS FOR LOW TEMPERATURE...4225
14.2 PRECAUTIONS AFTER COMPLETION OF WORK...4227
14.3 AFTER COLD WEATHER...4227
15. LONG TERM STORAGE...4228
15.1 BEFORE STORAGE...4228
15.2 DURING STORAGE...4228
15.3 AFTER STORAGE...4228
16. TROUBLESHOOTING...4229
16.1 WHEN MACHINE RUNS OUT OF FUEL...4229
16.2 TOWING THE MACHINE...4230
16.3 IF BATTER IS DISCHARGED...4233
16.4 OTHER TROUBLE...4237
MAINTENANCE...4244
17. GUIDES TO MAINTENANCE...4245
18. OUTLINES OF SERVICE...4248
18.1 OUTLINE OF OIL, FUEL, COOLANT...4248
18.2 OUTLINE OF ELECTRIC SYSTEM...4251
19. WEAR PARTS LIST...4252
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...4253
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...4257
21.1 INTRODUCTION OF NECESSARY TOOLS...4257
21.2 TORQUE LIST...4258
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...4259
23. MAINTENANCE SCHEDULE CHART...4261
23.1 MAINTENANCE SCHEDULE CHART...4261
24. SERVICE PROCEDURE...4265
24.1 INITIAL 250 HOURS SERVICE...4265
REPLACE FUEL FILTER CARTRIDGE...4303
REPLACE TRANSMISSION OIL FILTER ELEMENT...4305
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...4312
CHECK ENGINE VALVE CLEARANCE, ADJUST...4316
24.2 WHEN REQUIRED...4266
24.2.1 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT...4266
24.2.2 CLEAN INSIDE OF COOLING SYSTEM...4269
24.2.3 CHECK TRANSMISSION OIL LEVEL, ADD OIL...4273
24.2.4 CHECK AXLE OIL LEVEL, ADD OIL...4274
24.2.5 CLEAN AXLE CASE BREATHER...4275
24.2.6 CLEAN RADIATOR FINS...4275
24.2.7 REPLACE BOLT-ON CUTTING EDGE (IF EQUIPPED)...4276
24.2.8 REPLACE BUCKET TEETH (IF EQUIPPED)...4277
24.2.9 CHECK AIR CONDITIONER (IF EQUIPPED)...4278
24.2.10 CLEAN CONDENER OF AIR CONDITIONER (IF EQUIPPED)...4279
24.2.11 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID (IF EQUIPPED)...4279
24.2.12 ADJUSTING PARKING BRAKE...4280
24.2.13 CHECK ELECTRICAL INTAKE AIR HEATER...4281
24.2.14 DRAIN WATER FROM WATER SEPARATOR (IF EQUIPPED)...4281
24.2.15 REPLACE SLOW BLOW FUSE...4282
24.2.16 SELECTION AND INSPECTION OF TIRES...4283
24.3 CHECK BEFORE STARTING...4285
24.3.1 CHECK MONITOR PANEL...4285
24.3.2 CHECK COOLANT LEVEL, ADD WATER...4285
24.3.3 CHECK FUEL LEVEL, ADD FUEL...4286
24.3.4 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...4287
24.3.5 CHECK AND REFILL OF OIL IN BRAKE OIL TANK...4288
24.3.6 CHECK DUST INDICATOR...4289
24.3.7 CHECK ELECTRIC WIRING...4289
24.3.8 CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR (IF EQUIPPED)...4290
24.3.9 CHECK EFFECT OF PARKING BRAKE...4291
24.3.10 CHECK EFFECT OF BRAKE...4292
24.3.11 CHECK ALARM SOUND OF HORN AND BACKUP ALARM...4292
24.3.12 CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE...4292
24.3.13 CHECK ENGINE EXHAUST COLOR AND SOUND...4292
24.3.14 CHECK OPERATION OF GAUGES...4292
24.3.15 CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING...4292
24.3.16 CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE (IF EQUIPPED)...4292
24.3.17 CHECK LOCK OF CAB DOOR (MACHINE EQUIPPED WITH CAB)...4292
24.3.18 CHECK INFLATION PRESSURE OF TIRES...4292
24.4 EVERY 50 HOURS SERVICE...4293
24.4.1 DRAIN WATER, SEDIMENT FROM FUEL TANK...4293
24.5 EVERY 100 HOURS SERVICE...4294
24.5.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...4294
24.5.2 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER (IF EQUIPPED)...4295
24.5.3 LUBRICATE REAR AXLE PIVOT PIN (2 POINTS)...4296
24.6 EVERY 250 HOURS SERVICE...4297
24.6.1 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...4297
24.6.2 CHECK BATTERY ELECTROLYTE LEVEL...4299
24.6.3 CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN...4300
24.6.4 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER (IF EQUIPPED)...4300
24.6.5 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST (IF EQUIPPED)...4301
24.6.6 LUBRICATING...4302
24.7 EVERY 500 HOURS SERVICE...4303
24.7.1 REPLACE FUEL FILTER CARTRIDGE...4303
24.7.2 REPLACE TRANSMISSION OIL FILTER ELEMENT...4305
24.7.3 LUBRICATE CENTER DRIVE SHAFT SPLINE (1 POINT)...4306
24.8 EVERY 1000 HOURS SERVICE...4307
24.8.1 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER...4307
24.8.2 CLEAN TRANSMISSION CASE BREATHER...4308
24.8.3 LUBRICATING...4309
24.8.4 CHECK TIGHTENING PARTS OF TURBOCHARGER...4311
24.8.5 CHECK PLAY OF TURBOCHARGER ROTOR...4311
24.8.6 REPLACE CORROSION RESISTOR CARTRIDGE...4311
24.8.7 CHECK FAN BELT TENSION AND REPLACE FAN BELT...4311
24.9 EVERY 2000 HOURS SERVICE...4312
24.9.1 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC TANK FILTER ELEMENT...4312
24.9.2 REPLACE HYDRAULIC TANK BREATHER ELEMENT...4314
24.9.3 CHANGE AXLE OIL...4315
24.9.4 CHECK BRAKE DISC WEAR...4316
24.9.5 CHECK ALTERNATOR, STARTING MOTOR...4316
24.9.6 CHECK ENGINE VALVE CLEARANCE, ADJUST...4316
24.9.7 CHECK VIBRATION DAMPER...4316
24.9.8 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER, FRESH AIR FILTER...4316
24.9.9 CLEAN AND CHECK TURBOCHARGER...4316
24.10 EVERY 4000 HOURS SERVICE...4317
24.10.1 CHECK WATER PUMP...4317
SPECIFICATIONS...4318
25. SPECIFICATIONS...4319
OPTIONS, ATTACHMENTS...4322
26. OPTIONAL PARTS AND ATTACHMENTS...4323
27. SELECTING BUCKETS AND TIRES...4324
28. CAR RADIO...4325
28.1 EXPLANATION OF COMPONENTS...4325
28.2 METHOD OF USE...4327
28.3 PRECAUTIONS WHEN USING RADIO...4328
29. AIR CONDITIONER...4329
29.1 GENERAL LOCATIONS AND FUNCITON OF CONTROL PANEL...4329
29.2 METHOD OF OPERATION...4331
29.3 COOL BOX...4331
30. HANDLING E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM)...4332
30.1 STRUCTURE AND FUNCTION OF E.C.S.S...4332
30.2 METHOD OF OPERATING E.C.S.S...4333
30.3 PRECAUTIONS WHEN OPERATING E.C.S.S. SWITCH...4333
30.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR...4334
31. HANDLING AUTOMATIC SHIFT...4335
31.1 EXPLANATION OF COMPONENTS...4335
31.2 AUTOMATIC SHIFT...4337
SEAM059200T - Wheel Loader GALEO WA250PTL-5 Operation & Maintenance Manual...4340
COVER...4340
FOREWORD...4341
FOREWORD...4342
SAFETY INFORMATION...4345
INTRODUCTION...4347
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...4347
NECESSARY INFORMATION...4348
MACHINE SERIAL NO. PLATE AND POSITION...4348
ENGINE SERIAL NO. PLATE AND POSITION...4348
POSITION OF SERVICE METER...4349
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...4349
CONTENTS...4350
SAFETY...4353
SAFETY...4354
SAFETY LABELS...4357
LOCATION OF SAFETY LABELS...4357
SAFETY LABELS...4358
GENERAL PRECAUTIONS...4363
SAFETY RULES...4363
IF ABNORMALITIES ARE FOUND...4363
CLOTHING AND PERSONAL PROTECTIVE ITEMS...4363
FIRE EXTINGUISHER AND FIRST AID KIT...4363
SAFETY FEATURES...4363
KEEP MACHINE CLEAN...4364
INSIDE OPERATOR'S COMPARTMENT...4364
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT...4364
HANDRAILS AND STEPS...4365
MOUNTING AND DISMOUNTING...4366
NO PEOPLE ON ATTACHMENTS...4366
DO NOT GET CAUGHT IN ARTICULATED PORTION...4366
PREVENTION OF BURNS...4366
FIRE PREVENTION...4367
ACTION IF FIRE OCCURS...4368
WINDOW WASHER LIQUID...4368
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)...4368
PRECAUTIONS FOR ATTACHMENTS...4368
UNAUTHORIZED MODIFICATION...4368
SAFETY AT WORKSITE...4369
WORKING ON LOOSE GROUND...4369
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...4369
ENSURE GOOD VISIBILITY...4370
BE CAREFUL ABOUT ASBESTOS DUST...4370
CHECKING SIGNALMAN'S SIGNALS AND SIGNS...4370
EMERGENCY EXIT FROM OPERATOR'S CAB...4370
VENTILATION FOR ENCLOSED AREAS...4371
PRECAUTIONS FOR OPERATION...4372
STARTING ENGINE...4372
CHECKS BEFORE STARTING ENGINE...4372
PRECAUTIONS WHEN STARTING...4373
PRECAUTIONS IN COLD AREAS...4373
OPERATION...4374
CHECKS BEFORE OPERATION...4374
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE...4374
PRECAUTIONS WHEN TRAVELING...4375
TRAVELING ON SLOPES...4376
PROHIBITED OPERATIONS...4377
PRECAUTIONS WHEN OPERATING...4377
METHODS OF USING BRAKE...4378
OPERATE CAREFULLY ON SNOW...4378
PARKING MACHINE...4379
TRANSPORTATION...4380
LOADING AND UNLOADING...4380
SHIPPING...4380
BATTERY...4381
BATTERY HAZARD PREVENTION...4381
STARTING WITH BOOSTER CABLES...4382
TOWING...4383
WHEN TOWING...4383
PRECAUTIONS FOR MAINTENANCE...4384
WARNING TAG...4384
KEEP WORK PLACE CLEAN AND TIDY...4384
APPOINT LEADER WHEN WORKING WITH OTHERS...4384
MAINTENANCE WITH ENGINE RUNNING...4385
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...4386
INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF...4386
PROPER TOOLS...4387
ACCUMULATOR...4387
PERSONNEL...4387
ATTACHMENTS...4387
WORK UNDER THE MACHINE...4388
NOISE...4388
PRECAUTIONS WHEN USING HAMMER...4388
REPAIR WELDING...4388
REMOVING BATTERY TERMINAL...4388
PRECAUTIONS WITH HIGH-PRESSURE OIL...4389
HANDLING HIGH-PRESSURE HOSES...4389
WASTE MATERIALS...4389
MAINTENANCE OF AIR CONDITIONER...4389
COMPRESSED AIR...4390
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...4390
PRECAUTIONS WITH TIRES...4391
HANDLING TIRES...4391
PRECAUTIONS WHEN STORING TIRE...4391
OPERATION...4392
GENERAL VIEW...4393
GENERAL VIEW OF MACHINE...4393
GENERAL VIEW OF CONTROLS AND GAUGES...4394
EXPLANATION OF COMPONENTS...4396
MACHINE MONITOR...4396
SWITCHES...4422
CONTROL LEVERS, PEDALS...4431
STEERING TILT LOCK LEVER...4435
CAP AND COVER WITH LOCK...4435
SAFETY BAR...4436
TOWING PIN...4437
GREASE PUMP...4437
CAB DOOR INNER LOCK...4437
CAB DOOR OPEN LOCK...4438
CAB WINDOW OPEN LOCK CANCEL KNOB...4438
FUSE...4438
SLOW BLOW FUSE...4440
POWER OUTLET...4440
STORAGE BOX...4440
AM/FM RADIO-CASSETTE STEREO...4441
AIR CONDITIONER...4449
HANDLING CAB WIPER...4454
OPERATION...4455
CHECK BEFORE STARTING ENGINE, ADJUST...4455
STARTING ENGINE...4470
OPERATIONS AND CHECKS AFTER STARTING ENGINE...4472
STOPPING ENGINE...4474
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...4475
TURNING...4480
OPERATION OF WORK EQUIPMENT...4482
HANDLING HYDRAULIC QUICK COUPLER...4484
WORK POSSIBLE USING WHEEL LOADER...4488
ADJUSTING WORK EQUIPMENT POSTURE...4495
PARKING MACHINE...4499
CHECK AFTER STOPPING ENGINE...4501
CHECKS AFTER COMPLETION OF OPERATION...4501
LOCKING...4501
HANDLING THE TIRES...4502
TRANSPORTATION...4504
TRANSPORTATION PROCEDURE...4504
LOADING, UNLOADING WORK WITH TRAILERS...4504
LIFTING MACHINE...4506
COLD WEATHER OPERATION...4509
PRECAUTIONS FOR LOW TEMPERATURE...4509
PRECAUTIONS AFTER COMPLETION OF WORK...4510
AFTER COLD WEATHER...4511
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...4511
LONG-TERM STORAGE...4512
BEFORE STORAGE...4512
DURING STORAGE...4512
AFTER STORAGE...4512
TROUBLESHOOTING...4513
WHEN MACHINE RUNS OUT OF FUEL...4513
TOWING THE MACHINE...4513
IF BATTERY IS DISCHARGED...4515
OTHER TROUBLE...4518
MAINTENANCE...4523
GUIDES TO MAINTENANCE...4524
OUTLINES OF SERVICE...4526
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...4526
OUTLINE OF ELECTRIC SYSTEM...4528
WEAR PARTS...4529
WEAR PARTS LIST...4529
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...4530
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS...4530
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...4535
TORQUE LIST...4535
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...4536
MAINTENANCE SCHEDULE CHART...4537
MAINTENANCE SCHEDULE CHART...4537
SERVICE PROCEDURE...4539
INITIAL 250 HOURS SERVICE...4539
WHEN REQUIRED...4540
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT...4540
CLEAN INSIDE OF COOLING SYSTEM...4543
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL...4546
CHECK AXLE OIL LEVEL, ADD OIL...4547
CHEAN AXLE CASE BREATHER...4548
CLEAN AIR CONDITIONER CONDENSER...4549
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID...4549
CLEAN RADIATOR FINS AND COOLER FINS...4550
CLEAN TRANSFER OIL COOLER FINS...4551
CHECK ELECTRICAL INTAKE AIR HEATER...4551
REPLACE BOLT ON CUTTING EDGE...4551
REPLACE BUCKET TEETH...4552
CHECK AIR CONDITIONER...4553
REPLACE SLOW BLOW FUSE...4554
SELECTION AND INSPECTION OF TIRES...4555
CHECK BEFORE STARTING...4557
EVERY 50 HOURS SERVICE...4558
DRAIN WATER, SEDIMENT FROM FUEL TANK...4558
EVERY 100 HOURS SERVICE...4559
LUBRICATE REAR AXLE PIVOT PIN...4559
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...4559
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...4560
EVERY 250 HOURS SERVICE...4561
CHECK BATTERY ELECTROLYTE LEVEL...4561
CHECK PARKING BRAKE...4563
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...4563
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN...4564
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...4565
LUBRICATING...4566
EVERY 500 HOURS SERVICE...4567
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...4567
REPLACE FUEL FILTER CARTRIDGE...4568
CLEAN WATER SEPARATOR STRAINER...4569
EVERY 1000 HOURS SERVICE...4570
CHANGE OIL IN TRANSFER CASE...4570
CLEAN TRANSFER CASE BREATHER...4571
REPLACE HST OIL FILTER ELEMENT...4572
LUBRICATING...4573
CHECK TIGHTENING PARTS OF TURBOCHARGER...4573
CHECK PLAY OF TURBOCHARGER ROTOR...4573
CHECK ALTERNATOR BELT TENSION AND REPLACEMENT...4573
EVERY 2000 HOURS SERVICE...4574
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...4574
REPLACE HYDRAULIC TANK BREATHER ELEMENT...4575
CHANGE AXLE OIL...4576
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER...4576
CHECK ALTERNATOR, STARTING MOTOR...4576
CHECK ENGINE VALVE CLEARANCE, ADJUST...4577
CHECK BRAKE DISC WEAR...4577
CLEAN AND CHECK TURBOCHARGER...4577
CHECK ACCUMULATOR GAS PRESSURE...4577
CHECK VIBRATION DAMPER...4578
EVERY 4000 HOURS SERVICE...4579
LUBRICATING...4579
CHECK WATER PUMP...4579
SPECIFICATIONS...4580
SPECIFICATIONS...4581
ATTACHMENTS, OPTIONS...4582
SELECTING BUCKET AND TIRES...4583
HANDLING FORK TOOL...4584
EXPLANATION OF COMPONENTS...4584
OPERATION...4585
INDEX...4588
SEBM033208 - Wheel Loader WA250-5, WA250PT-5 Shop Manual...4591
COVER...4591
CONTENTS...4592
01 GENERAL...4617
GENERAL ASSEMBLY DRAWINGS...4618
SPECIFICATIONS...4619
WEIGHT TABLE...4623
LIST OF LUBRICANT AND COOLANT...4625
10 STRUCTURE,FUNCTION AND MAINTENANCE STANDARD...4626
ENGINE MOUNT AND TRANSFER MOUNT...4627
DAMPER...4628
COOLING SYSTEM...4629
TRANSFER OIL COOLER...4630
POWER TRAIN...4633
POWER TRAIN SYSTEM DIAGRAM...4634
DRIVE SHAFT (PROPELLER SHAFT)...4636
HST HYDRAULIC PIPING DIAGRAM...4637
HST PUMP...4638
HIGH-PRESSURE RELIEF VALVE...4640
LOW-PRESSURE RELIEF VALVE...4642
HST CHARGE PUMP...4643
SPEED-RELATED VALVE (DA VALVE)...4644
HIGH-PRESSURE CUT-OFF VALVE...4645
HST MOTOR...4646
EP SERVO VALVE...4649
HA SERVO VALVE...4650
FORWARD-REVERSE SHUTTLE VALVE...4651
TRANSFER...4652
CLUTCH SOLENOID VALVE...4663
AXLE...4664
DIFFERENTIAL...4666
LIMITED-SLIP DIFFERENTIAL...4671
FINAL DRIVE...4677
AXLE MOUNTING AND CENTER HINGE PIN...4682
STEERING PIPING...4687
STEERING COLUMN...4688
PRIORITY VALVE...4689
ORBIT-ROLL VALVE...4692
2-WAY RESTRICTOR VALVE...4700
CUSHION VALVE...4701
STEERING CYLINDER...4702
EMERGENCY STEERING PIPING...4704
EMERGENCY STEERING VALVE...4705
BRAKE PIPING...4708
BRAKE VALVE...4709
INCHING VALVE...4713
CHARGE VALVE...4714
ACCUMULATOR (FOR BRAKE)...4718
SLACK ADJUSTER...4719
BRAKE...4721
PARKING BRAKE CONTROL...4726
PARKING BRAKE...4727
HYDRAULIC PIPING...4728
HYDRAULIC TANK...4732
4-GEAR PUMP UNIT...4738
ACCUMULATOR (FOR PPC CIRCUIT)...4740
LOCK VALVE...4741
BYPASS VALVE...4742
QUICK COUPLER VALVE...4748
E.C.S.S. VALVE...4749
ACCUMULATOR (FOR E.C.S.S.)...4751
HYDRAULIC PIPING OF COOLING SYSTEM...4752
COOLING FAN MOTOR...4753
WORK EQUIPMENT CONTROL VALVE...4755
WORK EQUIPMENT PPC VALVE...4768
ATTACHMENT PPC VALVE (IF EQUIPPED)...4776
WORK EQUIPMENT LINKAGE...4780
BUCKET...4784
CONTROL OF BUCKET POSITIONER, BOOM KICK-OUT, AND DUMP SPEED...4786
WORK EQUIPMENT CYLINDER...4800
AIR CONDITIONER (IF EQUIPPED)...4803
MACHINE MONITORING SYSTEM...4804
MACHINE MONITOR...4813
LIST OF ITEMS DISPLAYED ON MONITOR...4814
ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)...4840
HST CONTROLLER...4844
ENGINE START CIRCUIT...4845
ENGINE STOP CIRCUIT...4847
PREHEATING CIRCUIT (AUTOMATIC PREHEATING SYSTEM)...4848
PARKING BRAKE CIRCUIT...4849
ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM...4852
SENSORS...4853
20 TESTING AND ADJUSTING...4859
STANDARD VALUE TABLE FOR ENGINE...4860
STANDARD VALUE TABLE FOR CHASSIS...4861
TESTING AND ADJUSTING...4865
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...4866
MEASURING ENGINE SPEED...4868
MEASURING EXHAUST GAS COLOR...4869
ADJUSTING VALVE CLEARANCE...4870
MEASURING COMPRESSION PRESSURE...4872
MEASURING BLOW-BY PRESSURE...4873
TESTING AND ADJUSTING FUEL INJECTION TIMING...4874
MEASURING ENGINE OIL PRESSURE...4875
MEASURING,TESTING OPERATING FORCE OF ACCELERATOR PEDAL...4876
ADJUSTING ENGINE STOP SOLENOID...4878
ADJUSTING ENGINE SPEED SENSOR...4879
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION...4879
MEASURING DIRECTIONAL LEVER...4880
TESTING AND ADJUSTING HST OIL PRESSURE...4881
MEASURING CLUTCH CONTROL PRESSURE...4885
TESTING AND ADJUSTING STEERING WHEEL...4886
TESTING AND ADJUSTING STEERING OIL PRESSURE...4888
BLEEDING AIR FROM STEERING CIRCUIT...4889
TESTING HYDRAULIC FAN...4890
MEASURING BRAKE PEDAL...4891
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE...4892
MEASURING BRAKE PERFORMANCE...4893
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE...4894
MEASURING BRAKE OIL PRESSURE...4895
MEASURING WEAR OF BRAKE DISC...4897
BLEEDING AIR FROM BRAKE CIRCUIT...4898
MEASURING PARKING BRAKE PERFORMANCE...4899
TESTING AND ADJUSTING PARKING BRAKE LINKAGE...4900
MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL...4902
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE...4903
TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE...4904
BLEEDING AIR...4906
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...4907
TESTING AND ADJUSTING BUCKET POSITIONER...4908
TESTING AND ADJUSTING OF BOOM KICK-OUT...4909
CHECKING PROXIMITY SWITCH ACTUATION DISPLAY LAMP...4910
PROCEDURE FOR CHECKING DIODE...4911
SPECIAL FUNCTIONS OF MACHINE MONITOR...4912
FLOW OF MODES AND FUNCTIONS...4913
FAILURE CODE TABLE...4921
PM CLINIC INSPECTION CHART...4931
TROUBLESHOOTING...4933
POINTS TO REMEMBER WHEN TROUBLESHOOTING...4934
SEQUENCE OF EVENTS IN TROUBLESHOOTING...4935
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...4936
CHECK BEFORE TROUBLESHOOTING...4944
CATEGORIES,PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS...4945
PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO...4946
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...4949
T-ADAPTER TABLE...4971
CONNECTOR TYPES AND MOUNTING LOCATIONS...4974
CONNECTOR LAYOUT DRAWING...4980
TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)...4985
HST CONTROLLER SYSTEM DIAGRAM...4986
BEFORE TROUBLESHOOTING CODE DISPLAY...4988
BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM...4989
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...4990
ERROR CODE [989F00] (HST MOTOR PROTECTION CAUTION (00))...4992
ERROR CODE [DHH1KX] (HST OIL PRESSURE SENSOR INPUT SIGNAL OUTSIDE RANGE (KX))...4993
ERROR CODE [DLE2LC] (ENGINE REVOLUTION SENSOR REVOLUTION SPEED SIGNAL MISMATCH (LC))...4995
ERROR CODE [DW26KZ] (MOTOR 2 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))...4996
ERROR CODE [DX19KZ] (MOTOR 1 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))...4998
ERROR CODE [DX20KZ] (CLUTCH SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))...5000
TROUBLESHOOTING CODE [HST-1] (DEFECTIVE HST CONTROLLER POWER SOURCE (HST CONTROLLER DOES NOT FUNCTION))...5002
TROUBLESHOOTING CODE [HST-2] (TRAVEL SPEED DOES NOT SHIFTED)...5004
TROUBLESHOOTING CODE [HST-3] HST OUTPUT CONTROL (TRACTION CONTROL) CANNOT BE CONTROLLED...5007
TROUBLESHOOTING CODE [HST-4] (TRAVEL SPEED LIMIT CANNOT BE CHANGED WHEN GEAR SPEED SELECTOR SWITCH IS IN"1ST"POSITION)...5009
TROUBLESHOOTING CODE [HST-5] (TRAVEL SPEED IS NOT INCREASED)...5011
TROUBLESHOOTING OF ECSS (ECSS MODE) (IF EQUIPPED)...5013
RELATED ELECTRICAL CIRCUIT DIAGRAM...5014
ECSS-1 MALFUNCTION OF ECSS...5015
TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE)...5020
MONITOR SYSTEM CIRCUIT DIAGRAM...5021
BEFORE TROUBLESHOOTING CODE DISPLAY...5025
BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM...5026
INFORMATION CONTANED IN TROUBLESHOOTING TABLE...5027
ERROR CODE [15B0NX] (HST OIL FILTER CLOGGED (NX))...5029
ERROR CODE [2G42ZG] (DECREASED BRAKE OIL PRESSURE (ZG))...5030
ERROR CODE [989F00] (HST MOTOR PROTECTION CAUTION (00))...5031
ERROR CODE [989FN1] (HST OVERRUNNING (N1))...5032
ERROR CODE [AB00L6] (DEFECTIVE BATTERY CHARGING CIRCUIT (L6))...5033
ERROR CODE [AB00MA] (DEFECTIVE BATTERY CHARGING CIRCUIT (MA))...5034
ERROR CODE [B@BAZG] (DEGREASED ENGINE OIL PRESSURE (ZG))...5035
ERROR CODE [B@BCNS] (ENGINE WATER TEMPERATURE OVERHEATING (NS))...5036
ERROR CODE [B@BCZK] (ALARM INDICATING LOW COOLANT LEVEL (ZK))...5037
ERROR CODE [B@C7NS] (AXLE OIL TEMPERATURE OVERHEATING (NS))...5038
ERROR CODE [B@CRNS] (HST OIL TEMPERATURE OVERHEATING (NS))...5039
ERROR CODE [D5ZHL6] (STARTING SWITCH"C" (IGN"C") INPUT FAILURE (L6))...5040
ERROR CODE [DAF0KT] (CONTROLLER INSIDE FAILURE (KT))...5042
ERROR CODE [DAJ0KR] (HST CONTROLLER COMMUNICATION FAILURE (KR))...5043
ERROE CODE [DD15LD] (MONITOR PANEL MODE SELECTOR SWITCH 1 [■] (PANEL SWITCH 1) INPUT ERROR (LD))...5045
ERROR CODE [DD16LD] (MONITOR PANEL MODE SELECTOR SWITCH 1 [◇] (PANEL SWITCH 2) INPUT ERROR (LD))...5046
ERROR CODE [DD17LD] (MONITOR PANEL MODE SELECTOR SWITCH 2 [<] (PANEL SWITCH 3) INPUT ERROR (LD))...5047
ERROR CODE [DD18LD] (MONITOR PANEL MODE SELECTOR SWITCH 2 [>] (PANEL SWITCH 4) INPUT ERROR (LD))...5048
ERROR CODE [DDK3KB] (MULTIPLE DIRECTIONAL LEVER FR SIGNAL INPUT (KB))...5049
ERROR CODE [DDS5L6] (DECREASED STEERING OIL PRESSURE (L6))...5051
ERROR CODE [DGE2KX] (ENGINE WATER TEMPERATURE (HIGH TEMPERATURE) SENSOR SYSTEM FAILURE (KX))...5052
ERROR CODE [DGE3L6] (ENGINE WATER TEMPERATURE (LOW TEMPERATURE) SENSOR SYSTEM FAILURE (L6))...5053
ERROR CODE [DGH1KX] (HST OIL TEMPERATURE SENSOR SYSTEM FAILURE (KX))...5054
ERROR CODE [DGR4KA] (AXLE OIL TEMPERATURE SENSOR SYSTEM DISCONTINUITY (KA))...5055
ERROR CODE [DGR4KX] (AXLE OIL TEMPERATURE SENSOR SYSTEM FAILURE (KX))...5056
ERROR CODE [DHE4L6] (ENGINE OIL PRESSURE SENSOR SYSTEM DISCONTINUITY (L6))...5057
TROUBLESHOOTING CODE [MON-1] (THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT ON)...5058
TROUBLESHOOTING CODE [MON-2] (THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON)...5062
TROUBLESHOOTING CODE [MON-3] (THE ENGINE WATER TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON, OR AFTER THE ENGINE STARTS, THE ENGINE WATER TEMPERATURE GAUGE DOES NOT RISE.)...5063
TROUBLESHOOTING CODE [MON-4] (THE HST OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON, OR AFTER THE ENGINE STARTS,THE HST OIL TEMPERATURE GAUGE DOES NOT RISE.)...5064
TROUBLESHOOTING CODE [MON-5] (THE FUEL LEVEL GAUGE DOES NOT RISE OR DECREASE.)...5065
TROUBLESHOOTING CODE [MON-6] (THE RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT ON)...5066
TROUBLESHOOTING CODE [MON-7] (THE STEERING OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON)...5067
TROUBLESHOOTING CODE [MON-8] (THE EMERGENCY STEERING OIL PRESSURE INDICATOR LAMP DOES NOT LIGHT ON)...5068
TROUBLESHOOTING CODE [MON-9] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1 [■] (PANEL SWITCH 1))...5069
TROUBLESHOOTING CODE [MON-10] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1 [◇] (PANEL SWITCH 2))...5070
TROUBLESHOOTING CODE [MON-11] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2 [<] (PANEL SWITCH 3))...5071
TROUBLESHOOTING CODE [MON-12] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2 [>] (PANEL SWITCH 4))...5072
TROUBLESHOOTING CODE [MON-13] (THE ALARM BUZZER DOES NOT SOUND OR STOP)...5073
TROUBLESHOOTING CODE [MON-14] THE WIPER DOES NOT FUNCTION...5074
TROUBLESHOOTING CODE [MON-15] THE LAMPS DO NOT WORK PROPERLY...5074
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...5075
ELECTRICAL SYSTEM DIAGRAM...5076
PARKING BRAKE RELATED DIAGRAM...5079
BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM...5081
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...5082
TROUBLESHOOTING CODE [E-1] (THE ENGINE DOES NOT START)...5084
TROUBLESHOOTING CODE [E-2] (THE ENGINE DOES NOT STOP)...5088
TROUBLESHOOTING CODE [E-3] (PREHEATING IS IMPOSSIBLE OR CONSTANT)...5090
TROUBLESHOOTING CODE [E-4] (THE PARKING BRAKE(MECHANICAL TYPE)DOES NOT FUNCTION)...5094
TROUBLESHOOTING CODE [E-5] (DEFECTIVE BOOM KICK-OUT FUNCTION AND CANCELLATION)...5099
TROUBLESHOOTING CODE [E-6] (DEFECTIVE BUCKET POSITIONER FUNCTION AND CANCELLATION)...5102
TROUBLESHOOTING CODE [E-7] (DEFECTIVE LIFT ARM FLOATING HOLDING FUNCTION AND CANCELLATION)...5105
TROUBLESHOOTING CODE [E-8] (TRAVEL DIRECTION IS NOT CHANGED NORMALLY)...5106
TROUBLESHOOTING CODE [E-9] (THE WIPER DOES NOT FUNCTION)...5112
TROUBLESHOOTING CODE [E-10] (THE WINDOW WASHER DOES NOT FUNCTION)...5117
TROUBLESHOOTING CODE [E-11] (LAMPS DO NOT WORK PROPERLY)...5120
TROUBLESHOOTING CODE [E-12] (THE HORN DOES NOT SOUND)...5131
TROUBLESHOOTING CODE [E-13] (DEFECTIVE THE AIR CONDITIONER)...5133
TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM (H MODE)...5145
METHOD OF USING TROUBLESHOOTING CHART...5146
FAILURE CODE AND CAUSE TABLE...5148
H-1 THE MACHINE DOES NOT START...5150
H-2 THE TRAVEL SPEED IS SLOW...5151
H-3 THE THRUSTING FORCE IS WEAK...5152
H-4 ENGINE STALLS WHEN TRAVELING OR ENGINE SPEED DROPS EXCESSIVELY...5153
H-5 THE GEAR IS NOT SHIFTED...5154
H-6 THE STEERING WHEEL DOES NOT TURN...5155
H-7 THE STEERING WHEEL IS HEAVY...5156
H-8 STEERING WHEEL SHAKES OR JERKS...5157
H-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING...5157
H-10 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL...5158
H-11 THE BRAKE IS NOT RELEASED OR IS DRAGGED...5159
H-12 THE LIFT ARM DOES NOT RISE OR LOWER...5160
H-13 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT...5161
H-14 WHEN RISING, THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT...5162
H-15 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET (THE BUCKET RISES IN THE AIR)...5162
H-16 HYDRAULIC DRIFTS OF THE LIFT ARM OCCUR OFTEN...5162
H-17 THE LIFT ARM WOBBLES DURING OPERATION...5162
H-18 WHEN THE CONTROL LEVER IS SWITCHED FROM"HOLD"TO "RAISE", THE LIFT ARM FALLS TEMPORARILY...5163
H-19 THE BUCKET DOES NOT TILT BACK...5164
H-20 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT...5165
H-21 THE BUCKET COMES TO OPERATE SLOWLY IN HE MIDST OF TILTING-BACK...5166
H-22 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET...5166
H-23 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN...5166
H-24 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO(THE WORK EQUIPMENT VALVE IS SET TO"HOLD")...5167
H-25 WHEN THE CONTROL LEVER IS SWITCHED FROM"HOLD"TO"TILT", THE BUCKET FALLS TEMPORARILY...5167
H-26 THE CONTROL LEVERS OF THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY...5167
H-27 THE TRAVEL DAMPER DOES NOT OPERATE AND MACHINE PITCHES AND BOUNCES...5168
TROUBLESHOOTING OF ENGINE (S MODE)...5169
METHOD OF USING TROUBLESHOOTING CHARTS...5170
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...5174
S-2 ENGINE DOES NOT START...5176
(1) ENGINE DOES NOT TURN...5176
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)...5177
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...5178
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...5179
S-4 ENGINE STOPS DURING OPERATIONS...5180
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...5181
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)...5182
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...5183
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...5184
S-9 OIL BECOMES CONTAMINATED QUICKLY...5185
S-10 FUEL CONSUMPTION IS EXCESSIVE...5186
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN...5187
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)...5188
S-13 OIL LEVEL RISES (WATER,FUEL IN OIL)...5189
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...5190
S-15 ABNORMAL NOISE IS MADE...5191
S-16 VIBRATION IS EXCESSIVE...5192
30 DISASSEMBLY AND ASSEMBLY...5193
HOW TO READ THIS MANUAL...5195
REMOVAL AND INSTALLATION OF ASSEMBLIES...5195
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES...5196
PRECAUTIONS WHEN PERFORMING OPERATION...5197
SPECIAL TOOL LIST...5199
SKETCHES OF SPECIAL TOOLS...5202
REMOVAL, INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY...5209
SPECIAL TOOLS...5209
REMOVAL...5209
INSTALLATION...5211
REMOVAL, INSTALLATION OF NOZZLE HOLDER ASSEMBLY...5213
SPECIAL TOOLS...5213
REMOVAL...5213
INSTALLATION...5214
REMOVAL, INSTALLATION OF CYLINDER HEAD ASSEMBLY...5215
SPECIAL TOOLS...5215
REMOVAL...5215
INSTALLATION...5220
REMOVAL, INSTALLATION OF ENGINE ASSEMBLY...5223
REMOVAL...5223
INSTALLATION...5228
REMOVAL, INSTALLATION OF RADIATOR ASSEMBLY...5230
REMOVAL...5230
INSTALLATION...5231
REMOVAL, INSTALLATION OF AIR AFTERCOOLER...5232
REMOVAL...5232
INSTALLATION...5233
REMOVAL, INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY...5234
REMOVAL ...5234
INSTALLATION ...5235
REMOVAL, INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY...5236
REMOVAL...5236
INSTALLATION ...5237
REMOVAL, INSTALLATION OF FUEL TANK ASSEMBLY...5238
REMOVAL...5238
INSTALLATION...5239
REMOVAL, INSTALLATION OF TRANSFER...5240
REMOVAL...5240
INSTALLATION...5242
DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY...5243
SPECIAL TOOLS...5243
DISASSEMBLY...5243
ASSEMBLY...5251
REMOVAL, INSTALLATION OF PARKING BRAKE ASSEMBLY...5263
REMOVAL...5263
INSTALLATION...5264
DISASSEMBLY, ASSEMBLY OF PARKING BRAKE ASSEMBLY...5265
SPECIAL TOOLS...5265
DISASSEMBLY...5265
ASSEMBLY...5267
REMOVAL, INSTALLATION OF FRONT AXLE ASSEMBLY...5270
REMOVAL...5270
INSTALLATION...5271
REMOVAL, INSTALLATION OF REAR AXLE ASSEMBLY...5272
REMOVAL...5272
INSTALLATION...5274
DISASSEMBLY, ASSEMBLY OF AXLE HOUSING ASSEMBLY...5275
SPECIAL TOOLS...5275
DISASSEMBLY...5275
ASSEMBLY...5278
DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY...5284
SPECIAL TOOLS...5284
DISASSEMBLY...5284
ASSEMBLY...5293
DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY...5310
SPECIAL TOOLS LIST...5310
DISASSEMBLY...5310
ASSEMBLY...5319
DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY...5337
SPECIAL TOOLS LIST...5337
DISASSEMBLY...5337
ASSEMBLY...5346
REMOVAL, INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY...5353
REMOVAL...5353
INSTALLATION...5354
REMOVAL, INSTALLATION OF TRAVEL DAMPER VALVE ASSEMBLY (IF EQUIPPED)...5355
REMOVAL...5355
INSTALLATION...5356
REMOVAL, INSTALLATION OF HYDRAULIC TANK ASSEMBLY...5357
REMOVAL...5357
INSTALLATION...5358
REMOVAL, INSTALLATION OF WORK EQUIPMENT ASSEMBLY...5359
REMOVAL...5359
INSTALLATION...5362
DISASSEMBLY, ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY...5366
SPECIAL TOOLS...5366
DISASSEMBLY...5367
ASSEMBLY...5370
REMOVAL, INSTALLATION OF OPERATOR'S CAB ASSEMBLY...5375
REMOVAL...5375
INSTALLATION...5378
REMOVAL, INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)...5379
SPECIAL TOOLS...5379
REMOVAL...5379
INSTALLATION...5380
COATING MATERIALS...5386
REMOVAL, NSTALLATION OF CENTER HINGE PIN ...5387
REMOVAL...5387
INSTALLATION...5391
REMOVAL, INSTALLATION OF COUNTERWEIGHT...5396
REMOVAL...5396
INSTALLATION ...5397
REMOVAL, INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY...5398
SPECIAL TOOLS...5398
REMOVAL...5398
INSTALLATION...5399
REMOVAL, INSTALLATION OF CONDITIONER COMPRESSOR ASSEMBLY...5400
SPECIAL TOOLS...5400
REMOVAL...5400
INSTALLATION...5400
REMOVAL, INSTALLATION OF MONITOR PANEL...5401
REMOVAL...5401
INSTALLATION...5404
REMOVAL, INSTALLATION OF HST CONTROLLER ASSEMBLY...5405
REMOVAL...5405
INSTALLATION...5405
90 OTHERS...5406
HYDRAULIC CIRCUIT DIAGRAM WA250-5...5407
HYDRAULIC CIRCUIT DIAGRAM WA250PT-5...5408
ELECTRICAL CIRCUIT DIAGRAM 1/4 (1/4) (MACHINES EQUIPPED WITH ROPS CAB)...5409
ELECTRICAL CIRCUIT DIAGRAM 1/4 (2/4) (MACHINES EQUIPPED WITH ROPS CAB)...5410
ELECTRICAL CRICUIT DIAGRAM 1/4 (3/4) (MACHINES EQUIPPED WITH ROPS CAB)...5411
ELECTRICAL CRICUIT DIAGRAM 1/4 (4/4) (MACHINES EQUIPPED WITH ROPS CAB)...5412
ELECTRICAL CIRCUIT DIAGRAM 2/4 (MACHINES EQUIPPED WITH ROPS CAB)...5413
ELECTRICAL CIRCUIT DIAGRAM 3/4 (MACHINES EQUIPPED WITH ROPS CAB)...5414
ELECTRICAL CIRCUIT DIAGRAM 4/4 (MACHINES EQUIPPED WITH ROPS CAB)...5415
ELECTRICAL CIRCUIT DIAGRAM 1/4 (1/4) (MACHINES EQUIPPED WITH ROPS CANOPY...5416
ELECTRICAL CIRCUIT DIAGRAM 1/4 (2/4) (MACHINES EQUIPPED WITH ROPS CANOPY)...5417
ELECTRICAL CIRCUIT DIAGRAM 1/4 (3/4) (MACHINE EQUIPPED WITH ROPS CANOPY)...5418
ELECTRICAL CIRCUIT DIAGRAM 1/4 (4/4) (MACHINE EQUIPPED WITH ROPS CANOPY)...5419
ELECTRICAL CIRCUIT DIAGRAM 2/4 (MACHINES EQUIPPED WITH ROPS CANOPY)...5420
ELECTRICAL CIRCUIT DIAGRAM 3/4 (MACHINES EQUIPPED WITH ROPS CANOPY)...5421
ELECTRICAL CIRCUIT DIAGRAM 4/4 (MACHINES EQUIPPED WITH ROPS CANOPY)...5422
SEBM033209 - Wheel Loader WA250-5, WA250PT-5 Shop Manual...5423
COVER...5423
CONTENTS...5424
LIST OF REVISED PAGES...5425
SAFETY...5429
SAFETY NOTICE...5429
FOREWORD...5431
GENERAL...5431
HOW TO READ THE SHOP MANUAL...5432
HOISTING INSTRUCTIONS...5433
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER...5434
COATING MATERIALS...5436
STANDARD TIGHTENING TORQUE...5438
ELECTRIC WIRE CODE...5441
CONVERSION TABLE...5442
UNITS...5448
01 GENERAL...5449
GENERAL ASSEMBLY DRAWINGS...5450
SPECIFICATIONS...5451
WEIGHT TABLE...5455
LIST OF LUBRICANT AND COOLANT...5457
10 STRUCTURE,FUNCTION AND MAINTENANCE STANDARD...5459
ENGINE MOUNT AND TRANSFER MOUNT...5460
DAMPER...5461
COOLING SYSTEM...5462
TRANSFER OIL COOLER...5463
POWER TRAIN...5466
POWER TRAIN SYSTEM DIAGRAM...5468
DRIVE SHAFT (PROPELLER SHAFT)...5470
HST HYDRAULIC PIPING DIAGRAM...5471
HST PUMP...5472
HIGH-PRESSURE RELIEF VALVE...5474
LOW-PRESSURE RELIEF VALVE...5476
HST CHARGE PUMP...5477
SPEED-RELATED VALVE (DA VALVE)...5478
HIGH-PRESSURE CUT-OFF VALVE...5479
HST MOTOR...5480
EP SERVO VALVE...5483
HA SERVO VALVE...5484
FORWARD-REVERSE SHUTTLE VALVE...5485
TRANSFER...5486
CLUTCH SOLENOID VALVE...5497
AXLE...5498
DIFFERENTIAL...5500
LIMITED-SLIP DIFFERENTIAL...5506
FINAL DRIVE...5512
AXLE MOUNTING AND CENTER HINGE PIN...5518
STEERING PIPING...5523
STEERING COLUMN...5524
PRIORITY VALVE...5525
ORBIT-ROLL VALVE...5528
2-WAY RESTRICTOR VALVE...5536
CUSHION VALVE...5537
STEERING CYLINDER...5538
EMERGENCY STEERING PIPING...5540
EMERGENCY STEERING VALVE...5541
BRAKE PIPING...5544
BRAKE VALVE...5545
INCHING VALVE...5549
CHARGE VALVE...5550
ACCUMULATOR (FOR BRAKE)...5554
SLACK ADJUSTER...5555
BRAKE...5558
PARKING BRAKE CONTROL...5563
PARKING BRAKE...5564
HYDRAULIC PIPING...5566
HYDRAULIC TANK...5574
4-GEAR PUMP UNIT...5576
ACCUMULATOR (FOR PPC CIRCUIT)...5578
LOCK VALVE...5579
BYPASS VALVE...5580
QUICK COUPLER VALVE...5586
E.C.S.S. VALVE...5587
ACCUMULATOR (FOR E.C.S.S.)...5589
HYDRAULIC PIPING OF COOLING SYSTEM...5590
COOLING FAN MOTOR...5591
WORK EQUIPMENT CONTROL VALVE...5593
WORK EQUIPMENT PPC VALVE...5606
ATTACHMENT PPC VALVE (IF EQUIPPED)...5614
WORK EQUIPMENT LINKAGE...5618
BUCKET...5622
CONTROL OF BUCKET POSITIONER, BOOM KICK-OUT, AND DUMP SPEED...5624
WORK EQUIPMENT CYLINDER...5639
AIR CONDITIONER (IF EQUIPPED)...5642
MACHINE MONITORING SYSTEM...5643
MACHINE MONITOR...5653
LIST OF ITEMS DISPLAYED ON MONITOR...5654
ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)...5680
HST CONTROLLER...5684
ENGINE START CIRCUIT...5685
ENGINE STOP CIRCUIT...5687
PREHEATING CIRCUIT (AUTOMATIC PREHEATING SYSTEM)...5688
PARKING BRAKE CIRCUIT...5689
ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM...5692
SENSORS...5693
20 TESTING AND ADJUSTING...5699
STANDARD VALUE TABLE FOR ENGINE...5700
STANDARD VALUE TABLE FOR CHASSIS...5701
TESTING AND ADJUSTING...5705
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...5706
MEASURING ENGINE SPEED...5708
MEASURING EXHAUST GAS COLOR...5709
ADJUSTING VALVE CLEARANCE...5710
MEASURING COMPRESSION PRESSURE...5712
MEASURING BLOW-BY PRESSURE...5713
TESTING AND ADJUSTING FUEL INJECTION TIMING...5714
MEASURING ENGINE OIL PRESSURE...5715
MEASURING,TESTING OPERATING FORCE OF ACCELERATOR PEDAL...5716
ADJUSTING ENGINE STOP SOLENOID...5718
ADJUSTING ENGINE SPEED SENSOR...5719
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION...5719
MEASURING DIRECTIONAL LEVER...5720
TESTING AND ADJUSTING HST OIL PRESSURE...5721
MEASURING CLUTCH CONTROL PRESSURE...5726
TESTING AND ADJUSTING STEERING WHEEL...5727
TESTING AND ADJUSTING STEERING OIL PRESSURE...5729
BLEEDING AIR FROM STEERING CIRCUIT...5730
TESTING HYDRAULIC FAN...5731
MEASURING BRAKE PEDAL...5732
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE...5733
MEASURING BRAKE PERFORMANCE...5734
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE...5735
MEASURING BRAKE OIL PRESSURE...5736
MEASURING WEAR OF BRAKE DISC...5738
BLEEDING AIR FROM BRAKE CIRCUIT...5739
MEASURING PARKING BRAKE PERFORMANCE...5740
TESTING AND ADJUSTING PARKING BRAKE LINKAGE...5741
MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL...5743
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE...5744
TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE...5745
BLEEDING AIR...5747
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...5748
TESTING AND ADJUSTING BUCKET POSITIONER...5749
TESTING AND ADJUSTING OF BOOM KICK-OUT...5750
CHECKING PROXIMITY SWITCH ACTUATION DISPLAY LAMP...5751
PROCEDURE FOR CHECKING DIODE...5752
SPECIAL FUNCTIONS OF MACHINE MONITOR...5753
FLOW OF MODES AND FUNCTIONS...5754
FAILURE CODE TABLE...5762
PM CLINIC INSPECTION CHART...5772
TROUBLESHOOTING...5775
POINTS TO REMEMBER WHEN TROUBLESHOOTING...5776
SEQUENCE OF EVENTS IN TROUBLESHOOTING...5777
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...5778
CHECK BEFORE TROUBLESHOOTING...5786
CATEGORIES,PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS...5787
PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO...5788
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...5792
T-ADAPTER TABLE...5814
CONNECTOR TYPES AND MOUNTING LOCATIONS...5817
CONNECTOR LAYOUT DRAWING...5824
TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)...5829
HST CONTROLLER SYSTEM DIAGRAM...5830
BEFORE TROUBLESHOOTING CODE DISPLAY...5832
BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM...5833
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...5834
ERROR CODE [989F00] (HST MOTOR PROTECTION CAUTION (00))...5836
ERROR CODE [DHH1KX] (HST OIL PRESSURE SENSOR INPUT SIGNAL OUTSIDE RANGE (KX))...5837
ERROR CODE [DLE2LC] (ENGINE REVOLUTION SENSOR REVOLUTION SPEED SIGNAL MISMATCH (LC))...5839
ERROR CODE [DW26KZ] (MOTOR 2 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))...5840
ERROR CODE [DX19KZ] (MOTOR 1 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))...5842
ERROR CODE [DX20KZ] (CLUTCH SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))...5844
TROUBLESHOOTING CODE [HST-1] (DEFECTIVE HST CONTROLLER POWER SOURCE (HST CONTROLLER DOES NOT FUNCTION))...5846
TROUBLESHOOTING CODE [HST-2] (TRAVEL SPEED DOES NOT SHIFTED)...5848
TROUBLESHOOTING CODE [HST-3] HST OUTPUT CONTROL (TRACTION CONTROL) CANNOT BE CONTROLLED...5851
TROUBLESHOOTING CODE [HST-4] (TRAVEL SPEED LIMIT CANNOT BE CHANGED WHEN GEAR SPEED SELECTOR SWITCH IS IN"1ST"POSITION)...5853
TROUBLESHOOTING CODE [HST-5] (TRAVEL SPEED IS NOT INCREASED)...5855
TROUBLESHOOTING OF ECSS (ECSS MODE) (IF EQUIPPED)...5857
RELATED ELECTRICAL CIRCUIT DIAGRAM...5858
ECSS-1 MALFUNCTION OF ECSS...5859
TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE)...5865
MONITOR SYSTEM CIRCUIT DIAGRAM...5866
BEFORE TROUBLESHOOTING CODE DISPLAY...5870
BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM...5871
INFORMATION CONTANED IN TROUBLESHOOTING TABLE...5872
ERROR CODE [15B0NX] (HST OIL FILTER CLOGGED (NX))...5874
ERROR CODE [2G42ZG] (DECREASED BRAKE OIL PRESSURE (ZG))...5875
ERROR CODE [989F00] (HST MOTOR PROTECTION CAUTION (00))...5876
ERROR CODE [989FN1] (HST OVERRUNNING (N1))...5877
ERROR CODE [AB00L6] (DEFECTIVE BATTERY CHARGING CIRCUIT (L6))...5878
ERROR CODE [AB00MA] (DEFECTIVE BATTERY CHARGING CIRCUIT (MA))...5879
ERROR CODE [B@BAZG] (DEGREASED ENGINE OIL PRESSURE (ZG))...5880
ERROR CODE [B@BCNS] (ENGINE WATER TEMPERATURE OVERHEATING (NS))...5881
ERROR CODE [B@BCZK] (ALARM INDICATING LOW COOLANT LEVEL (ZK))...5882
ERROR CODE [B@C7NS] (AXLE OIL TEMPERATURE OVERHEATING (NS))...5883
ERROR CODE [B@CRNS] (HST OIL TEMPERATURE OVERHEATING (NS))...5884
ERROR CODE [D5ZHL6] (STARTING SWITCH"C" (IGN"C") INPUT FAILURE (L6))...5886
ERROR CODE [DAF0KT] (CONTROLLER INSIDE FAILURE (KT))...5888
ERROR CODE [DAJ0KR] (HST CONTROLLER COMMUNICATION FAILURE (KR))...5890
ERROE CODE [DD15LD] (MONITOR PANEL MODE SELECTOR SWITCH 1 [■] (PANEL SWITCH 1) INPUT ERROR (LD))...5892
ERROR CODE [DD16LD] (MONITOR PANEL MODE SELECTOR SWITCH 1 [◇] (PANEL SWITCH 2) INPUT ERROR (LD))...5893
ERROR CODE [DD17LD] (MONITOR PANEL MODE SELECTOR SWITCH 2 [<] (PANEL SWITCH 3) INPUT ERROR (LD))...5894
ERROR CODE [DD18LD] (MONITOR PANEL MODE SELECTOR SWITCH 2 [>] (PANEL SWITCH 4) INPUT ERROR (LD))...5895
ERROR CODE [DDK3KB] (MULTIPLE DIRECTIONAL LEVER FR SIGNAL INPUT (KB))...5896
ERROR CODE [DDS5L6] (DECREASED STEERING OIL PRESSURE (L6))...5898
ERROR CODE [DGE2KX] (ENGINE WATER TEMPERATURE (HIGH TEMPERATURE) SENSOR SYSTEM FAILURE (KX))...5899
ERROR CODE [DGE3L6] (ENGINE WATER TEMPERATURE (LOW TEMPERATURE) SENSOR SYSTEM FAILURE (L6))...5900
ERROR CODE [DGH1KX] (HST OIL TEMPERATURE SENSOR SYSTEM FAILURE (KX))...5901
ERROR CODE [DGR4KA] (AXLE OIL TEMPERATURE SENSOR SYSTEM DISCONTINUITY (KA))...5902
ERROR CODE [DGR4KX] (AXLE OIL TEMPERATURE SENSOR SYSTEM FAILURE (KX))...5903
ERROR CODE [DHE4L6] (ENGINE OIL PRESSURE SENSOR SYSTEM DISCONTINUITY (L6))...5904
TROUBLESHOOTING CODE [MON-1] (THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT ON)...5906
TROUBLESHOOTING CODE [MON-2] (THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON)...5910
TROUBLESHOOTING CODE [MON-3] (THE ENGINE WATER TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON, OR AFTER THE ENGINE STARTS, THE ENGINE WATER TEMPERATURE GAUGE DOES NOT RISE.)...5911
TROUBLESHOOTING CODE [MON-4] (THE HST OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON, OR AFTER THE ENGINE STARTS,THE HST OIL TEMPERATURE GAUGE DOES NOT RISE.)...5912
TROUBLESHOOTING CODE [MON-5] (THE FUEL LEVEL GAUGE DOES NOT RISE OR DECREASE.)...5913
TROUBLESHOOTING CODE [MON-6] (THE RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT ON)...5914
TROUBLESHOOTING CODE [MON-7] (THE STEERING OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON)...5915
TROUBLESHOOTING CODE [MON-8] (THE EMERGENCY STEERING OIL PRESSURE INDICATOR LAMP DOES NOT LIGHT ON)...5916
TROUBLESHOOTING CODE [MON-9] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1 [■] (PANEL SWITCH 1))...5917
TROUBLESHOOTING CODE [MON-10] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1 [◇] (PANEL SWITCH 2))...5918
TROUBLESHOOTING CODE [MON-11] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2 [<] (PANEL SWITCH 3))...5919
TROUBLESHOOTING CODE [MON-12] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2 [>] (PANEL SWITCH 4))...5920
TROUBLESHOOTING CODE [MON-13] (THE ALARM BUZZER DOES NOT SOUND OR STOP)...5921
TROUBLESHOOTING CODE [MON-14] THE WIPER DOES NOT FUNCTION...5922
TROUBLESHOOTING CODE [MON-15] THE LAMPS DO NOT WORK PROPERLY...5922
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...5923
ELECTRICAL SYSTEM DIAGRAM...5924
PARKING BRAKE RELATED DIAGRAM...5928
BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM...5930
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...5932
TROUBLESHOOTING CODE [E-1] (THE ENGINE DOES NOT START)...5934
TROUBLESHOOTING CODE [E-2] (THE ENGINE DOES NOT STOP)...5938
TROUBLESHOOTING CODE [E-3] (PREHEATING IS IMPOSSIBLE OR CONSTANT)...5940
TROUBLESHOOTING CODE [E-4] (THE PARKING BRAKE(MECHANICAL TYPE)DOES NOT FUNCTION)...5944
TROUBLESHOOTING CODE [E-5] (DEFECTIVE BOOM KICK-OUT FUNCTION AND CANCELLATION)...5951
TROUBLESHOOTING CODE [E-6] (DEFECTIVE BUCKET POSITIONER FUNCTION AND CANCELLATION)...5954
TROUBLESHOOTING CODE [E-7] (DEFECTIVE LIFT ARM FLOATING HOLDING FUNCTION AND CANCELLATION)...5957
TROUBLESHOOTING CODE [E-8] (TRAVEL DIRECTION IS NOT CHANGED NORMALLY)...5958
TROUBLESHOOTING CODE [E-9] (THE WIPER DOES NOT FUNCTION)...5964
TROUBLESHOOTING CODE [E-10] (THE WINDOW WASHER DOES NOT FUNCTION)...5970
TROUBLESHOOTING CODE [E-11] (LAMPS DO NOT WORK PROPERLY)...5973
TROUBLESHOOTING CODE [E-12] (THE HORN DOES NOT SOUND)...5984
TROUBLESHOOTING CODE [E-13] (DEFECTIVE THE AIR CONDITIONER)...5986
TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM (H MODE)...5999
METHOD OF USING TROUBLESHOOTING CHART...6000
FAILURE CODE AND CAUSE TABLE...6002
H-1 THE MACHINE DOES NOT START...6004
H-2 THE TRAVEL SPEED IS SLOW...6005
H-3 THE THRUSTING FORCE IS WEAK...6006
H-4 ENGINE STALLS WHEN TRAVELING OR ENGINE SPEED DROPS EXCESSIVELY...6007
H-5 THE GEAR IS NOT SHIFTED...6008
H-6 THE STEERING WHEEL DOES NOT TURN...6009
H-7 THE STEERING WHEEL IS HEAVY...6010
H-8 STEERING WHEEL SHAKES OR JERKS...6011
H-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING...6011
H-10 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL...6012
H-11 THE BRAKE IS NOT RELEASED OR IS DRAGGED...6013
H-12 THE LIFT ARM DOES NOT RISE OR LOWER...6015
H-13 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT...6016
H-14 WHEN RISING, THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT...6017
H-15 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET (THE BUCKET RISES IN THE AIR)...6017
H-16 HYDRAULIC DRIFTS OF THE LIFT ARM OCCUR OFTEN...6017
H-17 THE LIFT ARM WOBBLES DURING OPERATION...6017
H-18 WHEN THE CONTROL LEVER IS SWITCHED FROM"HOLD"TO "RAISE", THE LIFT ARM FALLS TEMPORARILY...6018
H-19 THE BUCKET DOES NOT TILT BACK...6019
H-20 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT...6020
H-21 THE BUCKET COMES TO OPERATE SLOWLY IN HE MIDST OF TILTING-BACK...6021
H-22 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET...6021
H-23 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN...6021
H-24 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO(THE WORK EQUIPMENT VALVE IS SET TO"HOLD")...6022
H-25 WHEN THE CONTROL LEVER IS SWITCHED FROM"HOLD"TO"TILT", THE BUCKET FALLS TEMPORARILY...6022
H-26 THE CONTROL LEVERS OF THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY...6022
H-27 THE TRAVEL DAMPER DOES NOT OPERATE AND MACHINE PITCHES AND BOUNCES...6023
TROUBLESHOOTING OF ENGINE (S MODE)...6025
METHOD OF USING TROUBLESHOOTING CHARTS...6026
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...6030
S-2 ENGINE DOES NOT START...6032
(1) ENGINE DOES NOT TURN...6032
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)...6033
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...6034
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...6035
S-4 ENGINE STOPS DURING OPERATIONS...6036
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...6037
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)...6038
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...6039
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...6040
S-9 OIL BECOMES CONTAMINATED QUICKLY...6041
S-10 FUEL CONSUMPTION IS EXCESSIVE...6042
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN...6043
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)...6044
S-13 OIL LEVEL RISES (WATER,FUEL IN OIL)...6045
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...6046
S-15 ABNORMAL NOISE IS MADE...6047
S-16 VIBRATION IS EXCESSIVE...6048
30 DISASSEMBLY AND ASSEMBLY...6049
HOW TO READ THIS MANUAL...6051
REMOVAL AND INSTALLATION OF ASSEMBLIES...6051
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES...6052
PRECAUTIONS WHEN PERFORMING OPERATION...6053
SPECIAL TOOL LIST...6055
SKETCHES OF SPECIAL TOOLS...6058
REMOVAL, INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY...6066
SPECIAL TOOLS...6066
REMOVAL...6066
INSTALLATION...6068
REMOVAL, INSTALLATION OF NOZZLE HOLDER ASSEMBLY...6070
SPECIAL TOOLS...6070
REMOVAL...6070
INSTALLATION...6071
REMOVAL, INSTALLATION OF CYLINDER HEAD ASSEMBLY...6072
SPECIAL TOOLS...6072
REMOVAL...6072
INSTALLATION...6077
REMOVAL, INSTALLATION OF ENGINE ASSEMBLY...6080
REMOVAL...6080
INSTALLATION...6085
REMOVAL, INSTALLATION OF RADIATOR ASSEMBLY...6087
REMOVAL...6087
INSTALLATION...6088
REMOVAL, INSTALLATION OF AIR AFTERCOOLER...6089
REMOVAL...6089
INSTALLATION...6090
REMOVAL, INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY...6091
REMOVAL ...6091
INSTALLATION ...6092
REMOVAL, INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY...6093
REMOVAL...6093
INSTALLATION ...6094
REMOVAL, INSTALLATION OF FUEL TANK ASSEMBLY...6095
REMOVAL...6095
INSTALLATION...6096
REMOVAL, INSTALLATION OF TRANSFER...6097
REMOVAL...6097
INSTALLATION...6099
DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY...6100
SPECIAL TOOLS...6100
DISASSEMBLY...6100
ASSEMBLY...6108
REMOVAL, INSTALLATION OF PARKING BRAKE ASSEMBLY...6120
REMOVAL...6120
INSTALLATION...6121
DISASSEMBLY, ASSEMBLY OF PARKING BRAKE ASSEMBLY...6122
SPECIAL TOOLS...6122
DISASSEMBLY...6122
ASSEMBLY...6124
REMOVAL, INSTALLATION OF FRONT AXLE ASSEMBLY...6127
REMOVAL...6127
INSTALLATION...6128
REMOVAL, INSTALLATION OF REAR AXLE ASSEMBLY...6129
REMOVAL...6129
INSTALLATION...6131
DISASSEMBLY, ASSEMBLY OF AXLE HOUSING ASSEMBLY...6132
SPECIAL TOOLS...6132
DISASSEMBLY...6132
ASSEMBLY...6135
DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY...6141
SPECIAL TOOLS...6141
DISASSEMBLY...6141
ASSEMBLY...6150
DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY...6167
SPECIAL TOOLS LIST...6167
DISASSEMBLY...6167
ASSEMBLY...6176
DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY...6194
SPECIAL TOOLS LIST...6194
DISASSEMBLY...6194
ASSEMBLY...6203
REMOVAL, INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY...6210
REMOVAL...6210
INSTALLATION...6211
REMOVAL, INSTALLATION OF TRAVEL DAMPER VALVE ASSEMBLY (IF EQUIPPED)...6212
REMOVAL...6212
INSTALLATION...6213
REMOVAL, INSTALLATION OF HYDRAULIC TANK ASSEMBLY...6214
REMOVAL...6214
INSTALLATION...6215
REMOVAL, INSTALLATION OF WORK EQUIPMENT ASSEMBLY...6216
REMOVAL...6216
INSTALLATION...6219
DISASSEMBLY, ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY...6223
SPECIAL TOOLS...6223
DISASSEMBLY...6224
ASSEMBLY...6227
REMOVAL, INSTALLATION OF OPERATOR'S CAB ASSEMBLY...6233
REMOVAL...6233
INSTALLATION...6236
REMOVAL, INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)...6237
SPECIAL TOOLS...6237
REMOVAL...6237
INSTALLATION...6238
COATING MATERIALS...6244
REMOVAL, NSTALLATION OF CENTER HINGE PIN ...6245
REMOVAL...6245
INSTALLATION...6249
REMOVAL, INSTALLATION OF COUNTERWEIGHT...6254
REMOVAL...6254
INSTALLATION ...6255
REMOVAL, INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY...6256
SPECIAL TOOLS...6256
REMOVAL...6256
INSTALLATION...6257
REMOVAL, INSTALLATION OF CONDITIONER COMPRESSOR ASSEMBLY...6258
SPECIAL TOOLS...6258
REMOVAL...6258
INSTALLATION...6258
REMOVAL, INSTALLATION OF MONITOR PANEL...6259
REMOVAL...6259
INSTALLATION...6262
REMOVAL, INSTALLATION OF HST CONTROLLER ASSEMBLY...6263
REMOVAL...6263
INSTALLATION...6263
90 OTHERS...6265
HYDRAULIC CIRCUIT DIAGRAM WA250-5...6267
HYDRAULIC CIRCUIT DIAGRAM WA250PT-5...6268
ELECTRICAL CIRCUIT DIAGRAM 1/4 (1/4) (MACHINES EQUIPPED WITH ROPS CAB)...6269
ELECTRICAL CIRCUIT DIAGRAM 1/4 (2/4) (MACHINES EQUIPPED WITH ROPS CAB)...6270
ELECTRICAL CRICUIT DIAGRAM 1/4 (3/4) (MACHINES EQUIPPED WITH ROPS CAB)...6271
ELECTRICAL CRICUIT DIAGRAM 1/4 (4/4) (MACHINES EQUIPPED WITH ROPS CAB)...6272
ELECTRICAL CIRCUIT DIAGRAM 2/4 (MACHINES EQUIPPED WITH ROPS CAB)...6273
ELECTRICAL CIRCUIT DIAGRAM 3/4 (MACHINES EQUIPPED WITH ROPS CAB)...6274
ELECTRICAL CIRCUIT DIAGRAM 4/4 (MACHINES EQUIPPED WITH ROPS CAB)...6275
ELECTRICAL CIRCUIT DIAGRAM 1/4 (1/4) (MACHINES EQUIPPED WITH ROPS CANOPY...6276
ELECTRICAL CIRCUIT DIAGRAM 1/4 (2/4) (MACHINES EQUIPPED WITH ROPS CANOPY)...6277
ELECTRICAL CIRCUIT DIAGRAM 1/4 (3/4) (MACHINE EQUIPPED WITH ROPS CANOPY)...6278
ELECTRICAL CIRCUIT DIAGRAM 1/4 (4/4) (MACHINE EQUIPPED WITH ROPS CANOPY)...6279
ELECTRICAL CIRCUIT DIAGRAM 2/4 (MACHINES EQUIPPED WITH ROPS CANOPY)...6280
ELECTRICAL CIRCUIT DIAGRAM 3/4 (MACHINES EQUIPPED WITH ROPS CANOPY)...6281
ELECTRICAL CIRCUIT DIAGRAM 4/4 (MACHINES EQUIPPED WITH ROPS CANOPY)...6282
TEN00084-00 - Wheel Loader GALEO WA250L-5 Operation & Maintenance Manual...6283
COVER...6283
FOREWORD...6284
FOREWORD...6285
SAFETY INFORMATION...6288
INTRODUCTION...6290
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...6290
NECESSARY INFORMATION...6291
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...6291
ENGINE SERIAL NO. PLATE...6291
POSITION OF SERVICE METER...6292
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...6292
CONTENTS...6293
SAFETY...6296
SAFETY...6297
SAFETY LABELS...6300
LOCATION OF SAFETY LABELS...6300
SAFETY LABELS...6301
GENERAL PRECAUTIONS...6306
SAFETY RULES...6306
IF ABNORMALITIES ARE FOUND...6306
CLOTHING AND PERSONAL PROTECTIVE ITEMS...6306
FIRE EXTINGUISHER AND FIRST AID KIT...6306
SAFETY FEATURES...6306
KEEP MACHINE CLEAN...6307
INSIDE OPERATOR'S COMPARTMENT...6307
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT...6307
HANDRAILS AND STEPS...6308
MOUNTING AND DISMOUNTING...6309
NO PEOPLE ON ATTACHMENTS ...6309
DO NOT GET CAUGHT IN ARTICULATED PORTION...6309
PREVENTION OF BURNS...6309
FIRE PREVENTION...6310
ACTION IF FIRE OCCURS...6311
WINDOW WASHER LIQUID...6311
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)...6311
PRECAUTIONS FOR ATTACHMENTS, OPTIONS...6311
UNAUTHORIZED MODIFICATION...6311
SAFETY AT WORKSITE...6312
WORKING ON LOOSE GROUND...6312
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...6312
ENSURE GOOD VISIBILITY...6313
VENTILATION FOR ENCLOSED AREAS...6313
CHECKING SIGNALMAN'S SIGNALS AND SIGNS...6313
EMERGENCY EXIT FROM OPERATOR'S CAB...6313
BE CAREFUL ABOUT ASBESTOS DUST...6314
PRECAUTIONS FOR OPERATION...6315
STARTING ENGINE...6315
CHECKS BEFORE STARTING ENGINE...6315
PRECAUTIONS WHEN STARTING...6315
PRECAUTIONS IN COLD AREAS...6316
OPERATION...6317
CHECKS BEFORE OPERATION...6317
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE...6317
PRECAUTIONS WHEN TRAVELING...6318
TRAVELING ON SLOPES...6319
PROHIBITED OPERATIONS...6320
PRECAUTIONS WHEN OPERATING...6320
METHODS OF USING BRAKE...6321
OPERATE CAREFULLY ON SNOW...6321
PARKING MACHINE...6322
TRANSPORTATION...6323
LOADING AND UNLOADING...6323
SHIPPING...6323
BATTERY...6324
BATTERY HAZARD PREVENTION...6324
STARTING WITH BOOSTER CABLES...6325
TOWING...6326
WHEN TOWING...6326
PRECAUTIONS FOR MAINTENANCE...6327
WARNING TAG...6327
KEEP WORK PLACE CLEAN AND TIDY...6327
APPOINT LEADER WHEN WORKING WITH OTHERS...6327
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...6328
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...6329
INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF...6329
PROPER TOOLS...6330
ACCUMULATOR...6330
PERSONNEL...6330
ATTACHMENTS...6330
WORK UNDER THE MACHINE...6331
NOISE...6331
PRECAUTIONS WHEN USING HAMMER...6331
REPAIR WELDING...6331
REMOVING BATTERY TERMINAL...6331
PRECAUTIONS WITH HIGH-PRESSURE OIL...6332
HANDLING HIGH-PRESSURE HOSES...6332
WASTE MATERIALS...6332
MAINTENANCE OF AIR CONDITIONER...6332
COMPRESSED AIR...6333
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...6333
PRECAUTIONS WITH TIRES...6334
HANDLING TIRES...6334
PRECAUTIONS WHEN STORING TIRES...6334
OPERATION...6335
GENERAL VIEW...6336
GENERAL VIEW OF MACHINE...6336
GENERAL VIEW OF CONTROLS AND GAUGES...6337
EXPLANATION OF COMPONENTS...6339
MACHINE MONITOR...6339
SWITCHES...6365
CONTROL LEVERS, PEDALS...6374
STEERING TILT LOCK LEVER...6378
CAP AND COVER WITH LOCK...6378
FRAME LOCK BAR...6379
TOWING PIN...6380
GREASE PUMP...6380
CAB DOOR INNER LOCK...6380
CAB DOOR OPEN LOCK...6381
CAB WINDOW OPEN LOCK CANCEL KNOB...6381
FUSE...6381
SLOW BLOW FUSE...6383
POWER OUTLET...6383
STORAGE BOX...6383
AM/FM RADIO-CASSETTE STEREO...6384
AIR CONDITIONER...6392
HANDLING CAB WIPER...6397
OPERATION...6398
CHECK BEFORE STARTING ENGINE, ADJUST...6398
STARTING ENGINE...6413
OPERATIONS AND CHECKS AFTER STARTING ENGINE...6415
STOPPING ENGINE...6417
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...6418
TURNING...6423
OPERATION OF WORK EQUIPMENT...6425
WORK POSSIBLE USING WHEEL LOADER...6427
PRECAUTIONS FOR OPERATION...6432
ADJUSTING WORK EQUIPMENT POSTURE...6434
PARKING MACHINE...6436
CHECKS AFTER COMPLETION OF OPERATION...6438
LOCKING...6438
HANDLING THE TIRES...6439
TRANSPORTATION...6441
TRANSPORTATION PROCEDURE...6441
LOADING, UNLOADING WORK WITH TRAILERS...6441
LIFTING MACHINE...6445
COLD WEATHER OPERATION...6447
PRECAUTIONS FOR LOW TEMPERATURE...6447
PRECAUTIONS AFTER COMPLETION OF WORK...6448
AFTER COLD WEATHER...6448
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...6449
LONG-TERM STORAGE...6450
BEFORE STORAGE...6450
DURING STORAGE...6450
AFTER STORAGE...6450
TROUBLESHOOTING...6451
WHEN MACHINE RUNS OUT OF FUEL...6451
METHOD OF TOWING MACHINE...6451
IF BATTERY IS DISCHARGED...6453
OTHER TROUBLE...6456
MAINTENANCE...6461
GUIDES TO MAINTENANCE...6462
OUTLINES OF SERVICE...6464
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...6464
OUTLINE OF ELECTRIC SYSTEM...6467
WEAR PARTS...6468
WEAR PARTS LIST...6468
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...6469
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...6470
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...6471
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...6472
TORQUE LIST...6472
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...6473
MAINTENANCE SCHEDULE CHART...6474
MAINTENANCE SCHEDULE CHART...6474
SERVICE PROCEDURE...6476
INITIAL 250 HOURS SERVICE...6476
WHEN REQUIRED...6477
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT...6477
CLEAN INSIDE OF COOLING SYSTEM...6480
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL...6483
CHECK AXLE OIL LEVEL, ADD OIL...6484
CLEAN AXLE CASE BREATHER...6485
CLEAN AIR CONDITIONER CONDENSER...6486
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID...6486
CLEAN RADIATOR FINS AND COOLER FINS...6487
CLEAN TRANSFER OIL COOLER FINS...6487
CHECK ELECTRICAL INTAKE AIR HEATER...6487
TURN, REPLACE BOLT-ON CUTTING EDGE...6488
REPLACE BUCKET TEETH...6489
CHECK AIR CONDITIONER...6490
REPLACE SLOW BLOW FUSE...6491
CHECKING FUNCTION OF ACCUMULATOR...6492
SELECTION AND INSPECTION OF TIRES...6493
CHECK BEFORE STARTING...6495
EVERY 50 HOURS SERVICE...6496
DRAIN WATER, SEDIMENT FROM FUEL TANK...6496
EVERY 100 HOURS SERVICE...6497
LUBRICATE REAR AXLE PIVOT PIN...6497
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...6497
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...6498
EVERY 250 HOURS SERVICE...6499
CHECK BATTERY ELECTROLYTE LEVEL...6499
CHECK PARKING BRAKE...6501
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...6501
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN...6502
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...6503
CHECKING FUNCTION OF ACCUMULATOR...6503
LUBRICATING...6504
EVERY 500 HOURS SERVICE...6505
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...6505
REPLACE FUEL FILTER CARTRIDGE...6506
CLEAN WATER SEPARATOR STRAINER...6507
EVERY 1000 HOURS SERVICE...6508
CHANGE OIL IN TRANSFER CASE...6508
CLEAN TRANSFER CASE BREATHER...6509
REPLACE HST OIL FILTER ELEMENT...6510
LUBRICATING...6511
CHECK TIGHTENING PARTS OF TURBOCHARGER...6511
CHECK PLAY OF TURBOCHARGER ROTOR...6511
CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT...6511
EVERY 2000 HOURS SERVICE...6512
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...6512
REPLACE HYDRAULIC TANK BREATHER ELEMENT...6513
CHANGE AXLE OIL...6514
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER...6514
CLEAN BRAKE CIRCUIT STRAINER...6515
CHECK BRAKE DISC WEAR...6516
CHECKING FUNCTION OF ACCUMULATOR...6517
CHECK ALTERNATOR, STARTING MOTOR...6517
CHECK ENGINE VALVE CLEARANCE, ADJUST...6517
CLEAN AND CHECK TURBOCHARGER...6517
CHECK VIBRATION DAMPER...6517
EVERY 4000 HOURS SERVICE...6518
LUBRICATING...6518
CHECK WATER PUMP...6518
SPECIFICATIONS...6519
SPECIFICATIONS...6520
ATTACHMENTS, OPTIONS...6521
SELECTING BUCKET AND TIRES...6522
INDEX...6523
TEN00085-00 - Wheel Loader GALEO WA250PT-5 Operation & Maintenance Manual...6526
COVER...6526
FOREWORD...6527
FOREWORD...6528
SAFETY INFORMATION...6531
INTRODUCTION...6533
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...6533
NECESSARY INFORMATION...6534
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...6534
ENGINE SERIAL NO. PLATE...6534
POSITION OF SERVICE METER...6535
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...6535
CONTENTS...6536
SAFETY...6539
SAFETY...6540
SAFETY LABELS...6543
LOCATION OF SAFETY LABELS...6543
SAFETY LABELS...6544
GENERAL PRECAUTIONS...6548
SAFETY RULES...6548
IF ABNORMALITIES ARE FOUND...6548
CLOTHING AND PERSONAL PROTECTIVE ITEMS...6548
FIRE EXTINGUISHER AND FIRST AID KIT...6548
SAFETY FEATURES...6548
KEEP MACHINE CLEAN...6549
INSIDE OPERATOR'S COMPARTMENT...6549
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT...6549
HANDRAILS AND STEPS...6550
MOUNTING AND DISMOUNTING...6551
NO PEOPLE ON ATTACHMENTS...6551
DO NOT GET CAUGHT IN ARTICULATED PORTION...6551
PREVENTION OF BURNS...6551
FIRE PREVENTION...6552
ACTION IF FIRE OCCURS...6553
WINDOW WASHER LIQUID...6553
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)...6553
PRECAUTIONS FOR ATTACHMENTS, OPTIONS...6553
UNAUTHORIZED MODIFICATION...6553
SAFETY AT WORKSITE...6554
WORKING ON LOOSE GROUND...6554
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...6554
ENSURE GOOD VISIBILITY...6555
VENTILATION FOR ENCLOSED AREAS...6555
CHECKING SIGNALMAN'S SIGNALS AND SIGNS...6555
EMERGENCY EXIT FROM OPERATOR'S CAB...6555
BE CAREFUL ABOUT ASBESTOS DUST...6556
PRECAUTIONS FOR OPERATION...6557
STARTING ENGINE...6557
CHECKS BEFORE STARTING ENGINE...6557
PRECAUTIONS WHEN STARTING...6557
PRECAUTIONS IN COLD AREAS...6558
OPERATION...6559
CHECKS BEFORE OPERATION...6559
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE...6559
PRECAUTIONS WHEN TRAVELING...6560
TRAVELING ON SLOPES...6561
PROHIBITED OPERATIONS...6562
PRECAUTIONS WHEN OPERATING...6562
METHODS OF USING BRAKE...6563
OPERATE CAREFULLY ON SNOW...6563
PARKING MACHINE...6564
TRANSPORTATION...6565
LOADING AND UNLOADING...6565
SHIPPING...6565
BATTERY...6566
BATTERY HAZARD PREVENTION...6566
STARTING WITH BOOSTER CABLES...6567
TOWING...6568
WHEN TOWING...6568
PRECAUTIONS FOR MAINTENANCE...6569
WARNING TAG...6569
KEEP WORK PLACE CLEAN AND TIDY...6569
APPOINT LEADER WHEN WORKING WITH OTHERS...6569
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...6570
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...6571
INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF...6571
PROPER TOOLS...6572
ACCUMULATOR...6572
PERSONNEL...6572
ATTACHMENTS...6572
WORK UNDER THE MACHINE...6573
NOISE...6573
PRECAUTIONS WHEN USING HAMMER...6573
REPAIR WELDING...6573
REMOVING BATTERY TERMINAL...6573
PRECAUTIONS WITH HIGH-PRESSURE OIL...6574
HANDLING HIGH-PRESSURE HOSES...6574
WASTE MATERIALS...6574
MAINTENANCE OF AIR CONDITIONER...6574
COMPRESSED AIR...6575
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...6575
PRECAUTIONS WITH TIRES...6576
HANDLING TIRES...6576
PRECAUTIONS WHEN STORING TIRES...6576
OPERATION...6577
GENERAL VIEW...6578
GENERAL VIEW OF MACHINE...6578
GENERAL VIEW OF CONTROLS AND GAUGES...6579
EXPLANATION OF COMPONENTS...6581
MACHINE MONITOR...6581
SWITCHES...6607
CONTROL LEVERS, PEDALS...6615
STEERING TILT LOCK LEVER...6619
CAP AND COVER WITH LOCK...6619
FRAME LOCK BAR...6620
TOWING PIN...6621
GREASE PUMP...6621
CAB DOOR INNER LOCK...6621
CAB DOOR OPEN LOCK...6622
CAB WINDOW OPEN LOCK CANCEL KNOB...6622
FUSE...6622
SLOW BLOW FUSE...6624
POWER OUTLET...6624
STORAGE BOX...6624
AM/FM RADIO...6625
AM/FM RADIO-CASSETTE STEREO...6631
AIR CONDITIONER...6639
HANDLING CAB WIPER...6644
OPERATION...6645
CHECK BEFORE STARTING ENGINE, ADJUST...6645
STARTING ENGINE...6660
OPERATIONS AND CHECKS AFTER STARTING ENGINE...6662
STOPPING ENGINE...6664
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...6665
TURNING...6669
OPERATION OF WORK EQUIPMENT...6671
HANDLING HYDRAULIC QUICK COUPLER...6673
WORK POSSIBLE USING WHEEL LOADER...6676
PRECAUTIONS FOR OPERATION...6681
ADJUSTING WORK EQUIPMENT POSTURE...6683
PARKING MACHINE...6687
CHECKS AFTER COMPLETION OF OPERATION...6689
LOCKING...6689
HANDLING THE TIRES...6690
TRANSPORTATION...6692
TRANSPORTATION PROCEDURE...6692
LOADING, UNLOADING WORK WITH TRAILERS...6692
LIFTING MACHINE...6696
COLD WEATHER OPERATION...6698
PRECAUTIONS FOR LOW TEMPERATURE...6698
PRECAUTIONS AFTER COMPLETION OF WORK...6699
AFTER COLD WEATHER...6699
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...6700
LONG-TERM STORAGE...6701
BEFORE STORAGE...6701
DURING STORAGE...6701
AFTER STORAGE...6701
TROUBLESHOOTING...6702
WHEN MACHINE RUNS OUT OF FUEL...6702
METHOD OF TOWING MACHINE...6702
IF BATTERY IS DISCHARGED...6704
OTHER TROUBLE...6707
MAINTENANCE...6712
GUIDES TO MAINTENANCE...6713
OUTLINES OF SERVICE...6715
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...6715
OUTLINE OF ELECTRIC SYSTEM...6718
WEAR PARTS...6719
WEAR PARTS LIST...6719
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...6720
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...6721
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...6722
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...6723
TORQUE LIST...6723
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...6724
MAINTENANCE SCHEDULE CHART...6725
MAINTENANCE SCHEDULE CHART...6725
SERVICE PROCEDURE...6727
INITIAL 250 HOURS SERVICE...6727
WHEN REQUIRED...6728
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT...6728
CLEAN INSIDE OF COOLING SYSTEM...6731
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL...6734
CHECK AXLE OIL LEVEL, ADD OIL...6735
CLEAN AXLE CASE BREATHER...6736
CLEAN AIR CONDITIONER CONDENSER...6737
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID...6737
CLEAN RADIATOR FINS AND COOLER FINS...6738
CLEAN TRANSFER OIL COOLER FINS...6738
CHECK ELECTRICAL INTAKE AIR HEATER...6738
TURN, REPLACE BOLT-ON CUTTING EDGE...6739
REPLACE BUCKET TEETH...6740
CHECK AIR CONDITIONER...6742
REPLACE SLOW BLOW FUSE...6743
CHECKING FUNCTION OF ACCUMULATOR...6744
SELECTION AND INSPECTION OF TIRES...6745
CHECK BEFORE STARTING...6747
EVERY 50 HOURS SERVICE...6748
DRAIN WATER, SEDIMENT FROM FUEL TANK...6748
EVERY 100 HOURS SERVICE...6749
LUBRICATE REAR AXLE PIVOT PIN...6749
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...6749
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...6750
EVERY 250 HOURS SERVICE...6751
CHECK BATTERY ELECTROLYTE LEVEL...6751
CHECK PARKING BRAKE...6753
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...6753
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN...6754
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...6755
CHECKING FUNCTION OF ACCUMULATOR...6755
LUBRICATING...6756
EVERY 500 HOURS SERVICE...6757
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...6757
REPLACE FUEL FILTER CARTRIDGE...6758
REPLACEMENT OF FILTER CARTRIDGE FOR POOR-QUALITY FUEL...6759
CLEAN WATER SEPARATOR STRAINER...6760
EVERY 1000 HOURS SERVICE...6761
CHANGE OIL IN TRANSFER CASE...6761
CLEAN TRANSFER CASE BREATHER...6762
REPLACE HST OIL FILTER ELEMENT...6763
REPLACE CORROSION RESISTOR CARTRIDGE...6764
LUBRICATING...6764
CHECK TIGHTENING PARTS OF TURBOCHARGER...6764
CHECK PLAY OF TURBOCHARGER ROTOR...6764
CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT...6765
EVERY 2000 HOURS SERVICE...6766
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...6766
REPLACE HYDRAULIC TANK BREATHER ELEMENT...6767
CHANGE AXLE OIL...6768
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER...6768
CLEAN BRAKE CIRCUIT STRAINER...6769
CHECK BRAKE DISC WEAR...6770
CHECKING FUNCTION OF ACCUMULATOR...6771
CHECK ALTERNATOR, STARTING MOTOR...6771
CHECK ENGINE VALVE CLEARANCE, ADJUST...6771
CLEAN AND CHECK TURBOCHARGER...6771
CHECK VIBRATION DAMPER...6771
EVERY 4000 HOURS SERVICE...6772
LUBRICATING...6772
CHECK WATER PUMP...6772
SPECIFICATIONS...6773
SPECIFICATIONS...6774
ATTACHMENTS, OPTIONS...6775
SELECTING BUCKET AND TIRES...6776
HANDLING FORK TOOL...6777
EXPLANATION OF COMPONENTS...6777
OPERATION...6778
INDEX...6781
TEN00086-00 - Wheel Loader GALEO WA250PTL-5 Operation & Maintenance Manual...6784
COVER...6784
FOREWORD...6785
FOREWORD...6786
SAFETY INFORMATION...6789
INTRODUCTION...6791
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...6791
NECESSARY INFORMATION...6792
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...6792
ENGINE SERIAL NO. PLATE ...6792
POSITION OF SERVIVE METER...6793
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...6793
CONTENTS...6794
SAFETY...6797
SAFETY...6798
SAFETY LABELS...6801
LOCATION OF SAFETY LABELS...6801
SAFETY LABELS...6802
GENERAL PRECAUTIONS...6807
SAFETY RULES...6807
IF ABNORMALITIES ARE FOUND...6807
CLOTHING AND PERSONAL PROTECTIVE ITEMS...6807
FIRE EXTINGUISHER AND FIRST AID KIT...6807
SAFETY FEATURES...6807
KEEP MACHINE CLEAN...6808
INSIDE OPERATOR'S COMPARTMENT...6808
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT...6808
HANDRAILS AND STEPS...6809
MOUNTING AND DISMOUNTING...6810
NO PEOPLE ON ATTACHMENTS...6810
DO NOT GET CAUGHT IN ARTICULATED PORTION...6810
PREVENTION OF BURNS...6810
FIRE PREVENTION...6811
ACTION IF FIRE OCCURS...6812
WINDOW WASHER LIQUID...6812
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)...6812
PRECAUTIONS FOR ATTACHMENTS, OPTIONS...6812
UNAUTHORIZED MODIFICATION...6812
SAFETY AT WORKSITE...6813
WORKING ON LOOSE GROUND...6813
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...6813
ENSURE GOOD VISIBILITY...6814
VENTILATION FOR ENCLOSED AREAS...6814
CHECKING SIGNALMAN'S SIGNALS AND SIGNS...6814
EMERGENCY EXIT FROM OPERATOR'S CAB...6814
BE CAREFUL ABOUT ASBESTOS DUST...6815
PRECAUTIONS FOR OPERATION...6816
STARTING ENGINE...6816
CHECKS BEFORE STARTING ENGINE...6816
PRECAUTIONS WHEN STARTING...6816
PRECAUTIONS IN COLD AREAS...6817
OPERATION...6818
CHECKS BEFORE OPERATION...6818
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE...6818
PRECAUTIONS WHEN TRAVELING...6819
TRAVELING ON SLOPES...6820
PROHIBITED OPERATIONS...6821
PRECAUTIONS WHEN OPERATING...6821
METHODS OF USING BRAKE...6822
OPERATE CAREFULLY ON SNOW...6822
PARKING MACHINE...6823
TRANSPORTATION...6824
LOADING AND UNLOADING...6824
SHIPPING...6824
BATTERY...6825
BATTERY HAZARD PREVENTION...6825
STARTING WITH BOOSTER CABLES...6826
TOWING...6827
WHEN TOWING ...6827
PRECAUTIONS FOR MAINTENACE...6828
WARNING TAG...6828
KEEP WORK PLACE CLEAN AND TIDY...6828
APPOINT LEADER WHEN WORKING WITH OTHERS...6828
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...6829
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...6830
INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.SWITCH OFF...6830
PROPER TOOLS...6831
ACCUMULATOR...6831
PERSONNEL...6831
ATTACHMENTS...6831
WORK UNDER THE MACHINE...6832
NOISE...6832
PRECAUTIONS WHEN USING HAMMER...6832
REPAIR WELDING...6832
REMOVING BATTERY TERMINAL...6832
PRECAUTIONS WITH HIGH-PRESSURE OIL...6833
HANDLING HIGH-PRESSURE HOSES...6833
WASTE MATERIALS...6833
MAINTENANCE OF AIR CONDITIONER...6833
COMPRESSED AIR...6834
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...6834
PRECAUTIONS WITH TIRES...6835
HANDLING TIRES...6835
PRECAUTIONS WHEN STORING TIRES...6835
OPERATION...6836
GENERAL VIEW...6837
GENERAL VIEW OF MACHINE...6837
GENERAL VIEW OF CONTROLS AND GAUGES...6838
EXPLANATION OF COMPONENTS...6840
MACHINE MONITOR...6840
SWITCHES...6866
CONTROL LEVERS, PEDALS...6876
STEERING TILT LOCK LEVER...6880
CAP AND COVER WITH LOCK...6880
FRAME LOCK BAR...6881
TOWING PIN...6882
GREASE PUMP...6882
CAB DOOR INNER LOCK...6882
CAB DOOR OPEN LOCK...6883
CAB WINDOW OPEN LOCK CANCEL KNOB...6883
FUSE...6883
SLOW BLOW FUSE...6885
POWER OUTLET...6885
STORAGE BOX...6885
AM/FM RADIO-CASSETTE STEREO...6886
AIR CONDITIONER...6894
HANDLING CAB WIPER...6899
OPERATION...6900
CHECK BEFORE STARTING ENGINE, ADJUST...6900
STARTING ENGINE...6915
OPERATIONS AND CHECKS AFTER STARTING ENGINE...6917
STOPPING ENGINE...6919
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...6920
TURNING...6925
OPERATION OF WORK EQUIPMENT...6927
HANDLING HYDRAULIC QUICK COUPLER...6929
WORK POSSIBLE USING WHEEL LOADER...6933
PRECAUTIONS FOR OPERATION...6938
ADJUSTING WORK EQUIPMENT POSTURE...6940
PARKING MACHINE...6944
CHECKS AFTER COMPLETION OF OPERATION...6946
LOCKING...6946
HANDLING THE TIRES...6947
TRANSPORTATION...6949
TRANSPORTATION PROCEDURE...6949
LOADING,UNLOADING WORK WITH TRAILERS...6949
LIFTING MACHINE...6953
COLD WEATHER OPERATION...6955
PRECAUTIONS FOR LOW TEMPERATURE...6955
PRECAUTIONS AFTER COMPLETION OF WORK...6956
AFTER COLD WEATHER...6956
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...6957
LONG-TERM STORAGE...6958
BEFORE STORAGE...6958
DURING STORAGE...6958
AFTER STORAGE...6958
TROUBLESHOOTING...6959
WHEN MACHINE RUNS OUT OF FUEL...6959
METHOD OF TOWING MACHINE...6959
IF BATTERY IS DISCHARGED...6961
OTHER TROUBLE...6964
MAINTENANCE...6969
GUIDES TO MAINTENANCE...6970
OUTLINES OF SERVICE...6972
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...6972
OUTLINE OF ELECTRIC SYSTEM...6975
WEAR PARTS...6976
WEAR PARTS LIST...6976
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...6977
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...6978
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...6979
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...6980
TORQUE LIST...6980
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...6981
MAINTENANCE SCHEDULE CHART...6982
MAINTENANCE SCHEDULE CHART...6982
SERVICE PROCEDURE...6984
INITIAL 250 HOURS SERVICE...6984
WHEN REQUIRED...6985
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT...6985
CLEAN INSIDE OF COOLING SYSTEM...6988
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL...6991
CHECK AXLE OIL LEVEL, ADD OIL...6992
CLEAN AXLE CASE BREATHER...6993
CLEAN AIR CONDITIONER CONDENSER...6994
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID...6994
CLEAN RADIATOR FINS AND COOLER FINS...6995
CLEAN TRANSFER OIL COOLER FINS...6995
CHECK ELECTRICAL INTAKE AIR HEATER...6995
TURN, REPLACE BOLT-ON CUTTING EDGE...6996
REPLACE BUCKET TEETH...6997
CHECK AIR CONDITIONER...6998
REPLACE SLOW BLOW FUSE...6999
CHECKING FUNCTION OF ACCUMULATOR...7000
SELECTION AND INSPECTION OF TIRES...7001
CHECK BEFORE STARTING...7003
EVERY 50 HOURS SERVICE...7004
DRAIN WATER, SEDIMENT FROM FUEL TANK...7004
EVERY 100 HOURS SERVICE...7005
LUBRICATE REAR AXLE PIVOT PIN...7005
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...7005
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...7006
EVERY 250 HOURS SERVICE...7007
CHECK BATTERY ELECTROLYTE LEVEL...7007
CHECK PARKING BRAKE...7009
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...7009
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN...7010
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...7011
CHECKING FUNCTION OF ACCUMULATOR...7011
LUBRICATING...7012
EVERY 500 HOURS SERVICE...7013
CHANGE OIL IN ENGINE OIL PAN,REPLACE ENGINE OIL FILTER CARTRIDGE...7013
REPLACE FUEL FILTER CARTRIDGE...7014
CLEAN WATER SEPARATOR STRAINER...7015
EVERY 1000 HOURS SERVICE...7016
CHANGE OIL IN TRANSFER CASE...7016
CLEAN TRANSFER CASE BREATHER...7017
REPLACE HST OIL FILTER ELEMENT...7018
LUBRICATING...7019
CHECK TIGHTENING PARTS OF TURBOCHARGER...7019
CHECK PLAY OF TURBOCHARGER ROTOR...7019
CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT ...7019
EVERY 2000 HOURS SERVICE...7020
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...7020
REPLACE HYDRAULIC TANK BREATHER ELEMENT...7021
CHANGE AXLE OIL...7022
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER...7022
CLEAN BRAKE CIRCUIT STRAINER...7023
CHECK BRAKE DISC WEAR...7024
CHECKING FUNCTION OF ACCUMULATOR...7025
CHECK ALTERNATOR,STARTING MOTOR...7025
CHECK ENGINE VALVE CLEARANCE, ADJUST...7025
CLEAN AND CHECK TURBOCHARGER...7025
CHECK VIBRATION DAMPER...7025
EVERY 4000 HOURS SERVICE...7026
LUBRICATING...7026
CHECK WATER PUMP...7026
SPECIFICATIONS...7027
SPECIFICATIONS...7028
ATTACHMENTS, OPTIONS...7029
SELECTING BUCKET AND TIRES...7030
HANDLING FORK TOOL...7031
EXPLANATION OF COMPONENTS...7031
OPERATION...7032
INDEX...7035
TEN00155-00 - Wheel Loader GALEO WA250-5 Operation & Maintenance Manual...7038
COVER...7038
FOREWORD...7039
FOREWORD...7040
SAFETY INFORMATION...7043
INTRODUCTION...7045
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...7045
NECESSARY INFORMATION...7046
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...7046
ENGINE SERIAL NO. PLATE...7046
POSITION OF SERVICE METER...7047
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...7047
CONTENTS...7048
SAFETY...7051
SAFETY...7052
SAFETY LABELS...7055
LOCATION OF SAFETY LABELS...7055
SAFETY LABELS...7056
GENERAL PRECAUTIONS...7061
SAFETY RULES...7061
IF ABNORMALITIES ARE FOUND...7061
CLOTHING AND PERSONAL PROTECTIVE ITEMS...7061
FIRE EXTINGUISHER AND FIRST AID KIT...7061
SAFETY FEATURES...7061
KEEP MACHINE CLEAN...7062
INSIDE OPERATOR'S COMPARTMENT...7062
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT...7062
HANDRAILS AND STEPS...7063
MOUNTING AND DISMOUNTING...7064
NO PEOPLE ON ATTACHMENTS...7064
DO NOT GET CAUGHT IN ARTICULATED PORTION...7064
PREVENTION OF BURNS...7064
FIRE PREVENTION...7065
ACTION IF FIRE OCCURS...7066
WINDOW WASHER LIQUID...7066
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)...7066
PRECAUTIONS FOR ATTACHMENTS, OPTIONS...7066
UNAUTHORIZED MODIFICATION...7066
SAFETY AT WORKSITE...7067
WORKING ON LOOSE GROUND...7067
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...7067
ENSURE GOOD VISIBILITY...7068
VENTILATION FOR ENCLOSED AREAS...7068
CHECKING SIGNALMAN'S SIGNALS AND SIGNS...7068
EMERGENCY EXIT FROM OPERATOR'S CAB...7068
BE CAREFUL ABOUT ASBESTOS DUST...7069
PRECAUTIONS FOR OPERATION...7070
STARTING ENGINE...7070
CHECKS BEFORE STARTING ENGINE...7070
PRECAUTIONS WHEN STARTING...7070
PRECAUTIONS IN COLD AREAS...7071
OPERATION...7072
CHECKS BEFORE OPERATION...7072
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE...7072
PRECAUTIONS WHEN TRAVELING...7073
TRAVELING ON SLOPES...7074
PROHIBITED OPERATIONS...7075
PRECAUTIONS WHEN OPERATING...7075
METHODS OF USING BRAKE...7076
OPERATE CAREFULLY ON SNOW...7076
PARKING MACHINE...7077
TRANSPORTATION...7078
LOADING AND UNLOADING...7078
SHIPPING...7078
BATTERY...7079
BATTERY HAZARD PREVENTION...7079
STARTING WITH BOOSTER CABLES...7080
TOWING...7081
WHEN TOWING...7081
PRECAUTIONS FOR MAINTENANCE...7082
WARNING TAG...7082
KEEP WORK PLACE CLEAN AND TIDY...7082
APPOINT LEADER WHEN WORKING WITH OTHERS...7082
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...7083
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...7084
INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF...7084
PROPER TOOLS...7085
ACCUMULATOR...7085
PERSONNEL...7085
ATTACHMENTS...7085
WORK UNDER THE MACHINE...7086
NOISE...7086
PRECAUTIONS WHEN USING HAMMER...7086
REPAIR WELDING...7086
REMOVING BATTERY TERMINAL...7086
PRECAUTIONS WITH HIGH-PRESSURE OIL...7087
HANDLING HIGH-PRESSURE HOSES...7087
WASTE MATERIALS...7087
MAINTENANCE OF AIR CONDITIONER...7087
COMPRESSED AIR...7088
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...7088
PRECAUTIONS WITH TIRES...7089
HANDLING TIRES...7089
PRECAUTIONS WHEN STORING TIRES...7089
OPERATION...7090
GENERAL VIEW...7091
GENERAL VIEW OF MACHINE...7091
GENERAL VIEW OF CONTROLS AND GAUGES...7092
EXPLANATION OF COMPONENTS...7094
MACHINE MONITOR...7094
SWITCHES...7120
CONTROL LEVERS, PEDALS...7127
STEERING TILT LOCK LEVER...7131
CAP AND COVER WITH LOCK...7131
FRAME LOCK BAR...7132
TOWING PIN...7133
GREASE PUMP...7133
CAB DOOR INNER LOCK...7133
CAB DOOR OPEN LOCK...7134
CAB WINDOW OPEN LOCK CANCEL KNOB...7134
FUSE...7134
SLOW BLOW FUSE...7136
POWER OUTLET...7136
STORAGE BOX...7136
AM/FM RADIO...7137
AM/FM RADIO-CASSETTE STEREO...7143
AIR CONDITIONER...7151
HANDLING CAB WIPER...7156
OPERATION...7157
CHECK BEFORE STARTING ENGINE, ADJUST...7157
STARTING ENGINE...7172
OPERATIONS AND CHECKS AFTER STARTING ENGINE...7174
STOPPING ENGINE...7176
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...7177
TURNING...7181
OPERATION OF WORK EQUIPMENT...7183
WORK POSSIBLE USING WHEEL LOADER...7185
PRECAUTIONS FOR OPERATION...7190
ADJUSTING WORK EQUIPMENT POSTURE...7192
PARKING MACHINE...7194
CHECKS AFTER COMPLETION OF OPERATION...7196
LOCKING...7196
HANDLING THE TIRES...7197
TRANSPORTATION...7199
TRANSPORTATION PROCEDURE...7199
LOADING, UNLOADING WORK WITH TRAILERS...7199
LIFTING MACHINE...7203
COLD WEATHER OPERATION...7205
PRECAUTIONS FOR LOW TEMPERATURE...7205
PRECAUTIONS AFTER COMPLETION OF WORK...7206
AFTER COLD WEATHER...7206
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...7207
LONG-TERM STORAGE...7208
BEFORE STORAGE...7208
DURING STORAGE...7208
AFTER STORAGE...7208
TROUBLESHOOTING...7209
WHEN MACHINE RUNS OUT OF FUEL...7209
METHOD OF TOWING MACHINE...7209
IF BATTERY IS DISCHARGED...7211
OTHER TROUBLE...7214
MAINTENANCE...7219
GUIDES TO MAINTENANCE...7220
OUTLINES OF SERVICE...7222
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...7222
OUTLINE OF ELECTRIC SYSTEM...7225
WEAR PARTS...7226
WEAR PARTS LIST...7226
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...7227
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...7228
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...7229
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...7230
TORQUE LIST...7230
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...7231
MAINTENANCE SCHEDULE CHART...7232
MAINTENANCE SCHEDULE CHART...7232
SERVICE PROCEDURE...7234
INITIAL 250 HOURS SERVICE...7234
WHEN REQUIRED...7235
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT...7235
CLEAN INSIDE OF COOLING SYSTEM...7238
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL...7241
CHECK AXLE OIL LEVEL, ADD OIL...7242
CLEAN AXLE CASE BREATHER...7243
CLEAN AIR CONDITIONER CONDENSER...7244
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID...7244
CLEAN RADIATOR FINS AND COOLER FINS...7245
CHECK ELECTRICAL INTAKE AIR HEATER...7245
TURN, REPLACE BOLT-ON CUTTING EDGE...7246
REPLACE BUCKET TEETH...7247
CHECK AIR CONDITIONER...7249
REPLACE SLOW BLOW FUSE...7250
CHECKING FUNCTION OF ACCUMULATOR...7251
SELECTION AND INSPECTION OF TIRES...7252
CHECK BEFORE STARTING...7254
EVERY 50 HOURS SERVICE...7255
DRAIN WATER, SEDIMENT FROM FUEL TANK...7255
EVERY 100 HOURS SERVICE...7256
LUBRICATE REAR AXLE PIVOT PIN...7256
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...7256
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...7257
EVERY 250 HOURS SERVICE...7258
CHECK BATTERY ELECTROLYTE LEVEL...7258
CHECK PARKING BRAKE...7260
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...7260
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN...7261
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...7262
CHECKING FUNCTION OF ACCUMULATOR...7262
LUBRICATING...7263
EVERY 500 HOURS SERVICE...7264
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...7264
REPLACE FUEL FILTER CARTRIDGE...7265
REPLACEMENT OF FILTER CARTRIDGE FOR POOR-QUALITY FUEL...7266
CLEAN WATER SEPARATOR STRAINER...7267
EVERY 1000 HOURS SERVICE...7268
CHANGE OIL IN TRANSFER CASE...7268
CLEAN TRANSFER CASE BREATHER...7269
REPLACE HST OIL FILTER ELEMENT...7270
REPLACE CORROSION RESISTOR CARTRIDGE...7271
LUBRICATING...7271
CHECK TIGHTENING PARTS OF TURBOCHARGER...7271
CHECK PLAY OF TURBOCHARGER ROTOR...7271
CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT...7272
EVERY 2000 HOURS SERVICE...7273
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...7273
REPLACE HYDRAULIC TANK BREATHER ELEMENT...7274
CHANGE AXLE OIL...7275
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER...7275
CLEAN BRAKE CIRCUIT STRAINER...7276
CHECK BRAKE DISC WEAR...7277
CHECKING FUNCTION OF ACCUMULATOR...7278
CHECK ALTERNATOR, STARTING MOTOR...7278
CHECK ENGINE VALVE CLEARANCE, ADJUST...7278
CLEAN AND CHECK TURBOCHARGER...7278
CHECK VIBRATION DAMPER...7278
EVERY 4000 HOURS SERVICE...7279
LUBRICATING...7279
CHECK WATER PUMP...7279
SPECIFICATIONS...7280
SPECIFICATIONS...7281
ATTACHMENTS, OPTIONS...7282
SELECTING BUCKET AND TIRES...7283
INDEX...7284
TEN00157-00 - Wheel Loader GALEO WA250PT-5 Operation & Maintenance Manual...7287
COVER...7287
FOREWORD...7289
FOREWORD...7290
SAFETY INFORMATION...7293
INTRODUCTION...7295
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...7295
NECESSARY INFORMATION...7296
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...7296
ENGINE SERIAL NO. PLATE...7296
POSITION OF SERVICE METER...7297
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...7297
CONTENTS...7298
SAFETY...7301
SAFETY...7302
SAFETY LABELS...7305
LOCATION OF SAFETY LABELS...7305
SAFETY LABELS...7306
GENERAL PRECAUTIONS...7311
SAFETY RULES...7311
IF ABNORMALITIES ARE FOUND...7311
CLOTHING AND PERSONAL PROTECTIVE ITEMS...7311
FIRE EXTINGUISHER AND FIRST AID KIT...7311
SAFETY FEATURES...7311
KEEP MACHINE CLEAN...7312
INSIDE OPERATOR'S COMPARTMENT...7312
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT...7312
HANDRAILS AND STEPS...7313
MOUNTING AND DISMOUNTING...7314
NO PEOPLE ON ATTACHMENTS...7314
DO NOT GET CAUGHT IN ARTICULATED PORTION...7314
PREVENTION OF BURNS...7314
FIRE PREVENTION...7315
ACTION IF FIRE OCCURS...7316
WINDOW WASHER LIQUID...7316
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)...7316
PRECAUTIONS FOR ATTACHMENTS, OPTIONS...7316
UNAUTHORIZED MODIFICATION...7316
SAFETY AT WORKSITE...7317
WORKING ON LOOSE GROUND...7317
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...7317
ENSURE GOOD VISIBILITY...7318
VENTILATION FOR ENCLOSED AREAS...7318
CHECKING SIGNALMAN'S SIGNALS AND SIGNS...7318
EMERGENCY EXIT FROM OPERATOR'S CAB...7318
BE CAREFUL ABOUT ASBESTOS DUST...7319
PRECAUTIONS FOR OPERATION...7320
STARTING ENGINE...7320
CHECKS BEFORE STARTING ENGINE...7320
PRECAUTIONS WHEN STARTING...7320
PRECAUTIONS IN COLD AREAS...7321
OPERATION...7322
CHECKS BEFORE OPERATION...7322
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE...7322
PRECAUTIONS WHEN TRAVELING...7323
TRAVELING ON SLOPES...7324
PROHIBITED OPERATIONS...7325
PRECAUTIONS WHEN OPERATING...7325
METHODS OF USING BRAKE...7326
OPERATE CAREFULLY ON SNOW...7326
PARKING MACHINE...7327
TRANSPORTATION...7328
LOADING AND UNLOADING...7328
SHIPPING...7328
BATTERY...7329
BATTERY HAZARD PREVENTION...7329
STARTING WITH BOOSTER CABLES...7330
TOWING...7331
WHEN TOWING...7331
PRECAUTIONS FOR MAINTENANCE...7332
WARNING TAG...7332
KEEP WORK PLACE CLEAN AND TIDY...7332
APPOINT LEADER WHEN WORKING WITH OTHERS...7332
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...7333
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...7334
INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF...7334
PROPER TOOLS...7335
ACCUMULATOR...7335
PERSONNEL...7335
ATTACHMENTS...7335
WORK UNDER THE MACHINE...7336
NOISE...7336
PRECAUTIONS WHEN USING HAMMER...7336
REPAIR WELDING...7336
REMOVING BATTERY TERMINAL...7336
PRECAUTIONS WITH HIGH-PRESSURE OIL...7337
HANDLING HIGH-PRESSURE HOSES...7337
WASTE MATERIALS...7337
MAINTENANCE OF AIR CONDITIONER...7337
COMPRESSED AIR...7338
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...7338
PRECAUTIONS WITH TIRES...7339
HANDLING TIRES...7339
PRECAUTIONS WHEN STORING TIRES...7339
OPERATION...7341
GENERAL VIEW...7342
GENERAL VIEW OF MACHINE...7342
GENERAL VIEW OF CONTROLS AND GAUGES...7343
EXPLANATION OF COMPONENTS...7345
MACHINE MONITOR...7345
SWITCHES...7371
CONTROL LEVERS, PEDALS...7379
STEERING TILT LOCK LEVER...7383
CAP AND COVER WITH LOCK...7383
FRAME LOCK BAR...7384
TOWING PIN...7385
GREASE PUMP...7385
CAB DOOR INNER LOCK...7385
CAB DOOR OPEN LOCK...7386
CAB WINDOW OPEN LOCK CANCEL KNOB...7386
FUSE...7386
SLOW BLOW FUSE...7388
POWER OUTLET...7388
STORAGE BOX...7388
AM/FM RADIO...7389
AM/FM RADIO-CASSETTE STEREO...7395
AIR CONDITIONER...7403
HANDLING CAB WIPER...7408
OPERATION...7409
CHECK BEFORE STARTING ENGINE, ADJUST...7409
STARTING ENGINE...7424
OPERATIONS AND CHECKS AFTER STARTING ENGINE...7426
STOPPING ENGINE...7428
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...7429
TURNING...7433
OPERATION OF WORK EQUIPMENT...7435
HANDLING HYDRAULIC QUICK COUPLER...7437
WORK POSSIBLE USING WHEEL LOADER...7440
PRECAUTIONS FOR OPERATION...7445
ADJUSTING WORK EQUIPMENT POSTURE...7447
PARKING MACHINE...7451
CHECKS AFTER COMPLETION OF OPERATION...7453
LOCKING...7453
HANDLING THE TIRES...7454
TRANSPORTATION...7456
TRANSPORTATION PROCEDURE...7456
LOADING, UNLOADING WORK WITH TRAILERS...7456
LIFTING MACHINE...7460
COLD WEATHER OPERATION...7462
PRECAUTIONS FOR LOW TEMPERATURE...7462
PRECAUTIONS AFTER COMPLETION OF WORK...7463
AFTER COLD WEATHER...7463
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...7464
LONG-TERM STORAGE...7465
BEFORE STORAGE...7465
DURING STORAGE...7465
AFTER STORAGE...7465
TROUBLESHOOTING...7466
WHEN MACHINE RUNS OUT OF FUEL...7466
METHOD OF TOWING MACHINE...7466
IF BATTERY IS DISCHARGED...7468
OTHER TROUBLE...7471
MAINTENANCE...7477
GUIDES TO MAINTENANCE...7478
OUTLINES OF SERVICE...7480
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...7480
OUTLINE OF ELECTRIC SYSTEM...7483
WEAR PARTS...7484
WEAR PARTS LIST...7484
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...7485
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...7486
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...7487
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...7488
TORQUE LIST...7488
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...7489
MAINTENANCE SCHEDULE CHART...7490
MAINTENANCE SCHEDULE CHART...7490
SERVICE PROCEDURE...7492
INITIAL 250 HOURS SERVICE...7492
WHEN REQUIRED...7493
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT...7493
CLEAN INSIDE OF COOLING SYSTEM...7496
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL...7499
CHECK AXLE OIL LEVEL, ADD OIL...7500
CLEAN AXLE CASE BREATHER...7501
CLEAN AIR CONDITIONER CONDENSER...7502
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID...7502
CLEAN RADIATOR FINS AND COOLER FINS...7503
CHECK ELECTRICAL INTAKE AIR HEATER...7503
TURN, REPLACE BOLT-ON CUTTING EDGE...7504
REPLACE BUCKET TEETH...7505
CHECK AIR CONDITIONER...7507
REPLACE SLOW BLOW FUSE...7508
CHECKING FUNCTION OF ACCUMULATOR...7509
SELECTION AND INSPECTION OF TIRES...7510
CHECK BEFORE STARTING...7512
EVERY 50 HOURS SERVICE...7513
DRAIN WATER, SEDIMENT FROM FUEL TANK...7513
EVERY 100 HOURS SERVICE...7514
LUBRICATE REAR AXLE PIVOT PIN...7514
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...7514
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...7515
EVERY 250 HOURS SERVICE...7516
CHECK BATTERY ELECTROLYTE LEVEL...7516
CHECK PARKING BRAKE...7518
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...7518
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN...7519
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...7520
CHECKING FUNCTION OF ACCUMULATOR...7520
LUBRICATING...7521
EVERY 500 HOURS SERVICE...7522
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...7522
REPLACE FUEL FILTER CARTRIDGE...7523
REPLACEMENT OF FILTER CARTRIDGE FOR POOR-QUALITY FUEL...7524
CLEAN WATER SEPARATOR STRAINER...7525
EVERY 1000 HOURS SERVICE...7526
CHANGE OIL IN TRANSFER CASE...7526
CLEAN TRANSFER CASE BREATHER...7527
REPLACE HST OIL FILTER ELEMENT...7528
REPLACE CORROSION RESISTOR CARTRIDGE...7529
LUBRICATING...7529
CHECK TIGHTENING PARTS OF TURBOCHARGER...7529
CHECK PLAY OF TURBOCHARGER ROTOR...7529
CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT...7530
EVERY 2000 HOURS SERVICE...7531
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...7531
REPLACE HYDRAULIC TANK BREATHER ELEMENT...7532
CHANGE AXLE OIL...7533
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER...7533
CLEAN BRAKE CIRCUIT STRAINER...7534
CHECK BRAKE DISC WEAR...7535
CHECKING FUNCTION OF ACCUMULATOR...7536
CHECK ALTERNATOR, STARTING MOTOR...7536
CHECK ENGINE VALVE CLEARANCE, ADJUST...7536
CLEAN AND CHECK TURBOCHARGER...7536
CHECK VIBRATION DAMPER...7536
EVERY 4000 HOURS SERVICE...7537
LUBRICATING...7537
CHECK WATER PUMP...7537
SPECIFICATIONS...7539
SPECIFICATIONS...7540
ATTACHMENTS, OPTIONS...7541
SELECTING BUCKET AND TIRES...7542
HANDLING FORK TOOL...7543
EXPLANATION OF COMPONENTS...7543
OPERATION...7544
INDEX...7547
TEN00217-01 - Wheel Loader WA250PT-5 Operation & Maintenance Manual...7550
COVER...7550
FOREWORD...7551
FOREWORD...7552
SAFETY INFORMATION...7555
INTRODUCTION...7557
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...7557
NECESSARY INFORMATION...7558
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...7558
ENGINE SERIAL NO. PLATE...7558
POSITION OF SERVICE METER...7559
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...7559
CONTENTS...7560
SAFETY...7563
SAFETY...7564
SAFETY LABELS...7567
LOCATION OF SAFETY LABELS...7567
SAFETY LABELS...7568
GENERAL PRECAUTIONS...7573
PRECAUTIONS FOR OPERATION...7582
STARTING ENGINE...7582
OPERATION...7584
TRANSPORTATION...7590
BATTERY...7591
TOWING...7593
PRECAUTIONS FOR MAINTENANCE...7594
PRECAUTIONS WITH TIRES...7601
OPERATION...7603
GENERAL VIEW...7604
GENERAL VIEW OF MACHINE...7604
GENERAL VIEW OF CONTROLS AND GAUGES...7605
EXPLANATION OF COMPONENTS...7607
MACHINE MONITOR...7607
SWITCHES...7633
CONTROL LEVERS, PEDALS...7641
STEERING TILT LOCK LEVER...7645
CAP AND COVER WITH LOCK...7645
FRAME LOCK BAR...7646
TOWING PIN...7647
GREASE PUMP...7647
CAB DOOR INNER LOCK...7647
CAB DOOR OPEN LOCK...7648
CAB WINDOW OPEN LOCK CANCEL KNOB...7648
FUSE...7648
SLOW BLOW FUSE...7650
POWER OUTLET...7650
STORAGE BOX...7650
AM/FM RADIO...7651
AM/FM RADIO-CASSETTE STEREO...7657
AIR CONDITIONER...7665
HANDLING CAB WIPER...7670
HANDLING MACHINES EQUIPPED WITH KOMTRAX...7671
OPERATION...7672
CHECK BEFORE STARTING ENGINE, ADJUST...7672
STARTING ENGINE...7687
OPERATIONS AND CHECKS AFTER STARTING ENGINE...7689
STOPPING ENGINE...7691
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...7692
TURNING...7696
OPERATION OF WORK EQUIPMENT...7698
HANDLING HYDRAULIC QUICK COUPLER...7700
WORK POSSIBLE USING WHEEL LOADER...7703
PRECAUTIONS FOR OPERATION...7708
ADJUSTING WORK EQUIPMENT POSTURE...7710
PARKING MACHINE...7714
CHECKS AFTER COMPLETION OF OPERATION...7716
LOCKING...7716
HANDLING THE TIRES...7717
TRANSPORTATION...7719
TRANSPORTATION PROCEDURE...7719
LOADING, UNLOADING WORK WITH TRAILERS...7719
LIFTING MACHINE...7723
COLD WEATHER OPERATION...7725
PRECAUTIONS FOR LOW TEMPERATURE...7725
PRECAUTIONS AFTER COMPLETION OF WORK...7726
AFTER COLD WEATHER...7726
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...7727
LONG-TERM STORAGE...7728
BEFORE STORAGE...7728
DURING STORAGE...7728
AFTER STORAGE...7728
TROUBLESHOOTING...7729
WHEN MACHINE RUNS OUT OF FUEL...7729
METHOD OF TOWING MACHINE...7729
IF BATTERY IS DISCHARGED...7731
OTHER TROUBLE...7734
MAINTENANCE...7739
GUIDES TO MAINTENANCE...7740
OUTLINES OF SERVICE...7742
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...7742
OUTLINE OF ELECTRIC SYSTEM...7745
WEAR PARTS...7746
WEAR PARTS LIST...7746
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...7747
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...7748
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...7749
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...7750
TORQUE LIST...7750
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...7751
MAINTENANCE SCHEDULE CHART...7752
MAINTENANCE SCHEDULE CHART...7752
SERVICE PROCEDURE...7754
INITIAL 250 HOURS SERVICE...7754
WHEN REQUIRED...7755
CHECK BEFORE STARTING...7775
EVERY 50 HOURS SERVICE...7776
EVERY 100 HOURS SERVICE...7777
EVERY 250 HOURS SERVICE...7779
EVERY 500 HOURS SERVICE...7785
EVERY 1000 HOURS SERVICE...7789
EVERY 2000 HOURS SERVICE...7794
EVERY 4000 HOURS SERVICE...7800
SPECIFICATIONS...7801
SPECIFICATIONS...7802
ATTACHMENTS, OPTIONS...7803
SELECTING BUCKET AND TIRES...7804
HANDLING FORK TOOL...7805
EXPLANATION OF COMPONENTS...7805
OPERATION...7806
INDEX...7809
VEAM230100 - Wheel Loader WA250-5H Operation & Maintenance Manual...7813
WA250-5H...7813
FOREWORD...7815
Foreword...7816
Safety information...7818
Introduction...7820
Directions of machine...7820
Necessary information...7821
Machine serial No. plate and position...7821
Engine serial No. plate and position...7821
Position of service meter...7822
Table to enter serial No. and distributor...7822
Contents...7823
Dimensions, weights and operating data...7829
WA250-5H: Dimensions, weights and operating data...7829
CE-conforming equipment...7830
CE-conforming equipment...7830
Manufacturer-supplied CE-conforming equipment, according to document 421-93-H1900...7831
SAFETY...7835
Safety labels...7837
Location of safety labels...7837
Presentation of safety labels...7838
General precautions...7841
Safety rules...7841
Precautions for operation...7850
Starting engine...7850
Operation...7851
Transportation...7858
Battery...7859
Towing...7861
Precautions for maintenance...7862
Safety instructions...7862
Precautions with tires...7868
Handling tires...7868
Precautions when storing tires...7868
OPERATION...7869
General view...7871
General view of machine...7871
General view of controls and gauges...7872
Explanation of components...7874
Machine monitor...7874
Monitor system...7875
Types of warning...7876
Central warning lamp...7877
Character display portion...7878
Emergency stop item...7882
Caution items...7884
Warning/limit functions for travel speed...7886
Inspection and maintenance item...7887
Pilot display portion...7889
Meter display portion...7892
Other functions of machine monitor...7894
Switches...7898
Control levers, pedals...7905
Steering tilt lock lever...7908
Cap and cover with lock...7909
Safety bar...7910
Towing pin...7910
Grease pump...7910
Cab door inner lock...7911
Cab door open lock...7911
Cab window open lock cancel knob...7911
Fuse...7912
Fuse capacity and name of circuit...7912
Slow blow fuse...7913
Power outlet...7914
Air conditioner...7915
General locations and function of control panel...7915
Method of operation...7918
Precautions when using...7919
Handling cab wiper...7920
Preventing damage to wiper arm bracket...7920
Operation...7921
Check before starting engine, adjust...7921
Walk-around check...7921
Check before starting...7924
Adjustment...7929
Operations and checks before starting engine...7933
Starting engine...7935
Operations and checks after starting engine...7937
Breaking-in the machine...7937
Normal operation...7937
Stopping engine...7938
Moving the machine (Directional, speed), stopping the machine...7939
Moving the machine...7939
Changing direction...7941
Stopping the machine...7943
Turning...7944
Emergency steering...7944
Operation of work equipment...7945
Work possible using wheel loader...7946
Digging operations...7946
Leveling operations...7948
Pushing operation...7948
Load and carry operations...7948
Loading operations...7949
Precautions for operation...7951
Permissible water depth...7951
If wheel brake does not work...7951
Precautions when driving up or down slopes...7951
Adjusting work equipment posture...7952
Adjusting boom kickout...7952
Adjusting bucket positioner...7953
Bucket level indicator...7953
Parking machine...7954
Check after stopping engine...7956
Checks after completion of operation...7956
Locking...7956
Handling the tires...7957
Precautions when handling tires...7957
Tire pressure...7957
Precautions for using load and car method...7958
Transportation...7959
Transportation procedure...7959
Loading, unloading work with trailers...7959
Loading...7959
Securing machine...7960
Unloading...7960
Lifting machine...7961
Location of lifting position mark...7962
Weight table...7962
Lifting procedure...7963
Cold weather operation...7964
Precautions for low temperature...7964
Fuel and lubricants...7964
Coolant...7964
Battery...7965
Precautions after completion of work...7966
After cold weather...7966
Warming-up operation for steering hydraulic circuit in cold weather...7966
Long-term storage...7967
Before storage...7967
During storage...7967
After storage...7967
Troubleshooting...7968
When machine runs out of fuel...7968
Towing the machine...7968
When engine can be used...7969
When engine cannot be used...7969
If battery is discharged...7970
Removal and installation of battery...7970
Precautions for charging battery...7971
Starting engine with booster cable...7971
Other trouble...7973
Electrical system...7973
Chassis...7974
Engine...7976
MAINTENANCE...7979
Guides to maintenance...7980
Outlines of service...7982
Handling oil, fuel, coolant and performing oil clinic...7982
Oil...7982
Fuel...7982
Coolant...7982
Grease...7982
Carrying out KOWA (Komatsu Oil Wear Analysis)...7983
Storing oil and fuel...7983
Filters...7984
Biodegradable hydraulic oil and lubricants...7984
Outline of electric system...7984
Wear parts...7985
Wear parts list...7985
Fuel, coolant and lubricants...7986
Lubrication chart...7986
Proper selection of fuel, coolant and lubricants...7987
Standard tightening torques for bolts and nuts...7991
Torque list...7991
Periodic replacement of safety critical parts...7993
Safety critical parts...7993
Maintenance schedule chart...7995
Maintenance schedule chart...7995
Service procedure...7997
Initial 250 hours service (only after the first 250 hours)...7997
When required...7998
Check, clean, or replace air cleaner element...7998
Dust pre-extractor "Turbo II": check, clean...8001
Clean inside of cooling system...8002
Check oil level in transfer case, add oil...8005
Check axle oil level, add oil...8006
Clean axle case breather...8007
Clean air conditioner condenser...8007
Check window washing fluid level, add fluid...8008
Clean radiator fins and cooler fins...8008
Clean transfer oil cooler fins...8009
Check electrical intake air heater...8009
Replace bolt on cutting edge...8009
Replace bucket teeth...8010
Check air conditioner...8011
Replace slow blow fuse...8012
Selection and inspection of tires...8013
Check before starting...8015
Every 50 hours service...8016
Drain water, sediment from fuel tank...8016
Every 100 hours service...8017
Lubricate rear axle pivot pin...8017
Clean element in air conditioner fresh air filter...8017
Check oil level in hydraulic tank, add oil...8018
Every 250 hours service...8019
Check battery electrolyte level...8019
Check parking brake...8021
Check air conditioner compressor belt tension, adjust...8021
Check for loose wheel hub bolts, tighten...8022
Clean element in air conditioner recirculation filter...8023
Lubricating...8024
Every 500 hours service...8025
Change oil in engine oil pan, replace engine oil filter cartridge...8025
Replace fuel filter cartridge...8026
Every 1000 hours service...8027
Change oil in transfer case...8027
Clean transfer case breather...8028
Replace HST oil filter element...8029
Lubricating...8030
Check tightening parts of turbocharger...8030
Check play of turbocharger rotor...8030
Check fan belt tension, replace...8030
Every 2000 hours service...8031
Change oil in hydraulic tank, replace hydraulic filter element...8031
Replace hydraulic tank breather element...8032
Change axle oil...8033
Replace element in air conditioner recirculation air filter, fresh air filter...8033
Check alternator, starting motor...8033
Check engine valve clearance, adjust...8033
Check brake disc wear...8034
Clean and check turbocharger...8034
Check accumulator gas pressure...8034
Check vibration damper...8034
Every 4000 hours service...8035
Lubricating...8035
Check water pump...8035
TECHNICAL DATA...8037
Technical data...8038
Noise emission levels...8040
Vibration level...8040
ATTACHMENTS, OPTIONS...8041
Selecting bucket and tires...8042
Method of using 2 levers...8043
Explanation of components...8043
Lift arm control lever...8043
Bucket control lever...8044
Directional selector switch...8044
Directional selector actuation switch...8044
Operation...8045
Using switch to change between forward and reverse...8045
Central lubrication system...8047
Operating the central lubrication system...8047
Display and control unit...8047
Led-display...8047
Pushbuttons...8048
Changing the lubrication interval times...8048
INDEX...8049
Index...8051
VEAM230101 - Wheel Loader WA250-5H Operation & Maintenance Manual...8054
FOREWORD...8056
Foreword...8057
Safety information...8059
Introduction...8061
Intended use...8061
Directions of machine...8061
Necessary information...8062
PIN Machine serial No. plate and position...8062
Engine serial No. plate and position...8062
ROPS/FOPS-cab serial no. plate...8063
Axle serial no. plate...8063
Transmission serial no. plate...8063
Seat operator serial no. plate...8064
Position of service meter...8064
Table to enter serial No. and distributor...8064
Contents...8065
Dimensions, weights and operating data...8071
WA250-5H: Dimensions, weights and operating data...8071
CE-conforming equipment...8072
CE-conforming equipment...8072
Manufacturer-supplied CE-conforming equipment, according to document 421-93-H1900...8074
SAFETY...8078
Safety labels...8080
Location of safety labels...8080
Presentation of safety labels...8081
General precautions...8084
Safety rules...8084
Precautions for operation...8093
Starting engine...8093
Operation...8094
Transportation...8101
Battery...8102
Towing...8104
Precautions for maintenance...8105
Safety instructions...8105
Precautions with tires...8112
Handling tires...8112
Precautions when storing tires...8112
OPERATION...8114
General view...8116
General view of machine...8116
General view of controls and gauges...8117
Explanation of components...8119
Machine monitor...8119
Monitor system...8120
Types of warning...8121
Character display portion...8122
Emergency stop item...8126
Caution items...8128
Warning/limit functions for travel speed...8130
Inspection and maintenance item...8131
Pilot display portion...8133
Meter display portion...8136
Other functions of machine monitor...8138
Switches...8142
Control levers, pedals...8150
Steering tilt lock lever...8153
Cap and cover with lock...8154
Safety bar...8155
Towing pin...8155
Grease pump...8155
Cab door inner lock...8156
Cab door open lock...8156
Cab window open lock cancel knob...8156
Fuse...8157
Fuse capacity and name of circuit...8157
Slow blow fuse...8158
Power outlet...8159
Air conditioner...8160
General locations and function of control panel...8160
Method of operation...8163
Precautions when using...8164
Handling cab wiper...8164
Preventing damage to wiper arm bracket...8164
Operation...8165
Check before starting engine, adjust...8165
Walk-around check...8165
Check before starting...8168
Adjustment...8173
Operations and checks before starting engine...8176
Starting engine...8178
Operations and checks after starting engine...8180
Breaking-in the machine...8180
Normal operation...8180
Stopping engine...8181
Moving the machine (Directional, speed), stopping the machine...8182
Moving the machine...8182
Changing direction...8184
Stopping the machine...8186
Turning...8187
Emergency steering...8187
Operation of work equipment...8188
Work possible using wheel loader...8189
Digging operations...8189
Leveling operations...8191
Pushing operation...8191
Load and carry operations...8191
Loading operations...8192
Precautions for operation...8194
Permissible water depth...8194
If wheel brake does not work...8194
Precautions when driving up or down slopes...8194
Adjusting work equipment posture...8195
Adjusting boom kickout...8195
Adjusting bucket positioner...8196
Bucket level indicator...8196
Parking machine...8197
Check after stopping engine...8199
Checks after completion of operation...8199
Locking...8199
Handling the tires...8200
Precautions when handling tires...8200
Tire pressure...8200
Precautions for using load and car method...8201
Transportation...8202
Transportation procedure...8202
Loading, unloading work with trailers...8202
Loading...8202
Securing machine...8203
Unloading...8203
Lifting machine...8204
Location of lifting position mark...8205
Weight table...8205
Lifting procedure...8206
Cold weather operation...8207
Precautions for low temperature...8207
Fuel and lubricants...8207
Coolant...8207
Battery...8208
Precautions after completion of work...8209
After cold weather...8209
Warming-up operation for steering hydraulic circuit in cold weather...8209
Long-term storage...8210
Before storage...8210
During storage...8210
After storage...8210
Troubleshooting...8211
When machine runs out of fuel...8211
Towing the machine...8211
When engine can be used...8212
When engine cannot be used...8212
If battery is discharged...8213
Removal and installation of battery...8213
Precautions for charging battery...8214
Starting engine with booster cable...8214
Other trouble...8216
Electrical system...8216
Chassis...8217
Engine...8219
MAINTENANCE...8222
Guides to maintenance...8223
Outlines of service...8225
Handling oil, fuel, coolant and performing oil clinic...8225
Oil...8225
Fuel...8225
Coolant...8225
Grease...8225
Carrying out KOWA (Komatsu Oil Wear Analysis)...8226
Storing oil and fuel...8226
Filters...8227
Biodegradable hydraulic oil and lubricants...8227
Outline of electric system...8227
Wear parts...8228
Wear parts list...8228
Fuel, coolant and lubricants...8229
Lubrication chart...8229
Proper selection of fuel, coolant and lubricants...8230
Standard tightening torques for bolts and nuts...8232
Torque list...8232
Periodic replacement of safety critical parts...8234
Safety critical parts...8234
Maintenance schedule chart...8236
Maintenance schedule chart...8236
Service procedure...8238
Initial 50 hours service (only after the first 50 hours)...8238
Check for loose wheel hub bolts, tighten...8238
Initial 250 hours service (only after the first 250 hours)...8238
When required...8239
Check, clean, or replace air cleaner element...8239
Dust pre-extractor "Turbo II": check, clean...8242
Clean inside of cooling system...8243
Check oil level in transfer case, add oil...8246
Check axle oil level, add oil...8247
Clean axle case breather...8248
Clean air conditioner condenser...8248
Check window washing fluid level, add fluid...8249
Clean radiator fins and cooler fins...8249
Clean transfer oil cooler fins...8250
Check electrical intake air heater...8250
Replace bolt on cutting edge...8250
Replace bucket teeth...8251
Check air conditioner...8252
Replace slow blow fuse...8253
Selection and inspection of tires...8254
Check before starting...8256
Every 50 hours service...8256
Drain water, sediment from fuel tank...8256
Every 100 hours service...8257
Lubricate rear axle pivot pin...8257
Clean element in air conditioner fresh air filter...8257
Check oil level in hydraulic tank, add oil...8258
Every 250 hours service...8259
Check battery electrolyte level...8259
Check parking brake...8261
Check air conditioner compressor belt tension, adjust...8261
Check for loose wheel hub bolts, tighten...8262
Clean element in air conditioner recirculation filter...8263
Lubricating...8264
Every 500 hours service...8265
Change oil in engine oil pan, replace engine oil filter cartridge...8265
Replace fuel filter cartridge...8266
Clean water separator strainer...8267
Every 1000 hours service...8268
Change oil in transfer case...8268
Clean transfer case breather...8269
Replace HST oil filter element...8270
Lubricating...8271
Check tightening parts of turbocharger...8271
Check play of turbocharger rotor...8271
Check alternator driving belt tension and replacement...8271
Every 2000 hours service...8272
Change oil in hydraulic tank, replace hydraulic filter element...8272
Replace hydraulic tank breather element...8273
Cleaning the strainer of the brake filter...8274
Change axle oil...8275
Replace element in air conditioner recirculation air filter, fresh air filter...8275
Check alternator, starting motor...8275
Check engine valve clearance, adjust...8275
Check brake disc wear...8276
Clean and check turbocharger...8276
Check accumulator gas pressure...8276
Check vibration damper...8276
Every 4000 hours service...8277
Lubricating...8277
Check water pump...8277
TECHNICAL DATA...8278
Technical data...8279
Noise emission levels...8281
Vibration levels...8281
Operating condition:...8281
Guide to Reduce Vibration Levels on Machine...8281
ATTACHMENTS, OPTIONS...8284
Selecting bucket and tires...8285
Method of using 2 levers...8286
Explanation of components...8286
Lift arm control lever...8286
Bucket control lever...8287
Directional selector switch...8287
Directional selector actuation switch...8287
Operation...8288
Using switch to change between forward and reverse...8288
Central lubrication system...8290
Operating the central lubrication system...8290
Display and control unit...8290
Led-display...8290
Pushbuttons...8291
Changing the lubrication interval times...8291
INDEX...8292
Index...8294
NOTES...8296
NOTES...8297
VEAM290100 - Wheel Loader WA250PT-5H Operation & Maintenance Manual...8299
FOREWORD...8301
Foreword...8302
Safety information...8304
Introduction...8306
Directions of machine...8306
Necessary information...8307
Machine serial No. plate and position...8307
Engine serial No. plate and position...8307
Position of service meter...8308
Table to enter serial No. and distributor...8308
Contents...8309
Dimensions, weights and operating data...8315
WA250PT-5H: Dimensions, weights and operating data...8315
CE-conforming equipment...8316
CE-conforming equipment...8316
Manufacturer-supplied CE-conforming equipment, according to document421-93-H1900...8317
SAFETY...8321
Safety labels...8323
Location of safety labels...8323
Presentation of safety labels...8324
General precautions...8327
Safety rules...8327
Precautions for operation...8336
Starting engine...8336
Operation...8337
Transportation...8344
Battery...8345
Towing...8347
Precautions for maintenance...8348
Safety instructions...8348
Precautions with tires...8355
Handling tires...8355
Precautions when storing tires...8355
OPERATION...8357
General view...8359
General view of machine...8359
General view of controls and gauges...8360
Explanation of components...8362
Machine monitor...8362
Monitor system...8363
Types of warning...8364
Central warning lamp...8365
Character display portion...8366
Emergency stop item...8370
Caution items...8372
Warning/limit functions for travel speed...8374
Inspection and maintenance item...8375
Pilot display portion...8377
Meter display portion...8380
Other functions of machine monitor...8382
Switches...8386
Control levers, pedals...8394
Steering tilt lock lever...8397
Cap and cover with lock...8398
Safety bar...8399
Towing pin...8399
Grease pump...8399
Cab door inner lock...8400
Cab door open lock...8400
Cab window open lock cancel knob...8400
Fuse...8401
Fuse capacity and name of circuit...8401
Slow blow fuse...8402
Power outlet...8403
Air conditioner...8404
General locations and function of control panel...8404
Method of operation...8407
Precautions when using...8408
Handling cab wiper...8409
Preventing damage to wiper arm bracket...8409
Operation...8410
Check before starting engine, adjust...8410
Walk-around check...8410
Check before starting...8413
Adjustment...8418
Operations and checks before starting engine...8422
Starting engine...8424
Operations and checks after starting engine...8426
Breaking-in the machine...8426
Normal operation...8426
Stopping engine...8428
Moving the machine (Directional, speed), stopping the machine...8429
Moving the machine...8429
Changing direction...8431
Stopping the machine...8434
Turning...8435
Emergency steering...8435
Operation of work equipment...8436
Handling hydraulic quick coupler...8437
Installing the attachment...8437
Removal and installation of the attachment...8439
Precautions for use...8439
Precautions when removing the attachment...8439
Work possible using wheel loader...8440
Digging operations...8440
Leveling operations...8442
Pushing operation...8442
Load and carry operations...8442
Loading operations...8443
Precautions for operation...8445
Permissible water depth...8445
If wheel brake does not work...8445
Precautions when driving up or down slopes...8445
Adjusting work equipment posture...8446
Adjusting boom kickout...8446
Adjusting bucket positioner...8447
Adjusting fork positioner...8448
Bucket level indicator...8448
Parking machine...8449
Check after stopping engine...8451
Checks after completion of operation...8451
Locking...8451
Handling the tires...8452
Precautions when handling tires...8452
Tire pressure...8452
Precautions for using load and car method...8453
Transportation...8454
Transportation procedure...8454
Loading, unloading work with trailers...8454
Loading...8454
Securing machine...8455
Unloading...8455
Lifting machine...8456
Location of lifting position mark...8457
Weight table...8457
Lifting procedure...8458
Cold weather operation...8459
Precautions for low temperature...8459
Fuel and lubricants...8459
Coolant...8459
Battery...8460
Precautions after completion of work...8461
After cold weather...8461
Warming-up operation for steering hydraulic circuit in cold weather...8461
Long-term storage...8462
Before storage...8462
During storage...8462
After storage...8462
Troubleshooting...8463
When machine runs out of fuel...8463
Towing the machine...8463
When engine can be used...8464
When engine cannot be used...8464
If battery is discharged...8465
Removal and installation of battery...8465
Precautions for charging battery...8466
Starting engine with booster cable...8466
Other trouble...8468
Electrical system...8468
Chassis...8469
Engine...8471
MAINTENANCE...8473
Guides to maintenance...8474
Outlines of service...8476
Handling oil, fuel, coolant and performing oil clinic...8476
Oil...8476
Fuel...8476
Coolant...8476
Grease...8476
Carrying out KOWA (Komatsu Oil Wear Analysis)...8477
Storing oil and fuel...8477
Filters...8478
Biodegradable hydraulic oil and lubricants...8478
Outline of electric system...8478
Wear parts...8479
Wear parts list...8479
Fuel, coolant and lubricants...8480
Lubrication chart...8480
Proper selection of fuel, coolant and lubricants...8481
Standard tightening torques for bolts and nuts...8485
Torque list...8485
Periodic replacement of safety critical parts...8487
Safety critical parts...8487
Maintenance schedule chart...8489
Service schedule...8489
Service procedure...8491
Initial 250 hours service (only after the first 250 hours)...8491
When required...8492
Check, clean, or replace air cleaner element...8492
Dust pre-extractor "Turbo II": check, clean...8495
Clean inside of cooling system...8496
Check oil level in transfer case, add oil...8499
Check axle oil level, add oil...8500
Clean axle case breather...8501
Clean air conditioner condenser...8501
Check window washing fluid level, add fluid...8502
Clean radiator fins and cooler fins...8502
Clean transfer oil cooler fins...8503
Check electrical intake air heater...8503
Replace bolt on cutting edge...8503
Replace bucket teeth...8504
Check air conditioner...8505
Replace slow blow fuse...8506
Selection and inspection of tires...8507
Check before starting...8509
Every 50 hours service...8510
Drain water, sediment from fuel tank...8510
Every 100 hours service...8511
Lubricate rear axle pivot pin...8511
Clean element in air conditioner fresh air filter...8511
Check oil level in hydraulic tank, add oil...8512
Every 250 hours service...8513
Check battery electrolyte level...8513
Check parking brake...8515
Check air conditioner compressor belt tension, adjust...8515
Check for loose wheel hub bolts, tighten...8516
Clean element in air conditioner recirculation filter...8517
Lubricating...8518
Every 500 hours service...8519
Change oil in engine oil pan, replace engine oil filter cartridge...8519
Replace fuel filter cartridge...8520
Clean water separator strainer...8521
Every 1000 hours service...8522
Change oil in transfer case...8522
Clean transfer case breather...8523
Replace HST oil filter element...8524
Lubricating...8525
Check tightening parts of turbocharger...8525
Check play of turbocharger rotor...8525
Check alternator driving belt tension and replacement...8525
Every 2000 hours service...8526
Change oil in hydraulic tank, replace hydraulic filter element...8526
Replace hydraulic tank breather element...8527
Change axle oil...8528
Replace element in air conditioner recirculation air filter, fresh air filter...8528
Check alternator, starting motor...8528
Check engine valve clearance, adjust...8528
Check brake disc wear...8529
Clean and check turbocharger...8529
Check accumulator gas pressure...8529
Check vibration damper...8529
Every 4000 hours service...8530
Lubricating...8530
Check water pump...8530
TECHNICAL DATA...8531
Technical data...8532
Noise emission levels...8534
Vibration level...8534
ATTACHMENTS, OPTIONS...8535
Selecting bucket and tires...8536
Handling fork tool...8537
Explanation of components...8537
Work equipment lever...8537
Operation...8538
Loading operation...8538
Method of using 3 levers...8541
Explanation of components...8541
Lift arm control lever...8541
Bucket control lever...8542
Auxiliary control lever...8542
Directional selector switch...8542
Directional selector actuation switch...8543
Operation...8544
Using switch to change between forward and reverse...8544
Central lubrication system...8546
Operating the central lubrication system...8546
Display and control unit...8546
Led-display...8546
Pushbuttons...8547
Changing the lubrication interval times...8547
INDEX...8549
Index...8551
VEBM230102 - Wheel Loader WA250-5H, WA250PT-5H Shop Manual...8554
FOREWORD...8562
01 GENERAL...8580
GENERAL ASSEMBLY DRAWINGS...8581
SPECIFICATIONS...8582
WEIGHT TABLE...8586
LIST OF LUBRICANT AND COOLANT...8588
10 STRUCTURE & FUNCTION...8590
ENGINE MOUNT AND TRANSFER MOUNT...8591
DAMPER...8592
COOLING SYSTEM...8593
POWER TRAIN...8594
POWER TRAIN SYSTEM DIAGRAM...8595
DRIVE SHAFT (PROPELLER SHAFT)...8597
HST HYDRAULIC PIPING DIAGRAM...8598
HST PUMP...8599
HIGH-PRESSURE RELIEF VALVE...8601
LOW-PRESSURE RELIEF VALVE...8603
HST CHARGE PUMP...8604
SPEED-RELATED VALVE (DA VALVE)...8605
HIGH-PRESSURE CUT-OFF VALVE...8606
HST MOTOR...8607
EP SERVO VALVE...8610
HA SERVO VALVE...8611
FORWARD-REVERSE SHUTTLE VALVE...8612
TRANSFER...8613
TRANSFER OIL COOLER...8624
CLUTCH SOLENOID VALVE...8625
AXLE...8626
DIFFERENTIAL...8629
LIMITED-SLIP DIFFERENTIAL...8635
FINAL DRIVE...8641
AXLE MOUNTING AND CENTER HINGE PIN...8647
STEERING PIPING...8652
STEERING COLUMN...8653
PRIORITY VALVE...8654
ORBIT-ROLL VALVE...8657
2-WAY RESTRICTOR VALVE...8665
STEERING CYLINDER...8666
EMERGENCY STEERING PIPING...8668
EMERGENCY STEERING VALVE...8669
BRAKE PIPING...8672
BRAKE VALVE...8673
INCHING VALVE...8677
CHARGE VALVE...8679
ACCUMULATOR (FOR BRAKE)...8683
SLACK ADJUSTER...8684
BRAKE...8687
PARKING BRAKE CONTROL...8692
PARKING BRAKE...8693
HYDRAULIC PIPING...8695
WORK EQUIPMENT LEVER LINKAGE...8699
HYDRAULIC TANK...8703
4-GEAR PUMP UNIT...8705
ACCUMULATOR (FOR PPC CIRCUIT)...8707
LOCK VALVE...8708
BYPASS VALVE...8709
QUICK COUPLER VALVE...8715
E.C.S.S. VALVE...8716
ACCUMULATOR (FOR E.C.S.S.)...8718
HYDRAULIC PIPING OF COOLING SYSTEM...8719
COOLING FAN MOTOR...8720
WORK EQUIPMENT CONTROL VALVE...8722
WORK EQUIPMENT PPC VALVE...8735
ATTACHMENT PPC VALVE (IF EQUIPPED)...8747
WORK EQUIPMENT LINKAGE...8751
BUCKET...8755
CONTROL OF BUCKET POSITIONER,...8757
WORK EQUIPMENT CYLINDER...8771
AIR CONDITIONER...8775
MACHINE MONITORING SYSTEM...8776
MACHINE MONITOR...8786
LIST OF ITEMS DISPLAYED ON MONITOR...8787
ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)...8813
HST CONTROLLER...8817
FUNCTION OF SELECTING FORWARD-REVERSE SELECTOR SWITCH...8818
ENGINE START CIRCUIT...8820
ENGINE STOP CIRCUIT...8822
PREHEATING CIRCUIT...8823
PARKING BRAKE CIRCUIT...8824
ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM...8827
SENSORS...8828
20 TESTING & ADJUSTING...8834
STANDARD VALUE TABLE FOR ENGINE...8835
STANDARD VALUE TABLE FOR CHASSIS...8836
TESTING AND ADJUSTING...8840
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...8841
MEASURING ENGINE SPEED...8843
MEASURING EXHAUST GAS COLOR...8844
ADJUSTING VALVE CLEARANCE...8845
MEASURING COMPRESSION PRESSURE...8847
MEASURING BLOW-BY PRESSURE...8848
TESTING AND ADJUSTING FUEL INJECTION TIMING...8849
MEASURING ENGINE OIL PRESSURE...8850
MEASURING, TESTING OPERATING FORCE OF ACCELERATOR PEDAL...8851
ADJUSTING ENGINE STOP SOLENOID...8853
ADJUSTING ENGINE SPEED SENSOR...8854
MEASURING DIRECTIONAL LEVER...8855
TESTING AND ADJUSTING HST OIL PRESSURE...8856
MEASURING CLUTCH CONTROL PRESSURER...8861
TESTING AND ADJUSTING STEERING WHEEL...8862
TESTING AND ADJUSTING STEERING OIL PRESSURE...8864
BLEEDING AIR FROM STEERING CIRCUIT...8865
TESTING HYDRAULIC FAN...8866
MEASURING BRAKE PEDAL...8867
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE...8868
MEASURING BRAKE PERFORMANCE...8869
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE...8870
MEASURING BRAKE OIL PRESSURER...8871
MEASURING WEAR OF BRAKE DISC...8873
BLEEDING AIR FROM BRAKE CIRCUIT...8874
MEASURING PARKING BRAKE PERFORMANCE...8875
TESTING AND ADJUSTING PARKING BRAKE LINKAGE...8876
MEASURING PARKING BRAKE RELEASE PRESSURE...8877
MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER...8878
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE...8879
TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE...8880
BLEEDING AIR...8882
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...8883
TESTING AND ADJUSTING BUCKET POSITIONER...8884
TESTING AND ADJUSTING OF BOOM KICK-OUT...8885
CHECKING PROXIMITY SWITCH ACTUATION DISPLAY LAMP...8886
PROCEDURE FOR CHECKING DIODE...8887
SPECIAL FUNCTIONS OF MACHINE MONITOR...8888
FLOW OF MODES AND FUNCTIONS...8889
PM CLINIC INSPECTION CHART...8907
TROUBLESHOOTING...8910
TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)...8964
TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)...8996
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...9052
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)...9122
TROUBLESHOOTING OF ENGINE (S MODE)...9146
30 DISASSEMBLY & ASSEMBLY...9170
HOW TO READ THIS MANUAL...9172
PRECAUTIONS WHEN PERFORMING OPERATION...9174
SPECIAL TOOL LIST...9176
SKETCHES OF SPECIAL TOOLS...9179
REMOVAL, INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY...9185
REMOVAL, INSTALLATION OF NOZZLE HOLDER ASSEMBLY...9189
REMOVAL, INSTALLATION OF CYLINDER HEAD ASSEMBLY...9191
REMOVAL, INSTALLATION OF ENGINE ASSEMBLY...9199
REMOVAL, INSTALLATION OF RADIATOR ASSEMBLY...9206
REMOVAL, INSTALLATION OF AIR AFTERCOOLER...9208
REMOVAL, INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY...9210
REMOVAL, INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY...9212
REMOVAL, INSTALLATION OF FUEL TANK ASSEMBLY...9214
REMOVAL, INSTALLATION OF TRANSFER...9216
DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY...9219
REMOVAL, INSTALLATION OF PARKING BRAKE ASSEMBLY...9239
DISASSEMBLY, ASSEMBLY OF PARKING BRAKE ASSEMBLY...9241
REMOVAL, INSTALLATION OF FRONT AXLE ASSEMBLY...9246
REMOVAL, INSTALLATION OF REAR AXLE ASSEMBLY...9248
DISASSEMBLY, ASSEMBLY OF AXLE HOUSING ASSEMBLY...9251
DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY...9260
REMOVAL, INSTALLATION OF HST PUMP AND 4-GEAR PUMP ASSEMBLY...9286
DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY...9289
REMOVAL, INSTALLATION OF HST MOTOR 1 ASSEMBLY...9315
REMOVAL, INSTALLATION OF HST MOTOR 2 ASSEMBLY...9316
DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY...9317
REMOVAL, INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY...9333
REMOVAL, INSTALLATION OF TRAVEL DAMPER VALVE ASSEMBLY...9335
REMOVAL, INSTALLATION OF HYDRAULIC TANK ASSEMBLY...9337
REMOVAL, INSTALLATION OF WORK EQUIPMENT ASSEMBLY...9339
DISASSEMBLY, ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY...9346
REMOVAL, INSTALLATION OF OPERATOR'S CAB ASSEMBLY...9354
REMOVAL, INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)...9358
REMOVAL, INSTALLATION OF CENTER HINGE PIN...9366
REMOVAL, INSTALLATION OF COUNTERWEIGHT...9375
REMOVAL, INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY...9377
REMOVAL, INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY...9379
REMOVAL, INSTALLATION OF MONITOR PANEL...9380
90 OTHERS...9384
Komatsu Wheel Loaders WA250, WA250L, WA250MC, WA250H, WA250PT, WA250PTL, WA250PTH, WA250PTMC Repair Service Manual
