Service manual Komatsu WA250-5L A73001 & Up, WA250PT-5L A79001 & Up | CEBM011604

Komatsu WA250-5L A73001 & Up, WA250PT-5L A79001 & Up CEBM011604 (Preview)

CEBM011604 – WA250-5L/WA250PT-5L
– CONTENTS
– List of revised pages Rev4.pdf
01 GENERAL
– SPECIFICATION
— WA250-5L/WA250PT-5L DIMENSIONS
— SYSTEM OPERATING PERAMETERS
— WEIGHT TABLE
– FUEL, COOLANT AND LUBRICANTS
10 STRUCTURE AND FUNCTION
– ENGINE AND DRIVE SYSTEM MOUNTING
– DRIVE SYSTEM DAMPER
– COOLING SYSTEM
— REVERSING FAN SYSTEM
— REVERSING FAN MANIFOLD
— PROPORTIONAL RELIEF VALVE
— 2-POSITION, 4-WAY SPOOL VALVE
— FAN CONTROLLER
– POWER TRAIN
— POWER TRAIN SYSTEM DIAGRAM
— DRIVE SHAFT
– HST HYDRAULIC PIPING DIAGRAM
– HST PUMP
— HIGH-PRESSURE RELIEF VALVE
— LOW-PRESSURE RELIEF VALVE
— CHARGE PUMP
— SPEED-RELATED VALVE (DA VALVE)
– HIGH-PRESSURE CUT-OFF VALVE
– HST MOTORS
— HST MOTOR 1
— HST MOTOR 2
— EP SERVO VALVE
— HA SERVO VALVE
— FORWARD-REVERSE SHUTTLE VALVE
– TRANSFER
— INPUT SHAFT PORTION
— OUTPUT SHAFT PORTION
— CLUTCH OPERATION
– TRANSFER OIL COOLER
– CLUTCH SOLENOID VALVE
– AXLES
— FRONT AXLE
— REAR AXLE
– DIFFERENTIALS
— FRONT DIFFERENTIAL
— REAR DIFFERENTIAL
– LIMITED-SLIP DIFFERENTIAL
— FRONT
— REAR
– FINAL DRIVE
— FRONT
— REAR
– AXLE MOUNTING AND CENTER HINGE CARIER
– STEERING PIPING SYSTEM
– STEERING COLUMN
– PRIORITY VALVE
– ORBIT-ROLL VALVE
— STEERING WHEEL IN NEUTRAL
— STEERING WHEEL TURNED (TURNING LEFT)
— CONNECTION BETWEEN HAND PUMP AND SLEEVE
– 2-WAY RESTRICTOR VALVE
– STEERING CYLINDER
– EMERGENCY STEERING PIPING
– EMERGENCY STEERING VALVE
– BRAKE PIPING
– BRAKE VALVE
– INCHING VALVE
– CHARGE VALVE
– ACCUMULATOR (FOR BRAKE)
– SLACK ADJUSTER
– BRAKE
— FRONT
— REAR
– PARKING BRAKE CONTROL
– PARKING BRAKE
– HYDRAULIC PIPING
— WA250PT-5L
— WA250PT-5L
– WORK EQUIPMENT LEVER LINKAGE
— WA250-5L
— MULTI-FUNCTION JOYSTICK TYPE
— JOYSTICK TYPE (IF EQUIPPED)
— WA250PT-5
— MULTI-FUNCTION JOYSTICK TYPE
— JOYSTICK TYPE (IF EQUIPPED)
– HYDRAULIC TANK
— BREATHER
— PREVENTION OF NEGATIVE PRESSURE IN TANK
— PREVENTION OF RISE OF PRESSURE IN TANK
– 4-GEAR PUMP UNIT
– ACCUMULATOR (FOR PPC CIRCUIT)
– LOCK VALVE
– BY-PASS VALVE
— WA250-5L
— WHEN LIFT ARM IS “RAISED”
— WHEN LIFT ARM IS “LOWERED”
— WA250PT-5L
— WHEN BUCKET IS “DUMP” IN FAST MODE (FROM TILT-BACK POSITION TO JUST BEFORE DUMP END)
— WHEN BUCKET IS “DUMP” IN FAST MODE (FROM JUST BEFORE DUMP END TO DUMP END)
– QUICK COUPLER SOLENOID VALVE
– E.C.S.S. VALVE (IF EQUIPPED)
– ACCUMULATOR (FOR E.C.S.S.) (IF EQUIPPED)
– HYDRAULIC PIPING OF COOLING SYSTEM
– COOLING FAN MOTOR
– WORK EQUIPMENT CONTROL VALVE
— 2-SPOOL VALVE
— 3-SPOOL VALVE
— RELIEF VALVE
— SAFETY SUCTION VALVE
— SUCTION VALVE
— OPERATION OF THE WORK EQUIPMENT CONTROL VALVE
— NEUTRAL POSITION OF THE LIFT ARM AND BUCKET SPOOLS
— RAISE POSITION OF THE LIFT ARM SPOOL
— LOWER POSITION OF THE LIFT ARM SPOOL
— FLOAT POSITION OF THE LIFT ARM SPOOL
— ROLL BACK POSITION OF THE BUCKET SPOOL
— DUMP POSITION OF THE BUCKET SPOOL
– WORK EQUIPMENT PPC VALVE
— WHEN IN NEUTRAL
— WHEN IN FINE CONTROL
— WHEN LEVER IS OPERATED TO STROKE END
— WHEN LIFT ARM IS FLOATED
— WHEN FLOAT STATE OF LIFT ARM IS RESET
– ATTACHMENT PPC VALVE (IF EQUIPPED)
— AT THE NEUTRAL POSITION
— AT THE FINE CONTROL POSITION
— AT FULL STROKE
– WORK EQUIPMENT LINKAGE
— WA250-5L
— WA250PT-5L
– BUCKET
— WA250-5L
— WA250PT-5L
– BUCKET POSITIONER, BOOM KICK-OUT, AND DUMP SPEED
— WA250-5L
— BUCKET POSITIONER
— BOOM KICK-OUT
— OPERATION OF PROXIMITY SWITCH
— WA250PT-5L
— BUCKET POSITIONER OR FORK POSITIONER
— BOOM KICK-OUT
— DUMP SPEED CONTROL
— OPERATION OF PROXIMITY SWITCH
– WORK EQUIPMENT CYLINDER
— WA250-5L
— LIFT CYLINDER
— BUCKET CYLINDER
— WA250PT-5L
— LIFT CYLINDER
— BUCKET CYLINDER
— COUPLER PLUNGER
– AIR CONDITIONER PIPING
– MACHINE MONITORING SYSTEM
— OUTLINE
— NORMAL MODE
— SERVICE MODE
— SERVICE METER SETTING
– INDIVIDUAL CIRCUIT DIAGRAMS OF THE MACHINE MONITOR
— STARTING AND LIGHTING
— POWER SUPPLY AND NETWORK
— SENSING
— HST SAFETY CONTROL
— AUTOMATIC PREHEATING
— POWER SUPPLY AND NETWORK
– MACHINE MONITOR
— LIST OF ITEMS DISPLAYED ON MONITOR
— SERVICE MODE FUNCTIONS
— OPERATING METHOD
— ITEMS RELATED TO THE FAULT HISTORY OF ELECTRIC SYSTEM
— ITEMS RELATED TO THE FAULT HISTORY OF MACHINE SYSTEM
— REAL-TIME MONITOR FUNCTION
— HOW TO INPUT INTERVAL
— FUNCTION OF SELECTING OPTIONAL DEVICE
– ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)
– HST CONTROLLER
– SELECTING FORWARD-REVERSE SELECTOR SWITCH
– ENGINE STARTING CIRCUIT
– ENGINE STOP CIRCUIT
– PREHEATING CIRCUIT (AUTOMATIC PREHEAT SYSTEM)
– PARKING BRAKE CIRCUIT
– ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM
– COUPLER PLUNGER CONTROL SYSTEM
– SENSORS
— ENGINE SPEED SENSOR
— TRAVEL SPEED SENSOR
— ENGINE OIL PRESSURE SENSOR
— FUEL LEVEL SENSOR
— COOLANT AND HST OIL TEMPERATURE SENSOR (FOR MONITOR)
— COOLANT TEMPERATURE SENSOR (FOR PREHEATING)
— AXLE OIL TEMPERATURE SENSOR
— HST OIL PRESSURE SENSOR
— STEERING AND EMERGENCY STEERING OIL PRESSURE SENSOR (IF EQUIPPED)
— HST FILTER CLOGGING SENSOR
— COOLANT LEVEL SENSOR
– KOMTRAX SYSTEM
— KOMTRAX TERMINAL SYSTEM
— KOMTRAX TERMINAL
— INPUT AND OUTPUT SIGNALS
20 TESTING, ADJUSTING AND TROUBLESHOOTING
– STANDARD VALUE TABLE
— ENGINE
— CHASSIS
– SPECIAL TOOLS
– ENGINE COMPONENTS
— MEASURING EXHAUST SMOKE
— MEASURING EXHAUST TEMPERATURE
— ADJUSTING VALVE CLEARANCE
— MEASURING COMPRESSION PRESSURE
— MEASURING CRANCASE PRESSURE
— MEASURING ENGINE OIL PRESSURE
— MEASURING BOOST PRESSURE
— MEASURING FUEL PRESSURE
— ADJUSTING ENGINE SPEED SENSOR
— BLEEDING AIR FROM FUEL SYSTEM
– MEASURING ENGINE SPEED
— MEASURING ENGINE SPEED (LOW AND HIGH IDLE)
— MEASURING HST STALL SPEED
— MEASURING HYDRAULIC STALL
— MEASURING FULL STALL SPEED
– OPERATING FORCE OF ACCELERATOR PEDAL
— TESTING OPERATING FORCE
– OPERATING ANGLE OF PEDAL
– ADJUSTING ENGINE STOP SOLENOID
– ADJUSTING ENGINE SPEED SENSOR
– REFRIGERANT COMPRESSOR BELT
– MEASURING DIRECTIONAL LEVER EFFORT
– HST OIL PRESSURE
— MEASURING
— ADJUSTING
– MEASURING CLUTCH CONTROL PRESSURE
– STEERING WHEEL
— MEASURING STEERING WHEEL END PLAY
— MEASURING OPERATING FORCE ON STEERING WHEEL
— MEASURING OPERATING TIME FOR STEERING WHEEL
– STEERING OIL PRESSURE
— MEASURING MAIN RELIEF PRESSURE
— ADJUSTING MAIN RELIEF PRESSURE
— BLEEDING AIR FROM STEERING CIRCUIT
– HYDRAULIC FAN
— MEASURING FAN SPEED
— MEASURING OIL PRESSURE
– REVERSING FAN CONTROLLER, IF EQUIPPED
— LED INDICATORS
– MEASURING BRAKE PEDAL
– BRAKE PEDAL LINKAGE
– MEASURING BRAKE PERFORMANCE
– ACCUMULATOR CHARGE PRESSURE
– MEASURING BRAKE OIL PRESSURE
– MEASURING WEAR OF BRAKE DISC
– BLEEDING AIR FROM BRAKE CIRCUIT
– MEASURING PARKING BRAKE PERFORMANCE
– PARKING BRAKE LINKAGE
– MEASURING PARKING BRAKE RELEASE PRESSURE
– WORK EQUIPMENT CONTROL LEVER
– WORK EQUIPMENT PRESSURE
– WORK EQUIPMENT PPC OIL PRESSURE
— TESTING AND ADJUSTING
— BLEEDING AIR
– RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
– BUCKET POSITIONER
– BOOM KICK-OUT
— TESTING
— ADJUSTING
– PROXIMITY SWITCH ACTUATION DISPLAY LAMP
– PROCEDURE FOR CHECKING DIODE
– SPECIAL FUNCTIONS OF MACHINE MONITOR
– FLOW OF MODES AND FUNCTIONS
— OPERATOR MODE
— SERVICE MODE 1
— SERVICE MODE 2
— CHARACTER DISPLAY
— OPERATING SWITCHES
— OPERATOR MODE OPERATION AND DISPLAYS
— FAILURE CODE TABLE
— *SEPARATE TABLE: DETAILED PHENOMENA OF PROBLEM CODE (L*)
— PROCEDURE FOR SWITCHING TO SERVICE MODE 1 AND SCREEN DISPLAY
— REAL-TIME MONITORING ITEMS
– PM CLINIC INSPECTION CHART
20-101 TROUBLESHOOTING (GENERAL)
– POINTS TO REMEMBER WHEN TROUBLESHOOTING
– SEQUENCE OF EVENTS IN TROUBLESHOOTING
– PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
— PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT
— HANDLING CONTROL BOX
— POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS
— POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT
– CHECKS BEFORE TROUBLESHOOTING
— CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS
— PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO.
– CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
– T-ADAPTER TABLE
– CONNECTOR TYPES AND MOUNTING LOCATIONS
– CONNECTOR LAYOUT DRAWING
20-301 TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)
– POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM
— POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL
— USER CODE MEMORY RETENTION FUNCTION
– HST CONTROLLER SYSTEM DIAGRAM
– TROUBLESHOOTING CODE DISPLAY
— ERROR CODE AND POSSIBLE CAUSE TABLE
– FUSE SYSTEM CHECK
— FUSE PANNEL CONNECTION TABLE
– INFORMATION CONTAINED IN TESTING PROCEDURES
— CODE KEY TABLE
– ERROR CODE: [989F00]
— TRANSMISSION PROTECTION ALERT (00)
– ERROR CODE: [DHH1KX]
— HST OIL PRESSURE SIGNAL OUT OF RANGE
– ERROR CODE: [DLE2LC]
— ENGINE SPEED SENSOR OUT OF RANGE
– ERROR CODE: [DW26KZ]
— MOTOR 2 SOLENOID SYSTEM OPEN OR SHORTED
– ERROR CODE: [DX19KZ]
— MOTOR 1 SOLENOID SYSTEM OPEN OR SHORTED
– ERROR CODE: [DX20KZ]
— CLUTCH SOLENOID SYSTEM OPEN OR SHORTED
– TROUBLESHOOTING CODE: [HST-1]
— DEFECTIVE HST POWER CONTROLLER SOURCE
– TROUBLESHOOTING CODE: [HST-2]
— TRAVEL SPEED RANGES DO NOT CHANGE
– TROUBLESHOOTING CODE: [HST-3]
— TRAVEL SPEED DOES NOT REGISTER
– TROUBLESHOOTING CODE: [HST-4]
— CANNOT CONTROL TRAVEL SPEED WHEN 1ST. GEAR IS SELECTED
– TROUBLESHOOTING CODE: [HST-5]
— TRACTION CONTROL INNOPERABLE
20-402 TROUBLESHOOTING OF HST MONITOR SYSTEM (HST MODE)
– POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM
— POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL
— USER CODE MEMORY RETENTION FUNCTION
– MONITOR SYSTEM CIRCUIT DIAGRAM
– TROUBLESHOOTING CODE DISPLAY
— ERROR CODE AND POSSIBLE CAUSE TABLE
– FUSE SYSTEM CHECK
— FUSE PANNEL CONNECTION TABLE
– INFORMATION CONTAINED IN TESTING PROCEDURES
— CODE KEY TABLE
– ERROR CODE: [15B0NX]
— HST OIL FILTER SHOWING CLOGGED CONDITION
– ERROR CODE: [2G42ZG]
— LOW ACCUMULATOR OIL PRESSURE INDICATED
– ERROR CODE: [989F00]
— TRANSMISSION PROTECTION CAUTION INDICATED
– ERROR CODE: [989FN1]
— HST OVERSPEED CONDITION
– ERROR CODE: [AB00L6]
— DEFECTIVE BATTERY CHARGING CIRCUIT
– ERROR CODE: [AB00MA]
— DEFECTIVE BATTERY CHARGING CIRCUIT
– ERROR CODE: [B@BAZG]
— ABNORMAL ENGINE OIL PRESSURE INDICATED
– ERROR CODE: [B@BCNS]
— ENGINE COOLANT INDICATING OVERHEAT CONDITION
– ERROR CODE: [B@BCZK]
— ABNORMAL COOLANT LEVEL INDICATION
– ERROR CODE: [B@C7NS]
— BRAKE COOLING OIL INDICATING OVERHEATING CONDITION
– ERROR CODE: [B@CRNS]
— HST OIL SHOWING OVERHEATING CONDITION
– ERROR CODE: [D5ZHL6]
— STARTING SWITCH “C” (IGN) INPUT FAILURE INDICATED
– ERROR CODE: [DAF0KT]
— CONTROLLER INTERNAL FAILURE)
– ERROR CODE: [DAJ0KR]
— HST CONTROLLER COMMUNICATION FAILURE
– ERROR CODE: [DD15LD]
— MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET
– ERROR CODE: [DD16LD]
— MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET
– ERROR CODE: [DD17LD]
— MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET
– ERROR CODE: [DD18LD]
— MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET
– ERROR CODE: [DDK3KB]
— IMPROPER INPUT FOR MULTIPUL SHIFT (FNR) LEVER
– ERROR CODE: [DDS5L6]
— DECREASED STEERING OIL PRESSURE
– ERROR CODE: [DGE2KX]
— ENGINE COOLANT TEMPERATURE SENSOR OUT OF RANGE
– ERROR CODE: [DGE3KX]
— ENGINE COOLANT TEMPERATURE SENSOR OUT OF RANGE
– ERROR CODE: [DGH1KX]
— HST OIL SHOWING OVERHEATING CONDITION
– ERROR CODE: [DGR1KX]
— BRAKE COOLING OIL INDICATING SHORT CIRCUIT
– ERROR CODE: [DGR4KX]
— BRAKE COOLING OIL INDICATING OPEN CIRCUIT
– ERROR CODE: [DHE4KA]
— ENGINE OIL PRESSURE INDICATING A SHORT OR OPEN IN THE SYSTEM
– TROUBLESHOOTING CODE: [MON-1]
— PARKING BRAKE INDICATOR LAMP DOES NOT WORK
– TROUBLESHOOTING CODE: [MON-2]
— BRAKE OIL PRESSURE NOT INDICATING CORRECTLY
– TROUBLESHOOTING CODE: [MON-3]
— ENGINE COOLANT SENSOR NOT INDICATING CORRECTLY
– TROUBLESHOOTING CODE: [MON-4]
— HST OIL TEMPERATURE NOT INDICATING CORRECTLY
– TROUBLESHOOTING CODE: [MON-5]
— FUEL LEVEL GAUGE DOES NOT INDICATE PROPERLY
– TROUBLESHOOTING CODE: [MON-6]
— ABNORMAL COOLANT LEVEL INDICATION
– TROUBLESHOOTING CODE: [MON-7]
— STEERING OIL PRESSURE NOT READING CORRECTLY
– TROUBLESHOOTING CODE: [MON-8]
— EMERGENCY STEERING OIL PRESSURE NOT READING CORRECTLY
– TROUBLESHOOTING CODE: [MON-9]
— MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY
– TROUBLESHOOTING CODE: [MON-10]
— MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY
– TROUBLESHOOTING CODE: [MON-11]
— MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY
– TROUBLESHOOTING CODE: [MON-12]
— MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY
– TROUBLESHOOTING CODE: [MON-13]
— ALARM BUZZER DOES NOT STOP OR REMAINS ON
– TROUBLESHOOTING CODE: [MON-14]
— FRONT WINDSHIELD WIPER DOES NOT WORK
— REAR WINDSHIELD WIPER DOES NOT WORK
– TROUBLESHOOTING CODE: [MON-15]
— HEADLAMPS (LO AND HIGH BEAM) DOES NOT FUNCTION
20-501 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
– POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM
— POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL
— USER CODE MEMORY RETENTION FUNCTION
– ELECTRICAL SYSTEM CIRCUIT DIAGRAM
– FUSE SYSTEM CHECK
— FUSE PANEL CONNECTION TABLE
– INFORMATION CONTAINED IN TESTING PROCEDURES
– CODE: (E-1)
— ENGINE WILL NOT CRANK
– CODE: (E-2)
— THE ENGINE DOES NOT SHUT DOWN
– CODE: (E-3)
— COLD START PREHEATER DOES NOT WORK PROPERLY
– CODE: (E-4)
— PARKING BRAKE DOES NOT FUNCTION PROPERLY
– CODE: (E-5)
— EMERGENCY BRAKE SYSTEM DOES NOT FUNCTION
– CODE: (E-6)
— BOOM KICK-OUT FUNCTION NOT WORKING PROPERLY
– CODE: (E-7)
— BUCKET LEVER FUNCTION NOT WORKING PROPERLY
– CODE: (E-8)
— FLOAT HOLD FUNCTION NOT WORKING PROPERLY
– CODE: (E-9)
— FRONT WINDSHIELD WIPER DOES NOT WORK
– CODE: (E-9)
— REAR WINDSHIELD WIPER DOES NOT WORK
– CODE: (E-10)
— THE WINDOW WASHER DOES NOT WORK
– CODE: (E-11)
— HEADLAMPS (LO AND HIGH BEAM) DOES NOT FUNCTION
– CODE: (E-11)
— HEADLAMPS (LO BEAM) DO NOT FUNCTION
– CODE: (E-11)
— HEADLAMPS (HI BEAM) DO NOT FUNCTION
– CODE: (E-11)
— CLEARANCE LAMPS DO NOT FUNCTION
– CODE: [E-11]
— TURN SIGNALS DO NOT FUNCTION
– CODE: (E-11)
— WORK LAMPS DO NOT FUNCTION
– CODE: (E-12)
— HORN DOES NOT SOUND
– CODE: (E-13)
— AIR CONDITIONER SYSTEM DOES NOT WORK
– CODE: (E-13)
— AIR DOES NOT FLOW FROM SYSTEM AND CANNOT BE ADJUSTED
– CODE: (E-13)
— AIR DOES NOT COOL OR TEMPERATURE CANNOT BE ADJUSTED
– CODE: (E-13)
— CANNOT SWITCH BETWEEN CIRCULATED AND VENT FUNCTIONS
– CODE: (E-13)
— CANNOT SWITCH VENT FUNCTIONS
20-601 TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE)
– METHOD OF USING TROUBLESHOOTING CHART
– FAILURE CODE AND CAUSE TABLE
– CODE: (H-1)
— THE MACHINE DOES NOT START
– CODE: (H-2)
— THE TRAVEL SPEED IS SLOW
– CODE: (H-3)
— THE THRUST FORCE IS WEAK
– CODE: (H-4)
— ENGINE STALLS OR ENGINE SPEED DROPS EXCESSIVELY
– CODE: (H-5)
— THE GEARS DO NOT CHANGE SPEED RANGE
– CODE: (H-6)
— THE STEERING WHEEL DOES NOT TURN
– CODE: (H-7)
— STEERING WHEEL MOVEMENT IS HEAVY
– CODE: (H-8)
— STEERING WHEEL SHAKES OR HAS JERKY MOVEMENT
– CODE: (H-9)
— BRAKES DO NOT WORK OR WORKS POORLY
– CODE: (H-10)
— BRAKES IS NOT RELEASING OR DRAGGED
– CODE: (H-11)
— THE PARKING BRAKE IS NOT WORK
– CODE: (H-12)
— THE LIFT ARM DOES NOT RISE OR LOWER
– CODE: (H-13)
— LIFT ARM MOVES SLOW OR RISING FORCE IS POOR
– CODE: (H-14)
— WHEN RISING LIFT ARM, ARM MOVES SLOWLY AT SPECIFIC HEIGHTS
– CODE: (H-15)
— THE LIFT ARM CYLINDER WILL NOT HOLD DOWN THE BUCKET (THE BUCKET RISES)
– CODE: (H-16)
— HYDRAULIC DRIFT ON THE LIFT ARM OCCURS OFTEN
– CODE: (H-17)
— THE LIFT ARM WOBBLES DURING OPERATION
– CODE: (H-18)
— WHEN THE CONTROL LEVER IS SWITCHED FROM “HOLD” TO “RAISE,” THE LIFT ARM FALLS TEMPORARILY
– CODE: (H-19)
— THE BUCKET DOES NOT TILT BACK
– CODE: (H-20)
— BUCKET MOVES SLOW OR THE TILTING-BACK FORCE IS INSUFFICIENT
– CODE: (H-21)
— THE BUCKET OPERATES SLOWLY IN TILTING-BACK
– CODE: (H-22)
— BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET
– CODE: (H-23)
— HYDRAULIC DRIFTS OF THE BUCKET OCCURS OFTEN
– CODE: (H-24)
— THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVE IS SET TO “HOLD”)
– CODE: (H-25)
— WHEN THE CONTROL LEVER IS SWITCHED FROM “HOLD” TO “TILT,” THE BUCKET FALLS TEMPORARILY
– CODE: (H-26)
— CONTROL LEVERS FOR THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY
20-701 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)
– METHOD OF USING TROUBLESHOOTING CHARTS
– (S-1) ENGINE STARTING PERFORMANCE IS POOR
– (S-2) ENGINE HAS STARTING PROBLEMS
— ENGINE DOES NOT CRANK
— ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT OF STACK
— SMOKE COMES OUT OF STACK BUT ENGINE DOES NOT START
– (S-3) ENGINE DOES NOT RUN SMOOTHLY
– (S-4) ENGINE STOPS DURING OPERATIONS
– (S-5) ENGINE SPEED HUNTS
– (S-6) ENGINE LACKS POWER
– (S-7) EXHAUST SMOKE IS BLACK
– (S-8) OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE
– (S-9) OIL BECOMES CONTAMINATED QUICKLY
– (S-10) FUEL CONSUMPTION IS EXCESSIVE
– (S-11) OIL FOUND IN COOLANT, OR COOLANT SPURTS FROM RADIATOR
– (S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP
– (S-13) OIL LEVEL RISES (COOLANT OR FUEL FOUND IN OIL)
– (S-14) COOLANT TEMPERATURE TOO HIGH (OVERHEATING)
– (S-15) ABNORMAL NOISE IS HEARD WHEN ENGINE IS RUNNUNG
– (S-16) EXCESSIVE VIBRATION WHEN ENGINE IS RUNNING
20-901 TROUBLESHOOTING AIR CONDITIONING
– AIR CONDITIONING SYSTEM
— ENVIRONMENTAL IMPACT
— OPERATOR CAB AIR CONDITIONING
— PRINCIPLES OF REFRIGERATION
— AIR CONDITIONING
— THE ACT OF COOLING
— THE REFRIGERATION CYCLE
— AIR CONDITIONER SYSTEM COMPONENTS
— COMPRESSOR (REFRIGERANT PUMP)
— SERVICE VALVES
— CONDENSER
— RECEIVER-DRIER
— THERMOSTATIC EXPANSION VALVE
— EVAPORATOR
— ELECTRICAL CIRCUIT
— THERMOSTAT
— COMPRESSOR CLUTCH
— SAFETY SWITCHES
— SYSTEM SERVICING
— R-134A REFRIGERANT CONTAINERS
— SERVICE TOOLS AND EQUIPMENT
— RECOVERY/RECYCLE STATION
— LEAK DETECTOR
— SERVICE VALVES
— VACUUM PUMP
— MANIFOLD GAUGE SET
— INSTALLING MANIFOLD GAUGE SET
— PURGING AIR FROM SERVICE HOSES
— ADDING REFRIGERANT TO THE SYSTEM (WITHOUT A CHARGING STATION)
— STABILIZING THE AC SYSTEM
— ADDING REFRIGERANT AND STABILIZING THE SYSTEM (WITH A RECOVERY/RECYCLING STATION)
— RECOVERING AND RECYCLING THE REFRIGERANT
— PERFORMING THE RECOVERY CYCLE
— PERFORMING THE RECYCLING PROCEDURE
— EVACUATING AND CHARGING THE AC SYSTEM
— SYSTEM PERFORMANCE TEST
— SYSTEM LEAK TESTING
— ELECTRONIC LEAK DETECTOR
— TRACER DYES
— SOAP AND WATER
— SYSTEM REPAIR
— HOSES AND FITTINGS
— LINES
— EXPANSION VALVE
— RECEIVER-DRIER
— THERMOSTAT
— CLUTCH
— COMPRESSOR
— CHECKING COMPRESSOR OIL LEVEL
— EVACUATING THE SYSTEM
— TROUBLESHOOTING – AIR CONDITIONING SYSTEM
— PRE-DIAGNOSIS CHECKS
— PREPARING FOR DIAGNOSIS
— PRELIMINARY STEPS
— SYSTEM PERFORMANCE TEST
— DIAGNOSIS OF GAUGE READINGS & SYSTEM PERFORMANCE
— TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS
— DEFECTIVE GROUND ON REFRIGERANT COMPRESSOR
— PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM
30 DISASSEMBLY AND ASSEMBLY
– HOW TO USE THIS MANUAL
— REMOVAL AND INSTALLATION OF COMPONANTS
— SPECIAL TOOLS
— OVERHAUL OF COMPONANTS
— SPECIAL TOOLS
— DISASSEMBLY
— ASSEMBLY
– PRECAUTIONS WHEN PERFORMING AN OPERATION
– SPECIAL TOOL LIST
– SKETCHES OF SPECIAL TOOLS
– CONNECTOR REPAIR PROCEDURES
— CONTACT TERMINAL REMOVAL (HD30 TYPE)
— STRIPING INSULATION
— CRIMPING CONTACT TERMINAL (HD30 TYPE)
— INSERTION OF CONTACT TERMINAL (HD30 TYPE)
— CONTACT TERMINAL REMOVAL (DT TYPE)
— STRIPING INSULATION
— CRIMPING CONTACT TERMINAL (DT TYPE)
— INSERTION OF CONTACT TERMINAL (DT TYPE)
– FUEL INJECTION PUMP ASSEMBLY
— SPECIAL TOOLS
— REMOVAL
— INSTALLATION
– NOZZLE HOLDER ASSEMBLY
— SPECIAL TOOLS
— REMOVAL
— INSTALLATION
– CYLINDER HEAD ASSEMBLY
— SPECIAL TOOLS
— REMOVAL
— INSTALLATION
– ENGINE ASSEMBLY
— REMOVAL
— INSTALLATION
– RADIATOR ASSEMBLY
— REMOVAL
— INSTALLATION
– AIR AFTERCOOLER
— REMOVAL
— INSTALLATION
– HYDRAULIC OIL COOLER
— REMOVAL
— INSTALLATION
– COOLING FAN AND FAN MOTOR
— REMOVAL
— INSTALLATION
– FUEL TANK
— REMOVAL
— INSTALLATION
– TRANSFER
— REMOVAL
— INSTALLATION
– TRANSFER ASSEMBLY
— SPECIAL TOOLS
— DISASSEMBLY
— ASSEMBLY
– PARKING BRAKE ASSEMBLY
— REMOVAL
— INSTALLATION
— DISASSEMBLY
— SPECIAL TOOLS
— ASSEMBLY
– FRONT AXLE ASSEMBLY
— REMOVAL
— INSTALLATION
– REAR AXLE ASSEMBLY
— REMOVAL
— INSTALLATION
– AXLE HOUSING ASSEMBLY
— SPECIAL TOOLS
— DISASSEMBLY
— ASSEMBLY
– DIFFERENTIAL ASSEMBLY
— SPECIAL TOOLS
— DISASSEMBLY
— ASSEMBLY
– HST PUMP AND 4-GEAR PUMP ASSEMBLY
— REMOVAL
— INSTALLATION
– HST PUMP ASSEMBLY
— DISASSEMBLY
— ASSEMBLY
– HST MOTOR 1 ASSEMBLY
— REMOVAL
— INSTALLATION
– HST MOTOR 2 ASSEMBLY
— REMOVAL
— INSTALLATION
– HST MOTOR ASSEMBLY
— DISASSEMBLY
— ASSEMBLY
– WORK EQUIPMENT CONTROL VALVE ASSEMBLY
— REMOVAL
— INSTALLATION
– TRAVEL DAMPER VALVE ASSEMBLY
— REMOVAL
— INSTALLATION
– HYDRAULIC TANK
— REMOVAL
— INSTALLATION
– WORK EQUIPMENT ASSEMBLY (Z-BAR LINKAGE)
— REMOVAL
— INSTALLATION
— BUCKET LINK PIN
— BUCKET HINGE PIN
— BUCKET CYLINDER PIN (ON ROD SIDE)
— LIFT CYLINDER PIN (ON ROD SIDE)
— LIFT ARM PIN (ON FRAME SIDE)
— BUCKET LINK PIN
– WORK EQUIPMENT ASSEMBLY (PARELLEL TOOL CARRIER)
— BUCKET (TILT) CYLINDER
— REMOVAL
— INSTALLATION
— BOOM (LIFT) CYLINDER
— REMOVAL
— INSTALLATION
— BOOM AND PARALLEL TOOL LINKAGE
— REMOVAL
— INSTALLATION
– HYDRAULIC CYLINDER ASSEMBLY
— SPECIAL TOOLS
— DISASSEMBLY
— ASSEMBLY
– OPERATOR’S CAB ASSEMBLY
— REMOVAL
— INSTALLATION
– OPERATOR’S CAB GLASS
— SPECIAL TOOLS
— REMOVAL
— INSTALLATION
— COATING MATERIALS
– CENTER HINGE PIN
— REMOVAL
— INSTALLATION
– COUNTERWEIGHT
— REMOVAL
— INSTALLATION
– AIR CONDITIONER UNIT ASSEMBLY
— SPECIAL TOOLS
— REMOVAL
— INSTALLATION
– AIR CONDITIONER COMPRESSOR ASSEMBLY
— SPECIAL TOOLS
— REMOVAL
— INSTALLATION
– MONITOR PANEL
— REMOVAL
— INSTALLATION
– KOMTRAX TERMINAL ASSEMBLY
— REMOVAL
— INSTALLATION
90 SCHEMATICS AND DIAGRAMS
– HYDRAULIC CIRCUIT DIAGRAM
— WA250-5L
— SHEET 1 OF 2
— SHEET 2 OF 2
— WA250PT-5L
— SHEET 1 OF 2
— SHEET 2 OF 2
– ELECTRICAL CIRCUIT DIAGRAM
— MAIN FLOOR HARNESS
— SHEET 1 OF 8
— SHEET 2 OF 8
— SHEET 3 OF 8
— SHEET 4 OF 8
— SHEET 5 OF 8
— SHEET 6 OF 8
— SHEET 7 OF 8
— SHEET 8 OF 8
— HST HARNESS
— ENGINE HARNESS AND REAR HARNESS
— CAB HARNESS
— FRONT HARNESS
— REVERSE FAN WIRING DIAGRAM