Wa250-3 50001-Up Sebm005910

SEBM005910
Machine model Serial number
WA250-3 50001 and up
• This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may
require. Materials and specifications are subject to change without notice.
• WA250-3 mount the S6D95L and S6D102E engine.

For details of the engine, see the 95 and 102 Series Engine Shop Manual.
© 2007
All Rights Reserved 00-1
Printed in Japan 10-07 (01) (10)
Contents
No. of page
01 General.............................................................................................................................. 01-1
10 Structure and function.............................................................................................. 10-1
20 Testing and adjusting ............................................................................................... 20-1
30 Disassembly and assembly ................................................................................... 30-1
40 Maintenance standard .............................................................................................. 40-1
90 Others ................................................................................................................................ 90-1
00-2 WA250-3
(9)
List of revised pages
The affected pages are indicated by the use of the

following marks. It is requested that necessary Mark Indication Action required
actions be taken to these pages according to the
table below. Q Page to be newly added Add
q Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made additions.
LIST OF REVISED PAGES
Time of Time of Time of Time of Time of

Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
q 00-1 (10) 01-1 (3) 10-18 10-46 10-73

00-2 (9) 01-2 (3) 10-19 10-47 10-74
q 00-2-1 (10) 01-3 (3) 10-20 10-48 10-75
q 00-2-2 (10) 01-4 (3) 10-21 10-49 10-76
q 00-2-3 (10) 01-5 (3) 10-22 10-50 10-77
q 00-2-4 (10) 01-6 (3) 10-23 10-51 10-78 (3)
q 00-2-5 (10) 01-7 (3) 10-25 (3) 10-52 10-79
00-3 01-8 (3) 10-26 10-53 10-80
00-4 01-9 (3) 10-27 10-54 (3) 10-81 (3)
00-5 01-10 (3) 10-28 (3) 10-55 10-82
00-6 10-29 10-56 10-83 (3)
00-7 10-30 10-57 (3) 10-84 (3)
00-8 10-1 (6) 10-31 10-58 10-85
00-9 10-2 (3) 10-32 10-59 10-86
00-10 10-4 10-33 10-60 10-87
00-11 10-5 (3) 10-34 10-61 10-88
00-12 10-6 (3) 10-35 10-62 10-89
00-13 10-8 (3) 10-36 10-63 10-90
00-14 10-9 (3) 10-37 10-64 10-91
00-15 10-10 (3) 10-38 (3) 10-65 10-92
00-16 10-11 (3) 10-39 (3) 10-66 10-93
00-17 10-12 10-40 10-67 10-94
00-18 10-13 (3) 10-41 10-68 10-95
00-19 10-14 (3) 10-42 10-69 10-96
00-20 10-15 (3) 10-43 10-70 (3) 10-97
00-21 10-16 (3) 10-44 10-71 (3) 10-98
00-22 10-17 (3) 10-45 10-72 10-99
WA250-3 00-2-1
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10-100 10-143 (6) 20-25 (1) 20-105 (1) 20-145 (1)

10-102 10-144 (6) 20-26 (1) 20-106 (1) 20-146 (1)
10-103 10-145 (6) 20-27 (1) 20-107 (1) 20-147 (1)
10-104 10-146 (6) 20-28 (1) 20-108 (1) 20-148 (1)
10-105 10-147 (6) 20-29 (1) 20-109 (1) 20-150 (1)
10-106 (3) 10-148 (6) 20-30 (1) 20-110 (1) 20-151 (1)
10-107 (3) 10-149 (6) 20-31 (1) 20-111 (1) 20-152 (1)
10-108 (3) 10-150 (6) 20-32 (1) 20-112 (1) 20-153 (1)
10-109 20-33 (1) 20-113 (1) 20-154 (1)
10-115 (1) 20-34 (1) 20-114 (7) 20-155 (1)
10-116 (6) 20-1 (6) 20-35 (1) 20-115 (1) 20-156 (1)
10-117 (6) 20-2 (4) 20-36 (7) 20-116 (1) 20-157 (1)
10-118 (6) 20-2-1 (4) 20-37 (1) 20-117 (1) 20-158-1 (4)
10-119 (3) 20-3 (1) 20-38 (1) 20-118 (1) 20-158-2 (4)
10-120 20-4 (1) 20-39 (1) 20-119 (1) 20-158-3 (4)
10-121 20-5 (4) 20-40 (1) 20-120 (1) 20-158-4 (4)
10-122 (6) 20-6 (4) 20-41 (1) 20-121 (1) 20-158-5 (4)
10-124 20-7 (4) 20-42 (1) 20-122 (4) 20-158-6 (4)
10-125 20-8 (4) 20-43 (1) 20-123 (4) 20-158-7 (4)
10-126 20-9 (1) 20-44 (1) 20-123-1 (4) 20-158-8 (4)
10-127 20-10 (4) 20-45 (1) 20-123-2 (4) 20-158-9 (4)
10-128 (3) 20-11 (4) 20-46 (1) 20-124 (1) 20-158-10 (4)
10-129 (3) 20-12 (4) 20-47 (1) 20-125 (1) 20-158-11 (4)
10-130 (3) 20-13 (4) 20-48 (1) 20-126 (1) 20-158-12 (4)
10-131 (3) 20-14 (4) 20-49 (1) 20-127 (1) 20-158-13 (4)
10-131-1 (3) 20-15 (4) 20-50 (1) 20-128 (1) 20-158-14 (4)
10-131-2 (3) 20-16 (4) 20-51 (1) 20-129 (1) 20-158-15 (4)
10-131-3 (3) 20-17 (4) 20-52 (1) 20-130 (1) 20-158-16 (4)
10-131-4 (3) 20-18 (4) 20-53 (1) 20-131 (1) 20-158-17 (4)
10-132 20-19 (4) 20-54 (1) 20-133 (1) 20-158-18 (4)
10-133 20-20 (4) 20-55 (1) 20-134 (1) 20-158-19 (4)
10-134 20-20-1 (4) 20-56 (1) 20-135 (1) 20-159 (1)
10-135 20-20-2 (4) 20-57 (1) 20-136 (1) 20-160 (1)
10-136 20-20-3 (4) 20-58 (1) 20-137 (1) 20-161 (1)
10-137 (3) 20-20-4 (4) 20-59 (1) 20-139 (4) 20-162 (1)
10-138 20-20-5 (4) 20-140 (1) 20-163 (1)
10-139 20-21 (1) 20-101 (7) 20-141 (1) 20-164 (1)
10-140 20-22 (1) 20-102 (1) 20-142 (1) 20-165 (1)
10-141 20-23 (1) 20-103 (1) 20-143 (1) 20-166 (1)
10-142 20-24 (1) 20-104 (1) 20-144 (1) 20-167 (1)
00-2-2 WA250-3
(10)

20-168 (1) 20-204 (1) 20-235-4 (4) 20-307 (7) 30-15-2 (5)
20-169 (1) 20-205 (1) 20-236 (1) 20-308 (7) 30-16 (5)
20-170 (1) 20-206 (1) 20-237 (1) 20-309 (7) 30-17 (5)
20-171 (1) 20-207 (1) 20-238 (1) 20-310 (7) 30-18 (2)
20-172 (1) 20-208 (1) 20-239 (1) 20-311 (7) 30-19 (5)
20-173 (1) 20-209 (1) 20-240 (1) 20-312 (7) 30-20 (2)
20-174 (1) 20-210 (1) 20-241 (1) 20-313 (7) 30-20-1 (5)
20-175 (1) 20-211 (1) 20-241-1 (7) 20-314 (7) 30-20-2 (5)
20-176 (1) 20-212 (1) 20-241-2 (7) 20-315 (7) 30-20-3 (5)
20-177 (1) 20-214 (4) 20-242 (1) 20-316 (7) 30-20-4 (5)
20-178 (1) 20-215 (1) 20-243 (1) 20-317 (7) 30-20-5 (5)
20-179 (1) 20-215-1 (4) 20-244 (1) 20-318 (7) 30-20-6 (5)
20-180 (1) 20-215-2 (4) 20-245 (1) 30-20-7 (5)
20-181 (4) 20-215-3 (4) 20-246 (1) 30-20-8 (5)
20-182 (4) 20-216 (4) 20-247 (1) 30-1 (5) 30-21 (5)
20-183 (1) 20-217 (4) 20-248 (1) 30-2 (5) 30-22 (2)
20-184 (1) 20-218 (4) 20-249 (1) 30-3 (2) 30-23 (2)
20-185 (1) 20-218-1 (4) 20-250 (1) 30-4 (2) 30-24 (5)
20-185-1 (4) 20-218-2 (4) 20-251 (1) 30-5 (2) 30-24-1 (5)
20-185-2 (4) 20-219 (7) 20-252 (1) 30-7 (5) 30-24-2 (5)
20-185-3 (4) 20-220 (7) 20-253 (1) 30-8 (5) 30-25 (5)
20-185-4 (4) 20-221 (1) 20-254 (1) 30-9 (5) 30-26 (2)
20-186 (4) 20-222 (7) 20-255 (1) 30-9-1 (5) 30-27 (2)
20-186-1 (4) 20-223 (1) 20-256 (1) 30-9-2 (5) 30-28 (5)
20-187 (1) 20-224 (1) 20-257 (1) 30-10 (5) 30-28-1 (5)
20-188 (4) 20-225 (1) 20-258 (1) 30-10-1 (5) 30-28-2 (5)
20-190 (1) 20-226 (1) 20-259 (1) 30-11 (5) 30-28-3 (5)
20-191 (1) 20-227 (1) 20-260 (1) 30-12 (5) 30-28-4 (5)
20-192 (1) 20-227-1 (7) 20-261 (1) 30-12-1 (5) 30-29 (2)
20-193 (1) 20-227-2 (7) 20-262 (1) 30-12-2 (5) 30-30 (2)
20-194 (1) 20-229 (1) 20-263 (1) 30-12-3 (5) 30-31 (2)
20-195 (1) 20-230 (1) 20-264 (1) 30-12-4 (5) 30-32 (2)
20-196 (1) 20-231 (1) 20-265 (1) 30-12-5 (5) 30-33 (2)
20-197 (1) 20-232 (1) 30-12-6 (5) 30-34 (2)
20-198 (1) 20-233 (1) 20-301 (7) 30-13 (5) 30-35 (2)
20-199 (1) 20-234 (4) 20-302 (7) 30-14 (5) 30-36 (2)
20-200 (1) 20-235 (4) 20-303 (7) 30-14-1 (5) 30-37 (2)
20-201 (1) 20-235-1 (4) 20-304 (7) 30-14-2 (5) 30-38 (2)
20-202 (1) 20-235-2 (4) 20-305 (7) 30-15 (5) 30-39 (2)
20-203 (1) 20-235-3 (4) 20-306 (7) 30-15-1 (5) 30-40 (2)
WA250-3 00-2-3
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30-41 (2) 30-81 (2) 30-121 (2) 30-161 (2) 30-201 (2)
30-42 (2) 30-82 (2) 30-122 (2) 30-162 (2) 30-202 (2)
30-43 (2) 30-83 (2) 30-123 (2) 30-163 (2) 30-203 (2)
30-44 (2) 30-84 (2) 30-124 (2) 30-164 (2) 30-204 (2)
30-45 (2) 30-85 (2) 30-125 (2) 30-165 (2) 30-205 (2)
30-46 (2) 30-86 (2) 30-126 (2) 30-166 (2) 30-206 (2)
30-47 (2) 30-87 (2) 30-127 (2) 30-167 (2) 30-207 (2)
30-48 (2) 30-88 (2) 30-128 (2) 30-168 (2) 30-208 (2)
30-49 (2) 30-89 (2) 30-129 (2) 30-169 (2) 30-209 (2)
30-50 (2) 30-90 (2) 30-130 (2) 30-170 (2) 30-210 (2)
30-51 (2) 30-91 (2) 30-131 (2) 30-171 (2) 30-211 (2)
30-52 (2) 30-92 (2) 30-132 (2) 30-172 (2) 30-212 (2)
30-53 (2) 30-93 (2) 30-133 (2) 30-173 (2)
30-54 (2) 30-94 (2) 30-134 (2) 30-174 (2)
30-55 (2) 30-95 (2) 30-135 (2) 30-175 (2) 40-1 (3)
30-56 (2) 30-96 (2) 30-136 (2) 30-176 (2) 40-2 (3)
30-57 (2) 30-97 (2) 30-137 (2) 30-177 (2) 40-2-1 (3)
30-58 (2) 30-98 (2) 30-138 (2) 30-178 (2) 40-3 (3)
30-59 (2) 30-99 (2) 30-139 (2) 30-179 (2) 40-4 (3)
30-60 (2) 30-100 (2) 30-140 (2) 30-180 (2) 40-6
30-61 (2) 30-101 (2) 30-141 (2) 30-181 (2) 40-7
30-62 (2) 30-102 (2) 30-142 (2) 30-182 (2) 40-8
30-63 (2) 30-103 (2) 30-143 (2) 30-183 (2) 40-9 (3)
30-64 (2) 30-104 (2) 30-144 (2) 30-184 (2) 40-10 (9)
30-65 (2) 30-105 (2) 30-145 (2) 30-185 (2) 40-11 (3)
30-66 (2) 30-106 (2) 30-146 (2) 30-186 (2) 40-12 (3)
30-67 (2) 30-107 (2) 30-147 (2) 30-187 (2) 40-13
30-68 (2) 30-108 (2) 30-148 (2) 30-188 (2) 40-14
30-69 (2) 30-109 (2) 30-149 (2) 30-189 (2) 40-15
30-70 (2) 30-110 (2) 30-150 (2) 30-190 (2) 40-16 (3)
30-71 (2) 30-111 (2) 30-151 (2) 30-191 (2) 40-17 (3)
30-72 (2) 30-112 (2) 30-152 (2) 30-192 (2) 40-18
30-73 (2) 30-113 (2) 30-153 (2) 30-193 (2) 40-19 (3)
30-74 (2) 30-114 (2) 30-154 (2) 30-194 (2) 40-20 (3)
30-75 (2) 30-115 (2) 30-155 (2) 30-195 (2) 40-21 (3)
30-76 (2) 30-116 (2) 30-156 (2) 30-196 (2) 40-22 (3)
30-77 (2) 30-117 (2) 30-157 (2) 30-197 (2) 40-23 (3)
30-78 (2) 30-118 (2) 30-158 (2) 30-198 (2) 40-24 (3)
30-79 (2) 30-119 (2) 30-159 (2) 30-199 (2) 40-25 (3)
30-80 (9) 30-120 (2) 30-160 (2) 30-200 (2) 40-26 (3)
00-2-4 WA250-3
(10)

40-27 (3)
40-28 (3)
40-29
40-30 (3)
40-31 (3)
40-32 (3)
40-34
40-35
40-36
40-37
40-38 (3)
40-39 (3)
40-40
40-41 (3)
40-42 (3)
40-43 (3)
90-1 (8)
90-3 (6)
90-5 (6)
90-7 (6)
90-9 (6)
90-11 (8)
90-13 (8)
WA250-3 00-2-5
(10)
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11.When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: · volume to cover all
models
PAGES next to the CONTENTS page.
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
k
Special safety precautions
Safety are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3
4
tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
5
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
Places where oil or water
6
item.
Drain must be drained, and
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may cause

k Heavy parts (25 kg or more) must be lifted the rope to slip off the hook during hoisting, and
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol 4
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
but sling with two or more ropes symmetrically
wound onto the load.
k Slinging with one rope may cause turning
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to of the load during hoisting, untwisting of
the table below: the rope, or slipping of the rope from its
original winding position on the load, which
Wire ropes can result in a dangerous accident.
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
Rope diameter Allowable load
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
mm kN tons with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6
vertically, at various hanging angles.
14 21.6 2.2
16 27.5 2.8
When two ropes sling a load vertically, up to
18 35.3 3.6 19.6 kN {2000 kg} of total weight can be sus-
20 43.1 4.4 pended. This weight becomes 9.8 kN {1000 kg}
22.4 54.9 5.6 when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
★ The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
★ The adapter can be pushed in about 3.5
mm.
★ Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
★ Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used to prevent rubber gaskets, rubber

LT-1A 790-129-9030 150 g Tube
cushions, and cock plug from coming out.
• Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pcs.) container polyprophylene, tetrafluoroethlene and
vinyl chloride), rubber, metal and non-
metal.
• Features:
Polyethylene Resistance to heat and chemicals
LT-2 09940-00030 50 g
container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for metal,
790-129-9060
1 kg glass and plastic.
(Set of adhesive
LT-3 Hardening Can
and hardening
agent:
agent)
Adhesives 500 g
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g
container
Holtz • Used as heat-resisting sealant for
790-126-9120 75 g Tube
MH 705 repairing engine.
• Quick hardening type adhesive
Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type
Aron-alpha Polyethylene
790-129-9130 2g (max. strength after 30 minutes)
201 container
• Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high
648-50 container
temperatures.
• Used as adhesive or sealant for gaskets
LG-1 790-129-9010 200 g Tube
and packing of power train case, etc.
• Used as sealant for various threads, pipe
joints, flanges.
LG-5 790-129-9080 1 kg Can
• Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance to
heat, cold
LG-6 790-129-9020 200 g Tube • Used as sealant for flange surface, tread.
• Used as sealant for oil pan, final drive
Gasket case, etc.
sealant • Features: Silicon based, quick hardening
type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel housing,
intake manifold, oil pan, thermostat
housing, etc.
Three bond • Used as heat-resisting sealant for
790-129-9090 100 g Tube
1211 repairing engine.
• Features: Silicone type, heat resistant,
Three bond vibration resistant, and impact resistant
419-15-18131 100 g Tube
1207B sealing material
• Used as sealing material for transfer case
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used as lubricant for sliding portion (to

LM-G 09940-00051 60 g Can
prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuffling of the
lubricant thread when press fitting or shrink fitting.
LM-P 09940-00040 200 g Tube
• Used as lubricant for linkage, bearings,
etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light load
SYG2-350CA bearing at places in contact with water or
G2-CA SYG2-400CA-A Various Various steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion
SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease
SYGA-16CNM 16 kg Can
LM-G (G2-M)
Hyper White • Seizure resistance and heat resistance
SYG2-400T-A
Grease G2-T higher than molybdenum disulfide grease
SYG2-16CNT 400 g Bellows type
G0-T (*) • Since this grease is white, it does not
SYG0-400T-A (*) 16 kg Can
*: For use in stand out against machine body.
SYG0-16CNT (*)
cold district
Biogrease G2B • Since this grease is decomposed by
SYG2-400B
G2-BT (*) bacteria in short period, it has less effects
SYGA-16CNB 400 g Bellows type
*: For high on microorganisms, animals, and plants.
SYG2-400BT (*) 16 kg Can
temperature
SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side
Glass
PAINT PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
417-926-3910
SUNSTAR • Used as primer for glass side
Glass
GLASS PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
SUNSTAR • Used as primer for painted surface on
Glass
PAINT PRIMER 22M-54-27230 20 ml cab side
Primer container
435-95 (Using limit: 4 months)
• Used as primer for black ceramic-
SUNSTAR
coated surface on glass side and for
GLASS PRIMER 22M-54-27240 150 ml Can
hard polycarbonate-coated surface
435-41
(Using limit: 4 months)
SUNSTAR • Used as primer for sash (Alumite).
Adhesive for cab glass
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months)
container
GP-402
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months)
SUPER 560 container)
SUNSTAR • “S” is used for high-temperature
PENGUINE season (April - October) and “W” for
Adhesive Polyethylene
SEAL 580 417-926-3910 320 ml low-temperature season (November -
container
SUPER “S” or April) as adhesive for glass.
“W” (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml
Sikaflex 256HV container (Using limit: 6 months)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months)
container
SEAL No. 2505
SEKISUI • Used to seal front window.
Caulking Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months)
material container
SEALANT
GE TOSHIBA • Used to seal joint of glasses.
SILICONES 22M-54-27220 333 ml Cartridge Translucent white seal.
TOSSEAL 381 (Using limit: 12 months)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5

8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5

18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1150 – 1440 118 – 147

30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0

8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below. SAD00483
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5

18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

03, 04 20 Varies depending 84 – 132 {8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 {9.5 – 12.5} 107.8 {11.0}
33 33 — 107.8 – 147.0 {11.0 – 15.0} 124.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 — 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 — 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
00-13
TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 0 2 1.02 0 0.20
8 24 0 4 2.45 0 0.41
10 43 0 6 4.38 0 0.61
12 77 0 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.20
1/2 24 0 4 2.45 0 0.41
3/4 36 0 5 3.67 0 0.51
1 60 0 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
type
Nominal size Width across
of hose flats Nominal thread
Thread size size Root diameter
Range Target - Threads per
(mm) inch, Thread series (mm) (Reference)
9
34 – 54 {3.5 – 5.5} 44 {4.5} – — – 18UN 14.3
02 19 16
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} – — – 16UN 17.5
03 16
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 — – 16UN 20.6
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 — – 12UN 30.2
16
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands (mm2) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Blue & Yellow
Green Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL n
6
Color — — — Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line
from (A).
(2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
(3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
(B)
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
(A) 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 04-05
10 STRUCTURE AND FUNCTION
Power train ................................................... 10- 2 Steering, hydraulic pump hydraulic

Path of power transmission ....................... 10- 4 circuit diagram ..................................... 10- 83
Torque converter, transmission piping ..... 10- 6 Work equipment control lever linkage ..... 10- 84
Torque converter, transmission hydraulic Hydraulic tank ............................................. 10- 85
system diagram .................................... 10- 8 Main control valve ...................................... 10- 88
Torque converter, transmission hydraulic Work equipment linkage ............................ 10-102
circuit diagram ...................................... 10- 9 Bucket .......................................................... 10-104
Torque converter ......................................... 10- 10 Bucket positioner and boom kickout ........ 10-105
Torque converter oil filter ........................... 10- 12 Cab ............................................................... 10-109
Transmission ............................................... 10- 13 Machine monitor system ........................... 10-115
Transmission control valve ........................ 10- 25 Main monitor .............................................. 10-116
Drive shaft .................................................... 10- 46 Maintenance monitor display function .... 10-121
041803
Axle ............................................................... 10- 47 Sensor and switches .................................. 10-124

Final drive .................................................... 10- 53 Engine starting circuit ................................ 10-129
Axle mount .................................................. 10- 54 Engine stop circuit ...................................... 10-131
Center hinge pin .......................................... 10- 56 Preheating circuit .................................... 10-131-2
Steering piping ............................................ 10- 57 Starting aid .............................................. 10-131-4
Steering column .......................................... 10- 58 Electrical transmission control .................. 10-132
Priority valve ................................................ 10- 59 Combination switch ................................... 10-133
Steering valve (orbit-roll) ............................ 10- 62 Transmission cut-off function ................... 10-134
2-way restrictor valve .................................. 10- 70 Parking brake neutralizer relay function ... 10-136
Brake piping ................................................. 10- 71 Kick-down switch ....................................... 10-137
Power master cylinder ................................ 10- 72 Kick-down electric circuit diagram ............ 10-138
Brake ............................................................. 10- 76 Transmission auto shift control system
Parking brake control .................................. 10- 78 (if equipped) ......................................... 10-143
Hydraulic piping .......................................... 10- 80
Steering, hydraulic pump hydraulic
system diagram ................................... 10- 82
WA250-3 10-1
(6)
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
1 2 3
041803
4 5 6 7 8
SBW00420
1. Transmission 4. Front axle 7. Rear drive shaft

2. Torque converter 5. Front drive shaft 8. Rear axle
3. Engine 6. Center drive shaft
Outline
• The motive force from engine (3) passes • The motive force from the output shaft of
through the engine flywheel and is transmit- the transmission passes through center drive
ted to torque converter (2), which is con- shaft (6), front drive shaft (5) and rear drive
nected to the input shaft of transmission (1). shaft (7), and is then transmitted to front
• The transmission has six hydraulically actu- axle (4) and rear axle (8) to drive the wheels.
ated clutches, and these provide four speed
ranges for both FORWARD and REVERSE.
The transmission speed ranges are selected
manually.
10-2 WA250-3
3
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM

Alternator terminal R
Starting motor terminal C
Battery
Dimmer switch Buzzer
Relays
CHECK lamps Switch signal

CAUTION lamps LED signal
Flashing synchronous signal
Auto-greasing Work
controller equipment
Main monitor controller
Maintenance monitor
Speed
ECSS range Parking
controller signal Neutral Travel speed
(engine speed)
Network circuit
Sensors
1. Fuel level
2. Engine water temperature
3. Torque converter oil temperature
4. Engine water level
041803
5. Engine oil level

6. Brake oil level
7. Engine oil pressure
SMW01176
Outline
• The machine monitor system uses the sen- • There are also various switches built into
sors and other devices installed to various the monitor panel which function to operate
parts of the machine to observe the condi- the machine.
tion of the machine. It processes this infor-
mation swiftly and displays it on the moni- ª When the optional controller are installed,
tor panel to inform the operator of the con- the main monitor communicates with the
dition of the machine. controller through the network wiring and
• The machine monitor system consists of the functions to display the controller failure
main monitor, maintenance monitor, sen- action code and failure code together with
sors, switches, relays, alarm buzzer, and the time elapsed since the failure (trouble
power source. data display mode).
• The displays can be broadly divided into the
following: Cautions displayed on the moni-
tors (abnormalities in the machine where an
alarm is given) and normal conditions which
are always displayed on the instrument panel
(pilot lamps and readings for the gauges,
speedometer, and service meter).
10-115
1
STRUCTURE AND FUNCTION MAIN MONITOR
MAIN MONITOR
041803
1. CHECK lamp 4C. Hi beam 5. Switches
2. CAUTION lamp 4D. Shift indicator 5A. Auto-greasing switch
3. Caution item 4E. Speedometer 5B. E.C.S.S. switch
3A. Emergency steering 4F. Parking brake 5C. Working lamp (front)
actuated 4G. Emergency steering normal switch
4. Pilot item 4H. Preheating 5D. Working lamp (rear)
4A. Turn signal (left) 4I. Failure action code switch
4B. Turn signal (right) 4J. Shift hold indicator 5E. Transmission cut-off
(If equipped) switch
5F. Auto-shift/Manual selector
switch (If equipped)
Outline
• The main motor has a display function for signals from the sensors and outputs the
the speedometer and other gauges and a display.
switching function to control the electric com- • A liquid crystal display and LEDs are used
ponents and controllers. for the display. The switches are embossed
• There is one CPU (Central Processing Unit) sheet switches.
installed internally, and this processes the
10-116 WA250-3
(6)
MAIN MONITOR DISPLAY FUNCTION
Display
Symbol Display item Display range Display method
category
When there is Display flashes (for details, see

Check Check abnormality display on MAINTENANCE MONITOR
maintenance monitor DISPLAY FUNCTION)
Emergency steering
When actuated Display flashes
actuated
Parking brake actuated,

Display flashes and buzzer
transmission not at
Caution sounds
neutral
Caution
Display flashes (buzzer may
When there is
also sound) (for details, see
abnormality display on
MAINTENANCE MONITOR
maintenance monitor
DISPLAY FUNCTION)
Hi beam When operated Display lights up
Turn signal
When operated Display lights up
(left, right)
Display lights up
Buzzer sounds when parking
041803
Parking brake When operated

brake is applied and shift lever
is not at N
Pilot When normal (oil is

Emergency steering
flowing in hydraulic Display lights up
normal
circuit)
Lights up
Lighting up time changes
according to engine water
Preheating When preheating temperature when starting
switch is turned ON (for details,
see PREHEATING OUTPUT
FUNCTION)
Shift hold
(If equipped) When shift is held Display lights up
Digital display (display switches

Speedo-
Travel speed 0 – 99 km/h between tachometer and
meter
speedometer)
Shift
Shift indicator 1–4N Digital display
indicator
When controller detects

failure and action by Digital display
Failure operator is needed, Buzzer sounds
action Failure action code CALL is displayed, (For details of the travel data
code or CALL and E M M display mode, see TROUBLE
(action code) are DATA DISPLAY MODE)
displayed in turn
WA250-3 10-117
(6)
MAIN MONITOR SWITCH FUNCTION
Item Function Display Actuation
Lights up (goes out Auto-greasing control actuated

momentarily when (automatic greasing carried
switch is turned ON) out at fixed interval)
Forced greasing is carried out Flashes (slowly) Grease empty

Auto-greasing while switch is being pressed
when display is lighted up Abnormality in auto-greasing
Flashes (rapidly)
controller system
Auto-greasing controller not

Goes out
installed
E.C.S.S. function is actuated or Lights up E.C.S.S. function actuated

E.C.S.S. stopped each time switch is
pressed Goes out E.C.S.S. function stopped
Front working lamp lights up

Lights up Front working lamp lights up
Working lamp or goes out each time switch is
(front) pressed when side lamps are
lighted up Goes out Front working lamp goes out
041803
Rear working lamp lights up or
Lights up Rear working lamp lights up
Working lamp goes out each time switch is
(rear) pressed when side lamps are
lighted up Goes out Rear working lamp goes out
Transmission cut-off function is Lights up Cut-off function actuated

Transmission
actuated or stopped each time
cut-off
switch is pressed Goes out Cut-off function stopped
Auto-shift mode is changed Lights up Manual mode

Auto-shift/
to manual mode when switch
Manual selector
is pressed Goes off Auto-shift mode
10-118 WA250-3
(6)
STRUCTURE AND FUNCTION MAINTENANCE MONITOR DISPLAY FUNCTION
MAINTENANCE MONITOR DISPLAY FUNCTION
3A 3B 3C
1A 1B1C 2A 2B 2B 4B
041803
6 4 5 SMW01283
1. Check items (CHECK BEFORE STARTING) 3. Gauges

1A. Engine water level 3A. Fuel level
1B. Engine oil level 3B. Engine water temperature
1C. Brake oil level 3C. Torque converter oil temperature
2. Caution items (CAUTION) 4. Service meter
2A. Engine oil pressure 4A. Service meter counter
2B. Battery charge 4B. Service meter pilot lamp
(1A. Engine water level) 5. Monitor module
(1C. Brake oil level) 6. Switch module
Outline
• The maintenance monitor has a display func- • The monitor module has a built-in CPU
tion for the caution items and gauges, and switch (Central Processing Unit). It processes the
functions to control the work equipment con- signal from the sensors, and carries out
troller (if equipped). the display and output.
• The maintenance monitor consists of the moni- • A liquid crystal display and LEDs are used
tor module, switch module, service meter, case, for the display portions. The switches are
and other mechanisms. embossed sheet switches.
10-121
STRUCTURE AND FUNCTION MAINTENANCE MONITOR DISPLAY FUNCTION
MAINTENANCE MONITOR DISPLAY FUNCTION

Display
Symbol Display item Display range Display method
category
Engine water level Below low level Displays when engine is stopped and
starting switch is ON
Display when normal : OFF
Display when abnormal : Flashes
Check Engine oil level Below low level CHECK lamp flashes
Brake oil level Below low level
Engine water level Below low level Displays when engine is running
Display when abnormal : Flashes
CAUTION lamp flashes
Brake oil level Below low level Buzzer sounds
Below specified
Engine oil pressure
pressure
––––––––––––––––––––-
Engine water temperature Above 102°C Buzzer sounds if above 105°C
041803
Caution ––––––––––––––––––––-
Torque converter oil tem- Above 120°C
perature Buzzer sounds if above 130°C
Displays when engine is running

Fuel level Below low level Display when abnormal : Flashes
CAUTION lamp flashes
Displays when engine is running

When charge is de- Display when normal : OFF
Battery charge
fective Display when abnormal : Flashes
CHECK lamp flashes
Actuated when charge is normal

Service meter 0 – 99999.9 h
Advances 1 for every hour
Service
meter
Lights up when service meter is run-
Service meter indicator
ning
EMPTY FULL
All lamps light up below applicable
1 2 3 4 5 6 7 level
Fuel level
E F Flashes when level is 1
Red Green
6 7 8 0 9 0 9 7 102 106 °C
One place lights up to show applica-

Gauges Engine water temperature 1 2 3 4 5 6 7 ble level
C H
Flashes when level is 6 or 7
White Green Red
50 70 9 0 110 120 130 °C
Torque converter oil tem- One place lights up to show applica-

perature
1 2 3 4 5 6 7 ble level
C H Flashes when level is 6 or 7
Green Red
10-122 WA250-3
(6)
STRUCTURE AND FUNCTION TRANSMISSION AUTO SHIFT CONTROL SYSTEM
TRANSMISSION AUTO SHIFT CONTROL SYSTEM (IF EQUIPPED)
SYSTEM STRUCTURE DIAGRAM
No. Input No. Output

(D) (D)
1 Directional switch signal (1) F solenoid
(D) (D)
2 Range switch signal (2) R solenoid
(D) (D)
3 Transmission cut-off signal (3) HL solenoid
(D) (D)
4 Kick-down switch signal (4) SP solenoid
(D) (D)
5 Holding switch signal Trans- (5) Alarm buzzer signal
(D) (N)
6 Neutralizer relay signal mission (6) Hold signal
(P) controller (N)
7 Travel speed signal (7) Buzzer signal
(P) (N)
8 Engine speed signal (8) Failure code
(D)
9 Model selection signal (Engine)
(D)
0 Manual switch signal
(D)
A Tire selection signal
D: Digital signal
P: Pulse signal
N: Network signal
CONTROL FUNCTION
Auto shift
Hold function
Kick-down function
Safety function
Troubleshooting
Model selection function (Engine)
Outline
• The auto shift control system receives the The transmission controller drives the gear
position signals from the directional (for- shift solenoid valve and automatically car-
ward/reverse) lever and range (gear speed) ries out shift control to select the optimum
lever, the engine speed signal, travel speed speed range for the transmission.
signal, and signals from other switches.
WA250-3 10-143
(6)
SHIFT CONTROL SYSTEM FUNCTION
INPUT SIGNALS OUTPUT SIGNALS

1. Directional lever 1. Transmission solenoid output
This selects F (FORWARD), R (REVERSE), and The F and R solenoids correspond to the F
N (Neutral). and R positions of the directional lever. Po-
sitions "1" to "4" of the speed lever actuate
2. Speed lever the H-L solenoid and speed solenoid to se-
This selects the maximum speed range when lect the clutches to give the 1st to 4th trans-
using auto shift FORWARD or REVERSE. mission speeds. (See Table 1.)
Normally, if the speed lever is at position 2
or above, the transmission will be set to 2nd Table 1. Transmission solenoid output
when the machine starts. Solenoid Clutch
When the auto shift is used, and the gear Speed
range F R HL SP F R 1 2 3 4
shift lever is moved 4 → 3 → 2 → 1 while
the machine is traveling with the transmis- N fi
sion in 4th, the transmission will also shift F1 fi fi fi fi
down immediately 4 → 3 → 2 → 1. (Priority
given to speed lever)
F2 fi fi fi
F3 fi fi fi fi
3. Engine speed sensor F4 fi fi fi fi fi
While the engine is running at low speed (less R1 fi fi fi fi
than 1,450rpm), the auto shift is stopped.
When the gear is shifted between forward
R2 fi fi fi
and reverse or while the machine is coast- R3 fi fi fi fi
ing, the present speed range is maintained R4 fi fi fi fi fi
and the shift shock is reduced.
While the machine is traveling in 2nd, if the
engine speed changes from low speed (less 2. Hold function (maintaining present speed
than 1,450rpm) to high speed (more than range)
1,450rpm), the speed range is kept at 2nd to If the holding switch is turned ON, the cur-
allow the machine to accelerate more easily. rent speed range is held as the maximum
speed range, and even if the travel speed
4. Travel speed sensor goes down, the transmission does not shift
The speed range is determined according to down. However, if the direction of travel is
the travel speed. In addition, the change in shifted between forward and reverse, the
speed is determined from the pulse count to transmission shifts down, and the it shifts
decide whether to shift up or down. up to the above speed range again accord-
ing to the change in the conditions. (This
5. Neutralizer relay prevents any unnecessary shift down on
The parking brake actuation signal is input level ground or unnecessary shift up when
to the controller to shift the transmission to traveling downhill.) (See Table 2., Item 5.)
neutral.
3. Kick-down function
6. Transmission cut-off signal If the operator wishes, he can override all
When the controller receives the transmis- the automatic conditions and shift down for-
sion cut-off signal, it shifts the transmission cibly to 1st (when traveling at a speed be-
to neutral. After the signal is canceled, it low 12.0km/h in 4th or 3rd, or when traveling
selects a speed range that matches the travel at any speed in 2nd). (See Table 2., Item 7.)
speed at the point.
10-144 WA250-3
(6)
When the transmission has been shifted to With the auto shift, the transmission
1st by the kick-down, the switch pump cut- does not shift down to 1st even if
off signal to the electronic governor control- the travel speed drops. Normally, the
ler is switched ON. transmission shifts to 1st only if the
When the travel speed rises, the transmis- speed lever is set to 1 or the kick-
sion is shifted up in accordance with the down switch is pressed.
auto shift up conditions, or it is shifted to b) REVERSE (See Table 2., Item 2.)
2nd when the direction is shifted between When the directional lever is at R
forward and reverse. and the speed lever at "4", the trans-
This function is also available while the mission range is shifted according
speed range is held (hold, engine at low to the travel speed in the same way
speed). as for a).
SHIFT CHARACTERISTICS 2. Changing direction (switching between for-

1. Auto shift (See Table 2., Item 1 and 2.) ward and reverse)
When the engine speed is above 1450rpm, (When the directional lever is shifted to the
the transmission is shifted as follows accord- opposite direction to the travel direction)
ing to the travel speed.
a) FORWARD (See Table 2., Item 1.) If the travel speed and engine speed are in
Directional lever at F, speed lever at "4" area I in Fig. 2, the transmission output shifts
to 2nd speed in the same direction as the
Shift up direction lever regardless of the speed range.
1 When the machine starts, the trans- Following this, the transmission shifts up to
mission is set to the F2 torque con- match the travel speed. (See Table 2., Item 8.)
verter range.
Example:
2 If the accelerator pedal is depressed,
Directional lever: F → N → R
the engine speed rises and the ma-
Transmission output: F4 → N → R2 → R3 → R4
chine travels faster. If the engine
speed continues to rise and the travel
In area II in Fig. 2, the transmission output
speed reaches 10.0km/h (10.5km/h),
reverses, but the speed range shifts down
the transmission is shifted up to F3.
to 2nd in accordance with the travel speed.
If the acceleration is insufficient, the
Then, after the actual direction of travel of
transmission shifts up when the
the machine changes to the same direction
travel speed reaches the figure
as the directional lever, the transmission
shown in ( ).
shifts up in accordance with the travel speed
3 Immediately after the transmission
(to prevent damage to the clutch). (See Ta-
shifts up, the engine speed will drop
ble 2, Items 9 and 10.)
momentarily, but if the machine con-
However, when the hold function is ON, the
tinues to travel faster and the travel
transmission does not shift down.
speed reaches 17.5km/h, the trans-
mission is shifted up to F4. Example:
Directional lever: F → N → R
Shift down Transmission output: F4 → N → R4 → R3 → R2
1 While the machine is traveling in F4, (The transmission shifts down while the ma-
if the load increases and the travel chine is coasting in forward.)
speed drops below 15.5km/h, the R2 → R3→ R4
transmission will shift down F3. (The machine shifts up when traveling in
2 If the travel speed drops further to reverse.)
10.5 km/h (10.0km/h), the transmis- However, if the speed lever is at "1", the
sion is shifted down to F2. transmission remains in 1st.
If the deceleration is insufficient, the
transmission shifts down when the 3. Switching F–N–F (R–N–R) (lever returned)
travel speed drops to the figure A speed range that matches the current
shown in ( ). speed is selected. (See Table 2., Items 11
and 12.)
WA250-3 10-145
(6)
4. Skip shift Table 2. Gear shift characteristics

While the machine is coasting in 3rd or 4th Speed No-Shift
Item Clutch (km/h) time (sec)
(engine speed below 1450rpm), if the accel-
erator pedal is depressed (engine speed 1. Normal gear shift 1→2 Min. 5.0 (5.2) 2
Directional lever: F 2→3 Min.10.0 (10.5) 2
above 1450rpm), the speed range is held if
3→4 Min. 17.5 1
the current travel speed is higher than 8km/ 4→3 Less than 15.5 1
h. If the current travel speed is less than 3→2 Less than 10.5 (10.0) 2
8km/h, the transmission is shifted down to 2. Normal gear shift 1→2 Min. 5.0 (5.2) 2
2nd to make it easier to accelerate. (See Ta- Directional lever: R 2→3 Min.10.0 (10.5) 2
ble 2., Item 4.) 3→4 Min. 18.2 1
4→3 Less than 16.2 1
3→2 Less than 10.5 (10.0) 2
5. No-shift time
This is the time that the speed range is held 3. Engine speed 4→2 Less than 1.0 0
(less than 1450rpm) 3→2 Less than 1.0 0
after shifting (to prevent shift hunting). No-
shift time varies with the shift conditions. 4. Engine speed 4→2 Less than 8.0
(less than 1450rpm→ 3→2 Less than 8.0 (ª1)
(See Table 2.)
more than 1450rpm)
5. Shifting up when 1→2 Min. 5.0 0
hold is ON 2→3 Min. 10.0 0
Directional lever: F 3→4 Min. 17.5 0
Fig. 1. Automatic gear shift graph 6. Shifting up when 1→2 Min. 5.0 0
hold is ON 2→3 Min. 10.0 0
Directional lever: R 3→4 Min. 18.2 0
7. Kick-down 2→1 all range 5
OFF → ON 3→1 Less than 12.0 5
4→1 Less than 12.0 5
8. Directional lever 4→2 Note 1) 2
(Area I) (F→)N→R 3→2 ............. 2
(R→)N→F 1→2 2
9. Directional lever →4 Min. 18.2 0
(Area II) (F→)N→R →3 Less than 16.0 – 0
18.2 Note 2)
(Area II) (R→)N→F →3 Less than 16.0 – 0
17.5 Note 3)
(F→)N→F →3 Less than 10.0 – 0
17.5
→2 Less than 10.5 0
(R→)N→R →3 Less than 10.0 – 0
18.2
→2 Less than 10.5 0
ª1
No-shift time before No-shift time after
shifting shifting
4th → 2nd 1.2 sec 2.0 sec
3rd → 2nd 0.8 sec 2.0 sec
Note 1) Engine speed less than 2000rpm and travel

speed less than 16km/h, or travel speed less
than 13km/h
Note 2) when engine speed is more than 2000rpm
→ 3: if travel speed is 13km/h to 18.0km/h
Note 3) when engine speed is more than 2000rpm
→ 3: if travel speed is 13km/h to 17.5km/h
See Fig. 2., for details of Area I and Area II.
10-146 WA250-3
(6)
SAFETY FUNCTION
1. Alarm buzzer 5. Manual shift
If the direction of travel is switched between If there should be any disconnection in the
forward and reverse in area III in Fig. 3 (travel travel speed sensor or any other failure, and
speed above 13km/h and engine speed above the input of the travel speed stops, the lever
1800rpm, or travel speed above 14km/h), the operation becomes manual.
alarm buzzer will sound to prevent damage Example:
to the clutch. Directional lever F, speed lever 4 → F4
2. N priority for directional lever Directional lever R, speed lever 2 → R2
The controller is equipped with an interlock 6. Speed limiter
function which always gives the neutral out- When the travel speed rises too high, warn-
put when the lever is at N. ing is given to the operator to protect the
3. Neutral safety brake. If the travel speed rises further, the
When the directional lever is at any position gear is shifted down automatically.
other than N, the transmission is set in neu- • Explanation of operation
tral and the machine does not start even if (1) When the travel speed exceeds 38 km/h,
the starter switch is turned ON. This condi- the caution buzzer sounds.
tion is canceled if the directional lever is (2) When the travel speed rises to 40 km/h,
returned to the N position. (To prevent un- the gear is shifted down from F4 to F3.
expected movement of the machine when (3) When the travel speed lowers to be-
the engine is started.) low 35 km/h, the caution buzzer stops
4. Speed lever priority sounding.
If the speed lever is shifted down when (4) When the travel speed lowers to be-
traveling downhill, the transmission is shifted low 17.5 km/h, the gear is shifted up
down immediately to make use of the brak- from F3 to F4.
ing force of the engine. • Tire selecting function of speed limiter
The tire selecting function is used to set
Fig. 2. Shift pattern between F and R the operating speed of the speed limiter,
depending on the tire size. Tire sizes are
selected with the wiring circuit installed
to the floor wiring harness in the right
console box of the operator’s seat.
20.5-25 tire (Overseas specification): Con-
nect one-pin connector (1).
The figure shows the inside of the right console box seen from above.
WA250-3 10-147
(6)
TROUBLSHOOTING
The controller always observes if the elec-

tronic devices such as the engine speed sen-
sor and travel speed sensor from which the
controller receives signals, the solenoid
valves which receives output signals of the
controller, etc. are functioning normally.
If there is any abnormality in any of these
devices, the controller judges the condition
and informs the operator of the result with
the alarm buzzer, and at the same time, dis-
plays the abnormality as a failure code on
the main monitor.
MODEL SELECTION SIGNALS
This controller has data tables for two mod-

els, and can handle them by means of the
following selection signals when the starter
switch is turned ON.
Pin
CNL74 [6] CNL74 [7]
Model
WA200/250 OPEN OPEN

GND: Connect to CN2 [9] (Signal ground)
Fig. 3. Alarm buzzer area for shifting

between F and R
10-148 WA250-3
(6)
TRANSMISSION CONTROLLER
Connector signals
CN1 CN2 CN3

1 NETWORK signal (To main monitor) 1 Direction switch, F 1
2 2 Range switch, 2 2
4 4 Neutralizer relay signal 4 Travel speed signal (+)
5 5 Manual selector switch 5 Engine revolution signal
6 6 Model selector 2 6
7 7 Model selector 1 7
8 Power supply input (+24 V) 8 Engine selector 8 Manual signal output
9 GND 9 Signal GND output 9
10 HL, Sol 10 10
11 SP, Sol 11 Direction switch, N 11
12 NETWORK signal (To main monitor) 12 Direction switch, R 12 Travel speed signal (-), Engine revolution signal (-)
13 Neutralizer relay power supply (+24 V) 13 Range switch, 1 13
15 15 Tire selector 15 Buzzer signal output
16 16 Transmission cut-off switch 16
17 Sol. power supply input (+24 V) 17 Kick-down switch
18 Power supply input (+24 V) 18 Hold switch
19 GND 19
20 R, Sol 20
21 F, Sol
WA250-3 10-149
(6)
LED Display
fl When reading the display, set the controller

connector to your side.
1. When normal
The software No. is displayed for about 6
seconds after the key is turned ON. Then,
the output gear speed is displayed. While
the software No. is displayed, the selecting
conditions of tire selection (Dot [1]) and en-
gine selection (Dot [2]) are displayed. (If an
item is selected, its dot lights up.)
(Software No.) ‘d d ’ → ‘7 8 ’ → ‘2 3 ’ → ‘1 3 ’
˚ ˚ ˚ ˚ ˚ ˚ ˚ ˚
→ ‘A 5 ’ → ‘0 0 ’ → ‘d d ’ → (Gear speed) ‘02’
˚ ˚ ˚ ˚ ˚ ˚
Gear speed display codes (Right letter indicates
direction and left figure indicates gear speed)
‘02’ : Neutral, 2nd
‘F1’ : Forward, 1st
‘F2’ : Forward, 2nd
‘A3’ : Reverse, 3rd
‘A4’ : Reverse, 4th
2. When trouble is detected

‘E-’ and the codes corresponding to the trou-
bles are displayed in order at intervals of 1
second.
The troubles are display in the order of de-
tection time. They are cleared and are not
saved when the key is turned OFF. The trou-
ble history is in the main monitor is main-
tained, as it is, however.
Example)
‘E-’ → ‘23’ → ‘E-’ → ‘14’ → Repeated
The above display indicates abnormality in

the engine speed sensor and auto-shift HL
solenoid system.
‘12’ : Abnormality in F sol system

‘13’ : Abnormality in R sol system
‘14’ : Abnormality in HL sol system
‘16’ : Abnormality in SP sol system
‘20’ : Abnormality in direction SW signal system
‘21’ : Abnormality in range SW signal system
‘22’ : Abnormality in travel speed sensor system
‘23’ : Abnormality in engine speed sensor system
10-150 WA250-3
(6)
TESTING AND ADJUSTING
20 TESTING AND ADJUSTING
Standard value table for engine ........................ 20- 2 Testing and adjusting steering wheel ............... 20- 31
Standard value table for chassis ........................ 20- 3 Measuring steering oil pressure ....................... 20- 34
Standard value table for electrical parts ........... 20- 6 Measuring brake pedal ....................................... 20- 36
Tools for testing, adjusting, Testing and adjusting brake pedal linkage ...... 20- 37
and troubleshooting ..................................... 20- 8 Measuring brake performance .......................... 20- 39
Adjusting valve clearance ................................... 20- 10 Measuring brake oil pressure ............................ 20- 40
Measuring compression pressure ...................... 20- 12 Measuring wear of brake disc ........................... 20- 41
Testing and adjusting fuel injection timing ...... 20- 13 Bleeding air from brake system ........................ 20- 42
Measuring exhaust color .................................... 20- 15 Measuring parking brake performance ............ 20- 43
Measuring blow-by pressure .............................. 20- 16 Testing and adjusting parking brake linkage .. 20- 44
Testing and adjusting fan belt tension ............. 20- 18 Testing parking brake piston storoke ............... 20- 45
Measuring engine speed ..................................... 20- 19 Measuring wear of parking brake disc ............. 20- 46
Method for adjusting engine Measuring and adjusting
stop motor cable ........................................ 20-20-1 work equipment control lever .................... 20- 47
Adjusting engine stop solenoid ...................... 20-20-3 Measuring storoke of
Measuring engine oil pressure ....................... 20-20-4 work equipment valve apool ...................... 20- 50
Measuring intake air pressure Measuring work equipment
041803
(Boost pressure) ......................................... 20-20-5 hydraulic pressure ....................................... 20- 51

Measuring exhaust gas temperature ................. 20- 21 Measuring work equipment ............................... 20- 53
Measuring accelerator pedal .............................. 20- 22 Testing and adjusting bucket positioner .......... 20- 55
Measuring shift lever ........................................... 20- 24 Testing and adjusting boom kick-out ............... 20- 56
Measuring stall speed ......................................... 20- 25 Adjusting main monitor
Measuring torque converter, (speedometer module) ................................ 20- 58
transmission, oil pressure ........................... 20- 27 Checking for abnormality in
Method of operating emergency fuel level sensor ........................................... 20- 59
manual spool ................................................ 20- 29 TROUBLESHOOTING .......................................... 20- 101
fl When using the standard value table to make judgement for testing and adjusting, and troubleshooting, the
following precautions are necessary.
1. The standard values in the table are the values for a new machine and are given as reference values for the
time when the machine is shipped from the factory. These values should be used as a guide when estimating
wear and tear after the machine is operated, and when carrying out repairs.
2. The permissible values given in the table are values estimated based on the results of various tests carried
out on the machines shipped from the factory, so they should be used together with the information on the
repair condition and other information such as the operating history of the machine when judging the
condition of the machine.
3. These standard values do not form a basis for judging claims.
¤ When carrying out testing, adjusting, or troubleshooting, park the machine on level ground and use the
safety pins and blocks to prevent the machine from moving.
¤ When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.
¤ When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
¤ Be careful not to get caught in the fan, fan belt, or other rotating parts.
WA250-3 20-1
(6)
1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE

Serial No. 50001 – 52999
Machine model WA250-3
Engine S6D95L-1
Cate-
gory Item Measurement conditions Unit Standard value Permissible value
+25 +25
Low idling 775 –50 775 –50
Engine speed rpm
Performance
+25 +25
High idling 2600 –50 2600 –50
Ambient temperature:
0°C (without starting aid) Min. 150 —
Speed needed to start rpm
Ambient temperature: Min. 100 —
–20°C (with starting aid)
Intake resistance Whole speed range mmH2O Max. 300 762
Intake, exhaust system
Air pressure
(Boost pressure) Whole speed range mmHg Min. 600 500
Whole speed range (am- Max. 650

Exhaust temperature bient temperature: 20°C) °C
At sudden acceleration Bosch Max. 6.0 7.5

Exhaust gas color
At high idling index Max. 1.0 2.0
Valve clearance Intake valve 0.35 —

mm
(normal temperature)
041803
Exhaust valve 0.50 —
Compression pressure Oil temperature: 40 – MPa 2 Min. 2.7 2.0

{kg/cm } {Min. 28.0} {20}
Engine
60°C (320 – 360 rpm)

proper
High idling (engine wa-

Blow-by pressure ter temperature gauge mmH2O Max. 50 100
within green range)
0.34 – 0.69 0.25
SAE30 oil {3.5 – 7.0} {2.5}
High idling
0.29 – 0.69 0.21
Lubrication system
Oil pressure SAE10 oil

(engine water tempera- MPa {3.0 – 7.0} {2.1}
ture gauge within green {kg/cm2} Min. 0.1 0.07
range) SAE30 oil {0.7}
{Min. 1.0}
Low idling
Min. 0.08 0.07
SAE10 oil {0.7}
{Min. 0.8}
Oil temperature Whole speed range 80 – 110 120

(inside oil pan) °C
Oil consumption ratio (at % Max. 0.5 1.0

Oil consumption continuous rated output)
19.6 +– 0.5
1.5
Fuel system
16.7
Fuel injection pressure Nozzle tester MPa
{kg/cm2} + 15
{200 – 5 } {170}
Fuel injection timing Before compression top °

(deg.) 20 ± 1 20 ± 1
dead center
MPa
Radiator pressure valve Cracking pressure 0.07 ± 0.01 0.07 ± 0.01
Cooling system
(differential pressure) {kg/cm2} {0.7 ± 0.1} {0.7 ± 0.1}

Fan speed Rated speed rpm 1,920 ± 50 1,920 ± 50
Deflection when
Fan belt tension pressed with finger
force of approx. 58.8 N mm 8 6 – 10
(alternator – fan pulley)
{6 kg}
20-2 WA250-3
4
1
TESTING AND ADJUSTING MEASURING BRAKE PEDAL
MEASURING BRAKE PEDAL

fl Measurement conditions q
• Engine water temperature: Within green range
on engine water temperature gauge
• Engine speed: Low idling
Operating effort of pedal

1. Install push gauge [1] to the operator’s foot.
fl Align the center of the push gauge with a
point 150 mm from the fulcrum of the pedal.
2. Start the engine, run at low idling, and measure
the operating effort when the pedal is depressed. TNW00952
Travel of pedal
1. Install push gauge [1] to the operator’s foot.
fl Align the center of the push gauge with a
point 150 mm from the fulcrum of the pedal. w
2. Start the engine, and measure the pedal angle
when running at low idling with the pedal de-
pressed with a force of 205.9 N (21 kg).
3. Next, put angle meter [2] in contact with the
pedal and measure operating angle "α" from
position "α1" to position "α2" when the pedal is
depressed with a force of 205.9 N (21 kg).
041803
fl Operating angle "α" = α1 – α2
TNW00953
α
15
0m
m
α2 α1
Pedal fulcrum
TMW00954
20-36
(7)
1
TROUBLESHOOTING
Points to remember when troubleshooting ........................................................................................ 20-102

Sequence of events in troubleshooting .............................................................................................. 20-103
Precautions when carrying out maintenance ..................................................................................... 20-104
Handling connectors .............................................................................................................................. 20-111
Checks before troubleshooting ............................................................................................................ 20-112
Judgement of power train ..................................................................................................................... 20-113
Method of using troubleshooting charts ............................................................................................ 20-114
Connector types and mounting locations ............................................................................................ 20-122
Connector pin arrangement diagram .................................................................................................. 20-123
Connection table for connector pin numbers .................................................................................... 20-124
Electrical circuit diagram for each system ........................................................................................... 20-133
Engine start, stop system ................................................................................................................ 20-133
Preheating system ............................................................................................................................ 20-134
Transmission control, parking brake system ................................................................................ 20-135
Machine monitor system ................................................................................................................. 20-136
Troubleshooting of engine (S6D95L) system (S mode) [Serial No.: 50001 – 52999] .................... 20-139
Troubleshooting of engine (S6D102E) system (S mode) [Serial No.: 53001 and up] ............... 20-158-1
Troubleshooting of hydraulic and mechanical system (Chassis related) (T mode) ...................... 20-159
Troubleshooting of electrical system for engine, transmission (E mode) ...................................... 20-181
041803
Troubleshooting of main monitor system (M mode) ........................................................................ 20-219

Troubleshooting of maintenance monitor system (K mode) ........................................................... 20-247
Troubleshooting of transmission controller system (A mode) ........................................................ 20-301
WA250-3 20-101
1
(7)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code number
Troubleshooting code No. Component
S- Troubleshooting of engine
M- Troubleshooting of main monitor
K- Troubleshooting of maintenance monitor
E- Troubleshooting of electrical system
T- Troubleshooting of hydraulic and mechanical system
A- Troubleshooting of transmission controller
2. Method of using troubleshooting table for each troubleshooting mode

1) Troubleshooting code number and problem
The title of the troubleshooting chart gives the troubleshooting code, service code, and failure
mode (problem with the machine). (See Example (1))
2) Distinguishing conditions
Even with the same failure mode (problem), the method of troubleshooting may differ accord-
ing to the model, component, or problem. In such cases, the failure mode (problem) is further
divided into sections marked with small letters (for example, (a)), so go to the appropriate
section to carry out troubleshooting.
If the troubleshooting table is not divided into sections, start troubleshooting from the first
check item in the failure mode. (See Example (2))
3) Method of following troubleshooting chart YES
• Check or measure the item inside NO
, and according to the answer follow either the
YES line or the NO line to go to the next . (Note: The number written at the top right
corner of the is an index number; it does not indicate the order to follow.)
041803
• Following the YES or NO lines according to the results of the check or measurement will
lead finally to the Cause column. Check the cause and take the action given in the Remedy
column on the right. (See Example (3))
• Below the [ ] there are the methods for inspection or measurement, and the judgement
values.
If the judgement values below the are correct or the answer to the question inside the
is YES, follow the YES line; if the judgement value is not correct, or the answer to the
question is NO, follow the NO line.
• Below the is given the preparatory work needed for inspection and measurement, and
the judgement values. If this preparatory work is neglected, or the method of operation or
handling is mistaken, there is danger that it may cause mistaken judgement, or the equip-
ment may be damaged. Therefore, before starting inspection or measurement, always read
the instructions carefully, and start the work in order from Item 1).
4) General precautions
When carrying out troubleshooting for the failure mode (problem), precautions that apply to all
items are given at the top of the page and marked with fl. (See Example (4))
The precautions marked fl are not given in the , but must always be followed when
carrying out the check inside the .
5) Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For de-
tails, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
6) Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin
number connection. When carrying out troubleshooting, see this chart for details of the con-
nector pin number and location for inspection and measurement of the wiring connector
number appearing in the troubleshooting flow chart for each failure mode (problem).
20-114
(7)
1
TROUBLESHOOTING OF
MAIN MONITOR SYSTEM
(M MODE)
Trouble data display ............................................................................................................................... 20-221

Table of action codes and failure codes .............................................................................................. 20-222
M- 1 Main monitor does not work .................................................................................................... 20-223
M- 2 When starting switch is turned ON and engine is started immediately,
all lamps stay lighted up ..................................................................................... 20-224
M- 3 Speedometer display does not work properly ....................................................................... 20-225
M- 4 Abnormality in shift indicator................................................................................................... 20-226
(a) Stays at N even when directional lever is at F ................................................................ 20-226
(b) Stays at N even when directional lever is at R ............................................................... 20-226
(c) Does not display N even when directional lever is at N
and displays E when directional lever is at F ................................................... 20-226
(d) Does not display N even when directional lever is at N
and displays E when directional lever is at R .................................................. 20-227
(e) Does not display 1st, 4th .................................................................................................... 20-227
( f ) Does not display 3rd, 4th ................................................................................................... 20-227
fl For auto shift control spec.
(e-1) Does not display 1st, 4th .............................................................................................. 20-227-1
(f-1) Does not display 3rd, 4th ............................................................................................. 20-227-1
(g) Does not display 2nd, 3rd ............................................................................................... 20-227-2
(h) Does not display 1st, 2nd ................................................................................................ 20-227-2
041803
M- 5 High beam does not light up ................................................................................................... 20-229

M- 6 Turn signal display does not light up ..................................................................................... 20-230
(a) L.H. turn signal does not light up ..................................................................................... 20-230
(b) R.H. turn signal does not light up ..................................................................................... 20-230
M- 7 Abnormality in parking display ................................................................................................ 20-231
(a) Parking lamp does not light up ......................................................................................... 20-231
(b) Parking lamp stays lighted up ........................................................................................... 20-231
M- 8 Abnormality in preheating system .......................................................................................... 20-232
(a) Does not carry out preheating ........................................................................................... 20-232
(1) Monitor display also does not light up ............................................................................ 20-232
(2) Only monitor display lights up .......................................................................................... 20-232
(b) Only monitor display does not light up ........................................................................... 20-233
(c) Always carries out preheating for 1 minute .................................................................... 20-233
(d) Preheating stays on ............................................................................................................. 20-233
(e) Preheating time becomes shorter, or is unstable ........................................................... 20-234
M- 9 Night lighting does not light up ............................................................................................... 20-236
M-10 Abnormality in front working lamp ......................................................................................... 20-237
(a) Neither monitor display nor front working lamp light up .............................................. 20-237
(b) Working lamp lights up but monitor display does not light up .................................... 20-237
(c) Monitor lights up but working lamp does not light up .................................................. 20-237
M-11 Abnormality in rear working lamp .......................................................................................... 20-238
(a) Neither monitor display nor rear working lamp light up ............................................... 20-238
(b) Working lamp lights up but monitor display does not light up .................................... 20-238
(c) Monitor lights up but working lamp does not light up .................................................. 20-238
20-219
1
(7)
M-12 Abnormality in transmission cut-off ........................................................................................ 20-240
(a) When monitor switch is pressed,
cut-off function is not switched and display is not given ............................... 20-240
(b) Monitor display goes out but cut-off function stays on ................................................. 20-240
(c) Monitor display lights up but cut-off function is not actuated ...................................... 20-241
(a) When monitor switch is pressed, cut-off function and its display do not change ....... 20-241-1
(b) Display on monitor goes off but cut-off function operates if pedal is pressed ........ 20-241-1
(c) If display of monitor is turned OFF, cut-off function always operates ...................... 20-241-1
(d) Cut-off function operates, regardless of display on monitor ...................................... 20-241-1
(e) Display on monitor lights up but cut-off function does not operate ......................... 20-241-2
M-13 Abnormality in parking brake dragging warning ................................................................... 20-242
(a) When parking brake is applied, buzzer sounds (intermittently)
even when directional lever is at N, and caution lamp flashes ..................... 20-242
(b) When parking brake is applied, buzzer does not sound and caution lamp
does not light up even when directional lever is at position other than N .. 20-242
M-14 When parking brake dragging warning is given, buzzer
and caution lamp are actuated continuously, or they are not actuated ....... 20-243
(a) Actuated continuously ........................................................................................................ 20-243
(b) Not actuated ......................................................................................................................... 20-243
041803
M-15 Abnormality in buzzer ............................................................................................................... 20-244
(a) Buzzer does not sound when starting switch is turned ON (during self-check) ......... 20-244
(b) Buzzer always sounds ......................................................................................................... 20-244
M-16 Condition of monitor switches is not stored in memory ...................................................... 20-245
M-17 Abnormality in failure display mode ....................................................................................... 20-246
(a) Does not enter failure display mode ................................................................................ 20-246
(b) Time for time elapsed since failure on failure display mode does not advance ........ 20-246
20-220
1
(7)
TROUBLESHOOTING TROUBLE DATA DISPLAY
TROUBLE DATA DISPLAY

1. Outline
The speedometer display on the main moni-
tor is used to display the troubleshooting
for each control system. The nature of the
troubleshooting is displayed as the failure
action code, failure code, and the time
elapsed since failure.
The signals between the main monitor and
each controller are transmitted in serial
through the network circuit. (Only the en-
gine controller uses a special parallel sig-
nal.)
2. Abnormality in failure action code

This code informs the operator directly of Example: When action code CALL is displayed
the abnormality, and takes action, such as
stopping the machine immediately. SPEED
There are four types of action code: E00,
E01+CALL (E01 and CALL are displayed al-
ternately), E03+CALL, and CALL. If a fail- km/h
ure occurs suddenly, one of these codes is Action code
shown on the speedometer display.
For details of the action taken by operator
for the action codes, see Item 4.
041803
TDW00283
3. Failure code and time elapsed since failure
The failures detected by each controller are
changed to a code and displayed. It is possi-
ble to tell from this code which system in Example: When failure code “41” has occurred
27 hours before
which controller has failed, so carry out trou-
bleshooting for the applicable controller.
For failures that have occurred and been re- SPEED Failure code
set, the failure code and the time elapsed
since failure are displayed to make it easy to
check failures that are not occurring at
Time elapsed
present. since failure
The failure codes for failures that are now
occurring flash, and the codes for failures
that are not occurring light up.
TDW00284
For details of the method of operating and
transferring data to the trouble data display
mode, see STRUCTURE AND FUNCTION for
the main monitor.
Note: If the engine is not stopped, it is im-
possible to switch to the trouble data
display mode, so the codes for fail-
ures which can only be detected
when the engine is operating light
up.
For the correspondence between the failure
codes for each controller and the failed sys-
tem, see Item 5.
20-221
1
TROUBLESHOOTING TROUBLE DATA DISPLAY
TABLE OF ACTION CODES AND FAILURE CODES

Action code table
Action code: "E +CALL" means that E and CALL are displayed alternately
Action Transmission control system Alarm Action by operator

code Problem system Action of machine buzzer
Travel speed sensor Gear speed does not change au- No

E00 (Disconnection) tomatically (It must be changed No Normal operation possible
manually). using manual gear shifting
H, L solenoid and speed sole- Gear speed is fixed (to 1st - 3rd, Travel under own power
E01+ noid systems depending on each case) Yes possible, call for service
CALL after moving to safe place
Gearshift lever system Gear speed is set in neutral (F/R Actuate emergency manual
solenoid output is OFF). spool, open modulation
E03+ Yes solenoid manually. This
CALL action makes it possible to
F, R solenoid system Gear speed is set in neutral (F/R travel under own power.
solenoid output is OFF). Call for service
Wiring harness on return side of Stops auto leveling function, Stop machine immediately,
CALL bucket (tilt, dump) solenoid short bucket moves, possible that con- Yes turn starting switch OFF,
circuiting with power source troller is burnt out then call for service
Failure code chart
041803
Transmission control system Work equipment control system
Bucket dump solenoid

12 F solenoid valve system 40 system
13 R solenoid valve system 41 Dump/tilt solenoid system
14 H, L solenoid valve system 42 Bucket tilt solenoid system
16 Speed solenoid system 48 Bucket kickout relay system
20 F, R lever input system 50 Auto leveler relay system
21 Gearshift lever input system 52 Boom angle sensor system
22 Travel speed sensor input system 53 Bucket angle sensor system
23 Engine speed input system
20-222
1
(7)
TROUBLESHOOTING M-4

Cause Remedy
(e-1) Does not display 1st, 4th
1 YES
Defective main monitor Replace
Is voltage between
L05 (female) (12) Defective contact, or
and chassis disconnection in wiring
ground normal? harness between L05 After inspection,
1) 50 – 70 Ω NO (female) (12) and L73 repair or replace
2) Disconnect L05 (female) (11)
(f-1) Does not display 3rd, 4th
1 YES
Is voltage between
L05 (female) (13)
and chassis Defective contact, or
ground normal? disconnection in wiring
harness between L05 After inspection,
1) 50 – 70 Ω NO (female) (13) and L73 repair or replace
2) Disconnect L05 (female) (10)
20-227-1 WA250-3
(7)
TROUBLESHOOTING M-4
Cause Remedy
(g) Does not display 2nd, 3rd
1 YES
Is voltage
between CNL05
(12) and chassis Contact of power source
ground normal? with wiring harness
After inspection,
between CNL05 (female)
1) 0 – 5 V NO repair or replace
(12) and CNL04 (5), or
2) Turn starting defective control lever
switch ON.
3) Speed lever: 2
(h) Does not display 1st, 2nd
1 YES
Is voltage
between CNL05 Contact of power source
(13) and chassis with wiring harness
ground normal? between CNL05 (female) After inspection,
(13) and CNL04 (7), or repair or replace
1) 0 – 5 V NO
2) Turn starting defective transmission
switch ON. lever
3) Speed lever: 2
WA250-3 20-227-2
(7)
TROUBLESHOOTING M-12
(a) When monitor switch is pressed, cut-off func-

tion and its display do not change
Cause Remedy
(b) Display on monitor goes off but cut-off function

operates if pedal is pressed Disconnection or
defective contact in Check, then
1 YES wiring harness between repair or
Is voltage L06 (female) (3) and L74 replace
between L06 (3) (female) (16)
and chassis
ground normal?
1) 0 - 3 V NO
2) Disconnect L26.
3) Turn starting
switch ON.
4) Turn cut-off
switch OFF.
(c) If display of monitor is turned OFF, cut-off func-

tion always operates
Disconnection or
defective contact in Check, then
2 YES wiring harness between repair or
Is there continuity L26 (female) and L74 replace
YES between L27 (female) (16)
1 (male) and Disconnection or
chassis ground? defective contact in Check, then
Is there continuity wiring harness between repair or
between L26 1) Disconnect L27. NO L27 (male) and chassis replace
ground
(male) and L27
(female)?
Defective transmission Replace
1) Disconnect L26. cut-off switch
2) Disconnect L27.
NO
(d) Cut-off function operates, regardless of display

on monitor
1 YES Defective transmission

Replace
Is voltage controller
between L74 (16)
and chassis Disconnection or
ground normal? defective contact in Check, then
wiring harness between repair or
1) 0 – 3 V NO L74 (female) (16) and L06 replace
(female) (3), L26 (female)
20-241-1 WA250-3
(7)
TROUBLESHOOTING M-12
(e) Display on monitor lights up but cut-off function does not operate
Cause Remedy
YES Defective transmission

Replace
cut-off switch
Does cut-off YES

function operate? Defective main monitor Replace
1) Disconnect L26. 2
2) Turn starting
switch ON. Does cut-off
NO function operate? YES Defective transmission
controller Replace
1) Disconnect L06.
3
2) Turn starting Is voltage
switch ON. between L74 (16)
NO and chassis
ground normal?
Ground fault in wiring
1) 20 – 30 V harness between L06 Check, then
2) Disconnect L26. (female) (3) and L74 repair or replace
NO
3) Disconnect L06. (female) (16), L26 (female)
4) Turn starting
switch ON.
WA250-3 20-241-2
(7)
TROUBLESHOOTING OF TRANSMISSION
CONTROLLER SYSTEM
(A MODE)
1. Function ......................................................................................................................................... 20-302

2. Note on troubleshooting .............................................................................................................. 20-302
3. Failure codes list ........................................................................................................................... 20-203
4. Table of failure modes and causes ............................................................................................ 20-303
5. System diagram related to transmission controller ................................................................. 20-304
A-1. Failure code [12] F solenoid signal system ............................................................................... 20-306
A-2. Failure code [13] R solenoid signal system ............................................................................... 20-306
A-3. Failure code [14] Abnormality in H-L solenoid signal system ................................................ 20-307
A-4. Failure code [16] Abnormality in speed solenoid signal system ............................................ 20-308
A-5. Failure code [20] Abnormality in directional lever signal system .......................................... 20-309
A-6. Failure code [21] Abnormality in gearshift lever signal system ............................................. 20-310
A-7. Failure code [22] Abnormality in travel speed signal system ................................................. 20-311
A-8. Failure code [23] Abnormality in engine speed signal ............................................................ 20-312
A-9. Holding switch system ................................................................................................................. 20-313
A-10. Kick-down switch system ............................................................................................................ 20-313
A-11. Transmission cut-off signal system ............................................................................................ 20-314
A-12. Neutralizer relay signal system ................................................................................................... 20-315
A-13. Alarm buzzer signal system ........................................................................................................ 20-316
A-14. Network signal system ................................................................................................................. 20-317
A-15. Controller power supply system ................................................................................................. 20-318
WA250-3 20-301
(7)
TROUBLESHOOTING TROUBLESHOOTING
1. Function
The control mechanism of the transmission con-
troller consists of the controller, sensors, input
switch, solenoid output, and buzzer output. The
controller controls the auto-shift operation by
receiving and processing the input signal and
controlling the solenoid to a gear speed matched
to the travel speed.
2. Note on troubleshooting
The controller has a troubleshooting function.
If a trouble is detected, the alarm buzzer sounds
to notify the operator of the trouble and the
failure code is displayed on the main monitor.
Failure codes No. A-9 - A-16 are displayed, how-
ever, when the display unit does not have a
display function and there is abnormality in con-
trol.
3. Failure codes list
No. Failure code Contents of trouble No. Failure code Contents of trouble
Abnormality in F solenoid
A-1 12 A-9 — Holding switch signal system
signal system
Abnormality in R solenoid
A-2 13 A-10 — Kick-down switch signal system
signal system
Abnormality in H-L solenoid
A-3 14 A-11 — Transmission cut-off signal system
signal system
Abnormality in speed solenoid
A-4 16 A-12 — Neutralizer relay signal system
signal system
Abnormality in directional lever
A-5 20 A-13 — Alarm buzzer signal system
signal system
Abnormality in gearshift lever
A-6 21 A-14 — Network signal system
signal system
Abnormality in travel speed Abnormality in controller
A-7 22 A-15 —
signal system source voltage
Abnormality in engine speed Abnormality in model selection
A-8 23 A-16 —
sensor signal wiring harness
20-302 WA250-3
(7)
4. Table of failure modes and causes
Cause of failure Related devices
Troubleshooting code when error code is not displayed

Transmission cut-off signal system
Travel speed sensor signal system
Controller power supply system

Neutralizer relay signal system
Directional lever signal system
Holding switch signal system

Gearshift lever signal system
Engine speed sensor system
Alarm buzzer signal system

Kick-down signal system
Speed solenoid system
Network signal system

H-L solenoid system
R solenoid system
F solenoid system
de
co
g
t in
oo h
es l
ub o
Tr
12 13 14 16 20 21 22 23 — — — — — — — —
Failure mode
Machine cannot travel fi fi fi fi fi fi H-1
Gear is not shifted automatically fi fi fi fi —
Setting of directional lever is not matched to travel direction fi —
Machine travels forward while directional lever is not in F fi —
Machine travels in reverse while directional lever is not in R fi —
Gear is shifted down, regardless of travel speed fi fi fi —
Gear is shifted up, regardless of travel speed fi fi —
Speed is set to position of gearshift lever, regardless of travel speed fi H-2
Gear shift shock is large fi H-3
Shift hunting occurs during travel fi —
Shift hunting occurs when gear speed is changed fi —
Gear speed cannot be controlled with gearshift lever fi —
Gear speed cannot be held fi A-9
Gear speed cannot be set in 1st with kick-down switch fi A-10
When kick-down switch is turned ON, scooping power is low fi A-10
When left brake is applied, transmission is not cut off fi A-11
Machine can travel while parking brake is applied fi A-12
When travel direction is changed between forward and reverse A-13
fi
during high-speed travel, alarm buzzer does not sound
Alarm buzzer keeps sounding fi A-13
Main monitor does not display information on transmission controller A-14
fi
(alarm buzzer, failure code, etc.)
Troubleshooting code when error code is displayed A-1 A-2 A-3 A-4 A-5 A-6 A-7 A-8 — — — — — — — —
WA250-3 20-303
(7)
5. System diagram related to transmission controller
20-304 WA250-3
(7)
WA250-3 20-305
(7)
TROUBLESHOOTING A-1, A-2
A-1. Failure code [12] F solenoid signal system

fl When disconnecting or connecting a connector, be sure to turn the power OFF.
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on to the next step.
Cause Remedy
YES
Defective controller Replace
1
• Disconnection, defective
Is resistance contact, or ground fault in
between L73 wiring harness between
(female) (21) and 2 YES L73 (female) (21) - T1 Repair or
(19) normal? (female) (1)
• Disconnection in wiring replace
Is resistance harness between T1
1) 46 – 58 Ω between T1 (male) (female) (2) - chassis
2) Turn starting NO (1) and (2) normal? ground
switch OFF.
Defective F solenoid Replace
3) Disconnect L73. 1) 46 – 58 Ω NO
2) Turn starting
switch OFF.
3) Disconnect T1.
A-2. Failure code [13] R solenoid signal system Cause Remedy
YES
1
• Disconnection, defective
Is resistance contact, or ground fault in
between L73 wiring harness between
(female) (20) and 2 YES L73 (female) (20) - T2 Repair or
(19) normal? (female) (1)
• Disconnection in wiring replace
Is resistance harness between T2
1) 46 – 58 Ω between T2 (male) (female) (2) - chassis
2) Turn starting NO (1) and (2) normal? ground
switch OFF.
Defective R solenoid Replace
3) Disconnect L73. 1) 46 – 58 Ω NO
2) Turn starting
switch OFF.
3) Disconnect T2.
A-1, A-2. Related electrical circuit diagram
20-306 WA250-3
(7)
TROUBLESHOOTING A-3
A-3. Failure code [14] Abnormality in H-L solenoid signal system

Cause Remedy
YES
Ground fault,
1 disconnection, or Repair or
YES defective contact in wiring
Is resistance replace
harness between L73
between L73 3 (female) (10) - FT1 (male)
(female) (10) and Is resistance (3), L05 (female) (13)
(19) normal? YES between FT1
(female) (3) and • Ground fault,
1) 46 – 58 Ω chassis ground disconnection, or
normal? defective contact in
2) Turn starting 2 wiring harness between
switch OFF. Is resistance 1) 46 – 58 Ω FT1 (female) (3) - T3 Repair or
3) Disconnect L73. between T3 2) Turn starting NO (female) (1) replace
switch OFF. • Disconnection in wiring
NO (male) (1) and (2) 3) Disconnect FT1.
harness between T3
normal? (female) (2) - chassis
ground
1) 46 – 58 Ω
2) Turn starting
switch OFF. Defective H-L solenoid Replace
NO
3) Disconnect T3.
A-3. Related electrical circuit diagram
WA250-3 20-307
(7)
TROUBLESHOOTING A-4
A-4. Failure code [16] Abnormality in speed solenoid signal system

Cause Remedy
YES
Ground fault,
1 disconnection, or Repair or
YES defective contact in wiring
Is resistance replace
harness between L73
between L73 3 (female) (11) - FT1 (male)
(female) (11) and Is resistance (4), L05 (female) (12)
(19) normal? YES between FT1
(female) (4) and • Ground fault,
1) 46 – 58 Ω chassis ground disconnection, or
normal? defective contact in
2) Turn starting 2 wiring harness between
switch OFF. Is resistance 1) 46 – 58 Ω FT1 (female) (4) - T4 Repair or
3) Disconnect L73. between T4 2) Turn starting NO (female) (1) replace
switch OFF. • Disconnection in wiring
NO (male) (1) and (2) 3) Disconnect FT1.
harness between T4
normal? (female) (2) - chassis
ground
1) 46 – 58 Ω
2) Turn starting
switch OFF. Defective speed solenoid Replace
NO
3) Disconnect T4.
20-308 WA250-3
(7)
TROUBLESHOOTING A-5
A-5. Failure code [20] Abnormality in directional lever signal system

fl Check that the combination switch of the directional lever and gearshift lever is normal.
Cause Remedy
3 YES
YES Is voltage • Ground fault, disconnection,

between L74 (12) or defective contact in wiring
2 and (9) normal? harness between L74 (female)
(12) - L04 (4) - directional Repair or
lever/gearshift lever switch
replace
YES Is voltage 1) Directional lever NO • Ground fault between L74
between L74 (1) R: 20 - 30 V (female) (12) - L08 (female) (8)
1 and (9) normal? Other than R: 0 V • Ground fault, disconnection,
2) Turn starting or defective contact in wiring
harness between L74 (female)
Is voltage 1) Directional lever switch ON. (1) - L04 (2) - directional Repair or
between L74 (11) F: 20 - 30 V lever/gearshift lever switch replace
NO • Ground fault between L74
and (9) normal? Other than F: 0 V (female) (1) - L08 (female) (7)
2) Turn starting switch ON.
• Ground fault, disconnection,
1) Directional lever or defective contact in wiring
N: 20 - 30 V harness between L74 (female)
(11) - L04 (3) - directional Repair or
Other than N: 0 V NO lever/gearshift lever switch
2) Turn starting • Ground fault between L74
switch ON. (female) (11) - L05 (female) (8)
WA250-3 20-309
(7)
TROUBLESHOOTING A-6
A-6. Failure code [21] Abnormality in gearshift lever signal system
Cause Remedy
4 YES
YES Is voltage
between L74 (3)
3 and (9) normal? Ground fault, disconnection,
or defective contact in wiring Repair or
harness between L74 (female)
YES Is voltage 1) Gearshift lever NO (3) - L04 (8) - directional replace
between L74 (14) lever/gearshift lever switch
and (9) normal? 4th: 20 - 30 V
2 Other than 4th: 0 V Ground fault, disconnection,
2) Turn starting switch ON. or defective contact in wiring Repair or
YES Is voltage 1) Gearshift lever harness between L74 (female)
between L74 (2) 3rd: 20 - 30 V (14) - L04 (7) - directional replace
and (9) normal? Other than 3rd: 0 V NO lever/gearshift lever switch
1 2) Turn starting switch ON.
Ground fault, disconnection,
Is voltage between 1) Gearshift lever or defective contact in wiring Repair or
L74 (13) and (9) 2nd: 20 - 30 V harness between L74 (female)
(2) - L04 (6) - directional replace
normal? Other than 2nd: 0 V NO lever/gearshift lever switch
2) Turn starting
Ground fault, disconnection,
1) Gearshift lever switch ON. or defective contact in wiring Repair or
1st: 20 - 30 V harness between L74 (female)
(13) - L04 (5) - directional replace
Other than 1st: 0 V NO lever/gearshift lever switch
2) Turn starting
switch ON.
20-310 WA250-3
(7)
TROUBLESHOOTING A-7
A-7. Failure code [22] Abnormality in travel speed signal system

Cause Remedy
YES
Disconnection or defective
1
YES contact in wiring harness Repair or
Is resistance between L75 (female) (4), replace
between L75 3
(12) - T10 (female) (1), (2)
(female) (4) and Is insulation
(12) normal? YES between L75
(female) (4), (12)
1) 0.5 – 1 KΩ and chassis ground
normal?
2) Turn starting 2 Ground fault or short
switch OFF. Is resistance 1) Min. 1 MΩ circuit in wiring harness Repair or
3) Disconnect L75. between T10 2) Turn starting NO between L75 (female) (4), replace
switch OFF. (12) - T10 (female) (1), (2)
NO (male) (1) and (2) 3) Disconnect L07,
normal?
L75, and T10.
1) 0.5 – 1 KΩ
2) Turn starting
switch OFF. Defective speed sensor Replace
NO
3) Disconnect T10.
WA250-3 20-311
(7)
TROUBLESHOOTING A-8
A-8. Failure code [23] Abnormality in engine speed signal

Cause Remedy
2 YES
Is continuity
YES between L75
(female) (5) and Disconnection or defective
1 (12) normal? contact in wiring harness Repair or replace
Is insulation between L75 (female) (5) -
between L75 1) Max. 1 Ω NO
(female) (5), (12) 2) Turn starting AS2 (female) (1)
and chassis
ground normal? switch OFF.
3) Disconnect L75, AS2, and L07. Ground fault between L75
1) Min. 1 MΩ 4) Short AS2 (female) (1) and (2). (female) (5), (12) - L07
2) Turn starting (female) (3), (2) or Repair or replace
switch OFF. NO between L75 (female) (5),
3) Disconnect L75, (12) - AS2 (female) (1), (2)
AS2, and L07.
20-312 WA250-3
(7)
TROUBLESHOOTING A-9, A-10
A-9. Holding switch system

Cause Remedy
YES
1
Is continuity
between L74 Ground fault,
(female) (18) and disconnection, or defective
2 YES Repair or
chassis ground contact in wiring harness
normal? Is continuity replace
between L74 (female) (18) -
1) Disconnect L74. between L77 L77 (female) (1)
2) Holding switch NO (male) (1) and (2)
ON: Max. 1 Ω normal?
Defective holding switch Replace
OFF: Min. 1 MΩ 1) Disconnect L77. NO
2) Holding switch
ON: Max. 1 Ω
OFF: Min. 1 MΩ
A-10. Kick-down switch system Cause Remedy
YES
1
Is continuity
(female) (17) and disconnection, or defective
2 YES Repair or
chassis ground contact in wiring harness
normal? Is continuity replace
between L74 (female) (17) -
1) Disconnect L74. between L39 L39 (female) (1)
2) Holding switch NO (male) (1) and (2)
ON: Max. 1 Ω normal?
Defective kick-down switch Replace
OFF: Min. 1 MΩ 1) Disconnect L39. NO
2) Holding switch
ON: Max. 1 Ω
OFF: Min. 1 MΩ
A-9, A-10. Related electrical circuit diagram
WA250-3 20-313
(7)
TROUBLESHOOTING A-11
A-11. Transmission cut-off signal system

Cause Remedy
YES
1
Is continuity • Ground fault, disconnection,
between L74 or defective contact in
(female) (16) and wiring harness between L74 Repair or
chassis ground 2 YES
(female) (16) - L26 (female)
normal? Is continuity • Ground fault between L74 replace
1) Turn starting between L26 (female) (16) - L06 (female)
(3)
switch OFF. NO (male) and L27
2) Disconnect L74. (female) normal? Defective transmission
3) Transmission cut-off switch Replace
1) Turn starting NO
cut-off switch switch OFF.
ON: Max. 1 Ω 2) Disconnect L26
OFF: Min. 1 MΩ and L27.
3) Transmission
cut-off switch
ON: Max. 1 Ω
OFF: Min. 1 MΩ
20-314 WA250-3
(7)
A-12. Neutralizer relay signal system

Cause Remedy
YES Defective transmission Replace

controller
3 YES
Defective neutralizer relay Replace
Is resistance
YES between L73
Is voltage (female) (13) and Disconnection or
2 L74 (female) (4) defective contact in wiring
between L74 (4) -
Is voltage normal? harness between L73
(9) normal? Repair or replace
YES between L33 1) Max. 1 Ω (female) (13) - L33
NO (female) (5), L33 (female)
(female) (1) and 2) Turn starting switch
1) 20 – 30 V chassis ground OFF. (3) - L74 (female) (4)
normal? 3) Disconnect L73, L74,
2) Insert T-adapter. and L33. Disconnection or defective
3) Turn starting 1 1) 20 – 30 V
4) Short L33 (3) and (5). contact in wiring harness
switch ON. Is resistance NO between L33 (female) (1) - Repair or replace
2) Disconnect L33. FS2 (female) (9)
4) Release parking between L33
(female) (2) and 3) Turn starting
brake. NO chassis ground switch ON.
Defective parking brake
normal? 4 YES
switch or wrong position Repair or replace
1) Max. 1 Ω Is resistance of switch
between L13
2) Turn starting (male) and
switch OFF. NO chassis ground Disconnection or
3) Disconnect L33. normal? defective contact in wiring Repair or replace
4) Release parking NO harness between L13
1) Max. 1 Ω
brake. (male) - R8
2) Turn starting
switch OFF.
3) Disconnect L13.
WA250-3 20-315
(7)
A-13. Alarm buzzer signal system

fl Check that the main monitor and alarm buzzer are operating normally.
Cause Remedy
2 YES Defective transmission

controller Replace
Is resistance
YES between L75
(female) (15) and
1 chassis ground Disconnection or defective
Is resistance normal? contact in wiring harness Repair or
between L75 between L75 (female) (15) replace
(female) (15) and 1) Max. 1 Ω NO
2) Turn starting switch OFF. - L08 (female) (6)
chassis ground 3) Disconnect L75 and L08.
normal? 4) Short L08 (female) (6) and
chassis ground. Ground fault between L75
1) Min. 1 MΩ Repair or
(female) (15) - L08 (female)
2) Turn starting NO replace
(6)
switch OFF.
3) Disconnect L75
and L08.
20-316 WA250-3
(7)
A-14. Network signal system

Cause Remedy
2 YES
Is continuity
YES between L73
(female) (1), (12)
1 and chassis Disconnection or defective
Is insulation ground normal? contact in wiring harness Repair or
between L73 between L73 (female) (1), replace
1) Max. 1 Ω NO
(female) (1), (12)
and chassis
2) Turn starting switch OFF. (12) - L08 (female) (1), (3)
3) Disconnect L73 and L08.
ground normal? 4) Short L08 (female) (1), (3)
and chassis ground. Ground fault between L73
1) Min. 1 MΩ Repair or
(female) (1), (12) - L08
2) Turn starting NO replace
(female) (1), (3)
switch OFF.
3) Disconnect L73
and L08.
WA250-3 20-317
(7)
A-15. Controller power supply system

fl Check that the fuse of the transmission controller power supply is normal.
Cause Remedy
YES
1
Is voltage
(female) (8), (17), disconnection, or defective Repair or
(18) and (9), (19) 2 YES
contact in wiring harness
normal? Is continuity between L73 (female) (8), replace
1) 20 – 30 V between L73 (17), (18) - FS2 (female) (8)
2) Disconnect L73. NO (female) (9), (19) Disconnection or defective
3) Turn starting normal? contact in wiring harness Repair or
switch ON. 1) Max. 1 Ω NO between L73 (female) (9), replace
(19) - chassis ground
2) Turn starting
switch OFF.
3) Disconnect L73.
20-318 WA250-3
(7)
c = 0.01 - 1.59 mm
(9)
0.01 1.59
(9)
OTHERS
90 OTHERS
Electrical circuit diagram (1/2)

(Serial No.:50001 – 53000) .....................90-3
(Serial No.:50001 – 53000) .....................90-5
(Serial No.:53001 and up) ......................90-7
(Serial No.:53001 and up) ......................90-9
For auto shift control spec.
(Serial No.:53001 and up) ................... 90-11
(Serial No.:53001 and up) ................... 90-13
WA250-3 90-1
(8)
ELECTRICAL CIRCUIT DIAGRAM (1/2)
Serial No.: 50001 – 53000
WA250-3 90-3
(6)
Serial No.: 50001 – 53000
WA250-3 90-5
(6)
Serial No.: 53001 and up
WA250-3 90-7
(6)
WA250-3 90-9
(6)
WA250-3 90-11
(8)
WA250-3 90-13
(8)

Wa250-3 50001-Up Sebm005910

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Copyright:

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Wa250-3 50001-Up Sebm005910

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Copyright:

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SEBM005910

Machine model Serial number

WA250-3 50001 and up

• WA250-3 mount the S6D95L and S6D102E engine.

10 Structure and function.............................................................................................. 10-1

20 Testing and adjusting ............................................................................................... 20-1

30 Disassembly and assembly ................................................................................... 30-1

40 Maintenance standard .............................................................................................. 40-1

90 Others ................................................................................................................................ 90-1

The affected pages are indicated by the use of the

q Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGES

Time of Time of Time of Time of Time of

q 00-1 (10) 01-1 (3) 10-18 10-46 10-73

Time of Time of Time of Time of Time of

10-100 10-143 (6) 20-25 (1) 20-105 (1) 20-145 (1)

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

Slinging near the edge of the hook may cause

• If a part cannot be smoothly removed from the

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets, rubber

• Used as lubricant for sliding portion (to

STANDARD TIGHTENING TORQUE

6 10 11.8 – 14.7 1.2 – 1.5

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

6 10 5.9 – 9.8 0.6 – 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 ± 4.9 2.5 ± 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque (Nm {kgm})

02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque (Nm {kgm})

08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES

ELECTRIC WIRE CODE

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

2 26 0.32 2.09 3.1 20 Lighting, signal etc.