Komatsu WA250-6 Wheel Loader Service Repair Manual SN75001 and up 1

SEN03979-03

WHEEL LOADER

-6 WA250 WA250PZ -6 SERIAL NUMBERS

WA250- 75001 WA250PZ- 75001

and up

SEN03988-03

Table of contents

100 Index Table of contents

1

00 Index and foreword 100 Index SEN03988-03 Composition of shop manual......................................................................................................................... 2 Table of contents ...........................................................................................................................................

4 200 Foreword and general information SEN03989-01 Safety notice .................................................................................................................................................

2 How to read the shop manual .......................................................................................................................

7 Explanation of terms for maintenance standard............................................................................................ 9 Handling of electric equipment and hydraulic component............................................................................. 11 Handling of connectors newly used for engines............................................................................................ 20 How to read electric wire code ...................................................................................................................... 23 Precautions when carrying out operation...................................................................................................... 26 Method of disassembling and connecting push-pull type coupler................................................................. 29 Standard tightening torque table ................................................................................................................... 32 Conversion table ........................................................................................................................................... 36 01 Specification 100 Specification and technical data SEN03990-01 Specification dimension drawing ...................................................................................................................

3 Specifications ................................................................................................................................................

4 Weight table ..................................................................................................................................................

8 Table of fuel, coolant and lubricants.............................................................................................................. 10 10 Structure, function and maintenance standard 100 Engine and cooling system SEN03991-01 Engine mount and transfer mount.................................................................................................................

2 Damper .........................................................................................................................................................

3 Cooling system..............................................................................................................................................

4 Cooling system hydraulic piping diagram......................................................................................................

5 Cooling fan motor..........................................................................................................................................

7 200 Power train SEN03992-01 Power train ....................................................................................................................................................

3 Power train system diagram.......................................................................................................................... 4 Drive shaft .....................................................................................................................................................

6 HST hydraulic piping diagram .......................................................................................................................

7 HST pump .....................................................................................................................................................

8 HST motor..................................................................................................................................................... 16 Transfer ......................................................................................................................................................... 22 Clutch solenoid valve .................................................................................................................................... 33 Axle ............................................................................................................................................................... 34 Differential ..................................................................................................................................................... 36 Torque proportioning differential.................................................................................................................... 41 Limited slip differential................................................................................................................................... 44 Final drive...................................................................................................................................................... 48 300 Steering system SEN03993-00 Steering piping diagram ................................................................................................................................ 3 Steering column ............................................................................................................................................

4 Priority valve..................................................................................................................................................

5 Orbit-roll valve ...............................................................................................................................................

8 2-way restrictor valve .................................................................................................................................... 16 Cushion valve................................................................................................................................................ 17 Steering cylinder............................................................................................................................................ 18 Emergency steering piping diagram.............................................................................................................. 20 Emergency steering valve............................................................................................................................. 21 Steering relief valve....................................................................................................................................... 24 00-100

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400 Brake system SEN03994-00 Brake piping diagram..................................................................................................................................... 3 Charge valve ................................................................................................................................................. 4 Brake valve.................................................................................................................................................... 8 Inching valve.................................................................................................................................................. 12 Accumulator (for brake) ................................................................................................................................. 13 Slack adjuster ................................................................................................................................................ 14 Brake ............................................................................................................................................................. 16 Parking brake control..................................................................................................................................... 21 Parking brake ................................................................................................................................................ 22 500 Undercarriage and frame SEN03995-00 Axle mount and center hinge pin ................................................................................................................... 2 Tires............................................................................................................................................................... 7 600 Hydraulic system SEN03996-00 Work equipment hydraulic piping diagram .................................................................................................... 2 Work equipment control lever linkage ........................................................................................................... 6 Hydraulic tank................................................................................................................................................ 12 4-gear pump .................................................................................................................................................. 14 Work equipment control valve ....................................................................................................................... 16 PPC valve...................................................................................................................................................... 41 Lock valve...................................................................................................................................................... 56 Accumulator (for PPC circuit) ........................................................................................................................ 57 Bypass valve ................................................................................................................................................. 58 Quick coupler solenoid valve......................................................................................................................... 61 ECSS valve ................................................................................................................................................... 62 Accumulator (for ECSS) ................................................................................................................................ 64 700 Work equipment SEN03997-01 Work equipment linkage ................................................................................................................................ 2 Bucket............................................................................................................................................................ 6 Bucket positioner and boom kick-out............................................................................................................. 10 Work equipment cylinder ............................................................................................................................... 22 800 Cab and its attachments SEN03998-00 Cab ................................................................................................................................................................ 3 Air conditioner................................................................................................................................................ 4 910 Electrical system, Part 1 SEN03999-00 Machine monitor system................................................................................................................................ 2 Machine monitor ............................................................................................................................................ 6 920 Electrical system, Part 2 SEN04000-02 Electrical system (HST controller system)..................................................................................................... 2 HST controller................................................................................................................................................ 18 ECSS system ................................................................................................................................................ 20 KOMTRAX system ........................................................................................................................................ 22 Engine starting circuit .................................................................................................................................... 24 Engine stopping circuit .................................................................................................................................. 26 Preheating circuit........................................................................................................................................... 27 Engine output derating function..................................................................................................................... 28 Automatic warm-up function .......................................................................................................................... 28 Parking brake circuit ...................................................................................................................................... 29 Coupler plunger control system..................................................................................................................... 32 Max. traction switch ....................................................................................................................................... 33 Multi-function knob ........................................................................................................................................ 34 Sensor ........................................................................................................................................................... 35 20 Standard value table 100 Standard service value table SEN04001-01 Standard service value table for engine ........................................................................................................ 2 Standard service value table for chassis ....................................................................................................... 3 WA250, 250PZ-6

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30 Testing and adjusting 110 Testing and adjusting, Part 1 SEN04002-01 Tools for testing, adjusting, and troubleshooting ........................................................................................... 2 Measuring engine speed............................................................................................................................... 7 Measuring exhaust gas color ........................................................................................................................ 9 Adjusting valve clearance ............................................................................................................................. 11 Measuring compression pressure ................................................................................................................. 13 Measuring blow-by pressure ......................................................................................................................... 16 Measuring engine oil pressure ...................................................................................................................... 17 Measuring intake air (boost) pressure........................................................................................................... 18 Handling fuel system equipment ................................................................................................................... 20 Releasing residual pressure in fuel system................................................................................................... 20 Measuring fuel pressure................................................................................................................................ 21 Measuring fuel return rate and leakage ........................................................................................................ 23 Bleeding air from fuel circuit.......................................................................................................................... 27 Checking leakage in fuel system................................................................................................................... 28 Handling cylinder cut-out mode operation..................................................................................................... 29 Handling no-injection cranking operation ...................................................................................................... 29 Handling controller voltage circuit ................................................................................................................. 30 Check of muffler and muffler stack for looseness and damage .................................................................... 30 Check of muffler function .............................................................................................................................. 31 Check of installed condition of cylinder head and manifolds......................................................................... 31 Check of engine piping for damage and looseness ...................................................................................... 32 Testing and adjusting air conditioner compressor belt tension...................................................................... 32 Replacing alternator belt ............................................................................................................................... 33 120 Testing and adjusting, Part 2 SEN04003-02 Checking operating force of accelerator pedal.............................................................................................. 3 Checking directional lever ............................................................................................................................. 4 Testing and adjusting HST oil pressure.........................................................................................................

5 Testing clutch control pressure......................................................................................................................

9 Testing and adjusting steering wheel ............................................................................................................ 10 Testing and adjusting steering oil pressure ................................................................................................... 12 Bleeding air from steering circuit................................................................................................................... 14 Testing hydraulic fan ..................................................................................................................................... 15 Measuring brake pedal.................................................................................................................................. 17 Testing and adjusting brake pedal linkage .................................................................................................... 18 Measuring brake performance ...................................................................................................................... 19 Testing and adjusting accumulator charge pressure..................................................................................... 20 Testing wheel brake oil pressure................................................................................................................... 22 Testing wear of brake disc............................................................................................................................. 25 Bleeding air from wheel brake circuit ............................................................................................................ 26 Releasing residual pressure in brake accumulator circuit............................................................................. 27 Testing parking brake performance............................................................................................................... 28 Testing and adjusting parking brake control cable ........................................................................................ 29 Measuring and adjusting work equipment control lever ................................................................................ 30 Testing and adjusting work equipment hydraulic pressure............................................................................ 31 Testing work equipment PPC oil pressure .................................................................................................... 32 Bleeding air from hydraulic circuit ................................................................................................................. 34 Releasing remaining pressure in hydraulic circuit......................................................................................... 35 Testing and adjusting bucket positioner ........................................................................................................ 36 Testing and adjusting of boom kick-out switch .............................................................................................. 37 Checking proximity switch operation pilot lamp ............................................................................................ 38 Procedure for testing diodes ......................................................................................................................... 39 Preparation work for troubleshooting for electric system .............................................................................. 41 Starting KOMTRAX terminal operations........................................................................................................ 45 Indicator lamps of KOMTRAX terminal ......................................................................................................... 49

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130 Testing and adjusting, Part 3 SEN04004-01 Adjusting machine monitor ............................................................................................................................ 2 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ............................ 3 Special functions of machine monitor (EMMS).............................................................................................. 5 Pm clinic inspection chart .............................................................................................................................. 58 40 Troubleshooting 100 Failure code table and fuse locations SEN04005-02 Failure codes table ........................................................................................................................................ 2 Fuse locations ............................................................................................................................................... 8 200 General information on troubleshooting SEN04006-01 Points to remember when troubleshooting .................................................................................................... 2 Sequence of events in troubleshooting ......................................................................................................... 3 Testing before troubleshooting ...................................................................................................................... 4 Classification and procedures of troubleshooting.......................................................................................... 5 Information contained in troubleshooting table .............................................................................................. 8 Connection table for connector pin numbers................................................................................................. 10 T- branch box and T- branch adapter table ................................................................................................... 46 310 Troubleshooting by failure code (Display of code), Part 1 SEN04007-01 Failure code [2G40ZG] Brake: Oil pressure reduction .................................................................................. 2 Failure code [6091NX] HST filter: Clogging................................................................................................... 4 Failure code [989FN1] Travel speed: Overrun alarm .................................................................................... 5 Failure code [AB00L6] Alternator R system: Hot short.................................................................................. 6 Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/Low charge voltage ................... 8 Failure code [B@BAZG] Engine: Oil pressure reduction............................................................................... 10 Failure code [B@BCNS] Engine: Overheat................................................................................................... 11 Failure code [B@BCZK] Engine: Low coolant level ...................................................................................... 12 Failure code [B@C6NS] Front brake: High oil temperature .......................................................................... 14 Failure code [B@CRNS] HST: High oil temperature ..................................................................................... 15 320 Troubleshooting by failure code (Display of code), Part 2 SEN04008-01 Failure code [CA111] Abnormality in engine controller .................................................................................. 3 Failure code [CA115] Engine Ne or Bkup speed sensor error....................................................................... 4 Failure code [CA122] Charge pressure sensor high error............................................................................. 6 Failure code [CA123] Charge pressure sensor low error .............................................................................. 8 Failure code [CA131] Throttle sensor high error ........................................................................................... 10 Failure code [CA132] Throttle sensor low error............................................................................................. 12 Failure code [CA144] Coolant sensor high error ........................................................................................... 14 Failure code [CA145] Coolant sensor low error............................................................................................. 16 Failure code [CA153] Charge temperature sensor high error ....................................................................... 18 Failure code [CA154] Charge temperature sensor low error......................................................................... 20 Failure code [CA155] Derating of speed by abnormally high charge temperature........................................ 22 Failure code [CA187] Sensor power supply 2 low error ................................................................................ 24 Failure code [CA221] Atmospheric pressure sensor high error..................................................................... 26 Failure code [CA222] Atmospheric sensor low error ..................................................................................... 28 Failure code [CA227] Sensor power supply 2 high error............................................................................... 30 Failure code [CA234] Engine overspeed....................................................................................................... 31 Failure code [CA238] Ne speed sensor power supply error.......................................................................... 32 Failure code [CA271] IMV (IMA) Short circuit................................................................................................ 33 Failure code [CA272] IMV (IMA) Disconnection ............................................................................................ 34 Failure code [CA322] Injector #1 open/short error ........................................................................................ 36 Failure code [CA323] Injector #5 open/short error ........................................................................................ 38 Failure code [CA324] Injector #3 open/short error ........................................................................................ 40 Failure code [CA325] Injector #6 open/short error ........................................................................................ 42 Failure code [CA331] Injector #2 open/short error ........................................................................................ 44 Failure code [CA332] Injector #4 open/short error ........................................................................................ 46 Failure code [CA342] Calibration code inconsistency ................................................................................... 48 Failure code [CA351] Injectors drive circuit error .......................................................................................... 50 WA250, 250PZ-6

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Failure code [CA352] Sensor power supply 1 low error................................................................................ 52 Failure code [CA386] Sensor power supply 1 high error .............................................................................. 54 330 Troubleshooting by failure code (Display of code), Part 3 SEN04009-02 Failure code [CA428] Abnormally high level in water sensor........................................................................

4 Failure code [CA429] Abnormally low level in water sensor .........................................................................

6 Failure code [CA431] Idle validation switch error.......................................................................................... 8 Failure code [CA432] Idle validation action error .......................................................................................... 12 Failure code [CA435] Engine oil pressure switch error ................................................................................. 16 Failure code [CA441] Battery voltage low error ............................................................................................ 17 Failure code [CA442] Battery voltage high error ........................................................................................... 20 Failure code [CA449] Common rail pressure high error 2............................................................................. 22 Failure code [CA451] Common rail pressure sensor high error.................................................................... 24 Failure code [CA452] Common rail pressure sensor low error ..................................................................... 26 Failure code [CA488] Derating of torque by abnormally high charge temperature ....................................... 28 Failure code [CA553] Common rail pressure high error 1............................................................................. 29 Failure code [CA559] Supply pump pressure very low error......................................................................... 30 Failure code [CA689] Engine Ne speed sensor error ................................................................................... 32 Failure code [CA731] Engine Bkup speed sensor phase error ..................................................................... 34 Failure code [CA757] All continuous data lost error...................................................................................... 35 Failure code [CA778] Engine Bkup speed sensor error................................................................................ 38 Failure code [CA1633] KOMNET datalink timeout error ............................................................................... 40 Failure code [CA2185] Throttle sensor supply voltage high error ................................................................. 44 Failure code [CA2186] Throttle sensor power supply low error .................................................................... 46 Failure code [CA2249] Supply pump pressure very low error 2.................................................................... 48 Failure code [CA2311] Abnormality in IMV (IMA) solenoid ........................................................................... 50 Failure code [CA2555] Intake heater relay disconnection error .................................................................... 52 Failure code [CA2556] Intake heater relay short circuit error........................................................................ 54 340 Troubleshooting by failure code (Display of code), Part 4 SEN04010-01 Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short ...........................................................

2 Failure code [D192KY] ECSS solenoid relay: Hot short ............................................................................... 4 Failure code [D1B0KA] HST safety relay: Disconnection ............................................................................. 6 Failure code [D1B0KB] HST safety relay: Ground fault ................................................................................ 8 Failure code [D1B0KY] HST safety relay: Hot short ..................................................................................... 10 Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection ............................................................. 12 Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection.................................................. 14 Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection ................................................ 16 Failure code [DAJ0KK] HST controller power supply: Low voltage .............................................................. 20 Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality .................................................... 22 Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault ................................... 24 Failure code [DAJ1L6] HST controller main power line: Hot short................................................................ 26 Failure code [DAJ2KK] Controller solenoid power supply: Low voltage ....................................................... 28 Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness............. 30 Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault ............ 32 Failure code [DAJ5KX] Sensor 5V power supply: Out of output range......................................................... 34 Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals............. 36 Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection ..................................................... 37 Failure code [DAJRMA] HST controller: Disagreement in option selection .................................................. 43 350 Troubleshooting by failure code (Display of code), Part 5 SEN04011-01 Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line....................................... 2 Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality ..................................................

8 Failure code [DD1NLD] Fan reverse switch signal: Abnormality .................................................................. 10 Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short ........................................ 12 Failure code [DDB6KB] Parking brake indicator signal: Ground fault ........................................................... 14 Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble................................................................................................................. 16 Failure code [DDB6L0] Parking brake reminder signal: Ground fault ........................................................... 18 Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short ......................................... 20 Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault ................................. 22 00-100

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Failure code [DDD7KY] Travel speed control dial signal: Hot short .............................................................. 24 Failure code [DDE5MA] Emergency steering operation switch: Disconnection ............................................ 26 Failure code [DDK3KA] Directional selector switch: Disconnection/Hot short............................................... 28 Failure code [DDK3KB] Directional selector switch: Ground fault ................................................................. 30 Failure code [DDK6KA] FNR lever: Disconnection/Ground fault................................................................... 32 Failure code [DDK6KY] FNR lever: Hot short................................................................................................ 36 Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering) ................................ 38 360 Troubleshooting by failure code (Display of code), Part 6 SEN04012-01 Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault ............................ 2 Failure code [DF10KB] Travel speed range selector switch: Hot short ......................................................... 6 Failure code [DGH1KX] HST oil temperature sensor: Ground fault .............................................................. 8 Failure code [DGR2KB] Brake oil temperature sensor: Ground fault ............................................................ 9 Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short.......................................... 10 Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault ............................................ 12 Failure code [DHH1KY] HST oil pressure sensor: Hot short ......................................................................... 14 Failure code [DHTCL6] HST filter clogging sensor: Functional defect .......................................................... 16 Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short .............................................................. 18 Failure code [DLT3KX] Travel speed sensor B: Abnormality......................................................................... 20 Failure code [DLT4KX] Travel speed sensor A: Abnormality......................................................................... 24 Failure code [DLT4LC] Travel speed sensor A & B: Abnormality .................................................................. 26 Failure code [DV00KY] Alarm buzzer: Hot short ........................................................................................... 28 Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault ........................................................ 30 Failure code [DW26KY] Motor 2 solenoid: Hot short..................................................................................... 32 Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short ................................................................... 34 Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault ...................................... 36 370 Troubleshooting by failure code (Display of code), Part 7 SEN04013-00 Failure code [DX16KA] Fan EPC solenoid: Disconnection ........................................................................... 2 Failure code [DX16KB] Fan EPC solenoid: Ground fault .............................................................................. 3 Failure code [DX16KY] Fan EPC solenoid: Hot short ................................................................................... 4 Failure code [DX19KA] Motor 1 solenoid: Disconnection.............................................................................. 6 Failure code [DX19KB] Motor 1 solenoid: Ground fault................................................................................. 8 Failure code [DX19KY] Motor 1 solenoid: Hot short...................................................................................... 10 Failure code [DX20KA] Clutch EPC solenoid: Disconnection ....................................................................... 12 Failure code [DX20KB] Clutch EPC solenoid: Ground fault .......................................................................... 14 Failure code [DX20KY] Clutch EPC solenoid: Hot short ............................................................................... 16 Failure code [DXH7KB] Reverse solenoid: Ground fault............................................................................... 18 Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short............................................................. 20 Failure code [DXH8KB] Forward solenoid: Ground fault ............................................................................... 22 Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short............................................................. 24 Failure code [J141N1] Steering pump: Overrun alarm .................................................................................. 26 Failure code [M100N1] HST pump: Overrun alarm ....................................................................................... 26 Failure code [M400N1] Motor 1: Overrun alarm ............................................................................................ 27 400 Troubleshooting of electrical system (E-mode) SEN04014-01 E-1 Engine does not start .............................................................................................................................. 4 E-2 Preheater does not operate normally...................................................................................................... 12 E-3 Travel speed is low or high ..................................................................................................................... 16 E-4 ECSS does not operate .......................................................................................................................... 22 E-5 ECSS keeps operating............................................................................................................................ 25 E-6 Defective boom kick-out function and cancellation ................................................................................. 28 E-7 Defective bucket positioner function and cancellation ............................................................................ 32 E-8 Defective lift arm FLOATING holding function and cancellation ............................................................. 36 E-9 Travel direction selection system does not function................................................................................ 40 E-10 Fan does not reverse ............................................................................................................................ 44 E-11 Fan keeps rotating in reverse................................................................................................................ 48 E-12 Wiper does not operate......................................................................................................................... 50 E-13 Windshield washer does not operate.................................................................................................... 54 E-14 Headlamp, clearance lamp and tail lamp do not light up or go off ........................................................ 58 E-15 Working lamp does not light up or go off............................................................................................... 66 WA250, 250PZ-6

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E-16 Turn signal lamp and hazard lamp do not light up or go off.................................................................. 71 E-17 Brake lamp does not light or it keeps lighting up .................................................................................. 78 E-18 Backup lamp does not light or it keeps lighting up ............................................................................... 80 E-19 Backup alarm does not sound or it keeps sounding............................................................................. 83 E-20 Horn does not sound or it keeps sounding ........................................................................................... 86 E-21 Alarm buzzer does not sound or it keeps sounding.............................................................................. 88 E-22 Air conditioner does not operate or stop............................................................................................... 90 E-22 Air conditioner does not operate or stop............................................................................................... 90 E-23 The KOMTRAX system does not work properly................................................................................... 93 500 Troubleshooting of hydraulic and mechanical system (H-mode) SEN04015-01 Method of using troubleshooting chart ..........................................................................................................

3 Failure code and cause table ........................................................................................................................ 6 H-1 The machine does not start....................................................................................................................

8 H-2 The travel speed is slow......................................................................................................................... 9 H-3 The traction force is weak ...................................................................................................................... 10 H-4 Engine stalls when traveling or engine speed drops excessively........................................................... 11 H-5 Speed range is not shifted...................................................................................................................... 12 H-6 The steering wheel does not turn ........................................................................................................... 13 H-7 The steering wheel is heavy................................................................................................................... 14 H-8 Steering wheel shakes or jerks............................................................................................................... 15 H-9 Machine deviates naturally to one side when traveling .......................................................................... 15 H-10 The brake does not work or does not work well ................................................................................... 16 H-11 The brake is not released or is dragged ............................................................................................... 17 H-12 The lift arm does not rise or lower ........................................................................................................ 18 H-13 The lift arm moves slowly or the lift arm rising force is insufficient ....................................................... 19 H-14 When rising, the lift arm comes to move slowly at specific height........................................................ 20 H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air)................................... 20 H-16 Hydraulic drifts of the lift arm occur often ............................................................................................. 20 H-17 The lift arm wobbles during operation .................................................................................................. 20 H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily .................. 21 H-19 The bucket does not tilt back................................................................................................................ 22 H-20 The bucket moves slowly or the tilting-back force is insufficient .......................................................... 23 H-21 The bucket comes to operate slowly in the midst of tilting-back .......................................................... 24 H-22 The bucket cylinder cannot hold down the bucket ............................................................................... 24 H-23 Hydraulic drifts of the bucket occur often ............................................................................................. 24 H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”) ................. 24 H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily ...................... 25 H-26 The control levers of the lift arm and bucket do not move smoothly and heavy................................... 25 H-27 The ECSS does not operate and machine pitches and bounces......................................................... 26 H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) ................ 27 600 Troubleshooting of engine (S-mode) SEN04016-01 Method of using troubleshooting charts ........................................................................................................

2 S-1 Starting performance is poor ..................................................................................................................

6 S-2 Engine does not start.............................................................................................................................. 7 S-3 Engine does not pick up smoothly.......................................................................................................... 10 S-4 Engine stops during operations .............................................................................................................. 11 S-5 Engine does not rotate smoothly ............................................................................................................ 12 S-6 Engine lacks output (or lacks power)...................................................................................................... 13 S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 14 S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 15 S-9 Oil becomes contaminated quickly ......................................................................................................... 16 S-10 Fuel consumption is excessive............................................................................................................. 17 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 18 S-12 Oil pressure drops ................................................................................................................................ 19 S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 20 S-14 Coolant temperature becomes too high (overheating) ......................................................................... 21 S-15 Abnormal noise is made ....................................................................................................................... 22 S-16 Vibration is excessive ........................................................................................................................... 23 00-100

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50 Disassembly and assembly 100 General information on disassembly and assembly SEN04017-01 How to read this manual................................................................................................................................ 2 Coating materials list ..................................................................................................................................... 4 Special tools list ............................................................................................................................................. 7 Sketches of special tools ............................................................................................................................... 11 200 Engine and cooling system SEN04018-02 Removal and installation of fuel supply pump assembly ............................................................................... 2 Removal and installation of fuel injector assembly ........................................................................................ 4 Removal and installation of cylinder head assembly..................................................................................... 12 Removal and installation of engine hood assembly ...................................................................................... 25 Removal and installation of radiator .............................................................................................................. 28 Removal and installation of air aftercooler..................................................................................................... 31 Removal and installation of hydraulic oil cooler assembly ............................................................................ 33 Removal and installation of engine assembly ............................................................................................... 35 Removal and installation of engine front oil seal assembly ........................................................................... 41 Removal and installation of engine rear oil seal assembly............................................................................ 44 Removal and installation of cooling fan and fan motor assembly.................................................................. 47 Removal and installation of fuel tank assembly............................................................................................. 50 310 Power train, Part 1 SEN04019-00 Removal and installation of transfer assembly .............................................................................................. 2 Disassembly and assembly of transfer assembly.......................................................................................... 6 Removal and installation of parking brake assembly..................................................................................... 26 Disassembly and assembly of parking brake assembly ................................................................................ 28 320 Power train, Part 2 SEN04020-00 Removal and installation of front axle assembly ........................................................................................... 2 Removal and installation of rear axle assembly ............................................................................................ 4 Disassembly and assembly of axle housing assembly.................................................................................. 7 Disassembly and assembly of differential assembly ..................................................................................... 16 400 Undercarriage and frame SEN04021-00 Removal and installation of center hinge pin................................................................................................. 2 Removal and installation of counterweight .................................................................................................... 12 500 Hydraulic system SEN04022-01 Removal and installation of HST pump and 4-gear pump assembly............................................................. 2 Disassembly and assembly of HST pump assembly..................................................................................... 6 Removal and installation of HST motor 1 assembly ...................................................................................... 33 Removal and installation of HST motor 2 assembly ...................................................................................... 35 Disassembly and assembly of HST motor assembly .................................................................................... 37 Removal and installation of work equipment control valve assembly............................................................ 53 Removal and installation of hydraulic tank .................................................................................................... 55 Disassembly and assembly of hydraulic cylinder assembly .......................................................................... 57 600 Work equipment SEN04023-00 Removal and installation of work equipment assembly................................................................................. 2 700 Cab and its attachments SEN04024-00 Removal and installation of operator's cab and floor frame assembly .......................................................... 2 Removal and installation of operator's cab glass (Stuck glass)..................................................................... 7 Removal and installation of air conditioner unit ............................................................................................. 15 800 Electrical system SEN04025-00 Removal and installation of monitor panel..................................................................................................... 2 Removal and installation of engine controller assembly................................................................................ 4 Removal and installation of HST controller assembly ................................................................................... 5 Removal and installation of KOMTRAX terminal assembly........................................................................... 6

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90 Diagrams and drawings 100 Hydraulic diagrams and drawings SEN04026-01 Automatic greasing circuit diagram ...............................................................................................................

2 Hydraulic circuit diagram............................................................................................................................... 5 200 Electrical diagrams and drawings SEN04027-01 Electrical circuit diagram ............................................................................................................................... 3 Connector list and stereogram ...................................................................................................................... 21

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200 Engine and cooling system Removal and installation of fuel supply pump assembly

SEN04018-02

Removal and installation of fuel supply pump assembly

5.

Disconnect fuel return hose (7) from fuel supply pump (4). a If mud is sticking, lock (L) may become stiff. Accordingly, clean the connecting area. a Press lock (L) from both sides and pull out hose (5). a Plug the disconnected hose to prevent fuel leakage.

6.

Disconnect fuel supply hose (8) from fuel supply pump (4). [*1]

7.

Remove 2 clamps of boot (9) and fuel highpressure pipe (10).

8.

Disconnect fuel high-pressure pipe (10) from fuel supply pump (4). [*2] a Remove the boot on the common rail side of high-pressure pipe (10) and loosen the sleeve nut.

1

Removal k

k

k

1.

Stop the machine on a level ground and set the lock bar to the frame to fix the front and rear frames.

Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires.

Disconnect the cable from the negative (–) terminal of the battery.

Open and fix right engine side cover (1). a Check that the cover is locked securely.

2.

Remove fuel prefilter and bracket assembly (2). a Fix fuel prefilter and bracket assembly (2) to the machine with ropes.

3.

Disconnect wiring harness connector CN-CP3 (3) from fuel supply pump (4).

4.

Disconnect fuel filter hoses (5) and (6) from fuel supply pump (4).

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200 Engine and cooling system Removal and installation of fuel supply pump assembly

9.

Remove 3 mounting nuts at part (A) and fuel supply pump assembly (11). [*3]

a

SEN04018-02 [*2] q

How to install high-pressure pipe (10)

1.

Tighten the sleeve nut with the fingers.

2.

Check that the high-pressure pipe is installed correctly and tighten the sleeve nut to the following torque.

3 Sleeve nut: 35 ± 3.5 Nm {3.57 ± 0.36 kgm} k Be sure to use the genuine fuel highp r e s s u r e p i pe c l a m p a nd s t r ic t l y o b s e r v e t h e s p e c i f i e d t i g ht e ni n g torque.

3.

Install boot (9). a Direct the slit of the boot down. a The boot is installed so that fuel will not spout over the hot parts of the engine and catch fire when it leaks for some reason.

Remove fuel supply pump assembly (11) and the gear together. The gear does not have a positioning mark (missing tooth), etc.

[*3] a If too much grease is applied to O-ring (13), it will ooze out. Accordingly, do not apply grease so much. (Apply grease to the O-ring groove area of part (B).) a When installing new fuel supply pump mounting stud bolts (14) to replace the existing ones, apply LOCTITE (LT-2) to them.

Install fuel supply pump (12).

3

Fuel supply pump mounting nut: 24 ± 4 Nm {2.45 ± 0.41 kgm}

Installation q

Carry out installation in the reverse order to removal. a The internal parts of the fuel hose adapter may be damaged when it is removed.

Accordingly, do not reuse the fuel hose but use new one when assembling again, as a rule.

[*1]

3

Joint bolt: 19.6 – 29.4 Nm {2.0 – 3.0 kgm}

q

WA250, 250PZ-6

Bleeding air Bleed air from the fuel system. For details, see Testing and adjusting, "Bleeding air from fuel system".

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3

200 Engine and cooling system Removal and installation of fuel injector assembly

SEN04018-02

Removal and installation of fuel injector assembly

A

Part name

Necessity Q'ty New/Remodel Sketch

Part No.

3

795-799-6700 Puller

t 1

4

795-799-1131 Gear

t 1

5

795-799-8150 Remover

q 1

Disconnect engine intake air heater wiring harness terminal CN-E07B (3). [*1]

5.

Remove clamp (4) and bracket (4a).

6.

Remove clamp (5), air hose (5a), mounting bolt (6a) and intake air inlet elbow (6). [*3] a Remove the engine intake air heater, too.

7.

Remove 2 wiring harness clamps (7).

8.

Disconnect wiring harness connector (8). a While pressing the lock of wiring harness connector (8) with flat-head screwdriver [1], pull the connector in the direction of the arrow. a Do not remove fuel pressure sensor (PS) except for replacement.

9.

Disconnect 3 wiring harness connectors (9). [*4] a While pressing the lock of the wiring harness connector with flat-head screwdriver [2], pull the connector. a Move wiring harness (10) toward the intake manifold.

1

Special tools

Symbol

4.

[*2]

Removal k

k

k k

1.

Stop the machine on a level ground and set the lock bar to the frame to fix the front and rear frames.

Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires.

Disconnect the cable from the negative (–) terminal of the battery.

If the radiator coolant temperature is high, you may scald yourself with the hot coolant. Wait until the coolant is cooled, and then drain the coolant.

Loosen the radiator cap to drain the coolant.

6

Radiator: Approx. 22 l

2.

Remove the engine hood assembly. For details, see "Removal and installation of engine hood assembly".

3.

Lift off muffler (1). a Take care that the muffler will not interfere with water drain tube (2).

4

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4

Muffler assembly: Approx. 35 kg

WA250, 250PZ-6

200 Engine and cooling system Removal and installation of fuel injector assembly

SEN04018-02 12. Remove 6 boots (14).

[*7]

13. Remove 6 high-pressure pipes (15). [*8] a Loosen the sleeve nut on the common rail side of each high-pressure pipe.

10. Using hexagonal wrench (width across flats: 3 mm), remove blow-by duct (11). [*5] 11. Remove 6 mounting nuts (12) and cylinder head cover (13). [*6]

WA250, 250PZ-6

14. Position the crankshaft according to the following procedure.

1) Remove plug (16) under the starting motor and set tool A4.

2) Rotate the crankshaft forward (counterclockwise seeing from the flywheel side) to set marks (M1) and (M2).

Mark (M1):Top of projection of front cover Mark (M2):A wide slit on slitted revolution sensor disc at rear of crankshaft pulley Mark (M3):Yellow paint on vibration damper (on prolongation of wide slit (M2)) a Set the projection top of mark (M1) within the wide slit (M2). a There is yellow paint mark (M3) on the prolongation of wide slit (M2). a When the marks are set as above, the piston of the No. 1 or No. 6 cylinder is 76 – 88° before the top dead center. a See Testing and adjusting, "Adjusting valve clearance". a Use tool A4 to rotate the crankshaft.

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5

SEN04018-02

200 Engine and cooling system Removal and installation of fuel injector assembly

15. Remove the 12 mounting bolts and rocker arm (17). a Loosen locknut (18), and then loosen adjustment screw (19) by 2 – 3 turns so that an excessive force will not be applied to the push rod when the rocker arm is installed.

17. Remove retaining nuts (21) and 6 inlet connectors (22). a Before removing, clean the inlet connectors carefully so that mud, etc. sticking around them will not enter their holes. a Tool A5 is set for removal of inlet connector (22). (See the special tools list.)

16. Remove 12 crossheads (20). a Record the positions and shapes of holes (a) and (b) of each crosshead. (Reinstall each crosshead in the same direction.)

18. Remove 2 wiring harness mounting nuts (24) from fuel injector assembly (23).

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6

Wiring harness color

Cylinder No.

White

1, 3, 5

Black

2, 4, 6

WA250, 250PZ-6

200 Engine and cooling system Removal and installation of fuel injector assembly

a

Do not remove the connector of injector harness (37) from rocker housing unless it is necessary.

SEN04018-02 Installation a

The internal parts of the fuel hose adapter may be damaged when it is removed. Accordingly, do not reuse the fuel hose but use new one when assembling again, as a rule.

When replacing the fuel injector assembly with new one, be sure to replace the inlet connector with new one, too.

1.

Fuel injector assembly a Check that the fuel injector sleeve (23a) is free from flaw and dirt.

19. Remove 2 mounting bolts (25) of fuel injector assembly (23).

1) 2)

3) 20. Using tool A3, remove fuel injector assembly (23). a Take care that dirt and foreign matter will not enter the fuel injector assembly mounting area.

WA250, 250PZ-6

Fit O-ring (26) and gasket (27) to fuel injector (23).

Apply engine oil (For details, see "Table of fuel, coolant and lubricants") to O-ring (26) of fuel injector (23) and the mounting hole on the cylinder head side.

While setting convex and concave parts (A), install holder (28) to fuel injector (23).

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7

200 Engine and cooling system Removal and installation of fuel injector assembly

SEN04018-02 4)

5)

6)

7)

8)

50-200

Insert fuel injector (23) in the cylinder head, directing its fuel inlet hole toward the air intake manifold.

Tighten 2 mounting bolts (25) of fuel injector (23) by 3 – 4 turns.

9)

Secure inlet connector (22) by tightening retaining nut (21) lightly.

3 Retaining nut (21): 15 ± 5 Nm {1.5 ± 0.5 kgm} 10) Tighten 2 mounting bolts (25) of fuel injector (23) alternately.

3 Fuel injector mounting bolt (25): 8.0 ± 0.8 Nm {0.8 ± 0.08 kgm} 11) Tighten retaining nut (21).

3 Retaining nut (21): 50 ± 5 Nm {5.1 ± 0.5 kgm}

Apply engine oil (For details, see "Table of fuel, coolant and lubricants") to the mounting hole of inlet connector (22) on the cylinder head side.

Apply engine oil (For details, see "Table of fuel, coolant and lubricants") to O-ring (29) of inlet connector (22).

Insert inlet connector (22) perfectly, while setting part (B) to the groove on the cylinder head side.

8

WA250, 250PZ-6

200 Engine and cooling system Removal and installation of fuel injector assembly

SEN04018-02

12) Install the wiring harnesses to fuel injector (23) and tighten 2 mounting nuts (24).

3 Wiring harness mounting nut (24): 1.5 ± 0.25 Nm {0.15 ± 0.03 kgm} a Installed positions of wiring harnesses Wiring harness color

Cylinder No.

White

1, 3, 5

Black

2, 4, 6

q

a

When the connector of injector harness is removed.

When assembling the injector harness connector (37) to the housing, apply gasket sealant (LG-7) to the O-ring portion (38) and the flange face of connector (39).

When applying gasket sealant (LG-7) to the O-ring portion, be sure to apply a string of LG-7 f3 mm in diameter until Oring groove is completely filled.

If O-ring is damaged, replace as a harness assembly.

3 Connector flange mounting bolt (40): 10 ± 2 Nm {1.0 ± 0.2 kgm}

WA250, 250PZ-6

Precautions for installing inlet connector 1) When replacing the fuel injector assembly with new one, be sure to replace inlet connector, too.

2) Check the inlet connector visually. If it has any of the following faults, replace it.

1] There is a burr or a worn part at front end (a) or rear end (b) of the inlet connector.

2] There is foreign matter in the edge filter at rear end (c) of the inlet connector.

3] The O-ring at upper part (d) of the inlet connector is cracked or deteriorated.

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9

200 Engine and cooling system Removal and installation of fuel injector assembly

SEN04018-02 3)

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Check the inlet connector visually. If it has any of the following faults, replace it and fuel injector assembly together. q There is a worn part or an uneven seat contact mark on sealing face (e) at the front end of the inlet connector. a If high-pressure fuel leaks through the inlet connector, the seal face has fine streaks or cracks.

10

2.

Crosshead and rocker arm assembly 1) Install the crosshead and rocker arm. a The shapes of holes (a) and (b) of each crosshead are different. Accordingly, when reusing the crossheads, install each of them to the same intake/exhaust valve in the same direction as it has been installed.

2) Check that the ball of adjustment screw (19) is set in the push rod socket securely and then tighten mounting bolts (30).

3 Rocker arm mounting bolt (30): 36 ± 5 Nm {3.7 ± 0.5 kgm} 3) Adjust the valve clearance. For details, see Testing and adjusting, "Adjusting valve clearance".

3 Locknut (18): 24 ± 4 Nm {2.4 ± 0.4 kgm}

WA250, 250PZ-6

200 Engine and cooling system Removal and installation of fuel injector assembly

q

SEN04018-02 1)

Carry out the following installation in the reverse order to removal.

[*1]

3

Wiring harness terminal CN-E07B (3): 4.0 ± 0.6 Nm {0.41 ± 0.06 kgm}

2)

[*2]

3

Clamp (4): 10.8 – 26.5 Nm {1.1 – 2.7 kgm}

[*3]

3 3

Clamp (5): 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} Intake air inlet elbow mounting bolt (6a): 24 ± 4 Nm {2.4 ± 0.4 kgm}

[*4]

k

Install each fuel high-pressure pipe and wiring harness at least 10 mm apart from each other.

3)

[*5]

3

Blow-by duct mounting bolt: 7 ± 2 Nm {0.7 ± 0.2 kgm}

[*6]

3

Cylinder head cover mounting nut (12): 24 ± 4 Nm {2.4 ± 0.4 kgm}

[*7], [*8] k Do not bend the fuel high-pressure pipe to correct before installing. k Be sure to use the genuine fuel high-pressure pipe clamps and observe the tightening torque. a If the taper seal area of the fuel high-pressure pipe has any of the following defects, replace the fuel high-pressure pipe. q There is visible lengthwise slit (b) or spot (c) in range (a) of 2 mm from the end. q Taper seal end (d) at 2 mm from the end has stepped-type wear which your nail can feel.

q

Bleeding air Bleed air from the fuel system. For details, see Testing and adjusting, "Bleeding air from fuel system".

q

Refilling with coolant Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again.

5

WA250, 250PZ-6

Temporarily install fuel high-pressure pipes (31) – (36).

3 Sleeve nut: 0.2 – 0.8 Nm {0.02 – 0.08 kgm} Tighten fuel high-pressure pipes (31) – (36) in the following order.

1] Tighten the cylinder head side of fuel high-pressure pipes (31) and (36).

2] Tighten the common rail side of fuel high-pressure pipes (31) and (36).

3] Tighten the cylinder head side of fuel high-pressure pipes (32), (33), (34) and (35).

4] Tighten the common rail side of fuel high-pressure pipes (32), (33), (34) and (35).

3 Sleeve nut: 35 ± 3.5 Nm {3.6 ± 0.4 kgm} Install 6 boots (14) to the fuel high-pressure pipes. a Direct the slit of the boot out and down. a The boots are installed so that fuel will not spout over the hot parts of the engine to catch fire when it leaks for some reason.

Total amount of coolant: Approx. 22 l (For details, see "Table of fuel, coolant and lubricants")

50-200

11

200 Engine and cooling system Removal and installation of cylinder head assembly

SEN04018-02

Removal and installation of cylinder head assembly

A

Part name

Necessity Q'ty New/Remodel Sketch

Part No.

3

795-799-6700 Puller

t 1

4

795-799-1131 Gear

t 1

5

795-799-8150 Remover

q 1

6

790-331-1120 Wrench (angle)

q 1

7

795-790-4510 Gauge

q 1

Disconnect engine intake air heater wiring harness terminal CN-E07B (3). [*1]

5.

Remove clamp (4) and bracket (4a).

6.

Remove clamp (5), air hose (5a), and intake air inlet elbow (6). [*3] a Remove the engine intake air heater, too.

7.

Remove bracket (7).

8.

Remove wiring harness clamp (8).

9.

Disconnect wiring harness connector (9).

1

Special tools

Symbol

4.

[*2]

Removal k

k

k k

1.

Stop the machine on a level ground and set the lock bar to the frame to fix the front and rear frames.

Lower the work equipment to the ground, stop the engine, apply the parking brake, and put chocks under the tires.

Disconnect the cable from the negative (–) terminal of the battery.

If the radiator coolant temperature is high, you may scald yourself with the hot coolant. Wait until the coolant is cooled, and then drain the coolant.

Loosen the radiator cap to drain the coolant.

6

Radiator: Approx. 22 l

2.

Remove the engine hood assembly. For details, see "Removal and installation of engine hood assembly".

3.

Lift off muffler (1). a Take care that the muffler will not interfere with water drain tube (2).

4

50-200

10. Remove air conditioner compressor assembly (10). [*4] a Fix air conditioner compressor assembly (10) to the machine with ropes.

Muffler assembly: Approx. 35 kg

12

WA250, 250PZ-6

Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING

NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.

200 Engine and cooling system Removal and installation of cylinder head assembly

SEN04018-02

11. Disconnect fuel filter hoses (11) and (12). a If mud is sticking, lock (L) may become stiff. Accordingly, clean the connecting area. a Press lock (L) from both sides and pull out hose (12). a Plug the disconnected hoses to prevent fuel leakage.

12. Disconnect fuel return hose (13).

13. Remove fuel prefilter hose clamp (14).

14. Remove 2 air conditioner compressor hose clamps (15).

15. Remove fuel filter and bracket assembly (16).

20. Remove 2 wiring harness clamps (21).

21. Disconnect wiring harness connector (22). a While pressing the lock of wiring harness connector (22) with flat-head screwdriver [1], pull the connector in the direction of the arrow. a Do not remove fuel pressure sensor (PS) except for replacement.

22. Disconnect 3 wiring harness connectors (23). [*5] a While pressing the lock of the wiring harness connector with flat-head screwdriver [2], pull the connector. a Move wiring harness (24) toward the intake manifold.

16. Remove 2 clamps (17).

17. Disconnect engine coolant temperature sensor connector (18).

18. Disconnect ambient air pressure sensor connector (19). a Move the lock of ambient air pressure sensor connector (19) in the direction of the arrow and pull out the connector while pressing the claw.

19. Disconnect intake air pressure sensor connector (20).

WA250, 250PZ-6

50-200

13

200 Engine and cooling system Removal and installation of cylinder head assembly

SEN04018-02

25. Remove 6 boots (27).

[*8]

26. Remove 6 high-pressure pipes (28). [*9] a Loosen the sleeve nut on the common rail side of each high-pressure pipe.

27. Disconnect radiator upper hose (29).

[*10]

28. Disconnect air aftercooler upper hose (30). [*11] 29. Disconnect heater hose (31).

30. Disconnect corrosion resistor hose (32).

23. Disconnect fuel drain hose (25).

[*6]

24. Disconnect high-pressure pipe (26).

[*7]

50-200

14

31. Remove corrosion resistor and bracket assembly (33).

WA250, 250PZ-6

200 Engine and cooling system Removal and installation of cylinder head assembly

32. Remove wiring harness clamp (34).

SEN04018-02 38. Remove alternator assembly (39).

33. Remove 2 heat insulation plates (35).

34. Remove heat insulation plate (36).

35. Remove cover (37).

36. Disconnect wiring [1] harness connectors CNE02 and CN-E03 (38).

37. Put the wrench in part (A) (width across flats: 12.7 mm) of tensioner assembly (40) and turn it in the unwinding direction to decrease the tension of fan belt (41). k Set the wrench [1] securely to part (A) of tensioner assembly (40) before turning it. (The spring of tensioner assembly (40) is strong. If the wrench [1] is set incompletely and turned, it comes off and that is very dangerous.) k After removing belt (41), return tensioner assembly (40) slowly and carefully. k Take care not to catch your finger between the pulley and fan belt (41) during work.

WA250, 250PZ-6

50-200

15