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Komatsu WA250-6, WA250PZ-6 up Wheel Loader Shop Manual 75001, 75160 and up, H00051 and up – DOWNLOAD
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Komatsu WA250-6, WA250PZ-6 up Wheel Loader Shop Manual
Book Code: VEBM610101
MACHINE MODEL SERIAL NUMBER
WA250-6 75001 and up
WA250PZ-6 75160 and up, H00051 and up
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Description
Komatsu WA250-6, WA250PZ-6 up Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA250-6, WA250PZ-6 up Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA250-6, WA250PZ-6
Serial Number: 75001 and up, 75160 and up, H00051 and up
Book Code: VEBM610101
Language: English
Pages: 1244
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA250-6, WA250PZ-6 up Wheel Loader Shop Manual
How to read the shop manual:
1. Composition of shop manual:
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword:
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification:
This section explains the specifications of the machine.
10. Structure, function and maintenance standard:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table:
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting:
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu WA250-6, WA250PZ-6 up Wheel Loader Shop Manual
VEBM610101............................................................................................................................ 1 00 Index and foreword................................................................................................................. 3 100 Index......................................................................................................................... 3 Composition of shop manual.................................................................................................... 4 Table of contents............................................................................................................. 6 200 Foreword and general information.............................................................................................. 15 Safety notice................................................................................................................. 16 How to read the shop manual................................................................................................... 21 Explanation of terms for maintenance standard................................................................................. 23 Handling of electric equipment and hydraulic component........................................................................ 25 Handling of connectors newly used for engines................................................................................. 34 How to read electric wire code................................................................................................ 37 Precautions when carrying out operation....................................................................................... 40 Method of disassembling and connecting push-pull type coupler................................................................. 43 Standard tightening torque table.............................................................................................. 46 Conversion table.............................................................................................................. 50 01 Specification...................................................................................................................... 55 100 Specification and technical data.............................................................................................. 55 Specification dimension drawing............................................................................................... 57 Specifications................................................................................................................ 58 Weight table.................................................................................................................. 62 Table of fuel, coolant and lubricants......................................................................................... 64 10 Structure, function and maintenance standard....................................................................................... 65 100 Engine and cooling system..................................................................................................... 65 Engine mount and transfer mount............................................................................................... 66 Damper........................................................................................................................ 67 Cooling system................................................................................................................ 68 Cooling system hydraulic piping diagram....................................................................................... 69 Cooling fan motor............................................................................................................. 71 200 Power train................................................................................................................... 79 Power train................................................................................................................... 81 Power train system diagram.................................................................................................... 82 Drive shaft................................................................................................................... 84 HST hydraulic piping diagram.................................................................................................. 85 HST pump...................................................................................................................... 86 HST motor..................................................................................................................... 94 Transfer...................................................................................................................... 100 Clutch solenoid valve......................................................................................................... 111 Axle.......................................................................................................................... 112 Differential.................................................................................................................. 114 Torque proportioning differential............................................................................................. 119 Limited slip differential..................................................................................................... 122 Final drive................................................................................................................... 126 300 Steering system............................................................................................................... 131 Steering piping diagram....................................................................................................... 133 Steering column............................................................................................................... 134 Priority valve................................................................................................................ 135 Orbit-roll valve.............................................................................................................. 138 2-way restrictor valve........................................................................................................ 146 Cushion valve................................................................................................................. 147 Steering cylinder............................................................................................................. 148 Emergency steering piping diagram............................................................................................. 150 Emergency steering valve...................................................................................................... 151 Steering relief valve......................................................................................................... 154 400 Brake system.................................................................................................................. 155 Brake piping diagram.......................................................................................................... 157 Charge valve.................................................................................................................. 158 Brake valve................................................................................................................... 162 Inching valve................................................................................................................. 166 Accumulator (for brake)....................................................................................................... 167 Slack adjuster................................................................................................................ 168 Brake......................................................................................................................... 170 Parking brake control......................................................................................................... 175 Parking brake................................................................................................................. 176 500 Undercarriage and frame....................................................................................................... 177 Axle mount and center hinge pin............................................................................................... 178 Tires......................................................................................................................... 183 600 Hydraulic system.............................................................................................................. 185 Work equipment hydraulic piping diagram....................................................................................... 186 Work equipment control lever linkage.......................................................................................... 190 Hydraulic tank................................................................................................................ 194 4-gear pump................................................................................................................... 196 Work equipment control valve.................................................................................................. 198 PPC valve..................................................................................................................... 223 Lock valve.................................................................................................................... 238 Accumulator (for PPC circuit)................................................................................................. 239 Bypass valve.................................................................................................................. 240 Quick coupler solenoid valve.................................................................................................. 243 ECSS valve.................................................................................................................... 244 Accumulator (for ECSS)........................................................................................................ 246 700 Work equipment................................................................................................................ 247 Work equipment linkage........................................................................................................ 248 Bucket........................................................................................................................ 252 Bucket positioner and boom kick-out........................................................................................... 256 Work equipment cylinder....................................................................................................... 269 800 Cab and its attachments....................................................................................................... 273 Cab........................................................................................................................... 275 Air conditioner............................................................................................................... 276 910 Electrical system, Part 1..................................................................................................... 289 Machine monitor system........................................................................................................ 290 Machine monitor............................................................................................................... 294 920 Electrical system, Part 2..................................................................................................... 315 Electrical system (HST controller system)..................................................................................... 316 HST controller................................................................................................................ 332 ECSS system................................................................................................................... 334 KOMTRAX system................................................................................................................ 336 Engine starting circuit....................................................................................................... 338 Engine stopping circuit....................................................................................................... 340 Preheating circuit............................................................................................................ 341 Engine output derating function............................................................................................... 342 Automatic warm-up function.................................................................................................... 342 Parking brake circuit......................................................................................................... 343 Coupler plunger control system................................................................................................ 346 Multi-function knob........................................................................................................... 347 Max. traction switch.......................................................................................................... 348 Sensor........................................................................................................................ 349 20 Standard value table............................................................................................................... 355 100 Standard service value table.................................................................................................. 355 Standard service value table for engine....................................................................................... 356 Standard service value table for chassis...................................................................................... 357 30 Testing and adjusting.............................................................................................................. 363 110 Testing and adjusting, Part 1................................................................................................. 363 Tools for testing, adjusting, and troubleshooting............................................................................. 364 Measuring engine speed........................................................................................................ 369 Measuring exhaust gas color................................................................................................... 371 Adjusting valve clearance..................................................................................................... 373 Measuring compression pressure................................................................................................ 375 Measuring blow-by pressure.................................................................................................... 378 Measuring engine oil pressure................................................................................................. 379 Measuring intake air (boost) pressure......................................................................................... 380 Handling fuel system equipment................................................................................................ 382 Releasing residual pressure in fuel system.................................................................................... 382 Measuring fuel pressure....................................................................................................... 383 Measuring fuel return rate and leakage........................................................................................ 385 Bleeding air from fuel circuit................................................................................................ 389 Testing leakage in fuel system................................................................................................ 390 Handling reduced cylinder mode operation...................................................................................... 391 Handling no-injection cranking operation...................................................................................... 391 Handling controller voltage circuit........................................................................................... 392 Check of muffler and muffler stack for looseness and damage................................................................... 392 Check of muffler function..................................................................................................... 393 Check of installed condition of cylinder head and manifolds................................................................... 393 Check of engine piping for damage and looseness............................................................................... 394 Testing and adjusting air conditioner compressor belt tension................................................................. 394 Replacing alternator belt..................................................................................................... 395 120 Testing and adjusting, Part 2................................................................................................. 397 Checking operating force of accelerator pedal................................................................................. 399 Checking directional lever.................................................................................................... 400 Testing and adjusting HST oil pressure........................................................................................ 401 Testing clutch control pressure............................................................................................... 405 Testing and adjusting steering wheel.......................................................................................... 406 Testing and adjusting steering oil pressure................................................................................... 408 Bleeding air from steering circuit............................................................................................ 410 Testing hydraulic fan......................................................................................................... 411 Measuring brake pedal......................................................................................................... 413 Testing and adjusting brake pedal linkage..................................................................................... 414 Measuring brake performance................................................................................................... 415 Testing and adjusting accumulator charge pressure............................................................................. 416 Testing wheel brake oil pressure.............................................................................................. 418 Testing wear of brake disc.................................................................................................... 421 Bleeding air from wheel brake circuit......................................................................................... 422 Releasing residual pressure in brake accumulator circuit...................................................................... 423 Testing parking brake performance............................................................................................. 424 Testing and adjusting parking brake control cable............................................................................. 425 Measuring and adjusting work equipment control lever.......................................................................... 426 Testing and adjusting work equipment hydraulic pressure....................................................................... 427 Testing work equipment PPC oil pressure....................................................................................... 428 Bleeding air from hydraulic circuit........................................................................................... 430 Releasing remaining pressure in hydraulic circuit............................................................................. 431 Testing and adjusting bucket positioner....................................................................................... 432 Testing and adjusting of boom kick-out switch................................................................................. 433 Checking proximity switch operation pilot lamp................................................................................ 434 Procedure for testing diodes.................................................................................................. 435 Preparation work for troubleshooting for electric system...................................................................... 437 Starting KOMTRAX terminal operations.......................................................................................... 441 Indicator lamps of KOMTRAX terminal........................................................................................... 445 130 Testing and adjusting, Part 3................................................................................................. 449 Adjusting machine monitor..................................................................................................... 450 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor........................................ 451 Special functions of machine monitor (EMMS)................................................................................... 453 Pm clinic inspection chart.................................................................................................... 507 40 Troubleshooting.................................................................................................................... 509 100 Failure code table and fuse locations......................................................................................... 509 Failure codes table........................................................................................................... 510 Fuse locations................................................................................................................ 516 200 General information on troubleshooting........................................................................................ 519 Points to remember when troubleshooting....................................................................................... 520 Sequence of events in troubleshooting......................................................................................... 521 Testing before troubleshooting................................................................................................ 522 Classification and procedures of troubleshooting.............................................................................. 523 Information contained in troubleshooting table................................................................................ 526 Connection table for connector pin numbers.................................................................................... 528 T- branch box and T- branch adapter table..................................................................................... 563 310 Troubleshooting by failure code (Display of code), Part 1..................................................................... 567 Failure code [2G40GZ] Brake: Oil pressure reduction........................................................................... 568 Failure code [6091NX] HST filter: Clogging.................................................................................... 570 Failure code [989FN1] Travel speed: Overrun alarm............................................................................. 572 Failure code [AB00L6] Alternator R system: Hot short.......................................................................... 574 Failure code [AB00MA] Alternator R system: Ground fault/Disconnection charge/Low charge voltage............................... 576 Failure code [B@BAZG] Engine: Oil pressure reduction.......................................................................... 578 Failure code [B@BCNS] Engine: Overheat........................................................................................ 579 Failure code [B@BCZK] Engine: Low coolant level............................................................................... 580 Failure code [B@C6NS] Front brake: High oil temperature....................................................................... 582 Failure code [B@CRNS] HST: High oil temperature............................................................................... 583 320 Troubleshooting by failure code (Display of code), Part 2..................................................................... 585 Failure code [CA111] Abnormality in engine controller......................................................................... 587 Failure code [CA115] Engine Ne or Bkup speed sensor error..................................................................... 588 Failure code [CA122] Charge pressure sensor high error........................................................................ 590 Failure code [CA123] Charge pressure sensor low error......................................................................... 592 Failure code [CA131] Throttle sensor high error............................................................................... 594 Failure code [CA132] Throttle sensor low error................................................................................ 596 Failure code [CA144] Coolant sensor high error................................................................................ 598 Failure code [CA145] Coolant sensor low error................................................................................. 600 Failure code [CA153] Charge temperature sensor high error..................................................................... 602 Failure code [CA154] Charge temperature sensor low error...................................................................... 604 Failure code [CA155] Derating of speed by abnormally high charge temperature.................................................. 606 Failure code [CA187] Sensor power supply 2 low error.......................................................................... 608 Failure code [CA221] Atmospheric pressure sensor high error................................................................... 610 Failure code [CA222] Atmospheric sensor low error............................................................................. 612 Failure code [CA227] Sensor power supply 2 high error......................................................................... 614 Failure code [CA234] Engine overspeed......................................................................................... 615 Failure code [CA238] Ne speed sensor power supply error....................................................................... 616 Failure code [CA271] IMV (IMA) Short circuit.................................................................................. 617 Failure code [CA272] IMV (IMA) Disconnection.................................................................................. 618 Failure code [CA322] Injector #1 open/short error............................................................................. 620 Failure code [CA323] Injector #5 open/short error............................................................................. 622 Failure code [CA324] Injector #3 open/short error............................................................................. 624 Failure code [CA325] Injector #6 open/short error............................................................................. 626 Failure code [CA331] Injector #2 open/short error............................................................................. 628 Failure code [CA332] Injector #4 open/short error............................................................................. 630 Failure code [CA342] Calibration code inconsistency........................................................................... 632 Failure code [CA351] Injectors drive circuit error............................................................................ 634 Failure code [CA352] Sensor power supply 1 low error.......................................................................... 636 Failure code [CA386] Sensor power supply 1 high error......................................................................... 638 330 Troubleshooting by failure code (Display of code), Part 3..................................................................... 639 Failure code [CA428] Abnormally high level in water sensor.................................................................... 642 Failure code [CA429] Abnormally low level in water sensor..................................................................... 644 Failure code [CA431] Idle validation switch error............................................................................. 646 Failure code [CA432] Idle validation action error............................................................................. 650 Failure code [CA435] Engine oil pressure switch error......................................................................... 654 Failure code [CA441] Battery voltage low error................................................................................ 655 Failure code [CA442] Battery voltage high error............................................................................... 658 Failure code [CA449] Common rail pressure high error 2........................................................................ 660 Failure code [CA451] Common rail pressure sensor high error................................................................... 662 Failure code [CA452] Common rail pressure sensor low error.................................................................... 664 Failure code [CA488] Derating of torque by abnormally high charge temperature................................................. 666 Failure code [CA553] Common rail pressure high error 1........................................................................ 667 Failure code [CA559] Supply pump pressure very low error...................................................................... 668 Failure code [CA689] Engine Ne speed sensor error............................................................................. 670 Failure code [CA731] Engine Bkup speed sensor phase error..................................................................... 672 Failure code [CA757] All continuous data lost error........................................................................... 673 Failure code [CA778] Engine Bkup speed sensor error........................................................................... 676 Failure code [CA1633] KOMNET datalink timeout error........................................................................... 678 Failure code [CA2185] Throttle sensor supply voltage high error............................................................... 682 Failure code [CA2186] Throttle sensor power supply low error.................................................................. 684 Failure code [CA2249] Supply pump pressure very low error 2................................................................... 686 Failure code [CA2311] Abnormality in IMV (IMA) solenoid....................................................................... 688 Failure code [CA2555] Intake heater relay disconnection error................................................................. 690 Failure code [CA2556] Intake heater relay short circuit error................................................................. 692 340 Troubleshooting by failure code (Display of code), Part 4..................................................................... 695 Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short............................................................ 696 Failure code [D192KY] ECSS solenoid relay: Hot short.......................................................................... 698 Failure code [D1B0KA] HST safety relay: Disconnection......................................................................... 700 Failure code [D1B0KB] HST safety relay: Ground fault.......................................................................... 702 Failure code [D1B0KY] HST safety relay: Hot short............................................................................. 704 Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection................................................................ 706 Failure code [DAF3KK] UNSW power supply: Ground fault/ Disconnection.......................................................... 708 Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection........................................................... 710 Failure code [DAJ0KK] HST controller power supply: Low voltage................................................................ 714 Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality............................................................. 716 Failure code [DAJ1L4] HST controller main power line: Disconnection/ Ground fault............................................. 718 Failure code [DAJ1L6] HST controller main power line: Hot short............................................................... 720 Failure code [DAJ2KK] Controller solenoid power supply: Low voltage........................................................... 722 Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness.............................. 724 Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault............................... 726 Failure code [DAJ5KX] Sensor 5V power supply: Out of output range............................................................. 728 Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals................................. 730 Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection............................................................ 731 Failure code [DAJRMA] HST controller: Disagreement in option selection........................................................ 737 350 Troubleshooting by failure code (Display of code), Part 5..................................................................... 739 Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line................................................. 741 Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality........................................................ 746 Failure code [DD1NLD] Fan reverse switch signal: Abnormality.................................................................. 748 Failure code [DDB6KA] Parking brake switch A: Disconnection/Hot short......................................................... 750 Failure code [DDB6KB] Parking brake switch B: Ground fault.................................................................... 752 Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble.... 754 Failure code [DDB6L0] Parking brake switch A: Ground fault.................................................................... 756 Failure code [DDB6L4] Parking brake switch B: Disconnection/Hot short......................................................... 758 Failure code [DDD7KX] Travel speed control dial signal: Disconnection/ Ground fault........................................... 760 Failure code [DDD7KY] Travel speed control dial signal: Hot short............................................................. 762 Failure code [DDE5MA] Emergency steering operation switch: Disconnection...................................................... 764 Failure code [DDK3KA] Directional selector switch: Disconnection/Hot short.................................................... 766 Failure code [DDK3KB] Directional selector switch: Ground fault............................................................... 768 Failure code [DDK6KA] FNR lever: Disconnection/Ground fault................................................................... 770 Failure code [DDK6KY] FNR lever: Hot short.................................................................................... 774 Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering)............................................ 776 360 Troubleshooting by failure code (Display of code), Part 6..................................................................... 779 Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault.......................................... 781 Failure code [DF10KB] Travel speed range selector switch: Hot short........................................................... 784 Failure code [DGH1KX] HST oil temperature sensor: Ground fault................................................................ 786 Failure code [DGR2KB] Brake oil temperature sensor: Ground fault.............................................................. 787 Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/ Hot short.................................................. 788 Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault..................................................... 790 Failure code [DHH1KY] HST oil pressure sensor: Hot short...................................................................... 792 Failure code [DHTCL6] HST filter clogging sensor: Functional defect........................................................... 794 Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short.............................................................. 796 Failure code [DLT3KX] Travel speed sensor B: Abnormality...................................................................... 798 Failure code [DLT4KX] Travel speed sensor A: Abnormality...................................................................... 802 Failure code [DLT4LC] Travel speed sensor A & B: Abnormality.................................................................. 804 Failure code [DV00KY] Alarm buzzer: Hot short................................................................................. 806 Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault............................................................ 808 Failure code [DW26KY] Motor 2 solenoid: Hot short............................................................................. 810 Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short................................................................. 812 Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/ Ground fault............................................... 814 370 Troubleshooting by failure code (Display of code), Part 7..................................................................... 817 Failure code [DX16KA] Fan EPC solenoid: Disconnection......................................................................... 818 Failure code [DX16KB] Fan EPC solenoid: Ground fault.......................................................................... 819 Failure code [DX16KY] Fan EPC solenoid: Hot short............................................................................. 820 Failure code [DX19KA] Motor 1 solenoid: Disconnection......................................................................... 822 Failure code [DX19KB] Motor 1 solenoid: Ground fault.......................................................................... 824 Failure code [DX19KY] Motor 1 solenoid: Hot short............................................................................. 826 Failure code [DX20KA] Clutch EPC solenoid: Disconnection...................................................................... 828 Failure code [DX20KB] Clutch EPC solenoid: Ground fault....................................................................... 830 Failure code [DX20KY] Clutch EPC solenoid: Hot short.......................................................................... 832 Failure code [DXH7KB] Reverse solenoid: Ground fault.......................................................................... 834 Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short............................................................... 836 Failure code [DXH8KB] Forward solenoid: Ground fault.......................................................................... 838 Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short............................................................... 840 Failure code [J141N1] Steering pump: Overrun alarm............................................................................ 842 Failure code [M100N1] HST pump: Overrun alarm................................................................................. 842 Failure code [M400N1] Motor 1: Overrun alarm.................................................................................. 843 400 Troubleshooting of electrical system (E-mode)................................................................................. 845 E-1 Engine does not start..................................................................................................... 847 E-2. Preheater does not operate normally...................................................................................... 854 E-3 Defective boom kick-out function and cancellation......................................................................... 858 E-4 Defective bucket positioner function and cancellation..................................................................... 862 E-5 Defective lift arm FLOATING holding function and cancellation............................................................. 866 E-6 Travel direction selection system does not function....................................................................... 870 E-7 Wiper does not operate.................................................................................................... 874 E-8 Windshield washer does not operate........................................................................................ 878 E-9 Headlamp, clearance lamp and tail lamp do not light up or go off.......................................................... 882 E-10 Working lamp does not light up or go off................................................................................. 890 E-11 Turn signal lamp and hazard lamp do not light up or go off............................................................... 895 E-12 Brake lamp does not light or it keeps lighting up........................................................................ 902 E-13 Backup lamp does not light or it keeps lighting up....................................................................... 904 E-14 Backup alarm does not sound or it keeps sounding......................................................................... 907 E-15 Horn does not sound or it keeps sounding................................................................................. 910 E-16 Alarm buzzer does not sound or it keeps sounding......................................................................... 912 E-17 Air conditioner does not operate or stop................................................................................. 914 E-18 The KOMTRAX system does not work properly................................................................................ 917 500 Troubleshooting of hydraulic and mechanical system (H-mode)................................................................... 921 Method of using troubleshooting chart......................................................................................... 923 Failure code and cause table.................................................................................................. 926 H-1 The machine does not start................................................................................................ 928 H-2 The travel speed is slow.................................................................................................. 929 H-3 The traction force is weak................................................................................................ 930 H-4 Engine stalls when traveling or engine speed drops excessively............................................................ 931 H-5 The gear is not shifted................................................................................................... 932 H-6 The steering wheel does not turn.......................................................................................... 933 H-7 The steering wheel is heavy............................................................................................... 934 H-8 Steering wheel shakes or jerks............................................................................................ 935 H-9 Machine deviates naturally to one side when traveling..................................................................... 935 H-10 The brake does not work or does not work well............................................................................ 936 H-11 The brake is not released or is dragged.................................................................................. 937 H-12 The lift arm does not rise or lower...................................................................................... 938 H-13 The lift arm moves slowly or the lift arm rising force is insufficient................................................... 939 H-14 When rising, the lift arm comes to move slowly at specific height........................................................ 940 H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air).......................................... 940 H-16 Hydraulic drifts of the lift arm occur often............................................................................. 940 H-17 The lift arm wobbles during operation.................................................................................... 940 H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily................................ 941 H-19 The bucket does not tilt back............................................................................................ 942 H-20 The bucket moves slowly or the tilting-back force is insufficient........................................................ 943 H-21 The bucket comes to operate slowly in the midst of tilting-back.......................................................... 944 H-22 The bucket cylinder cannot hold down the bucket.......................................................................... 944 H-23 Hydraulic drifts of the bucket occur often............................................................................... 944 H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”)................................... 944 H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily................................... 945 H-26 The control levers of the lift arm and bucket do not move smoothly and heavy............................................. 945 H-27 The ECSS does not operate and machine pitches and bounces................................................................ 946 H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)................................. 947 600 Troubleshooting of engine (S-mode)............................................................................................ 949 Method of using troubleshooting charts........................................................................................ 950 S-1 Starting performance is poor.............................................................................................. 954 S-2 Engine does not start..................................................................................................... 955 S-3 Engine does not pick up smoothly.......................................................................................... 958 S-4 Engine stops during operations............................................................................................ 959 S-5 Engine does not rotate smoothly........................................................................................... 960 S-6 Engine lacks output (or lacks power)...................................................................................... 961 S-7 Exhaust smoke is black (incomplete combustion)............................................................................ 962 S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................................... 963 S-9 Oil becomes contaminated quickly.......................................................................................... 964 S-10 Fuel consumption is excessive............................................................................................ 965 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).................................................... 966 S-12 Oil pressure drops....................................................................................................... 967 S-13 Oil level rises (Entry of coolant or fuel)............................................................................... 968 S-14 Coolant temperature becomes too high (overheating)....................................................................... 969 S-15 Abnormal noise is made................................................................................................... 970 S-16 Vibration is excessive................................................................................................... 971 50 Disassembly and assembly........................................................................................................... 973 100 General information on disassembly and assembly............................................................................... 973 How to read this manual....................................................................................................... 974 Coating materials list........................................................................................................ 976 Special tool list............................................................................................................. 979 Sketches of special tools..................................................................................................... 983 200 Engine and cooling system..................................................................................................... 993 Removal and installation of fuel supply pump assembly......................................................................... 994 Removal and installation of fuel injector assembly............................................................................ 996 Removal and installation of cylinder head assembly............................................................................1003 Removal and installation of engine hood assembly..............................................................................1016 Removal and installation of radiator..........................................................................................1019 Removal and installation of air aftercooler...................................................................................1022 Removal and installation of hydraulic oil cooler assembly.....................................................................1024 Removal and installation of engine assembly...................................................................................1026 Removal and installation of engine front oil seal assembly....................................................................1032 Removal and installation of engine rear oil seal assembly.....................................................................1035 Removal and installation of cooling fan and fan motor assembly................................................................1038 Removal and installation of fuel tank assembly................................................................................1041 310 Power train, Part 1...........................................................................................................1043 Removal and installation of transfer assembly.................................................................................1044 Disassembly and assembly of transfer assembly.................................................................................1048 Removal and installation of parking brake assembly............................................................................1068 Disassembly and assembly of parking brake assembly............................................................................1070 320 Power train, Part 2...........................................................................................................1075 Removal and installation of front axle assembly...............................................................................1076 Removal and installation of rear axle assembly................................................................................1078 Disassembly and assembly of axle housing assembly.............................................................................1081 Disassembly and assembly of differential assembly.............................................................................1090 400 Undercarriage and frame.......................................................................................................1117 Removal and installation of center hinge pin..................................................................................1118 Removal and installation of counterweight.....................................................................................1128 500 Hydraulic system..............................................................................................................1131 Removal and installation of HST pump and 4-gear pump assembly.................................................................1132 Disassembly and assembly of HST pump assembly.................................................................................1136 Removal and installation of HST motor 1 assembly..............................................................................1163 Removal and installation of HST motor 2 assembly..............................................................................1165 Disassembly and assembly of HST motor assembly................................................................................1167 Removal and installation of work equipment control valve assembly.............................................................1183 Removal and installation of hydraulic tank....................................................................................1185 Disassembly and assembly of hydraulic cylinder assembly.......................................................................1187 600 Work equipment................................................................................................................1193 Removal and installation of work equipment assembly...........................................................................1194 700 Cab and its attachments.......................................................................................................1201 Removal and installation of operator's cab and floor frame assembly...........................................................1202 Removal and installation of operator's cab glass (Stuck glass)................................................................1207 Removal and installation of air conditioner unit..............................................................................1215 800 Electrical system.............................................................................................................1221 Removal and installation of monitor panel.....................................................................................1222 Removal and installation of engine controller assembly........................................................................1224 Removal and installation of HST controller assembly...........................................................................1225 Removal and installation of KOMTRAX terminal assembly.........................................................................1226 90 Diagrams and drawings..............................................................................................................1227 100 Hydraulic diagrams and drawings...............................................................................................1227 Hydraulic circuit diagram WA250-6.............................................................................................1229 Hydraulic circuit diagram WA250PZ-6...........................................................................................1230 200 Electrical diagrams and drawings..............................................................................................1231 Electrical circuit diagram....................................................................................................1233 Electrical circuit diagram (1/9)..............................................................................................1233 Electrical circuit diagram (2/9)..............................................................................................1234 Electrical circuit diagram (3/9)..............................................................................................1235 Electrical circuit diagram (4/9)..............................................................................................1236 Electrical circuit diagram (5/9)..............................................................................................1237 Electrical circuit diagram (6/9)..............................................................................................1238 Electrical circuit diagram (7/9)..............................................................................................1239 Electrical circuit diagram (8/9)..............................................................................................1240 Electrical circuit diagram (9/9)..............................................................................................1241 Specific electrical circuit diagram (1/2) KOHAG Quick coupler version.........................................................1242 Specific electrical circuit diagram (2/2) KOHAG pinon version.................................................................1243 Connector list and stereogram.................................................................................................1244
KOMATSU WA250-6, WA250PZ-6 UP WHEEL LOADER SHOP MANUAL 75001, 75160 AND UP, H00051 AND UP – DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
