Professional Documents
Culture Documents
WA250PZ -6
WA250- 75001
SERIAL NUMBERS and up
WA250PZ- 75001
SEN03822-03
WHEEL LOADER
WA250-6
WA250PZ-6
100 Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in thefile after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
01 Specification SEN03815-00
100 Specification and technical data SEN03824-00
40 Troubleshooting SEN03819-01
100 Failure code table and fuse locations SEN03839-00
200 General information on troubleshooting SEN03840-01
310 Troubleshooting by failure code (Display of code), Part 1 SEN03841-00
320 Troubleshooting by failure code (Display of code), Part 2 SEN03842-00
330 Troubleshooting by failure code (Display of code), Part 3 SEN03843-00
340 Troubleshooting by failure code (Display of code), Part 4 SEN03844-00
350 Troubleshooting by failure code (Display of code), Part 5 SEN03845-00
360 Troubleshooting by failure code (Display of code), Part 6 SEN03846-00
370 Troubleshooting by failure code (Display of code), Part 7 SEN03847-00
400 Troubleshooting of electrical system (E-mode) SEN03848-00
500 Troubleshooting of hydraulic and mechanical system (H-mode) SEN03849-00
600 Troubleshooting of engine (S-mode) SEN03850-00
Table of contents 1
01 Specification
100 Specification and technical data SEN03824-00
Specification dimension drawing ................................................................................................................... 3
Specifications ................................................................................................................................................ 4
Weight table .................................................................................................................................................. 8
Table of fuel, coolant and lubricants.............................................................................................................. 10
40 Troubleshooting
100 Failure code table and fuse locations SEN03839-00
Failure codes table ........................................................................................................................................ 2
Fuse locations ............................................................................................................................................... 8
200 General information on troubleshooting SEN03840-01
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 SEN03841-00
Failure code [2G40GZ] Brake: Oil pressure reduction .................................................................................. 2
Failure code [6091NX] HST filter: Clogging................................................................................................... 4
Failure code [989FN1] Travel speed: Overrun alarm .................................................................................... 6
Failure code [AB00L6] Alternator R system: Hot short.................................................................................. 8
Failure code [AB00MA] Alternator R system: Ground fault/Disconnection charge/Low charge voltage ....... 10
Failure code [B@BAZG] Engine: Oil pressure reduction............................................................................... 12
Failure code [B@BCNS] Engine: Overheat................................................................................................... 13
Failure code [B@BCZK] Engine: Low coolant level ...................................................................................... 14
Failure code [B@C6NS] Front brake: High oil temperature .......................................................................... 16
Failure code [B@CRNS] HST: High oil temperature ..................................................................................... 17
320 Troubleshooting by failure code (Display of code), Part 2 SEN03842-00
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
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 SEN03846-00
Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault ............................ 3
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 SEN03847-00
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) SEN03848-00
E-1 Engine does not start .............................................................................................................................. 3
E-2. Preheater does not operate normally..................................................................................................... 10
E-3 Defective boom kick-out function and cancellation ................................................................................. 14
E-4 Defective bucket positioner function and cancellation ............................................................................ 18
E-5 Defective lift arm FLOATING holding function and cancellation ............................................................. 22
E-6 Travel direction selection system does not function................................................................................ 26
E-7 Wiper does not operate........................................................................................................................... 30
E-8 Windshield washer does not operate...................................................................................................... 34
E-9 Headlamp, clearance lamp and tail lamp do not light up or go off .......................................................... 38
E-10 Working lamp does not light up or go off............................................................................................... 46
E-11 Turn signal lamp and hazard lamp do not light up or go off .................................................................. 51
E-12 Brake lamp does not light or it keeps lighting up .................................................................................. 58
E-13 Backup lamp does not light or it keeps lighting up................................................................................ 60
E-14 Backup alarm does not sound or it keeps sounding ............................................................................. 63
E-15 Horn does not sound or it keeps sounding ........................................................................................... 66
©2011 KOMATSU
All Rights Reserved
Printed in Japan 01-11
00-100 14
SEN03823-01
WHEEL LOADER
WA250-6
WA250PZ-6
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
01. Specification
This section explains the specifications of the machine.
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.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
Example:
Standard size Tolerance
–0.022
120
–0.126
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 – 170, 12V140 engines
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 – 170, 12V140 engines tor (2) outward.
q Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE (95 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
q 114 engine
q 107 engine
q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
tor tric appliance General wiring
wire for AV
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
automobile
Heat-resis- Conduc- Annealed copper for elec-
tor tric appliance General wiring in extremely
tant low-volt-
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 9)
Type 3
1. Disconnection
1) Hold the tightening portion and push body
(9) straight until sliding prevention ring (8)
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 13)
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
Conversion table 1
Example: Method of using the conversion table to convert from millimeters to inches
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
©2009 KOMATSU
All Rights Reserved
Printed in Japan 06-09
00-200 42
SEN03824-00
WHEEL LOADER
WA250-6
WA250PZ-6
01 Specification 01
Specifications 1
Performance
HST motor 2
• Type Variable displacement bent axis type piston motor
• Pump capacity cc/rev 50 – 107
Counter-shaft double acting planetary type, spur gear
Transfer
constant-mesh type, switching between 2 power trains
Reduction gear unit Spiral bevel gear type, splash lubrication type
Differential Straight bevel gear type, torque proportioning
Final drive Planetary gear single reduction type, splash lubrication type
Drive wheel Front and rear wheel drive
Axle
Inflation pressure
• Front wheel kPa 280 {2.8}
• Rear wheel {kg/cm2} 280 {2.8}
*1:
Indicates the value at the lowest cooling fan speed.
*2:
Indicates the value of the engine alone (without cooling fan).
*3:
The battery capacity (Ah) is indicated in the 5-hour rate value.
a The engine rated output is indicated in the net value and gross value. Gross denotes the rated output measured of
an independent engine. While, net denotes the value measured of an engine under the condition essentially the
same as that when it is installed on machine.
a Following shows the rated output (net) at the maximum cooling fan speed.
100 kW {134 HP}/2,000 rpm
Steering pump
• Type Gear type
• Delivery cm3/rev 56.0
Work equipment pump
Hydraulic pump
Stroke mm 717
Max. distance between centers
mm 1,950.5
of pins
Min. distance between centers
mm 1,233.5
of pins
Type Double-acting piston type Double-acting piston type
Cylinder bore mm 150 170
Bucket cylinder
Stroke mm — 214
Max. distance between
mm — 586
centers of pins
Hydraulic equipment
Weight table 1
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Machine model name WA250-6 WA250PZ-6
Unit: kg
Machine model name WA250-6 WA250PZ-6
a For details of notes (Notes 1 and 2…) in the table, see "Operation and Maintenance Manual".
Unit: l
Reservoir Specified capacity Refill capacity
Engine oil pan 25.5 23.0
Transfer case 6.5 5.0
Hydraulic system 135 67
Axle (front/rear) 18 18
Cooling system 22 —
Fuel tank 186 —
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
01-100 12
SEN03825-00
WHEEL LOADER
WA250-6
WA250PZ-6
Damper 1
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Distance between HST pump
1 installation surface and boss tip
Adjust
75.1 ±0.8
3. Coupling Outline
4. Boss q The damper protects the drive systems on and
5. HST pump input shaft after the engine from torsional vibrations by
6. Cover reducing the torsional vibrations of the engine
7. Flywheel due to the fluctuations in torque.
q The power from the engine is transmitted to
coupling (3) through flywheel (7), absorbing
torsional vibrations on coupling (3). Then it is
transmitted to HST pump through boss (4).
Cooling system 1
Specifications
Radiator Oil cooler Aftercooler
Type: LMF16
1. Output shaft
2. Case
3. Thrust plate
4. Shoe
5. Piston
6. Cylinder block
7. Valve plate
8. End cover
9. Bearing
10. Center spring
11. Retainer shoe
12. Retainer guide
13. Bearing
14. Oil seal
15. Flow control spool
16. Suction safety valve
17. Reversible spool
Unit: mm
1. Hydraulic motor
Function
q This hydraulic motor is called a swash plate-
type axial piston motor. It converts the energy
of the pressurized oil sent from the hydraulic
pump into rotary motion.
Principle of operation
q The pressurized oil from the hydraulic pump
flows through valve plate (7) into cylinder block
(5).
q This pressurized oil can flow on only to one
side of the (Y - Y) line connecting the top dead
center and bottom dead center of the stroke of
piston (4).
q The pressurized oil sent to one side of cylinder
block (5) pushes piston (4) (2 or 3 pistons).
q A single piston generates the force F1 [F1 (kg)
= P (kg/cm2) x xD2/4 (cm2)].
q This force works on thrust plate (2).
q Since thrust plate (2) is fixed to the specific
angle (a) to output shaft (1), the force is
divided into components (F2) and (F3).
q The radial component (F3) generates torque [T
= F3 x ri] against the (Y - Y) line connecting the
top dead center and bottom dead center.
q The result of this torque [T = s (F3 x ri)] rotates
cylinder block (5) through piston (4).
q This cylinder block (5) is connected to output
shaft (1) with the spline.
q Output shaft (1) rotates to transmit the torque.
Operation
(1) When pump is started
q The pressurized oil from the pump is supplied
to port (P), increasing the (MA) side pressure.
q The starting torque is generated in the motor,
the motor starts revolution.
q The pressurized oil on motor outlet (MB) side
of the motor returns through port (T) to the
tank.
2) Safety function
Function
q When the engine is started, the pressure in
port (P) of the fan motor is heightened in some
cases.
q Suction safety valve (1) is installed to protect
the fan system circuit.
Operation
q If the pressure in port (P) rises above the
cracking pressure of suction safety valve (1),
valve (2) of suction safety valve (1) opens to
release the pressurized oil into port (T).
q By this operation, generation of abnormally
high pressure in port (P) is prevented.
Function
This valve supplies the necessary pump delivery to
the motor, and returns the excessive oil to the
hydraulic tank.
Operation
q For the flow control valve, the upstream pres-
sure of the orifice is conducted to the right side
of spool (1) and the downstream pressure of
the orifice is led to its left side.
q The differential pressure before and after ori-
fice (E) by the incoming flow rate to the motor
works on spring (2).
q In Fig. 1, when the flow rate (Q0) is increased
beyond, the differential pressure before and
after spool (1) becomes larger than the
installed load of spring (2).
q Spool (1) moves to the left and port (P) is con-
nected to port (T).
q The excessive oil in (Z) portion of Fig. 1 flows
to the hydraulic tank through the flow control
valve, and the motor speed is kept constant
from (A) to (C).
q This flow control valve is a continuously-vari-
able type.
q As shown in Fig. 2, it is possible to change the
flow control valve continuously while maintain-
ing the motor speed constant between (A') to
( C ') by c ha n g i n g t h e c o m m an d c u r r e n t
between the motor speed (A) and (C).
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
10-100 16
SEN03826-00
WHEEL LOADER
WA250-6
WA250PZ-6
Power train 1
1. Engine
2. Damper
3. HST pump
4. 4-gear pump
5. High-pressure hose
6. HST motor 1
7. HST motor 2
8. Transfer
9. Front drive shaft
10. Front axle
11. Rear drive shaft
12. Rear axle
1. Engine Outline
2. Damper q The power from engine (1) is transmitted to
3. HST pump HST pump (3) after its torsional vibrations have
4. Steering pump been reduced with damper (2) installed on the
5. Work equipment pump flywheel.
6. Brake and cooling fan pump q The power from engine (1) is also transmitted
7. Transfer lubrication pump to HST pump (3) and the HST charge pump
8. High-pressure hose being built in HST pump (3) as well as steering
9. HST motor 1 pump (4), work equipment pump (5), brake
10. HST motor 2 and cooling fan pump (6) and transfer lubrica-
11. Emergency steering valve (if equipped) tion pump (7) being connected to HST pump
12. Transfer (3).
13. Transfer clutch q The directional selector valve and servo piston
14. Parking brake installed on HST pump (3) continuously modify
15. Front drive shaft the oil discharge direction and discharged
16. Front axle amount responding to inclination of the swash
17. Differential plate.
18. Wet multiple disc type brake q HST motors (9) and (10) are installed on trans-
19. Final drive fer (12) and connected to HST pump (3)
20. Front tire through high-pressure hose (8).
21. Rear drive shaft q The hydraulic power from HST pump (3)
22. Rear axle changes the rotating direction and speed of
23. Differential HST m oto rs (9) and (1 0) to cont ro l th e
24. Wet multiple disc type brake machine forward and reverse travel and travel
25. Final drive speed.
26. Rear tire q The power from HST motor 1 (9) is transmitted
to the output shaft through transfer clutch (13)
in transfer (12).
The power from HST motor 2 (10) is transmit-
ted to the output shaft through the gear in
transfer (12).
q As the parking brake lever is operated, parking
brake (14) being contained in the rear side of
transfer (12) activates the wet multiple disc
type brake to stop the machine.
q The power to the front side is transmitted to
front axle (16) through front drive shaft (15).
The power to the rear side is transmitted to
rear axle (22) through rear drive shaft (21).
q Speed of the power transmitted to axles (16)
and (22) is reduced on the pinion gear of differ-
entials (17) and (23), then transmitted to the
sun gear through the sun gear shaft.
q Speed of the power transmitted to the sun gear
is reduced on the planetary mechanism of final
drives (19) and (25), then transmitted to tires
(20) and (26) through the axle shaft and wheel.
Drive shaft 1
1. Hydraulic tank
2. HST pump
3. HST drain oil filter
4. Clutch solenoid valve
5. HST oil filter
6. HST motor 1
7. HST motor 2
HST pump 1
Operation
Flow of power Flow of oil
q The HST pump is installed on the damper of q Inclination of swash plate (11) starts reciprocat-
the engine flywheel. ing movement of piston (10). The pumping
q The power from the engine is transmitted to action initiated by this reciprocating movement
the HST pump through the flywheel and suctions or discharges the oil in cylinder block
damper. (9) continuously.
q The HST pump is equipped with directional q The pumping action directs the oil flow in a cer-
selector solenoid valve (1) and servo cylinder tain definite direction so that it may flow to the
(6). HST motor.
q Driving the machine forward or reverse acti- q Reversing the inclination of swash plate (11)
vates directional selector solenoid valve (1), reverses the suction and discharge ports and,
tilting swash plate (11) and, as a result, caus- as a result, reversing the oil discharging direc-
ing the switch between the oil suction and dis- tion, too.
charge ports. q Piston (10) does not stroke when swash plate
q The HST pump is built-in cylinder block and 9 (11) is at neutral, thus the oil is not discharged.
pistons (10) rotate along with drive shaft (12). q Increasing or decreasing the inclination (angle)
q Tips of piston (10) slides on the swash plate of swash plate (11) changes the stroke of pis-
surface of swash plate (11) that does not ton (10), allowing to control the travel speed.
rotate. q If the amount of the oil in the low-pressure cir-
cuit (the oil to be returned from the motor to the
pump) becomes insufficient due to leakage of
oil in the HST pump, HST motor and control
valve, the charge pump supplies the oil
through speed-related valve (3) and the check
valve on high-pressure relief valve (7).
1. Nut Function
2. Locknut q This valve is installed on the HST pump. If the
3. Poppet spring oil pressure on the high pressure circuit side
4. Check spring across the HST pump and HST motor goes
5. Main piston beyond the set pressure, it drains the pressure
6. Valve seat to the low pressure circuit side.
7. Pilot poppet This valve sets the maximum pressure of the
8. Adjustment screw HST circuit in this manner to protect the circuit.
q If low level of the oil is detected in the circuit,
the valve conducts oil from the HST charge
pump in order to protect cavitation.
Operation
q Port (A) is connected to the high pressure cir- q As the oil pressure in chamber (B) goes lower,
cuit side of the HST pump, and ports (C) and the orifice of main piston (5) is activated and
(D) are connected to the low pressure circuit differential pressure is generated in port (A)
side of the pump. and chamber (B).
q Oil fills up chamber (B) after flowing through q The oil pressure in port (A) pushes main piston
the orifice of main piston (5). (5) in the left direction, relieving the abnormal
q Pilot poppet (7) is seated on valve seat (6). pressure generated in port (A) to port (C).
q If oil pressure in port (A) and chamber (B) goes q As the oil pressure in port (A) goes lower than
beyond the set pressure, pilot poppet (7) is that in port (C), check spring (4) pushes back
pushed in the left direction. As a result, the oil main piston (5) in the right direction.
pressure in chamber (B) is released to port (C) q The oil in port (C) is conducted to port (A)
through chamber (D) and the oil pressure in through chamber (D) so that the oil level in port
chamber (B) is decreased. (A) may not go low.
q Increasing or decreasing the repulsive force of
poppet spring (3) allows adjusting the set pres-
sure.
q When increasing the set pressure, remove the
nut to loosen the locknut and screw the adjust-
ment screw. When decreasing, loosen the
adjustment screw.
Low-pressure relief valve 1 q When increasing the set pressure, loosen lock-
nut (1) and screw adjustment screw (2). When
decreasing, loosen the adjustment screw.
1. Locknut
2. Adjustment screw
3. Piston
4. Spring
Function
q This valve is installed on the HST pump. If the
oil pressure on the low pressure circuit side
across the HST pump and HST motor goes
beyond the set pressure, it drains the oil to the
hydraulic tank.
This valve sets the oil pressure of the HST
pump charge circuit in this manner to protect
the circuit.
Operation
1. Locknut
2. Adjustment screw
3. Poppet spring
4. Spring seat
5. Pilot poppet
Function
q It diverges the oil from the HST charge pump
into 2 parts. One part flows to the directional
selector solenoid valve and other part flows to
the low-pressure relief valve.
Operation
q Port (A), port (D) and port (C) are connected to
the HST pump charge circuit, low-pressure
relief valve circuit and directional selector sole-
noid valve circuit, respectively.
q The oil from the HST charge pump constantly
flows to the low-pressure relief valve circuit
through port (A), orifice of pilot poppet (5),
chamber (B) and port (D).
q Orifice of pilot poppet (5) applies to the oil
pressure from the HST charge pump. As the
result, the differential pressure is generated in
port (A) and chamber (B).
q Oil pressure in port (A) pushes pilot poppet (5)
in the left direction to flow the oil in chamber
(B) to the directional selector solenoid valve
circuit through port (C).
q A set of pilot poppet (5) is consisted of poppet
spring (3) and spring seat (4).
q When decreasing the set pressure, loosen
locknut (1) and screw adjustment screw (2).
When increasing, loosen the adjustment
screw.
1. Adjustment screw
2. Locknut
3. Spring
4. Spool
5. Piston
6. Barrel
7. Shuttle spool
8. Valve seat
Function
q This valve is installed on the HST pump. If the
oil pressure on the high pressure circuit side
across the HST pump and HST motor goes
beyond the set pressure, it drains the oil in the
servo cylinder circuit to the hydraulic tank.
This valve sets the maximum pressure of the
HST pump circuit in this manner to protect the
circuit.
Operation
q Port (A), port (B), port (Pc) and port (T) are
connected to the high pressure circuit in the
reverse travel, high pressure circuit in the for-
ward travel, speed-related valve circuit and
drain circuit, respectively.
q As oil pressure in (A) side goes high, shuttle
spool (7) is pushed down and closes the port
(B) side circuit.
q Oil pressure on port (A) side pushes up piston
(5) and, at the same time, pushes up spool (4),
too, by compressing spring (3).
q Port (Pc) and port (T) are opened, releasing
abnormal pressure generated in port (Pc) to
port (T).
q As oil pressure in port (Pc) goes low, the
swash plate angle of the HST pump is
reduced. As a result, the pump delivery is
reduced and the HST pump circuit is pro-
tected.
HST motor 1
HST motor 1
HST motor 2
Principle Operation
q It is assumed that the shaft of the disc is sup- q Pressurized oil from the HST pump flows to the
ported to enable free rotation of the disc. Force back side of piston (2) through the HST motor
F being applied aslant to the disc is divided inlet port, and is activated by inclination of pis-
into force F1 orthogonal to the disc and force ton (2) and cylinder block (3) as the rotating
F2 that works in the circumferential direction of force of drive shaft (1).
the disc. Force F1 pushes the disc in the axial q As the HST motor is rotated forward or
direction and force F2 rotates the disc clock- reverse, the oil in the high pressure circuit side
wise. is conducted to the directional shuttle valve (6).
q Also when force F' works on the disc instead of q As a large load is applied to the motor being
force F, it is likewise divided into force F1' and connected to servo valve (5), the pressure dif-
F2'. Force F2' rotates the disc counterclock- ference is generated between the high pres-
wise. sure circuit side and directional shuttle valve
(6), allowing the servo cylinder to increase
inclination of cylinder block (3).
Structure
q 7 pistons (2) are installed on the disc portion of
drive shaft (1) like spherical joints. They are
housed in cylinder block (3) having a certain
angle to drive shaft (1).
q As external load to the HST motor is
increased, servo valve (5) and directional shut-
tle valve (6) work to increase inclination of cyl-
inder block (3) and piston (2), reducing the
revolving speed and increasing the torque.
EP servo valve 1
HA servo valve 1
Function
q This valve is installed in the rear side of HST
motor 2. It controls the destination of the oil
pressure to work on the HA servo valve refer-
encing the incoming signal, which corresponds
to the directional signal of the directional selec-
tor solenoid valve on the HST pump.
Above process reduces the decelerating
impacts that results when the oil pressure is
switched.
Operation
q Directional selector solenoid valve (1) inter-
locks with the directional selector valve on the
HST pump, since it has received the signal that
is corresponding to the directional signal to be
sent to the directional selector solenoid valve
on the HST pump.
q Directional shuttle valve (2) is activated by
directional selector solenoid valve (1) and con-
trols the destination of the oil pressure to work
on the HA servo valve.
Transfer 1
a: Clutch port
b: Lubrication inlet port
c: Lubrication suction port
Input shaft
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between input shaft and size Shaft Hole clearance limit
1 bearing (front) +0.011 0 –0.023 –
50 —
–0.005 –0.012 0.005
Clearance between input shaft 0 +0.013 –0.006 –
2 bearing and cage (front)
80
–0.013 –0.006 0.026
—
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
Thickness of separator plate
1.7 ±0.05 1.6
12
Strain on separator plate — 0.05 0.15
Output shaft
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between output shaft size Shaft Hole clearance limit
1 and bearing (front) +0.030 0 –0.045 –
60 —
+0.011 –0.015 –0.011
Clearance between output shaft 0 –0.015 –0.040 –
2 bearing and cage (front)
110
–0.018 –0.040 0.003
—
13 Free
shaft
rotational torque of output
3.9 – 5.9 Nm {0.4 – 0.6 kgm}
1. HST motor 2
2. Motor 2 gear (number of teeth: 44)
3. Strainer
4. Drain plug
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between input shaft and size Shaft Hole clearance limit
5 bearing +0.030 0 –0.045 –
55 —
+0.011 –0.015 –0.011
Replace
Clearance between input shaft 0 +0.022 –0.013 –
6 bearing and cage
90
–0.015 –0.013 0.037
—
Transfer clutch (1) is fixed to transmit power of both HST motor 1 (2) and HST motor 2 (3).
Power of HST motor 1 (2) Power of HST motor 2 (3)
O O
Input shaft (4) O
O O
Sun gear (5) O
O O
Planetary pinion (6) O
O O
Carrier (7) O
O O
Motor 1 gear (8) Motor 2 gear (9)
O O
Output gear (10) i i
O
Output shaft (11)
Transfer clutch (1) is released and, since HST motor 1 (2) stops, it transmits power of HST motor 2 (3) alone.
Power of HST motor 2 (3)
O
Motor 2 gear (9)
O
Output gear (10)
O
Output shaft (11)
Axle 1
Front axle 1
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet multiple disc type brake
6. Coupling
7. Oil filler port and level plug
8. Drain plug
9. Brake oil port
10. Air bleeder
11. Oil temperature sensor
Rear axle 1
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet multiple disc type brake
6. Coupling
7. Oil filler port and level plug
8. Drain plug
9. Brake oil port
10. Air bleeder
Differential 1
Front differential 1
Unit: mm
No. Check item Criteria Remedy
7 Starting torque of bevel gear 88.2 – 205.8 Nm {0.9 – 2.1 kgm} (outside of bevel gear) Adjust
14 Clearance of differential
side bearing Outer race 112.713
+0.025 –0.004 –0.054 –
—
0 –0.029 –0.004
+0.066 +0.013 –0.066 –
Inner race 69.85 —
+0.045 0 –0.032
0 –0.062 –0.074 –
Outer race 130 —
–0.018 –0.074 –0.044
15 Clearance of bearing on
pinion shaft gear side +0.037 0 –0.052 –
Inner race 60 —
+0.023 –0.015 –0.023
0 –0.053 –0.065 –
Clearance of bearing on Outer race 120
–0.015 –0.065 –0.038
—
16 pinion shaft coupling
side +0.039 0 –0.054 – Replace
Inner race 55 —
+0.020 –0.015 –0.020
17 Clearance
spider
between pinion gear and
28
–0.06
–0.11
+0.10
+0.05
0.11 –
0.21
—
Rear differential 1
Unit: mm
No. Check item Criteria Remedy
7 Starting torque of bevel gear 88.2 – 205.8 Nm {0.9 – 2.1 kgm} (outside of bevel gear) Adjust
14 Clearance of differential
side bearing Outer race 112.713
0 –0.004 –0.029 –
—
–0.018 –0.029 0.014
+0.066 0 –0.081 –
Inner race 69.85 —
+0.045 –0.015 –0.045
0 –0.023 –0.063 –
Outer race 130 —
–0.018 –0.063 –0.005
15 Clearance of bearing on
pinion shaft gear side +0.039 0 –0.054 –
Inner race 60 —
+0.020 –0.015 –0.020
0 –0.041 –0.076 – Replace
Clearance of bearing on Outer race 120
–0.015 –0.076 –0.026
—
16 pinion shaft coupling
side +0.039 0 –0.054 –
Inner race 55 —
+0.020 –0.015 –0.020
17 Clearance
spider
between pinion gear and
25.18
–0.13
–0.18
+0.10
+0.05
0.180 –
0.280
—
Outline Operation
Straight travel (When the road resistances
under both tires are the same)
(if equipped)
1. Plate
2. Disc
3. Pinion (number of teeth: 12)
4. Washer
5. Side gear (number of teeth: 24)
6. Bevel pinion
7. Shaft
8. Pressure ring
9. Bevel gear (number of teeth: 43)
10. Case
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
3
11 Thickness of plate
±0.02 2.9
3.1
+0.04
12 Thickness of disc 2.5
–0.03
2.45
When the drive forces of the right and left Difference in wheel drive force by type of differ-
wheels are unbalanced entials when either wheel slipped
[When the road conditions (coefficient of friction) Wheel drive force
under both wheels and the wheel loads are uneven, (drive force of slipping wheel is 1)
and either wheel slips more easily] Slipping wheel Locked wheel Total (ratio)
Example 1. When either wheel is on soft ground Limited slip
in digging work differential 1 2.64 3.64 (1.53)
(if equipped)
Example 2. When either wheel is on snow and
Torque
the other one is on asphalt in snow proportioning
1 1.38 2.38 (1)
removing work differential
Example 3. When the right and left wheel loads (standard)
are unbalanced in travel on a slope Conventional
1 1 2 (0.84)
differential
Final drive 1
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between planetary gear size Shaft Hole clearance limit
6 bearing and shaft +0.025 +0.013 –0.025 – Replace
33.338 —
+0.013 0 0
Clearance between axle housing +0.100 +0.100 –0.100 –
7 and ring gear
298
+0.030 0 +0.070
—
a Starting force of axle housing, see "Disassembly and assembly of axle housing" in Disassembly and
assembly.
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between planetary gear size Shaft Hole clearance limit
6 bearing and shaft +0.025 +0.013 –0.025 – Replace
33.338 —
+0.013 0 0
Clearance between axle housing +0.100 +0.100 –0.100 –
7 and ring gear
276
+0.030 0 +0.070
—
a Starting force of axle housing, see "Disassembly and assembly of axle housing" in Disassembly and
assembly.
Outline
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
10-200 54
SEN03827-01
WHEEL LOADER
WA250-6
WA250PZ-6
Steering column 1
1. Steering wheel
2. Steering column
3. Orbit-roll valve
4. Steering tilt lock lever
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between steering shaft size Shaft Hole clearance limit
5 and column bushing
Replace
0 +0.15 0.05 –
19 0.4
–0.08 +0.05 0.23
Priority valve 1
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Installed Installed
Free length Free length Installed load
length load
12 Control spring
187 ± 14.7 N Replace
187 N
63.4 47.6 63.4 ± 1 {19.1 ± 1.5
{19.1 kg}
kg}
132 N 132 ± 14.7 N
13 Relief spring 31 27.3
{13.3 kg}
—
{13.3 ± 1.5 kg}
Outline Operation
q The priority valve is installed between the
steering pump and Orbit-roll valve and work When steering wheel is at "neutral" position
equipment control valve. It diverges the oil
from the steering pump to the steering circuit
or work equipment circuit. It is also used for
controlling the oil pressure from the priority
valve to the Orbit-roll valve in order to protect
the circuit.
Set pressure: 18.6 MPa {190 kg/cm2}
When steering wheel is "turned left" When steering cylinder is at stroke end
q Turning the steering wheel left changes the q Trying to continuously turn the steering wheel
angle between the sleeve and spool on the after the steering cylinder has reached the
Orbit-roll valve, switching flow of the oil. (see stroke end increases oil pressure in port (S).
"Orbit-roll valve".) q As the oil pressure in port (S) goes beyond the
q Part of the oil from the pump that has flown to set pressure of relief valve (10), the relief valve
port (A) is then conducted to the R.H. steering (10) releases the oil pressure in port (S) to the
cylinder through port (B) and Gerotor, and the hydraulic tank through port (T).
remaining portion of the oil flows to chamber q It generates differential pressure before and
(R) through orifice (b) and port (J). after orifice (r), breaking down the balance
q Change in the angle between the sleeve and between the difference pressure up to port (A)
spool on the Orbit-roll valve generates a differ- and after port (B) and the repulsive force of
ence pressure between the oil pressure up to spring (4). As a result, oil pressure up to port
port (A) and that after port (B). (A) becomes relatively higher.
q Spool (3) stabilizes at a position where the dif- q As port (A) oil pressure is increased, oil in
ference pressure between that of up to port (A) chamber (P) pushes spool (3) in the right direc-
and after port (B) [chamber (P) pressure - tion by compressing spring (4).
chamber (R) pressure] is balanced with the q Port (M) and port (N) are almost closed, and
repulsive force of spring (4). port (M) and port (N) are nearly fully opened to
q The ratio of diversion is determined by the dis- stabilize spool (3).
placement in angle between the spool and
sleeve on the Orbit-roll valve, namely the
opening ratio of port (A) and port (B). And
changing the operating distance of the steering
wheel enables its stepless adjustment.
Orbit-roll valve 1
Outline Structure
q The Orbit-roll valve is connected to the drive q Top (A) of spool (9) is connected to the drive
shaft of the steering column. It changes the oil shaft of the steering column and further con-
flow from the steering pump to the right or left nected to sleeve (8) through center pin (7)
steering cylinder to decide the travel direction (which is not in contact with spool (9) while the
of the machine. steering wheel is at "neutral") and centering
q The Orbit-roll valve is roughly divided into spring (2).
spool (9) and sleeve (8) that have rotary type q Top (B) of drive shaft (3) is engaged with cen-
direction selecting function and Gerotor (5) ter pin (7) and united with sleeve (8) and the
(combination of rotor (5a) and stator (5b)) that bottom is engaged with the spline of rotor (5a)
operates as a hydraulic motor during the nor- of the Gerotor (5).
mal steering operation and as a hand pump q 4 ports are provided on valve body (4). Each
(the steering wheel's operating effort becomes port is respectively connected to the pump cir-
too high to operate it actually) when the oil is cuit, tank circuit, L.H. steering circuit and R.H.
not supplied because of a trouble of the steer- steering circuit. And the ports of the pump side
ing pump or engine. and tank side are connected by the check
valve in the body. If the pump or engine fails,
the oil can be sucked through this check valve
directly from the tank side.
Operation
When steering wheel is at "neutral" position
q Above figure shows the suction and discharge q As shown above, the ports in the discharge
ports (P) of the Gerotor and connections with state of the Gerotor are connected to the ports
the sleeve ports. being connected to the steering cylinder. The
q If the steering wheel is turned to the right, ports ports in the suction state are connected to the
(a), (c), (e), (g), (i), and (k) will be connected to pump circuit.
the pump side by the vertical grooves of the q The internal gear of the Gerotor advances by 1
spool. Likewise, ports (b), (d), (f), (h), (j), and (l) tooth with every 1/7 turn of the steering wheel
are connected to the R.H. steering cylinder and discharges the oil from the pump accord-
head side. ing to the steering angle of the steering wheel.
Under the condition in Fig. 1, ports (1), (2) and Accordingly, the discharge amount varies in
(3) are in the discharge state of the Gerotor proportion to the steering angle of the steering
and connected to ports (l), (b), and (d) and the wheel.
oil is sent to the steering cylinder. Ports (5), (6),
and (7) are also connected and the oil form the
pump flows in them.
Fig. 2 shows the state that has resulted from
turning the steering wheel by 90° continued for
above condition. Under this state, ports (2), (3),
and (4) are in the suction state and connected
to ports (k), (a), and (c). Ports (5), (6), and (7)
are in the discharge state and connected to
ports (d), (f), and (h).
1. Tube
2. Poppet
3. Body
Function
q In order to buffer the impacts resulting from the
momentum of the machine when switching the
steering, an orifice installed in the circuit near
to the cylinder controls the move of the cylinder
piston by giving pressure to the return oil.
Operation
q When flowing in the left direction (in the cylin- q When flowing in the right direction (to the cylin-
der's forward move direction), the oil pushes der's return direction), the oil conducted
open poppet (3), and flows from orifice (a) and through orifice (a) of poppet (3) alone, thus the
notch (b) of poppet (3). flow rate is restricted.
Cushion valve 1
Steering cylinder 1
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between bushing in size clearance limit
Shaft Hole
1 cylinder rod frame connecting part
and mounting pin 0 +0.180 0.042 –
40 —
–0.025 +0.042 0.205
Clearance between bushing in
0 +0.180 0.042 –
2 cylinder bottom frame connecting 40
–0.025 +0.042 0.205
—
Replace
part and mounting pin
Width of boss Width of hinge Standard (a + b) clearance
Connecting part of steering cylinder
3 and front frame Max. 0.5
50 53
(after shim is adjusted)
Connecting part of steering cylinder Max. 0.5
4 and rear frame
50 53
(after shim is adjusted)
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between piston rod and size Shaft Hole clearance limit
1 bushing –0.025 +0.132 0.031 –
40 0.519
–0.087 +0.006 0.219 Replace pin and
Clearance between piston rod 0 +0.180 0.042 – bushing
2 supporting shaft and bushing
40
–0.025 +0.042 0.205
1.0
(if equipped)
1. Steering pump
2. Priority valve
3. Orbit-roll valve
4. Check valve
5. Emergency steering valve
6. HST motor 2
7. Pressure switch (for detecting emergency steering operation)
8. Steering relief valve
9. Pressure switch (for detecting low oil pressure on steering)
(if equipped)
Operation
(if equipped)
1. Block
2. Relief valve
3. Orifice
©2007 KOMATSU
All Rights Reserved
Printed in Japan 10-07 (01)
10-300 26
SEN03828-00
WHEEL LOADER
WA250-6
WA250PZ-6
Charge valve 1
1. Valve body
2. Inverse shuttle valve
3. Plunger
4. Unload relief valve
5. Unload valve
6. Relief valve
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between inverse shuttle size Shaft Hole clearance limit
7 valve and body –0.006 +0.011 0.006 –
12 0.029
–0.014 0 0.025
Clearance between plunger and –0.005 +0.009 0.005 –
8 body
8
–0.012 0 0.021
0.024
11 Unload
(inside)
relief valve return spring
35.9 30.0
188 N
{19.2 kg}
—
160 N
{16.3 kg}
Unload relief valve return spring 137 N 116 N
12 (outside) 39.8 27.5
{14.0 kg}
—
{11.8 kg}
49 N 42 N
13 Unload valve return spring 51.6 45.0
{5.0 kg}
—
{4.3 kg}
4.9 N 4.2 N
14 Check valve return spring 11.5 9.0
{0.5 kg}
—
{0.43 kg}
Function
q The charge valve maintains the oil pressure
from the pump to the set pressure and accu-
mulates it in the accumulator.
q If the oil pressure from the pump goes beyond
t h e re lie f va lv e s e t p r e ss u re , th is va lv e
releases the oil pressure to the drain circuit in
order to reduce the load to the pump.
Operation
When oil is not supplied to accumulator When oil is supplied to accumulator
(cut-out state) 1. Cut-in state
q Plunger (1) is moved in the left direction by the q As the accumulator pressure goes low, pres-
accumulator pressure, and maintains unload sure on port (E) goes low, allowing plunger (1)
relief valve (2) being pushed open. to move in the right direction and unload relief
q The oil in the spring chamber of unload valve valve (2) to close the drain circuit.
(3) is drained to the hydraulic tank through port q Since the oil pressure in port (F) and the spring
(F), unload relief valve (2) and port (T). chamber of unload valve (3) increases, unload
q Since oil pressure in port (F) is decreased, valve (3) moves in the right direction.
unload valve (3) moves in the left direction q Port (C) and port (B) are opened, conducting
being subjected to the action of the oil from the oil from the pump to port (B).
chamber (B). q As oil pressure in port (B) increases beyond
q Port (C) and port (D) are opened, supplying the set pressure of check valve (4), check
most of the oil from the pump to the cooling fan valve opens, allowing the oil to be supplied to
motor through port (P), ports (C) and (D), and the accumulator through port (E). The pressure
port (A). for supplying oil to the accumulator depends
on the set pressure of check valve (4).
q Amount of oil supplied to the accumulator is
constant independent of the engine speed,
thus surplus of the oil flows to the cooling fan
motor through port (A).
q Inverse shuttle valve (5) supplies precedence
to the accumulator of lower pressure when
supplying oil.
q As pressure in port (F) reaches the set pres- q As oil pressure in chamber (B) reaches the set
sure (cut-out pressure of unload relief valve pressure of relief valve (6), relief valve (6) is
(2)), oil in the spring chamber of unload valve opened to drain the oil from the pump to the
(3) is drained to the hydraulic tank through port hydraulic tank through port (T).
(F), unload relief valve (2) and port (T). Above process protects the brake circuit by
q Plunger (1) is moved in the left direction by the restricting its maximum pressure.
accumulator pressure, and maintains unload
relief valve (2) being pushed open.
q Since oil pressure in port (F) is decreased,
unload valve (3) moves in the left direction
being subjected to the action of the oil from
chamber (B).
q Port (C) and port (D) are opened, supplying
most of the oil from the pump to the cooling fan
motor through port (P), ports (C) and (D), and
port (A).
Brake valve 1
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between inching valve size Shaft Hole clearance limit
8 spool and body –0.022 +0.033 0.020 –
22.4 0.096
–0.053 0 0.086
Clearance between inching valve –0.022 +0.033 0.020 –
9 guide and body
22.4
–0.053 0 0.086
0.096
Outline
q The brake valve is installed in the lower front
side of the operator's seat. Pressing the brake
pedal conducts oil to the brake piston, operat-
ing the brake.
q The left side and right side brake pedals are
mechanically interlocked. Pressing one of the
pedals operates another pedal at the same
time.
q The brake valve contains the inching valve to
regulate the control pressure of the HST pump.
Operation
When the brake pedal is pressed down
q Brake pedal (1) pressing effort is transmitted to When brake of one side is operated
spool (5) through rod (2), spool (3) and spring (when the other brake failed)
(4). q Even when only one side of the brakes
q As spool (5) is pushed in the right direction, remains operable due to, for instance, oil leak
port (Ta) is closed and the oil from the pump on the front or rear brake system, brake pedal
activates the rear brake after being conducted (1) pressing effort moves in the right direction
through the accumulator, port (PA), port (A) after being transmitted mechanically through
and rear brake piston. spool (5) and spool (6).
q As spool (5) is pushed in the right direction, q Oil from the pump is conducted normally to the
spool (6) is also pushed in the right direction, brake piston of the healthy system to enable
closing port (Tb). The oil from the pump flows stopping the machine as needed in order to
through the accumulator, port (PB) and port (B) ensure safety.
to the front brake piston to activate the front
brake.
Balancing operation
Inching valve 1
1. Cylinder
2. Free piston
Function
q The accumulator is installed between the
charge valve and brake valve. The space
between cylinder (1) and free piston (2) is filled
with nitrogen gas. The nitrogen gas absorbs
the hydraulic pulses generated by the hydrau-
lic pump and secures the braking force and
operability when the engine is stopped by uti-
lizing its compressibility.
Specifications
Gas used Nitrogen gas
Amount of gas (cc) 500
Charge pressure 3.5 ± 0.1 {35.7 ± 1}
(MPa {kg/cm2}) (at 20°C)
Max. pressure used
10 {102}
(MPa {kg/cm2})
Slack adjuster 1
1. Body
2. Check valve
3. Piston
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between piston and size Shaft Hole clearance limit
4 body –0.065 +0.052 0.065 –
30 0.163
–0.098 0 0.150
Clearance between check valve –0.013 +0.015 0.013 –
5 and body
10
–0.028 0 0.043
0.048
Function
q The slack adjuster is installed between the
brake valve and brake piston. It maintains the
time lag up to activation of the brake constant.
Operation
When brake is applied When brake is released
q The oil from the brake valve flows to port (A) q The oil being stopped between piston (1) and
and moves piston (1) in the right direction to brake piston pushes back piston (1) in the left
activate the brake using the oil being amassed direction, allowing the oil, equivalent in the vol-
between piston (1) and the brake piston. ume to piston (1) move distance, to return to
q The slack adjuster maintains the time lag up to the brake valve through port (A) then is drained
activation of the brake constant by operating to the hydraulic tank.
t h e b r a k e u s in g t h e o i l b e i n g a m a s s e d
between piston (1) and the brake piston.
q If the oil between piston (1) and brake piston
goes low due to wear on the brake disc and
like, it pushes open check valve (2) to make up
the deficit.
Brake 1
Front brake 1
1. Differential housing
2. Bearing carrier
3. Piston
4. Spring
5. Inner ring
6. Sun gear shaft
7. Axle housing
8. Outer ring
9. Disc (2 pieces)
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
10 Thickness of plate
6 ±0.1 5.5
Outline
q The front brake is a wet multiple disc type
brake, which consists of piston (3), inner ring
(5), disc (9), outer ring (8), and spring (4).
q The brake cylinder consists of differential
housing (1) and bearing carrier (2). And piston
(3) is assembled to them.
Inner ring (5) and outer ring (8) are coupled
with the spline of differential housing (1).
q Disc (9) has linings stuck to its both sides and
is installed between inner ring (5) and outer
ring (8), and they are coupled together by the
spline of sun gear shaft (6).
Rear brake 1
1. Differential housing
2. Bearing carrier
3. Piston
4. Spring
5. Inner ring
6. Sun gear shaft
7. Axle housing
8. Outer ring
9. Disc (2 pieces)
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
10 Thickness of plate
6 ±0.1 5.5
Outline
q The rear brake is a wet multiple disc type
brake, which consists of piston (3), inner ring
(5), disc (9), outer ring (8), and spring (4).
q The brake cylinder consists of differential
housing (1) and bearing carrier (2). And piston
(3) is assembled to them.
Inner ring (5) and outer ring (8) are coupled
with the spline of differential housing (1).
q Disc (9) has linings stuck to its both sides and
is installed between inner ring (5) and outer
ring (8), and they are coupled together by the
spline of sun gear shaft (6).
Operation
When brake is operated
Outline
q The parking brake is built in transfer (5). On
this mechanical parking brake, operating the
multi-disc brake lever (6) from parking brake
lever (1) allows "applying" or "releasing" the
parking brake.
q Pulling parking brake lever (1) on the opera-
tor's seat pulls up the multi-disc brake lever
(6), which is connected with control cable (4),
"applying" the parking brake.
q Returning parking brake lever (1) to its original
position pushes down the multi-disc brake
lever (6), which is connected with control cable
(4), "releasing" the parking brake.
q As long as the parking brake is "applied", cur-
rent to the directional solenoid valve on the
HST pump is cut off and the swash plate of the
HST pump is maintained at the neutral posi-
tion.
Parking brake 1
1. Lever 5. Plate
2. Housing 6. Disc
3. Ball 7. Wave spring
4. Piston 8. Output shaft
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
Thickness of plate
2.6 ±0.06 2.5
9
Strain on plate — 0.05 0.1
Replace
Thickness of brake disc 2.2 ±0.08 2.05
10
Strain on brake disc — 0.02 0.25
Outline
q This parking brake is a wet multiple disc type
brake being operated mechanically to apply
braking to output shaft (8).
q Lever (1) is connected to the control cable. Ball
(3) provided between piston (4) and housing
(2), that are connected to lever (1), moves on
the slope of the piston groove responding to
the pulling distance of the parking brake lever.
By this move of the ball, piston (4) compresses
plate (5) and disc (6) to each other, thereby
applying brake to output shaft (8).
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
10-400 24
SEN03829-00
WHEEL LOADER
WA250-6
WA250PZ-6
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between upper hinge pin size Shaft Hole clearance limit
1 and rear frame (small) –0.030 +0.100 0.030 –
65 —
–0.049 0 0.149
Clearance between upper hinge pin –0.030 +0.240 0.030 –
2 and spacer
65
–0.049 0 0.289
—
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
1 Thickness of thrust plate 0
10 —
–0.15
+0.3
2 Thickness of thrust washer 5
–0.1
—
Tires 1
The radial tires (if equipped) of this machine have the following features.
q High gripping force q Low fuel consumption
q High operator comfort q Long life
q Less frequency of burst q Less damages of machine
q Less uneven wear q Less generation of heat
Structure Structure
q The cords of carcass (1) are arranged at right q The cords of carcass (1) are arranged bias
angles to the center line of tread (T) (radially). from the center line of tread (T).
q Tread (T) is stabilized and protected by several q Side wall (W) and tread (T) are integral.
strong belts (2).
q Side wall (W) and tread (T) are independent
from each other.
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
10-500 8
SEN03830-00
WHEEL LOADER
WA250-6
WA250PZ-6
WA250-6
WA250PZ-6
WA250-6
Multi-function mono-lever type
WA250-6
2-lever type
(if equipped)
WA250PZ-6
Multi-function mono-lever type
WA250PZ-6
2-lever type
(if equipped)
Hydraulic tank 1
Breather 1
4-gear pump 1
Unit: mm
WA250-6
2-spool type
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
Free length x
Installed
Outside Installed load Free length Installed load
7 Spool return spring
diameter
length
92.2 N 73.8 N
42.5 x 27.5 41 —
{9.4 kg} {7.52 kg}
If damaged or
88.3 N 70.6 N
8 Spool return spring 56.9 x 26.3 55.3
{9.0 kg}
—
{7.2 kg}
deformed, replace
spring
178 N 142 N
9 Spool return spring 55.1 x 12.6 40.0
{18.1 kg}
—
{14.5 kg}
72.6 N 58.1 N
10 Spool return spring 42 x 27.5 41
{7.4 kg}
—
{5.92 kg}
29.4 N 23.5 N
11 Check valve spring 39.5 x 11.2 25
{3 kg}
—
{2.4 kg}
WA250-6
3-spool type
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
Free length x
Installed
Outside Installed load Free length Installed load
8 Spool return spring
diameter
length
92.2 N 73.8 N
42.5 x 27.5 41 —
{9.4 kg} {7.52 kg}
If damaged or
88.3 N 70.6 N
9 Spool return spring 56.9 x 26.3 55.3
{9.0 kg}
—
{7.2 kg}
deformed, replace
spring
178 N 142 N
10 Spool return spring 55.1 x 12.6 40.0
{18.1 kg}
—
{14.5 kg}
72.6 N 58.1 N
11 Spool return spring 42 x 27.5 41
{7.4 kg}
—
{5.92 kg}
29.4 N 23.5 N
12 Check valve spring 39.5 x 11.2 25
{3 kg}
—
{2.4 kg}
WA250PZ-6
2-spool type
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
Free length x
Installed
Outside Installed load Free length Installed load
7 Spool return spring
diameter
length
92.2 N 73.8 N
42.5 x 27.5 41 —
{9.4 kg} {7.52 kg}
If damaged or
55.9 N 45.1 N
8 Spool return spring 58.87 x 26.3 57.3
{5.7 kg}
—
{4.6 kg}
deformed, replace
spring
110.8 N 88.2 N
9 Spool return spring 53.35 x 12 38.5
{11.3 kg}
—
{9.0 kg}
72.6 N 58.1 N
10 Spool return spring 42 x 27.5 41
{7.4 kg}
—
{5.92 kg}
29.4 N 23.5 N
11 Check valve spring 39.5 x 11.2 25
{3 kg}
—
{2.4 kg}
WA250PZ-6
3-spool type
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
Free length x
Installed
Outside Installed load Free length Installed load
8 Spool return spring
diameter
length
92.2 N 73.8 N
42.5 x 27.5 41 —
{9.4 kg} {7.52 kg}
If damaged or
55.9 N 45.1 N
9 Spool return spring 58.87 x 26.3 57.3
{5.7 kg}
—
{4.6 kg}
deformed, replace
spring
110.8 N 88.2 N
10 Spool return spring 53.35 x 12 38.5
{11.3 kg}
—
{9 kg}
72.6 N 58.1 N
11 Spool return spring 42 x 27.5 41
{7.4 kg}
—
{5.92 kg}
29.4 N 23.5 N
12 Check valve spring 39.5 x 11.2 25
{3 kg}
—
{2.4 kg}
Relief valve
q As the pressurized oil in ports (A) and (B)
reaches the set pressure of spring (4), pilot
poppet (3) opens, leading the pressurized oil in
port (B) to port (C) through port (D), and pres-
sure in port (B) is decreased.
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
q As the pressure in port (B) goes low, the orifice
Function of main valve (1) generates differential pres-
q This valve is installed in the inlet of the work sure between ports (A) and (B). As a result, the
equipment control valve. When the oil pressure main valve is pushed open, and pressurized oil
increases beyond the specified level, it drains in port (A) flows to the drain circuit through port
the oil to the hydraulic tank. Above process (C) to release the abnormal pressure.
protects the work equipment circuit by restrict- q Using the repulsive force of spring (4) can
ing the maximum pressure. increase or decrease the set pressure.
q When increasing the set pressure, remove the
Operation cap nut to loosen the locknut and screw the
q Port (A) and port (C) are connected to the adjustment screw (5). When decreasing,
pump circuit and the drain circuit, respectively. loosen the adjustment screw (5).
Pressurized oil fills up port (B) after flowing
through the orifice of main valve (1). Pilot pop-
pet (3) is contacted with valve seat (2).
1. Piston
2. Main valve q If abnormal pressure is generated in port (A)
3. Piston spring and reaches the set pressure of spring (6),
4. Valve seat poppet (5) opens to drain the pressurized oil in
5. Poppet port (C) through port (D) and outer circumfer-
6. Poppet spring ence (a) of suction valve (7).
7. Suction valve
8. Suction valve spring
9. Adjustment screw
Function
q This valve is installed in the bucket cylinder cir-
cuit of the work equipment control valve. When
the bucket lever is set to the neutral position, if
abnor mal pr ess ure is gener ated due to
impacts to the cylinder, the abnormal pressure
is relieved through this valve to protect the
hydraulic equipment such as cylinder from
damage.
q And if negative pressure is generated in the
cylinder circuit, this valve works as a suction
valve. q Opening of poppet (5) decreases the pressure
in port (C), and piston (1) moves to the right.
Operation Piston (1) contacts the tip of poppet (5) and the
pressurized oil is drained from port (D) through
orifice (b).
1. Operation as safety valve
q Port (A) and port (B) are connected to the cyl-
inder circuit and drain circuit, respectively.
q Pressurized oil in port (A) is conducted to port
(C) through piston (1) hole. Main valve (2) is
contacted against the left side due to the rela-
tion (d2) < (d3).
q The relation between the size of cross sec-
tional diameters (cross section areas) can be
presented as (d5) > (d4) > (d1) > (d3) > (d2).
q Since the pressure in port (C) is lower than that Suction valve
in port (A), main valve (2) moves to the right
and the pressurized oil is conducted from port
(A) to port (B) to prevent generation of abnor-
mal pressure.
q Even if abnormal pressure is generated, suc-
tion valve (7) with the large cross sectional
diameter remains not operated because of the
relation (d1) < (d4).
1. Main poppet
2. Sleeve
3. Spring
Function
q This valve prevents to generate negative pres-
sure on the circuit.
Operation
2. Operation as suction valve q If negative pressure is generated in port (A) (lift
q If negative pressure is generated on the cylin- arm cylinder head) [if a pressure lower than
der circuit, negative pressure is set on both that in the tank circuit port (B) is generated],
port (A) and port (C) because they are con- main poppet (1) is opened by the difference in
nected to each other. Suction valve ( 7) area between (d1) and (d2), and the pressur-
receives the pressurized oil by the difference in ized oil flows to cylinder port (A) from tank port
area between (d4) and (d1). (B).
q When the differential pressure between port
(B) and port (A) increases beyond the set pres-
sure, suction valve (7) moves to the right. Thus
the pressurized oil flows from port (B) to port
(A) to prevent generation of negative pressure
in port (A).
1. When lift arm and bucket spool are at the neutral position
Operation
q The pressurized oil flows to port (A) through
pump (1) and the priority valve. And the maxi-
mum pressure is regulated by relief valve (2).
q The bypass circuit is open since bucket spool
(3) is at the neutral position. Thus, the pressur-
ized oil in port (A) flows to port (B) passing
through in vicinity of the spool.
q The bypass circuit is open since lift arm spool
(4) is at the neutral position. Thus, the pressur-
ized oil in port (B) enters port (C) of the drain
circuit passing through in vicinity of the spool,
and returns to the hydraulic tank through the
filter.
Operation
q Pulling the work equipment control lever pulls
out lift arm spool (4) to set it to the raise posi-
tion.
q The pressurized oil from pump (1) flows to the
bypass circuit of lift arm spool (4) through the
bypass circuit of bucket spool (3).
q Since the bypass circuit is closed by the spool,
the pressurized oil from port (B) pushes open
check valve (5).
q The pressurized oil from port (B) flows to the
cylinder bottom through port (D).
q The pressurized oil on the cylinder head side
returns to the hydraulic tank through port (E)
and drain port (C). Thus, the lift arm is moved
upward.
Operation
q Pushing the work equipment control lever
pushes in lift arm spool (4) to set it to the lower
position.
q The pressurized oil from pump (1) flows to the
bypass circuit of lift arm spool (4) through the
bypass circuit of bucket spool (3).
q Since the bypass circuit is closed by the spool,
the pressurized oil from port (B) pushes open
check valve (5).
q The pressurized oil from port (B) flows to the
cylinder rod side through port (E).
q The pressurized oil on the cylinder bottom side
returns to the hydraulic tank through port (D)
and drain port (C). Thus, the lift arm is moved
downward.
Operation
q Pushing the work equipment control lever fur- q As long as the bucket is contacting against the
ther from the lower position pushes in lift arm ground surface, the lift arm can be raised or
spool (4) to set it to the float position. lowered due to undulations on the ground sur-
q The pressurized oil from pump (1) flows to the face.
bypass circuit of lift arm spool (4) through the
bypass circuit of bucket spool (3).
q Since the pressurized oil in the bypass circuit
flows to the drain circuit by the spool, check
valve (5) cannot be pushed open.
q In addition, the lift arm descends by its own
weight since both the raise circuit (D) and
lower circuit (E) of the lift arm cylinder are con-
nected to the drain circuit.
Operation
q Pulling the work equipment control lever pulls
out bucket spool (3) to set it to the tilt position.
q Since the bypass circuit is closed by the spool,
the pressurized oil from port (A) pushes open
check valve (7).
q The pressurized oil from port (G) flows to the
cylinder bottom side.
q The pressurized oil on the cylinder rod side
returns to the hydraulic tank through port (H)
and drain port (C). Thus, the bucket tilts.
Operation
q Pushing the work equipment control lever
pushes in bucket spool (3) to set it to the dump
position.
q Since the bypass circuit is closed by the spool,
the pressurized oil from port (A) pushes open
check valve (7).
q The pressurized oil from port (H) flows to the
cylinder rod side.
q The pressurized oil on the cylinder bottom side
returns to the hydraulic tank through port (G)
and drain port (C). Thus, the bucket dumps.
PPC valve 1
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Piston
4. Rod 10. Retainer
5. Disc 11. Body
6. Nut (for connecting lever) 12. Filter
Operation
1. When in neutral
1. Spool 7. Plate
2. Metering spring 8. Piston
3. Centering spring 9. Retainer
4. Rod 10. Body
5. Lever 11. Filter
6. Ring
Operation
1. When in neutral
a For the details of operation, see the paragraph of "Work equipment PPC valve".
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Body
7. Filter
Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
Free length x
Outside Installed Installed load Free length Installed load
8 Centering spring
diameter
length If damaged or
deformed, replace
41.1 x 15.5 29 36.3 N — 29.0 N spring
{3.7 kg} {2.96 kg}
16.7 N 13.3 N
9 Metering spring 22.73 x 8.1 22 {1.7 kg} — {1.36 kg}
Lock valve 1
1. Lever
2. End cap
3. Ball
4. Seat
5. Body
Outline
q The lock valve is installed between the HST
charge pump and work equipment PPC valve.
As the work equipment lock lever is set to the
"Lock" position, this valve, in conjunction with
the work equipment lock lever, cuts off the oil
of the PPC circuit to disable the work equip-
ment operation.
1. Gas plug
2. Poppet
3. Holder
4. Bladder
5. Film
6. Shell
7. Oil port
Outline
q The accumulator is installed between the
charge valve and work equipment PPC valve.
Even if the engine stops with the work equip-
ment raised, the pressure of the compressed
nitrogen gas in the accumulator applies the
pilot oil pressure to the work equipment control
valve so that the work equipment will lower by
its weight.
Specifications
Gas used Nitrogen gas
Amount of gas (cc) 500
Charged pressure 1.18(+0.2/0) {12(+2/0)}
(MPa {kg/cm2}) (at 80°C)
Max. pressure used
3.92 {40}
(MPa {kg/cm2})
Bypass valve 1
WA250PZ-6
Operation
When lift arm is "RAISE" operation
WA250PZ-6
ECSS valve 1
(if equipped)
a ECSS: Abbreviation for Electronically Controlled Suspension System
1. Main spool
2. Solenoid valve
3. Flow control valve
4. Shuttle valve
5. Charge valve
(if equipped)
1. Valve
2. Top cover
3. Cylinder
4. Free piston
Function
q The accumulator is installed to the lift cylinder
bottom circuit. The space between cylinder (3)
and free piston (4) is filled with nitrogen gas.
The nitrogen gas absorbs the oil pressure
pulses generated on the lift cylinder bottom
side during travel for higher travel performance
and operating performance by utilizing its com-
pressibility.
Specifications
Gas used Nitrogen gas
Amount of gas (cc) 3,000
Charged pressure 2.0 ± 0.1 {20 ± 1}
(MPa {kg/cm2}) (at 20°C)
Max. pressure used
20.6 {210}
(MPa {kg/cm2})
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
10-600 64
SEN03831-00
WHEEL LOADER
WA250-6
WA250PZ-6
WA250-6
1. Bucket
2. Bell crank
3. Bucket cylinder
4. Lift cylinder
5. Lift arm
6. Bucket link
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between bushing and pin size Shaft Hole clearance limit
7 at each end of bucket link –0.030 +0.174 0.130 –
75 1.0
–0.076 +0.100 0.250
Clearance between bushing and pin –0.030 +0.174 0.130 –
8 connecting lift arm and bucket
75
–0.076 +0.100 0.250
1.0
+0.8
90 93 ±1.5 0.7 – 4.5
0
18 Connecting
bucket
part of bucket link and
85 ±1.0 88
+3.0
0
2.0 – 7.0
19 Connecting
frame
part of lift cylinder and
94
0
–0.5
98 ±1.5 2.5 – 6.0
20 Connecting
bucket link
part of bell crank and
85 ±1.0 93 ±1.5 5.5 – 10.5
21 Connecting
arm
part of bell crank and lift
161 ±1.5 164 ±1.5 0 – 6.0
WA250PZ-6
1. Bucket
2. Bell crank
3. Bucket cylinder
4. Lift cylinder
5. Lift arm
6. Bucket link
7. Quick coupler
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between bushing and pin size Shaft Hole clearance limit
8 at each end of bucket link –0.030 +0.174 0.130 –
75 1.0
–0.076 +0.100 0.250
Clearance between bushing and pin
–0.030 +0.174 0.130 –
9 connecting lift arm and quick 75
–0.076 +0.100 0.250
1.0
coupler
0
110 114 ±1.5 2.5 – 6.0
–0.5
20 Connecting
frame
part of lift cylinder and
94
0
–0.5
98 ±1.5 2.5 – 6.0
21 Connecting
bucket link
part of bell crank and
100 ±1.0 112 ±1.5 9.5 – 14.5
22 Connecting
arm
part of bell crank and lift
186 ±0.5 189 ±0.5 2.0 – 4.0
Bucket 1
WA250-6
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
5 Wear of cutting edge (thickness)
31.8 19
Reverse or replace
Tooth 46 21
7 Wear of bucket teeth Replace
Tip tooth 48 36
WA250PZ-6
Unit: mm
No. Check item Criteria Remedy
Tooth 46 21
7 Wear of bucket teeth Replace
Tip tooth 48 36
WA250-6
Unit: mm
No. Check item Criteria Remedy
Clearance on bucket positioner
7 proximity switch
3–5
Adjust
Clearance on boom kick-out
8 proximity switch
3–5
Outline
Bucket positioner
q The bucket positioner is driven electrically.
When the bucket is returned to an angle from
the dump position to the tilt position, the bucket
positioner returns the work equipment (bucket)
control lever from the "tilt" position to the "hold"
position to automatically stop the bucket at a
proper digging angle.
q Bar (3) is fixed to the rod side of bucket cylin-
der (4). And proximity switch (1) is fixed to the
cylinder side.
q Moving the work equipment (bucket) control
lever from "dump" position to "tilt" position
moves the rod of bucket cylinder (4) toward the
machine front side.
As bar (3) moves a specific distance, proximity
switch (1) detects that it is away from the sens-
ing face, and returns the work equipment
(bucket) control lever to "hold" position.
Boom kick-out
q The boom kick-out is driven electrically. As the
lift arm is raised to an angle before reaching
the maximum height, the boom kick-out returns
the work equipment (lift arm) control lever from
the "raise" position to the "hold" position to
stop the lift arm automatically at a desired
height.
q Plate (6) is fixed to lift arm (5). And proximity
switch (2) is fixed to the front frame.
q Moving the work equipment (lift arm) control
lever from "lower" position to "raise" position
moves lift arm (5) upward.
As plate (6) moves a specific distance, proxim-
ity switch (2) detects that it is away form the
sensing face, and returns the work equipment
(lift arm) control lever to "hold" position.
q While the bucket is dumped more than the q Shifting work equipment (bucket) control lever
position being set from the bucket positioner, (7) toward the tilt position moves spool (8) to
bar (2) moves on to the sensing face of prox- the position of the arrow. And spool is held
imity switch (1), turning on the proximity switch there by the energized coil of detent solenoid
(1) lamp. (6).
At this point, bucket positioner relay (4) is "ON" As a result, work equipment (bucket) control
and current flows to detent solenoid (6) of work lever (7) is held at "tilt" position and the bucket
equipment PPC valve (5) to energize the coil. tilts.
q While lift arm (3) is dumped beyond the posi- q Shifting work equipment (lift arm) control lever
tion set from the boom kick-out, plate (2) (7) toward the raise position moves spool (8) to
moves on to the sensing face of proximity the position of the arrow. And spool is held
switch (1), turning on the proximity switch (1) there by the energized coil of detent solenoid
lamp. (6).
At this point, boom kick-out relay (4) is "ON" As a result, work equipment (lift arm) control
and current flows to detent solenoid (6) of work lever (7) is held at "raise" position and lift arm
equipment PPC valve (5) to energize the coil. (3) rises.
WA250PZ-6
Unit: mm
No. Check item Criteria Remedy
Clearance on bucket positioner
8 proximity switch
3–5
Adjust
Clearance on boom kick-out
9 proximity switch
3–5
Outline
Boom kick-out
q The boom kick-out is driven electrically. As the
lift arm is raised to an angle before reaching
the maximum height, the boom kick-out returns
the work equipment (lift arm) control lever from
the "raise" position to the "hold" position to
stop the lift arm automatically at a desired
height.
q Plate (7) is fixed to lift arm (6). And proximity
switch (3) is fixed to the front frame.
q Moving the work equipment (lift arm) control
lever from "lower" position to "raise" position
moves lift arm (6) upward.
As plate (7) moves a specific distance, proxim-
ity switch (3) detects that it is away form the
sensing face, and returns the work equipment
(lift arm) control lever to "hold" position.
q While the bucket is dumped more than the q Shifting work equipment (bucket) control lever
position being set from the bucket positioner, (7) toward the tilt position moves spool (8) to
bar (2) moves on to the sensing face of prox- the position of the arrow. And spool is held
imity switch (1), turning on the proximity switch there by the energized coil of detent solenoid
(1) lamp. (6).
At this point, bucket positioner relay (4) is "ON" As a result, work equipment (bucket) control
and current flows to detent solenoid (6) of work lever (7) is held at "tilt" position and the bucket
equipment PPC valve (5) to energize the coil. tilts.
q While lift arm (3) is dumped beyond the posi- q Shifting work equipment (lift arm) control lever
tion set from the boom kick-out, plate (2) (7) toward the raise position moves spool (8) to
moves on to the sensing face of proximity the position of the arrow. And spool is held
switch (1), turning on the proximity switch (1) there by the energized coil of detent solenoid
lamp. (6).
At this point, boom kick-out relay (4) is "ON" As a result, work equipment (lift arm) control
and current flows to detent solenoid (6) of work lever (7) is held at "raise" position and lift arm
equipment PPC valve (5) to energize the coil. (3) rises.
WA250-6
Lift cylinder
Bucket cylinder
Unit: mm
No. Check item Criteria Remedy
Cylinder Standard Tolerance Standard Clearance
name size Shaft Hole clearance limit
Clearance between piston –0.030 +0.271 0.105 –
1 rod and bushing Lift 70 0.675 Replace bushing
–0.104 +0.075 0.375
–0.030 +0.291 0.107 –
Bucket 75 0.695
–0.104 +0.077 0.395
Tightening torque of
Lift 1,030 ± 103 Nm {105 ± 10.5 kgm}
cylinder head
2
Tightening torque of
Bucket 250 ± 24.5 Nm {25.5 ± 2.5 kgm}
cylinder head mounting bolt
Retighten
Tightening torque of
Lift 3,970 ± 397 Nm {405 ± 40.5 kgm} (width across flats: 80 mm)
cylinder piston locknut
3
Tightening torque of
Bucket 98 – 123 Nm {10 – 12.5 kgm}
cylinder piston lock bolt
WA250PZ-6
Lift cylinder
Bucket cylinder
Coupler plunger
Unit: mm
No. Check item Criteria Remedy
Cylinder Standard Tolerance Standard Clearance
name size Shaft Hole clearance limit
–0.030 +0.271 0.105 –
Lift 70 0.675
Clearance between piston –0.104 +0.075 0.375
1 rod and bushing
Replace bushing
–0.035 +0.270 0.095 –
Bucket 100 0.660
–0.090 +0.060 0.360
Coupler –0.020 +0.061 0.011 –
20 0.453
plunger –0.072 –0.009 0.153
Tightening torque of
Lift 1,030 ± 103 Nm {105 ± 10.5 kgm}
cylinder head
Tightening torque of
2 cylinder head mounting bolt
Bucket 343 ± 34.5 Nm {35 ± 3.5 kgm}
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
10-700 26
SEN03832-00
WHEEL LOADER
WA250-6
WA250PZ-6
Cab 1
Air conditioner 1
1. Engine
2. Compressor
3. Condenser
4. Receiver
5. Air conditioner unit
6. Dual pressure switch
Heater
q The heater circulates engine coolant in heater
core (2) to cause heat exchange (heating).
q Air taken in by the blower and intake unit is
heated with heater core (2) and then blown out
through the duct and grill.
Compressor 1
Specifications
Number of cylinders –
7 – 29.3 x 27.4
Bore x Stroke (mm)
Condenser 1
Specifications
Receiver 1
Specifications
Effective cubic capacity (cm3) 578
Weight of desiccating agent (g) 300
Display unit
Display Display
No. Display items Display range Display method Remarks
category color
Spurting out All segments below applicable level come
1 See above drawing
temperature on (8-step display)
Gauge
Air blasting All segments below applicable level come
2 See above drawing
volume on (4-step display)
The display indicates which is currently
Circulation of When circulating Liquid
taking place - internal air circulation or Black
internal air and internal air and crystal
3 external air introduction - responding to the
introduction of introducing
operation of the internal/external air
Pilot external air external air
changeover switch.
When air
Turns "ON" air conditioner switch, this lamp
4 Air conditioner conditioner switch
lights up.
is "ON"
Switch block
Circulation of
This switch is used to select either the circulation of internal air or
internal air
Internal/external air introduction of external air
5 IO
changeover switch (pilot display on the display unit is switched depending on the switch
Introduction of
setting)
external air
6 Air conditioner switch It turns on or off the cooling and the dehumidifying heating function. OFF io ON
Outline
q CPU (central processing unit) installed on the
panel processes input signals from respective
sensors and operation signals of the panel
switches to display and output them.
q The self-diagnosis function of CPU makes the
troubleshooting easier.
12 NC — 11 NC —
13 Day light sensor 2 Input 12 NC —
14 Day light sensor 1 Output 13 NC —
14 NC —
15 Magnet clutch Input
16 Air mix damper actuator limiter Input
17 Mode selector actuator limiter Input
18 Air mix damper actuator potentiometer Input
19 Mode selector actuator potentiometer Input
20 Blower gate Input
21 Blower feedback Input
22 Actuator potentiometer ground —
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
10-800 16
SEN03833-01
WHEEL LOADER
WA250-6
WA250PZ-6
Outline
q In the machine monitor system, each controller 4. In addition to the above, the following display,
on the network monitors controls the machine setting and adjustment functions are provided
condition with the sensors installed to various using the character display and the machine
parts of the machine, and then sends the result monitor mode selector switch, which is the
as network information to the machine monitor, operation switch of the character display.
which displays the information to notify the 1) Switching of traction level
operator of the machine condition. 2) Switching of HST reverse travel gear shift-
ing pattern
q The machine monitor displays the information 3) Display the odometer
in the operator mode or service mode. 4) Resetting the filter or oil replacement time
5) Input the telephone number
q The operator mode is used to display the infor- 6) Selecting the language
mation to the operator normally. The major 7) Adjusting the illuminance of nighttime light
functions used in the service mode are as fol- 8) Travel speed/engine speed display select-
lows. ing function
9) Function for setting display/no-display of
1. Items always displayed travel speed or engine speed to the char-
q Meters (speedometer or engine tachome- acter display
ter)
q Gauges (engine coolant temperature
gauge, HST oil temperature gauge and
fuel gauge)
q Pilot indicators
q Service meter
q The service mode function is provided for the 9. Optional device selecting function
ease of troubleshooting for the controllers on Verifies the installation of optional devices or
the network (including the machine monitor changes their setting.
itself). The major functions used in this mode
are as follows. 10. Machine serial number input function
Enters the machine serial number to identify
1. Electrical system failure history display func- the machine.
tion
The electrical system failures of each controller 11. Model selection function
saved in the machine monitor are displayed. Enters the information of applicable model.
The information of those failures is also
deleted with this function. 12. Initialize function
Sets the machine monitor to the state set when
2. Mechanical system failure history display func- the machine is delivered.
tion
The mechanical system failures of each con-
troller saved in the machine monitor are dis-
played.
6. Adjustment function
Functions are provided to correct and adjust
the installation errors and manufacturing dis-
persion of the sensors, solenoid valves, etc.
Function for changing control characteristics is
provided on user request.
Machine monitor 1
1. HST oil temperature gauge 20. Brake oil temperature caution lamp
2. HST oil temperature caution lamp 21. Quick coupler operation pilot lamp (*2)
3. Engine coolant temperature gauge 22. Cooling fan reverse rotation pilot lamp
4. Engine coolant temperature caution lamp 23. Maintenance caution lamp
5. Speedometer or engine tachometer 24. Parking brake reminder caution lamp
6. Turn signal pilot lamp (left) 25. Battery charge circuit caution lamp
7. Head lamp high beam pilot lamp 26. Steering oil pressure caution lamp (*2)
8. Turn signal pilot lamp (right) 27. Emergency steering pilot lamp (*2)
9. Fuel level caution lamp 28. Meter display pilot lamp
10. Fuel gauge 29. Character display portion
11. Central warning lamp 30. Preheating pilot lamp
12. Brake oil pressure caution lamp 31. Directional selector switch actuation pilot lamp
13. Engine oil pressure caution lamp 32. Economy operation display lamp
14. Water separator caution lamp 33. Shift hold pilot lamp (*1)
15. Engine oil level caution lamp (*1) 34. S mode operation pilot lamp
16. Radiator coolant level caution lamp 35. Traction control operation pilot lamp
17. HST oil filter clogging caution lamp 36. Travel speed range selector switch position
18. Air cleaner clogging caution lamp (*1) pilot lamp
19. Parking brake pilot lamp 37. Directional lever position pilot lamp
Display color
Display of message
Display of message
Individual display
Individual display
Central warning
Central warning
Alarm buzzer
Alarm buzzer
Detection
lamp
lamp
Turned ON with errors (E03
and E02) of each controller,
When error occurs E E E E E E E E simultaneously displaying
Central the message on the
Central
Red
warning 11 warning LED character display.
lamp For other than above, see
"Operating condition,
central warning lamp" of — — — — — —
other items. White
Display color
Display of message
Display of message
Individual display
Individual display
Central warning
Central warning
Alarm buzzer
Alarm buzzer
Detection
Category No. Item Device Operating condition Remarks
Reset
lamp
lamp
Operates when charging
Service meter normally at 1 : 1 to the — — — — — — Displays various codes and
Black
Character clock time items according to the
29 LCD
display machine condition and
Odometer Converts travel speed — — — — — — switch operation.
pulse into travel distance
x 100 r/min
Green
Engine speed When engine speed 0 0 — Q — — Q — (setting of a desired value is
display is selected available from the machine
monitor)
Unit 28 LED
km/h or MPH
Green
When travel speed display (setting of a desired value is
Travel speed is selected 0 0 — Q — — Q —
available from the machine
monitor)
When F is selected
Normal — — — — — —
14 Water
Red
LED
separator
Water mixing with fuel — Q — CA418 — Q — CA418
16 LED
coolant level
Low coolant level (OPEN) 30 1 — Q — B@BCZK — Q — B@BCZK
Normal (OPEN) — — — — — —
17 clogging LED
detected)
When abnormality is
detected (clogging was KEY — — — DHTCL6 — — — DHTCL6
detected as engine was 3 OFF
stopped)
Display color
Display of message
Display of message
Individual display
Individual display
Central warning
Central warning
Alarm buzzer
Alarm buzzer
Detection
Category No. Item Device Operating condition Remarks
Reset
lamp
lamp
Operation (OPEN) — Q — — Q —
Released (CLOSE) — — — — — —
Red
19 Parking brake LED
Engine is running, parking
brake operated and the
directional lever is at any 0 0 — — — A Q Q
position other than "N"
Red
LED 2. Oil temperature 125°C 5 5 w Q Q B@C6NS w Q Q B@C6NS
temperature or above and travel
consecutively at lower than
125°C for 5 sec.
speed 35 km/h or
above
When abnormality is — — — DGR2KB — — — DGR2KB
detected (ground fault)
When abnormality is
detected (disconnection or — — — DGR2KZ — — — DGR2KZ
hot short-circuit)
Alarm buzzer is sounded
Other than below — — — — — — when connection of quick
coupler is reset. Error
21 Quick coupler
Red
operation LED message is simultaneously
When quick coupler is 0 0 A Q — Remarks A Q — Remarks displayed on the character
disconnected display.
"PIN DISCONNECT"
Normal 0 0 — — — — — —
Error message is displayed
Orange
Cooling fan on the character display
22 reverse LED Reverse 0 0 — Q — Remarks — Q — Remarks when long as reverse
rotation rotation of fan is continued.
"COOLING FAN REVERSE"
Selecting reverse rotation 0 0 — w — — w —
Other Ordinary — — — — — —
symbols Message is simultaneously
Red
Display color
Display of message
Display of message
Individual display
Individual display
Central warning
Central warning
Alarm buzzer
Alarm buzzer
Detection
Category No. Item Device Operating condition Remarks
Reset
lamp
lamp
Other than below — — — — — —
Red
30 Preheating LED
When preheater is turned
on 0 0 — Q — — Q —
Green
selector switch is used
31 LED function" of the machine
switch Directional lever priority monitor.
actuation 0 0 A w Q A w Q
caution Not to be displayed when
Directional selector switch error is made in
neutral caution 0 0 A w Q A w Q communication.
Other
symbols
Other than below 0 0 — — — — — —
Green
32 Economy
operation
LED
Economy mode operation 0 0 — Q — — Q —
Green
The lamp goes off when
34 S mode
operation LED traction control is reset from
S mode operation is max. traction switch. When
selected 0 0 — Q — — Q —
traction control is reset with
max. traction switch, the
Traction Other than below — — — — — — lamp is lit again when
Green
35 control LED directional lever position is
operation Traction control operation switched.
is turned on 0 0 — Q — — Q —
Troubleshooting function 1
q The machine monitor monitors the input and output signals constantly for troubleshooting for the sys-
tem.
q If each controller detects abnormality by the self-diagnosis, abnormality information is forwarded to the
machine monitor over the network.
q Abnormality information can be checked on the character display using the failure code display mode of
the machine monitor.
q Machine monitor display and setting can be changed by using the character display.
q The range where operator is enabled to operate is within the portion of the "Operator mode" in the figure
below.
a For the operating method in the operator mode, see the Operation and maintenance manual.
*1: When an ID entered from the "ID entry" screen is once approved, display changes directly to the "Select
function" screen without displaying the "ID entry" screen until the starting switch is turned "OFF".
a When "SI unit specification" is selected for the "Factory mode" from the machine monitor, the character
display shows the engine speed in "rpm" and the monitor center display is fixed to the travel speed in
"km/h".
Example of a failure code screen (simultaneously occurring errors: DX16KA, B@BCZK and CA431)
*1: The screen automatically returns to the Warning screen if the switch is not pressed more than 10 sec-
onds in the Normal screen display.
*2: The screen returns to the Warning screen if the switch is not pressed more than 30 seconds in the fail-
ure code screen or if a new alarm is turned ON.
*3: Pressing the ">" switch on the Normal screen before 10 seconds lapse changes display to the initial fail-
ure code screen.
*1: These menus are displayed when "ADD" is selected for "13. RPM/SPEED" item from the "Optional
device selecting function" of the machine monitor.
*2: These menus are displayed when "ADD" is selected for "12. RPM/OPT" item from the "Optional device
selecting function" of the machine monitor.
k It is prohibited to select "ADD" for "12. RPM/OPT" from the "Optional device selecting function"
of the machine monitor in the regions where the applicable law requires to display the travel
speed.
q The machine monitor is provided with service mode function for the ease of troubleshooting for the con-
trollers on the network (including the machine monitor itself).
q Initial setting of the sensors and optional setting can be made in the service mode of the machine moni-
tor.
a Pressing "<" or ">" switch on the menu screen switches individual menus of the service mode sequen-
tially and endlessly.
a Pressing "U" switch on the target menu screen changes the screen to the detailed screen of the same
menu.
a Pressing "t" switch on the menu screen returns the screen to the 1st layer of the operator mode.
Electrical system failure history display func- Real-time monitoring function (REAL-TIME
tion (ELECTRIC FAULT) MONITOR)
a "**" field displays total number of the failure q This function is used to check on the input/out-
history currently recorded. (max. 20 histories to put signals, etc. each controller on the network
be stored) recognizes.
q The history is used to check on the electrical a For the operating procedure of this function,
system failures of each controller saved in the see "Special functions of machine monitor
machine monitor. After repairing the failure (EMMS)" in Testing and adjusting.
content and verifying normal function, the fail-
ure history may be erased.
a For the operating procedure of this function,
see "Special functions of machine monitor
(EMMS)" in Testing and adjusting.
Mechanical system failure history display func- Engine reduced-cylinder function (CYLINDER
tion (MACHINE FAULT) CUT-OUT)
a "**" field displays total number of the failure q This function is used for the purpose of speci-
history currently recorded. (max. 20 histories to fying cylinder having defective combustion by
be stored) stopping fuel injection to each cylinder from the
q The history is used to check on the mechanical fuel injector.
system failures of each controller saved in the a For the operating procedure of this function,
machine monitor. see "Special functions of machine monitor
a For the operating procedure of this function, (EMMS)" in Testing and adjusting.
see "Special functions of machine monitor
(EMMS)" in Testing and adjusting.
AMP070-20P[CN-L24]
Pin No. Specifications I/O Group Form of use Signal name Remarks
1 (NC) — — — —
2 (NC) — — — —
3 (NC) — — — —
4 NSW power supply (+24 V) I — Constant power NSW power supply (+24 V)
supply (+24 V)
5 NSW power supply (+24 V) I — Constant power NSW power supply (+24 V)
supply (+24 V)
16 (NC) — — — —
AMP070-18P(1)[CN-L25]
Pin No. Specifications I/O Group Form of use Signal name Remarks
6 (NC) — — — —
D_IN_12
7 I C D/I (+24 V) Turn signal lamp, right
(NSW24 V, 5 mA)
D_IN_14
8
(NSW24 V, 5 mA) I C D/I (+24 V) U switch
12 (NC) — — — —
13 (NC) — — — —
D_IN_9 Cooling fan automatic reverse
14 (24 V, 5 mA) I B D/I (+24 V) rotation switch (automatic)
15 (NC) — — — —
D_IN_13
16 (NSW24 V, 5 mA) I C D/I (+24 V) Turn signal lamp, left
D_IN_15
17 (NSW24 V, 5 mA) I C D/I (+24 V) t switch
A_IN_0
18 (0 – 30 V) I H A/I Alternator L signal
AMP070-12P(1)[CN-L26]
Pin No. Specifications I/O Group Form of use Signal name Remarks
D_IN_16
1 I D D/I (GND) Brake oil pressure
(24 V/GND, 5 mA)
2 (NC) — — — —
D_IN_20
3 (24 V/GND, 5 mA) I D D/I (GND) (air cleaner clogging)
D_IN_22
4 (24 V/GND, 5 mA)
I D D/I (GND) Traction control switch (S mode)
D_IN_24
5 (24 V/GND, 5 mA)
I E D/I (GND) HST oil filter clogging
10 (NC) — — — —
D_IN_25
11 I E D/I (GND) (optional switch)
(24 V/GND, 5 mA)
A_IN_1
12 I H A/I Clearance lamp and tail lamp
(0 – 30 V)
AMP070-18P(2)[CN-L27]
Pin No. Specifications I/O Group Form of use Signal name Remarks
13 (NC) — — — —
18 (NC) — — — —
AMP070-12P(2)[CN-L28]
Pin No. Specifications I/O Group Form of use Signal name Remarks
A_IN_2
1 I J A/I Fuel level sensor
(high-resistance input)
A_IN_4
2 I J A/I HST oil temperature sensor
(high-resistance input)
3 (NC) — — — —
4 (NC) — — — —
5 (NC) — — — —
9 (NC) — — — —
10 (NC) — — — —
12 (NC) — — — —
AMP070-12P(3)[CN-L29]
Pin No. Specifications I/O Group Form of use Signal name Remarks
1 (NC) — — — —
2 (NC) — — — —
4 (NC) — — — —
5 (NC) — — — —
7 (NC) — — — —
9 (NC) — — — —
10 (NC) — — — —
11 (NC) — — — —
12 (NC) — — — —
AMP070-14P[CN-L30]
Pin No. Specifications I/O Group Form of use Signal name Remarks
1 (NC) — — — —
2 (NC) — — — —
3 (NC) — — — —
4 (NC) — — — —
5 (NC) — — — —
6 (NC) — — — —
7 (NC) — — — —
8 (NC) — — — —
9 (NC) — — — —
10 (NC) — — — —
11 (NC) — — — —
12 (NC) — — — —
13 (NC) — — — —
14 (NC) — — — —
AMP040-8P
Pin No. Specifications I/O Group Form of use Signal name Remarks
Do not connect
1 (NC) — — — — wiring harness on
machine
Do not connect
2 (NC) — — — — wiring harness on
machine
Do not connect
3 (NC) — — — — wiring harness on
machine
Do not connect
4 (NC) — — — — wiring harness on
machine
Do not connect
5 (NC) — — — — wiring harness on
machine
Do not connect
6 (NC) — — — — wiring harness on
machine
Do not connect
7 (NC) — — — — wiring harness on
machine
Do not connect
8 (NC) — — — — wiring harness on
machine
©2007 KOMATSU
All Rights Reserved
Printed in Japan 10-07 (01)
10-910 28
SEN03834-01
WHEEL LOADER
WA250-6
WA250PZ-6
a Except where otherwise specified, the displayed travel speed in this document represents the one when
20.5-25 tire is worn.
Do o A Clutch solenoid
Solenoid output
Traction control switch
Directional lever (F, N, R) Do o A Cooling fan motor flow rate control EPC valve
Directional selector switch (F, N, R) Do o D Cooling fan motor reverse rotation solenoid relay
Directional selector switch actuation switch Do o D Directional solenoid (F, R)
Parking brake lever intermediate switch Do o D HST controller power holding relay
Parking brake lever bottom switch Do o D HST safety relay
Speed sensor A
CAN output
Coolant temperature (Eng_con) Co
HST controller
Cooling fan automatic reverse rotation (Mon) Co o C Load frequency information (KOMTRAX)
ECSS (Mon) Co
A: Analog signal
D: Digital signal
P: Pulse signal
C: CAN signal
Fixed to MAX –
4th 0 – 38 ON, OFF MAX – 0 Variable (ON, OFF) —
1. Directional indicators
The directional lever position pilot lamps of the machine monitor indicate the state of the directional
lever based on the input data to the HST controller.
When the directional lever is at the neutral position and no input signal is sent to the HST controller, all
the directional lever position pilot lamps of the machine monitor go off.
If two independent signals were sent to the HST controller by accident, two directional lever position
pilot lamps of the machine monitor may turn on at the same time.
As the directional lever is set to "R (reverse)" the HST controller activates the backup lamp relay to light
the reverse lamp and sound the back-up alarm.
2. Speed range indicator
The travel speed range selector switch position pilot lamp of the machine monitor displays the state of
the travel speed range selector switch being sent to the HST controller.
S mode function
q Receiving the S mode signal, this function reduces the maximum capacity of HST motor 1 and the upper
limit of the throttle opening ratio in order to secure an optimum drive force for the dozing work on very
slippery road surface (on the snow-covered road, sandy terrain, etc.).
q This function restricts sudden start in forward travel by reducing skidding of tires through control of the
drive force. And by securing smooth start of the machine, this function offers enhanced operating perfor-
mance.
q The S mode operation pilot lamp of the machine monitor remains lighted as long as the S mode opera-
tion is continued.
a The traction force control in the S mode is enabled when the directional lever is set to the "forward" posi-
tion and the machine is traveling forward or stopped.
a For the operating method of this function, see the "Operation and maintenance manual".
Features
Switch
Pilot lamp Traction level Road Guideline
position Traction Material condition
1
(OFF) OFF 1
Suitable for loading work. Improves work
efficiency and provides antislip by selecting
2A Powerful Hard-packed Un-slippery traction level depending on material and
I I I road conditions.
2 2 2B O O O
(ON) (ON) Soft Loose Slippery
Select when operating with the special
2C attachment which requires small traction
force.
Provides the best driving force on very Select when the machine tends to slip when
3 3 3
slippery road surfaces covered by snow, forwarding, such as on snow or sand
(S mode) (ON) sand, etc. Prevents the tires from slipping covered road surface.
to facilitate work.
Relationship between accelerator pedal angle and travel speed (A) for starting transfer clutch switch-
ing modulation
Accelerator pedal angle (%)
Transfer clutch
0 – 65 65 – 90 90 – 100
Engaged o
8 km/h 8 – 10 km/h 10 km/h
Disengaged (B)
Disengaged o 7 km/h 7 – 9 km/h 9 km/h
Engaged (C)
Neutralizer function
q When the parking brake lever is pulled (the switch at the bottom of the parking brake lever is "OFF"), this
function, independent of the directional lever position, holds HST pump at the neutral in order to prevent
dragging of the parking brake.
q In order to prompt the operator for the low fuel consumption operation, this function lights up the econ-
omy operation pilot lamp as long as the low fuel consumption operation is continued.
q The economy operation pilot lamp lights up as the opening ratio of the accelerator pedal is maintained at
less than 75% for 0.5 seconds or longer.
q The economy operation pilot lamp can be constantly turned off by selecting "NO ADD" for "4. ECO
LAMP" item from the "Optional device selecting function" of the machine monitor.
a For the setting procedure, see "Special functions of machine monitor (EMMS)" in Testing and adjusting.
Fan control
q Employment of the hydraulically driven cooling fan and the control of the flow rate of the hydraulic motor
allow reducing the horsepower loss and noises as well as cutting the warm-up operation time in a low
temperature environment.
q Engine speed, coolant temperature and boost air temperature received by the engine controller, and the
information of HST oil temperature received by the machine monitor are sent to the HST controller via
the network.
q Based on the received information, the HST controller sends the signal current to the cooling fan motor
flow rate control EPC valve in order to set the fan speed to a level suitable for the respective tempera-
ture levels and the engine speed.
*1: The target fan speed is determined based on the coolant temperature, HST oil temperature or boost air
temperature data, whichever is the highest.
*2: Within this range, the fan speed is set according to the coolant temperature, HST oil temperature and
boost air temperature.
*3: When the boost air temperature is at the lower limit or when the HST oil temperature is low, the fan
speed is decreased to increase the oil and coolant temperature (heater spurting out temperature) and
cut the warm-up operation time.
(the fan speed in this area is controlled based on the hysteresis of each temperature.)
The control (derating of the minimum fan speed) at start of engine is carried out if every condition in the fol-
lowing table is met.
*1: When the fan speed control conditions at low temperature are not applicable and the minimum boost air
temperature is 20°C or above.
The fan rotation is switched from "forward" to "reverse" as every condition in the following table is met.
Condition 1 The fan reverse rotation switch was set to "MANUAL" for 0.5 seconds or longer.
Condition 2 Engine speed over 500 rpm and below 1,200 rpm.
(*1) [above is required to prevent generation of peak pressure in the process of switching the direction.]
Coolant temperature is below 90°C.
Condition 3
[above is required to prevent overheating.]
HST oil temperature is below 95°C.
Condition 4
[above is required to prevent overheating.]
Boost air temperature is below 70°C.
Condition 5
[above is required to prevent overheating.]
30 seconds minimum have elapsed since the engine is started (since the engine speed reached 500
Condition 6 rpm or above).
[above is required to secure the oil to be supplied to the brake accumulator.]
The fan rotation is switched from "reverse" to "forward" if any of the following conditions is met.
Condition 1 While the fan is rotating reverse, the fan reverse switch was again set to "MANUAL" and the engine
(*1) speed went to below 1,200 rpm.
Condition 2 After the fan rotated in the reverse direction for 10 minutes, the engine speed went to less than 1,200
(*1) rpm.
Condition 3 The engine has stopped.
*1: The engine speed-related requirement (1,200 rpm) is exempted when the HST oil temperature is
30°C or above.
The fan rotation is switched from "forward" to "reverse" as every condition in the following table is met.
Condition 6 The fan rotation direction switching cycle or the specified reverse rotation duration has elapsed.
The fan rotation is switched from "reverse" to "forward" if any of the following conditions is met.
After the fan reverse rotation switch has been set to any position other than "AUTO" during the
Condition 1
reverse fan rotation, the HST oil temperature reached 30°C or above.
After the fan rotation direction switching cycle or the specified reverse rotation duration has elapsed,
Condition 2
the HST oil temperature reached 30°C or above.
5. Adjustment of the automatic fan switching cycle to reverse rotation and duration
Any cycle is settable for the switching cycle of fan rotation direction and also any duration is settable for
the reverse rotation duration by adjusting the items "Adjustment of interval of fan automatic reverse
operation" and "Adjustment of continuance of fan automatic reverse operation" with the adjusting func-
tion of the machine monitor.
a For the adjustment procedure, see "Special functions of machine monitor (EMMS)" in Testing and
adjusting.
HST controller 1
ECSS system 1
(if equipped)
a ECSS: Abbreviation for Electronically Controlled Suspension System
ECSS operation
ECSS switch Travel speed [km/h]
signal
OFF 0 – Max.
OFF
(*2) Max. 4
ON
(*1) Min. 5 ON
KOMTRAX system 1
q KOMTRAX terminal transmits various machine information by use of the radio communication. The
KOMTRAX operator is allowed to reference these information in the office and offer them to the cus-
tomer through various services.
a When offering the information to the customer, it is required to separately implement the KOMTRAX
system station opening procedure.
The information transmitted from the KOMTRAX terminal includes the following.
1. Traveling map
2. Service meter
3. Position information
4. Error history
KOMTRAX terminal 1
Outline
q The KOMTRAX terminal can send information
via wireless communication antenna, acquiring
various information of the machine from the
network signal in the machine and the input
signal. Also, the terminal incorporates CPU
(Central Processing Unit) and provide the wire-
less communication function and the GPS
(Global Positioning System) function.
q There are the LED lamp and the 7-segment
indicator lamp in the display area, and these
lamps are used for the testing and the trouble-
shooting.
1. Battery Function
2. Battery relay 1. The neutral safety circuit is employed to
3. Slow-blow fuse secure safety when the engine is started.
4. Fuse box 1 q The engine can not be started while the
5. Fuse box 2 directional lever is at any position other
6. Starting switch than N (neutral).
7. Directional lever q When the directional selector switch oper-
8. Neutral safety relay ating switch is turned "ON", the directional
9. KOMTRAX engine cut-out relay lever and the directional selector switch
10. HST controller power holding relay must be at "N (neutral)" to start the
11. Starting motor safety relay engine.
12. Starting motor
13. Alternator 2. The KOMTRAX engine cut-out circuit is
14. HST controller employed to disable the engine from starting
15. Engine controller when the KOMTRAX terminal receives an
16. Machine monitor engine cut command issued through external
17. KOMTRAX terminal operation.
18. Engine controller cut-out relay
19. CAN resistor
20. Directional selector switch operating switch
21. Directional selector switch
Operation
1. When starting switch is turned "ON"
q As the starting switch is turned "ON", ter-
minals B and BR of the starting switch are
closed and the current flows from the bat-
tery through the starting switch and bat-
tery relay coil to the ground, thereby
closing the contact of the battery relay. As
a result, the power is supplied to each cir-
cuit of the machine.
At this time, the ACC signal is sent from
terminal ACC of the starting switch to the
engine controller, readying the engine for
startup.
Operation
q Setting the starting switch to "OFF" cuts off
ACC signal from the starting switch terminal
ACC to the engine controller.
q Although ACC is cut off, the engine controller
keeps the engine controller cut-out relay work-
ing to maintain the current flow to the engine
controller until its internal processing is com-
plete.
q As ACC signal is cut off, the engine lowers its
speed and stops. At the same time, the alter-
nator stops power generation, stopping supply
of the voltage from the alternator terminal L.
And the current from the starting switch termi-
nal BR is also stopped and the contacts of the
battery relay are opened. Consequently, the
power supplied to each circuit of the machine
is stopped.
Preheating circuit 1
1. Battery Operation
2. Battery relay q Set the starting switch to "ON" to start the
3. Slow-blow fuse engine controller. At this time, if intake air tem-
4. Fuse box 1 perature is -4°C or below, the engine controller
5. Starting switch starts up the electrical intake air heater imme-
6. Engine controller diately after the starting switch is turned "ON"
7. Machine monitor to initiate preheating by the electrical intake air
8. Electrical intake air heater relay heater.
9. Electrical intake air heater q The preheating time is set as shown below.
10. Boost pressure and temperature sensor
Outline
q The automatic preheating system is installed
so that the engine will start easily in a cold dis-
trict.
q The automatic preheating system is capable of
cutting the preheating time short as the starting
switch is set to "ON". This system is also capa-
ble of automatically setting the preheating
duration referencing temperature of intake air.
q Setting the starting switch to "ON" lights the
preheater pilot lamp of the machine monitor
and starts preheating of intake air with the
electrical intake air heater.
The engine controller sets the preheating dura-
tion referencing the intake air temperature
being sent from the boost pressure sensor and
temperature sensor.
q The pilot lamp remains turned on as long as
preheating is continued. Keep the starting
switch in the "ON" position during this time.
Setting the starting switch to "START" from this
state resets preheating.
q If the engine controller detects a failure, it pro- q When starting the engine in a cold district, this
tects the engine by derating the engine torque function warms it up by increasing the engine
or speed. low idle speed.
q If the coolant temperature is below 20°C at
q Following figure shows the engine torque per- starting of the engine, this function increases
formance when the torque was derated. the low idle speed to 1,000 rpm. The condition
required for increasing the low idle speed
depends on the coolant temperature as shown
in the figure below.
Operation
Parking brake lever area Free Mid Lock Free Mid Lock Free Mid Lock
WA250PZ-6
Outline
q The coupler plunger is extracted or retracted
by operating the quick coupler attachment
switch to connect and release each attachment
and the coupler.
Operation
When quick coupler attachment switch is in When quick coupler attachment switch is in
"Release" position "Connect" position
q If the quick coupler attachment switch (1) is set q If the quick coupler attachment switch (1) is set
in the “Release” position, quick coupler sole- in the “Connect” position, quick coupler sole-
noid valve (2) is energized. noid valve (2) is de-energized.
If the work equipment (bucket) control lever is If the work equipment (bucket) control lever is
moved to the tilt side, the oil flows into the moved to the tilt side, the oil flows into the bot-
head side of coupler plunger (3). Then, coupler tom side of coupler plunger (3). Then, coupler
plunger (3) is retracted and the attachment and plunger (3) is extracted and the attachment
coupler are released. and coupler are connected.
Multi-function knob 1
2-lever type
(if equipped)
Sensor 1
Speed sensor
Function
q The speed sensor is installed on the transfer case. It generates two different types of pulses depending
on the rotational direction and speed of the gear.
Function
q The HST oil temperature sensor and the brake oil temperature sensor are installed on the motor 2
hydraulic piping and front axle, respectively. They generate the signal for the change in temperature as
variation in the resistance of the thermistor.
Function
q The HST oil pressure sensor is installed on the motor 2 solenoid block to measure the oil pressure in the
HST circuit and generate the corresponding signal.
1. Terminal 2. Plug
Function
q This sensor is installed on the HST oil filter to monitor the oil pressure before and after the filter. If the
pressure goes beyond the specified level, the switch is set to "ON".
1. Float 3. Connector
2. Sensor 4. Sub-tank
Function
q This sensor is installed in the bulkhead. As the coolant goes below the specified level, the float moves
down, and the switch is set to "OFF".
Function
q This sensor is installed on the side face of the fuel tank. The float moves up and down according to the
fuel level.
The float moves the variable resistor through the arm. The resistance changes according to the operat-
ing angle and signal voltage is generated from the source voltage according to the change of the resis-
tance.
Function
q This sensor is installed on the surface of the
floor. It outputs the accelerator signal or idle
validation signal depending on the accelerator
pedal pressing angle.
Accelerator signal
q Magnitude of the accelerator pedal displace-
ment being detected by the sensor is output in
variable voltage from No. 2 pin.
Water-in-fuel sensor
1. Connector 3. Sensor
2. Tube 4. O-ring
Function
q This sensor is installed in the cup of the fuel pre-filter. It outputs the signal as entrainment of water in fuel
is sensed.
Function
q The boom kick-out proximity switch is installed in the lift arm left side connecting part of the front frame.
And the bucket positioner proximity switch is installed on the bucket cylinder. As long as the plate is
positioned on the detector plane, the switch lights up the operation indication lamp and turns itself "ON".
©2007 KOMATSU
All Rights Reserved
Printed in Japan 10-07 (01)
10-920 42
SEN03835-00
WHEEL LOADER
WA250-6
WA250PZ-6
*: Value when mounted on machine (Different from value in Engine Shop Manual)
N– 5.9 (+5.9/0)
13.7 {1.4}
FORWARD N {0.6 (+0.6/0)}
Directional lever
Operating effort
N– {kg} 5.9 (+5.9/0)
13.7 {1.4}
REVERSE • Engine stopped {0.6 (+0.6/0)}
N– • Measure at 10 mm from top of lever
FORWARD 45 ± 10 45 ± 20
Travel mm
N– 45 ± 10 45 ± 20
REVERSE
7.8 ± 4.9 15.7
1st – 2nd
Speed switch (Dial switch)
• Engine stopped
Play mm 20 ± 20 Max. 60
• Machine facing straight to front
• Flat, level, straight, dry, and paved road 9.8 ± 2.9 Max.14.7
Operating effort N {kg}
Steering wheel
• Engine speed: Low idle (Bucket empty) {1.0 ± 0.3} {Max. 1.5}
• Engine speed:
When brake pedal 2.6 (+0.2/0) 2.6 (+0.2/–0.1)
HST oil Full speed
releasing {26.5 (+2/0)} {26.5 (+2/–1)}
pressure Servo piston • Hydraulic oil
control oil pres- temperature:
sure 45 – 55°C
When brake pedal Max. 0.6 Max. 0.6
• Directional depressing {Max. 6} {Max. 6}
lever: N MPa
{kg/cm2}
• Hydraulic oil temperature: 45 – 55°C
• Gear speed selector switch: 1st
• Travel speed control dial: “1” on Min.
Servo piston
side 2.6 (+0.2/0) 2.6 ± 0.2
operating pres-
• Directional lever: Measure in both for- {26.5 (+2/0)} {26.5 ± 2}
sure
ward and reverse position.
• Measure while driving at full throttle
(Max. speed: 5 km/h).
• Hydraulic oil temperature:
45 – 55°C
Clutch control 2.6 (+0.2/0) 2.6 (+0.2/–0.1)
Transfer • Directional lever: FORWARD
pressure {26.5 (+2/0)} {26.5 (+2/–1)}
• Speed switch: 3rd or 4th speed
• Travel at a speed of at least 10 km/h
• Engine speed: High idle
Steering
sure
• Flat paved road with 1/5 (11°20') grade
Performance — Holds position Holds position
• Machine at operating condition
a For measuring posture, see Fig. C and
Fig. D at the end of this section
Work equipment control valve
*1: Time taken to raise bucket from contact with ground (bottom of bucket horizontal) to max. height of lift
arm.
*2: Time taken to move bucket from max. tilt to max. dump.
*3: Time taken to move bucket from horizontal position to max. tilt.
a Fig. A a Fig. D
a Fig. B a Fig. E
a Fig. C a Fig. F
a Fig. G
a Fig. H
a Fig. J
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
20-100 10
SEN03836-01
WHEEL LOADER
WA250-6
WA250PZ-6
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
Socket
3. Measuring hydraulic stall speed 4. Measuring HST stall and hydraulic stall (full
1) Referring to “Special function of machine stall) speed
monitor”, select the real time monitoring 1) Set the machine monitor as in “2. Measur-
function of the service mode. ing HST stall speed”.
2) Display “ENG SPEED” from the monitor- 2) Start the engine.
ing items of the machine monitor. 3) Lower the bucket to near the ground, then
a Monitoring item drive the machine forward and thrust the
Code No. 01001: ENG SPEED bucket into the stockpile of soil or rock
(Engine speed) (portion a).
3) Run the engine at high idle. 4) While running the engine at high idle, stall
4) Relieve the lift arm cylinder or bucket cyl- the HST and relieve the lift arm cylinder or
inder on the extraction side and measure bucket cylinder on the extraction side
the engine speed. simultaneously and measure the engine
a Finish measurement in a short time speed at this time.
so that the hydraulic oil temperature a Do not keep stalling the HST for more
will not exceed 120°C. than 20 seconds. Take care that the
HST oil temperature will not exceed
120°C.
Measuring compression pressure1 4. Loosen injector terminal nut (4) and remove
the terminal from the injector.
a Necessary tools
Symbol Part No. Part Name 5. Set the cylinder to be checked to the compres-
sion top dead center.
1 795-799-6700 Puller
a How to turn the crankshaft, refer to
2 795-502-1590 Gauge assembly “Adjusting valve clearance”.
C
3 795-790-4410 Adapter a When the cylinder is at the compression
4 6754-11-3130 Gasket top dead center, the rocker arm of the cyl-
inder can be moved by the valve clear-
k When measuring the compression pres- ance with the hand.
sure, take care not to burn yourself on the
exhaust manifold or muffler or get caught 6. Remove rocker arm assembly (5).
in a rotating part.
a Measure the compression pressure after the
engine is warmed up.
(Engine oil temperature: 40 – 60°C)
Measuring blow-by pressure 1 5. While pressing the brake pedal, set the direc-
tional lever or switch to the F (forward) or R
a Necessary tools (reverse) position.
Symbol Part No. Part Name k Keep pressing the brake pedal securely.
Measuring engine oil pressure 1 4. Start the engine and heighten the coolant tem-
perature to the operating range.
a Necessary tools
Symbol Part No. Part Name 5. While running the engine at low idle and high
idle, measure the oil pressure.
1 799-101-5002 Hydraulic tester
2 799-301-1230 Nipple
E
3 799-101-5160 Nipple
4 799-401-2320 Gauge
a Necessary tools
Symbol Part No. Part name
1 795-790-4700 Tester kit
2 795-790-6700 Adapter
6754-71-5340 Connector
3
6754-71-5350 Washer
H Commercially
4 Measuring cylinder
available
Commercially
5 Stopwatch
available
6
Commercially
Hose (Inside diameter 14 mm)
4) Crank the engine for 30 seconds and
available measure the delivery with measuring cyl-
inder H4.
a Prepare receiving pan of about 20 liters to a Adjust the route of the test hose so
receive the fuel flowing out during measure- that it will not slacken and put its end
ment. in receiving pan.
a Do not crank the engine for more than
k Put chocks under the tires securely. 30 seconds to protect the starting
k When measuring, check that there are no motor in any case other than this
persons around the machine. measurement.
a If the supply pump delivery is in the
1. Measuring supply pump delivery following standard range, it is normal.
1) Open the engine right side cover.
2) Loosen clamp (1) of supply pump dis- At cranking speed
Min. 75 cc
(125 rpm)
charge tube (2) and disconnect the tube.
At cranking speed
Min. 90 cc
(150 rpm)
2. Measuring return rate from supply pump 5) Run the engine at low idle and measure
1) Open the engine right side cover. the return rate in 25 seconds with measur-
2) Disconnect return hose (1) of the supply ing cylinder H4.
pump. a If the return rate from the supply
a The return hose is connected by a pump is in the following range, it is
quick coupler. normal.
At low idle Max. 400 cc
3) Install removed connector bolt (3) and cap 4. Measuring return rate from injector
nut [1] of tester kit H1 to the return hose to a The leakage from the injector is measured
stop the fuel from flowing out. while the return hose of the pressure lim-
4) Install connector H3 to the common rail iter is connected. Accordingly, before
and connect test hose [2] of tester kit H1. measuring the leakage from the injector,
a Lay the test hose so that it will not check that the leakage from the pressure
slacken and put its end in the receiv- limiter is normal.
ing pan. 1) Referring to “Measuring return rate from
supply pump”, set the supply pump for
measurement.
k The fuel returning from the supply
pump flows out during measure-
ment of the return rate from the
injector. Accordingly, keep the test
hose end in the receiving pan.
2) Remove connector bolt (4) of the return
block.
Testing leakage in fuel system 1 9. Inspect the fuel piping and devices for fuel
leakage.
k Very high pressure is generated in the high- a Check mainly around the high-pressure
pressure circuit of the fuel system. If fuel circuit parts coated with the color checker
leaks while the engine is running, it is dan- for fuel leakage.
gerous since it can catch fire. a If fuel leakage is recognized, repeat the
After testing the fuel system or removing procedure from step 1 after repairing the
its parts, test it for fuel leakage according leakage.
to the following procedure. a If no fuel leakage is detected, check is
a Clean and degrease the engine and the parts completed.
around it in advance so that you can test it eas-
ily for fuel leakage.
a Reduced cylinder mode operation means to a No-injection cranking means to crank the
run the engine with the fuel injectors of 1 or engine with the starting motor while all the
more cylinders disabled electrically to reduce injections are stopped electrically. The purpose
the number of effective cylinders. The pur- and effect of this operation are as follows.
poses and effects of this operation are as fol- q When a machine or engine has been stored for
lows. a long time, implementing the no-injection
cranking before starting the engine lubricates
1. This operation is used to find out a cylinder the engine parts and thus prevents its seizure.
which does not output power normally (or, a The no-injection cranking operation is set from
combustion in it is abnormal). the service mode of the machine monitor. For
details, see “Special functions of machine
2. When a cylinder is selected for the reduced monitor (EMMS)”, “6. No-injection cranking
cylinder mode operation, if the engine speed function”.
and output do not change from the normal
operation (all-cylinder operation), that cylinder
has 1 or more defects. The possible defects
are as follows.
q Compression leakage through cylinder
head gasket
q Defective injection
q Defective piston, piston ring, or cylinder
liner
q Defective valve mechanism (Moving valve
system)
q Defect in electrical system
between the engine controller and engine, be 1. Check the muffler and muffler stack visually for
sure to turn the starting switch OFF. a crack and damage. If any part is damaged,
replace it.
2. If a T-adapter is inserted in or connected to a
connector between the engine controller and 2. Check the mounting bolts and nuts of the muf-
engine for troubleshooting, do not start the fler and muffler stack for looseness. If they are
engine. loosened, retighten them.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
ference in sound from a new machine. If it Check the installed condition of the cylinder head
makes abnormal sound, repair it, referring to and air intake manifold and exhaust manifold. If
the Troubleshooting Volume. they are loosened, retighten them.
a For the tightening torque, see the "Disassem-
bly and assembly" volume.
Fuel system:
Check the piping for damage, looseness of the
mounting bolts and nuts, and leakage of fuel
through the joints. If it is loosened or dam-
aged, retighten or repair.
Adjusting
a If the deflection is abnormal, adjust it according
to the following procedure.
©2009 KOMATSU
All Rights Reserved
Printed in Japan 06-09
30-110 38
SEN03837-01
WHEEL LOADER
WA250-6
WA250PZ-6
Checking operating force of a After greasing, wipe off grease completely (No
accelerator pedal 1
grease is adhered on roller surface and roller
sliding surface).
Necessary tools
Symbol Part No. Part Name
J 79A-264-0021 Push-pull scale
Necessary tools
Symbol Part No. Part Name
1 79A-264-0021 Push-pull scale
K Commercially
2 Scale
available
Necessary tools
Symbol Part No. Part Name
799-101-5002 Analog type hydraulic tester
L
790-261-1204 Digital type hydraulic tester
Necessary tools
Symbol Part No. Part Name
799-101-5002 Analog type hydraulic tester
1
790-261-1204 Digital type hydraulic tester
M
799-401-3100 Adapter
2
02896-11008 O-ring
a Measurement conditions
q Road surface:
Flat, horizontal, dry paved surface
q Engine coolant temperature:
Within green range on engine coolant
temperature gauge
q Hydraulic oil temperature:
45 – 55°C
q Tire inflation pressure:
Specified pressure
q Engine speed
Low idle and high idle
Testing and adjusting steering oil 3. Fit a nipple P [3] to the steering circuit pressure
pressure 1
measurement plug hole, then install oil pres-
sure gauge P [1], P [2] (40 MPa {400 kg/cm2}).
Necessary tools
Symbol Part No. Part Name
799-101-5002 Analog type hydraulic tester
P
790-261-1204 Digital type hydraulic tester
a Measuring condition
q Hydraulic oil temperature:45 – 55°C
q Engine speed: High idle
Adjusting main relief pressure 4. Loosen lock screw (5), and then turn adjust-
ment screw (6) to adjust.
1. Stop the engine. a Turn the adjustment screw to adjust as fol-
2. Remove cover (1) at the lower right of the lows.
operator's cab. q To INCREASE pressure, turn
CLOCKWISE.
q To DECREASE pressure, turn
COUNTERCLOCKWISE.
a Pressure adjustment for one turn of
adjustment screw: Approx. 6.9 MPa {70
kg/cm2}
a Tool [1] for adjusting adjustment screw:
Size 7/32 inch, hexagonal
a Do not carry out any adjustment if the
relief pressure cannot be measured accu-
rately.
3 Adjustment screw (6):
2.3 – 6.8 Nm {0.23 – 0.69 kgm}
3 Lock screw (5):
3. Disconnect hose (3) and fitting (4) connected 14.7 ± 2 Nm {1.5 ± 0.2 kgm}
to port (T) of the priority valve (2).
a Measurement conditions
q Engine coolant temperature: Within green
range on engine coolant temperature gauge
q Engine speed: Low idle
Testing
Adjusting
9JF01100
a Measurement conditions
q Road surface:
Flat, horizontal, dry paved surface
q Travel speed:
35 km/h when brakes are applied
q Tire inflation pressure:
Specified pressure
q Tire size:
20.5 – 25
q Delay in applying brakes:
0.1 sec
q Specified operating force:
322 N {33 kg}
Measurement method
Necessary tools
Symbol Part No. Part Name
799-101-5002 Analog type hydraulic tester
R
790-261-1204 Digital type hydraulic tester
Measuring
4. Measure the accumulator charge cut-in pres-
q Hydraulic oil temperature: 45 – 55°C sure. Start the engine, run the engine at low
k Stop the engine, then depress the brake idle, and measure the oil pressure when the
pedal at least 100 times to release the pres- brake pressure caution lamp on the monitor
sure inside the accumulator circuit. panel goes out.
q Cut-in pressure:
1. Remove the rear frame left side cover (1). 5.9 +0.2 +2
0 MPa {60 0 kg/cm }
2
Adjusting
Testing wheel brake oil pressure 1 2. Remove brake tube (2) of the measured side.
a The right side is shown as an example in
a Necessary tools the figure.
Symbol Part No. Part Name
3. Remove union (3) and install adapter S4 and
1 793-605-1001 Brake test kit
nipple S5.
2 790-101-1430 Coupler a Use the O-ring fitted to the union.
3 790-101-1102 Pump
S 4 790-301-1720 Adapter
5 799-101-5160 Nipple
6 799-401-2220 Hose
7 790-261-1130 Coupling
T 793-463-1100 Stopper
Testing wear of brake disc 1 2. While pressing the brake pedal, insert testing
gauge U in the inspection plug hole and pinch
Necessary tools the inspection projection around piston (2) and
Symbol Part No. Part name plate (3) with the inspection gauge tip.
U 418-98-31110 Testing gauge
Reference: Testing gauge U is component part
of tool kit.
a If you can pinch the inspection projection
k Stop the machine on a level ground, lower around piston (2) and plate (3) with the
the work equipment to the ground, and set inspection gauge tip, the brake disc is
chocks under the tire securely. worn more than the repair limit. In this
a There are inspection plugs on the right and left case, replace the brake disc.
sides of the front and rear axles. Check at all of
the 4 plugs similarly.
Bleeding air from wheel brake 3. Connect hose [1] to bleeder screw (2) and
circuit 1
place hose [1] in the oil receive pan.
a Work on the rear side similarly from under-
Necessary tools side of the machine.
Symbol Part No. Part name
T 793-403-1100 Stopper
1. Start the engine to accumulate pressure in the 5. Repeat this operation until the oil flowing
accumulator and then stop the engine. through hose [1] becomes free from bubbles.
Then press the pedal fully and tighten bleeder
2. Remove front frame inspection cover (1). screw (2) while the oil is flowing.
k When raising the lift arm and removing a As accumulated pressure in the accumu-
the inspection cover, place support lator is decreased, start the engine to
stand [1] under the lift arm to support accumulate pressure in the accumulator.
the lift arm securely or set stopper T to Then bleed air using the same procedure
the lift arm cylinder to prevent the work as described above.
equipment from falling. a After finishing bleeding air, run the engine
at low idle and check the oil level in the
hydraulic tank. If the level is low, add oil up
to the specified level.
a Measurement condition
q Tire inflation pressure: Specified pressure
q Road: 1/5 gradient (11° 20'), flat, and dry road
q Machine: Ready for operation
Measuring method
1. Start the engine and set the machine in the
straight travel position, and then drive up a
slope of 1/5 gradient with no load in the bucket.
Measuring condition
q Hydraulic oil temperature: 45 – 55°C
Measuring
Necessary tools
Symbol Part No. Part Name
799-101-5002 Analog type hydraulic tester
Y
790-261-1204 Digital type hydraulic tester
T 793-463-1100 Stopper
Testing PPC valve basic pressure when carrying out preparatory operations
with the lift arm raised, set support [1] or
1. Remove plug (4) (10 mm, P = 1.25 mm) for
lift arm drop prevention stopper T in posi-
measuring the work equipment EPC valve
tion before starting the operation.
basic pressure (same as low-pressure relief
pressure) from under the machine.
a A: Bucket TILT
B: Bucket DUMP
C: Lift arm RAISE
D: Lift arm LOWER
Testing and adjusting bucket 2) Adjust and secure clearance (a) between
positioner 1
the sensitive surface of proximity switch
(1) and detection bar (2) to the standard
a Measuring condition range with the shim and mounting bolt of
q Engine coolant temperature: White range the proximity switch bracket.
of engine coolant thermometer a Standard clearance (a): 3 – 5 mm
q Hydraulic oil temperature: 45 – 55°C a Adjust detection bar (2) with the shim
so that clearance (a) will be in the
Testing standard range through the stroke of
1. Stop the engine and check that clearance (a) the detection bar (2).
between proximity switch (1) and detection bar
(2) is in the standard range. 2. Adjusting installing position (stopping
a Standard clearance (a): 3 – 5 mm position).
1) Lower the bucket to the ground and set it
to a desired digging angle, then return the
lever to the holding position and stop the
engine.
2) Adjust with switch mounting nut (4) so that
clearance (b) of the detection bar (2) of
proximity switch (1) is within the standard
value, then secure in position.
3 Switch mounting nut:
14.7 – 19.6 Nm {1.5 – 2.0 kgm}
q The installing position may be
checked by checking the operation of
the pilot lamp of the proximity switch
with the starting switch at the ON
2. Run the engine at same as usual working position.
speed and check the operating point. (Mea- a For ON/OFF of the pilot lamp, see
sure 3 times and obtain the average.) “Checking proximity switch working
pilot lamp”.
Adjusting
1. Adjusting clearance.
1) Adjust and secure clearance (b) between
the tip of switch protector (3) and the sen-
sitive surface of the switch to the standard
range with switch nuts (4).
a Standard clearance (b): 0.5 – 1.0 mm
3 Mounting nut:
14.7 – 19.6 Nm {1.5 – 2.0 kgm}
Testing and adjusting of boom 4. Adjust the switch so that clearance (a) between
kick-out switch 1
the sensing surface of the switch and plate (2)
is the standard value, then secure in position.
Testing 3 Switch mounting nut:
14.7 – 19.6 Nm {1.5 – 2.0 kgm}
1. With the engine stopped, check that clearance q The installing position may be checked by
(a) between detection surface of switch (1) and checking the operation of the pilot lamp of
plate (2) is the standard value. the proximity switch with the starting
a Standard clearance (a): 3 – 5 mm switch at the ON position.
a For ON/OFF of the pilot lamp, see “Check-
ing proximity switch working pilot lamp”.
a After adjusting, start the engine, operate
the work equipment control lever and
check that the boom kickout is actuated at
the desired position.
Adjusting
Procedure for testing diodes 1 1. When using digital type circuit tester
1) Switch the testing mode to diode range
a Check an assembled-type diode (8 pins) and and confirm the indicated value.
independent diode (2 pins) in the following a Voltage of the battery inside is dis-
manner. played with conventional circuit testers.
a The conductive directions of the assembled- 2) Put the red probe (+) of the test lead to the
type diode are indicated on the surface of the anode (P) of and the black probe (–) to the
diode as shown in the following figure. cathode (N) of diode, and confirm the indi-
cated value.
3) Determine acceptability of the diode from
the indicated value.
q Indicated value remains unchanged:
Conduction is absent (Failure)
q The indicated value changes: The
diode has conductivity (Normal) (See
a below.)
a A value between 460 to 600 is indi-
cated for silicon diodes.
2. HST controller
1) Remove cover (1) from the rear of the cab. 2) Connect diagnosis T-adapter to connec-
tor L80 of KOMTRAX terminal (3).
a If the connector cannot be discon-
nected and connected easily, remove
the KOMTRAX terminal.
a Since the connector is secured with
screws, loosen those screws before
disconnecting.
a When connecting the connector again,
tighten its screws to the specified
torque.
3 Screw:
2.2 – 2.8 Nm {0.23 – 0.29 kgm}
4. Boost pressure and temperature sensor 6. Common rail pressure sensor (FUEL RAIL
(BOOST PRESS & IMT) PRESS)
a Disconnection and connection of connector a Disconnection and connection of connector
The connector of the boost pressure and The connector of the common rail pres-
temperature sensor has a special locking sure sensor has a special locking mecha-
mechanism. Disconnect it according to nism. Disconnect it according to steps (a)
steps (a) – (b) and connect it according to – (b) and connect it according to steps (c)
steps (c) – (d) as shown below. – (d) as shown below.
Disconnection: Disconnection:
(a) Unlock – (b) Disconnect connector. (a) Unlock – (b) Disconnect connector.
Connection: Connection:
(c) Connect connector – (d) Lock. (c) Connect connector – (d) Lock.
2. Registration of machine
The KOMTRAX operations administrator shall
use a KOMTRAX client PC to register the
machine.
a Refer to “Manual for KOMTRAX opera-
tions administrator” for the procedure.
a Now the terminal is ready for use.
LED lamps for CPU 7-segment and dot displays for CPU
1. LED-C1 (State of R or ACC signal) 7. 7 segments (Number of unsent mails)
2. LED-C2 (Starting output state) 8. Dot (GPS positioning state)
3. LED-C3 (State of S-NET or C signal)
4. LED-C4 (CAN state)
5. LED-C5 (Download write state)
6. LED-C6 (Download write state)
In the KOMTRAX system, various information and processing details are displayed on the LED on the upper
surface of the KOMTRAX terminal. Therefore, if a detect is suspected in the system, perform the following
checks.
q Check of antennas
q Check of terminal LED displays
Before using the KOMTRAX system, make sure that the application for starting its use is completed as well
as the station opening check in the machine side.
Check of antennas
a Before checking the LED displays, check that there is no abnormality around the communication
antenna and GPS antenna.
q The communication antenna should not be off or damaged.
q The communication antenna cable should not be broken and normally be connected to the KOMTRAX
terminal.
q The GPS antenna should not be off or damaged.
q The GPS antenna cable should not be broken and normally be connected to the KOMTRAX terminal.
Display
No. LED Name/function Description
(*1)
ON Starting switch ACC signal: ON, Alternator R signal: ON
States of starting switch Fast blink Starting switch ACC signal: OFF, Alternator R signal: ON
1 LED-C1 ACC signal and alternator R
signal Slow blink Starting switch ACC signal: ON, Alternator R signal: OFF
OFF Starting switch ACC signal: OFF, Alternator R signal: OFF
ON Engine control signal: ON
2 LED-C2 State of engine control signal
OFF Engine control signal: OFF
ON S-NET: Connected, Starting switch C signal: OFF
States of S-NET connection Fast blink Starting switch C signal: ON
3 LED-C3
and starting switch C signal Slow blink (Not used)
OFF S-NET: Not connected, Starting switch C signal: OFF
ON CAN: Connected (without fuel sensor)
Fast blink CAN: Connected (with fuel sensor)
4 LED-C4 State of CAN connection
Slow blink CAN: Not connected (with fuel sensor)
OFF CAN: Not connected (without fuel sensor)
Display
No. LED Name/function Description
(*2)
The number indicates the number of unsent mails. (10 or more
0 to 9
unsent mails are indicated by “9”.) Light-on indicates that the
Number of unsent displayed
machine is in process of capturing the satellite.
7 7 segments mails, satellite
capture state The number indicates the number of unsent mails. (10 or more
0 to 9
unsent mails are indicated by “9”.) Fast blink indicates that the
fast blink
satellite is not captured.
GPS positioning was completed. (The position can be con-
ON
GPS positioning firmed. *3)
8 Dot
status GPS positioning was not completed. (The position cannot be
OFF
confirmed. *3)
©2011 KOMATSU
All Rights Reserved
Printed in Japan 01-11
30-120 52
SEN03838-00
WHEEL LOADER
WA250-6
WA250PZ-6
Layout of rotary switches (SW1, SW2, and SW3) and DIP switches (SW5 and SW6)
q Do not change the setting of the rotary switches (SW1, SW2, and SW3) and DIP switches (SW5 and
SW6) on the back side of the machine monitor.
q The switches shown in the figure are set as when the monitor is delivered.
*1: Description No. of “Service mode” in “Special functions of machine monitor (EMMS)”
*1: Description No. of “Service mode” in “Special functions of machine monitor (EMMS)”
*2: Change of the indication unit of the speedometer of the specification for the SI unit countries cannot be
set.
*3: When selecting “NO ADD” in optional select, cannot change travel speed/engine speed.
⇔
6 Telephone number input function 7 Adjustment function
7 Language selection function 8 Maintenance monitoring function
8 Monitor brightness adjustment function 9 Operating information display function
Travel speed/engine speed display selecting
9 10 Optional device selecting function
function (*2)
Function of turning ON/OFF travel speed/
10 11 Machine serial number input function
engine speed display on character display (*3)
11 Action code display function 12 Model selection function
12 Failure code display function 13 Initialize function
12. Failure code display function a The service code display function displays
Pressing [>] switch once while an action is dis- the following information.
played on the machine monitor displays the A: Failure code (location code + problem
failure code corresponding to the failure cur- code)
rently warned. B: Controller code
a The failure codes detected in the past are MON: Machine monitor
divided into failures of the electrical sys- HST: HST controller
tem and the mechanical system and are ENG: Engine controller
recorded as fault history. (For details, see C: The system where failure occurred
“Service mode”.)
a When two or more failures are involved,
pressing [>] switch displays further codes.
a If [>] switch is pressed again after it was
pressed to display every involved failure
code, the service meter display screen will
be restored.
Pressing [>] switch one more time dis-
plays the failure codes from the first.
If [>] switch is not touched for 3 seconds,
the action code display screen is automat-
ically displayed.
[4] CYLINDER CUT-OUT: Engine 2. Electrical system fault history display func-
reduced-cylinder function tion (ELECTRIC FAULT)
[5] NO INJECTION: No injection crank- The machine monitor records the past failures
ing function in the electric system as the failure codes. The
[6] TUNING: Adjustment function failure codes are displayed from the following
[7] MAINTENANCE MONITOR: Mainte- operations.
nance monitoring function 2-1. Selecting the menu
[8] OPERATION INFO: Operating infor- Select the ELECTRIC FAULT from the menu
mation display function screen of Service mode.
[9] OPTIONAL SELECT: Optional device a [**] field displays total number of the fault
selecting function his to ry cu r re n tly re co r de d ( up to 2 0
[10] MACHINE No. SET: Machine serial cases).
number input function
[11] MACHINE: Model selection function
[12] INITIALIZE: Initialize function (Func-
tion specialized for plant)
a The menu is indicated in the parts of [*].
a For details of a displayed failure code, see 2-6. Deleting all fault history
“Failure code list” of the failure code dis- 1) Press [<] or [>] switch while the fault his-
play function. tory is on the screen to display the ALL
a Note that part of the information displayed CLEAR menu screen.
from the electrical system fault history dis-
play function and the failure code display
function is not identical.
a When the requested fault history is not
recorded, [–] is indicated in the display
space.
a Failure codes:
The failure code table is written in alphabetical order and also starting from small number.
The failure code in parentheses is not recorded in the failure history for both electrical system and
mechanical system.
a Applicable equipment:
Applicable equipment indicates in which controller system the failure has occurred.
MON : machine monitor system
ENG : Engine controller system
HST : HST controller system
a Action codes:
Action codes indicate what in displayed in the operator mode when a failure is detected.
a History classification:
History classification indicates in which system, either electrical system or mechanical system in the fail-
ure history display function, a failure has been recorded.
a Note: Optional equipment is also included in table.
3) Press [<] or [>] switch to select a monitor- 4-5. Setting 2 items simultaneous monitoring
ing item. 1) Select 2 ITEMS from the sub menu
a The monitoring items are scrolled accord- screen.
ing to the internally set order. 2) Press [U] switch while the sub menu is
a Holding down [U] switch turns on high- selected to display the monitoring code
speed scrolling. input screen.
a Holding and cancelling the monitoring
data: Pressing [U] switch while the moni-
toring is in progress holds the monitoring
data and [U] mark starts flashing.Press-
ing [U] switch again restores the active
state.
Unit
Contents of display in normal state Remarks
(*4)
Condition
As per software No. 3rd – 10th digits from right of part No. are displayed.
display
Condition
As per software application version No.
display
Condition
As per software data version
display
Gauge enters red range(105°C): 2.07 V When sensor is disconnected has hot-short: Gauge MIN
V
(80°C): 2.91 V When sensor has ground fault: Gauge MAX
(120°C): 1.62 V
V
1(80°C): 2.91 V
----- V
a No use these items.
----- MPa
----- V
*1: All items, including ones for which sensors are not installed on some models and optional components,
are displayed.
*2: Abbreviated as number of characters is limited.
*3: A number out of the display range is displayed as “-----”.
*4: If a unit is necessary, the SI unit is used.
Unit
Contents of display in normal state Remarks
(*4)
----- MPa
----- V
a No use these items.
----- MPa
----- t
Condition
a Do not move from initial position.
display
Condition
a Do not move from initial position.
display
Condition
a Do not move from initial position.
display
Condition
a Do not move from initial position.
display
Condition
a Do not move from initial position.
display
Condition
display
Condition
display
Condition
display
Condition
display
Condition
display
Condition
display
19 44200 Throttle quantity upper limit value output THROT LIMIT UP 0.0 – 100.0
20 44201 Throttle quantity lower limit value output THROT LIMIT LO 0.0 – 100.0
Condition display
Condition display
Condition display
Condition display
0 km/h = 0 min-1
10 km/h = 754 min-1
“min-1” is SI unit of rotation speed.
20 km/h = 1509 min-1 min-1
(1 min-1 = 1 rpm)
30 km/h = 2264 min-1
40 km/h = 3019 min-1
Ordinary: 100%
%
Forward travel in S mode: 50 – 100%
0 – 30 V V
*1: All items, including ones for which sensors are not installed on some models and optional components,
are displayed.
*2: Abbreviated as number of characters is limited.
*3: A number out of the display range is displayed as “-----”.
*4: If a unit is necessary, the SI unit is used.
D-IN-5 — —
D-IN-6 — —
D-IN-7 — —
D-OUT-0 — —
D-OUT-1 — —
D-OUT-2 — —
D-OUT-3 — —
2 40978
D-OUT-4 — —
D-OUT-5 — —
D-OUT-6 — —
D-OUT-7 — —
D-OUT-8 — —
D-OUT-9 — —
D-OUT-10 — —
D-OUT-11 — —
3 40979
D-OUT-12 — —
D-OUT-13 — —
D-OUT-18 Fan reverse solenoid relay HST pump F solenoid = ON (24 V)/OFF (OPEN)
D-OUT-19 HST pump R solenoid (Reverse) HST pump R solenoid = ON (24 V)/OFF (OPEN)
4 40980
D-OUT-20 — —
D-OUT-21 — —
D-OUT-22 — —
D-OUT-23 — —
*1: All items are displayed including those for which sensors are not provided depending on the given
model or option.
*2: Abbreviated expression is employed because of number of characters usable is restricted.
*3: A number out of the display range is displayed as “-----”.
*4: SI units alone are employed whenever a unit is needed.
3) With the [<] and [>] switches, select 03: 7-2. Adjustment of continuance of fan automatic
FAN REV PD screen. reverse operation
a This function is used to change the contin-
uance of the reverse operation when the
fan automatic reverse operation is
selected.
a The continuance of the fan automatic
reverse operation is adjustable in the
range from 0.5 minutes to 10 minutes. It
must be set to below 1/2 of the interval of
the fan automatic reverse operation, how-
ever, and cannot be set longer than 1/2.
a When the machine is delivered, the con-
tinuance of fan automatic reverse opera-
tion is set to 2.0 minutes.
a When the machine is delivered, the inter-
4) Press the [U] switch to settle. val of the fan automatic reverse operation
a If the [U] switch is pressed, the screen is set to 2.0 h.
to adjust the interval of fan automatic 1) On the service mode menu screen, dis-
reverse operation is displayed. play the TUNING screen.
5) With the [<] and [>] switches, select an
interval in the range from “0.1” to “200”
(Unit: h).
6) Press the [t] switch to settle the setting.
a The selected interval of fan automatic
reverse operation is not changed to a
value less than twice the continuance
of the fan automatic reverse operation.
3) With the [<] and [>] switches, select 04: 7-5. Adjustment of ECSS operation travel speed
FAN REV PD screen. (if equipped)
a This function is used to adjust the ECSS
operation/reset travel speed.
a The initial ECSS operation travel speed is
5 km/h (3.1 MPH).
a The ECSS reset travel speed is the ECSS
operation travel speed minus 1 km/h (0.6
MPH).
Example: q If the ECSS operation travel
speed is 5 km/h (3.1 MPH),
the ECSS reset travel speed
is 4 km/h (2.5 MPH).
q If the ECSS operation travel
speed is 8 km/h (5.0 MPH),
the ECSS reset travel speed
4) Press the [U] switch to settle. is 7 km/h (4.4 MPH).
a If the [U] switch is pressed, the 1) Display the “TUNING” screen from the
screen to adjust the continuance of menu screen of Service mode.
fan automatic reverse operation is
displayed.
5) With the [<] and [>] switches, select a con-
tinuance in the range from “0.5” to “10”
(Unit: minute).
6) Press the [t] switch to settle the setting.
a The selected continuance of fan auto-
matic re verse operation is not
changed to a value longer than 1/2 of
the in ter val o f the fan au tom atic
reverse operation.
3) Select “07: ECSS SPEED” with [<] or [>] 8. Maintenance monitoring function
switch. The maintenance function offers the following
capabilities in the maintenance of filters and
oils.
q Change of maintenance interval time
q Selection between enabling or disabling
timer by item
q Setting of a default value
q Selection between enabling or disabling
timer for items
8-1. Changing maintenance interval time
1) Display the MAINTENANCE MONITOR
screen from the menu screen of Service
mode.
4) Settle the target items of interval change a When you have entered a wrong value to
by use of [U] switch. a position except the highest-order digit,
move to the highest-order digit using [t]
switch and repeat the procedure from the
first. In this case, the value that had been
entered remains as it is until modified.
When the cursor is at the highest-order
digit, move to the higher layer using [t]
switch.
6) Select “YES” or “NO” using [<] or [>] a When “Timer by item” is disabled, the
switch. order of display becomes OFF o ON.
a The selected cursor will start flashing. If a The default display is ON.
“Y E S ” is se l e ct e d a n d [t ] s w it ch is
pressed, the information will be deleted. If
“NO” is select ed and [t] s witc h is
pressed, deletion is cancelled and the
maintenance interval change item screen
is restored.
a By default, the cursor is set to NO (cancel)
to prevent resetting error.
a When an interval time is changed, the
timer remaining time is changed as shown
below.
q Timer remaining time = Interval time being
set – Elapsed time from the last replace-
ment
2) Press [U] switch from this state.
a If “Timer by item” is disabled, OFF will be
displayed in the upper column.
3) Select “YES” or “NO” using [<] or [>] 3) Press [U] switch from this state.
switch. 4) Select “YES” or “NO” using [<] or [>] switch.
a The selected cursor will start flashing. If a The selected cursor will start flashing. If
“ Y ES ” is s e le c te d a n d [ t ] sw i tc h i s “Y E S ” is s e le ct e d a n d [ t ] s w itc h is
pressed, the information will be deleted. If pressed, the change will be enabled If
“ N O ” is s e l e c t e d a n d [ t ] s w i t c h i s “NO” is select ed and [ t] s witc h is
pressed, deletion is cancelled and the pressed, the change will not be imple-
maintenance interval change item screen mented and the maintenance monitoring
is restored. screen will be restored.
a By default, the cursor is set to NO (cancel) a By default, the cursor is set to NO (cancel)
to prevent resetting error.
to prevent resetting error.
a An interval time is changed, the timer
remaining time is change d a s shown
below.
q Timer remaining time = Interval time being
set – Elapsed time from the last replace-
ment
2) Using [<] or [>] switch, select the ALL 5) Press [U] switch from the ALL ITEMS o
ITEMS OFF OR ON screen from the fol- OFF screen or the ALL ITEMS o ON
lowing table. screen.
a When [U] switch is pressed from the ALL
ITEMS o OFF screen, OFF will be is dis-
played in the upper space.
7) As the timer stop for all items is executed: 3) Using [<] or [>] switch, select the item to
a The timer function for all items is stopped be displayed from 1] – 4] on the fuel con-
a n d t h e M A I N TE N A N C E M O N I TOR sumption ratio and average fuel consump-
screen is restored. tion screen.
a Setting for individual items is also disabled. 1] Fuel consumption ratio and average
a If cancelled: The operation is cancelled fuel consumption screen
a n d t h e M A I N TE N A N C E M O N I TOR a The upper column displays fuel con-
screen is restored. sumption [L/km or L/mile] per 1 km (or
8) When timer enable for all items is executed: 1 mile) from the last resetting.
a Interval time being set for all items is exe- q Above value is computed from the
cuted to the set value before disabled fuel consumption ratio and travel dis-
i n d e p e n d e n t o f w h e t h e r o r n o t it i s tance (odometer distance).
enabled or disabled for a specific item. q The counting is stopped at 99999.9,
a The timer remaining time is reset. (The the upper limit.
reset frequency remains the same as a The lower column displays the aver-
before the resetting.) age fuel consumption [L/h] from the
a The MAINTENANCE MONITOR screen is last resetting.
restored. q The counting is stopped at 99999.9,
a Setting for individual items is also enabled. the upper limit.
a If cancelled: The operation is cancelled a Calculation is done only for the dura-
a n d t h e M A I N TE N A N C E M O N I TOR tion in which the engine is run.
screen is restored.
1) Display the OPTIONAL SELECT screen 10-1. Option setting/not setting selection
from the menu screen of Service mode. a Among the items included in the list of installed
optional devices and their setting, the option
setting/not setting selection applies to the fol-
lowing items.
a If the options are not selected, the option non-
selection screen (NO ADD) is displayed.
10-2. Selection of optional tire type 10-4. Setting tire deflection option
a Select “1: TIRE TYPE” from “Optional device a Select 9: TIRE SIZE from the list of installed
installation setting table”. optional devices and their setting.
Reference: This screen appears first when the a Pressing [U] switch sequentially displays
scr ee n is ch an g ed from the “O PTIO NAL [@@]% in the following order.
SELECT” screen. a The display progresses from +00 through –10.
a Each time [U] switch is pressed, the tire type Pressing [U] switch at this point returns the
changes from small to large. display to +00.
Selectable size: 17.5 and 20.5 (default)
a If the tire type is changed, the operation accep- Order No.1 No.2 No.3 No.4 No.5 No.6 No.7
tance tone (peep) sounds. @@ +00 +02 +04 +06 +08 +10 +12
10-6. Storing option selection 11. Machine serial number input function
1) When the option selection was changed, 1) Display the MACHINE No. SET screen
turn off the starting switch once to stop the from the menu screen of Service mode.
controller operation completely. (After turn-
ing off the starting switch, wait for 15 sec-
onds without doing any switch operation.)
2) The specified option selection is enabled
as the starting switch is turned on.
a Whenever an option selection is made, turn
off the starting switch once and then turn it
on again in approximately 15 seconds.
12. Machine model select function 3) With the [<] and [>] switches, select the
(MACHINE WA***) machine model.
a The setting of the machine model of the a Selectable models
machine monitor can be changed with the q WA100
machine model select function. q WA150
a If the machine monitor is initialized, per- q WA200
form the machine model select operation q WA250
first. q WA270
a If the machine model select operation is q WA320
performed, the setting of options is reset. a If wrong model and tire are set,
Accordingly, start with the option select machine does not work correctly.
operation and select all the options. a Press [t] switch when stopping the model
selection.
12-1. Implementing the model change a As the operation is stopped, the sound
1) Display the MACHINE screen from the (beep) indicating acceptance of the opera-
menu screen of Service mode. tio n will be g en er ate d , re sto ring th e
a The currently selected machine model is MACHINE screen.
displayed on the lower line. 4) With the [U] switch, settle the changed
machine model and tire size.
a As the selection is settled, the sound
(beep) indicating acceptance of the opera-
tio n will be g en er ate d , re sto ring th e
MACHINE screen.
a Check that the desired machine model is
displayed on the machine model select
screen.
Max. coolant temp. (During operation) Max. HST oil temp. (During operation)
Segment color W G G G G R R Segment color G G G G G R R
1 2 3 4 5 6 7 1 2 3 4 5 6 7
Full stall (HST stall + hydraulic stall) 1,840 – 2,170 1,740 – 2,270
Blow-by kPa Max. 0.98 1.96
At rated output
pressure {mmH2O} {Max. 100} {200}
Min. 0.29 0.25
High idle {Min. 3.0} {2.5}
MPa
Oil pressure SAE15W-40 {kg/cm2}
Low idle Min. 0.10 0.07
{Min. 1.0} {0.7}
a Before starting the inspection, check that the machine does not move when the directional lever is placed in position.
k When measuring the transfer clutch control pressure, carry out the measurement at a place where the machine can travel
safety at a speed of more than 10 km/h.
Directional lever: F
Speed selector
High-pressure 44.6 – 46.6 43.1 – 46.6
cut-off pressure switch: 2nd {455 – 475} {440 – 475}
Traction control
switch: ON
Low-pressure
relief pressure
(work equip- 2.6 – 2.8 2.5 – 2.8
Directional lever: N
ment PPC cir- {26.5 – 28.5} {25.5 – 28.5}
cuit basic
pressure) • Engine:
Full throttle
Directional lever: N 2.6 – 2.8 2.5 – 2.8
Servo piston • Hydraulic Brake: released {26.5 – 28.5} {25.5 – 28.5}
oil temp.: MPa
HST
control pres-
sure 45 – 55°C Directional lever: N {kg/cm2} Max. 0.6 Max. 0.6
Brake: pressed {Max. 6} {Max. 6}
Directional lever: For-
ward and reverse
Gear speed selector
Servo piston switch: 1st
actuation pres- Travel speed control 2.6 – 2.8 2.4 – 2.8
{26.5 – 28.5} {24.5 – 28.5}
sure dial: Min. side
Measure while driv-
ing at full throttle
(Approx. 5 km/h).
Transfer clutch Hydraulic oil Directional lever: F
control pres- temp.: Speed selector 2.6 – 2.8 2.5 – 2.8
{26.5 – 28.5} {25.5 – 28.5}
sure 45 – 55°C switch: 3rd or 4th
MEMO
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
30-130 62
SEN03839-00
WHEEL LOADER
WA250-6
WA250PZ-6
40 Troubleshooting 40
a Failure codes:
The failure code table is written in alphabetical order and also starting from small number.
The failure code in parentheses is not recorded in the failure history for both electrical system and
mechanical system.
a Applicable equipment:
Applicable equipment indicates in which controller system the failure has occurred.
MON : machine monitor system
ENG : Engine controller system
HST : HST controller system
a Action codes:
Action codes indicate what in displayed in the operator mode when a failure is detected.
a History classification:
History classification indicates in which system, either electrical system or mechanical system in the fail-
ure history display function, a failure has been recorded.
a Note: Optional equipment is also included in table.
Fuse locations 1
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
40-100 12
SEN03840-01
WHEEL LOADER
WA250-6
WA250PZ-6
40 Troubleshooting 40
k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to
understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
4. Check of level and type of oil in engine oil pan Between H and L Add oil
Lubricating oil and coolant
7. Check of level and type of hydraulic oil Between H and L Add oil
8. Check of level and type of HST oil Between H and L Add oil
Retighten or
12. Check of battery terminal cables for looseness and corrosion —
replace
Electrical parts
21. Check of battery electrolyte level Between U.L and L.L Add or replace
Electrical equipment
22. Check wires for discoloration, burn, and removal of cover — Replace
23. Check for removed wire clamp and drooping wire — Repair
24. Check wiring for wetting with water (Check connectors and Disconnect and dry
—
terminals for wetting with water, in particular) connectors
25. Check of slow-blow fuses and fuses for disconnection and
— Replace
corrosion
26. Check of alternator voltage (with engine at medium speed or After several-minute
Repair or replace
higher) operation: 27.5 – 29.5 V
27. Check of operating sound of battery relay (Starting switch
— Replace
OFF o ON)
Classification of troubleshooting
Mode Contents
Display of
Troubleshooting by failure code (Display of code)
code
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine
1. Procedure for troubleshooting to be taken when action code is displayed on machine monitor:
If an action code is displayed on the machine monitor, display the failure code in the failure code display
mode (for the electrical system and the mechanical system) of the machine monitor (EMMS).
Carry out troubleshooting in [Display of failure code] according to the displayed failure code.
a Each failure code “flashes” when the trouble corresponding to it is detected. Even if a failure code
“lights up” when the starting switch is turned ON, the trouble corresponding to that failure code may
not have been repaired (Some troubles can be detected by simply turning the starting switch ON).
a If a failure code is recorded, be sure to perform the operation for reproducing it to see if the trouble
corresponding to it has been repaired (For the method of reproducing the failure code, see the trou-
bleshooting in [Display of code]).
3. Procedure of troubleshooting to be taken when action code is not displayed and failure code is
not recorded:
If a failure code is not recorded in the machine monitor (EMMS), a trouble that the machine cannot find
out by itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of “Phenomena looking like troubles and troubleshooting Nos.“, and then carry out trouble-
shooting related to that phenomenon in the “E-mode“, “H-mode“, or “S-mode“.
Troubleshooting
No. Phenomena looking like trouble Code
E-mode H-mode S-mode
display
Phenomena related to action codes and failure codes
1 Action codes are displayed on machine monitor Check failure code
2 If failure code display function is checked, failure codes are displayed q
Phenomena related to engine
3 Engine does not start easily (Starting performance is poor) S-1
4 Engine does not turn E-1 S-2 a)
5 Engine turns but no exhaust smoke comes out S-2 b)
Engine does not start
Exhaust smoke comes out but engine does not
6 S-2 c)
start (Fuel is injected)
7 Engine does not pick up smoothly S-3
8 Engine stops during operation H-4 S-4
9 Engine does not rotate smoothly S-5
10 Engine lacks output (or lacks power) S-6
11 Exhaust smoke is black (Incomplete combustion) S-7
12 Oil consumption is excessive (or exhaust smoke is blue) S-8
13 Oil becomes contaminated quickly S-9
14 Fuel consumption is excessive S-10
15 Oil is in coolant (or coolant spurts back or coolant level goes down) S-11
16 Oil pressure drops S-12
17 Oil level rises (Entry of coolant or fuel) S-13
18 Coolant temperature becomes too high (overheating) S-14
19 Abnormal noise is made S-15
20 Vibration is excessive S-16
21 Preheater does not operate normally E-2
Phenomena related to power train
22 The machine does not start H-1
23 The travel speed is slow H-2
24 The traction force is weak H-3
25 Engine stalls when traveling or engine speed drops excessively H-4
26 The gear is not shifted H-5
27 Travel direction selection system does not function E-6
Phenomena related to steering
28 The steering wheel does not turn H-6
29 The steering wheel is heavy H-7
30 Steering wheel shakes or jerks H-8
31 Machine deviates naturally to one side when traveling H-9
Phenomena related to brake
32 The brake does not work or does not work well H-10
33 The brake is not released or is dragged H-11
<Described contents>
• Standard value in normal state to judge assumed cause
(good or not)
• Remarks required to judge whether the cause is good
1
<Phenomenon of defective wiring harness>
• Disconnection in wiring
The connector connection is defective or the wiring harness
is disconnected.
• Grounding fault
A harness not connected to ground (earth) circuit comes
into contact with the ground (earth) circuit.
• Hot short circuit
2 A harness not connected to the power (24 V) circuit comes
into contact with the power (24 V) circuit.
• Short circuit
Possible causes Possible causes of trouble A harnesses of an independent circuit abnormally comes
and standard is assumed to be detected into contact with one of another circuit.
value in normal (The order number indicates
state a serial number, not a priority <Notes on troubleshooting>
sequence.) (1) Method of indicating connector number and handling T-
branch
For troubleshooting, insert or connect T-branch adapter
3
as shown below unless especially specified.
• When “male” or “female” is not indicated for a con-
nector number, disconnect the connector, and insert
the T-branch adapter in both the male and female.
• When “male” and “female” is indicated for a connec-
tor number, disconnect the connector, and insert the
T-branch adapter in only either the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–)
4 leads as shown below unless especially specified.
• Connect the plus (+) lead to a pin or harness indi-
cated in the front.
• Connect the minus (–) lead to a pin or harness indi-
cated in the rear.
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
795-799-5470 Cable for engine (HPI-T2) 3 — q
795-799-5480 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
Adapter for engine (CRI-T3)
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
Adapter for engine (CRI-T3)
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
Socket for engine (CRI-T3)
799-601-4190* 3 1,2,3L q q
Commonrail pressure
Socket for engine (CRI-T3)
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
Socket for engine (CRI-T3)
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280* Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
©2009 KOMATSU
All Rights Reserved
Printed in Japan 06-09
40-200 50
SEN03841-00
WHEEL LOADER
WA250-6
WA250PZ-6
40 Troubleshooting 40
Contents of • While engine was running (for at least 30 seconds), brake oil pressure sensor detected that oil pres-
trouble sure was below 4.4 MPa {45 kg/cm2} (circuit is open).
• Turns central warning lamp and caution buzzer ON.
• Turns brake oil pressure caution lamp ON.
Action of
machine monitor • Central warning lamp, alarm buzzer and caution lamp operate for a maximum of 30 seconds after the
engine starts, but no failure codes are displayed.
• if cause of failure disappears, system resets itself.
Problem that
appears on • If machine is used as it is, brake may not work.
machine
Related • Input state (ON/OFF) from brake oil pressure sensor can be checked with monitoring function
information (Monitoring code: MONITOR PANEL – 40902 – D-IN-16).
• Front brake (axle) high oil temperature was detected (Details are as follows).
Contents of
trouble • Oil temperature above 130°C (when travel speed was below 35 km/h) or above 125°C (when travel
speed was above 35 km/h) was detected for 5 seconds continuously.
Action of • Turns central warning lamp and caution buzzer ON.
machine monitor • Turns brake oil temperature caution lamp ON.
Problem that
appears on • If machine is used as it is, brake may be damaged.
machine
• If temperature above 120°C is detected for 5 seconds continuously, only caution lamp is turned ON
as preliminary warning.
Related
information • Brake oil temperature can be checked with monitoring function.
(Monitoring code: MONITOR PANEL – 30201 – F BRAKE OIL (°C))
(Monitoring code: MONITOR PANEL – 30204 – F BRAKE OIL (V))
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
40-310 18
SEN03842-00
WHEEL LOADER
WA250-6
WA250PZ-6
40 Troubleshooting 40
Related
• Method of reproducing failure code: Start engine
information
• The input state (temperature) from the engine coolant temperature sensor can be checked with the
monitoring function (Code: ENGINE, 04104, COOLANT TEMP).
Related
• The input state (voltage) from the engine coolant temperature sensor can be checked with the moni-
information
toring function (Code: ENGINE, 04105, COOLANT TEMP).
• Method of reproducing failure code: Turn the starting switch ON.
• The input state (temperature) from the engine coolant temperature sensor can be checked with the
monitoring function (Code: ENGINE, 04104, COOLANT TEMP).
Related
• The input state (voltage) from the engine coolant temperature sensor can be checked with the moni-
information
toring function (Code: ENGINE, 04105, COOLANT TEMP).
• Method of reproducing failure code: Turn the starting switch ON.
• The input state (temperature) from the charge temperature sensor (boost temperature sensor) can
be checked with the monitoring function (Code: ENGINE, 18500, CHG TEMP).
Related
• The input state (voltage) from the charge temperature sensor (boost temperature sensor) can be
information
checked with the monitoring function (Code: ENGINE, 18501, CHG TEMP).
• Method of reproducing failure code: Turn the starting switch ON.
• The input state (temperature) from the charge temperature sensor (boost temperature sensor) can
be checked with the monitoring function (Code: ENGINE, 18500, CHG TEMP).
Related
• The input state (voltage) from the charge temperature sensor (boost temperature sensor) can be
information
checked with the monitoring function (Code: ENGINE, 18501, CHG TEMP).
• Method of reproducing failure code: Turn the starting switch ON.
Action code Failure code Derating of speed by abnormally high charge temperature
Trouble
E03 CA155 (Engine controller system)
Contents of
• Temperature signal of boost pressure sensor and temperature sensor is above upper control limit.
trouble
Action of • Limits output and continues operation.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
• Engine output drops.
appears on
machine • Engine stops
• The input state (temperature) from the charge temperature sensor (boost temperature sensor) can
be checked with the monitoring function (Code: ENGINE, 18500, CHG TEMP).
Related
• The input state (voltage) from the charge temperature sensor (boost temperature sensor) can be
information
checked with the monitoring function (Code: ENGINE, 18501, CHG TEMP).
• Method of reproducing failure code: Start engine
• The input state (atmospheric pressure) from the atmospheric pressure sensor can be checked with
the monitoring function (Code: ENGINE, 37400, AMBIENT PRESS).
Related
• The input state (voltage) from the atmospheric pressure sensor can be checked with the monitoring
information
function (Code: ENGINE, 37402, AMBIENT PRESS).
• Method of reproducing failure code: Turn the starting switch ON.
• The input state (atmospheric pressure) from the atmospheric pressure sensor can be checked with
the monitoring function (Code: ENGINE, 37400, AMBIENT PRESS).
Related
• The input state (voltage) from the atmospheric pressure sensor can be checked with the monitoring
information
function (Code: ENGINE, 37402, AMBIENT PRESS).
• Method of reproducing failure code: Turn the starting switch ON.
Related
• Method of reproducing failure code: Turn the starting switch ON.
information
Related
• Method of reproducing failure code: Turn the starting switch ON.
information
Related
• Method of reproducing failure code: Start engine
information
Related
• Method of reproducing failure code: Start engine
information
Related
• Method of reproducing failure code: Start engine
information
Related
• Method of reproducing failure code: Start engine
information
Related
• Method of reproducing failure code: Start engine
information
Related
• Method of reproducing failure code: Start engine
information
Related
• Method of reproducing failure code: Turn the starting switch ON.
information
Related
• Method of reproducing failure code: Turn the starting switch ON.
information
Related
• Method of reproducing failure code: Turn the starting switch ON.
information
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
40-320 56
SEN03843-00
WHEEL LOADER
WA250-6
WA250PZ-6
40 Troubleshooting 40
Fig. 1
Throttle: Throttle sensor signal voltage
Idle validation: Idle validation switch signal voltage
A: Voltage when pedal opened + 0.03 x
(Voltage when pedal pressed – Voltage
when pedal opened)
B: Voltage when pedal opened + 0.1 x
(Voltage when pedal pressed – Voltage
when pedal opened)
Fig. 1
Throttle: Throttle sensor signal voltage
Idle validation: Idle validation switch signal voltage
A: Voltage when pedal opened + 0.03 x
(Voltage when pedal pressed – Voltage
when pedal opened)
B: Voltage when pedal opened + 0.1 x
(Voltage when pedal pressed – Voltage
when pedal opened)
Related
• Method of reproducing failure code: Starting switch ON or start engine
information
Related
• Method of reproducing failure code: Turn the starting switch ON.
information
• The input state (common rail pressure) from the common rail pressure sensor can be checked with
the monitoring function (Code: ENGINE, 36400, RAIL PRESS).
Related
• The input state (voltage) from the common rail pressure sensor can be checked with the monitoring
information
function (Code: ENGINE, 36402, RAIL PRESS).
• Method of reproducing failure code: Start engine
Action code Failure code Common rail pressure sensor high error
Trouble
E03 CA451 (Engine controller system)
Contents of
• High voltage occurred in common rail pressure sensor.
trouble
Action of • Limits output and continues operation.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
• The engine does not start.
appears on
machine • Engine speed or output drops.
• The input state (common rail pressure) from the common rail pressure sensor can be checked with
the monitoring function (Code: ENGINE, 36400, RAIL PRESS).
Related
• The input state (voltage) from the common rail pressure sensor can be checked with the monitoring
information
function (Code: ENGINE, 36402, RAIL PRESS).
• Method of reproducing failure code: Turn the starting switch ON.
Action code Failure code Common rail pressure sensor low error
Trouble
E03 CA452 (Engine controller system)
Contents of
• Low voltage occurred in common rail pressure sensor.
trouble
Action of • Limits output and continues operation.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
• The engine does not start.
appears on
machine • Engine speed or output drops.
• The input state (common rail pressure) from the common rail pressure sensor can be checked with
the monitoring function (Code: ENGINE, 36400, RAIL PRESS).
Related
• The input state (voltage) from the common rail pressure sensor can be checked with the monitoring
information
function (Code: ENGINE, 36402, RAIL PRESS).
• Method of reproducing failure code: Turn the starting switch ON.
Action code Failure code Derating of torque by abnormally high charge temperature
Trouble
E03 CA488 (Engine controller system)
Contents of
• Temperature signal of boost pressure sensor and temperature sensor is above upper control limit.
trouble
Action of • Limits output and continues operation.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
• The input state (boost temperature) from the boost pressure and temperature sensors can be
checked with the monitoring function (Code: ENGINE, 18500, CHG TEMP).
Related
• The input state (boost temperature sensor voltage) from the boost pressure and temperature sen-
information
sors can be checked with the monitoring function (Code: ENGINE, 18501, CHG TEMP).
• Method of reproducing failure code: Start engine
• The input state (common rail pressure) from the common rail pressure sensor can be checked with
the monitoring function (Code: ENGINE, 36400, RAIL PRESS).
Related
• The input state (voltage) from the common rail pressure sensor can be checked with the monitoring
information
function (Code: ENGINE, 36402, RAIL PRESS).
• Method of reproducing failure code: Start engine
Action code Failure code Supply pump pressure very low error
Trouble
E03 CA559 (Engine controller system)
Contents of
• No-pressure feed (1) occurred in common rail circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that • Engine does not start or starting performance is poor
appears on • Exhaust smoke is black.
machine • Engine output drops.
• The input state (common rail pressure) from the common rail pressure sensor can be checked with
the monitoring function (Code: ENGINE, 36400, RAIL PRESS).
Related
• The input state (voltage) from the common rail pressure sensor can be checked with the monitoring
information
function (Code: ENGINE, 36402, RAIL PRESS).
• Method of reproducing failure code: Start engine
Action code Failure code Engine Bkup speed sensor phase error
Trouble
E03 CA731 (Engine controller system)
Contents of
• Abnormal phase is detected in signals of engine Ne speed sensor and engine Bkup speed sensor.
trouble
Action of • Controls Ne speed sensor with signals of Bkup speed sensor.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that • Engine does not start or is difficult to start.
appears on • Idle speed is unstable.
machine • Exhaust smoke is black.
Related
• Method of reproducing failure code: Start engine
information
Related
• Method of reproducing failure code: Start engine
information
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
state (47) – HST (female) (28), (38) tance
Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
Disconnection in wiring har- (47) – L29 (female) (3), (8) tance
ness Wiring harness between EC2 (female) (46), Resis-
2 Max. 1 z
(Disconnection or defective (47) – L72 (female) (22), (32) tance
contact in connector) Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
(47) – L80 (female) (7), (8) tance
Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
(47) – CAN1 (female) (A), (B) tance
Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
(47) – CAN2 (female) (A), (B) tance
Action code Failure code Throttle sensor supply voltage high error
Trouble
E03 CA2185 (Engine controller system)
Contents of
• High voltage (min. 5.25V) occurred in throttle sensor power supply circuit.
trouble
Action of • Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 50% when it is ON.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • The engine does not reach full throttle.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information
Action code Failure code Throttle sensor power supply voltage low error
Trouble
E03 CA2186 (Engine controller system)
Contents of
• Low voltage occurred in throttle sensor power supply circuit.
trouble
Action of • Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 50% when it is ON.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • The engine does not reach full throttle.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information
Action code Failure code Supply pump pressure very low error 2
Trouble
E03 CA2249 (Engine controller system)
Contents of
• No-pressure feed (2) occurred in common rail circuit.
trouble
Action of • Limits output and continues operation.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that • Starting performance is poor
appears on • Exhaust smoke is black.
machine • Engine output lowers.
• The input state (common rail pressure) from the common rail pressure sensor can be checked with
the monitoring function (Code: ENGINE, 36400, RAIL PRESS).
Related
• The input state (voltage) from the common rail pressure sensor can be checked with the monitoring
information
function (Code: ENGINE, 36402, RAIL PRESS).
• Method of reproducing failure code: Start engine
Action code Failure code Intake heater relay short circuit error
Trouble
E01 CA2556 (Engine controller system)
Contents of
• There is short circuit in intake air heater relay.
trouble
Action of
• None in particular.
controller
Problem that
• Intake air heater does not function. (Poor starting performance, white exhaust smoke at low temper-
appears on
ature)
machine
• The input state (boost temperature) can be checked with the monitoring function (Code : ENGINE,
Related 18500, CHG TEMP)
information • Method of reproducing failure code: Turn the starting switch ON when boost temperature is –4°C or
less.
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
40-330 56
SEN03844-00
WHEEL LOADER
WA250-6
WA250PZ-6
40 Troubleshooting 40
Contents of • When accessory power supply (power supply for operation) voltage is above 17 V, UNSW power
trouble supply (power supply for memory) has ground fault.
Action of
• None in particular.
machine monitor
Problem that • Service meter time gains or loses.
appears on • Odometer does not advance.
machine • Fault history data is not saved.
Related
• Method of reproducing failure code: Turn starting switch ON.
information
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal Wiring harness between HST (female) (28), Resis-
Max. 1 z
state (38) – L80 (female) (7), (8) tance
Wiring harness between HST (female) (28), Resis-
Max. 1 z
Disconnection in wiring har- (38) – L29 (female) (3), (8) tance
ness Wiring harness between HST (female) (28), Resis-
2 Max. 1 z
(Disconnection or defective (38) – EC2 (female) (46), (47) tance
contact in connector) Wiring harness between HST (female) (28), Resis-
Max. 1 z
(38) – C140 (female) (28), (38) tance
Wiring harness between HST (female) (28), Resis-
Max. 1 z
(38) – CAN1 (female) (A), (B) tance
Wiring harness between HST (female) (28), Resis-
Max. 1 z
(38) – CAN2 (female) (A), (B) tance
Related • If gear is set in neutral and engine is restarted while controller voltage is above 20 V, system is reset.
information • Method of reproducing failure code: Turn starting switch ON
Failure code [DAJ1L6] HST controller main power line: Hot short
Action code Failure code HST controller main power line: Hot short
Trouble
E01 DAJ1L6 (HST controller system)
Contents of
• Hot short was detected in HST controller main power line (battery relay drive voltage system).
trouble
• Continues key OFF processing on assumption that battery relay is turned OFF.
Action of (Turns controller self-holding circuit OFF on assumption that alternator L signal voltage system is
machine monitor turned OFF.)
• Displays error next time when starting switch is turned ON.
Problem that
appears on • Battery voltage may lower earlier.
machine
Related
• After error is detected, it is displayed next time when starting switch is turned ON.
information
Related
• If gear is set in neutral and engine is restarted while solenoid voltage is above 19 V, system is reset.
information
Failure code [DAJ2L3] HST controller load power supply holding line:
Hot short in wiring harness
Action code Failure code HST controller load power supply holding line: Hot short in wiring
Trouble harness
E01 DAJ2L3 (HST controller system)
Contents of • Hot short was detected in HST controller load power supply holding line.
trouble (When output command was ON, output terminal voltage above 5.7 V was detected.)
Action of
• Turns output OFF (Control protection function works).
machine monitor
Problem that • When starting switch is turned OFF, parking brake check cannot be controlled and machine moves
appears on down.
machine • If starting switch is turned OFF while fan is rotating in reverse, peak pressure may occur.
Related
information
Failure code [DAJ2L4] HST controller load power supply holding line:
Disconnection/Ground fault
Action code Failure code HST controller load power supply holding line: Disconnection/
Trouble Ground fault
E01 DAJ2L4 (HST controller system)
• Disconnection or ground fault was detected in load power supply holding line during HST controller
Contents of
final check.
trouble
(During final check, when output command was OFF, voltage below 5.7 V was detected.
Action of
• Relay cannot be driven while there is disconnection.
machine monitor
• While there is disconnection, when starting switch is turned OFF, parking brake check cannot be
Problem that
controlled and machine moves down.
appears on
machine • If starting switch is turned OFF while disconnection is made or fan is rotating in reverse, peak pres-
sure may occur.
Related
information
Related
• Method of reproducing failure code: Turn the starting switch ON.
information
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal Wiring harness between HST (female) (28), Resis-
Max. 1 z
state (38) – L80 (female) (7), (8) tance
Wiring harness between HST (female) (28), Resis-
Max. 1 z
Disconnection in wiring har- (38) – L29 (female) (3), (8) tance
ness Wiring harness between HST (female) (28), Resis-
2 Max. 1 z
(Disconnection or defective (38) – EC2 (female) (46), (47) tance
contact in connector) Wiring harness between HST (female) (28), Resis-
Max. 1 z
(38) – C140 (female) (28), (38) tance
Wiring harness between HST (female) (28), Resis-
Max. 1 z
(38) – CAN1 (female) (A), (B) tance
Wiring harness between HST (female) (28), Resis-
Max. 1 z
(38) – CAN2 (female) (A), (B) tance
Related circuit diagram (When HST controller power supply circuit is defective)
Contents of • Disagreement between the option setting done by the machine monitor and the option recognition by
trouble done the HST controller.
Action of • The HST controller follows the option setting being recognized by itself.
machine monitor • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • The option setting does not work normally.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
40-340 44
SEN03845-00
WHEEL LOADER
WA250-6
WA250PZ-6
40 Troubleshooting 40
Related
• Method of reproducing failure code: Turn the starting switch ON.
information
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
state (47) – HST (female) (28), (38) tance
Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
Disconnection in wiring har- (47) – L80 (female) (7), (8) tance
ness Wiring harness between EC2 (female) (46), Resis-
2 Max. 1 z
(Disconnection or defective (47) – L29 (female) (3), (8) tance
contact in connector) Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
(47) – C140 (female) (28), (38) tance
Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
(47) – CAN1 (female) (A), (B) tance
Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
(47) – CAN2 (female) (A), (B) tance
Related circuit diagram (When engine controller power supply circuit is defective)
• Input state from fan automatic reverse switch can be checked with monitoring function
Related
(Code: HST – 93400 – FAN REVERSE SW) (Code: MONITOR PANEL – 40901 – D-IN-9).
information
• Method of reproducing failure code: Turn starting switch ON.
Contents of • Parking brake indicator signal was closed and opening of parking brake reminder signal was
trouble detected.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
machine monitor • Turns parking brake indicator and parking brake remind caution lamp ON.
Problem that • While parking brake is in intermediate position, parking brake reminder caution lamp does not light.
appears on • While parking brake is in intermediate position, parking brake reminder buzzer does not sound.
machine • While parking brake is in intermediate position, centralized warning lamp does not light.
• Input state (ON/OFF) of parking brake indicator signal and reminder signal can be checked with
Related monitoring function.
information (Monitoring code: MONITOR PANEL – 40903 – D-IN-26, 28)
(Monitoring code: MONITOR PANEL – 40904 – D-IN-35, 36)
Related
• If failure code [DAJ5KX] is also displayed, carry out troubleshooting for it first.
information
Failure code [DDD7KY] Travel speed control dial signal: Hot short
Action code Failure code Travel speed control dial signal: Hot short
Trouble
E01 DDD7KY (HST controller system)
Contents of
• Travel speed control dial signal voltage exceeded 4.7 V.
trouble
Action of
• None in particular.
controller
Problem that
• Travel speed cannot be adjusted with travel speed control dial.
appears on
machine • If speed range selector switch is set in 1st, travel speed is set to about 4 km/h.
Related
• If failure code [DAJ5KX] is also displayed, carry out troubleshooting for it first.
information
Contents of • While engine was stopped, steering pump oil pressure was sensed because of disconnection in
trouble steering oil pressure reduction switch (emergency steering operation switch) system.
Action of
• None in particular.
machine monitor
Problem that
appears on • When steering oil pressure reduces, steering oil pressure caution lamp does not light.
machine
• This code is applied to only emergency steering specification model and is not turned ON if not
selected as option with machine monitor.
Related
information • Input state (ON/OFF) from steering oil pressure reduction switch can be checked with monitoring
function.
(Monitoring code: MONITOR PANEL – 40904 – D-IN-39)
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
40-350 40
SEN03846-00
WHEEL LOADER
WA250-6
WA250PZ-6
40 Troubleshooting 40
Action code Failure code Travel speed range selector switch: Disconnection/Ground fault
Trouble
E01 DF10KA (HST controller system)
Contents of • Travel speed range selector switch signal is not input because of disconnection or ground fault in
trouble travel speed range selector switch input signal system.
Action of • Fixes gear to speed range before error occurrence.
controller • If trouble disappears, system resets itself.
• Once starting switch is turned OFF, gear speed is assumed to be 4th for control, regardless of
Problem that selected speed range.
appears on • Gear is not set in selected speed range.
machine • Indicator displays range before error occurrence.
(Once starting switch is turned OFF, 4th gear is displayed)
Related
• Method of reproducing failure code: Turn starting switch ON + Operate speed range selector switch.
information
Failure code [DF10KB] Travel speed range selector switch: Hot short
Action code Failure code Travel speed range selector switch: Hot short
Trouble
E01 DF10KB (HST controller system)
Contents of • Multiple travel speed range selector switch signal is input because of hot short in travel speed range
trouble selector switch input signal system.
Action of • Fixes gear to speed range before error occurrence.
controller • If trouble disappears, system resets itself.
• Once starting switch is turned OFF, gear speed is assumed to be 4th for control, regardless of
Problem that selected speed range.
appears on • Gear is not set in selected speed range.
machine • Indicator displays range before error occurrence.
(Once starting switch is turned OFF, 4th gear is displayed)
Related
• Method of reproducing failure code: Turn starting switch ON + Operate speed range selector switch.
information
• Input state from front brake oil temperature sensor can be checked with monitoring function.
Related (Monitoring code: MONITOR PANEL – 30201 – F BRAKE OIL (°C)
information (Monitoring code: MONITOR PANEL – 30204 – F BRAKE OIL (V)
• System resets itself after brake oil temperature reduces below 130°C.
Defective front brake (axle) F14 (male) Brake oil temperature Resistance
2 oil temperature sensor (Inter- At 25°C 35 – 50 kz
nal defect) Between (1) – (2)
Possible causes At 100°C 3.1 – 4.5 kz
and standard Between (1) (2) and
value in normal – (Anytime) Min. 1 Mz
ground
state
Ground fault in wiring har-
Between wiring harness F14 (female) (1) – Resis-
3 ness (Contact with GND cir- Min. 1 Mz
L28 (female) (7) and ground tance
cuit)
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
4 Defective machine monitor L25, L28 Brake oil temperature Voltage
Between L28 (7) – At 25°C 4.4 – 4.6 V
L25 (9) At 100°C 2.1 – 2.3 V
• Disconnection or hot short was detected in front brake oil temperature signal circuit.
Contents of
Reference: Detection is made by sudden change of brake oil temperature or by logic of comparison
trouble
with HST oil temperature.
Action of
• None in particular.
machine monitor
Problem that
• Brake oil temperature gauge indicates lower limit.
appears on
machine • Brake may be broken and brake may not work because of brake oil temperature error.
• Input state from front brake oil temperature sensor can be checked with monitoring function.
Related (Monitoring code: MONITOR PANEL – 30201 – F BRAKE OIL (°C)
information (Monitoring code: MONITOR PANEL – 30204 – F BRAKE OIL (V)
• System resets itself after brake oil temperature increases above 25°C.
Contents of • HST oil pressure sensor signal is not input because of disconnection or ground fault in HST oil pres-
trouble sure sensor system (Input voltage is below 0.3 V)
• If trouble occurs during travel, control value (output) before trouble occurrence is held.
Action of
• Once machine stops, gear is assumed to be in 1st for control.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
• Once machine stops, gear is set in 1st. (Travel speed can be controlled with travel speed control
appears on
dial, however.)
machine
• If [DAJ5KX] is displayed, carry out troubleshooting for it first.
Related • Input state from HST oil pressure sensor can be checked with monitoring function.
information (Monitoring code: HST 32600 HST PRESS (MPa))
(Monitoring code: HST 32601 HST PRESS (V))
Ground fault in wiring har- a Prepare with starting switch OFF, then start engine, travel at con-
3 ness (Contact with GND cir- stant speed, and carry out troubleshooting.
cuit) Below 1 V
– Above
Between wiring harness HST (36) – T09 (4) 4V
Voltage
and ground (Changes
at regular
intervals)
a Prepare with starting switch OFF, then start engine, travel at con-
stant speed, and carry out troubleshooting.
Below 1 V
Hot short (Contact with 24V – Above
4
circuit) in wiring harness Between wiring harness HST (36) – T09 (4) 4V
Voltage
and ground (Changes
at regular
intervals)
a When [DLT3KX] and [DLT4KX] (Travel speed sensor A: Abnormality) are turned ON simultaneously
Contents of • While machine was traveling at speed above about 4 km/h, input signals of travel speed sensors A
trouble and B were lost.
• Keeps outputs to HST motor 1, HST motor 2 and clutch at values before trouble.
Action of
• Keeps output values after clutch is engaged or disengaged completely, if clutch is being controlled.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
Problem that
• Travel speed does not increase or traction force is insufficient.
appears on
machine • Machine monitor indicates 0 km/h as travel speed.
• If trouble occurs while machine is stopped or traveling at low speed (below about 4 km/h), error is not
Related turned ON.
information • In above case, machine monitor indicates 0 km/h as travel speed and actual travel speed is limited to
4 – 7 km/h.
Ground fault in wiring har- a Prepare with starting switch OFF, then start engine, travel at con-
3 ness (Contact with GND cir- stant speed, and carry out troubleshooting.
cuit) Below 1 V
– Above
Between wiring harness HST (26) – T09 (3) 4V
Voltage
and ground (Changes
at regular
intervals)
a Prepare with starting switch OFF, then start engine, travel at con-
stant speed, and carry out troubleshooting.
Below 1 V
Hot short (Contact with 24V – Above
4
circuit) in wiring harness Between wiring harness HST (26) – T09 (3) 4V
Voltage
and ground (Changes
at regular
intervals)
Contents of • Fan reverse solenoid relay cannot be controlled because of disconnection or ground fault in fan
trouble reverse solenoid relay output system.
Action of • Keeps output to fan reverse solenoid turned OFF and stops fan reverse control function.
controller • Even if trouble disappears, system does not reset itself until starting switch is turned OFF.
Problem that • Manual reverse function and automatic reverse function do not work.
appears on • Fan always turns forward (When there is disconnection).
machine • Fan always turns in reverse (When there is ground fault).
• Output state (ON/OFF) to fan reverse solenoid relay can be checked with monitoring function.
Related
(Monitoring code: HST – 40980 – D-OUT-17)
information
• Method of reproducing failure code: Turn starting switch ON.
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
40-360 38
SEN03847-00
WHEEL LOADER
WA250-6
WA250PZ-6
40 Troubleshooting 40
• Reverse solenoid is not turned ON (HST pressure selector relay does not operate) (when there is
Contents of
disconnection).
trouble
• Reverse solenoid cannot be turned OFF (Where there is hot short).
Action of • Turns output to reverse solenoid OFF.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that • Machine does not travel in reverse (when there is disconnection).
appears on • Machine may start in reverse suddenly (when there is hot short).
machine • Gear is not set in neutral (when there is hot short).
• Output state to HST pump R (Reverse) solenoid of HST controller can be checked with monitoring
Related
function.
information
(Monitoring code: HST – 40980 – D-OUT-19)
• Forward solenoid is not turned ON (HST pressure selector relay does not operate) (when there is
Contents of
disconnection).
trouble
• Forward solenoid cannot be turned OFF (Where there is hot short).
Action of • Turns output to forward solenoid OFF.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that • Machine does not travel forward (when there is disconnection).
appears on • Machine may start forward suddenly (when there is hot short).
machine • Gear is not set in neutral (when there is hot short).
• Output state to HST pump F (Forward) solenoid of HST controller can be checked with monitoring
Related
function.
information
(Monitoring code: HST – 40980 – D-OUT-18)
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
40-370 28
SEN03848-00
WHEEL LOADER
WA250-6
WA250PZ-6
40 Troubleshooting 40
Contents of
• The engine does not start.
trouble
• Before starting troubleshooting, check the following.
a. Directional lever is not in N (Neutral).
b. Directional switch is not in N (Neutral).
c. Starting of engine is prohibited by function of KOMTRAX.
d. Battery cable is not disconnected from battery.
Related • The engine does not start, because the starting motor does not run due to troubles in the starting
information motor system and starting switch terminal C signal system.
• Check that fuse is normal.
(If it is broken, check the related wiring harness for grounding fault.)
• The input state (ON/OFF) to the machine monitor from the starting switch terminal C can be checked
with the monitoring function (Code: MONITOR PANEL 40900, D-IN-2).
• If failure code is indicated, carry out troubleshooting for it first.
8 a Prepare with starting switch OFF, then carry out troubleshooting with-
out turning starting switch ON.
Defective directional L63 (male) Switch position Resistance
selector switch actuation ON (Directional
switch (Internal defect) Max. 1 z
switch is selected)
Between (3) – (4)
OFF
Min. 1 Mz
(Lever is selected)
a Prepare with starting switch OFF, then carry out troubleshooting with-
out turning starting switch ON.
D21 (male) Diode range Continuity
Defective diodes (D21, Measure at (2) in
Between (2) and (1) Continue
D22) (Internal trouble) diode range.
9
a Only when both diodes a Prepare with starting switch OFF, then carry out troubleshooting with-
Possible are detective out turning starting switch ON.
causes and D22 (male) Diode range Continuity
standard value
Measure at (2) in
in normal state Between (2) and (1) Continue
diode range.
a Prepare with starting switch OFF, then carry out troubleshooting with-
out turning starting switch ON.
D01 (male) Diode range Continuity
Defective diodes (D01)
10 Measure at (5) in
(Internal trouble) Between (5) and (1) Continue
diode range.
Measure at (6) in
Between (6) and (2) Continue
diode range.
a Prepare with starting switch OFF, then carry out troubleshooting with-
out turning starting switch ON.
D03 (male) Diode range Continuity
Defective diodes (D03)
11 Measure at (7) in
(Internal trouble) Between (7) and (3) Continue
diode range.
Measure at (8) in
Between (8) and (4) Continue
diode range.
a Prepare with starting switch OFF, then carry out troubleshooting with-
out turning starting switch ON.
Defective diode (D10)
12 D10 (male) Diode range Continuity
(Internal defect)
Measure on (2) side
Between (2) – (1) Continuity is secured
in diode range
Possible a Prepare with starting switch OFF, then carry out troubleshooting
causes and Ground fault in wiring harness without turning starting switch ON.
2
standard value (Contact with GND circuit) Between wiring harness EC2 (40) – E06 (5) Resis-
Min. 1 Mz
in normal state and ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
When
Hot short (Contact with 24V preheater Voltage 20 – 30 V
3
circuit) in wiring harness Between wiring harness E07A – is ON
E07B and ground When
preheater Voltage Max. 1 V
is OFF
If cause 1 – 3 are not detected, engine controller may be defective.
4 Defective engine controller
(Since trouble is in system, troubleshooting cannot be carried out.)
Contents of • Boom kick-out does not function or cannot be cancelled due to defective boom kick-out proximity
trouble switch system, lift arm PPC detent system and lift arm detent relay system.
Related
—
information
Contents of • Bucket positioner does not function or cannot be cancelled due to defective bucket positioner proxim-
trouble ity switch system, bucket PPC detent system and bucket detent relay system.
Related
—
information
Contents of • Lift arm FLOATING holding does not function or cannot be cancelled due to defective lift arm FLOAT-
trouble ING PPC detent system.
Related
—
information
a) When parking brake is released, parking brake indicator of machine monitor keeps lighting.
Contents of • Machine does not travel forward because of trouble in parking brake system, forward solenoid valve
trouble system or directional lever system.
• Before starting troubleshooting, check following items (1) and (2).
(1) Parking brake is released.
(2) Parking brake is released and parking brake indicator lamp is OFF.
• If any failure code is displayed, carry out troubleshooting for it first.
Related
information • Input state of directional lever FNR input signal can be checked with indicator lamp or monitoring
function of machine monitor.
(Monitoring code: HST – 40977 – D-IN-0, D-IN-1, D-IN-2)
• Output state of directional solenoid FR output can be checked with monitoring function.
(Monitoring code: HST – 40980 – D-OUT-18, D-OUT-19)
b) When parking brake is released, parking brake indicator of machine monitor goes off but machine
does not travel forward
Contents of • Machine does not travel forward because of trouble in parking brake system, forward solenoid valve
trouble system or directional lever system.
• Before starting troubleshooting, check following items (1) and (2).
(1) Parking brake is released.
(2) Parking brake is released and parking brake indicator lamp is OFF.
• If any failure code is displayed, carry out troubleshooting for it first.
Related
information • Input state of directional lever FNR input signal can be checked with indicator lamp or monitoring
function of machine monitor.
(Monitoring code: HST – 40977 – D-IN-0, D-IN-1, D-IN-2)
• Output state of directional solenoid FR output can be checked with monitoring function.
(Monitoring code: HST – 40980 – D-OUT-18, D-OUT-19)
Contents of
(1) Front wiper does not operate.
trouble
Related
• The front wiper does not operate due to the defective front wiper switch, timer, or wiring harness.
information
Contents of
(2) Rear wiper does not operate.
trouble
Related
• Since the rear wiper switch or wiring harness is defective, the rear wiper does not operate.
information
Contents of
Windshield washer does not operate.
trouble
• Since the windshield washer motor, switch, timer (for only front), or wiring harness is defective, the
Related windshield washer does not operate.
information • Perform the following troubleshooting when the wiper operates normally. (If the wiper does not oper-
ate normally, carry out troubleshooting for “E-7 Wiper does not operate” first.)
E-9 Headlamp, clearance lamp and tail lamp do not light up or go off 1
Contents of
(1) Headlamp, clearance lamp and tail lamp do not light up or go off.
trouble
• Since the lamp system GND circuit is disconnected or shorted with the ground, none of the lamps
lights up.
• Headlamp at SMALL position: Clearance lamp, tail lamp, machine monitor night lamp light up (when
normal).
• Headlamp at HEAD position: Above lamps and headlamp light up (when normal).
Related
information • The input state (voltage) from the lamp switch (small lamp) to the machine monitor can be checked
with the monitoring function (Code: MONITOR PANEL 40200, SMALL LAMP).
• The input state (ON/OFF) to the machine monitor from the lamp switch (head lamp) can be checked
with the monitoring function (Code: MONITOR PANEL 40900, D-IN-0).
• The input state (ON/OFF) to the machine monitor from the dimmer switch (high beam) can be
checked with the monitoring function (Code: MONITOR PANEL 40904, D-IN-34).
Contents of
(2) Either of headlamp (low and high beams) does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the headlamp (low and high beams) is defective.
• Carry out the following troubleshooting when the clearance lamp and tail lamp light up and go off nor-
mally.
Related
information • The input state (ON/OFF) to the machine monitor from the lamp switch (head lamp) can be checked
with the monitoring function (Code: MONITOR PANEL 40900, D-IN-0).
• The input state (ON/OFF) to the machine monitor from the dimmer switch (high beam) can be
checked with the monitoring function (Code: MONITOR PANEL 40904, D-IN-34).
Disconnection in wiring har- Wiring harness between L120 (female) (5) – Resis-
Max. 1 z
ness L25 (female) (1), – left FLH (female) (B) tance
6
(Disconnection or defective a Carry out above 3 items when left side does not light.
contact in connector) Wiring harness between L04 (female) (2) – Resis-
Max. 1 z
L119 (female) (2) tance
Wiring harness between fuse No. 9 of fuse Resis-
Max. 1 z
box (FS1) – L119 (female) (1), (3) tance
Wiring harness between L119 (female) (5) – Resis-
Max. 1 z
right FLH (female) (B) tance
a Carry out above 3 items when right side does not light.
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Wiring harness between L04 (female) (2) –
Resis-
L120 (female) (2), – circuit branch end and Min. 1 Mz
tance
ground
a Carry out above when left side does not go off.
Possible
causes and Wiring harness between fuse No. 8 of fuse
Resis-
standard value box (FS1) – L120 (female) (1), (3) and Min. 1 Mz
tance
in normal state ground
Wiring harness between L120 (female) (5) –
Resis-
Ground fault in wiring harness L25 (female) (1), – left FLH (female) (B) and tance
Min. 1 Mz
7 ground
(Contact with ground circuit)
a Carry out above 2 items when left side does not light.
Wiring harness between L04 (female) (2) – Resis-
Min. 1 Mz
L119 (female) (2) and ground tance
a Carry out above when right side does not go off.
Wiring harness between fuse No. 9 of fuse
Resis-
box (FS1) – L119 (female) (1), (3) and Min. 1 Mz
tance
ground
Wiring harness between L119 (female) (5) – Resis-
Min. 1 Mz
right FLH (female) (B) and ground tance
a Carry out above 2 items when right side does not light.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
• Headlamp switch is OFF
Wiring harness between L120 (female) (5) –
Hot short in wiring harness L25 (female) (1), – left FLH (female) (B) and Voltage Max. 1 V
8 ground
(Contact with 24V circuit)
a Carry out above when left side does not go off.
Wiring harness between L119 (female) (5) –
Voltage Max. 1 V
right FLH (female) (B) and ground
a Carry out above when left side does not light.
Contents of
(3) Headlamp (low beam) does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the headlamp (low beam) is disconnected or shorted with the
ground.
• Carry out the following troubleshooting when the high beam lights up (goes off) normally.
Related
information • The input state (ON/OFF) to the machine monitor from the lamp switch (head lamp) can be checked
with the monitoring function (Code: MONITOR PANEL 40900, D-IN-0).
• The input state (ON/OFF) to the machine monitor from the dimmer switch (high beam) can be
checked with the monitoring function (Code: MONITOR PANEL 40904, D-IN-34).
Contents of
(4) Headlamp (high beam) does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the headlamp (high beam) is disconnected or shorted with the
ground.
• Carry out the following troubleshooting when the low beam lights up (goes off) normally.
Related
information • The input state (ON/OFF) to the machine monitor from the lamp switch (head lamp) can be checked
with the monitoring function (Code: MONITOR PANEL 40900, D-IN-0).
• The input state (ON/OFF) to the machine monitor from the dimmer switch (high beam) can be
checked with the monitoring function (Code: MONITOR PANEL 40904, D-IN-34).
Possible a Carry out above when right side does not light.
causes and Wiring harness between L117 (female) (5) –
Resis-
standard value FLC1 (female) (A), – R22 (female) (6) and Min. 1 Mz
tance
in normal state ground
Wiring harness between L118 (female) (5) –
Resis-
FLC (female) (A), – R23 (female) (6) and Min. 1 Mz
tance
ground
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
• Headlamp switch is OFF
Wiring harness between L04 (female) (1) –
L117 (female) (2), – L118 (female) (2), – cir- Voltage Max. 1 V
Hot short in wiring harness cuit branch end and ground
8
(Contact with 24V circuit) Wiring harness between L117 (female) (5) –
FLC1 (female) (A), – R22 (female) (6), – cir- Voltage Max. 1 V
cuit branch end and ground
Wiring harness between L118 (female) (5) –
FLC (female) (A), – R23 (female) (6), – cir- Voltage Max. 1 V
cuit branch end and ground
Contents of
(1) Front working lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the front working lamp system is defective
Related • When the rear working lamp is normal
information • If the clearance lamp does not light up or go off either, carry out troubleshooting for the clearance
lamp first.
Contents of
(2) Rear working lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the rear working lamp system is defective.
Related • When the front working lamp is normal
information • If the clearance lamp does not light up or go off either, carry out troubleshooting for the clearance
lamp first.
E-11 Turn signal lamp and hazard lamp do not light up or go off 1
Contents of
(1) Either of turn signal lamp and hazard lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the turn signal lamp and hazard lamp system is defective.
• The input state (ON/OFF) to the machine monitor from the turn signal lamp & hazard lamp switch
(right turn signal lamp) can be checked with the monitoring function (Code: MONITOR PANEL 40901,
Related
D-IN-12).
information
• The input state (ON/OFF) to the machine monitor from the turn signal lamp & hazard lamp switch (left
turn signal lamp) can be checked with the monitoring function (Code: MONITOR PANEL 40901, D-
IN-13).
Contents of
(2) Turn signal lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the turn signal lamp system is defective.
• When the hazard lamp lights up.
• The input state (ON/OFF) to the machine monitor from the turn signal lamp and hazard lamp switch
Related (right turn signal lamp) can be checked with the monitoring function (Code: MONITOR PANEL 40901,
information D-IN-12).
• The input state (ON/OFF) to the machine monitor from the turn signal lamp and hazard lamp switch
(left turn signal lamp) can be checked with the monitoring function (Code: MONITOR PANEL 40901,
D-IN-13).
Contents of
(3) Hazard lamp does not light up or go off.
trouble
Related • The switch or lamp of the hazard lamp is defective.
information • Carry out the following troubleshooting when the turn signal lamp flashes normally.
Contents of
Brake lamp does not light or it keeps lighting up.
trouble
Related
• The lamp or wiring harness of the brake lamp system is abnormal.
information
Contents of
Backup lamp does not light or it keeps lighting up.
trouble
• The machine monitor monitors the primary circuit of the backup lamp relay for a trouble.
Related (If hot short occurs in the primary side of the back lamp relay, failure code [D160KY] is indicated.
information Carry out troubleshooting for it first.)
• If another failure code is displayed, carry out troubleshooting for it first.
Contents of
Backup alarm does not sound or it keeps sounding.
trouble
• The machine monitor monitors the primary circuit of the backup lamp relay for a trouble.
Related (If hot short occurs in the primary side of the back lamp relay, failure code [D160KY] is indicated. In
information such case, give precedence to the troubleshooting of the failure indicated with the code.)
• If another failure code is displayed, carry out troubleshooting for it first.
Contents of
Horn does not sound or it keeps sounding.
trouble
Related
—
information
Contents of
• Alarm buzzer does not sound or it keeps sounding.
trouble
• Disconnection or ground fault in alarm buzzer output circuit
Related • The output state (ON/OFF) from the alarm buzzer to the machine monitor can be checked with the
information monitoring function (Code: MONITOR PANEL 40952, D-OUT-0).
• If failure code is indicated, carry out troubleshooting for it first.
Contents of
Air conditioner does not operate or stop.
trouble
• The following is troubleshooting applicable only to the power supply and GND circuit between the air
Related
conditioner and operator's cab. For troubleshooting of the air conditioner unit, see the Shop Manual
information
for the air conditioner.
Pressure switch ON 20 – 30 V
Possible
Disconnection in wiring har- (5A fuse line of main
causes and OFF Max. 1 V
ness of relay power supply circuit) and ground
standard value 4
in normal state (Disconnection or defective a Prepare with starting switch OFF, then carry out troubleshooting
contact in connector) without turning starting switch ON.
Wiring harness between fuse No. 1 of fuse
Resis-
box (FS2) – blower OFF relay (on the 15A Max. 1 z
tance
fuse line)
Wiring harness between fuse No. 1 of fuse
Resis-
box (FS2) – blower OFF relay (on the 5A fuse Max. 1 z
tance
line of main circuit)
Wiring harness between fuse No. 1 of fuse
Resis-
box (FS2) – pressure switch (on the 5A fuse Max. 1 z
tance
line of main circuit)
Wiring harness between pressure switch – Resis-
Max. 1 z
compressor clutch relay tance
1 Defective power supply a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
L80 Signal Voltage
Between (39), (40) – Constant power sup-
20 – 30 V
(37) and (38) ply
a Turn the starting switch ON, then carry out troubleshooting.
2 Defective communication LED (2) Normal state
LED-A2 ON
a Turn the starting switch ON, then start engine and carry out trou-
bleshooting.
LED (6) Normal state
LED-C1 ON
Defective starting switch a Prepare with starting switch OFF, then start engine and carry out
3 ACC signal and alternator R troubleshooting.
signal L80 Signal Voltage
Possible Between (36) and
causes and Starting switch ACC 20 – 30 V
(37), (38)
standard value
Between (28) – (37),
in normal state Alternator R 20 – 30 V
(38)
a Turn the starting switch ON, then carry out troubleshooting.
LED (8) Normal state
During cranking: Blinking
LED-C3
Other than above: OFF
a Prepare with starting switch OFF, then turn starting switch ON
Defective starting switch C and carry out troubleshooting.
4
signal L80 Signal Voltage
Between (10) and (9) S-NET 6–9V
During cranking:
Between (27) and 20 – 30 V
Starting switch C
(37), (38) Other than above:
Max. 1 V
a Turn the starting switch ON, and carry out troubleshooting.
LED (9) Normal state
LED-C4 ON
Defective CAN connection
5 a Prepare with starting switch OFF, then carry out troubleshooting
state
without turning starting switch ON.
L80 (female) Signal Resistance
Between (7) and (8) CAN 40 – 80 z
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
40-400 76
SEN03849-00
WHEEL LOADER
WA250-6
WA250PZ-6
40 Troubleshooting 40
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
This troubleshooting chart determines the location from the problem occurring on the machine and catego-
rizes the problem under one of the main components, such as the steering system or work equipment
hydraulic system. Use the following procedure to carry out accurate troubleshooting swiftly.
3. Operate the machine and carry out trouble- 6. Repeat the operation in Steps 3, 4, and 5 until
shooting of the items not checked in Step 1. the cause is narrowed down to 1 item (1 com-
Operate the machine in the same way as in mon item).
Step 1, and if any problem occurs, put a check a If cause items are 2 or more, continue until
against the item. (In Troubleshooting item 5 in number of items becomes minimum.
the d ia gr am b elo w, the p rob lem w as re -
enacted.) 7. Remedy
After narrowing down the common causes,
4. Find the matching cause in the Cause column. take the action given in the remedy line.
In the same way as in Step 2), if a problem is Marks and remedies in remedy line
found, the Q marks on the same line for the ×: Replace E: Repair A: Adjust C: Clean
troubleshooting item are the causes. (In Diag-
nosis item 5 in the diagram below the cause is
(b) or (e).)
Inching valve
Motor body
Motor body
DA valve
Damper
(SOL a)
(SOL b)
valve
Failure Code
Does not travel forward or in reverse Q Q Q Q Q Q Q Q Q Q Q
Does not travel forward (reverse is normal) Q Q
The machine does not start at reverse (Forward is normal) Q Q
Speed is slow in both forward and reverse Q Q Q Q Q Q Q Q Q Q Q
HST related
or engine overheats)
fan
Q Q
Q Q Q
Q Q
Q Q Q
Clutch
Transfer
Work equipment and steering pump
Q
Q
Q
Brake pump
Q
Orbit-roll
Steering valve
Q
Q Q Q
Q Q Q
Priority valve
Q
Q
Q
Relief valve
Safety valve
Q Q Q
Steering cylinder
Q
Tire inflation pressure
Accumulator charge valve
Q Q Q Q Q Q
Brake valve
Slack adjuster
Q Q Q
Brake disc and plate
Axle
Brake piston
Wheel brake linkage
Main relief valve
Q
Q
Q
Q Q
Q Q
Q Q
Work equipment
control valve
Lift arm spool
Q
Bucket spool
Q
Q Q
Q Q
Q Q
Q
Suction valve
Q Q
Q
Q
Bucket cylinder
Q
Q
Q
Q
Q
Q
Q
Q
Q
Bypass valve
Q
Cushion valve
ECSS solenoid valve
Q Q
Accumulator
Q
SEN03849-00
Fan pump
Q Q Q
Fan motor
40-500
Charge valve
H-28
H-27
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-10
H-12
H-11
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
Troubleshooting No.
7
HST motor 2
HST motor 1
q
HST pump
Damper
o Breakage of HST pump and motor related
Others
equipment
q Was there any problem of not traveling before?
o Internal wear of HST pump and motor related
a b c d e f g h i j k l m n o
equipment, defective seal
Transfer
Damper
Clutch
E E E E E E E E E E E E E E E
Remedy
No. X X X X X X X X X X X X X X X
Diagnosis A
1 Does not travel forward or in reverse Q Q Q Q Q Q Q Q Q Q Q Q Q Q
2 Does not travel forward (reverse is normal) Q Q
3 Does not start at reverse (Forward is normal) Q Q
Does not travel forward or in reverse, motor makes sound of
4 Q Q Q
rotation
Clutch solenoid
Inching valve
appropriate?
Motor body
Motor body
Is the any external oil leak found around
DA valve
q
Clutch
the hydraulic piping, pump and motor?
E E E E E E E E E E E E E E E
Remedy X X X X X X X X X X X X X X X
No.
Diagnosis A
1 Travel speed is slow in both forward and reverse Q Q Q Q Q Q Q Q Q Q Q Q Q
The travel speed is slow at forward (Reverse is nor-
2 Q Q
mal)
The travel speed is slow at reverse (Forward is nor-
3 Q Q
mal)
Maximum travel speed in both forward and reverse
4 Q
is approx. 4 km/h
Maximum travel speed in both forward and reverse
5 Q
is approx. 18 km/h
Abnormal sound comes from motor in both forward
6 Q Q
and reverse when travel speed is 10 km/h or more
a When the travel speed is slow, carry out troubleshooting for Cause
H-2 first. HST HST HST
Others
pump motor 2 motor 1
a b c d e f g h i j
Motor body
Transfer
Clutch
E E E E E E E E E E
Remedy
No. X X X X X X X X X X
Diagnosis A
1 The traction force is weak in both forward and reverse Q Q Q Q Q Q Q Q Q
2 The traction force is weak at forward (Reverse is normal) Q
3 The traction force is weak at reverse (Forward is normal) Q
The traction force is weak in both forward and reverse, but maxi- Q Q Q
4
mum travel speed is reached the line.
a If the speed range switch and the monitor display do not match, check Cause
the electrical wiring. HST HST
a When the travel speed is slow, carry out troubleshooting for H-2 first. Others
motor 2 motor 1
a b c d
Clutch solenoid
Clutch
E E E E
Remedy
No. X X X X
Diagnosis
Priority valve
Spool
E E E E
Remedy
No. X X X X X X X
Diagnosis
1 Steering wheel does not turn in both directions (left and right) Q Q Q Q Q Q
2 In condition in Item 1, movement of work equipment is abnormal Q
3 In condition in Item 1, movement of work equipment is normal Q
4 Steering wheel turns only in one direction (left or right) Q Q Q
5 Steering wheel is heavy and does not turn Q Q Q Q
6 Oil pressure of steering circuit is low or there is no pressure Q
7 Emergency steering does not function in both directions (left and right) Q
a There is a close connection between the steering circuit and work equipment circuit, so if any abnormal-
ity is felt in the steering, check the operation of the work equipment also.
a If the steering pump is abnormal (broken), check the priority valve at the same time.
*1. This warning is given only when the emergency steering is installed.
Priority valve
q Is the any external oil leak found around the hydraulic piping,
valve and cylinder?
q Is there any gouging of center hinge pin bearing and steering
cylinder pin, bushing?
q Is the tire inflation pressure correct?
Relief valve
Spool
E E E E E E E
Remedy
No. X X X X X X X
Diagnosis A C C
1 Steering wheel is heavy when turned in both directions (left and right) Q Q Q Q Q
2 Steering wheel is heavy when turned in one direction (left and right) Q Q
Steering wheel is heavy particularly when engine is running at low Q Q Q Q
3
speed
4 Lift arm lifting speed is slow when engine is running at full speed Q Q
5 Steering wheel is heavy and there is jerking Q Q
6 Hydraulic oil overheats Q Q Q
7 Oil pressure of steering circuit is low or there is no pressure Q Q
8 Pressure rises in return piping of steering cylinder Q
Defect inside steering cylinder (inside surface of cylinder, piston seal, nut, bolt)
q Is there any variation in the tire inflation pressure?
q Is the steering wheel play correct?
E E E
Remedy
No. X X X X
Diagnosis
H-10 The brake does not work or does not work well 1
1 When the brake pedal is stepped on, only a little resistance is felt Q Q Q Q Q
2 When the brake pedal is stepped on, a strong resistance is felt Q Q
When the brake works, an abnormal noise occurs from the axle
3 Q Q
brake
When the four wheels are jacked up, the axle is placed on a table
4 and the brake is applied at the first forward speed, only a specific Q Q Q Q
wheel rotates
An airflow is observed in bleeding air from brake circuit, and the Q
5
brake returns to normal after the bleeding
6 Brake oil leaks abnormally from the axle during inspection Q
7 Much metal powders are mixed in the axle oil Q
The brake pedal leg-power and stroke are normal, but the brake
8 Q Q Q Q Q Q Q Q Q
does not work well
9 The brake does not work often when the engine is stopped Q Q Q Q Q Q
10 The accumulator is not charged, and a buzzer sounds Q Q Q
11 The brake works after some time lag Q Q Q
Remedy C E E E E E E
No. E X X X X X X X X X
Diagnosis
The bucket cannot operate and the lift arm cannot
1 Q Q Q Q Q Q Q Q
rise
2 The bucket operates but the lift arm cannot rise Q Q
The lift arm can rise without load but cannot rise
3 Q Q Q Q
when loaded
4 The hydraulic pump causes an abnormal noise Q Q Q Q
5 Large hydraulic drift of lift arm cylinder Q Q
When the engine is at full throttle, the steering opera-
6 Q Q
tion is heavy and slow
H-13 The lift arm moves slowly or the lift arm rising force is insufficient 1
Inspection before diagnosis Cause
q Is the stroke of the lift arm control lever appropri- Tank to Priority HST PPC Work equipment
Cylinder
ate? Pump valve pump valve valve
a b c d e f g h
Check of abnormality
H-14 When rising, the lift arm comes to move slowly at specific height 1
Cause
q Expansion of lift arm cylinder tube or damage inside
a For other abnormal phenomena during lift arm rise, see “H-13. The lift arm moves slowly or the lift arm
rising force is insufficient.”
H-15 The lift arm cylinder cannot hold down the bucket (The bucket
rises in the air) 1
See “H-13. The lift arm moves slowly or the lift arm rising force is insufficient.”
Cause
q Defective seat of suction valve on the lift arm cylinder rod side of work equipment valve
q Oil leak from lift arm cylinder piston seal
The bucket and the lift arm moves up and down as the topography goes in digging or leveling with the lift arm
control lever in the “HOLD” position.
a Frequent hydraulic drifts o The suction valve on the lift arm cylinder rod side is defective
H-18 When the control lever is switched from “HOLD” to “RAISE,” the
lift arm falls temporarily 1
Check of Phenomenon
q When the control lever is switched from “HOLD” to “RAISE” gradually at low idle of the engine, the lift
arm falls temporarily due to its own weight. When the control lever is completely set to “RAISE,” the lift
arm returns to normal.
Cause
q Improper adhesion of lift arm spool check valve of the work equipment valve
The HST charge pump (which is used as PPC pump, too) is defective
time (And where)?
q Was there the phenomenon that the bucket
worked slowly?
o Wear of parts or deformation of
C E E E E A
Remedy
No. E X X X X X X X X
Diagnosis
The lift arm cannot operate and the bucket can-
1 Q Q Q Q Q Q Q
not tilt back
The bucket can lift the machine but cannot tilt
2 back, or the lift arm operates but the bucket can- Q Q Q
not tilt back
The bucket can tilt back without load but cannot
3 Q Q Q
in digging or scooping up
4 The hydraulic pump causes an abnormal noise Q Q Q
5 Large hydraulic drift of bucket cylinder Q Q
When the engine is at full throttle, the steering
6 Q Q
operation is heavy and slow
Remedy C E E E E A E
No. E X X X X X X X X
Diagnosis
The lift arm rising force and speed are
1 abnormal, and the bucket tilting force and Q Q Q Q Q
speed are abnormal
The lift arm rising force and speed are nor-
2 mal, and the bucket tilting force and speed Q Q Q Q
are abnormal
When the oil temperature rises in item 1, the
3 Q Q
bucket speed becomes worse
The hydraulic pump is causing an abnormal Q Q
4
noise
5 Large hydraulic drift of bucket cylinder Q Q Q
The relief oil pressure from the relief valve of Q Q Q
6
the work equipment valves is low
The relief oil pressure from the relief valve of
7 Q
the work equipment valves is too high
Cause
q Expansion of bucket cylinder tube or damage inside
q For other abnormal phenomena during bucket operation, see “H-20. The bucket moves slowly or the tilt-
ing-back force is insufficient.”
See “H-20. The bucket moves slowly or the tilting-back force is insufficient.”
Cause
q Defective seat of suction valve on the bucket cylinder rod side of work equipment valve
q Oil leak from bucket cylinder piston seal
Check of Abnormality
q Refer to the criterion value table and check if the hydraulic drift of the bucket occurs often practically
Cause
q Oil leak in bucket cylinder
q Improper adhesion of safety valve (With suction valve) on the bottom side
q Improper oil tight of bucket spool
Cause
q Defective seal of bucket cylinder piston
q Defective operation of safety valve (With suction valve) on bucket cylinder rod side. For other abnormal
phenomena, refer to diagnoses for relevant abnormal phenomena.
H-25 When the control lever is switched from “HOLD” to “TILT,” the
bucket falls temporarily 1
Check of Phenomenon
q When the control lever is switched from “HOLD” to “TILT” gradually at low idle of the engine, the bucket
falls temporarily due to its own weight. When the control lever is completely set to “TILT,” the bucket
returns to normal.
Cause
q Improper adhesion of bucket spool check valve of the work equipment valve
H-26 The control levers of the lift arm and bucket do not move smoothly
and heavy 1
H-27 The ECSS does not operate and machine pitches and bounces 1
Malfunction of controller
proper type up to a proper level.
q Check that the ECSS switch is set properly.
Remedy
No. X X X X
Troubleshooting
Travel speed to start operation of ECSS (6 km/h) changes
1 Q Q
largely
2 ECSS does not work while machine is loaded Q Q
3 ECSS does not work while machine is empty Q Q
Lift arm lowers more than 30 cm at maximum when ECSS Q
4
operated while machine is loaded
5 ECSS does not work at all Q Q Q Q
Malfunction of controller
tank.
Check the hydraulic hoses, pump and motor for oil
Remedy C Note
No. E E E E E E E
Troubleshooting X X X X X X X X X
1 Fan speed is low (in fan 100% mode) Q Q Q Q Q Q
2 Fan hunts Q Q Q Q Q
3 Fan does not revolve Q Q Q Q
4 Fan always revolves in reverse Q Q Q
5 Fan does not revolve in reverse Q Q Q
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
40-500 28
SEN03850-00
WHEEL LOADER
WA250-6
WA250PZ-6
40 Troubleshooting 40
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, or w.
E : Causes to be referred to for questions and check items
Q : Causes related to questions and check items
w : Causes highly probable among ones marked with Q
a When narrowing the “causes“, apply the items marked with w before those marked with Q.
When narrowing the causes, do not apply the items marked with E. (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
If we look from these 3 symptoms to find the causes, we find that there is a relationship with 5 causes. Let us
explain here the method of using this causal relationship to pinpoint the most probable cause.
Defective injector
nomenon does not indicate a trouble, however.
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in display q
of code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change q
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
Replace
Replace
Replace
Replace
Correct
Remedy —
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Add
Remedy
c) Exhaust smoke comes out but engine does not start Causes
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
Black w Q w w
When engine is cranked, abnormal sound is generated around cylinder head w
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w
There is hunting from engine (rotation is irregular) Q Q Q
Blow-by gas is excessive w
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Remedy
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Clean
Add
Remedy
—
Remedy
(air leakage)
Confirm recent repair history
Degree of use of machine Operated for long period E E E E
Suddenly Q w Q Q Q Q
Questions
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Remedy
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Remedy
Turbocharger
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
See S-7
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy —
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in display of code q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q
Much fuel returns from the injector q
Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” in display
of code q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is in coolant Causes
Internal leakage in lubrication system
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Add
Remedy —
Replace
Replace
Replace
Correct
Remedy
Sudden overheated Q w Q
Condition overheating
Always tends to overheat Q Q w w Q
Rises quickly Q Q w
Coolant temperature gauge
Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level Q w
Engine oil level has risen, oil is milky w w Q
Fan belt tension is low w
When fan pulley is turned, it has play w
Milky oil is floating on coolant Q Q w
There are excessive air bubbles in radiator, coolant spurts back w
Check items
When light bulb is held behind radiator core, no light passes through w
Radiator shroud, inside of underguard are clogged with dirt or mud w w
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Power train oil temperature enters red range faster than engine coolant w
temperature
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Add
Remedy —
Gradually occurred Q Q
Condition of abnormal noise
Suddenly occurred Q Q Q
Non-specified fuel is being used Q
Oil must be added more frequently w
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, interference sound is generated around turbocharger w
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is generated around muffler w
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Remedy
Replace
Replace
Replace
Adjust
Remedy
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
40-600 24
SEN03851-01
WHEEL LOADER
WA250-6
WA250PZ-6
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
•Quick-setting adhesive.
•Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
LG-6 790-129-9160 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
Gasket sealant
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
LG-10 • Used as lubricant/sealant when the radiator
ThreeBond 790-129-9320 200 g Tube hoses are inserted.
Gasket sealant
• Spray type
• Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
— 09995-00250 190 g Can
ing each other.
• Applicable for the propeller shaft splines, needle
bearings, pins and bolts of various links, etc.
• Feature: Seizure and scuffing prevention com-
prevention
compound
Seizure
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
a Tools with part number 79QT-QQQ-QQQQ can not be supplied (they are items to be locally manufac-
tured).
a Necessity : t ........ Cannot be substituted, should always be installed (used)
: q ........ Extremely useful if available or can be substituted with commercially avail-
able part
a New/remodel: : N......... Tools with new part numbers, newly developed for this model
: R......... Tools with upgraded part numbers, remodeled from items already avail-
able for other models
: Blank .. Tools already available for other models, can be used without any modifi-
cation
a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See
Sketches of special tools).
New/Remodel
Necessity
Sketch
Q'ty
Component Symbol Part No. Part name Nature of work, remarks
New/Remodel
Necessity
Sketch
Q'ty
Component Symbol Part No. Part name Nature of work, remarks
New/Remodel
Necessity
Sketch
Q'ty
Component Symbol Part No. Part name Nature of work, remarks
New/Remodel
Necessity
Sketch
Q'ty
Component Symbol Part No. Part name Nature of work, remarks
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
D2 Push tool
9JF00891
D4 Push tool
9JF00892
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
COW16161
9JF00902
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
H1 Push tool
9JF00893
H1 Push tool
9JF00894
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
H2 Seal support
9JF00896
H2 Seal support
9JF00895
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
H3 Push tool
9JF00899
H4 Holder
9JF00897
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
H8 Push tool
COW16159
9JF00898
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
9JF00901
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
H22 Plate
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
©2009 KOMATSU
All Rights Reserved
Printed in Japan 06-09
50-100 20
SEN03852-00
WHEEL LOADER
WA250-6
WA250PZ-6
Removal and installation of fuel 5. Disconnect fuel return hose (7) from fuel sup-
supply pump assembly 1
ply pump (4).
a If mud is sticking, lock (L) may become
Removal stiff. Accordingly, clean the connecting
k Stop the machine on a level ground and set area.
the lock bar to the frame to fix the front and a Press lock (L) from both sides and pull out
rear frames. hose (5).
k Lower the work equipment to the ground, a Plug the disconnected hose to prevent
stop the engine, apply the parking brake, fuel leakage.
and put chocks under the tires.
k Disconnect the cable from the negative (–)
terminal of the battery.
2. Remove fuel prefilter and bracket assembly 8. Disconnect fuel high-pressure pipe (10) from
(2). fuel supply pump (4). [*2]
a Fix fuel prefilter and bracket assembly (2) a Remove the boot on the common rail side
to the machine with ropes. of high-pressure pipe (10) and loosen the
sleeve nut.
[*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 mount-
ing stud bolts (14) to replace the existing ones,
apply LOCTITE (LT-2) to them.
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 Bleeding air
Bleed air from the fuel system. For details, see
Testing and adjusting, "Bleeding air from fuel
system".
Removal and installation of fuel 4. Disconnect engine intake air heater wiring har-
injector assembly 1
ness terminal CN-E07B (3). [*1]
New/Remodel
6. Remove clamp (5), air hose (5a), mounting
Necessity
Sketch
bolt (6a) and intake air inlet elbow (6). [*3]
Q'ty
Symbol Part No. Part name
a Remove the engine intake air heater, too.
3 795-799-6700 Puller t 1
A 4 795-799-1131 Gear t 1
5 795-799-8150 Remover q 1
Removal
k Stop the machine on a level ground and set
the lock bar to the frame to fix the front and
rear frames.
k Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires.
k Disconnect the cable from the negative (–) 7. Remove 2 wiring harness clamps (7).
terminal of the battery.
k If the radiator coolant temperature is high, 8. Disconnect wiring harness connector (8).
you may scald yourself with the hot cool- a While pressing the lock of wiring harness
ant. Wait until the coolant is cooled, and connector (8) with flat-head screwdriver
then drain the coolant. [1], pull the connector in the direction of
the arrow.
1. Loosen the radiator cap to drain the coolant. a Do not remove fuel pressure sensor (PS)
6 Radiator: Approx. 22 l except for replacement.
15. Remove the 12 mounting bolts and rocker arm 17. Remove retaining nuts (21) and 6 inlet connec-
(17). tors (22).
a Loosen locknut (18), and then loosen a Before removing, clean the inlet connec-
adjustment screw (19) by 2 – 3 turns so tors carefully so that mud, etc. sticking
that an excessive force will not be applied around them will not enter their holes.
to the push rod when the rocker arm is a Tool A5 is set for removal of inlet connec-
installed. tor (22). (See the special tools list.)
16. Remove 12 crossheads (20). 18. Remove 2 wiring harness mounting nuts (24)
a Record the positions and shapes of holes from fuel injector assembly (23).
(a) and (b) of each crosshead. (Reinstall
Wiring harness
each crosshead in the same direction.) Cylinder No.
color
White 1, 3, 5
Black 2, 4, 6
4) Insert fuel injector (23) in the cylinder 9) Secure inlet connector (22) by tightening
head, directing its fuel inlet hole toward retaining nut (21) lightly.
the air intake manifold. 3 Retaining nut (21):
5) Tighten 2 mounting bolts (25) of fuel injec- 15 ± 5 Nm {1.5 ± 0.5 kgm}
tor (23) by 3 – 4 turns. 10) Tighten 2 mounting bolts (25) of fuel injec-
tor (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}
q Precautions for installing inlet connector 2. Crosshead and rocker arm assembly
1) When replacing the fuel injector assembly 1) Install the crosshead and rocker arm.
with new one, be sure to replace inlet con- a The shapes of holes (a) and (b) of
nector, too. each crosshead are different. Accord-
2) Check the inlet connector visually. If it has ingly, when reusing the crossheads,
any of the following faults, replace it. install each of them to the same
1] There is a bur or a worn part at front intake/exhaust valve in the same
end (a) or rear end (b) of the inlet direction as it has been installed.
connector. 2) Check that the ball of adjustment screw
2] There is foreign matter in the edge fil- (19) is set in the push rod socket securely
ter at rear end (c) of the inlet connec- and then tighten mounting bolts (30).
tor. 3 Rocker arm mounting bolt (30):
3] The O-ring at upper part (d) of the 36 ± 5 Nm {3.7 ± 0.5 kgm}
inlet connector is cracked or deterio- 3) Adjust the valve clearance. For details,
rated. see Testing and adjusting, "Adjusting
valve clearance".
3 Locknut (18):
24 ± 4 {2.4 ± 0.4 kgm}
q Carry out the following installation in the 1) Temporarily install fuel high-pressure
reverse order to removal. pipes (31) – (36).
3 Sleeve nut:
[*1] 0.2 – 0.8 Nm {0.02 – 0.08 kgm}
3 Wiring harness terminal CN-E07B (3): 2) Tighten fuel high-pressure pipes (31) –
4.0 ± 0.6 Nm {0.41 ± 0.06 kgm} (36) in the following order.
1] Tighten the cylinder head side of fuel
[*2] high-pressure pipes (31) and (36).
3 Clamp (4): 10.8 – 26.5 Nm {1.1 – 2.7 kgm} 2] Tighten the common rail side of fuel
high-pressure pipes (31) and (36).
[*3] 3] Tighten the cylinder head side of fuel
3 Clamp (5): 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} high-pressure pipes (32), (33), (34)
3 Intake air inlet elbow mounting bolt (6a): and (35).
24 ± 4 Nm {2.4 ± 0.4 kgm} 4] Tighten the common rail side of fuel
high-pressure pipes (32), (33), (34)
[*4] and (35).
k Install each fuel high-pressure pipe and 3 Sleeve nut:
wiring harness at least 10 mm apart from 35 ± 3.5 Nm {3.6 ± 0.4 kgm}
each other. 3) Install 6 boots (14) to the fuel high-pres-
sure pipes.
[*5] a Direct the slit of the boot out and
3 Blow-by duct mounting bolt: down.
7 ± 2 Nm {0.7 ± 0.2 kgm} a The boots are installed so that fuel
will not spout over the hot parts of the
[*6] engine to catch fire when it leaks for
3 Cylinder head cover mounting nut (12): some reason.
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-pres-
sure pipe clamps and observe the tighten-
ing 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".
Removal and installation of 4. Disconnect engine intake air heater wiring har-
cylinder head assembly 1
ness terminal CN-E07B (3). [*1]
New/Remodel
6. Remove clamp (5), air hose (5a), and intake air
Necessity
Sketch
inlet elbow (6). [*3]
Q'ty
Symbol Part No. Part name
a Remove the engine intake air heater, too.
3 795-799-6700 Puller t 1
4 795-799-1131 Gear t 1
A 5 795-799-8150 Remover q 1
6 790-331-1120 Wrench (angle) q 1
7 795-790-4510 Gauge q 1
Removal
k Stop the machine on a level ground and set
the lock bar to the frame to fix the front and
rear frames.
k Lower the work equipment to the ground,
stop the engine, apply the parking brake, 7. Remove bracket (7).
and put chocks under the tires.
k Disconnect the cable from the negative (–) 8. Remove wiring harness clamp (8).
terminal of the battery.
k If the radiator coolant temperature is high, 9. Disconnect wiring harness connector (9).
you may scald yourself with the hot cool-
ant. Wait until the coolant is cooled, and 10. Remove air conditioner compressor assembly
then drain the coolant. (10). [*4]
a Fix air conditioner compressor assembly
1. Loosen the radiator cap to drain the coolant. (10) to the machine with ropes.
6 Radiator: Approx. 22 l
15. Remove fuel filter and bracket assembly (16). 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.
23. Disconnect fuel drain hose (25). [*6] 31. Remove corrosion resistor and bracket assem-
bly (33).
24. Disconnect high-pressure pipe (26). [*7]
32. Remove wiring harness clamp (34). 38. Remove alternator assembly (39).
39. Disconnect turbocharger lubricating oil inlet 44. Using hexagonal wrench (width across flats: 3
tube (42) and drain hose (43). [*12] mm), remove blow-by duct (47). [*14]
47. Remove the 12 mounting bolts and rocker arm 49. Remove retaining nuts (55) and 6 inlet connec-
(51). tors (56).
a Loosen locknut (52), and then loosen a Before removing, clean the inlet connec-
adjustment screw (53) by 2 – 3 turns so tors carefully so that mud, etc. sticking
that an excessive force will not be applied around them will not enter their holes.
to the push rod when the rocker arm is a Tool A5 is set for removal of inlet connec-
installed. tor (55). (See the special tools list.)
48. Remove 12 crossheads (54). 50. Remove 2 wiring harness mounting nuts (58)
a Record the positions and shapes of holes from fuel injector assembly (57).
(a) and (b) of each crosshead. (Reinstall
Wiring harness
each crosshead in the same direction.) Cylinder No.
color
White 1, 3, 5
Black 2, 4, 6
51. Remove 2 mounting bolts (59) of fuel injector 55. Remove 26 mounting bolts (63) and lift off cyl-
assembly (57). inder head assembly (64).
4 Cylinder head assembly: 75 kg
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.
q When not using angle tightening tool 4) Install rocker housing (62).
4] After steps 1] and 2], make marks on the 3 Rocker housing mounting bolt (61):
cylinder head and each bolt with a marker. 24 ± 4 Nm {2.4 ± 0.4 kgm}
5] Tighten the bolt by 90 ± 5°. 5) Install push rods (60).
8) Apply engine oil (For details, see "Table of 14) Install the wiring harnesses to fuel injector
fuel, coolant and lubricants") to the mount- (57) and tighten 2 mounting nuts (58).
ing hole of inlet connector (56) on the cyl- 3 Wiring harness mounting nut (58):
inder head side. 1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}
9) Apply engine oil (For details, see "Table of a Installed positions of wiring har-
fuel, coolant and lubricants") to O-ring (69) nesses
of inlet connector (56).
Wiring harness
10) Insert inlet connector (56) perfectly, while Cylinder No.
color
setting part (B) to the groove on the cylin-
der head side. White 1, 3, 5
Black 2, 4, 6
q Precautions for installing inlet connector 3. Crosshead and rocker arm assembly
1) When replacing the fuel injector assembly 1) Install the crosshead and rocker arm.
with new one, be sure to replace inlet con- a The shapes of holes (a) and (b) of
nector, too. each crosshead are different. Accord-
2) Check the inlet connector visually. If it has ingly, when reusing the crossheads,
any of the following faults, replace it. install each of them to the same
1] There is a bur or a worn part at front intake/exhaust valve in the same
end (a) or rear end (b) of the inlet direction as it has been installed.
connector. 2) Check that the ball of adjustment screw
2] There is foreign matter in the edge fil- (71) is set in the push rod socket securely
ter at rear end (c) of the inlet connec- and then tighten mounting bolts (72).
tor. 3 Rocker arm mounting bolt (72):
3] The O-ring at upper part (d) of the 36 ± 5 Nm {3.7 ± 0.5 kgm}
inlet connector is cracked or deterio- 3) Adjust the valve clearance. For details,
rated. see Testing and adjusting, "Adjusting
valve clearance".
3 Locknut (70):
24 ± 4 {2.4 ± 0.4 kgm}
q Carry out the following installation in the 1) Temporarily install fuel high-pressure
reverse order to removal. pipes (73) – (78).
3 Sleeve nut:
[*1] 0.2 – 0.8 Nm {0.02 – 0.08 kgm}
3 Wiring harness terminal CN-E07B (3): 2) Tighten fuel high-pressure pipes (73) –
4.0 ± 0.6 Nm {0.41 ± 0.06 kgm} (78) in the following order.
1] Tighten the cylinder head side of fuel
[*2] high-pressure pipes (73) and (78).
3 Clamp (4): 10.8 – 26.5 Nm {1.1 – 2.7 kgm} 2] Tighten the common rail side of fuel
high-pressure pipes (73) and (78).
[*3] 3] Tighten the cylinder head side of fuel
3 Clamp (5): 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} high-pressure pipes (74), (75), (76)
3 Intake air inlet elbow mounting bolt (6a): and (77).
24 ± 4 Nm {2.4 ± 0.4 kgm} 4] Tighten the common rail side of fuel
high-pressure pipes (74), (75), (76)
[*4] and (77).
Adjust the air conditioner compressor belt tension. 5] Tighten the pump side of high-pres-
For details, see "Adjusting air conditioner compres- sure pipe (26) and then tighten the
sor belt tension". common rail side.
3 Sleeve nut:
[*5] 35 ± 3.5 Nm {3.6 ± 0.4 kgm}
k Install each fuel high-pressure pipe and 3) Install 6 boots (27) to the fuel high-pres-
wiring harness at least 10 mm apart from sure pipes.
each other. a Direct the slit of the boot out and
down.
[*6], [*7], [*8], [*9] a The boots are installed so that fuel
k Do not bend the fuel high-pressure pipe to will not spout over the hot parts of the
correct before installing. engine to catch fire when it leaks for
k Be sure to use the genuine fuel high-pres- some reason.
sure pipe clamps and observe the tighten- 4) Install fuel drain hose (25).
ing torque. 3 Joint bolt:
a If the taper seal area of the fuel high-pressure 24 ± 4 Nm {2.4 ± 0.4 kgm}
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.
[*10]
2 Radiator upper hose insertion area:
Gasket sealant
(THREEBOND 1206E or equivalent)
3 Radiator upper hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*11]
3 Air aftercooler upper hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*12]
3 Mounting bolt of turbocharger lubricating oil
inlet tube (42): 35 ± 5 Nm {3.5 ± 0.5 kgm}
3 Mounting bolt of turbocharger lubricating oil
outlet hose (43): 24 ± 4 Nm {2.4 ± 0.4 kgm}
[*13]
q Tighten the exhaust manifold mounting bolts
according to the following procedure.
3 Exhaust manifold mounting bolts
1st time: Tighten [1] – [12] to 24 ± 4 Nm {2.4
± 0.4 kgm} in order.
2nd time:Tighten [1] – [12] to 53 ± 6 Nm {5.4
± 0.6 kgm} in order.
3rd time: Tighten only [1] – [4] to 53 ± 6 Nm
{5.4 ± 0.6 kgm} in order.
[*14]
3 Blow-by duct mounting bolt:
7 ± 2 Nm {0.7 ± 0.2 kgm}
[*15]
3 Cylinder head cover mounting nut (48):
24 ± 4 Nm {2.4 ± 0.4 kgm}
q Bleeding air
Bleed air from the fuel system. For details, see
Testing and adjusting, "Bleeding air from fuel
system".
8. Disconnect 2 washer hoses (11) from part (a). 12. Remove 2 heat insulation sheet fixing plates
(14).
[*1]
3 Hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
Removal and installation of 4. Remove right and left stays (3), (4) and (5).
radiator 1
5. Remove 2 heat insulation plates (6).
Removal a Remove all the wiring harness clamps and
k Stop the machine on a level ground and set hose clamps installed to heat insulation
the lock bar to the frame to fix the front and plates (6).
rear frames.
k Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires.
k Disconnect the cable from the negative (–)
terminal of the battery.
k If the radiator coolant temperature is high,
you may scald yourself with the hot cool-
ant. Wait until the coolant is cooled, and
then drain the coolant.
8. Remove 3 hose clamps (8). 13. Remove 2 mounting bolts (15) and fix cooling
fan and fan motor assembly (16) open.
9. Remove air conditioner receiver tank and a Check that the cooling fan and fan motor
bracket assembly (9). [*3] assembly is locked securely.
[*5]
a Fit grommet (23) to the mounting hole.
a Check that projection (A) of the radiator is fit-
ted to grommet.
a When installing the radiator, set drain hose
(24) in mounting hole (B) securely.
Installation
q Carry out installation in the reverse order to
removal.
[*1]
3 Air aftercooler upper hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*2]
2 Radiator upper hose insertion area: q Refilling with coolant
Gasket sealant Add coolant through the coolant filler to the
(THREEBOND 1206E or equivalent) specified level. Run the engine to circulate the
3 Radiator upper hose clamp: coolant through the system. Then, check the
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} coolant level again.
5 Total amount of coolant: Approx. 22 l
[*3]
3 Air conditioner receiver tank mounting U- (For details, see "Table of fuel, coolant and
clamp: 10.8 – 26.0 Nm {1.1 – 2.7 kgm} lubricants")
Removal and installation of air 4. Remove upper 2 air aftercooler mounting bolts
aftercooler 1
(2).
Removal
k Stop the machine on a level ground and set
the lock bar to the frame to fix the front and
rear frames.
k Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires.
k Disconnect the cable from the negative (–)
terminal of the battery.
k If the radiator coolant temperature is high,
you may scald yourself with the hot cool-
ant. Wait until the coolant is cooled, and
then drain the coolant.
5. Remove air aftercooler (3) from the left side.
1. Loosen the radiator cap to drain the coolant. [*2]
a When removing the air aftercooler, take
6 Radiator: Approx. 22 l
care not to damage it.
Installation
q Carry out installation in the reverse order to
removal.
[*1]
3 Air aftercooler lower hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*2]
a Fit grommet (4) to the mounting hole.
a Check that projection (A) of the radiator is fit-
ted to grommet (4).
Removal and installation of 4. Disconnect hydraulic oil cooler lower hose (2).
hydraulic oil cooler assembly 1
a Plug the disconnected hose to prevent oil
leakage.
Removal
k Stop the machine on a level ground and set
the lock bar to the frame to fix the front and
rear frames.
k Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires.
k Disconnect the cable from the negative (–)
terminal of the battery.
k If the radiator coolant temperature is high,
you may scald yourself with the hot cool-
ant. Wait until the coolant is cooled, and
then drain the coolant.
1. Loosen the radiator cap to drain the coolant. 5. Remove upper 2 hydraulic oil cooler mounting
bolts (3).
6 Radiator: Approx. 22 l
2. Remove the engine hood. For details, see 6. Disconnect alternator wiring harness terminals
"Removal and installation of engine hood". CN-E02 (4) and CN-E03 (5).
9. Disconnect starting motor wiring harness con- 17. Disconnect engine intake air heater wiring har-
nector CN-E01 (8). ness terminal CN-E07B (16). [*2]
13. Remove hose clamp (12). 20. Disconnect connectors CN-EC2 (20) and CN-
EC3 (21).
14. Disconnect heater inlet hose (13).
22. Disconnect air conditioner compressor con- 26. Remove 2 wiring harness clamps (27).
nector CN-E10 (23).
a Move the engine wiring harness toward 27. Remove hose clamp (28).
the frame so that it will not interfere with
the other parts.
23. Remove hose clamp (24). 29. Remove 2 heat insulation plates (30).
32. Disconnect air aftercooler lower hose (33). 36. Remove 12 damper cover mounting bolts (37).
[*6] [*9]
a Do not remove HST pump mounting bolts
33. Disconnect radiator lower hose (34). [*7] (38) to disconnect the HST pump. If the
HST pump is disconnected from the
engine assembly, you cannot see if the
gears are meshed when installing the
engine assembly and the damper may be
damaged consequently.
35. Place bars [1] and [2] over the frame. Using
lever blocks [3] and [4], sling HST pump
assembly (36) temporarily.
[*2]
3 Wiring harness terminal CN-E07B (16):
4.0 ± 0.6 Nm {0.41 ± 0.06 kgm}
[*3]
3 Wiring harness connector mounting bolt:
3 ± 0.1 Nm {0.31 ± 0.01 kgm}
[*4]
3 Air aftercooler upper hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*5]
41. Lift up engine assembly (42) a little and move it 2 Radiator upper hose:
toward the rear of the machine to disconnect it Gasket sealant
from the HST pump assembly. [*13]. (THREEBOND 1206E or equivalent)
3 Radiator upper hose clamp:
42. Lift off engine assembly (42). 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
a Check that all the electric wiring and
hydraulic piping are disconnected. [*6]
a When removing the engine, take care that 3 Air aftercooler lower hose clamp:
it will not interfere with the radiator, air 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
aftercooler and hydraulic oil cooler.
[*7]
4 Engine assembly: 650 kg 2 Radiator lower hose:
Gasket sealant
(THREEBOND 1206E or equivalent)
3 Radiator lower hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*8]
Adjust the air conditioner compressor belt tension.
For details, see "Adjusting air conditioner compres-
sor belt tension".
[*9]
2 Damper cover mating face:
Gasket sealant (LG-6)
3 Damper cover mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
[*10]
3 Right and left engine mounting bolts (39) at
rear of machine:
245 – 308.9 Nm {25.0 – 31.5 kgm}
[*11]
3 Right and left engine mounting bolts (40) at
front of machine:
245 – 308.9 Nm {25.0 – 31.5 kgm}
[*12]
3 Right and left engine mount bracket mount-
ing bolts (41a) at front of machine:
98 – 123 Nm {10.0 – 12.5 kgm}
a Adjust clearances (a) and (b) of right and left
engine mount adjustment bolts (41b) and (41c)
at front of machine to the following dimensions
and lock the adjustment bolts.
Clearance (a): 2 mm
Clearance (b): 2 mm
q Bleeding air
Bleed air from the fuel system. For details, see
Testing and adjusting, "Bleeding air from fuel
system".
Removal and installation of 2. Remove right and left stays (2), (3) and (4).
engine front oil seal assembly 1
3. Remove 2 heat insulation plates (5).
Special tools a Remove all the wiring harness clamps and
hose clamps installed to heat insulation
New/Remodel
plates (5).
Necessity
Sketch
Q'ty
Symbol Part No. Part name
Removal
k Stop the machine on a level ground and set
the lock bar to the frame to fix the front and
rear frames.
k Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires. 4. Remove cover (6).
k Disconnect the cable from the negative (–)
terminal of the battery.
5. Put the wrench [1] in part (A) (width across 6. Remove 6 mounting bolts (9) and vibration
flats: 12.7 mm) of tensioner assembly (7) and damper (10).
turn it in the unwinding direction to decrease
the tension of fan belt (8).
k Set the wrench [1] securely to part (A)
of tensioner assembly (7) before turn-
ing it. (The spring of tensioner assem-
bly (7) is strong. If the wrench [1] is set
incompletely and turned, it comes off
and that is very dangerous.)
k After removing belt (8), return ten-
sioner assembly (7) slowly and care-
fully.
k Take care not to catch your finger
between the pulley and fan belt (8) dur-
ing work.
7. Remove engine front oil seal (11).
Removal and installation of 5. Install eyebolt [1] to the damper mounting bolt
engine rear oil seal assembly 1
hole and sling flywheel assembly (4).
New/Remodel
Necessity
Sketch
7. Remove other 6 mounting bolts (3) and lift off
Q'ty
Symbol Part No. Part name
flywheel assembly (4). [*2]
4 Flywheel assembly: 45 kg
A 2 795-799-6500 Seal puller t 1
Removal
k Stop the machine on a level ground and set
the lock bar to the frame to fix the front and
rear frames.
k Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires.
k Disconnect the cable from the negative (–)
terminal of the battery.
k If the radiator coolant temperature is high,
you may scald yourself with the hot cool-
ant. Wait until the coolant is cooled, and
then drain the coolant. 8. Engine rear oil seal
1) Install tool A2 to the crankshaft.
1. Loosen the radiator cap to drain the coolant. 2) Tighten tapping screw [3] of tool A2 into
the seal carrier of engine rear oil seal (5).
6 Radiator: Approx. 22 l 3) Rotate the wrench handle clockwise to
remove engine rear oil seal (5).
2. Remove the engine hood assembly. For
details, see "Removal and installation of
engine hood assembly".
Installation
q Measuring runout
a Radial runout: Max. 0.13 mm
1) Install the stand to dial gauge [6] and
install them to flywheel housing [7].
2) Set the dial gauge so that its probe will be
perpendicular to spigot portion (b) or
periphery of the flywheel.
3) Rotate the flywheel by 1 turn and measure q Bleeding air
the difference between the lowest and Bleed air from the fuel system. For details, see
highest values indicated by the dial gauge. Testing and adjusting, "Bleeding air from fuel
a After rotating the flywheel by 1 turn, system".
check that the dial gauge indicates
the value at the start of rotation. 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 Total amount of coolant: Approx. 22 l
(For details, see "Table of fuel, coolant and
lubricants")
Removal and installation of 4. Remove 3 fuel tank breather hose clamps (4a).
cooling fan and fan motor
5. Remove clip (4b) and disconnect hose (4c)
assembly 1
from breather (4d).
Special tools
6. Remove breather (4d).
New/Remodel
Necessity
Sketch
Sym-
Q'ty
Part No. Part name
bol
A 8 791-415-2002 Remover t 1
Removal
k Stop the machine on a level ground and set
the lock bar to the frame to fix the front and
rear frames.
k Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires.
k Disconnect the cable from the negative (–) 7. Remove 2 wiring harness clamps (5).
terminal of the battery.
8. Disconnect wiring harness connectors CN-R59
1. Open radiator grille (1). (6) and CN-R29 (7).
12. Move the lock portion of stopper link (15) to 16. Remove fan guard (23) from shroud (22).
hole (A) of bracket (16) to remove it from the
bracket.
Installation [*4]
q Carry out installation in the reverse order to a Before installing fan motor assembly (28), add
removal. hydraulic oil (for details, see "Table of fuel,
coolant and lubricants") until it flows over plug
[*1] (29) mounting hole and then install the plug.
a Adjust clearances (a) – (d) between the side of
the shroud and end of the fan ring as follows.
Clearance (a) : 7.5 mm
Clearance (b) : 15.5 mm
Clearance (c) : 15.5 mm
Clearance (d) : 15.5 mm
[*3]
a Check that key (30) is fitted securely to the key
way on the shaft of fan motor assembly (28).
a When installing cooling fan assembly (21), set
its key way to key (30).
Removal and installation of fuel 6. Remove 3 breather hose clamps (5a) of the
tank assembly 1
fuel tank.
11. Remove power train oil cooler hose clamps 15. Remove fuel tank rear mounting bolt (15) from
(10) and (11) under the front of the radiator. the counterweight bottom. [*2]
12. Remove hydraulic oil cooler hose clamps (12) 16. Lower transmission jack [1] gradually and
and (13) under the front of the hydraulic oil remove fuel tank assembly (16).
cooler. a Take care extremely that the fuel tank will
not come off the transmission jack.
4 Fuel tank assembly:
90 kg (excluding fuel)
[*1], [*2]
3 Fuel tank mounting bolts (14) and (15):
245 – 309 Nm {25.0 – 31.5 kgm}
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
50-200 52
SEN03853-00
WHEEL LOADER
WA250-6
WA250PZ-6
Removal and installation of 5. Remove the cover at the rear of the left ladder
transfer assembly 1
and disconnect HST motor 1 drain hose (1)
and charge valve drain hose (2).
Removal
k Stop the machine on a level ground and set
the lock bar to the frame to fix the front and
rear frames.
k Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires.
k Operate the work equipment control lever 2
– 3 times to release the residual pressure in
the work equipment circuit.
k Press the brake pedal at least 100 times to
release the residual pressure in the brake
accumulator circuit.
k Disconnect the cable from the negative (–)
terminal of the battery. 6. Remove the cover at the rear of the right lad-
der and disconnect HST motor 2 drain hose
q Precautions for handling refrigerant (3).
k Collect refrigerant (R134a) beforehand.
a Ask professional traders for collecting
and filling the refrigerant (R134a).
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant (R134a) gets inside
ones eyes, it may cause blindness.
Therefore, make sure to wear protec-
tive glasses when collecting or filling
the refrigerant. Collecting and filling
work must be conducted by a qualified
person.
k If the radiator coolant temperature is
high, you may scald yourself with the
hot coolant when disconnecting the 7. Remove 2 hose clamps (4).
heater hoses and draining the coolant.
Wait until the coolant is cooled, and 8. Disconnect hose (5).
then drain the coolant.
9. Disconnect hose (6) and remove PPC accu-
1. Recover the refrigerant (R134a). [*1] mulator and bracket assembly (7).
a Fix PPC accumulator and bracket assem-
2. Loosen the radiator cap to drain the coolant. bly (7) to the machine with ropes.
6 Radiator: 22 l
10. Disconnect brake strainer hose (8). 13. Remove parking brake cable clamp and
bracket assembly (11) in the left frame.
[*1]
a When installing the hoses of the air conditioner
circuit, take care that dirt, dust, water, etc. will
not enter them.
a When installing each air conditioner hose,
check that O-ring (70) is fitted to it.
a Check O-ring (70) for a flaw and deterioration.
a When connecting each refrigerant pipe, apply
compressor oil for new refrigerant (R134a)
(DENSO: ND-OIL8 or ZEXEL ZXL100PT
(equivalent to PAG46) to O-ring (70).
19. Remove right and left transfer mounting bolts 3 Threaded part of hose (M16 × 1.5):
(16). [*5] 12 – 15 Nm {1.2 – 1.5 kgm}
[*2], [*3]
3 Drive shaft mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
[*4]
3 Transfer cushion mounting bolt:
M10 bolt: 59 – 74 Nm {6.0 – 7.5 kgm}
M12 bolt: 98 – 123 Nm {10.0 – 12.5 kgm}
[*5]
3 Transfer mount mounting bolt:
610 – 765 Nm {62.5 – 78.0 kgm}
Special tools
New/Remodel
Necessity
Sketch
Q'ty
Symbol Part No. Part name
1 790-201-2840 Spacer t 1
2 793T-417-1110 Push tool t 1 Q
790-101-5201 Push took kit t 1
790-101-5311 • Plate 1
3 3) Disconnect the following wiring harness
790-101-5221 • Grip 1
connectors from the brake accumulator.
01010-51225 • Bolt 1
q (4a): CN-T11
793T-417-1120 Push tool t 1 Q q (4b): CN-T07
4 790-101-5221 Grip t 1 q (4c): CN-T06
01010-81225 Bolt t 1 q (4d): CN-T10
5 799-301-1500 Oil leak tester t 1
8 790-201-3260 Bolt (12 x 1.75 mm) q 2
9 790-102-2900 Puller q 1
10 792-735-2420 Collar t 1
D 11 790-101-2501 Puller q 1
12 790-201-1320 Spacer t 1
13 799-101-3101 Bearing puller q 1
14 793T-417-1130 Push tool t 1 N Q
15 790-101-3501 Gear puller q 1
16 790-101-3401 Bearing puller q 1
17 79G-17L-1000 Bar t 1
18 795-100-1291 Sleeve driver t 1
19 796-430-1110 Push tool t 1 4) Disconnect the following wiring harness
20 790-470-1410 Collar t 1 connectors.
q (4e): CN-T05
21 796-667-1310 Collar t 1
q (4f): CN-T18
22 791-126-0130 Push tool t 1
q (4g): CN-T15A
Commercially
23 available Torque wrench q 1
Disassembly
1. Draining transfer oil
6 Transfer case: Approx. 5 l
2. Related parts
1) Disconnect speed sensor wiring harness
connector (1).
2) Remove bracket (2) and speed sensor (3).
5) Disconnect the following wiring harness 9) Remove pin (9a), parking brake cable (9)
connectors from the back side of the and bracket (9b).
transfer filter.
q (4h): CN-T14 (Ground)
q (4j): CN-T13
q (4k): CN-T12
CPW15393
AJF00417
AJF00415
AJF00418
AJF00437
AJF00420
AJF15394
AJF16148
AJF00439
3) Remove dust seal (76) and oil seal (77) 12. Removal of HST motor 1 shaft and ring gear
from cage (78). 1) Remove HST motor 1 shaft and ring gear
4) Remove outer race (79). assembly (28).
AJF00449 9JF01027
AJF00450
9JF15396
AJF00425
AJF15395
AJF00426
9JF15398
AJF00430
16. Holder
1) Remove the mounting bolts and holder
(45).
AJF00428
9JF01029
2) Remove seal rings (46) and (47) from 19. Removal of output shaft and gear assembly
holder (45). 1) Remove 2 mounting bolts of cover (67).
2) Remove output shaft and gear assembly
(68) and cover (67).
AJF00432
9JF01031
9JF01030
AJF15399 AJF00446
9JF16144
AJF16142
AJF16145
9JF06143
9JF01037
9JF16147
9JF16146
AJF00906
1. Rear case
1) Press fit outer race (81) to rear case (80).
9JF01031
9JF00845
AJF16149
AJF16150
9JF01030
AJF00471
9JF16151
AJF00432
AJF00430
AJF16153
9JF01041
AJF00486
AJF15154
AJF00484
5) Install snap ring (31). 13. Installation of HST motor 1 shaft and ring
gear
1) Install HST motor 1 shaft and ring gear
assembly (28).
AJF00426
9JF01027
9JF16155
9JF00819
2) Install front case (63). 16. Clutch discs, plates, and springs
3 Mounting bolt: 1) Install end plate (25).
98 – 123 Nm {10.0 – 12.5 kgm}
AJF00910
AJF00907
AJF01036
AJF00420
AJF00909
AJF00911
AJF00416
AJF00912
AJF00417
21. Hub
1) Turn over the transfer assembly, install
hub (17).
2) Install snap ring (16).
2 Spline of output shaft:
Lubricant containing molybde-
19. Cage num disulfide (LM-P)
1) Install cage (18).
a Tighten the mounting bolts evenly
and gradually.
q Installed load of belleville springs
(6-piece set): 21,500 N {2,190 kg}
3 Mounting bolt:
245 – 308 Nm {25.0 – 31.5 kgm} AJF00415
AJF00915
AJF00449
9JF16156
9JF00844
25. Coupling
1) Install coupling (59) on the cage side.
2 Spline of coupling:
Molybdenum disulfide grease
(LM-G)
4) Calculate shim thickness ( t ) . 2) Install holder (58) and tighten the mount-
q Shim thickness (t) = Average of clear- ing bolt.
ance (k) + (0.15 mm to 0.20 mm)
5) Insert selected shims (61) between cage
(78) and the front case.
6) Tighten the cage mounting bolts.
3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
AJF00504
AJF00499
3) Install coupling (14) on the parking brake 4) Install parking brake cable (9) and bracket
side. (9b).
2 Spline of coupling: a After inserting the cotter pin of park-
Molybdenum disulfide ing brake cable pin (9a), open it to
grease (LM-G) 180° to fix the cable pin.
4) Install breather tube (13). 5) Insert suction hose (8).
8) Connect the following wiring harnesses 10) Connect the following wiring harnesses to
connectors to the rear side of the transfer the brake accumulator.
filter. (4a) : CN-T11
(4h) : CN-T14 (Ground) (4b) : CN-T07
(4j) : CN-T13 (4c) : CN-T06
(4k) : CN-T12 (4d) : CN-T10
AJF00504 AJF00504
9) Connect the following wiring harnesses. 11) Install speed sensor (3) and bracket (2).
(4e) : CN-T05
(4f) : CN-T18 12) Connect the speed sensor wiring harness
(4g) : CN-T15A connector (1).
AJF00504 AJF00504
Removal and installation of 4. Pull out the cotter pin and remove pin (3) to
parking brake assembly 1
disconnect parking brake cable (4). [*2]
New/Remodel
Necessity
Sketch
Q'ty
Symbol Part No. Part name
AJF16208
AJF00504
AJF00504
Installation
q Carry out installation in the reverse order to
removal.
[*1]
3 Rear drive shaft mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
[*2]
a After installing the parking brake, open cotter
pin (3) to 180° to fix.
[*3]
a Using tool D8, install parking brake assembly
(6).
3 Parking brake mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
New/Remodel
Necessity
Sketch
Q'ty
Symbol Part No. Part name
AJF00510
AJF00507
3. Cam plate
1) Remove cam plate (8).
2) Remove strainer (2).
AJF00511
AJF00508
4. Ball 6. Pin
1) Remove 6 balls (9). 1) Remove pin (12).
AJF00512
AJF00517
5. Lever
1) Remove the mounting bolt and lever (10).
AJF00513
AJF00522
AJF00514
Assembly
a Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with
power train oil (for details, see "Table of fuel,
coolant and lubricants") before installing.
a Do not reuse the gasket but remove it com-
pletely. 9JF00852
AJF00523
2. Oil seal and dust seal
1) Using tools D3 and D4, press fit oil seal
(14) and dust seal (13).
2 Lips and clearances of oil seal and
dust seal: Silicone grease (Three-
Bond 1855 or equivalent)
4. Lever
1) Install levers (11) and (10).
(Perform the work with the gasket removed.)
9JF00851
AJF00524
AJF00525
5. Balls
1) Install 6 balls (9).
a Check that dirt is not sticking to the
balls.
(Perform the work with the gasket
removed.) 9JF00853
AJF00512
7. Plates, disc, and springs
1) Install 4 discs (7), 4 wave springs (6), and
5 plates (5).
a Soak the disc in clean power train oil
(for details, see "Table of fuel, coolant
and lubricants") for at least 2 minutes
before installing them.
6. Cam plate a Check that dirt is not sticking to the
1) Install cam plate (8). discs and plates.
a Check that dirt is not sticking to the (Perform the work with the gasket
ball grooves, inside of parking brake removed.)
housing, cam plate, discs, and plates.
(Perform the work with the gasket
removed.)
AJF00510
2) Using tool D24, press plate (5) lightly with 2) Install the O-ring and cover (1).
a press and install 2 spacers (4) and 2 2 O-ring: Grease (G2-LI)
clamping bolts (3). 3 Mounting bolt:
a Take care not to press plate (5) too 98 – 123 Nm {10.0 – 12.5 kgm}
much and not to damage it.
a Press plate (5) until it is flush with the
parking brake case.
a Move the lever and check that it
returns normally.
2 Clamping bolt: Adhesive (LT-2)
3 Clamping bolt: AJF00507
19.6 – 27.4 Nm {2.0 – 2.8 kgm}
(Perform the work with the gasket
removed.)
AJF16158
8. Strainer
1) Install strainer (2).
AJF00508
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
50-310 34
SEN03854-00
WHEEL LOADER
WA250-6
WA250PZ-6
Removal and installation of front 3. Remove work equipment upper cover (2).
axle assembly 1
Removal
k Stop the machine on a level ground and set
the lock bar to the frame to fix the front and
rear frames.
k Lower the work equipment to the ground, AJF00643
stop the engine, apply the parking brake,
and set chocks under the tires.
k Release the residual pressure in the brake
a cc um ula t or c ir c uit. F or de ta ils , s ee
"Releasing remaining pressure in hydraulic
circuit".
1. Raise the chassis with the work equipment and 4. Disconnect brake hose (3).
set stands [1] under the frame in front of the
front wheels to float the front of the chassis. 5. Disconnect wiring connector CN-F14 (3).
AJF00641 AJF00644
2. Lift off the front wheel (1). [*1] 6. Disconnect front drive shaft (5). [*2]
a Lift off the front wheel on the other side
similarly.
4 Front wheel (1 side): 280 kg
AJF00645
AJF00642
[*2]
a When installing the drive shaft, check that the
key way of the spider cap is fitted to the key
way of the mating yoke, and then tighten the
AJF00646 mounting bolts.
3 Front drive shaft mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
[*3]
3 Front axle mounting bolt:
785 – 980 Nm {80 – 100 kgm}
q Bleeding air
Bleed air from the brake system. For details,
see Testing and adjusting, "Bleeding air from
brake circuit".
Removal and installation of rear 5. Disconnect brake hose (2) from the left inside
axle assembly 1
of the frame.
Removal
k Stop the machine on a level ground and set
the lock bar to the frame to fix the front and
rear frames.
k Lower the work equipment to the ground,
stop the engine, apply the parking brake, AJF00649
and set chocks under the tires.
k Release the residual pressure in the brake
a cc um ula t or c ir c uit. F or de ta ils , s ee
"Releasing remaining pressure in hydraulic
circuit".
AJF00647
AJF00648
8. Remove the bolts and coupling (5). [*3] 12. Lower the crane and jack [5] simultaneously to
a Remove coupling (5) so that dust seal (8) remove rear axle assembly (7).
in step 11 will not be damaged.
4 Rear axle assembly: 500 kg
AJF00652
AJF16163
AJF16162
11. Pull out the rear axle assembly toward the rear
of the chassis and disconnect it from the rear
frame assembly.
a Take care not to damage dust seal (8) of
rear frame (7).
AJF00654
Installation
q Carry out installation in the reverse order to
removal.
[*1]
3 Rear wheel mounting bolt:
785 – 980 Nm {80 – 100 kgm}
[*2]
a Check that the radial runout of the rear axle
from the transfer in lateral direction is not
larger than 3 mm. If it is larger than 3 mm,
reduce it by moving the transfer mount.
a When installing the drive shaft, check that the
key way of the spider cap is fitted to the key
way of the mating yoke, and then tighten the
mounting bolts.
3 Rear drive shaft mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
[*3]
2 Coupling mounting bolt: Adhesive (LT-2)
3 Coupling mounting bolt:
245 – 309 Nm {25.0 – 31.5 kgm}
[*4]
3 Support mounting bolt:
785 – 980 Nm {80 – 100 kgm}
q Bleeding air
Bleed air from the brake system. For details,
see Testing and adjusting, "Bleeding air from
brake circuit".
New/Remodel
Necessity
Sketch
Q'ty
Symbol Part No. Part Name
AJF00624
Disassembly
a The following photos and illustrations show the
front axle housing as an example.
1. Draining oil
6 Axle (Each of front and rear axles): 18 l
AJF00625
AJF00626
AJF00629
AJF00627
AJF16164
AJF00628
9JF00881
9JF00882
9JF16165
8. Planetary carrier 3) Pull roll pin (15) out of removed shaft (16).
1) Using tool H9, drive in roll pin (15) of plan-
etary carrier (14) until it is in the range of
shaft (16).
a Take care not to drive in the roll pin
too deep.
AJF00634
9JF00883
AJF00635
AJF16167
AJF16168
9JF00886
9JF00884
9JF00885
3. Selecting shims
1) After bearings (7) and (20) are fitted well,
measure the turning force of hole (d) of
axle housing (11).
a Do not install planetary carrier (14).
q Turning force (Not static friction, but
dynamic friction)
(Including seal resistance)
Front axle:17.6 – 44.1 N {1.8 – 4.5 kg}
Rear axle:14.7 – 44.1 N {1.5 – 4.5 kg}
AJF00637
AJF00901
AJF00635
9JF00890
AJF16169
AJF00638
AJF00626
AJF16170
5) Rotate axle housing (11) 10 or more turns • Refilling with oil (Axle housing)
to fit it. Then, using tool H12, measure the Tighten the drain plug and add axle oil through
starting torque at the mounting bolt hole of the oil filler to the specified level, and then
the axle housing assembly. check the oil level.
q Starting torque (including seal resis-
tance) 5 Axle oil (Each of front and rear):
Front axle: 39.2 – 63.7 N {4.0 – 6.5 kgm} 18 l (AXO80)
Rear axle: 34.3 – 63.7 N {3.5 – 6.5 kgm}
a If the starting torque exceeds the
above range, adjust it again, referring
to 3 "Selecting shims" above.
AJF16171
AJF00624
New/Remodel
Necessity
Sketch
Q'ty
Symbol Part No. Part Name
Disassembly
1. Draining oil
6 Axle (Each of front and rear axles): 18 l
2. Brake piping
9JF00855
1) Remove brake tube and hose assembly
(2).
AJF00532
AJF00530
6. Differential assemblies
1) Place and stabilize differential assemblies
(12) and (13) on blocks.
a (12): Front differential
(13): Rear differential
AJF00533
AJF00528
AJF00534
AJF00529
4) Using tool H13, supply air to the brake 10. Removal of long cage assembly (Only front
port to remove piston (20). differential)
k Do not stand in front of the piston. 1) Remove coupling (23).
(Check that there is no person in a Remove the coupling protector only
front of the piston.) when it needs to be removed.
a Supply air slowly. 2) Remove long cage assembly (24).
AJF16172 AJF00536
5) Remove seal (87) from piston (20). 11. Disassembly of long cage assembly (Only
front differential)
1) Remove oil seal (25).
9JF00879
AJF00537
8. Top cover
1) Remove the mounting bolts, and then
remove top cover (21), using tool H24. 2) Using tool H23, push shaft (26) with a
press to remove it from long cage (27).
9. Slack adjuster
1) Remove 2 slack adjusters (22).
AJF16174
AJF16173
3) Remove snap ring (28) and ring (29), and 13. Removal of rear cage assembly (For rear
then remove bearing (30) from long cage differential)
(27). 1) Before removing cage assembly, loosen
the mounting bolts of coupling (41).
2) Remove the mounting bolts. Using tool
H24, remove rear cage assembly (42).
a Check the thickness and quantity of
the shims.
9JF00857
AJF16177
AJF16175
9JF00858
AJF16176
AJF00541
3) Remove spacer (34) and bearing (35) 2) Remove oil seal (82).
from pinion gear (36).
AJF00545
9JF00859
9JF00860
AJF00546
AJF16179
3) Remove seal (84) and ring (85) from each 18. Disassembly of standard differential carrier
bearing carrier (44). assembly
4) Remove outer race (86). a When keeping the parts on both sides,
make marks on them so that they will not
be mistaken.
1) Remove 12 mounting bolts (46).
a Do not remove 4 mounting bolts (47)
of spider shaft (a).
AJF00598
AJF00549
AJF00548
AJF00550
AJF16180
4) Remove washer (51) and side gear (52). 7) Remove side gear (57).
AJF00552 AJF00555
AJF00554 AJF00556
6) Remove 4 spherical washers (54) and 4 9) Remove 4 mounting bolts, and then
pinion gears (55) from spider shaft (56). remove bevel gear and bearing assembly
(59) from case (60).
AJF00553
AJF00557
10) Using tool H26, remove bearing (61) from 2) Using tool H27, remove bearing (64) from
bevel gear (62). bevel gear (65).
AJF16181 AJF16182
AJF00559
AJF00562
5) Remove pressure ring (69). 8) Remove 4 pinion gears (72) from spider
a Insert a finger in the hole on the side shaft (73).
of the case to raise the pressure ring.
AJF00566
AJF00563
AJF00568
AJF00564
AJF00567
AJF00565
AJF16184
AJF00571
AJF00571
AJF16183
3) Install 2 discs (77) and 2 plates (76). 5) Install side gear (74).
2 Before installing the discs and a Referring to step 10) below, match
plates, soak them in the axle oil the cut of the inside of the disc to the
(AXO80). oil groove of the side gear.
AJF00570 AJF00568
4) Install pressure ring (75). 6) Install 4 pinion gears (72) to spider shaft
(73).
AJF00567
AJF00566
AJF00565
AJF00577
AJF00564
AJF00562
12) Install bearing (64) to bevel gear (65). 14) Install bevel gear and bearing assembly
a Install the bearing by shrink fit at tem- (63).
perature below 100°C or by using tool a Match the match marks made when
H28 and a press. the assembly was removed.
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
245 – 309 Nm {25.0 – 31.5 kgm}
AJF16186
AJF00559
9JF00863
16) Measure the no-load operation torque. 2) Install bevel gear and bearing assembly
1] Install sun gear shafts (14) to both (59) to case (60) with the 4 mounting
s id e s o f li mi te d - s li p d i ffe r e n t ia l bolts.
assembly (83). a Match the match marks made when
2] Fix the sun gear shaft on one side the assembly was removed.
and install tool H15 to the sun gear a Install the mounting bolts to the 4
shaft on the other side. places of the spider shaft.
3] Install tool H30 (torque wrench) to 2 Mounting bolt: Adhesive (LT-2)
tool H15 and measure the no-load 3 Mounting bolt:
operation torque. 245 – 309 Nm {25.0 – 31.5 kgm}
a When measuring, let the case
rotate freely.
q No-load operation torque:
Max. 10 Nm {1.0 kgm}
q If the no-load operation torque
exceeds the standard value, dis-
assemble the limited-slip differ- AJF00557
ential again and perform "11)
Selection of thickness of plate"
and "15) Adjust the clearance of
the side gear in the axial direc-
tion".
AJF00556
AJF16188 AJF00555
5) Install 4 pinion gears (55) and 4 spherical 8) Install bearing (49) to case (50).
bushings (54) to spider shaft (56). a Install the bearing by shrink fit at tem-
perature below 100°C or by using tool
H28 and a press.
AJF00553
AJF16189
AJF00905
10) Install case and bearing assembly (48).
a Match the match marks made when
the assembly was removed.
a Turn over the assembly and tighten
the mounting bolts.
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
245 – 309 Nm {25.0 – 31.5 kgm}
AJF16191
AJF00598
5. Assembly of front cage assembly (For front 4) Erect pinion gear assembly (81) and
differential) install cage assembly (88).
1) Install outer races (39) and (38) to cage 5) Install bearing (37) to pinion gear assem-
(40). bly (81).
a Install the bearing by shrink fit at tem-
perature below 100°C or by using tool
H17 and a press.
9JF00865
9JF16193
9JS01486
AJF16196
9JF00868
9. Adjusting backlash
1) Measure the backlash of the bevel gear
with tool H31.
q Standard backlash: 0.20 – 0.33 mm
a Measure the backlash at 3 places on
the periphery of the bevel gear and
check that the dispersion of the mea-
sured values is 0.1 mm or less.
CJH11994
AJF16197
9JF00872
3) Install 1 disc (17A), 1 disc (17B), 1 plate 5) Install sun gear shaft (14).
(18), 2 wave springs (19A), and 2 wave
springs (19B).
a Install these parts in order of (19A),
(17A), (18), (19B), and (17B).
AJF00532
AJF00904
9JF00877
AJS16199
AJF00533
13. Brake oil leakage test a If the oil leaks (If the pressure drops
a Action of the piston of the slack adjuster more than the standard), remove the
lowers pressure during the low-pressure brake piston and check the seals for
leakage test. To prevent this, use tool damage.
H19. a If the hose is moved while the pres-
1) Keep plate [1] (equivalent to tool H19) set. sure is measured, the pressure fluctu-
k If the brake oil leakage test is per- ates. Accordingly, do not move the
formed without setting plate [1], hose.
the piston will jump out, and that is 5) Remove tools H20, H21, and H22 and
dangerous. plate [1] (equivalent to tool H19), and then
2) Install tools H22, H21 and H20 to the perform the test on the opposite side.
brake port and bleed all air from the brake
system through the bleeder. 14. Top cover
a Be sure to fit the O-ring to tool H22. 1) Remove bleeder screw (100) temporarily
3 Mounting bolt of tool H22: and install top cover (21).
98 – 123 Nm {10.0 – 12.5 kgm} 2 Mating face of cover: Adhesive
a Bleed air by operating pump H20. (LOCTITE 515 or equivalent)
3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
2) Install slack adjusters (22) to the right and
left.
a Take care that the O-rings will not
come off.
AJS16200 3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
15. Axle oil temperature sensor (Only front 3) Install ring (29) and snap ring (28).
axle)
1) Install axle oil temperature sensor (11).
2 Threads: Gasket sealant (LG-5)
3 Axle oil temperature sensor:
29.4 – 49.0 Nm {3 – 5 kgm}
2) Install cover (10).
3 Mounting bolt: 9JF00874
98 – 123 Nm {10.0 – 12.5 kgm}
9JF01122
9JF00855
9JF01122
9JF01117
AJF00527
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
50-320 44
SEN03855-00
WHEEL LOADER
WA250-6
WA250PZ-6
New/Remodel
Necessity
6. Remove operator's cab and floor frame
Sketch
Q'ty
Symbol Part No. Part Name assembly (1). For details, see "Removal and
installation of operator's cab and floor frame
assembly".
1 793T-623-1170 Push tool t 1 Q
2 791-830-1410 Push tool t 1
J
Commercially
3 Thickness gauge q 1
available
Removal 9JF00918
k Stop the machine on a level ground and set
the lock bar to the frame to fix the front and
rear frames.
k Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires.
8. Disconnect front drive shaft (2) from the trans- 11. Disconnect the PPC hoses (5) – (8) from the
fer. [*2] work equipment valve. [*4]
AJF00730
AJF00727
AJF00730
AJF00729
AJF00731
14. Remove the lower hinge pin. [*6] 4) Remove upper spacer (18).
1) Remove lock bolt (12). a The upper spacer may be removed
2) Remove lower hinge pin (13). after the front frame is disconnected.
AJF00733 AJF00738
15. Remove the upper hinge pin. [*7] 16. Disconnect the front frame and rear frame.
1) Remove mounting bolt (14). [*9]
2) Remove mounting nut (15). 1) Set hand lift truck [4] under bucket (19).
AJF00734 AJF00736
3) Adjust the height of the front frame and 2) Using a bar, etc., raise front frame assem-
rear frame with the hydraulic jack so that bly (20) by 1 – 2 mm to move lower spacer
you can pull out the pin easily, and then (21) from rear frame assembly (22).
remove upper hinge pin (16) and shims a You may raise the front frame assem-
(17). [*8] bly by 1 – 2 mm with a large-sized
a Check the thickness and quantity of crane, if available.
the shims.
9JF00909
AJF00735
3) Turn the tires to move front frame assem- 4) Remove bearing (27a) and spacer (27b).
bly (20) forward.
9JF00910
AJF00737
AJF00739 AJF00741
2) Remove retainer (24) and shims (25). 3) Remove retainer (30) and shim (31).
a Check the thickness and quantity of a Check the thickness and quantity of
the shims. the shims.
3) Remove dust seal (26) from retainer (24). 4) Remove dust seal (32) from retainer (30).
AJF00740 AJF00742
[*1]
a When installing the hoses of the air conditioner
circuit, take care that dirt, dust, water, etc. will
9JF00911 not enter them.
a When installing each air conditioner hose,
check that O-ring (70) is fitted to it.
a Check O-ring (70) for a flaw and deterioration.
a When connecting each refrigerant pipe, apply
compressor oil for new refrigerant (R134a)
(D ENSO: ND -OIL 8 o r ZEXEL ZXL 10 0PT
(equivalent to PAG46) to O-ring (70).
19. Remove 2 bushings (34) from the lower hinge 3 Threaded part of hose (M16 × 1.5):
of the rear frame. [*12] 12 – 15 Nm {1.2 – 1.5 kgm}
3 Threaded part of hose (M22 × 1.5):
20 – 25 Nm {2.0 – 2.5 kgm}
3 Threaded part of hose (M24 × 1.5):
30 – 35 Nm {3.0 – 3.5 kgm}
AJF00743
[*2]
3 Front drive shaft mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
a When installing the drive shaft, check that the
key way of the spider cap is fitted in the key
way of the mating yoke, and then tighten the
mounting bolts.
[*3]
a Bleed air from the brake. For details, see Test-
ing and adjusting, "Bleeding air from brake cir-
cuit".
AJF00741
4) Press fit dust seal (32) to retainer (30). 7) Insert selected shim (31) and tighten the 6
a Press fit the dust seal with the lip out. mounting bolts.
2 Lip of dust seal: Grease (G2-LI) 3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
9JF00913
AJF00745
AJF16205
9JF16206
2) Press fit dust seal (23) to the front frame. 4) Tighten the 3 mounting bolts of retainer
a Press fit the dust seal with the lip out. (24) evenly.
2 Lip of dust seal: Grease (G2-LI) 3 Retainer mounting bolt:
14.7 Nm {1.5 kgm}
5) Measure the clearance between retainer
(24) and front frame with tool J3, and then
select shims so that the maximum clear-
ance will be less than 0.1 mm when the
shims are inserted.
AJF00739 q Standard shim thickness: 0.85 mm
q Varieties of shim thickness:
0.1 mm, 0.2 mm, 0.5 mm
AJF00747
AJF00738
AJF15388
AJF00749
9JF00909
7. Measure clearance (a) between upper hinge q Refilling with oil (Hydraulic tank)
pin (16) and rear frame top with a clearance Add oil through the oil filler to the specified
gauge, and then select shims so that the maxi- level. Run the engine to circulate the oil
mum clearance will be less than 0.1 mm when through the system. Then, check the oil level
the shims are inserted. again.
q Standard shim thickness: 1.45 mm
5 Hydraulic oil (For details, see "Table of
q Varieties of shim thickness:
fuel, coolant and lubricants"):
0.1 mm, 0.2 mm, 0.5 mm, 1.0 mm
Only necessary quantity
AJF00735
9JF00917
Removal and installation of 5. Open the engine left side cover and disconnect
counterweight 1
wiring connector CN-BR1 (8).
Removal
k Stop the machine on a level ground and set
the lock bar to the frame to fix the front and
rear frames.
k Lower the work equipment to the ground,
stop the engine, apply the parking brake, AJF00929
and put chocks under the tires.
AJF00929
AJF00929
AJF00930 AJF00929
AJF00931
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
50-400 14
SEN03856-00
WHEEL LOADER
WA250-6
WA250PZ-6
2. Loosen the radiator cap to drain the coolant. q (8): Hose between HST pump – PPC
6 Radiator: 22 l accumulator
q (9): Hose between HST pump – HST drain
filter
3. Remove the operator's cab and floor frame q (10): HST pump T2 port hose (Keep this
assembly. For details, see "Removal and hose installed since it is disconnected
installation of operator's cab and floor frame under the floor)
assembly". q (11): Steering pump suction tube [*2]
q (12): Hose between charge pump Fe port
– HST filter
q (13): Hose between charge pump Fa port
– HST filter
q (14): Brake and fan pump discharge hose
q (15): Transfer lubrication hose
Installation [*4]
q Carry out installation in the reverse order to 2 Mating face of HST pump and 4-gear pump
removal. assembly: Gasket sealant (LG-6)
3 HST pump and 4-gear pump assembly
[*1] mounting bolts:
a When installing the hoses of the air conditioner M12 (22) (4 pieces):
circuit, take care that dirt, dust, water, etc. will 98 – 123 Nm {10.0 – 12.5 kgm}
not enter them. M16 (23) (2 pieces):
a When installing each air conditioner hose, 245 – 309 Nm {25.0 – 31.5 kgm}
check that O-ring (70) is fitted to it.
a Check O-ring (70) for a flaw and deterioration. 1. If boss (24) was removed from the HST pump
a When connecting each refrigerant pipe, apply assembly, install it according to the following
compressor oil for new refrigerant (R134a) procedure.
(DEN SO : ND-O IL8 or ZEXE L ZXL1 00 PT a Install boss (24) so that it will be flush with
(equivalent to PAG46) to O-ring (70). the shaft end face of pump shaft (25).
3 Threaded part of hose (M16 × 1.5): q Level difference between boss and pump
12 – 15 Nm {1.2 – 1.5 kgm} shaft end face: Max. 0.5 mm
3 Threaded part of hose (M22 × 1.5):
20 – 25 Nm {2.0 – 2.5 kgm}
3 Threaded part of hose (M24 × 1.5):
30 – 35 Nm {3.0 – 3.5 kgm}
[*2]
2 Hose insertion area of steering pump suction
tube (11): Gasket sealant (THREEBOND
1206E or equivalent)
3 Hose clamp of steering pump suction tube
(11): 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*3]
2 Insertion area of hydraulic tank return hose
(17): Gasket sealant (THREEBOND 1206E q Refilling with oil (Hydraulic tank)
or equivalent) Add oil through the oil filler to the specified
3 Clamp of hydraulic tank return hose (17): level. Run the engine to circulate the oil
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} through the system. Then, check the oil level
again.
5 Hydraulic oil (For details, see "Table of fuel,
coolant and lubricants"):
Only necessary quantity
New/Remodel
Necessity
Sketch
Q'ty
Symbol Part No. Part name
Disassembly
a If the pump body is disassembled, the assem-
bly special tool will be required. See "Assem- 2) Disassemble the low pressure relief valve
bly 3. 5)". according to the following procedure, if
a General view necessary.
a Before loosening the adjustment
screw, check the adjustment dimen-
sion.
1] Remove spring (3) and spring seat
(4).
2] Remove piston (5).
3] Remove locknut (6).
4] Remove adjustment screw (7) from
holder (8).
6. Charge pump assembly (44) 3) Mark position of the port plate, (m1).
1) Remove the 4 mounting bolts (97) and 4) Loosen port plate fixation.
charge pump assembly (44).
2) Remove wear plate (43).
3) Remove gear (46).
4) Remove coupling (48) and key (49).
a Do not remove bearing metal (47) from
flange (45).
1] Remove the assembly of pistons (57) 5] Remove snap ring (63) from the cylin-
and retainer (58) from cylinder block der block.
(56). k Snap ring (63) will jump out. Take
2] Remove 9 pistons (57) from retainer care.
(58). 6] Remove spring (62) and 2 shims (65).
a Check of pistons
q Check that there are no scratches or
metal deposits on sliding surface (b),
and there is no axial play (c), (other-
wise: pistons must be replaced in
sets).
11. Swivel cradle (73) and bearing cups (74) q Bearing surfaces (j) of cradle (76).
1) Remove swivel cradle (73).
2) Remove bearing cups (74).
a Check
q Bearing cups set.
3) Install seal ring (93) over O-ring (94). a Assemble either side first, then assemble
a The deformation of the seal has to be the other side.
done with care so as not to damage 2] Install collar (89).
the sealing edges. 3] Install small spring (88) and large
a Check the position of the seal ring spring (87).
(93), if necessary, straighten using a 4] Install collar (83).
finger.
a When any of rod (91), collar (83), 3) Insert completely swivel cradle (73) into
snap ring (85), piston (90), and ring housing.
(84) needs to be replaced, replace all a Assistance: Devices, e.g. clamp, rub-
of the servo piston assembly (82) ber rings, grease and string.
since a dimension of ring (84) must a Pay attention for correct seat of the
be adjusted. swivel cradle (73) in the housing.
a Check: Location of the swivel-bearing 6) Hold swivel (73) in position utilizing the
in the bearing. seat screw.
q Centralize swivel (73) by using a k Do not use force.
measu rin g d evice (d ia l g aug e o r 7) Install second holding device [6] diago-
depth measurement [5]). nally and fix swivel (73).
q The measured values at the 2 points
of (P1) and (P2) in the following figure
must be the same.
4. Drive shaft assembly a Before setting seal (68), perform the fol-
a Install the bearing to the shaft in the cor- lowing procedures.
rect direction. 6) Measure depth (d1) to the groove bottom
1) Install the ring to the shaft first, and then of snap ring (67).
install the bearing to the shaft. 7) Make a mark of the insertion depth of
2) Using tool S2, press fit bearing (71) to push tool S3 (finishing position) (m4 = d1)
drive shaft (72). on push tool S3.
8) Using tool S3, press fit seal (68).
a Threads of shaft: M16, Thread depth: 36
mm
1] Install 2 shims (65) and spring (62) to 2) Remove holding device [6].
the cylinder block. a Fit cylinder completely with pistons
2] Compress spring (62) and install snap and retaining device.
ring (63).
3] Install spring (61) and shim (60) to
cylinder block (56).
a When any of cylinder block (56), con-
trol plate (52), retainer guide (59),
retainer (58), and shim (60) needs to
be replaced, replace the whole cylin-
der block since a dimension of shim
(60) must be adjusted.
4] Install retainer guide (59).
3) Assembly aid:
Hold cylinder block and piston assembly
(54) by using O-ring (96).
10. Forward-reverse solenoid valve (34) 2) Install 2 solenoid valves (36) to valve
1) Assemble valve housing assembly (35) housing assembly (35).
according to the following procedure. a Fit the tube to the solenoid valve
1] Install plug (42) to housing. housing and install coil (36A) and cap
2 Threads of plug: (36B).
ThreeBond No. 1305
2] Install 4 plugs (41).
3 Plug: 5.6 Nm {0.57 kgm}
3] Install piston (39).
4] Install 2 collars (38) and 2 springs
(37).
13. Low pressure relief valve assembly 14. High pressure relief valve assembly
1) Assemble the low pressure relief valve Fit the O-ring and install 2 high pressure relief
assembly according to the following pro- valve assemblies (1).
cedure. 3 High pressure relief valve assembly:
1] Install adjustment screw (7) to holder 200 ± 10 Nm {20.39 ± 1.02 kgm}
(8).
2] Install locknut (6).
3] Install piston (5).
4] Install spring seat (4) and spring (3) to
the pump case.
2) Plugs
1] Plugs with internal hexagon and pro-
file seal ring
M27 x 2 90 9.18
3/4-16UNF 72 7.34
Tightening torque
Thread
Nm kgm
M6 10 1.02
M6 x 0.5 11 1.12
M8 22 2.24
M8 x 1 24 2.45
M10 40 4.08
M10 x 1 44 4.49
M12 69 7.04
10.9 11.9
Thread
Tightening torque
Nm kgm Nm kgm
M3 2.1 0.21 — —
M4 4.7 0.48 — —
M6 15.8 1.61 — —
M8 37.7 3.84 — —
Removal and installation of HST 4. Disconnect front drive shaft (1) from the trans-
motor 1 assembly 1
fer. [*2]
Removal
k Stop the machine on a level ground and set
the lock bar to the frame to fix the front and
rear frames.
k Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires.
k Operate the work equipment control lever 2
– 3 times to release the residual pressure in
the work equipment circuit.
k Press the brake pedal at least 100 times to
release the residual pressure in the brake
accumulator circuit.
k Disconnect the cable from the negative (–) 5. Disconnect the following wiring harness con-
terminal of the battery. nectors from the brake accumulator.
q (2): CN-T06
q Precautions for handling refrigerant q (3): CN-T11
k Collect refrigerant (R134a) beforehand.
a Ask professional traders for collecting and
filling the refrigerant (R134a).
a Never release the refrigerant (R134a) to
the atmosphere.
k If the refrigerant (R134a) gets inside
ones eyes, it may cause blindness.
Therefore, make sure to wear protec-
tive glasses when collecting or filling
the refrigerant. Collecting and filling
work must be conducted by a qualified
person.
k If the radiator coolant temperature is
high, you may scald yourself with the
hot coolant when disconnecting the 6. Disconnect the following hoses from HST
heater hoses and draining the cool- motor 1.
ant. Wait until the coolant is cooled, q (4): T1 port hose
and then drain the coolant. q (5): T2 port hose
q (6): A port hose
1. Recover the refrigerant (R134a). [*1] q (7): B port hose
[*2]
3 Drive shaft mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
[*3]
3 HST motor 1 assembly mounting bolt:
Installation 245 – 309 Nm {25.0 – 31.5 kgm}
q Carry out installation in the reverse order to
removal. q Refilling with oil (Hydraulic tank)
Add oil through the oil filler to the specified
[*1] level. Run the engine to circulate the oil
a When installing the hoses of the air conditioner through the system. Then, check the oil level
circuit, take care that dirt, dust, water, etc. will again.
not enter them.
5 Hydraulic oil (For details, see "Table of fuel,
a When installing each air conditioner hose,
check that O-ring (70) is fitted to it. coolant and lubricants"):
a Check O-ring (70) for a flaw and deterioration. Only necessary quantity
a When connecting each refrigerant pipe, apply
compressor oil for new refrigerant (R134a) q Refilling with coolant
(DEN SO : ND-O IL8 or ZEXE L ZXL1 00 PT Add coolant through the coolant filler to the
(equivalent to PAG46) to O-ring (70). specified level. Run the engine to circulate the
3 Threaded part of hose (M16 × 1.5): coolant through the system. Then, check the
12 – 15 Nm {1.2 – 1.5 kgm} coolant level again.
3 Threaded part of hose (M22 × 1.5):
5 Total amount of coolant: Approx. 22 l
20 – 25 Nm {2.0 – 2.5 kgm}
3 Threaded part of hose (M24 × 1.5):
(For details, see "Table of fuel, coolant and
30 – 35 Nm {3.0 – 3.5 kgm} lubricants")
Removal and installation of HST 4. Disconnect front drive shaft (1) from the trans-
motor 2 assembly 1
fer. [*2]
Removal
k Stop the machine on a level ground and set
the lock bar to the frame to fix the front and
rear frames.
k Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires.
k Operate the work equipment control lever 2
– 3 times to release the residual pressure in
the work equipment circuit.
k Press the brake pedal at least 100 times to
release the residual pressure in the brake
accumulator circuit.
k Disconnect the cable from the negative (–) 5. Disconnect the following wiring harness con-
terminal of the battery. nectors from the brake accumulator.
q (2): CN-T07
q Precautions for handling refrigerant q (3): CN-T10
k Collect refrigerant (R134a) beforehand.
a Ask professional traders for collecting and
filling the refrigerant (R134a).
a Never release the refrigerant (R134a) to
the atmosphere.
k If the refrigerant (R134a) gets inside
ones eyes, it may cause blindness.
Therefore, make sure to wear protec-
tive glasses when collecting or filling
the refrigerant. Collecting and filling
work must be conducted by a qualified
person.
k If the radiator coolant temperature is
high, you may scald yourself with the
hot coolant when disconnecting the 6. Disconnect the following hoses from HST
heater hoses and draining the cool- motor 1.
ant. Wait until the coolant is cooled, q (4): T1 port hose
and then drain the coolant. q (5): T2 port hose
q (6): A port hose
1. Recover the refrigerant (R134a). [*1] q (7): B port hose
[*2]
3 Drive shaft mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
[*3]
3 HST motor 2 assembly mounting bolt:
245 – 309 Nm {25.0 – 31.5 kgm}
Installation
q Carry out installation in the reverse order to q Refilling with oil (Hydraulic tank)
removal. Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
[*1] through the system. Then, check the oil level
a When installing the hoses of the air conditioner again.
circuit, take care that dirt, dust, water, etc. will
5 Hydraulic oil (For details, see "Table of fuel,
not enter them.
a When installing each air conditioner hose, coolant and lubricants"):
check that O-ring (70) is fitted to it. Only necessary quantity
a Check O-ring (70) for a flaw and deterioration.
a When connecting each refrigerant pipe, apply q Refilling with coolant
compressor oil for new refrigerant (R134a) Add coolant through the coolant filler to the
(DEN SO : ND-O IL8 or ZEXE L ZXL1 00 PT specified level. Run the engine to circulate the
(equivalent to PAG46) to O-ring (70). coolant through the system. Then, check the
3 Threaded part of hose (M16 × 1.5): coolant level again.
12 – 15 Nm {1.2 – 1.5 kgm}
5 Total amount of coolant: Approx. 22 l
3 Threaded part of hose (M22 × 1.5):
20 – 25 Nm {2.0 – 2.5 kgm} (For details, see "Table of fuel, coolant and
3 Threaded part of hose (M24 × 1.5):
lubricants")
30 – 35 Nm {3.0 – 3.5 kgm}
Special tools
New/Remodel
Necessity
Sketch
Q'ty
Symbol Part No. Part name
CJW12101
4 02010-20783 Bolt q 1
790-201-2740 Push tool t 1
S
5 793T-417-1120 Push tool q 1
02010-20783 Bolt q 1
Disassembly
1. Seal
1) Protect drive shaft (1) with a tape etc.
2) Remove snap ring (2) and shim (3).
CJW11980
CJW11982
CJW11981
CJW11987
CJW11983
CJW12104
CJW12163
CJW12103
1) Remove the 4 mounting bolts and sole- 4) Disassemble 2 solenoids and housing
noid valve and housing assembly (27) assembly (27).
from port plate (6). 1] Remove caps (36) and (37), coils (38)
a Take care of the spring which may and (39), and bushing (40) of the
jump out. solenoid in order.
CJW12105 CJW12106
CJW12125
CJW12108
CJW12107
CJW12112
CJW12164
CJW12165
7) Make match marks (c) between port plate a Check of port plate
(6) and housing (82). q Sliding surface and side guides free
8) Remove port plate assembly (6). of scoring and no wear.
CJW12115 CJW12002
CJW12039
CJW12113
CJW12119
CJW12127
CJW12008
CJW12005
CJW12006
CJW12009
CJW12007
CJW12011
CJW12014
CJW12010
CJW12116
CJW12128
CJW12013
CJW12128 CJW12169
3) Insert shim (84), center pin (88), and pis- 2. Installation of rotary group assembly
ton (86) in cylinder block (83). 1) Heat housing (82) to 80°C.
a Make sure all parts are fitted in cor-
rectly.
CJW12024
CJW12021
2) Insert shaft and rotary group assembly 3. Port plate assembly (6)
(81) into housing (82) to seat position. 1) Assemble port plate assembly (6) accord-
ing to the following procedure.
1] Install valve seat (79).
2] Install poppet (78).
3] Install valve guide (77).
CJW12117
CJW12119
CJW12118
CJW12113
CJW12122
CJW12115
5. HA servo valve and forward-reverse shuttle 3] Install spool (62), spring seat (61),
valve assembly and flushing valve assem- and spring (60).
bly (53) (HST motor 2) 4] Install 2 plugs (59).
1) Assemble the flushing valve assembly 3 Plug: 40 Nm {4.1 kgm}
according to the following procedure. 5] Install snap ring (58), orifice (57),
1] Install guide (66), orifice (65), and plunger (56), and spring (55).
guide (64). 6] Install plug (54).
3 Guide (66): 3 Nm {0.31 kgm} 3 Plug: 50 Nm {5.1 kgm}
3 Guide (64): 8 Nm {0.81 kgm}
2] Install plug (63).
3 Plug:
29 – 38 Nm {2.96 – 3.89 kgm}
CJW12164
2) Install flushing valve assembly (53) to port 6] Install 2 solenoids to housing (35).
plate (6). a Install bushing (40), coils (39) and
3 Plug: (38), and caps (37) and (36) of the
55 – 60 Nm {5.61 – 6.12 kgm} solenoid in order.
CJW12112 CJW12106
CJW12108
6) Install solenoid valve and housing assem- 2) Assemble housing assembly (5) according
bly (27) with the 4 mounting bolts to port to the following procedure.
plate (6). 1] Install plug (24) to housing (13).
2] Install pin (20).
3] Install bushing (19) and spool (18) to
housing (13).
a Plugs (23) are already in the housing
(13).
CJW12105
CJW12103
CJW12102
CJW11987
3) Install spring (10) and spring seat (11) to 5) Protect drive shaft (1) with a tape etc.
port plate (6). 6) Install snap ring (2).
4) Install spring (12) and spring seat (9).
5) Install spring (8) and spring seat (7).
CJW11980
CJW11983
CJW12036
CJW11982
Removal and installation of work 4. Disconnect the following hoses and tubes from
equipment control valve work equipment control valve assembly (2).
[*1]
assembly 1
a Plug the disconnected hoses to prevent oil
Removal leakage.
k Stop the machine on a level ground, apply a Put tags to the disconnected hoses and
the parking brake, and put chocks under record the installed positions etc. on them.
the tires. q (3): T port hose (return)
q (4): T port hose
1. Articulate the machine to the left and raise the q (5): Lift arm raise PPC hose
lift arm. q (6): Bucket tilt PPC hose
Removal and installation of 5. Remove tube (7) between the hydraulic tank
hydraulic tank 1
and hydraulic oil filter.
8. Disconnect hoses (12), (13), (14), (15), (16) 12. Lift off hydraulic tank and ladder assembly
and (17) from the block on the hydraulic tank. (20).
a Plug the disconnected hoses to prevent oil
4 Hydraulic tank and ladder assembly:
leakage.
160 kg (including hydraulic oil)
a Put tags to the disconnected hoses and
record the installed positions etc. on them.
[*2]
3 Upper mounting bolt (18) of hydraulic tank:
98 – 123 Nm {10.0 – 12.5 kgm}
[*3]
3 Lower mounting bolt (19) of hydraulic tank:
98 – 123 Nm {10.0 – 12.5 kgm}
11. Remove lower mounting bolt (19) of the
hydraulic tank. [*3] q Refilling with oil (Hydraulic tank)
Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
5 Hydraulic oil (For details, see "Table of fuel,
coolant and lubricants"):
Only necessary quantity
New/Remodel
2. Cylinder head and piston rod assembly
Necessity
Sketch
(Steering cylinder and lift cylinder)
Q'ty
Symbol Part No. Part Name
1) Using tool U2, remove cylinder head (2)
from the cylinder.
9JF01063
9JF01066
9JF01064
9JF01067
9JF01069
9JF01068
9JF01067
9JF01070
2. Assembly of cylinder head assembly (Lift 3. Assembly of piston assembly (Steering cyl-
and bucket cylinder assembly) inder assembly)
1) Using tool U4, press fit bushing (16). 1) Using tool U6, expand piston ring (10).
a Set the tool to the piston ring and turn
its handle by 8 – 10 turns to expand
the piston ring.
9JF01071
9JF01073
9JF01068
9JF01074
9JF01072
9JF01065
9JF01062
9JF01064
8. Bucket positioner
Adjust the bucket positioner plate to the follow-
ing dimensions and tighten the bolts.
Dimension (a): 41.5 ± 1 mm
Dimension (b): 105 ± 2 mm
9JF115389
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
50-500 64
SEN03857-01
WHEEL LOADER
WA250-6
WA250PZ-6
Removal and installation of work 3. Move the machine to the rear and disconnect
equipment assembly 1
the bucket.
AJF01021
AJF01023
CEW02153
5. Set supports [2] under the end of the lift arm 7. Disconnect boom positioner proximity switch
and release the residual pressure in the connector CN-F04 (7).
hydraulic piping.
8. Remove boom kick-out switch (8). [*5]
CJW11351
DBW01810
CJW11354
11. Sling bucket link assembly (12) temporarily, 14. Pull dust seal (17) and bushing (18) out of lift
pull out mounting pin (13), and remove the arm (16). [*8]
bucket link assembly from the bell crank
assembly. [*7]
4 Bucket link assembly: 30 kg
CJW11357
CJW11355
15. Pull dust seal (19) and bushing (20) out of bell
crank (14). [*8]
CJW11356 16. Pull dust seal (21) and bushing (22) out of
bucket link (12). [*8]
CJW11359
Installation [*2]
q Carry out installation in the reverse order to Procedure for installing bucket hinge pin
removal. 1. Operate the control lever to align the holes for
k When starting the engine, check that the bucket mounting pin (2) and install cord ring
directional lever is in neutral and the park- (25).
ing brake is applied.
k When aligning the pin holes, use a bar. 2. Insert shims in clearance (b).
Never insert your fingers in the pin holes. q Clearance (b) (On each side): Max. 1.5
a Supply grease until it comes out of the joint. mm
a After applying grease to every part, idle the q Varieties of shim thickness: 1.5, 3.0 mm
engine at low speed, and then tilt and dump
the bucket and raise and lower the lift arm a 3. Install mounting pin (1) and lock it with bolt
few times to allow grease to spread all over the (26).
pin. k Never insert your fingers in the pin
holes.
[*1] a Take care that the cord ring will not be
Procedure for installing bucket link pin caught.
1. Sling the bucket link and install cord ring (23), a Take care not to damage the pin.
aligning the holes for mounting pin (1). a Before installing the pin, apply lubricant
containing molybdenum disulfide to the
2. Insert shims on both sides so that clearances inside of the bushing.
(a) on both sides will be the same. 2 Inside of bushing:
q Clearance (a) (On each side): Max. 1.5 Lubricant containing molybde-
mm num disulfide (LM-P or equiva-
q Varieties of shim thickness: Only 1.5 mm lent)
a After installing the pin, supply grease.
3. Install mounting pin (1) and lock it with bolt 2 Grease:
(24). Hyper White G2-T or equivalent
k Never insert your fingers in the pin
holes.
a Take care that the cord ring will not be
caught.
9JF01055
9JF01054
[*3] [*4]
Procedure for installing bucket cylinder pin (on Procedure for installing lift cylinder pin (on rod
rod side) side)
a It is not necessary to adjust shims for clear- k When starting the engine, check that the
ance (c). directional lever is in neutral and the park-
1. Install mounting pin (4) and lock it with bolt ing brake is applied.
(27). 1. Insert shims in clearance (d).
k Never insert your fingers in the pin q Clearance (d) (On each side): Max. 1.5
holes. mm
a Take care not to damage the pin. q Varieties of shim thickness: Only 1.5 mm
a Before installing the pin, apply lubricant
containing molybdenum disulfide to the 2. Install mounting pin (5) and lock it with bolt
inside of the bushing. (28).
2 Inside of bushing: k Never insert your fingers in the pin
Lubricant containing molybde- holes.
num disulfide (LM-P or equiva- a Take care not to damage the pin.
lent) a Before installing the pin, apply lubricant
a After installing the pin, supply grease con- containing molybdenum disulfide to the
taining molybdenum disulfide. inside of the bushing.
2 Grease: 2 Inside of bushing:
Hyper White G2-T or equivalent Lubricant containing molybde-
num disulfide (LM-P or equiva-
lent)
a After installing the pin, supply grease con-
taining molybdenum disulfide.
2 Grease:
Hyper White G2-T or equivalent
9JF01056
9JF01057
[*5]
a Adjust the boom kick-out. For details, see
Testing and adjusting, "Testing and adjusting of
boom kick-out".
[*6] [*7]
Procedure for installing lift arm pin (on frame Procedure for installing bucket link pin
side) 1. Insert shims so that clearances ( f ) on both
1. Insert shims in clearance (e). sides will be even.
a When installing the right-hand lift arm pin, q Clearance ( f) (On each side): Max. 1.5
fit the boss on the right inside of the frame mm
to the lift arm boss to eliminate the clear- q Varieties of shim thickness: Only 3.0 mm
ance and insert shims in the clearance on a Secure the bell crank to the lift arm with
the opposite side. chains, etc.
a When installing the left-hand lift arm pin, 2. Install cord rings (30), aligning the holes for
insert shims evenly on both sides. bucket link mounting pin (13).
q Clearance (e) (On each side of left-hand
boom pin): Max. 1.5 mm 3. Install mounting pin (13) and lock it with bolt
q Varieties of shim thickness: 1.5 mm, 3.0 (31).
mm k Never insert your fingers in the pin
holes.
2. Install mounting pin (11) and lock it with bolt a Take care that the cord ring will not be
(29). caught.
k Never insert your fingers in the pin a Take care not to damage the pin.
holes. a Before installing the pin, apply lubricant
a Take care not to damage the pin. containing molybdenum disulfide to the
a Before installing the pin, apply lubricant inside of the bushing.
containing molybdenum disulfide to the 2 Inside of bushing:
9JF01059
9JF01058
[*8]
Press fit bushings (18), (20), and (22) to lift arm
(16), bell crank (14), and bucket link (12) respec-
tively with hydraulic cylinder [3], etc., and then
install the dust seals.
2 Bushing: Grease (G2-LI)
a Apply grease to the seal so that the seal will
not be damaged.
9JF01060
9JF01061
q Greasing
Supply grease to each pin.
a Supply grease until it comes out of the
joint.
©2007 KOMATSU
All Rights Reserved
Printed in Japan 10-07 (01)
50-600 10
SEN03858-00
WHEEL LOADER
WA250-6
WA250PZ-6
Removal and installation of 3. Open and fix right engine side cover (1).
operator's cab and floor frame a Check that the cover is locked securely.
assembly 1
4. Remove right fender (2).
Removal 4 Fender: 25 kg
k Stop the machine on a level ground and set
the lock bar to the frame to fix the front and
rear frames.
k Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires.
k Disconnect the cable from the negative (–) AJF00729
terminal of the battery.
AJF00729
AJF00729
AJF00729
13. Disconnect the following hoses from Orbit-roll 18. Remove air conditioner external air filter case
valve (14). [*2] cover (25).
q (15): LS port hose (Right)
q (16): P port hose (Left lower)
q (17): R port hose (Right lower)
q (18): L port hose (Right upper)
q (13): T port hose (Left upper)
(Since hose (13) was disconnected in
the previous step from the hydraulic AJF00729
tank, it does not need to disconnect in
this step.)
a Plug the disconnected hoses to prevent oil
leakage.
a Put tags to the disconnected hoses and
record the installed positions etc. on them.
19. Disconnect the following wiring harness con- 21. Disconnect 2 washer hoses (39) from the
nectors. engine compartment side.
q (26): CN-LR1
q (27): CN-LR10 22. Disconnect air conditioner pipes (40) and (41).
q (28): CN-LR7
q (29): CN-LR3 23. Disconnect heater hoses (42) and (43) from
q (30): CN-LR2 the engine side.
q (31): CN-LR4 a Put tags to the disconnected hoses and
pipes and record the installed positions
etc. on them.
AJF00729
AJF00729
q (32): CN-LT1
q (33): CN-LT2
q (34): CN-LR7 24. Remove air conditioner pipe clamps (44) and
q (35): CN-LR11 (45) from the lower left of the floor.
q (36): CN-LR6
a Put tags to the disconnected connectors
and record the installed positions etc. on
them.
AJF00729
AJF00729
AJF00729
AJF00729
AJF00729
Installation [*5]
q Carry out installation in the reverse order to 3 Right and left rear operator's cab mounting
removal. nuts (63): 824 – 1,030 Nm {84 – 105 kgm}
[*1]
a When installing the hoses of the air conditioner q Refilling with oil (Hydraulic tank)
circuit, take care that dirt, dust, water, etc. will Add oil through the oil filler to the specified
not enter them. level. Run the e ngin e to circulate the oil
a When installing each air conditioner hose, through the system. Then, check the oil level
check that O-ring (70) is fitted to it. again.
a Check O-ring (70) for a flaw and deterioration.
5 Hydraulic oil (For details, see "Table of fuel,
a When connecting each refrigerant pipe, apply
coolant and lubricants"):
compressor oil for new refrigerant (R134a)
Only necessary quantity
(DEN SO : ND-O IL8 or ZEXE L ZXL1 00 PT
(equivalent to PAG46) to O-ring (70).
3 Apply engine oil (EO15W-40) to threaded
part and seat of mounting bolt. q Refilling with coolant
3 Threaded part of hose (M16 × 1.5): Add coolant through the coolant filler to the
12 – 15 Nm {1.2 – 1.5 kgm} specified level. Run the engine to circulate the
3 Threaded part of hose (M22 × 1.5): coolant through the system. Then, check the
20 – 25 Nm {2.0 – 2.5 kgm} coolant level again.
3 Threaded part of hose (M24 × 1.5):
5 Total amount of coolant: Approx. 22 l
30 – 35 Nm {3.0 – 3.5 kgm}
(For details, see "Table of fuel, coolant and
lubricants")
[*2]
Bleed air from the steering circuit. For details, see
Testing and adjusting, "Bleeding air from steering
circuit".
[*3]
Bleed air from the brake system. For details, see
Testing and adjusting, "Bleeding air from brake cir-
cuit".
[*4]
3 Right and left front operator's cab mounting
nuts (62): 824 – 1,030 Nm {84 – 105 kgm}
Removal and installation of a If the glass is narrow, you may cut the
operator's cab glass (Stuck glass) adhesive by the following method. Insert
a fine wire [2] (piano wire, etc.) in the
Special tools adhesive and grip its both ends with priors
[3], etc. (or hold them by winding them
New/Remodel
onto something) and cut the adhesive with
Necessity
Sketch
the wire.
Q'ty
Symbol Part No. Part Name
2 793-498-1210 Lifter t 2
(Suction cups)
Removal
a All sides of each glass of the operator's cab of
this machine are stuck.
a Remove the window glass to be replaced
according to the following procedure. a The broken window glass may be
removed with knife [4] and a screwdriver.
1. Using seal cutter [1], cut the adhesive between (If the screwdriver is applied directly to the
broken window glass (1) and operator's cab normal window glass, the glass will be
(2). broken.)
a When using knife [4], insert a screwdriver
in the cut to widen it and move the knife
forward.
Installation
1. Using scraper [5], remove the remaining adhe-
sive.
a Do not scratch the paint.
a When sticking the both-sided adhesive 3) Using tool X2 (suction cups), place win-
tape around a side or a rear window glass, dow glass (3) on tool X1-1 (5 mm spacer)
start at center of the top and make a clear- and match it to the operator's cab.
ance of about 5 mm at end joint (c).
CWW11608
a Do not apply the primer to the 1) Break aluminum seal (10) of the outlet of
boarder about 5 mm wide between adhesive cartridge (9) and install the noz-
the black part and transparent part of zle.
the glass.
a After applying the primer, leave it for
at least 5 minutes (within 8 hours) to
dry.
a If the paint primer is applied by mis-
take, wipe it off with white gasoline.
(If wrong primer is applied, the glass
will not be stuck.)
CPW11631
CPW11632
Removal and installation of air 3. Pull out each switch from panel cover (1) on
conditioner unit 1
the left side of the operator's seat and discon-
nect the following connectors.
Removal q (2): CN-L10
k Stop the machine on a level ground and set q (3): CN-L11
the lock bar to the frame to fix the front and q (4): CN-L09
rear frames. a Different specifications use different
k Lower the work equipment to the ground, switches and connectors.
stop the engine, apply the parking brake,
and put chocks under the tires.
k Disconnect the cable from the negative (–)
terminal of the battery.
5. Remove 8 mounting bolts (1a) and panel cover 8. Remove monitor panel assembly (11).
(1). [*2]
CPW11631
CPW11631
CPW11631
CPW11631
CPW11631
14. Remove left duct (17) and right duct (18). 20. Disconnect wiring harness connector (28) and
fuse (29).
CPW11631
CPW11631
CPW11631
CPW11631
CPW11631
CPW11631
24. Disconnect blower motor wiring harness con- 26. Blower motor assembly
nector (37) from the lower left of the operator's 1) Remove side cover (39) and front cover
cab floor and pull out the wiring harness and (40) at the lower left of the operator's cab.
grommet (38) together above the floor. 2) Remove air conditioner external air filter
case (41).
CPW11631
CPW11631
CPW11631
CPW11631
Installation
q Carry out installation in the reverse order to
removal.
[*1]
a When installing the hoses of the air conditioner
CPW11631 circuit, take care that dirt, dust, water, etc. will
not enter them.
a When installing each air conditioner hose,
check that O-ring (70) is fitted to it.
a Check O-ring (70) for a flaw and deterioration.
a When connecting each refrigerant pipe, apply
compressor oil for new refrigerant (R134a)
(DEN SO: N D-OIL8 or ZEXEL ZXL1 00 PT
(equivalent to PAG46) to O-ring (70).
3 Threaded part of hose (M16 × 1.5):
12 – 15 Nm {1.2 – 1.5 kgm}
3 Threaded part of hose (M22 × 1.5):
20 – 25 Nm {2.0 – 2.5 kgm}
3 Threaded part of hose (M24 × 1.5):
CPW11631 30 – 35 Nm {3.0 – 3.5 kgm}
CPW11631
[*2]
3 Panel cover mounting bolt (1a):
3.4 – 4.4 Nm {0.35 – 0.45 kgm}
[*3]
3 Monitor panel mounting bolts (9) and (10):
2.75 – 2.94 Nm {0.28 – 0.30 kgm}
[*4]
a Do not remove the plugs installed when the
piping was disconnected to prevent entry of
foreign matter until just before connecting the
piping.
2 O-ring and threaded part:
Compressor oil for R134a
(SANDEN: SP-10)
3 Hose adapter mounting bolt (44):
8 – 12 Nm {0.8 – 1.2 kgm}
CPW11631
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
50-700 22
SEN03859-00
WHEEL LOADER
WA250-6
WA250PZ-6
Removal and installation of 3. Remove 8 mounting bolts (1a) and panel cover
monitor panel 1
(1). [*1]
Removal
k Stop the machine on a level ground and set
the lock bar to the frame to fix the front and
rear frames.
k Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires.
k Disconnect the cable from the negative (–)
terminal of the battery.
Removal
k Stop the machine on a level ground and set
the lock bar to the frame to fix the front and
rear frames.
k Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires.
k Disconnect the cable from the negative (–)
terminal of the battery.
Installation
q Carry out installation in the reverse order to
removal.
a Before installing, remove foreign materials
(dirt, water, etc.) from the wiring harness con-
nector of the engine controller assembly.
[*1]
3 Wiring harness connector mounting bolt:
3 ± 0.1 Nm {0.31 ± 0.01 kgm}
Installation
q Carry out installation in the reverse order to
3. Remove KOMTRAX terminal assembly (2). removal.
a Before installing, remove foreign materials
(dirt, water, etc.) from the wiring harness con-
nector of the KOMTRAX terminal assembly.
[*1]
a Connect the antenna cable connectors first
and then connect the machine wiring harness
connector.
[*2]
3 Hexagon socket head screw at center of wir-
ing harness connector CN-L80 (3):
2.82 Nm {0.288 kgm}
©2007 KOMATSU
All Rights Reserved
Printed in Japan 09-07 (01)
50-800 8
SEN03860-01
WHEEL LOADER
WA250-6
WA250PZ-6
WA250-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN03860-01
WA250, 250PZ-6
90-100 3
Hydraulic circuit diagram
Hydraulic circuit diagram WA250PZ-6
1
WA250PZ-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN03860-01
WA250, 250PZ-6
90-100 5
100 Hydraulic diagrams and drawings
SEN03860-01
©2007 KOMATSU
All Rights Reserved
Printed in Japan 10-07 (01)
90-100 8
SEN03861-01
WHEEL LOADER
WA250-6
WA250PZ-6
SEN03861-01
WA250, 250PZ-6
90-200 3
Electrical circuit diagram (2/9)
Electrical circuit diagram (2/9) WA250, 250PZ-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN03861-01
WA250, 250PZ-6
90-200 5
Electrical circuit diagram (3/9)
Electrical circuit diagram (3/9) WA250, 250PZ-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN03861-01
WA250, 250PZ-6
90-200 7
Electrical circuit diagram (4/9)
Electrical circuit diagram (4/9) WA250, 250PZ-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN03861-01
WA250, 250PZ-6
90-200 9
Electrical circuit diagram (5/9)
Electrical circuit diagram (5/9) WA250, 250PZ-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN03861-01
WA250, 250PZ-6
90-200 11
Electrical circuit diagram (6/9)
Electrical circuit diagram (6/9) WA250, 250PZ-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN03861-01
WA250, 250PZ-6
90-200 13
Electrical circuit diagram (7/9)
Electrical circuit diagram (7/9) WA250, 250PZ-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN03861-01
WA250, 250PZ-6
90-200 15
Electrical circuit diagram (8/9)
Electrical circuit diagram (8/9) WA250, 250PZ-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN03861-01
WA250, 250PZ-6
90-200 17
Electrical circuit diagram (9/9)
Electrical circuit diagram (9/9) WA250, 250PZ-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN03861-01
WA250, 250PZ-6
90-200 19
Connector list and stereogram
Connector list and stereogram WA250-6, WA250PZ-6 WA250-6, WA250PZ-6
Connector No. Model Number Component name Address of Connector No. Model Number Component name Address of Connector No. Model Number Component name Address of
of pins stereogram of pins stereogram of pins stereogram
— — 2 Water in fuel sensor F11 DT-T 2 Steering pump pressure switch L71 DT-T 4 Intermediate connector W-2
AL1 DT-T 6 Intermediate connector T-1 F12 DT-T 2 Emergency steering pressure switch L79 — 5 KOMTRAX engine cut relay P-6
AMBAIR
PRESURE — 3 Ambient pressure sensor AC-3 F14 DT-T 2 Brake oil temperature switch C-1 L80 DRC key A 40 KOMTRAX controller T-8
B01 DT-T 2 Rear work lamp RH K-9 F15 DT2 3 Lift arm angle sensor (for load meter) A-4 L100 Terminal 1 GND (floor) Y-3
B02 DT-T 2 Rear work lamp LH M-7 F16 DT2 3 Lift arm bottom sensor (for load meter) F-1 L101 — 6 FR press select relay AB-7
B03 DT-T 2 Back buzzer M-7 F17 DT2 3 Lift arm rod sensor (for load meter) F-1 L102 — 5 VIS power hold relay Z-8
B05 DT-T 2 Coolant level sensor J-9 FL1 DT-T 12 Intermediate connector D-7, V-1 L103 — 5 Motor 2 solenoid relay Z-8
B05 Terminal 1 GND (license lamp) M-7 FL2 DT-T 6 Intermediate connector D-8, V-2 L104 — 5 Fan reverse solenoid relay Z-8
B06 08027 2 (R) Window sealed washer motor K-9 FL3 DT-T 4 Intermediate connector W-2 L105 — 5 Electrical parking brake relay AA-7
B07 08027 2 (F) Window sealed washer motor M-5 FL4 DT-T 6 Intermediate connector V-2 L106 — 5 Neutral safety relay AA-7
B08 DT-T 2 Diode M-3 FLC DT-T 3 Front combination lamp RH C-6 L107 — 5 Engine controller cut 1 relay Z-7
B09 DT-T 2 Diode L-3 FLC1 DT-T 3 Front combination lamp LH G-1 L108 — 5 Engine controller cut 2 relay Z-8
BL1 DT-T 6 Intermediate connector X-2 FLH DT-T 3 Head lamp RH B-5 L109 — 5 Back alarm/lamp 1 relay AB-7
BOOST PRESS & — 4 Boost pressure sensor FLH DT-T 3 Head lamp LH G-1 L110 — 5 ECSS relay AB-7
INT
BR1 DT-T 4 Intermediate connector M-8 FS1 — 15 Fuse box V-9 L111 — 5 HST solenoid safety relay AB-8
C04 DT 2 Front work lamp (RH) 24V/70W E-8 FS2 — 15 Fuse box V-9 L112 — 5 Air clearner clog relay AB-8
C05 DT 2 Front work lamp (LH) 24V/70W J-9 FUEL RAIL — 3 Common rail pressure sensor AG-5 L113 — 5 Boom kick out relay AB-9
PRESS
C07 YAZAKI 2 Room lamp I-9 HEAD L DT-T 6 Intermediate connector G-1 L114 — 5 Bucket leveler relay AA-9
7123-2228
YAZAKI
C08 -08056 1 Door switch (LH) (room lamp) H-9 HEAD R DT-T 6 Intermediate connector A-4 L115 — 5 Detent active relay AA-9
C09 YAZAKI 1 Door switch (RH) (room lamp) E-8 HST DRC 40 HST controller Z-6 L116 — 5 Horn relay AA-9
-08056
C10 Terminal 1 GND to radio body F-9 INJ. CYL. 1 & 2 — 4 Injector #1 & #2 AE-4 L117 — 5 Small lamp relay LH AA-6
C11 YAZAKI PA 9 AM/FM radio E-8 INJ. CYL. 3 & 4 — 4 Injector #3 & #4 AF-5 L118 — 5 Small lamp relay RH AA-5
C12 M 2 Speaker LH I-9 INJ. CYL. 5 & 6 — 4 Injector #5 & #6 AG-5 L119 — 5 Head lamp relay LH AA-5
C13 M 2 Speaker RH H-9 J01 M6409-0075 20 Joint connector R-6 L120 — 5 Head lamp relay RH AA-5
C14 198-Z11-2650 2 Lighter D-7 J02 M6409-0255 20 Joint connector R-6 L121 — 5 Stop lamp relay Z-5
C15 DT 3 Intermediate connector J03 M6409-0071 20 Joint connector V-1 L122 — 5 Front work lamp relay AA-4
C16 DT 2 Warning lamp (beacon) J04 M6409-0075 20 Joint connector Y-9 L123 — 5 Rear work lamp relay AB-4
C17 SWP 6 Warning lamp (beacon) switch (If equipped) J05 M6409-0072 20 Joint connector Y-9 L124 — 6 Hazard/turn signal relay AB-4
C18 SWP 6 Warning lamp (pat. light) switch (If equipped) J06 M6409-0071 20 Joint connector Y-9 L125 — 5 Hazard relay AB-4
C18 Terminal 1 GND (cabin) E-8 J07 M6409-0072 20 Joint connector R-8 L126 — 5 Back alarm/lamp 2 relay AB-6
C19 SWP 6 Rear glass heater switch G-9 J08 M6409-0075 20 Joint connector Q-4 L151 — 5 Front work lamp (yellow) relay (If equipped)
C20 — 5 Relay for rear glass heater G-9 J09 M6440-0128 20 Joint connector Y-9 L152 — 5 Warning lamp (beacon) relay
C21 YAZAKI 1 Rear glass heater H-9 J10 M6409-0255 20 Joint connector Y-9 L153 — 5 Warning lamp (pat.light) relay (If equipped)
7116-2270
YAZAKI
C22 7116-2270 1 Rear glass heater J-9 J11 M6440-0135 20 Joint connector Z-8 L154 — 6 Warning lamp (pat.light) switch relay (If equipped)
C23 DT 4 Intermediate connector D-8 J12 M6409-0075 20 Joint connector Z-8 LR1 #8 1 Intermediate connector N-3, AB-2
C47 — 22 Manual A/C control amp F-9 J13 M6409-0128 20 Joint connector R-6 LR2 DT-T 12 Intermediate connector N-3, AB-2
C48 — 14 Manual A/C control amp F-9 J14 M6409-0075 20 Joint connector Z-8 LR3 DT-T 6 Intermediate connector N-2, AB-1
C49 DT-T 12 Intermediate connector F-1 J15 M6440-0128 20 Joint connector O-4 LR4 #8 1 Intermediate connector N-2, AB-1
C50 DT-T 12 Intermediate connector F-1 J16 M6409-0128 20 Joint connector Z-7 LR6 #8 1 Intermediate connector M-2, X-1
C140 DRC 40 Tachograph controller J17 M6409-0072 20 Joint connector Z-7 LR7 DT-T 12 Intermediate connector M-3, X-1
C142 YAZAKI 17 Tachograph L02 DT-T 4 Starting switch R-9 LR10 DT-T 3 Intermediate connector N-3, AB-2
7119-3170
CAM SENSOR — 3 G sensor AD-1 L03 DT-T 4 Speed range selector switch R-8 LR11 DTP 4 Intermediate connector M-3, X-1
CAN1 DT-T 3 CAN resistor AG-1 L04 SWP 8 Combination lamp switch T-1 LR12 #8 1 Intermediate connector N-2, AB-1
CAN2 DT-T 3 CAN resistor S-1 L05 S 10 Wiper switch (front, rear) S-1 LT1 DT-T 12 Intermediate connector M-3, X-2
CHK0 X 1 KOMTRAX inspection connector P-6 L06 SWP 6 Hazard switch R-6 LT2 DT-T 6 Intermediate connector M-3, X-2
CHK1 X 1 KOMTRAX inspection connector P-6 L07 SWP 6 Front work lamp switch Q-5 MF1 DTM 12 Multi function lever switch
CL1 SWP 6 Intermediate connector A-5, O-2 L08 SWP 6 Rear work lamp switch R-6 OIL PRESURE — — Engine pressure switch (low) AH-2
SWITCH
CL2 SWP 8 Intermediate connector C-6, O-3 L09 SWP 6 ECSS switch T-1 PD1 DT-T 6 Throttle pedal switch O-2
CL31 DT-T 2 Diode L10 SWP 6 Monitor 1 switch U-1 PD2 DT-T 2 Throttle pedal switch O-2
CL32 DT-T 2 Diode L11 SWP 6 Monitor 2 switch T-1 R00 Terminal 1 GND M-7
COOLANT TEMP — 2 Engine coolant temperature sensor AD-4 L13 DT-T 2 Horn switch T-1 R01 Terminal 1 Battery relay A-8
CP3 PUMP — 2 IMA fuel pump actuator AH-4 L15 DT-T 4 FNR switch S-2 R02 Terminal 1 Slow blow fuse A-9
REGULATOR
CRANK SENSOR — 3 Ne sensor AD-1 L16 SWP 6 Loadmeter A/B (If equipped) U-1 R03 Terminal 1 Slow blow fuse B-9
D01 SWP 8 Diode O-8 L17 SWP 6 Loadmeter total (If equipped) V-1 R04 Terminal 1 Battery relay A-9
D02 SWP 8 Diode O-8 L19 SWP 6 Parking brake switch S-7 R05 Terminal 1 Slow blow fuse B-9
D03 SWP 8 Diode O-8 L24 AMP 070 20 Monitor panel R-2 R05A Terminal 1 Slow blow fuse B-9
D07 DT-T 2 Diode O-7 L25 AMP 070 18 Monitor panel R-2 R06 Terminal 1 Slow blow fuse B-9
D08 DT-T 2 Diode O-7 L26 AMP 070 12 Monitor panel R-2 R11 Terminal 1 Slow blow fuse B-9
D09 DT-T 2 Diode O-7 L27 AMP 070 18 Monitor panel Q-3 R15 Terminal 1 Battery relay B-7
D10 DT-T 2 Diode O-7 L28 AMP 070 12 Monitor panel Q-4 R16 Terminal 1 Battery relay A-7
D21 DT-T 2 Diode K-2 L29 AMP 070 12 Monitor panel T-7 R20 Terminal 1 GND (rear frame) J-1
D22 DT-T 2 Diode J-1 L30 AMP 070 14 Monitor panel S-7 R21 DT-T 2 Fuel level sensor M-4
E01 DT-T 2 Starting motor safety relay AF-5 L34 DT-T 2 Stop lamp switch W-2 R22 DT-T 6 Rear combination lamp LH M-6
SUMITOMO
E02 6189-0442 3 Alternator M-5 L35 DT 2 PPC valve with electrical detent Q-9 R23 DT-T 6 Rear combination lamp RH K-9
E03 Terminal 1 Alternator terminal B M-6 L36 DT 2 PPC valve with electrical detent R-6 R24 DT-T 2 License lamp (If equipped) L-8
E05 Terminal 1 Heater relay terminal B C-8 L37 DT 2 PPC valve with electrical detent R-6 R26 Terminal 1 GND (rear frame) H-1
E06 Terminal 1 Heater relay C-9 L38 DT-T OPT 2 UN switch +24 V (If equipped) Z-4 R29 DT-T 2 Oil fan EPC solenoid L-8
E06A DT-T 2 Diode K-2 L39 DT-T OPT 2 Key on +24 V (If equipped) Z-4 R59 DT-T 2 Fan reverse solenoid L-8
E07A Terminal 1 Heater relay terminal A AF-5 L45 DT-T 6 Auto lubrication AB-2 R90 Terminal 1 Heater relay terminal E L-2
E07B — 1 Electrical intake air heater AD-9 L46 M 2 Buzzer W-9 SV DT-T 12 Service connector Y-8
E10 DT-T 2 Freon compressor magnet clutch AH-1 L47 DT 2 Parking brake indicator switch Y-3 T01 DT-T 4 HST pump solenoid AC-5
E14 Terminal 1 GND (engine controller) AG-1 L48 08027 6 Wiper timer X-2 T01A — 2 Diode AD-4
E15 Terminal 1 GND (engine controller) AH-1 L49 08027 4 Flasher AA-3 T01B — 2 Diode AD-4
E19 Terminal 1 Starting motor safety relay AG-6 L50 DT-T 12 Intermediate connector Z-6 T05 DT-T 2 Clutch control EPC solenoid N-2
E20 Terminal 1 Starting motor safety relay AF-6 L52 M 4 Rear wiper motor X-9 T06 DT-T 2 HST motor 1 EPC solenoid L-1, AI-5
E21 Terminal 1 Starting motor terminal C AC-6 L53 DT 2 Parking brake remind switch Z-5 T07 DT-T 4 HST motor 2 solenoid & motor 2 overrun solenoid L-1, AI-7
E30 Terminal 1 Starting motor terminal B AC-7 L54 DT-T 3 Variable shift control switch T-8 T09 DT-T 4 Speed sensor AJ-8
E41 DT-T 2 Intermediate connector AF-1 L55 DT 2 Air suspension seat Z-5 T10 DT-T 2 HST oil temperature sensor L-1, AJ-8
E42 DT-T 2 Intermediate connector AH-2 L57 M 6 Front wiper motor Q-3 T11 DT-T 3 HST oil pressure sensor L-1, AI-6
EC1 DRC 60 Engine controller module AE-1 L58 M 2 12V option converter output Z-4 T12 DT-T 2 Accumurator pressure switch M-1
EC2 DRC 50 Engine controller module AD-2 L59 DT-T 4 Bucket lever LDM cancel switch (If equipped) Q-6 T13 — 1 HST filter clogging sensor M-1
EC3 DTP 4 Engine controller module AF-1 L60 DT-T 6 Intermediate connector Z-4 T14 Terminal 1 GND N-1
ER1 DT-T 12 Intermediate connector AE-5 L61 DT-T 4 Boom lever TCS cancel switch Q-6 T15 DT-T 2 Parking brake solenoid H-1, AM-8
ER2 DT-T 12 Intermediate connector AE-5 L62 DT-T 4 Intermediate connector Q-6 T15A DT-T 2 Diode N-1
ER3 DT-T 2 Intermediate connector AE-5 L63 SWP 6 FNR active switch Q-9 T18 DT-T 2 Parking brake pressure switch (for monitor indicator) N-2, AM-7
F01 08160-70001 2 Horn (high) D-1 L64 SWP 6 Traction switch Q-9 T31 DT-T 2 Diode
F02 08160-70001 2 Horn (low) E-1 L65 SWP 6 Work lamp (yellow) (If equipped) R-6 T32 DT-T 2 Diode
F03 DT-T 3 Bucket positioner proximity switch A-2 L66 X 1 Intermediate connector O-3 TEL DT-T 12 Intermediate connector P-6
F04 DT-T 3 Lift arm positioner proximity switch F-1 L67 DT-T 12 Intermediate connector W-9 TOOL PORT — 3 CAN resistor
F07 DT-T 2 ECSS solenoid valve E-1 L68 DT-T 2 Resistor O-7 Z01 DT-T 2 Diode
F07A DT-T 2 Diode E-1 L69 SWP 6 Auto reversible fan switch Q-9 Z02 DT-T 2 Diode
F10 Terminal 1 GND (front frame) F-1 L70 SWP 8 Speed range select resistor O-9
SEN03861-01
WA250, 250PZ-6
90-200 21
200 Electrical diagrams and drawings
SEN03861-01
©2007 KOMATSU
All Rights Reserved
Printed in Japan 10-07 (01)
90-200 24