SlideShare a Scribd company logo
1 of 25
Download to read offline
MACHINE MODEL SERIAL NUMBER
WA250-6 75001 and up
WA250PZ-6 75160 and up
H00051 and up
• This shop manual may contain attachments and optional equipment that are not available in your
area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
• WA250-6 and WA250PZ-6 mounts the SAA6D107E-1 engine.
VEBM610101
© 2011
All Rights Reserved
Printed in Europe 2011-04
WA250-6
WA250PZ-6
SEN03822-01
00-100 4 WA250, 250PZ-6
Table of contents
100 Index
Table of contents 1
00 Index and foreword
100 Index SEN03822-01
Composition of shop manual......................................................................................................................... 2
Table of contents........................................................................................................................................... 4
200 Foreword and general information SEN03823-00
Safety notice ................................................................................................................................................. 2
How to read the shop manual ....................................................................................................................... 7
Explanation of terms for maintenance standard............................................................................................ 9
Handling of electric equipment and hydraulic component............................................................................. 11
Handling of connectors newly used for engines............................................................................................ 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
01 Specification
100 Specification and technical data SEN03824-00
Specification dimension drawing................................................................................................................... 3
Specifications ................................................................................................................................................ 4
Weight table .................................................................................................................................................. 8
Table of fuel, coolant and lubricants.............................................................................................................. 10
10 Structure, function and maintenance standard
100 Engine and cooling system SEN03825-00
Engine mount and transfer mount................................................................................................................. 2
Damper ......................................................................................................................................................... 3
Cooling system.............................................................................................................................................. 4
Cooling system hydraulic piping diagram...................................................................................................... 5
Cooling fan motor.......................................................................................................................................... 7
200 Power train SEN03826-00
Power train.................................................................................................................................................... 3
Power train system diagram.......................................................................................................................... 4
Drive shaft..................................................................................................................................................... 6
HST hydraulic piping diagram....................................................................................................................... 7
HST pump..................................................................................................................................................... 8
HST motor..................................................................................................................................................... 16
Transfer......................................................................................................................................................... 22
Clutch solenoid valve .................................................................................................................................... 33
Axle ............................................................................................................................................................... 34
Differential..................................................................................................................................................... 36
Torque proportioning differential.................................................................................................................... 41
Limited slip differential................................................................................................................................... 44
Final drive...................................................................................................................................................... 48
300 Steering system SEN03827-01
Steering piping diagram ................................................................................................................................ 3
Steering column ............................................................................................................................................ 4
Priority valve.................................................................................................................................................. 5
Orbit-roll valve............................................................................................................................................... 8
2-way restrictor valve .................................................................................................................................... 16
Cushion valve................................................................................................................................................ 17
Steering cylinder............................................................................................................................................ 18
Emergency steering piping diagram.............................................................................................................. 20
Emergency steering valve............................................................................................................................. 21
Steering relief valve....................................................................................................................................... 24
SEN03822-01
WA250, 250PZ-6 00-100 5
Table of contents
100 Index
400 Brake system SEN03828-00
Brake piping diagram..................................................................................................................................... 3
Charge valve ................................................................................................................................................. 4
Brake valve.................................................................................................................................................... 8
Inching valve.................................................................................................................................................. 12
Accumulator (for brake)................................................................................................................................. 13
Slack adjuster................................................................................................................................................ 14
Brake ............................................................................................................................................................. 16
Parking brake control..................................................................................................................................... 21
Parking brake ................................................................................................................................................ 22
500 Undercarriage and frame SEN03829-00
Axle mount and center hinge pin................................................................................................................... 2
Tires............................................................................................................................................................... 7
600 Hydraulic system SEN03830-00
Work equipment hydraulic piping diagram .................................................................................................... 2
Work equipment control lever linkage ........................................................................................................... 6
Hydraulic tank................................................................................................................................................ 10
4-gear pump .................................................................................................................................................. 12
Work equipment control valve ....................................................................................................................... 14
PPC valve...................................................................................................................................................... 39
Lock valve...................................................................................................................................................... 54
Accumulator (for PPC circuit) ........................................................................................................................ 55
Bypass valve ................................................................................................................................................. 56
Quick coupler solenoid valve......................................................................................................................... 59
ECSS valve ................................................................................................................................................... 60
Accumulator (for ECSS) ................................................................................................................................ 62
700 Work equipment SEN03831-00
Work equipment linkage................................................................................................................................ 2
Bucket............................................................................................................................................................ 6
Bucket positioner and boom kick-out............................................................................................................. 10
Work equipment cylinder ............................................................................................................................... 23
800 Cab and its attachments SEN03832-00
Cab................................................................................................................................................................ 3
Air conditioner................................................................................................................................................ 4
910 Electrical system, Part 1 SEN03833-01
Machine monitor system................................................................................................................................ 2
Machine monitor............................................................................................................................................ 6
920 Electrical system, Part 2 SEN03834-01
Electrical system (HST controller system)..................................................................................................... 2
HST controller................................................................................................................................................ 18
ECSS system ................................................................................................................................................ 20
KOMTRAX system ........................................................................................................................................ 22
Engine starting circuit .................................................................................................................................... 24
Engine stopping circuit .................................................................................................................................. 26
Preheating circuit........................................................................................................................................... 27
Engine output derating function..................................................................................................................... 28
Automatic warm-up function.......................................................................................................................... 28
Parking brake circuit...................................................................................................................................... 29
Coupler plunger control system..................................................................................................................... 32
Multi-function knob ........................................................................................................................................ 33
Max. traction switch....................................................................................................................................... 34
Sensor ........................................................................................................................................................... 35
20 Standard value table
100 Standard service value table SEN03835-00
Standard service value table for engine ........................................................................................................ 2
Standard service value table for chassis ....................................................................................................... 3
SEN03822-01
00-100 6 WA250, 250PZ-6
Table of contents
100 Index
30 Testing and adjusting
110 Testing and adjusting, Part 1 SEN03836-00
Tools for testing, adjusting, and troubleshooting........................................................................................... 2
Measuring engine speed............................................................................................................................... 7
Measuring exhaust gas color ........................................................................................................................ 9
Adjusting valve clearance ............................................................................................................................. 11
Measuring compression pressure................................................................................................................. 13
Measuring blow-by pressure......................................................................................................................... 16
Measuring engine oil pressure...................................................................................................................... 17
Measuring intake air (boost) pressure........................................................................................................... 18
Handling fuel system equipment................................................................................................................... 20
Releasing residual pressure in fuel system................................................................................................... 20
Measuring fuel pressure................................................................................................................................ 21
Measuring fuel return rate and leakage ........................................................................................................ 23
Bleeding air from fuel circuit.......................................................................................................................... 27
Testing leakage in fuel system ...................................................................................................................... 28
Handling reduced cylinder mode operation................................................................................................... 29
Handling no-injection cranking operation...................................................................................................... 29
Handling controller voltage circuit ................................................................................................................. 30
Check of muffler and muffler stack for looseness and damage .................................................................... 30
Check of muffler function .............................................................................................................................. 31
Check of installed condition of cylinder head and manifolds......................................................................... 31
Check of engine piping for damage and looseness ...................................................................................... 32
Testing and adjusting air conditioner compressor belt tension...................................................................... 32
Replacing alternator belt ............................................................................................................................... 33
120 Testing and adjusting, Part 2 SEN03837-00
Checking operating force of accelerator pedal.............................................................................................. 3
Checking directional lever............................................................................................................................. 4
Testing and adjusting HST oil pressure......................................................................................................... 5
Testing clutch control pressure...................................................................................................................... 9
Testing and adjusting steering wheel ............................................................................................................ 10
Testing and adjusting steering oil pressure................................................................................................... 12
Bleeding air from steering circuit................................................................................................................... 14
Testing hydraulic fan ..................................................................................................................................... 15
Measuring brake pedal.................................................................................................................................. 17
Testing and adjusting brake pedal linkage .................................................................................................... 18
Measuring brake performance ...................................................................................................................... 19
Testing and adjusting accumulator charge pressure..................................................................................... 20
Testing wheel brake oil pressure................................................................................................................... 22
Testing wear of brake disc............................................................................................................................. 25
Bleeding air from wheel brake circuit ............................................................................................................ 26
Releasing residual pressure in brake accumulator circuit............................................................................. 27
Testing parking brake performance............................................................................................................... 28
Testing and adjusting parking brake control cable ........................................................................................ 29
Measuring and adjusting work equipment control lever................................................................................ 30
Testing and adjusting work equipment hydraulic pressure............................................................................ 31
Testing work equipment PPC oil pressure .................................................................................................... 32
Bleeding air from hydraulic circuit ................................................................................................................. 34
Releasing remaining pressure in hydraulic circuit......................................................................................... 35
Testing and adjusting bucket positioner ........................................................................................................ 36
Testing and adjusting of boom kick-out switch.............................................................................................. 37
Checking proximity switch operation pilot lamp ............................................................................................ 38
Procedure for testing diodes ......................................................................................................................... 39
Preparation work for troubleshooting for electric system .............................................................................. 41
Starting KOMTRAX terminal operations........................................................................................................ 45
Indicator lamps of KOMTRAX terminal ......................................................................................................... 49
SEN03822-01
WA250, 250PZ-6 00-100 7
Table of contents
100 Index
130 Testing and adjusting, Part 3 SEN03838-00
Adjusting machine monitor ............................................................................................................................ 2
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ............................ 3
Special functions of machine monitor (EMMS).............................................................................................. 5
Pm clinic inspection chart.............................................................................................................................. 59
40 Troubleshooting
100 Failure code table and fuse locations SEN03839-00
Failure codes table ........................................................................................................................................ 2
Fuse locations ............................................................................................................................................... 8
200 General information on troubleshooting SEN03840-00
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 ................................................................................................... 45
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
SEN03822-01
00-100 8 WA250, 250PZ-6
Table of contents
100 Index
Failure code [CA352] Sensor power supply 1 low error................................................................................ 52
Failure code [CA386] Sensor power supply 1 high error .............................................................................. 54
330 Troubleshooting by failure code (Display of code), Part 3 SEN03843-00
Failure code [CA428] Abnormally high level in water sensor........................................................................ 4
Failure code [CA429] Abnormally low level in water sensor ......................................................................... 6
Failure code [CA431] Idle validation switch error.......................................................................................... 8
Failure code [CA432] Idle validation action error .......................................................................................... 12
Failure code [CA435] Engine oil pressure switch error................................................................................. 16
Failure code [CA441] Battery voltage low error ............................................................................................ 17
Failure code [CA442] Battery voltage high error........................................................................................... 20
Failure code [CA449] Common rail pressure high error 2............................................................................. 22
Failure code [CA451] Common rail pressure sensor high error.................................................................... 24
Failure code [CA452] Common rail pressure sensor low error ..................................................................... 26
Failure code [CA488] Derating of torque by abnormally high charge temperature....................................... 28
Failure code [CA553] Common rail pressure high error 1............................................................................. 29
Failure code [CA559] Supply pump pressure very low error......................................................................... 30
Failure code [CA689] Engine Ne speed sensor error ................................................................................... 32
Failure code [CA731] Engine Bkup speed sensor phase error..................................................................... 34
Failure code [CA757] All continuous data lost error...................................................................................... 35
Failure code [CA778] Engine Bkup speed sensor error................................................................................ 38
Failure code [CA1633] KOMNET datalink timeout error ............................................................................... 40
Failure code [CA2185] Throttle sensor supply voltage high error................................................................. 44
Failure code [CA2186] Throttle sensor power supply low error .................................................................... 46
Failure code [CA2249] Supply pump pressure very low error 2.................................................................... 48
Failure code [CA2311] Abnormality in IMV (IMA) solenoid ........................................................................... 50
Failure code [CA2555] Intake heater relay disconnection error.................................................................... 52
Failure code [CA2556] Intake heater relay short circuit error........................................................................ 54
340 Troubleshooting by failure code (Display of code), Part 4 SEN03844-00
Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short ........................................................... 2
Failure code [D192KY] ECSS solenoid relay: Hot short ............................................................................... 4
Failure code [D1B0KA] HST safety relay: Disconnection ............................................................................. 6
Failure code [D1B0KB] HST safety relay: Ground fault ................................................................................ 8
Failure code [D1B0KY] HST safety relay: Hot short ..................................................................................... 10
Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection ............................................................. 12
Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection.................................................. 14
Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection ................................................ 16
Failure code [DAJ0KK] HST controller power supply: Low voltage .............................................................. 20
Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality.................................................... 22
Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault................................... 24
Failure code [DAJ1L6] HST controller main power line: Hot short................................................................ 26
Failure code [DAJ2KK] Controller solenoid power supply: Low voltage ....................................................... 28
Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness............. 30
Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault............ 32
Failure code [DAJ5KX] Sensor 5V power supply: Out of output range......................................................... 34
Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals............. 36
Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection..................................................... 37
Failure code [DAJRMA] HST controller: Disagreement in option selection .................................................. 43
350 Troubleshooting by failure code (Display of code), Part 5 SEN03845-00
Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line....................................... 3
Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality .................................................. 8
Failure code [DD1NLD] Fan reverse switch signal: Abnormality .................................................................. 10
Failure code [DDB6KA] Parking brake switch A: Disconnection/Hot short ................................................... 12
Failure code [DDB6KB] Parking brake switch B: Ground fault...................................................................... 14
Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch
(intermediate switch): Trouble................................................................................................................. 16
Failure code [DDB6L0] Parking brake switch A: Ground fault ...................................................................... 18
Failure code [DDB6L4] Parking brake switch B: Disconnection/Hot short.................................................... 20
Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault................................. 22
SEN03822-01
WA250, 250PZ-6 00-100 9
Table of contents
100 Index
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
SEN03822-01
00-100 10 WA250, 250PZ-6
Table of contents
100 Index
E-16 Alarm buzzer does not sound or it keeps sounding.............................................................................. 68
E-17 Air conditioner does not operate or stop............................................................................................... 70
E-18 The KOMTRAX system does not work properly................................................................................... 73
500 Troubleshooting of hydraulic and mechanical system (H-mode) SEN03849-00
Method of using troubleshooting chart.......................................................................................................... 3
Failure code and cause table........................................................................................................................ 6
H-1 The machine does not start.................................................................................................................... 8
H-2 The travel speed is slow......................................................................................................................... 9
H-3 The traction force is weak ...................................................................................................................... 10
H-4 Engine stalls when traveling or engine speed drops excessively........................................................... 11
H-5 The gear is not shifted............................................................................................................................ 12
H-6 The steering wheel does not turn........................................................................................................... 13
H-7 The steering wheel is heavy................................................................................................................... 14
H-8 Steering wheel shakes or jerks............................................................................................................... 15
H-9 Machine deviates naturally to one side when traveling.......................................................................... 15
H-10 The brake does not work or does not work well................................................................................... 16
H-11 The brake is not released or is dragged............................................................................................... 17
H-12 The lift arm does not rise or lower........................................................................................................ 18
H-13 The lift arm moves slowly or the lift arm rising force is insufficient....................................................... 19
H-14 When rising, the lift arm comes to move slowly at specific height........................................................ 20
H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air)................................... 20
H-16 Hydraulic drifts of the lift arm occur often ............................................................................................. 20
H-17 The lift arm wobbles during operation .................................................................................................. 20
H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily.................. 21
H-19 The bucket does not tilt back................................................................................................................ 22
H-20 The bucket moves slowly or the tilting-back force is insufficient .......................................................... 23
H-21 The bucket comes to operate slowly in the midst of tilting-back .......................................................... 24
H-22 The bucket cylinder cannot hold down the bucket ............................................................................... 24
H-23 Hydraulic drifts of the bucket occur often ............................................................................................. 24
H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”) ................. 24
H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily ...................... 25
H-26 The control levers of the lift arm and bucket do not move smoothly and heavy................................... 25
H-27 The ECSS does not operate and machine pitches and bounces......................................................... 26
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) ................ 27
600 Troubleshooting of engine (S-mode) SEN03850-00
Method of using troubleshooting charts ........................................................................................................ 2
S-1 Starting performance is poor .................................................................................................................. 6
S-2 Engine does not start.............................................................................................................................. 7
S-3 Engine does not pick up smoothly.......................................................................................................... 10
S-4 Engine stops during operations.............................................................................................................. 11
S-5 Engine does not rotate smoothly............................................................................................................ 12
S-6 Engine lacks output (or lacks power)...................................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 15
S-9 Oil becomes contaminated quickly......................................................................................................... 16
S-10 Fuel consumption is excessive............................................................................................................. 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 18
S-12 Oil pressure drops ................................................................................................................................ 19
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 20
S-14 Coolant temperature becomes too high (overheating) ......................................................................... 21
S-15 Abnormal noise is made....................................................................................................................... 22
S-16 Vibration is excessive........................................................................................................................... 23
SEN03822-01
WA250, 250PZ-6 00-100 11
Table of contents
100 Index
50 Disassembly and assembly
100 General information on disassembly and assembly SEN03851-00
How to read this manual................................................................................................................................ 2
Coating materials list ..................................................................................................................................... 4
Special tool list............................................................................................................................................... 7
Sketches of special tools............................................................................................................................... 11
200 Engine and cooling system SEN03852-00
Removal and installation of fuel supply pump assembly............................................................................... 2
Removal and installation of fuel injector assembly........................................................................................ 4
Removal and installation of cylinder head assembly..................................................................................... 11
Removal and installation of engine hood assembly ...................................................................................... 24
Removal and installation of radiator .............................................................................................................. 27
Removal and installation of air aftercooler..................................................................................................... 30
Removal and installation of hydraulic oil cooler assembly ............................................................................ 32
Removal and installation of engine assembly ............................................................................................... 34
Removal and installation of engine front oil seal assembly........................................................................... 40
Removal and installation of engine rear oil seal assembly............................................................................ 43
Removal and installation of cooling fan and fan motor assembly.................................................................. 46
Removal and installation of fuel tank assembly............................................................................................. 49
310 Power train, Part 1 SEN03853-00
Removal and installation of transfer assembly.............................................................................................. 2
Disassembly and assembly of transfer assembly.......................................................................................... 6
Removal and installation of parking brake assembly..................................................................................... 26
Disassembly and assembly of parking brake assembly................................................................................ 28
320 Power train, Part 2 SEN03854-00
Removal and installation of front axle assembly ........................................................................................... 2
Removal and installation of rear axle assembly ............................................................................................ 4
Disassembly and assembly of axle housing assembly.................................................................................. 7
Disassembly and assembly of differential assembly ..................................................................................... 16
400 Undercarriage and frame SEN03855-00
Removal and installation of center hinge pin................................................................................................. 2
Removal and installation of counterweight.................................................................................................... 12
500 Hydraulic system SEN03856-00
Removal and installation of HST pump and 4-gear pump assembly............................................................. 2
Disassembly and assembly of HST pump assembly..................................................................................... 6
Removal and installation of HST motor 1 assembly...................................................................................... 33
Removal and installation of HST motor 2 assembly...................................................................................... 35
Disassembly and assembly of HST motor assembly .................................................................................... 37
Removal and installation of work equipment control valve assembly............................................................ 53
Removal and installation of hydraulic tank .................................................................................................... 55
Disassembly and assembly of hydraulic cylinder assembly.......................................................................... 57
600 Work equipment SEN03857-01
Removal and installation of work equipment assembly................................................................................. 2
700 Cab and its attachments SEN03858-00
Removal and installation of operator's cab and floor frame assembly .......................................................... 2
Removal and installation of operator's cab glass (Stuck glass)..................................................................... 7
Removal and installation of air conditioner unit............................................................................................. 15
800 Electrical system SEN03859-00
Removal and installation of monitor panel..................................................................................................... 2
Removal and installation of engine controller assembly................................................................................ 4
Removal and installation of HST controller assembly ................................................................................... 5
Removal and installation of KOMTRAX terminal assembly........................................................................... 6
SEN03822-01
00-100 12 WA250, 250PZ-6
Table of contents
100 Index
90 Diagrams and drawings
100 Hydraulic diagrams and drawings SEN03860-01
Hydraulic circuit diagram............................................................................................................................... 3
200 Electrical diagrams and drawings SEN03861-01
Electrical circuit diagram ............................................................................................................................... 3
Connector list and stereogram...................................................................................................................... 21
SEN03852-00
50-200 2 WA250, 250PZ-6
200 Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of fuel
supply pump 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,
stop the engine, apply the parking brake,
and put chocks under the tires.
k Disconnect the cable from the negative (–)
terminal of the battery.
1. Open and fix right engine side cover (1).
a Check that the cover is locked securely.
2. Remove fuel prefilter and bracket assembly
(2).
a Fix fuel prefilter and bracket assembly (2)
to the machine with ropes.
3. Disconnect wiring harness connector CN-CP3
(3) from fuel supply pump (4).
4. Disconnect fuel filter hoses (5) and (6) from
fuel supply pump (4).
5. Disconnect fuel return hose (7) from fuel sup-
ply pump (4).
a If mud is sticking, lock (L) may become
stiff. Accordingly, clean the connecting
area.
a Press lock (L) from both sides and pull out
hose (5).
a Plug the disconnected hose to prevent
fuel leakage.
6. Disconnect fuel supply hose (8) from fuel sup-
ply pump (4). [*1]
7. Remove 2 clamps of boot (9) and fuel high-
pressure pipe (10).
8. Disconnect fuel high-pressure pipe (10) from
fuel supply pump (4). [*2]
a Remove the boot on the common rail side
of high-pressure pipe (10) and loosen the
sleeve nut.
SEN03852-00
WA250, 250PZ-6 50-200 3
200 Engine and cooling system
Removal and installation of fuel supply pump assembly
9. Remove 3 mounting nuts at part (A) and fuel
supply pump assembly (11). [*3]
a Remove fuel supply pump assembly (11)
and the gear together. The gear does not
have a positioning mark (missing tooth),
etc.
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}
[*2]
q How to install high-pressure pipe (10)
1. Tighten the sleeve nut with the fingers.
2. Check that the high-pressure pipe is installed
correctly and tighten the sleeve nut to the fol-
lowing torque.
3 Sleeve nut:
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
k Be sure to use the genuine fuel high-
pressure pipe clamp and strictly
observe the specified tightening
torque.
3. Install boot (9).
a Direct the slit of the boot down.
a The boot is installed so that fuel will not
spout over the hot parts of the engine and
catch fire when it leaks for some reason.
[*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.
Install fuel supply pump (12).
3 Fuel supply pump mounting nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
q Bleeding air
Bleed air from the fuel system. For details, see
Testing and adjusting, "Bleeding air from fuel
system".
SEN03852-00
50-200 4 WA250, 250PZ-6
200 Engine and cooling system
Removal and installation of fuel injector assembly
Removal and installation of fuel
injector assembly 1
Special tools
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.
6 Radiator: Approx. 22 l
2. Remove the engine hood assembly. For
details, see "Removal and installation of
engine hood assembly".
3. Lift off muffler (1).
a Take care that the muffler will not interfere
with water drain tube (2).
4 Muffler assembly: Approx. 35 kg
4. Disconnect engine intake air heater wiring har-
ness terminal CN-E07B (3). [*1]
5. Remove clamp (4) and bracket (4a). [*2]
6. Remove clamp (5), air hose (5a), mounting
bolt (6a) and intake air inlet elbow (6). [*3]
a Remove the engine intake air heater, too.
7. Remove 2 wiring harness clamps (7).
8. Disconnect wiring harness connector (8).
a While pressing the lock of wiring harness
connector (8) with flat-head screwdriver
[1], pull the connector in the direction of
the arrow.
a Do not remove fuel pressure sensor (PS)
except for replacement.
9. Disconnect 3 wiring harness connectors (9).
[*4]
a While pressing the lock of the wiring har-
ness connector with flat-head screwdriver
[2], pull the connector.
a Move wiring harness (10) toward the
intake manifold.
Symbol Part No. Part name
Necessity
Q'ty
New/Remodel
Sketch
A
3 795-799-6700 Puller t 1
4 795-799-1131 Gear t 1
5 795-799-8150 Remover q 1
SEN03852-00
WA250, 250PZ-6 50-200 5
200 Engine and cooling system
Removal and installation of fuel injector assembly
10. Using hexagonal wrench (width across flats:
3 mm), remove blow-by duct (11). [*5]
11. Remove 6 mounting nuts (12) and cylinder
head cover (13). [*6]
12. Remove 6 boots (14). [*7]
13. Remove 6 high-pressure pipes (15). [*8]
a Loosen the sleeve nut on the common rail
side of each high-pressure pipe.
14. Position the crankshaft according to the follow-
ing procedure.
1) Remove plug (16) under the starting motor
and set tool A4.
2) Rotate the crankshaft forward (counter-
clockwise seeing from the flywheel side)
to set marks (M1) and (M2).
Mark (M1):Top of projection of front cover
Mark (M2):A wide slit on slitted revolution
sensor disc at rear of crank-
shaft pulley
Mark (M3):Yellow paint on vibration
damper (on prolongation of
wide slit (M2))
a Set the projection top of mark (M1)
within the wide slit (M2).
a There is yellow paint mark (M3) on
the prolongation of wide slit (M2).
a When the marks are set as above,
the piston of the No. 1 or No. 6 cylin-
der is 76 – 88° before the top dead
center.
a See Testing and adjusting, "Adjusting
valve clearance".
a Use tool A4 to rotate the crankshaft.
SEN03852-00
50-200 6 WA250, 250PZ-6
200 Engine and cooling system
Removal and installation of fuel injector assembly
15. Remove the 12 mounting bolts and rocker arm
(17).
a Loosen locknut (18), and then loosen
adjustment screw (19) by 2 – 3 turns so
that an excessive force will not be applied
to the push rod when the rocker arm is
installed.
16. Remove 12 crossheads (20).
a Record the positions and shapes of holes
(a) and (b) of each crosshead. (Reinstall
each crosshead in the same direction.)
17. Remove retaining nuts (21) and 6 inlet connec-
tors (22).
a Before removing, clean the inlet connec-
tors carefully so that mud, etc. sticking
around them will not enter their holes.
a Tool A5 is set for removal of inlet connec-
tor (22). (See the special tools list.)
18. Remove 2 wiring harness mounting nuts (24)
from fuel injector assembly (23).
Wiring harness
color
Cylinder No.
White 1, 3, 5
Black 2, 4, 6
SEN03852-00
WA250, 250PZ-6 50-200 7
200 Engine and cooling system
Removal and installation of fuel injector assembly
19. Remove 2 mounting bolts (25) of fuel injector
assembly (23).
20. Using tool A3, remove fuel injector assembly
(23).
a Take care that dirt and foreign matter will
not enter the fuel injector assembly
mounting area.
Installation
a The internal parts of the fuel hose adapter may
be damaged when it is removed. Accordingly,
do not reuse the fuel hose but use new one
when assembling again, as a rule.
When replacing the fuel injector assembly with
new one, be sure to replace the inlet connector
with new one, too.
1. Fuel injector assembly
a Check that the fuel injector sleeve (23a) is
free from flaw and dirt.
1) Fit O-ring (26) and gasket (27) to fuel
injector (23).
2) Apply engine oil (For details, see "Table of
fuel, coolant and lubricants") to O-ring (26)
of fuel injector (23) and the mounting hole
on the cylinder head side.
3) While setting convex and concave parts
(A), install holder (28) to fuel injector (23).
SEN03852-00
50-200 8 WA250, 250PZ-6
200 Engine and cooling system
Removal and installation of fuel injector assembly
4) Insert fuel injector (23) in the cylinder
head, directing its fuel inlet hole toward
the air intake manifold.
5) Tighten 2 mounting bolts (25) of fuel injec-
tor (23) by 3 – 4 turns.
6) Apply engine oil (For details, see "Table of
fuel, coolant and lubricants") to the mount-
ing hole of inlet connector (22) on the cyl-
inder head side.
7) Apply engine oil (For details, see "Table of
fuel, coolant and lubricants") to O-ring (29)
of inlet connector (22).
8) Insert inlet connector (22) perfectly, while
setting part (B) to the groove on the cylin-
der head side.
9) Secure inlet connector (22) by tightening
retaining nut (21) lightly.
3 Retaining nut (21):
15 ± 5 Nm {1.5 ± 0.5 kgm}
10) Tighten 2 mounting bolts (25) of fuel 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}
12) Install the wiring harnesses to fuel injector
(23) and tighten 2 mounting nuts (24).
3 Wiring harness mounting nut (24):
1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}
a Installed positions of wiring har-
nesses
Wiring harness
color
Cylinder No.
White 1, 3, 5
Black 2, 4, 6
SEN03852-00
WA250, 250PZ-6 50-200 9
200 Engine and cooling system
Removal and installation of fuel injector assembly
q Precautions for installing inlet connector
1) When replacing the fuel injector assembly
with new one, be sure to replace inlet con-
nector, too.
2) Check the inlet connector visually. If it has
any of the following faults, replace it.
1] There is a bur or a worn part at front
end (a) or rear end (b) of the inlet
connector.
2] There is foreign matter in the edge fil-
ter at rear end (c) of the inlet connec-
tor.
3] The O-ring at upper part (d) of the
inlet connector is cracked or deterio-
rated.
3) Check the inlet connector visually. If it has
any of the following faults, replace it and
fuel injector assembly together.
q There is a worn part or an uneven
seat contact mark on sealing face (e)
at the front end of the inlet connector.
a If high-pressure fuel leaks
through the inlet connector, the
seal face has fine streaks or
cracks.
2. Crosshead and rocker arm assembly
1) Install the crosshead and rocker arm.
a The shapes of holes (a) and (b) of
each crosshead are different. Accord-
ingly, when reusing the crossheads,
install each of them to the same
intake/exhaust valve in the same
direction as it has been installed.
2) Check that the ball of adjustment screw
(19) is set in the push rod socket securely
and then tighten mounting bolts (30).
3 Rocker arm mounting bolt (30):
36 ± 5 Nm {3.7 ± 0.5 kgm}
3) Adjust the valve clearance. For details,
see Testing and adjusting, "Adjusting
valve clearance".
3 Locknut (18):
24 ± 4 {2.4 ± 0.4 kgm}
SEN03852-00
50-200 10 WA250, 250PZ-6
200 Engine and cooling system
Removal and installation of fuel injector assembly
q Carry out the following installation in the
reverse order to removal.
[*1]
3 Wiring harness terminal CN-E07B (3):
4.0 ± 0.6 Nm {0.41 ± 0.06 kgm}
[*2]
3 Clamp (4): 10.8 – 26.5 Nm {1.1 – 2.7 kgm}
[*3]
3 Clamp (5): 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
3 Intake air inlet elbow mounting bolt (6a):
24 ± 4 Nm {2.4 ± 0.4 kgm}
[*4]
k Install each fuel high-pressure pipe and
wiring harness at least 10 mm apart from
each other.
[*5]
3 Blow-by duct mounting bolt:
7 ± 2 Nm {0.7 ± 0.2 kgm}
[*6]
3 Cylinder head cover mounting nut (12):
24 ± 4 Nm {2.4 ± 0.4 kgm}
[*7], [*8]
k Do not bend the fuel high-pressure pipe to
correct before installing.
k Be sure to use the genuine fuel high-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.
1) Temporarily install fuel high-pressure
pipes (31) – (36).
3 Sleeve nut:
0.2 – 0.8 Nm {0.02 – 0.08 kgm}
2) Tighten fuel high-pressure pipes (31) –
(36) in the following order.
1] Tighten the cylinder head side of fuel
high-pressure pipes (31) and (36).
2] Tighten the common rail side of fuel
high-pressure pipes (31) and (36).
3] Tighten the cylinder head side of fuel
high-pressure pipes (32), (33), (34)
and (35).
4] Tighten the common rail side of fuel
high-pressure pipes (32), (33), (34)
and (35).
3 Sleeve nut:
35 ± 3.5 Nm {3.6 ± 0.4 kgm}
3) Install 6 boots (14) to the fuel high-pres-
sure pipes.
a Direct the slit of the boot out and
down.
a The boots are installed so that fuel
will not spout over the hot parts of the
engine to catch fire when it leaks for
some reason.
q Bleeding air
Bleed air from the fuel system. For details, see
Testing and adjusting, "Bleeding air from fuel
system".
q Refilling with coolant
Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
5 Total amount of coolant: Approx. 22 l
(For details, see "Table of fuel, coolant and
lubricants")
SEN03852-00
WA250, 250PZ-6 50-200 11
200 Engine and cooling system
Removal and installation of cylinder head assembly
Removal and installation of
cylinder head assembly 1
Special tools
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.
6 Radiator: Approx. 22 l
2. Remove the engine hood assembly. For
details, see "Removal and installation of
engine hood assembly".
3. Lift off muffler (1).
a Take care that the muffler will not interfere
with water drain tube (2).
4 Muffler assembly: Approx. 35 kg
4. Disconnect engine intake air heater wiring har-
ness terminal CN-E07B (3). [*1]
5. Remove clamp (4) and bracket (4a). [*2]
6. Remove clamp (5), air hose (5a), and intake air
inlet elbow (6). [*3]
a Remove the engine intake air heater, too.
7. Remove bracket (7).
8. Remove wiring harness clamp (8).
9. Disconnect wiring harness connector (9).
10. Remove air conditioner compressor assembly
(10). [*4]
a Fix air conditioner compressor assembly
(10) to the machine with ropes.
Symbol Part No. Part name
Necessity
Q'ty
New/Remodel
Sketch
A
3 795-799-6700 Puller t 1
4 795-799-1131 Gear t 1
5 795-799-8150 Remover q 1
6 790-331-1120 Wrench (angle) q 1
7 795-790-4510 Gauge q 1
SEN03852-00
50-200 12 WA250, 250PZ-6
200 Engine and cooling system
Removal and installation of cylinder head assembly
11. Disconnect fuel filter hoses (11) and (12).
a If mud is sticking, lock (L) may become
stiff. Accordingly, clean the connecting
area.
a Press lock (L) from both sides and pull out
hose (12).
a Plug the disconnected hoses to prevent
fuel leakage.
12. Disconnect fuel return hose (13).
13. Remove fuel prefilter hose clamp (14).
14. Remove 2 air conditioner compressor hose
clamps (15).
15. Remove fuel filter and bracket assembly (16).
16. Remove 2 clamps (17).
17. Disconnect engine coolant temperature sensor
connector (18).
18. Disconnect ambient air pressure sensor con-
nector (19).
a Move the lock of ambient air pressure
sensor connector (19) in the direction of
the arrow and pull out the connector while
pressing the claw.
19. Disconnect intake air pressure sensor connec-
tor (20).
20. Remove 2 wiring harness clamps (21).
21. Disconnect wiring harness connector (22).
a While pressing the lock of wiring harness
connector (22) with flat-head screwdriver
[1], pull the connector in the direction of
the arrow.
a Do not remove fuel pressure sensor (PS)
except for replacement.
22. Disconnect 3 wiring harness connectors (23).
[*5]
a While pressing the lock of the wiring har-
ness connector with flat-head screwdriver
[2], pull the connector.
a Move wiring harness (24) toward the
intake manifold.
Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.
SEN03852-00
WA250, 250PZ-6 50-200 13
200 Engine and cooling system
Removal and installation of cylinder head assembly
23. Disconnect fuel drain hose (25). [*6]
24. Disconnect high-pressure pipe (26). [*7]
25. Remove 6 boots (27). [*8]
26. Remove 6 high-pressure pipes (28). [*9]
a Loosen the sleeve nut on the common rail
side of each high-pressure pipe.
27. Disconnect radiator upper hose (29). [*10]
28. Disconnect air aftercooler upper hose (30).
[*11]
29. Disconnect heater hose (31).
30. Disconnect corrosion resistor hose (32).
31. Remove corrosion resistor and bracket assem-
bly (33).
SEN03852-00
50-200 14 WA250, 250PZ-6
200 Engine and cooling system
Removal and installation of cylinder head assembly
32. Remove wiring harness clamp (34).
33. Remove 2 heat insulation plates (35).
34. Remove heat insulation plate (36).
35. Remove cover (37).
36. Disconnect wiring [1] harness connectors CN-
E02 and CN-E03 (38).
37. Put the wrench in part (A) (width across flats:
12.7 mm) of tensioner assembly (40) and turn
it in the unwinding direction to decrease the
tension of fan belt (41).
k Set the wrench [1] securely to part (A)
of tensioner assembly (40) before turn-
ing it. (The spring of tensioner assem-
bly (40) is strong. If the wrench [1] is
set incompletely and turned, it comes
off and that is very dangerous.)
k After removing belt (41), return ten-
sioner assembly (40) slowly and care-
fully.
k Take care not to catch your finger
between the pulley and fan belt (41)
during work.
38. Remove alternator assembly (39).
SEN03852-00
WA250, 250PZ-6 50-200 15
200 Engine and cooling system
Removal and installation of cylinder head assembly
39. Disconnect turbocharger lubricating oil inlet
tube (42) and drain hose (43). [*12]
40. Remove the 2 mounting bolts and bracket (44).
41. Remove the mounting bolts of exhaust mani-
fold (45), leaving some of them installed.
[*13]
42. Temporarily sling exhaust manifold and turbo-
charger assembly (46) and remove the remain-
ing mounting bolts.
43. Lift off exhaust manifold and turbocharger
assembly (46).
4 Exhaust manifold and turbocharger
assembly: 45 kg
44. Using hexagonal wrench (width across flats: 3
mm), remove blow-by duct (47). [*14]
45. Remove 6 mounting nuts (48) and cylinder
head cover (49). [*15]
46. Position the crankshaft according to the follow-
ing procedure.
1) Remove plug (50) under the starting motor
and set tool A4.
2) Rotate the crankshaft forward (counter-
clockwise seeing from the flywheel side)
to set marks (M1) and (M2).
Mark (M1): Top of projection of front cover
Mark (M2): A wide slit on slitted revolution
sensor disc at rear of crank-
shaft pulley
Mark (M3): Yellow paint on vibration
damper (on prolongation of
wide slit (M2))
a Set the projection top of mark (M1)
within the wide slit (M2).
a There is yellow paint mark (M3) on
the prolongation of wide slit (M2).
a When the marks are set as above,
the piston of the No. 1 or No. 6 cylin-
der is 76 – 88° before the top dead
center.
a See Testing and adjusting, "Adjusting
valve clearance".
a Use tool A4 to rotate the crankshaft.

More Related Content

More from ufjjsjefkksemm

Mc cormick 9 7 series (2014- ) - rs37 - 9095 - 90105 ism tractor service repa...
Mc cormick 9 7 series (2014- ) - rs37 - 9095 - 90105 ism tractor service repa...Mc cormick 9 7 series (2014- ) - rs37 - 9095 - 90105 ism tractor service repa...
Mc cormick 9 7 series (2014- ) - rs37 - 9095 - 90105 ism tractor service repa...ufjjsjefkksemm
 
Mc cormick 9 7 series (2014- ) - rs37 - 7070 - 7080 arm tractor service repai...
Mc cormick 9 7 series (2014- ) - rs37 - 7070 - 7080 arm tractor service repai...Mc cormick 9 7 series (2014- ) - rs37 - 7070 - 7080 arm tractor service repai...
Mc cormick 9 7 series (2014- ) - rs37 - 7070 - 7080 arm tractor service repai...ufjjsjefkksemm
 
Mc cormick (2011 ) - rs43 - 6450 ism-vrm tractor service repair manual
Mc cormick (2011  ) - rs43 - 6450 ism-vrm tractor service repair manualMc cormick (2011  ) - rs43 - 6450 ism-vrm tractor service repair manual
Mc cormick (2011 ) - rs43 - 6450 ism-vrm tractor service repair manualufjjsjefkksemm
 
Komatsu d31 pl 20 dozer bulldozer service repair manual
Komatsu d31 pl 20 dozer bulldozer service repair manualKomatsu d31 pl 20 dozer bulldozer service repair manual
Komatsu d31 pl 20 dozer bulldozer service repair manualufjjsjefkksemm
 
Komatsu d31 p 20a dozer bulldozer service repair manual
Komatsu d31 p 20a dozer bulldozer service repair manualKomatsu d31 p 20a dozer bulldozer service repair manual
Komatsu d31 p 20a dozer bulldozer service repair manualufjjsjefkksemm
 
Komatsu d31 p 20 dozer bulldozer service repair manual
Komatsu d31 p 20 dozer bulldozer service repair manualKomatsu d31 p 20 dozer bulldozer service repair manual
Komatsu d31 p 20 dozer bulldozer service repair manualufjjsjefkksemm
 
Komatsu d31 e 20 dozer bulldozer service repair manual
Komatsu d31 e 20 dozer bulldozer service repair manualKomatsu d31 e 20 dozer bulldozer service repair manual
Komatsu d31 e 20 dozer bulldozer service repair manualufjjsjefkksemm
 
Komatsu d21 a,p 8 dozer bulldozer service repair manual (sn 83001 and up)
Komatsu d21 a,p 8 dozer bulldozer service repair manual (sn 83001 and up)Komatsu d21 a,p 8 dozer bulldozer service repair manual (sn 83001 and up)
Komatsu d21 a,p 8 dozer bulldozer service repair manual (sn 83001 and up)ufjjsjefkksemm
 
Komatsu 12 v170 1 diesel engine service repair manual
Komatsu 12 v170 1 diesel engine service repair manualKomatsu 12 v170 1 diesel engine service repair manual
Komatsu 12 v170 1 diesel engine service repair manualufjjsjefkksemm
 
John deere 500 trail buck utility atv service repair manual (tm2160)
John deere 500 trail buck utility atv service repair manual (tm2160)John deere 500 trail buck utility atv service repair manual (tm2160)
John deere 500 trail buck utility atv service repair manual (tm2160)ufjjsjefkksemm
 
John deere 500 buck utility atv service repair manual (tm2153)
John deere 500 buck utility atv service repair manual (tm2153)John deere 500 buck utility atv service repair manual (tm2153)
John deere 500 buck utility atv service repair manual (tm2153)ufjjsjefkksemm
 
John deere 315 d side shift loader service repair technical manual (tm1497)
John deere 315 d side shift loader service repair technical manual (tm1497)John deere 315 d side shift loader service repair technical manual (tm1497)
John deere 315 d side shift loader service repair technical manual (tm1497)ufjjsjefkksemm
 
John deere 314 f walk behind tillers service repair manual (tm1687)
John deere 314 f walk behind tillers service repair manual (tm1687)John deere 314 f walk behind tillers service repair manual (tm1687)
John deere 314 f walk behind tillers service repair manual (tm1687)ufjjsjefkksemm
 
John deere 310 d backhoe loaders service repair technical manual (tm1497)
John deere 310 d backhoe loaders service repair technical manual (tm1497)John deere 310 d backhoe loaders service repair technical manual (tm1497)
John deere 310 d backhoe loaders service repair technical manual (tm1497)ufjjsjefkksemm
 
John deere 300 d backhoe loaders service repair technical manual (tm1497)
John deere 300 d backhoe loaders service repair technical manual (tm1497)John deere 300 d backhoe loaders service repair technical manual (tm1497)
John deere 300 d backhoe loaders service repair technical manual (tm1497)ufjjsjefkksemm
 
John deere 50 d compact excavator service repair technical manual (tm2264)
John deere 50 d compact excavator service repair technical manual (tm2264)John deere 50 d compact excavator service repair technical manual (tm2264)
John deere 50 d compact excavator service repair technical manual (tm2264)ufjjsjefkksemm
 
John deere 35 g (sn. from k270001) compact excavator service repair technical...
John deere 35 g (sn. from k270001) compact excavator service repair technical...John deere 35 g (sn. from k270001) compact excavator service repair technical...
John deere 35 g (sn. from k270001) compact excavator service repair technical...ufjjsjefkksemm
 
John deere 35 d compact excavator service repair technical manual (tm2264)
John deere 35 d compact excavator service repair technical manual (tm2264)John deere 35 d compact excavator service repair technical manual (tm2264)
John deere 35 d compact excavator service repair technical manual (tm2264)ufjjsjefkksemm
 
John deere 27 zts compact excavator service repair technical manual (tm1837)
John deere 27 zts compact excavator service repair technical manual (tm1837)John deere 27 zts compact excavator service repair technical manual (tm1837)
John deere 27 zts compact excavator service repair technical manual (tm1837)ufjjsjefkksemm
 
John deere 4x2 and 4x6 gator utility vehicle service repair manual (tm1518)
John deere 4x2 and 4x6 gator utility vehicle service repair manual (tm1518)John deere 4x2 and 4x6 gator utility vehicle service repair manual (tm1518)
John deere 4x2 and 4x6 gator utility vehicle service repair manual (tm1518)ufjjsjefkksemm
 

More from ufjjsjefkksemm (20)

Mc cormick 9 7 series (2014- ) - rs37 - 9095 - 90105 ism tractor service repa...
Mc cormick 9 7 series (2014- ) - rs37 - 9095 - 90105 ism tractor service repa...Mc cormick 9 7 series (2014- ) - rs37 - 9095 - 90105 ism tractor service repa...
Mc cormick 9 7 series (2014- ) - rs37 - 9095 - 90105 ism tractor service repa...
 
Mc cormick 9 7 series (2014- ) - rs37 - 7070 - 7080 arm tractor service repai...
Mc cormick 9 7 series (2014- ) - rs37 - 7070 - 7080 arm tractor service repai...Mc cormick 9 7 series (2014- ) - rs37 - 7070 - 7080 arm tractor service repai...
Mc cormick 9 7 series (2014- ) - rs37 - 7070 - 7080 arm tractor service repai...
 
Mc cormick (2011 ) - rs43 - 6450 ism-vrm tractor service repair manual
Mc cormick (2011  ) - rs43 - 6450 ism-vrm tractor service repair manualMc cormick (2011  ) - rs43 - 6450 ism-vrm tractor service repair manual
Mc cormick (2011 ) - rs43 - 6450 ism-vrm tractor service repair manual
 
Komatsu d31 pl 20 dozer bulldozer service repair manual
Komatsu d31 pl 20 dozer bulldozer service repair manualKomatsu d31 pl 20 dozer bulldozer service repair manual
Komatsu d31 pl 20 dozer bulldozer service repair manual
 
Komatsu d31 p 20a dozer bulldozer service repair manual
Komatsu d31 p 20a dozer bulldozer service repair manualKomatsu d31 p 20a dozer bulldozer service repair manual
Komatsu d31 p 20a dozer bulldozer service repair manual
 
Komatsu d31 p 20 dozer bulldozer service repair manual
Komatsu d31 p 20 dozer bulldozer service repair manualKomatsu d31 p 20 dozer bulldozer service repair manual
Komatsu d31 p 20 dozer bulldozer service repair manual
 
Komatsu d31 e 20 dozer bulldozer service repair manual
Komatsu d31 e 20 dozer bulldozer service repair manualKomatsu d31 e 20 dozer bulldozer service repair manual
Komatsu d31 e 20 dozer bulldozer service repair manual
 
Komatsu d21 a,p 8 dozer bulldozer service repair manual (sn 83001 and up)
Komatsu d21 a,p 8 dozer bulldozer service repair manual (sn 83001 and up)Komatsu d21 a,p 8 dozer bulldozer service repair manual (sn 83001 and up)
Komatsu d21 a,p 8 dozer bulldozer service repair manual (sn 83001 and up)
 
Komatsu 12 v170 1 diesel engine service repair manual
Komatsu 12 v170 1 diesel engine service repair manualKomatsu 12 v170 1 diesel engine service repair manual
Komatsu 12 v170 1 diesel engine service repair manual
 
John deere 500 trail buck utility atv service repair manual (tm2160)
John deere 500 trail buck utility atv service repair manual (tm2160)John deere 500 trail buck utility atv service repair manual (tm2160)
John deere 500 trail buck utility atv service repair manual (tm2160)
 
John deere 500 buck utility atv service repair manual (tm2153)
John deere 500 buck utility atv service repair manual (tm2153)John deere 500 buck utility atv service repair manual (tm2153)
John deere 500 buck utility atv service repair manual (tm2153)
 
John deere 315 d side shift loader service repair technical manual (tm1497)
John deere 315 d side shift loader service repair technical manual (tm1497)John deere 315 d side shift loader service repair technical manual (tm1497)
John deere 315 d side shift loader service repair technical manual (tm1497)
 
John deere 314 f walk behind tillers service repair manual (tm1687)
John deere 314 f walk behind tillers service repair manual (tm1687)John deere 314 f walk behind tillers service repair manual (tm1687)
John deere 314 f walk behind tillers service repair manual (tm1687)
 
John deere 310 d backhoe loaders service repair technical manual (tm1497)
John deere 310 d backhoe loaders service repair technical manual (tm1497)John deere 310 d backhoe loaders service repair technical manual (tm1497)
John deere 310 d backhoe loaders service repair technical manual (tm1497)
 
John deere 300 d backhoe loaders service repair technical manual (tm1497)
John deere 300 d backhoe loaders service repair technical manual (tm1497)John deere 300 d backhoe loaders service repair technical manual (tm1497)
John deere 300 d backhoe loaders service repair technical manual (tm1497)
 
John deere 50 d compact excavator service repair technical manual (tm2264)
John deere 50 d compact excavator service repair technical manual (tm2264)John deere 50 d compact excavator service repair technical manual (tm2264)
John deere 50 d compact excavator service repair technical manual (tm2264)
 
John deere 35 g (sn. from k270001) compact excavator service repair technical...
John deere 35 g (sn. from k270001) compact excavator service repair technical...John deere 35 g (sn. from k270001) compact excavator service repair technical...
John deere 35 g (sn. from k270001) compact excavator service repair technical...
 
John deere 35 d compact excavator service repair technical manual (tm2264)
John deere 35 d compact excavator service repair technical manual (tm2264)John deere 35 d compact excavator service repair technical manual (tm2264)
John deere 35 d compact excavator service repair technical manual (tm2264)
 
John deere 27 zts compact excavator service repair technical manual (tm1837)
John deere 27 zts compact excavator service repair technical manual (tm1837)John deere 27 zts compact excavator service repair technical manual (tm1837)
John deere 27 zts compact excavator service repair technical manual (tm1837)
 
John deere 4x2 and 4x6 gator utility vehicle service repair manual (tm1518)
John deere 4x2 and 4x6 gator utility vehicle service repair manual (tm1518)John deere 4x2 and 4x6 gator utility vehicle service repair manual (tm1518)
John deere 4x2 and 4x6 gator utility vehicle service repair manual (tm1518)
 

Recently uploaded

-VDA-Special-Characteristics Special characteristics.pdf
-VDA-Special-Characteristics Special characteristics.pdf-VDA-Special-Characteristics Special characteristics.pdf
-VDA-Special-Characteristics Special characteristics.pdfBorja ARRIZABALAGA URIARTE
 
Automotive Bootloader Complete Guide with UDS Frame Format
Automotive Bootloader Complete Guide with UDS Frame FormatAutomotive Bootloader Complete Guide with UDS Frame Format
Automotive Bootloader Complete Guide with UDS Frame FormatKapil Thakar
 
Timer Handling in UDS | S3 Server Timer | P2 and P2 Start Timer
Timer Handling in UDS | S3 Server Timer | P2 and P2 Start TimerTimer Handling in UDS | S3 Server Timer | P2 and P2 Start Timer
Timer Handling in UDS | S3 Server Timer | P2 and P2 Start TimerKapil Thakar
 
Introduction to UDS over CAN | UDS Service
Introduction to UDS over CAN | UDS ServiceIntroduction to UDS over CAN | UDS Service
Introduction to UDS over CAN | UDS ServiceKapil Thakar
 
Advanced Technology for Auto Part Industry Inventory Solutions
Advanced Technology for Auto Part Industry Inventory SolutionsAdvanced Technology for Auto Part Industry Inventory Solutions
Advanced Technology for Auto Part Industry Inventory Solutionscontactcaysonandres
 
technical report on EV. EVs can offer benefitssuch as lower operating costs a...
technical report on EV. EVs can offer benefitssuch as lower operating costs a...technical report on EV. EVs can offer benefitssuch as lower operating costs a...
technical report on EV. EVs can offer benefitssuch as lower operating costs a...Bijay Sharma
 
CBC used in Indian Railways for train coupling.pptx
CBC used in Indian Railways for train coupling.pptxCBC used in Indian Railways for train coupling.pptx
CBC used in Indian Railways for train coupling.pptxGaurav Singh
 
Essential Maintenance Tips For Commercial Vans.
Essential Maintenance Tips For Commercial Vans.Essential Maintenance Tips For Commercial Vans.
Essential Maintenance Tips For Commercial Vans.commercialvansolutions
 
Quicker and better: South Korea’s new high-speed train 'EMU-320'
Quicker and better: South Korea’s new high-speed train 'EMU-320'Quicker and better: South Korea’s new high-speed train 'EMU-320'
Quicker and better: South Korea’s new high-speed train 'EMU-320'Hyundai Motor Group
 
CAMIONES TOYOTA N04C- Engine y HINO 300.
CAMIONES TOYOTA N04C- Engine y HINO 300.CAMIONES TOYOTA N04C- Engine y HINO 300.
CAMIONES TOYOTA N04C- Engine y HINO 300.JavierAlejandroCordo1
 
5s-5S 5S 5S 5S 5S 5S 5S PRESENTATION .ppt
5s-5S 5S 5S 5S 5S 5S 5S PRESENTATION  .ppt5s-5S 5S 5S 5S 5S 5S 5S PRESENTATION  .ppt
5s-5S 5S 5S 5S 5S 5S 5S PRESENTATION .ppthiren65650
 
What Should You Do If Your Jaguar XF Bluetooth Isn't Working
What Should You Do If Your Jaguar XF Bluetooth Isn't WorkingWhat Should You Do If Your Jaguar XF Bluetooth Isn't Working
What Should You Do If Your Jaguar XF Bluetooth Isn't WorkingAuto Assets
 
Why Won't Your Audi A3 Shift Into Reverse Gear Let's Investigate
Why Won't Your Audi A3 Shift Into Reverse Gear Let's InvestigateWhy Won't Your Audi A3 Shift Into Reverse Gear Let's Investigate
Why Won't Your Audi A3 Shift Into Reverse Gear Let's InvestigateAutowerks
 
Car Seat Covers and Seat Protection Guide
Car Seat Covers and Seat Protection GuideCar Seat Covers and Seat Protection Guide
Car Seat Covers and Seat Protection GuideAskXX.com
 
Introduction to Automotive Bootloader | Programming Sequence
Introduction to Automotive Bootloader | Programming SequenceIntroduction to Automotive Bootloader | Programming Sequence
Introduction to Automotive Bootloader | Programming SequenceKapil Thakar
 
What Should BMW Owners Know About Steptronic Transmission Problems
What Should BMW Owners Know About Steptronic Transmission ProblemsWhat Should BMW Owners Know About Steptronic Transmission Problems
What Should BMW Owners Know About Steptronic Transmission ProblemsSchearer's Sales & Service Inc
 
Basic of Firmware & Embedded Software Programming in C
Basic of Firmware & Embedded Software Programming in CBasic of Firmware & Embedded Software Programming in C
Basic of Firmware & Embedded Software Programming in CKapil Thakar
 

Recently uploaded (18)

-VDA-Special-Characteristics Special characteristics.pdf
-VDA-Special-Characteristics Special characteristics.pdf-VDA-Special-Characteristics Special characteristics.pdf
-VDA-Special-Characteristics Special characteristics.pdf
 
Automotive Bootloader Complete Guide with UDS Frame Format
Automotive Bootloader Complete Guide with UDS Frame FormatAutomotive Bootloader Complete Guide with UDS Frame Format
Automotive Bootloader Complete Guide with UDS Frame Format
 
Timer Handling in UDS | S3 Server Timer | P2 and P2 Start Timer
Timer Handling in UDS | S3 Server Timer | P2 and P2 Start TimerTimer Handling in UDS | S3 Server Timer | P2 and P2 Start Timer
Timer Handling in UDS | S3 Server Timer | P2 and P2 Start Timer
 
Introduction to UDS over CAN | UDS Service
Introduction to UDS over CAN | UDS ServiceIntroduction to UDS over CAN | UDS Service
Introduction to UDS over CAN | UDS Service
 
Advanced Technology for Auto Part Industry Inventory Solutions
Advanced Technology for Auto Part Industry Inventory SolutionsAdvanced Technology for Auto Part Industry Inventory Solutions
Advanced Technology for Auto Part Industry Inventory Solutions
 
technical report on EV. EVs can offer benefitssuch as lower operating costs a...
technical report on EV. EVs can offer benefitssuch as lower operating costs a...technical report on EV. EVs can offer benefitssuch as lower operating costs a...
technical report on EV. EVs can offer benefitssuch as lower operating costs a...
 
CBC used in Indian Railways for train coupling.pptx
CBC used in Indian Railways for train coupling.pptxCBC used in Indian Railways for train coupling.pptx
CBC used in Indian Railways for train coupling.pptx
 
Essential Maintenance Tips For Commercial Vans.
Essential Maintenance Tips For Commercial Vans.Essential Maintenance Tips For Commercial Vans.
Essential Maintenance Tips For Commercial Vans.
 
Quicker and better: South Korea’s new high-speed train 'EMU-320'
Quicker and better: South Korea’s new high-speed train 'EMU-320'Quicker and better: South Korea’s new high-speed train 'EMU-320'
Quicker and better: South Korea’s new high-speed train 'EMU-320'
 
CAMIONES TOYOTA N04C- Engine y HINO 300.
CAMIONES TOYOTA N04C- Engine y HINO 300.CAMIONES TOYOTA N04C- Engine y HINO 300.
CAMIONES TOYOTA N04C- Engine y HINO 300.
 
5s-5S 5S 5S 5S 5S 5S 5S PRESENTATION .ppt
5s-5S 5S 5S 5S 5S 5S 5S PRESENTATION  .ppt5s-5S 5S 5S 5S 5S 5S 5S PRESENTATION  .ppt
5s-5S 5S 5S 5S 5S 5S 5S PRESENTATION .ppt
 
What Should You Do If Your Jaguar XF Bluetooth Isn't Working
What Should You Do If Your Jaguar XF Bluetooth Isn't WorkingWhat Should You Do If Your Jaguar XF Bluetooth Isn't Working
What Should You Do If Your Jaguar XF Bluetooth Isn't Working
 
Why Won't Your Audi A3 Shift Into Reverse Gear Let's Investigate
Why Won't Your Audi A3 Shift Into Reverse Gear Let's InvestigateWhy Won't Your Audi A3 Shift Into Reverse Gear Let's Investigate
Why Won't Your Audi A3 Shift Into Reverse Gear Let's Investigate
 
Tips for Securing Manufacturing Opertaions.pdf
Tips for Securing Manufacturing Opertaions.pdfTips for Securing Manufacturing Opertaions.pdf
Tips for Securing Manufacturing Opertaions.pdf
 
Car Seat Covers and Seat Protection Guide
Car Seat Covers and Seat Protection GuideCar Seat Covers and Seat Protection Guide
Car Seat Covers and Seat Protection Guide
 
Introduction to Automotive Bootloader | Programming Sequence
Introduction to Automotive Bootloader | Programming SequenceIntroduction to Automotive Bootloader | Programming Sequence
Introduction to Automotive Bootloader | Programming Sequence
 
What Should BMW Owners Know About Steptronic Transmission Problems
What Should BMW Owners Know About Steptronic Transmission ProblemsWhat Should BMW Owners Know About Steptronic Transmission Problems
What Should BMW Owners Know About Steptronic Transmission Problems
 
Basic of Firmware & Embedded Software Programming in C
Basic of Firmware & Embedded Software Programming in CBasic of Firmware & Embedded Software Programming in C
Basic of Firmware & Embedded Software Programming in C
 

Komatsu wa250 6 wheel loader service repair manual sn75001 and up

  • 1. MACHINE MODEL SERIAL NUMBER WA250-6 75001 and up WA250PZ-6 75160 and up H00051 and up • This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. • WA250-6 and WA250PZ-6 mounts the SAA6D107E-1 engine. VEBM610101 © 2011 All Rights Reserved Printed in Europe 2011-04 WA250-6 WA250PZ-6
  • 2. SEN03822-01 00-100 4 WA250, 250PZ-6 Table of contents 100 Index Table of contents 1 00 Index and foreword 100 Index SEN03822-01 Composition of shop manual......................................................................................................................... 2 Table of contents........................................................................................................................................... 4 200 Foreword and general information SEN03823-00 Safety notice ................................................................................................................................................. 2 How to read the shop manual ....................................................................................................................... 7 Explanation of terms for maintenance standard............................................................................................ 9 Handling of electric equipment and hydraulic component............................................................................. 11 Handling of connectors newly used for engines............................................................................................ 20 How to read electric wire code...................................................................................................................... 23 Precautions when carrying out operation...................................................................................................... 26 Method of disassembling and connecting push-pull type coupler................................................................. 29 Standard tightening torque table ................................................................................................................... 32 Conversion table ........................................................................................................................................... 36 01 Specification 100 Specification and technical data SEN03824-00 Specification dimension drawing................................................................................................................... 3 Specifications ................................................................................................................................................ 4 Weight table .................................................................................................................................................. 8 Table of fuel, coolant and lubricants.............................................................................................................. 10 10 Structure, function and maintenance standard 100 Engine and cooling system SEN03825-00 Engine mount and transfer mount................................................................................................................. 2 Damper ......................................................................................................................................................... 3 Cooling system.............................................................................................................................................. 4 Cooling system hydraulic piping diagram...................................................................................................... 5 Cooling fan motor.......................................................................................................................................... 7 200 Power train SEN03826-00 Power train.................................................................................................................................................... 3 Power train system diagram.......................................................................................................................... 4 Drive shaft..................................................................................................................................................... 6 HST hydraulic piping diagram....................................................................................................................... 7 HST pump..................................................................................................................................................... 8 HST motor..................................................................................................................................................... 16 Transfer......................................................................................................................................................... 22 Clutch solenoid valve .................................................................................................................................... 33 Axle ............................................................................................................................................................... 34 Differential..................................................................................................................................................... 36 Torque proportioning differential.................................................................................................................... 41 Limited slip differential................................................................................................................................... 44 Final drive...................................................................................................................................................... 48 300 Steering system SEN03827-01 Steering piping diagram ................................................................................................................................ 3 Steering column ............................................................................................................................................ 4 Priority valve.................................................................................................................................................. 5 Orbit-roll valve............................................................................................................................................... 8 2-way restrictor valve .................................................................................................................................... 16 Cushion valve................................................................................................................................................ 17 Steering cylinder............................................................................................................................................ 18 Emergency steering piping diagram.............................................................................................................. 20 Emergency steering valve............................................................................................................................. 21 Steering relief valve....................................................................................................................................... 24
  • 3. SEN03822-01 WA250, 250PZ-6 00-100 5 Table of contents 100 Index 400 Brake system SEN03828-00 Brake piping diagram..................................................................................................................................... 3 Charge valve ................................................................................................................................................. 4 Brake valve.................................................................................................................................................... 8 Inching valve.................................................................................................................................................. 12 Accumulator (for brake)................................................................................................................................. 13 Slack adjuster................................................................................................................................................ 14 Brake ............................................................................................................................................................. 16 Parking brake control..................................................................................................................................... 21 Parking brake ................................................................................................................................................ 22 500 Undercarriage and frame SEN03829-00 Axle mount and center hinge pin................................................................................................................... 2 Tires............................................................................................................................................................... 7 600 Hydraulic system SEN03830-00 Work equipment hydraulic piping diagram .................................................................................................... 2 Work equipment control lever linkage ........................................................................................................... 6 Hydraulic tank................................................................................................................................................ 10 4-gear pump .................................................................................................................................................. 12 Work equipment control valve ....................................................................................................................... 14 PPC valve...................................................................................................................................................... 39 Lock valve...................................................................................................................................................... 54 Accumulator (for PPC circuit) ........................................................................................................................ 55 Bypass valve ................................................................................................................................................. 56 Quick coupler solenoid valve......................................................................................................................... 59 ECSS valve ................................................................................................................................................... 60 Accumulator (for ECSS) ................................................................................................................................ 62 700 Work equipment SEN03831-00 Work equipment linkage................................................................................................................................ 2 Bucket............................................................................................................................................................ 6 Bucket positioner and boom kick-out............................................................................................................. 10 Work equipment cylinder ............................................................................................................................... 23 800 Cab and its attachments SEN03832-00 Cab................................................................................................................................................................ 3 Air conditioner................................................................................................................................................ 4 910 Electrical system, Part 1 SEN03833-01 Machine monitor system................................................................................................................................ 2 Machine monitor............................................................................................................................................ 6 920 Electrical system, Part 2 SEN03834-01 Electrical system (HST controller system)..................................................................................................... 2 HST controller................................................................................................................................................ 18 ECSS system ................................................................................................................................................ 20 KOMTRAX system ........................................................................................................................................ 22 Engine starting circuit .................................................................................................................................... 24 Engine stopping circuit .................................................................................................................................. 26 Preheating circuit........................................................................................................................................... 27 Engine output derating function..................................................................................................................... 28 Automatic warm-up function.......................................................................................................................... 28 Parking brake circuit...................................................................................................................................... 29 Coupler plunger control system..................................................................................................................... 32 Multi-function knob ........................................................................................................................................ 33 Max. traction switch....................................................................................................................................... 34 Sensor ........................................................................................................................................................... 35 20 Standard value table 100 Standard service value table SEN03835-00 Standard service value table for engine ........................................................................................................ 2 Standard service value table for chassis ....................................................................................................... 3
  • 4. SEN03822-01 00-100 6 WA250, 250PZ-6 Table of contents 100 Index 30 Testing and adjusting 110 Testing and adjusting, Part 1 SEN03836-00 Tools for testing, adjusting, and troubleshooting........................................................................................... 2 Measuring engine speed............................................................................................................................... 7 Measuring exhaust gas color ........................................................................................................................ 9 Adjusting valve clearance ............................................................................................................................. 11 Measuring compression pressure................................................................................................................. 13 Measuring blow-by pressure......................................................................................................................... 16 Measuring engine oil pressure...................................................................................................................... 17 Measuring intake air (boost) pressure........................................................................................................... 18 Handling fuel system equipment................................................................................................................... 20 Releasing residual pressure in fuel system................................................................................................... 20 Measuring fuel pressure................................................................................................................................ 21 Measuring fuel return rate and leakage ........................................................................................................ 23 Bleeding air from fuel circuit.......................................................................................................................... 27 Testing leakage in fuel system ...................................................................................................................... 28 Handling reduced cylinder mode operation................................................................................................... 29 Handling no-injection cranking operation...................................................................................................... 29 Handling controller voltage circuit ................................................................................................................. 30 Check of muffler and muffler stack for looseness and damage .................................................................... 30 Check of muffler function .............................................................................................................................. 31 Check of installed condition of cylinder head and manifolds......................................................................... 31 Check of engine piping for damage and looseness ...................................................................................... 32 Testing and adjusting air conditioner compressor belt tension...................................................................... 32 Replacing alternator belt ............................................................................................................................... 33 120 Testing and adjusting, Part 2 SEN03837-00 Checking operating force of accelerator pedal.............................................................................................. 3 Checking directional lever............................................................................................................................. 4 Testing and adjusting HST oil pressure......................................................................................................... 5 Testing clutch control pressure...................................................................................................................... 9 Testing and adjusting steering wheel ............................................................................................................ 10 Testing and adjusting steering oil pressure................................................................................................... 12 Bleeding air from steering circuit................................................................................................................... 14 Testing hydraulic fan ..................................................................................................................................... 15 Measuring brake pedal.................................................................................................................................. 17 Testing and adjusting brake pedal linkage .................................................................................................... 18 Measuring brake performance ...................................................................................................................... 19 Testing and adjusting accumulator charge pressure..................................................................................... 20 Testing wheel brake oil pressure................................................................................................................... 22 Testing wear of brake disc............................................................................................................................. 25 Bleeding air from wheel brake circuit ............................................................................................................ 26 Releasing residual pressure in brake accumulator circuit............................................................................. 27 Testing parking brake performance............................................................................................................... 28 Testing and adjusting parking brake control cable ........................................................................................ 29 Measuring and adjusting work equipment control lever................................................................................ 30 Testing and adjusting work equipment hydraulic pressure............................................................................ 31 Testing work equipment PPC oil pressure .................................................................................................... 32 Bleeding air from hydraulic circuit ................................................................................................................. 34 Releasing remaining pressure in hydraulic circuit......................................................................................... 35 Testing and adjusting bucket positioner ........................................................................................................ 36 Testing and adjusting of boom kick-out switch.............................................................................................. 37 Checking proximity switch operation pilot lamp ............................................................................................ 38 Procedure for testing diodes ......................................................................................................................... 39 Preparation work for troubleshooting for electric system .............................................................................. 41 Starting KOMTRAX terminal operations........................................................................................................ 45 Indicator lamps of KOMTRAX terminal ......................................................................................................... 49
  • 5. SEN03822-01 WA250, 250PZ-6 00-100 7 Table of contents 100 Index 130 Testing and adjusting, Part 3 SEN03838-00 Adjusting machine monitor ............................................................................................................................ 2 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ............................ 3 Special functions of machine monitor (EMMS).............................................................................................. 5 Pm clinic inspection chart.............................................................................................................................. 59 40 Troubleshooting 100 Failure code table and fuse locations SEN03839-00 Failure codes table ........................................................................................................................................ 2 Fuse locations ............................................................................................................................................... 8 200 General information on troubleshooting SEN03840-00 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 ................................................................................................... 45 310 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
  • 6. SEN03822-01 00-100 8 WA250, 250PZ-6 Table of contents 100 Index Failure code [CA352] Sensor power supply 1 low error................................................................................ 52 Failure code [CA386] Sensor power supply 1 high error .............................................................................. 54 330 Troubleshooting by failure code (Display of code), Part 3 SEN03843-00 Failure code [CA428] Abnormally high level in water sensor........................................................................ 4 Failure code [CA429] Abnormally low level in water sensor ......................................................................... 6 Failure code [CA431] Idle validation switch error.......................................................................................... 8 Failure code [CA432] Idle validation action error .......................................................................................... 12 Failure code [CA435] Engine oil pressure switch error................................................................................. 16 Failure code [CA441] Battery voltage low error ............................................................................................ 17 Failure code [CA442] Battery voltage high error........................................................................................... 20 Failure code [CA449] Common rail pressure high error 2............................................................................. 22 Failure code [CA451] Common rail pressure sensor high error.................................................................... 24 Failure code [CA452] Common rail pressure sensor low error ..................................................................... 26 Failure code [CA488] Derating of torque by abnormally high charge temperature....................................... 28 Failure code [CA553] Common rail pressure high error 1............................................................................. 29 Failure code [CA559] Supply pump pressure very low error......................................................................... 30 Failure code [CA689] Engine Ne speed sensor error ................................................................................... 32 Failure code [CA731] Engine Bkup speed sensor phase error..................................................................... 34 Failure code [CA757] All continuous data lost error...................................................................................... 35 Failure code [CA778] Engine Bkup speed sensor error................................................................................ 38 Failure code [CA1633] KOMNET datalink timeout error ............................................................................... 40 Failure code [CA2185] Throttle sensor supply voltage high error................................................................. 44 Failure code [CA2186] Throttle sensor power supply low error .................................................................... 46 Failure code [CA2249] Supply pump pressure very low error 2.................................................................... 48 Failure code [CA2311] Abnormality in IMV (IMA) solenoid ........................................................................... 50 Failure code [CA2555] Intake heater relay disconnection error.................................................................... 52 Failure code [CA2556] Intake heater relay short circuit error........................................................................ 54 340 Troubleshooting by failure code (Display of code), Part 4 SEN03844-00 Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short ........................................................... 2 Failure code [D192KY] ECSS solenoid relay: Hot short ............................................................................... 4 Failure code [D1B0KA] HST safety relay: Disconnection ............................................................................. 6 Failure code [D1B0KB] HST safety relay: Ground fault ................................................................................ 8 Failure code [D1B0KY] HST safety relay: Hot short ..................................................................................... 10 Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection ............................................................. 12 Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection.................................................. 14 Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection ................................................ 16 Failure code [DAJ0KK] HST controller power supply: Low voltage .............................................................. 20 Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality.................................................... 22 Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault................................... 24 Failure code [DAJ1L6] HST controller main power line: Hot short................................................................ 26 Failure code [DAJ2KK] Controller solenoid power supply: Low voltage ....................................................... 28 Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness............. 30 Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault............ 32 Failure code [DAJ5KX] Sensor 5V power supply: Out of output range......................................................... 34 Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals............. 36 Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection..................................................... 37 Failure code [DAJRMA] HST controller: Disagreement in option selection .................................................. 43 350 Troubleshooting by failure code (Display of code), Part 5 SEN03845-00 Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line....................................... 3 Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality .................................................. 8 Failure code [DD1NLD] Fan reverse switch signal: Abnormality .................................................................. 10 Failure code [DDB6KA] Parking brake switch A: Disconnection/Hot short ................................................... 12 Failure code [DDB6KB] Parking brake switch B: Ground fault...................................................................... 14 Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble................................................................................................................. 16 Failure code [DDB6L0] Parking brake switch A: Ground fault ...................................................................... 18 Failure code [DDB6L4] Parking brake switch B: Disconnection/Hot short.................................................... 20 Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault................................. 22
  • 7. SEN03822-01 WA250, 250PZ-6 00-100 9 Table of contents 100 Index 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
  • 8. SEN03822-01 00-100 10 WA250, 250PZ-6 Table of contents 100 Index E-16 Alarm buzzer does not sound or it keeps sounding.............................................................................. 68 E-17 Air conditioner does not operate or stop............................................................................................... 70 E-18 The KOMTRAX system does not work properly................................................................................... 73 500 Troubleshooting of hydraulic and mechanical system (H-mode) SEN03849-00 Method of using troubleshooting chart.......................................................................................................... 3 Failure code and cause table........................................................................................................................ 6 H-1 The machine does not start.................................................................................................................... 8 H-2 The travel speed is slow......................................................................................................................... 9 H-3 The traction force is weak ...................................................................................................................... 10 H-4 Engine stalls when traveling or engine speed drops excessively........................................................... 11 H-5 The gear is not shifted............................................................................................................................ 12 H-6 The steering wheel does not turn........................................................................................................... 13 H-7 The steering wheel is heavy................................................................................................................... 14 H-8 Steering wheel shakes or jerks............................................................................................................... 15 H-9 Machine deviates naturally to one side when traveling.......................................................................... 15 H-10 The brake does not work or does not work well................................................................................... 16 H-11 The brake is not released or is dragged............................................................................................... 17 H-12 The lift arm does not rise or lower........................................................................................................ 18 H-13 The lift arm moves slowly or the lift arm rising force is insufficient....................................................... 19 H-14 When rising, the lift arm comes to move slowly at specific height........................................................ 20 H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air)................................... 20 H-16 Hydraulic drifts of the lift arm occur often ............................................................................................. 20 H-17 The lift arm wobbles during operation .................................................................................................. 20 H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily.................. 21 H-19 The bucket does not tilt back................................................................................................................ 22 H-20 The bucket moves slowly or the tilting-back force is insufficient .......................................................... 23 H-21 The bucket comes to operate slowly in the midst of tilting-back .......................................................... 24 H-22 The bucket cylinder cannot hold down the bucket ............................................................................... 24 H-23 Hydraulic drifts of the bucket occur often ............................................................................................. 24 H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”) ................. 24 H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily ...................... 25 H-26 The control levers of the lift arm and bucket do not move smoothly and heavy................................... 25 H-27 The ECSS does not operate and machine pitches and bounces......................................................... 26 H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) ................ 27 600 Troubleshooting of engine (S-mode) SEN03850-00 Method of using troubleshooting charts ........................................................................................................ 2 S-1 Starting performance is poor .................................................................................................................. 6 S-2 Engine does not start.............................................................................................................................. 7 S-3 Engine does not pick up smoothly.......................................................................................................... 10 S-4 Engine stops during operations.............................................................................................................. 11 S-5 Engine does not rotate smoothly............................................................................................................ 12 S-6 Engine lacks output (or lacks power)...................................................................................................... 13 S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 14 S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 15 S-9 Oil becomes contaminated quickly......................................................................................................... 16 S-10 Fuel consumption is excessive............................................................................................................. 17 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 18 S-12 Oil pressure drops ................................................................................................................................ 19 S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 20 S-14 Coolant temperature becomes too high (overheating) ......................................................................... 21 S-15 Abnormal noise is made....................................................................................................................... 22 S-16 Vibration is excessive........................................................................................................................... 23
  • 9. SEN03822-01 WA250, 250PZ-6 00-100 11 Table of contents 100 Index 50 Disassembly and assembly 100 General information on disassembly and assembly SEN03851-00 How to read this manual................................................................................................................................ 2 Coating materials list ..................................................................................................................................... 4 Special tool list............................................................................................................................................... 7 Sketches of special tools............................................................................................................................... 11 200 Engine and cooling system SEN03852-00 Removal and installation of fuel supply pump assembly............................................................................... 2 Removal and installation of fuel injector assembly........................................................................................ 4 Removal and installation of cylinder head assembly..................................................................................... 11 Removal and installation of engine hood assembly ...................................................................................... 24 Removal and installation of radiator .............................................................................................................. 27 Removal and installation of air aftercooler..................................................................................................... 30 Removal and installation of hydraulic oil cooler assembly ............................................................................ 32 Removal and installation of engine assembly ............................................................................................... 34 Removal and installation of engine front oil seal assembly........................................................................... 40 Removal and installation of engine rear oil seal assembly............................................................................ 43 Removal and installation of cooling fan and fan motor assembly.................................................................. 46 Removal and installation of fuel tank assembly............................................................................................. 49 310 Power train, Part 1 SEN03853-00 Removal and installation of transfer assembly.............................................................................................. 2 Disassembly and assembly of transfer assembly.......................................................................................... 6 Removal and installation of parking brake assembly..................................................................................... 26 Disassembly and assembly of parking brake assembly................................................................................ 28 320 Power train, Part 2 SEN03854-00 Removal and installation of front axle assembly ........................................................................................... 2 Removal and installation of rear axle assembly ............................................................................................ 4 Disassembly and assembly of axle housing assembly.................................................................................. 7 Disassembly and assembly of differential assembly ..................................................................................... 16 400 Undercarriage and frame SEN03855-00 Removal and installation of center hinge pin................................................................................................. 2 Removal and installation of counterweight.................................................................................................... 12 500 Hydraulic system SEN03856-00 Removal and installation of HST pump and 4-gear pump assembly............................................................. 2 Disassembly and assembly of HST pump assembly..................................................................................... 6 Removal and installation of HST motor 1 assembly...................................................................................... 33 Removal and installation of HST motor 2 assembly...................................................................................... 35 Disassembly and assembly of HST motor assembly .................................................................................... 37 Removal and installation of work equipment control valve assembly............................................................ 53 Removal and installation of hydraulic tank .................................................................................................... 55 Disassembly and assembly of hydraulic cylinder assembly.......................................................................... 57 600 Work equipment SEN03857-01 Removal and installation of work equipment assembly................................................................................. 2 700 Cab and its attachments SEN03858-00 Removal and installation of operator's cab and floor frame assembly .......................................................... 2 Removal and installation of operator's cab glass (Stuck glass)..................................................................... 7 Removal and installation of air conditioner unit............................................................................................. 15 800 Electrical system SEN03859-00 Removal and installation of monitor panel..................................................................................................... 2 Removal and installation of engine controller assembly................................................................................ 4 Removal and installation of HST controller assembly ................................................................................... 5 Removal and installation of KOMTRAX terminal assembly........................................................................... 6
  • 10. SEN03822-01 00-100 12 WA250, 250PZ-6 Table of contents 100 Index 90 Diagrams and drawings 100 Hydraulic diagrams and drawings SEN03860-01 Hydraulic circuit diagram............................................................................................................................... 3 200 Electrical diagrams and drawings SEN03861-01 Electrical circuit diagram ............................................................................................................................... 3 Connector list and stereogram...................................................................................................................... 21
  • 11. SEN03852-00 50-200 2 WA250, 250PZ-6 200 Engine and cooling system Removal and installation of fuel supply pump assembly Removal and installation of fuel supply pump 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, stop the engine, apply the parking brake, and put chocks under the tires. k Disconnect the cable from the negative (–) terminal of the battery. 1. Open and fix right engine side cover (1). a Check that the cover is locked securely. 2. Remove fuel prefilter and bracket assembly (2). a Fix fuel prefilter and bracket assembly (2) to the machine with ropes. 3. Disconnect wiring harness connector CN-CP3 (3) from fuel supply pump (4). 4. Disconnect fuel filter hoses (5) and (6) from fuel supply pump (4). 5. Disconnect fuel return hose (7) from fuel sup- ply pump (4). a If mud is sticking, lock (L) may become stiff. Accordingly, clean the connecting area. a Press lock (L) from both sides and pull out hose (5). a Plug the disconnected hose to prevent fuel leakage. 6. Disconnect fuel supply hose (8) from fuel sup- ply pump (4). [*1] 7. Remove 2 clamps of boot (9) and fuel high- pressure pipe (10). 8. Disconnect fuel high-pressure pipe (10) from fuel supply pump (4). [*2] a Remove the boot on the common rail side of high-pressure pipe (10) and loosen the sleeve nut.
  • 12. SEN03852-00 WA250, 250PZ-6 50-200 3 200 Engine and cooling system Removal and installation of fuel supply pump assembly 9. Remove 3 mounting nuts at part (A) and fuel supply pump assembly (11). [*3] a Remove fuel supply pump assembly (11) and the gear together. The gear does not have a positioning mark (missing tooth), etc. 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} [*2] q How to install high-pressure pipe (10) 1. Tighten the sleeve nut with the fingers. 2. Check that the high-pressure pipe is installed correctly and tighten the sleeve nut to the fol- lowing torque. 3 Sleeve nut: 35 ± 3.5 Nm {3.57 ± 0.36 kgm} k Be sure to use the genuine fuel high- pressure pipe clamp and strictly observe the specified tightening torque. 3. Install boot (9). a Direct the slit of the boot down. a The boot is installed so that fuel will not spout over the hot parts of the engine and catch fire when it leaks for some reason. [*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. Install fuel supply pump (12). 3 Fuel supply pump mounting nut: 24 ± 4 Nm {2.45 ± 0.41 kgm} q Bleeding air Bleed air from the fuel system. For details, see Testing and adjusting, "Bleeding air from fuel system".
  • 13. SEN03852-00 50-200 4 WA250, 250PZ-6 200 Engine and cooling system Removal and installation of fuel injector assembly Removal and installation of fuel injector assembly 1 Special tools 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. 6 Radiator: Approx. 22 l 2. Remove the engine hood assembly. For details, see "Removal and installation of engine hood assembly". 3. Lift off muffler (1). a Take care that the muffler will not interfere with water drain tube (2). 4 Muffler assembly: Approx. 35 kg 4. Disconnect engine intake air heater wiring har- ness terminal CN-E07B (3). [*1] 5. Remove clamp (4) and bracket (4a). [*2] 6. Remove clamp (5), air hose (5a), mounting bolt (6a) and intake air inlet elbow (6). [*3] a Remove the engine intake air heater, too. 7. Remove 2 wiring harness clamps (7). 8. Disconnect wiring harness connector (8). a While pressing the lock of wiring harness connector (8) with flat-head screwdriver [1], pull the connector in the direction of the arrow. a Do not remove fuel pressure sensor (PS) except for replacement. 9. Disconnect 3 wiring harness connectors (9). [*4] a While pressing the lock of the wiring har- ness connector with flat-head screwdriver [2], pull the connector. a Move wiring harness (10) toward the intake manifold. Symbol Part No. Part name Necessity Q'ty New/Remodel Sketch A 3 795-799-6700 Puller t 1 4 795-799-1131 Gear t 1 5 795-799-8150 Remover q 1
  • 14. SEN03852-00 WA250, 250PZ-6 50-200 5 200 Engine and cooling system Removal and installation of fuel injector assembly 10. Using hexagonal wrench (width across flats: 3 mm), remove blow-by duct (11). [*5] 11. Remove 6 mounting nuts (12) and cylinder head cover (13). [*6] 12. Remove 6 boots (14). [*7] 13. Remove 6 high-pressure pipes (15). [*8] a Loosen the sleeve nut on the common rail side of each high-pressure pipe. 14. Position the crankshaft according to the follow- ing procedure. 1) Remove plug (16) under the starting motor and set tool A4. 2) Rotate the crankshaft forward (counter- clockwise seeing from the flywheel side) to set marks (M1) and (M2). Mark (M1):Top of projection of front cover Mark (M2):A wide slit on slitted revolution sensor disc at rear of crank- shaft pulley Mark (M3):Yellow paint on vibration damper (on prolongation of wide slit (M2)) a Set the projection top of mark (M1) within the wide slit (M2). a There is yellow paint mark (M3) on the prolongation of wide slit (M2). a When the marks are set as above, the piston of the No. 1 or No. 6 cylin- der is 76 – 88° before the top dead center. a See Testing and adjusting, "Adjusting valve clearance". a Use tool A4 to rotate the crankshaft.
  • 15. SEN03852-00 50-200 6 WA250, 250PZ-6 200 Engine and cooling system Removal and installation of fuel injector assembly 15. Remove the 12 mounting bolts and rocker arm (17). a Loosen locknut (18), and then loosen adjustment screw (19) by 2 – 3 turns so that an excessive force will not be applied to the push rod when the rocker arm is installed. 16. Remove 12 crossheads (20). a Record the positions and shapes of holes (a) and (b) of each crosshead. (Reinstall each crosshead in the same direction.) 17. Remove retaining nuts (21) and 6 inlet connec- tors (22). a Before removing, clean the inlet connec- tors carefully so that mud, etc. sticking around them will not enter their holes. a Tool A5 is set for removal of inlet connec- tor (22). (See the special tools list.) 18. Remove 2 wiring harness mounting nuts (24) from fuel injector assembly (23). Wiring harness color Cylinder No. White 1, 3, 5 Black 2, 4, 6
  • 16. SEN03852-00 WA250, 250PZ-6 50-200 7 200 Engine and cooling system Removal and installation of fuel injector assembly 19. Remove 2 mounting bolts (25) of fuel injector assembly (23). 20. Using tool A3, remove fuel injector assembly (23). a Take care that dirt and foreign matter will not enter the fuel injector assembly mounting area. Installation a The internal parts of the fuel hose adapter may be damaged when it is removed. Accordingly, do not reuse the fuel hose but use new one when assembling again, as a rule. When replacing the fuel injector assembly with new one, be sure to replace the inlet connector with new one, too. 1. Fuel injector assembly a Check that the fuel injector sleeve (23a) is free from flaw and dirt. 1) Fit O-ring (26) and gasket (27) to fuel injector (23). 2) Apply engine oil (For details, see "Table of fuel, coolant and lubricants") to O-ring (26) of fuel injector (23) and the mounting hole on the cylinder head side. 3) While setting convex and concave parts (A), install holder (28) to fuel injector (23).
  • 17. SEN03852-00 50-200 8 WA250, 250PZ-6 200 Engine and cooling system Removal and installation of fuel injector assembly 4) Insert fuel injector (23) in the cylinder head, directing its fuel inlet hole toward the air intake manifold. 5) Tighten 2 mounting bolts (25) of fuel injec- tor (23) by 3 – 4 turns. 6) Apply engine oil (For details, see "Table of fuel, coolant and lubricants") to the mount- ing hole of inlet connector (22) on the cyl- inder head side. 7) Apply engine oil (For details, see "Table of fuel, coolant and lubricants") to O-ring (29) of inlet connector (22). 8) Insert inlet connector (22) perfectly, while setting part (B) to the groove on the cylin- der head side. 9) Secure inlet connector (22) by tightening retaining nut (21) lightly. 3 Retaining nut (21): 15 ± 5 Nm {1.5 ± 0.5 kgm} 10) Tighten 2 mounting bolts (25) of fuel 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} 12) Install the wiring harnesses to fuel injector (23) and tighten 2 mounting nuts (24). 3 Wiring harness mounting nut (24): 1.5 ± 0.25 Nm {0.15 ± 0.03 kgm} a Installed positions of wiring har- nesses Wiring harness color Cylinder No. White 1, 3, 5 Black 2, 4, 6
  • 18. SEN03852-00 WA250, 250PZ-6 50-200 9 200 Engine and cooling system Removal and installation of fuel injector assembly q Precautions for installing inlet connector 1) When replacing the fuel injector assembly with new one, be sure to replace inlet con- nector, too. 2) Check the inlet connector visually. If it has any of the following faults, replace it. 1] There is a bur or a worn part at front end (a) or rear end (b) of the inlet connector. 2] There is foreign matter in the edge fil- ter at rear end (c) of the inlet connec- tor. 3] The O-ring at upper part (d) of the inlet connector is cracked or deterio- rated. 3) Check the inlet connector visually. If it has any of the following faults, replace it and fuel injector assembly together. q There is a worn part or an uneven seat contact mark on sealing face (e) at the front end of the inlet connector. a If high-pressure fuel leaks through the inlet connector, the seal face has fine streaks or cracks. 2. Crosshead and rocker arm assembly 1) Install the crosshead and rocker arm. a The shapes of holes (a) and (b) of each crosshead are different. Accord- ingly, when reusing the crossheads, install each of them to the same intake/exhaust valve in the same direction as it has been installed. 2) Check that the ball of adjustment screw (19) is set in the push rod socket securely and then tighten mounting bolts (30). 3 Rocker arm mounting bolt (30): 36 ± 5 Nm {3.7 ± 0.5 kgm} 3) Adjust the valve clearance. For details, see Testing and adjusting, "Adjusting valve clearance". 3 Locknut (18): 24 ± 4 {2.4 ± 0.4 kgm}
  • 19. SEN03852-00 50-200 10 WA250, 250PZ-6 200 Engine and cooling system Removal and installation of fuel injector assembly q Carry out the following installation in the reverse order to removal. [*1] 3 Wiring harness terminal CN-E07B (3): 4.0 ± 0.6 Nm {0.41 ± 0.06 kgm} [*2] 3 Clamp (4): 10.8 – 26.5 Nm {1.1 – 2.7 kgm} [*3] 3 Clamp (5): 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} 3 Intake air inlet elbow mounting bolt (6a): 24 ± 4 Nm {2.4 ± 0.4 kgm} [*4] k Install each fuel high-pressure pipe and wiring harness at least 10 mm apart from each other. [*5] 3 Blow-by duct mounting bolt: 7 ± 2 Nm {0.7 ± 0.2 kgm} [*6] 3 Cylinder head cover mounting nut (12): 24 ± 4 Nm {2.4 ± 0.4 kgm} [*7], [*8] k Do not bend the fuel high-pressure pipe to correct before installing. k Be sure to use the genuine fuel high-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. 1) Temporarily install fuel high-pressure pipes (31) – (36). 3 Sleeve nut: 0.2 – 0.8 Nm {0.02 – 0.08 kgm} 2) Tighten fuel high-pressure pipes (31) – (36) in the following order. 1] Tighten the cylinder head side of fuel high-pressure pipes (31) and (36). 2] Tighten the common rail side of fuel high-pressure pipes (31) and (36). 3] Tighten the cylinder head side of fuel high-pressure pipes (32), (33), (34) and (35). 4] Tighten the common rail side of fuel high-pressure pipes (32), (33), (34) and (35). 3 Sleeve nut: 35 ± 3.5 Nm {3.6 ± 0.4 kgm} 3) Install 6 boots (14) to the fuel high-pres- sure pipes. a Direct the slit of the boot out and down. a The boots are installed so that fuel will not spout over the hot parts of the engine to catch fire when it leaks for some reason. q Bleeding air Bleed air from the fuel system. For details, see Testing and adjusting, "Bleeding air from fuel system". q Refilling with coolant Add coolant through the coolant filler to the specified level. Run the engine to circulate the coolant through the system. Then, check the coolant level again. 5 Total amount of coolant: Approx. 22 l (For details, see "Table of fuel, coolant and lubricants")
  • 20. SEN03852-00 WA250, 250PZ-6 50-200 11 200 Engine and cooling system Removal and installation of cylinder head assembly Removal and installation of cylinder head assembly 1 Special tools 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. 6 Radiator: Approx. 22 l 2. Remove the engine hood assembly. For details, see "Removal and installation of engine hood assembly". 3. Lift off muffler (1). a Take care that the muffler will not interfere with water drain tube (2). 4 Muffler assembly: Approx. 35 kg 4. Disconnect engine intake air heater wiring har- ness terminal CN-E07B (3). [*1] 5. Remove clamp (4) and bracket (4a). [*2] 6. Remove clamp (5), air hose (5a), and intake air inlet elbow (6). [*3] a Remove the engine intake air heater, too. 7. Remove bracket (7). 8. Remove wiring harness clamp (8). 9. Disconnect wiring harness connector (9). 10. Remove air conditioner compressor assembly (10). [*4] a Fix air conditioner compressor assembly (10) to the machine with ropes. Symbol Part No. Part name Necessity Q'ty New/Remodel Sketch A 3 795-799-6700 Puller t 1 4 795-799-1131 Gear t 1 5 795-799-8150 Remover q 1 6 790-331-1120 Wrench (angle) q 1 7 795-790-4510 Gauge q 1
  • 21. SEN03852-00 50-200 12 WA250, 250PZ-6 200 Engine and cooling system Removal and installation of cylinder head assembly 11. Disconnect fuel filter hoses (11) and (12). a If mud is sticking, lock (L) may become stiff. Accordingly, clean the connecting area. a Press lock (L) from both sides and pull out hose (12). a Plug the disconnected hoses to prevent fuel leakage. 12. Disconnect fuel return hose (13). 13. Remove fuel prefilter hose clamp (14). 14. Remove 2 air conditioner compressor hose clamps (15). 15. Remove fuel filter and bracket assembly (16). 16. Remove 2 clamps (17). 17. Disconnect engine coolant temperature sensor connector (18). 18. Disconnect ambient air pressure sensor con- nector (19). a Move the lock of ambient air pressure sensor connector (19) in the direction of the arrow and pull out the connector while pressing the claw. 19. Disconnect intake air pressure sensor connec- tor (20). 20. Remove 2 wiring harness clamps (21). 21. Disconnect wiring harness connector (22). a While pressing the lock of wiring harness connector (22) with flat-head screwdriver [1], pull the connector in the direction of the arrow. a Do not remove fuel pressure sensor (PS) except for replacement. 22. Disconnect 3 wiring harness connectors (23). [*5] a While pressing the lock of the wiring har- ness connector with flat-head screwdriver [2], pull the connector. a Move wiring harness (24) toward the intake manifold.
  • 22. Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
  • 23. SEN03852-00 WA250, 250PZ-6 50-200 13 200 Engine and cooling system Removal and installation of cylinder head assembly 23. Disconnect fuel drain hose (25). [*6] 24. Disconnect high-pressure pipe (26). [*7] 25. Remove 6 boots (27). [*8] 26. Remove 6 high-pressure pipes (28). [*9] a Loosen the sleeve nut on the common rail side of each high-pressure pipe. 27. Disconnect radiator upper hose (29). [*10] 28. Disconnect air aftercooler upper hose (30). [*11] 29. Disconnect heater hose (31). 30. Disconnect corrosion resistor hose (32). 31. Remove corrosion resistor and bracket assem- bly (33).
  • 24. SEN03852-00 50-200 14 WA250, 250PZ-6 200 Engine and cooling system Removal and installation of cylinder head assembly 32. Remove wiring harness clamp (34). 33. Remove 2 heat insulation plates (35). 34. Remove heat insulation plate (36). 35. Remove cover (37). 36. Disconnect wiring [1] harness connectors CN- E02 and CN-E03 (38). 37. Put the wrench in part (A) (width across flats: 12.7 mm) of tensioner assembly (40) and turn it in the unwinding direction to decrease the tension of fan belt (41). k Set the wrench [1] securely to part (A) of tensioner assembly (40) before turn- ing it. (The spring of tensioner assem- bly (40) is strong. If the wrench [1] is set incompletely and turned, it comes off and that is very dangerous.) k After removing belt (41), return ten- sioner assembly (40) slowly and care- fully. k Take care not to catch your finger between the pulley and fan belt (41) during work. 38. Remove alternator assembly (39).
  • 25. SEN03852-00 WA250, 250PZ-6 50-200 15 200 Engine and cooling system Removal and installation of cylinder head assembly 39. Disconnect turbocharger lubricating oil inlet tube (42) and drain hose (43). [*12] 40. Remove the 2 mounting bolts and bracket (44). 41. Remove the mounting bolts of exhaust mani- fold (45), leaving some of them installed. [*13] 42. Temporarily sling exhaust manifold and turbo- charger assembly (46) and remove the remain- ing mounting bolts. 43. Lift off exhaust manifold and turbocharger assembly (46). 4 Exhaust manifold and turbocharger assembly: 45 kg 44. Using hexagonal wrench (width across flats: 3 mm), remove blow-by duct (47). [*14] 45. Remove 6 mounting nuts (48) and cylinder head cover (49). [*15] 46. Position the crankshaft according to the follow- ing procedure. 1) Remove plug (50) under the starting motor and set tool A4. 2) Rotate the crankshaft forward (counter- clockwise seeing from the flywheel side) to set marks (M1) and (M2). Mark (M1): Top of projection of front cover Mark (M2): A wide slit on slitted revolution sensor disc at rear of crank- shaft pulley Mark (M3): Yellow paint on vibration damper (on prolongation of wide slit (M2)) a Set the projection top of mark (M1) within the wide slit (M2). a There is yellow paint mark (M3) on the prolongation of wide slit (M2). a When the marks are set as above, the piston of the No. 1 or No. 6 cylin- der is 76 – 88° before the top dead center. a See Testing and adjusting, "Adjusting valve clearance". a Use tool A4 to rotate the crankshaft.