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WA250PZ-6
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Komatsu WA250PZ-6 Shop Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
Wa250Pz-6
200 Foreword and General Information
Safety Notice
How to Read the Shop Manual
Explanation of Terms for Maintenance Standard
Handling of Electric Equipment and Hydraulic Component
Handling of Connectors Newly Used for Engines
How to Read Electric Wire Code
Precautions When Carrying out Operation
Method of Disassembling and Connecting Push-Pull Type Coupler
Standard Tightening Torque Table
Conversion Table
Specification
100 Specification and Technical Data
Specification Dimension Drawing
Specifications
Weight Table
Table of Fuel, Coolant and Lubricants
Table of Fuel, Coolant and Lubricants
Structure, Function and Maintenance Standard
100 Engine and Cooling System
Engine Mount and Transfer Mount
Damper
Cooling System
Cooling System Hydraulic Piping Diagram
Cooling Fan Motor
Structure, Function and Maintenance Standard
200 Power Train
Power Train
Power Train System Diagram
Drive Shaft
HST Hydraulic Piping Diagram
HST Pump
HST Motor
Transfer
Clutch Solenoid Valve
Axle
Differential
Torque Proportioning Differential
Limited Slip Differential
Final Drive
Structure, Function and Maintenance Standard
Steering Piping Diagram
Steering Column
Priority Valve
Orbit-Roll Valve
2-Way Restrictor Valve
Cushion Valve
Steering Cylinder
Emergency Steering Piping Diagram
Emergency Steering Valve
Steering Relief Valve
Wa250Pz-6
Brake Piping Diagram
Charge Valve
Brake Valve
Inching Valve
Accumulator (for Brake)
Slack Adjuster
Brake
Parking Brake Control
Parking Brake
Structure, Function and Maintenance Standard
Undercarriage and Frame SEN03829-00
Axle Mount and Center Hinge Pin
Tires
Structure, Function and Maintenance Standard
600 Hydraulic System
Work Equipment Hydraulic Piping Diagram
Work Equipment Control Lever Linkage
Hydraulic Tank
4-Gear Pump
Work Equipment Control Valve
PPC Valve
Lock Valve
Accumulator (for PPC Circuit)
Bypass Valve
Quick Coupler Solenoid Valve
ECSS Valve
Accumulator (for ECSS)
Structure, Function and Maintenance Standard
700 Work Equipment
Work Equipment Linkage
Bucket
Bucket Positioner and Boom Kick-Out
Work Equipment Cylinder
Cab and Its Attachments SEN03832-00
Structure, Function and Maintenance Standard
Cab
Air Conditioner
Electrical System, Part
Structure, Function and Maintenance Standard
Machine Monitor System
Machine Monitor
Electrical System, Part
Structure, Function and Maintenance Standard
Electrical System (HST Controller System)
Electrical System, Part
HST Controller
ECSS System
KOMTRAX System
Engine Starting Circuit
Engine Stopping Circuit
Preheating Circuit
Automatic Warm-Up Function
Engine Output Derating Function
Parking Brake Circuit
Coupler Plunger Control System
Multi-Function Knob
Max. Traction Switch
Sensor
20 Standard Value Table
Standard Service Value Table SEN03835-00
Standard Service Value Table for Engine
Standard Service Value Table for Chassis
Wa250Pz-6
Testing and Adjusting 110 Testing and Adjusting, Part
Tools for Testing, Adjusting, and Troubleshooting
Sketches of Special Tools
Measuring Engine Speed
Measuring Exhaust Gas Color
Adjusting Valve Clearance
Measuring Compression Pressure
Measuring Blow-By Pressure
Measuring Engine Oil Pressure
Measuring Intake Air (Boost) Pressure
Handling Fuel System Equipment
Releasing Residual Pressure in Fuel System
Measuring Fuel Pressure
Measuring Fuel Return Rate and Leakage
Bleeding Air from Fuel Circuit
Testing Leakage in Fuel System
Handling No-Injection Cranking Operation
Handling Reduced Cylinder Mode Operation
Check of Muffler and Muffler Stack for Looseness and Damage
Handling Controller Voltage Circuit
Check of Installed Condition of Cylinder Head and Manifolds
Check of Muffler Function
Check of Engine Piping for Damage and Looseness
Testing and Adjusting Air Conditioner Compressor Belt Tension
Replacing Alternator Belt
Wa250Pz-6
Testing and Adjusting, Part
Checking Operating Force of Accelerator Pedal
Checking Directional Lever
Testing and Adjusting HST Oil Pressure
Testing Clutch Control Pressure
Testing and Adjusting Steering Wheel
Testing and Adjusting Steering Oil Pressure
Bleeding Air from Steering Circuit
Testing Hydraulic Fan
Measuring Brake Pedal
Testing and Adjusting Brake Pedal Linkage
Measuring Brake Performance
Testing and Adjusting Accumulator Charge Pressure
Testing Wheel Brake Oil Pressure
Testing Wear of Brake Disc
Bleeding Air from Wheel Brake Circuit
Releasing Residual Pressure in Brake Accumulator Circuit
Testing Parking Brake Performance
Testing and Adjusting Parking Brake Control Cable
Measuring and Adjusting Work Equipment Control Lever
Testing and Adjusting Work Equipment Hydraulic Pressure
Testing Work Equipment PPC Oil Pressure
Bleeding Air from Hydraulic Circuit
Releasing Remaining Pressure in Hydraulic Circuit
Testing and Adjusting Bucket Positioner
Testing and Adjusting of Boom Kick-Out Switch
Checking Proximity Switch Operation Pilot Lamp
Procedure for Testing Diodes
Preparation Work for Troubleshooting for Electric System
Starting KOMTRAX Terminal Operations
Indicator Lamps of KOMTRAX Terminal
Testing and Adjusting, Part
Adjusting Machine Monitor
Adjusting Replaced, Reassembled or Added Sensor, Controller, Etc. with Machine Monitor
Special Functions of Machine Monitor (EMMS)
Pm Clinic Inspection Chart
40 Troubleshooting
Failure Codes Table
Fuse Locations
Wa250Pz-6
General Information on Troubleshooting
Points to Remember When Troubleshooting
Troubleshooting
Sequence of Events in Troubleshooting
Testing before Troubleshooting
Classification and Procedures of Troubleshooting
Information Contained in Troubleshooting Table
Connection Table for Connector Pin Numbers
T- Branch Box and T- Branch Adapter Table
Troubleshooting by Failure Code (Display of Code), Part
Failure Code [2G40GZ] Brake: Oil Pressure Reduction
Failure Code [6091NX] HST Filter: Clogging
Failure Code [989FN1] Travel Speed: Overrun Alarm
Failure Code [AB00L6] Alternator R System: Hot Short
Failure Code [AB00MA] Alternator R System: Ground Fault/Disconnection Charge/Low Charge Voltage
Failure Code [B@BAZG] Engine: Oil Pressure Reduction
Failure Code [B@BCNS] Engine: Overheat
Failure Code [B@BCZK] Engine: Low Coolant Level
Failure Code [B@C6NS] Front Brake: High Oil Temperature
Failure Code [B@CRNS] HST: High Oil Temperature
Troubleshooting by Failure Code (Display of Code), Part
Failure Code [CA111] Abnormality in Engine Controller
Failure Code [CA115] Engine Ne or Bkup Speed Sensor Error
Failure Code [CA122] Charge Pressure Sensor High Error
Failure Code [CA123] Charge Pressure Sensor Low Error
Failure Code [CA131] Throttle Sensor High Error
Failure Code [CA132] Throttle Sensor Low Error
Failure Code [CA144] Coolant Sensor High Error
Failure Code [CA145] Coolant Sensor Low Error
Failure Code [CA153] Charge Temperature Sensor High Error
Failure Code [CA154] Charge Temperature Sensor Low Error
Failure Code [CA155] Derating of Speed by Abnormally High Charge Temperature
Failure Code [CA187] Sensor Power Supply 2 Low Error
Failure Code [CA221] Atmospheric Pressure Sensor High Error
Failure Code [CA222] Atmospheric Sensor Low Error
Failure Code [CA227] Sensor Power Supply 2 High Error
Failure Code [CA234] Engine Overspeed
Failure Code [CA238] Ne Speed Sensor Power Supply Error
Failure Code [CA271] IMV (IMA) Short Circuit
Failure Code [CA272] IMV (IMA) Disconnection
Failure Code [CA322] Injector #1 Open/Short Error
Failure Code [CA323] Injector #5 Open/Short Error
Failure Code [CA324] Injector #3 Open/Short Error
Failure Code [CA325] Injector #6 Open/Short Error
Failure Code [CA331] Injector #2 Open/Short Error
Failure Code [CA332] Injector #4 Open/Short Error
Failure Code [CA342] Calibration Code Inconsistency
Failure Code [CA351] Injectors Drive Circuit Error
Failure Code [CA352] Sensor Power Supply 1 Low Error
Failure Code [CA386] Sensor Power Supply 1 High Error
Troubleshooting by Failure Code (Display of Code), Part
Failure Code [CA428] Abnormally High Level in Water Sensor
Failure Code [CA429] Abnormally Low Level in Water Sensor
Failure Code [CA431] Idle Validation Switch Error
Failure Code [CA432] Idle Validation Action Error
Failure Code [CA435] Engine Oil Pressure Switch Error
Failure Code [CA441] Battery Voltage Low Error
Failure Code [CA442] Battery Voltage High Error
Failure Code [CA449] Common Rail Pressure High Error 2
Failure Code [CA451] Common Rail Pressure Sensor High Error
Failure Code [CA452] Common Rail Pressure Sensor Low Error
Failure Code [CA488] Derating of Torque by Abnormally High Charge Temperature
Failure Code [CA553] Common Rail Pressure High Error 1
Failure Code [CA559] Supply Pump Pressure very Low Error
Failure Code [CA689] Engine Ne Speed Sensor Error
Failure Code [CA731] Engine Bkup Speed Sensor Phase Error
Failure Code [CA757] All Continuous Data Lost Error
Failure Code [CA778] Engine Bkup Speed Sensor Error
Failure Code [CA1633] KOMNET Datalink Timeout Error
Failure Code [CA2185] Throttle Sensor Supply Voltage High Error
Failure Code [CA2186] Throttle Sensor Power Supply Low Error
Failure Code [CA2249] Supply Pump Pressure very Low Error 2
Failure Code [CA2311] Abnormality in IMV (IMA) Solenoid
Failure Code [CA2555] Intake Heater Relay Disconnection Error
Failure Code [CA2556] Intake Heater Relay Short Circuit Error
Troubleshooting by Failure Code (Display of Code), Part
Failure Code [D160KY] Backup Alarm/Lamp Relay 1 Circuit: Hot Short
Failure Code [D192KY] ECSS Solenoid Relay: Hot Short
Failure Code [D1B0KA] HST Safety Relay: Disconnection
Failure Code [D1B0KB] HST Safety Relay: Ground Fault
Failure Code [D1B0KY] HST Safety Relay: Hot Short
Failure Code [D5ZHL6] IGN C System: Ground Fault/Disconnection
Failure Code [DAF3KK] UNSW Power Supply: Ground Fault/Disconnection
Failure Code [DAFRKR] Machine Monitor CAN-NET Signal: Disconnection
Failure Code [DAJ0KK] HST Controller Power Supply: Low Voltage
Failure Code [DAJ0KT] HST Controller Memory (EEPROM): Abnormality
Failure Code [DAJ1L4] HST Controller Main Power Line: Disconnection/Ground Fault
Failure Code [DAJ1L6] HST Controller Main Power Line: Hot Short
Failure Code [DAJ2KK] Controller Solenoid Power Supply: Low Voltage
Failure Code [DAJ2L3] HST Controller Load Power Supply Holding Line: Hot Short in Wiring Harness
Failure Code [DAJ2L4] HST Controller Load Power Supply Holding Line: Disconnection/Ground Fault
Failure Code [DAJ5KX] Sensor 5V Power Supply: out of Output Range
Failure Code [DAJ9KQ] HST Controller Model Selection: Disagreement of Model Selection Signals
Failure Code [DAJRKR] HST Controller CAN-NET Signal: Disconnection
Failure Code [DAJRMA] HST Controller: Disagreement in Option Selection
Troubleshooting by Failure Code (Display of Code), Part
Failure Code [DB2RKR] Engine Controller CAN-NET: Disconnection in Signal Line
Failure Code [DD1NL4] Fan Automatic Reverse Switch Signal: Abnormality
Failure Code [DD1NLD] Fan Reverse Switch Signal: Abnormality
Failure Code [DDB6KA] Parking Brake Switch A: Disconnection/Hot Short
Failure Code [DDB6KB] Parking Brake Switch B: Ground Fault
Failure Code [DDB6KZ] Parking Brake Switch (Bottom Switch) or Parking Brake Reminder Switch (Intermediate Switch): Trouble
Failure Code [DDB6L0] Parking Brake Switch A: Ground Fault
Failure Code [DDB6L4] Parking Brake Switch B: Disconnection/Hot Short
Failure Code [DDD7KX] Travel Speed Control Dial Signal: Disconnection/Ground Fault
Failure Code [DDD7KY] Travel Speed Control Dial Signal: Hot Short
Failure Code [DDE5MA] Emergency Steering Operation Switch: Disconnection
Failure Code [DDK3KA] Directional Selector Switch: Disconnection/Hot Short
Failure Code [DDK3KB] Directional Selector Switch: Ground Fault
Failure Code [DDK6KA] FNR Lever: Disconnection/Ground Fault
Failure Code [DDK6KY] FNR Lever: Hot Short
Failure Code [DDS5L6] Steering: Low Oil Pressure (Operation of Emergency Steering)
Troubleshooting by Failure Code (Display of Code), Part
Failure Code [DF10KA] Travel Speed Range Selector Switch: Disconnection/Ground Fault
Failure Code [DF10KB] Travel Speed Range Selector Switch: Hot Short
Failure Code [DGH1KX] HST Oil Temperature Sensor: Ground Fault
Failure Code [DGR2KB] Brake Oil Temperature Sensor: Ground Fault
Failure Code [DGR2KZ] Brake Oil Temperature Sensor: Disconnection/Hot Short
Failure Code [DHH1KX] HST Oil Pressure Sensor: Disconnection/Ground Fault
Failure Code [DHH1KY] HST Oil Pressure Sensor: Hot Short
Failure Code [DHTCL6] HST Filter Clogging Sensor: Functional Defect
Failure Code [DJF1KA] Fuel Level Sensor: Disconnection/Hot Short
Failure Code [DLT3KX] Travel Speed Sensor B: Abnormality
Failure Code [DLT4KX] Travel Speed Sensor A: Abnormality
Failure Code [DLT4LC] Travel Speed Sensor a & B: Abnormality
Failure Code [DV00KY] Alarm Buzzer: Hot Short
Failure Code [DW26KA] Motor 2 Solenoid: Disconnection/Ground Fault
Failure Code [DW26KY] Motor 2 Solenoid: Hot Short
Failure Code [DW7BKY] Fan Reverse Solenoid Circuit: Hot Short
Failure Code [DW7BKZ] Fan Reverse Solenoid Circuit: Disconnection/Ground Fault
Troubleshooting by Failure Code (Display of Code), Part
Failure Code [DX16KA] Fan EPC Solenoid: Disconnection
Failure Code [DX16KB] Fan EPC Solenoid: Ground Fault
Failure Code [DX16KY] Fan EPC Solenoid: Hot Short
Failure Code [DX19KA] Motor 1 Solenoid: Disconnection
Failure Code [DX19KB] Motor 1 Solenoid: Ground Fault
Failure Code [DX19KY] Motor 1 Solenoid: Hot Short
Failure Code [DX20KA] Clutch EPC Solenoid: Disconnection
Failure Code [DX20KB] Clutch EPC Solenoid: Ground Fault
Failure Code [DX20KY] Clutch EPC Solenoid: Hot Short
Failure Code [DXH7KB] Reverse Solenoid: Ground Fault
Failure Code [DXH7KZ] Reverse Solenoid: Disconnection/Hot Short
Failure Code [DXH8KB] Forward Solenoid: Ground Fault
Failure Code [DXH8KZ] Forward Solenoid: Disconnection/Hot Short
Failure Code [J141N1] Steering Pump: Overrun Alarm
Failure Code [M100N1] HST Pump: Overrun Alarm
Failure Code [M400N1] Motor 1: Overrun Alarm
E-1 Engine Does Not Start
E-2. Preheater Does Not Operate Normally
E-3 Defective Boom Kick-Out Function and Cancellation
E-4 Defective Bucket Positioner Function and Cancellation
E-5 Defective Lift Arm FLOATING Holding Function and Cancellation
E-6 Travel Direction Selection System Does Not Function
E-7 Wiper Does Not Operate
E-8 Windshield Washer Does Not Operate
E-9 Headlamp, Clearance Lamp and Tail Lamp Do Not Light up or Go off
E-10 Working Lamp Does Not Light up or Go off
E-11 Turn Signal Lamp and Hazard Lamp Do Not Light up or Go off
E-12 Brake Lamp Does Not Light or It Keeps Lighting up
E-13 Backup Lamp Does Not Light or It Keeps Lighting up
E-14 Backup Alarm Does Not Sound or It Keeps Sounding
E-15 Horn Does Not Sound or It Keeps Sounding
E-16 Alarm Buzzer Does Not Sound or It Keeps Sounding
E-17 Air Conditioner Does Not Operate or Stop
E-18 the KOMTRAX System Does Not Work Properly
Method of Using Troubleshooting Chart
Failure Code and Cause Table
H-1 the Machine Does Not Start
H-2 the Travel Speed Is Slow
H-3 the Traction Force Is Weak
H-4 Engine Stalls When Traveling or Engine Speed Drops Excessively
H-5 the Gear Is Not Shifted
H-6 the Steering Wheel Does Not Turn
H-7 the Steering Wheel Is Heavy
H-8 Steering Wheel Shakes or Jerks
H-9 Machine Deviates Naturally to One Side When Traveling
H-10 the Brake Does Not Work or Does Not Work Well
H-11 the Brake Is Not Released or Is Dragged
H-12 the Lift Arm Does Not Rise or Lower
H-13 the Lift Arm Moves Slowly or the Lift Arm Rising Force Is Insufficient
H-14 When Rising, the Lift Arm Comes to Move Slowly at Specific Height
H-16 Hydraulic Drifts of the Lift Arm Occur Often
H-17 the Lift Arm Wobbles During Operation
The Lift Arm Cylinder Cannot Hold down the Bucket (the Bucket Rises in the Air)
When the Control Lever Is Switched from "HOLD" to "RAISE," the Lift Arm Falls Temporarily
H-19 the Bucket Does Not Tilt Back
H-20 the Bucket Moves Slowly or the Tilting-Back Force Is Insufficient
H-21 the Bucket Comes to Operate Slowly in the Midst of Tilting-Back
H-22 the Bucket Cylinder Cannot Hold down the Bucket
H-23 Hydraulic Drifts of the Bucket Occur Often
The Bucket Wobbles During Travel with Load (the Work Equipment Valve Is Set to "HOLD")
The Control Levers of the Lift Arm and Bucket Do Not Move Smoothly and Heavy
When the Control Lever Is Switched from "HOLD" to "TILT," the Bucket Falls Temporarily
H-27 the ECSS Does Not Operate and Machine Pitches and Bounces
Fan Revolution Is Abnormal (Fan Sound/Vibration Is Abnormally Large or Engine Overheats)
Method of Using Troubleshooting Charts
S-1 Starting Performance Is Poor
S-2 Engine Does Not Start
S-3 Engine Does Not Pick up Smoothly
S-4 Engine Stops During Operations
S-5 Engine Does Not Rotate Smoothly
Engine Lacks Output (or Lacks Power)
Exhaust Smoke Is Black (Incomplete Combustion)
Oil Consumption Is Excessive (or Exhaust Smoke Is Blue)
S-9 Oil Becomes Contaminated Quickly
S-10 Fuel Consumption Is Excessive
Oil Is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)
S-12 Oil Pressure Drops
Oil Level Rises (Entry of Coolant or Fuel)
Coolant Temperature Becomes too High (Overheating)
S-15 Abnormal Noise Is Made
S-16 Vibration Is Excessive
50 Disassembly and Assembly
How to Read this Manual
Coating Materials List
Special Tool List
Sketches of Special Tools
Removal and Installation of Fuel Supply Pump Assembly
Removal and Installation of Fuel Injector Assembly
Removal and Installation of Cylinder Head Assembly
Removal and Installation of Engine Hood Assembly
Removal and Installation of Radiator
Removal and Installation of Air Aftercooler
Removal and Installation of Hydraulic Oil Cooler Assembly
Removal and Installation of Engine Assembly
Removal and Installation of Engine Front Oil Seal Assembly
Removal and Installation of Engine Rear Oil Seal Assembly
Removal and Installation of Cooling Fan and Fan Motor Assembly
Removal and Installation of Fuel Tank Assembly
Power Train, Part
Removal and Installation of Transfer Assembly
Disassembly and Assembly of Transfer Assembly
Removal and Installation of Parking Brake Assembly
Disassembly and Assembly of Parking Brake Assembly
Power Train, Part
Removal and Installation of Front Axle Assembly
Removal and Installation of Rear Axle Assembly
Disassembly and Assembly of Axle Housing Assembly
Disassembly and Assembly of Differential Assembly
Removal and Installation of Center Hinge Pin
Removal and Installation of Counterweight
Removal and Installation of HST Pump and 4-Gear Pump Assembly
Disassembly and Assembly of HST Pump Assembly
Removal and Installation of HST Motor 1 Assembly
Removal and Installation of HST Motor 2 Assembly
Disassembly and Assembly of HST Motor Assembly
Removal and Installation of Work Equipment Control Valve Assembly
Removal and Installation of Hydraulic Tank
Disassembly and Assembly of Hydraulic Cylinder Assembly
Removal and Installation of Work Equipment Assembly
Removal and Installation of Operator's Cab and Floor Frame Assembly
Removal and Installation of Operator's Cab Glass (Stuck Glass)
Removal and Installation of Air Conditioner Unit
Removal and Installation of Monitor Panel
Removal and Installation of Engine Controller Assembly
Removal and Installation of HST Controller Assembly
Removal and Installation of KOMTRAX Terminal Assembly
90 Diagrams and Drawings
Hydraulic Diagrams and Drawings SEN03860-01
Connector List and Stereogram
Electrical Circuit Diagram
Electrical Diagrams and Drawings SEN03861-01
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WHEEL LOADER
WA250
WA250PZ
SERIAL NUMBERS
SEN03813-03
-6
-6
WA250-
75001
WA250PZ- 75001
and up
Table of
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Chapters
Table of Contents
5
Wa250Pz-6
16
Specification
58
Structure, Function and Maintenance Standard
70
Structure, Function and Maintenance Standard
86
Structure, Function and Maintenance Standard
140
Wa250Pz-6
166
Structure, Function and Maintenance Standard
198
Structure, Function and Maintenance Standard
262
Structure, Function and Maintenance Standard
332
Wa250Pz-6
384
Wa250Pz-6
422
Wa250Pz-6
548
Table of Contents
Troubleshooting
Tools for testing, adjusting, and troubleshooting
387
Preparation work for troubleshooting for electric system
462
40 Troubleshooting
536
Points to remember when troubleshooting
549
Sequence of events in troubleshooting
550
Testing before troubleshooting
551
Classification and procedures of troubleshooting
552
Information contained in troubleshooting table
555
Troubleshooting by failure code (Display of code), Part
598
Troubleshooting by failure code (Display of code), Part
616
Troubleshooting by failure code (Display of code), Part
672
Troubleshooting by failure code (Display of code), Part
728
Troubleshooting by failure code (Display of code), Part
772
Troubleshooting by failure code (Display of code), Part
812
Troubleshooting by failure code (Display of code), Part
850
Method of using troubleshooting chart
956
Method of using troubleshooting charts
983
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