Komatsu Wheel Loaders WA250, WA250PZ Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loaders WA250, WA250PZ, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Wheel Loader WA250-6, WA250PZ-6 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
SEN03813-05 - Wheel Loader WA250-6, WA250PZ-6 Shop Manual.pdf
VEBM610101 - Wheel Loader WA250-6, WA250PZ-6 Shop Manual.pdf
VEBM945100 - Wheel Loader WA250PZ-5 Shop Manual.pdf
TEN00204-04 - Wheel Loader WA250-6 Operation & Maintenance Manual.pdf
TEN00259-04 - Wheel Loader WA250PZ-6 Operation & Maintenance Manual.pdf
TEN00408-00 - Wheel Loader WA250PZ-6 Operation & Maintenance Manual.pdf
TEN00455-01 - Wheel Loader WA250PZ-6 Operation & Maintenance Manual.pdf
VEAM945101 - Wheel Loader WA250PZ-5 Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 2,112 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
SEN03813-05 - Wheel Loader WA250-6, WA250PZ-6 Shop Manual....2
Cover....2
00 Index and foreword....0
100 Index....4
Composition of shop manual....5
Table of contents....7
200 Foreword and general information....18
Safety notice....19
How to read the shop manual....24
Explanation of terms for maintenance standard....26
Handling of electric equipment and hydraulic component....28
Handling of connectors newly used for engines....37
How to read electric wire code....40
Precautions when carrying out operation....43
Method of disassembling and connecting push-pull type coupler....46
Standard tightening torque table....49
Conversion table....53
01 Specification....0
100 Specification and technical data....60
Specification dimension drawing....62
Specifications....63
Weight table....67
Table of fuel, coolant and lubricants....69
10 Structure, function and maintenance standard....0
100 Engine and cooling system....72
Engine mount and transfer mount....73
Damper....74
Cooling system....75
Cooling system hydraulic piping diagram....76
Cooling fan motor....78
200 Power train....88
Power train....90
Power train system diagram....91
Drive shaft....93
HST hydraulic piping diagram....94
HST pump....95
HST motor....103
Transfer....109
Clutch solenoid valve....120
Axle....121
Differential....123
Torque proportioning differential....128
Limited slip differential....131
Final drive....135
300 Steering system....142
Steering piping diagram....144
Steering column....145
Priority valve....146
Orbit-roll valve....149
2-way restrictor valve....157
Cushion valve....158
Steering cylinder....159
Emergency steering piping diagram....161
Emergency steering valve....162
Steering relief valve....165
400 Brake system....168
Brake piping diagram....170
Charge valve....171
Brake valve....175
Inching valve....179
Accumulator (for brake)....180
Slack adjuster....181
Brake....183
Parking brake control....188
Parking brake....189
500 Undercarriage and frame....192
Axle mount and center hinge pin....193
Tires....198
600 Hydraulic system....200
Work equipment hydraulic piping diagram....201
Work equipment control lever linkage....205
Hydraulic tank....209
4-gear pump....211
Work equipment control valve....213
PPC valve....238
Lock valve....253
Accumulator (for PPC circuit)....254
Bypass valve....255
Quick coupler solenoid valve....258
ECSS valve....259
Accumulator (for ECSS)....261
700 Work equipment....264
Work equipment linkage....265
Bucket....269
Bucket positioner and boom kick-out....273
Work equipment cylinder....286
800 Cab and its attachments....290
Cab....292
Air conditioner....293
910 Electrical system, Part 1....306
Machine monitor system....307
Machine monitor....311
920 Electrical system, Part 2....334
Electrical system (HST controller system)....335
HST controller....351
ECSS system....353
KOMTRAX system....355
Engine starting circuit....357
Engine stopping circuit....359
Preheating circuit....360
Engine output derating function....361
Automatic warm-up function....361
Parking brake circuit....362
Coupler plunger control system....365
Multi-function knob....366
Max. traction switch....367
Sensor....368
20 Standard value table....0
100 Standard service value table....376
Standard service value table....377
Standard service value table for chassis....378
30 Testing and adjusting....0
110 Testing and adjusting, Part 1....386
Tools for testing, adjusting, and troubleshooting....389
Sketches of special tools....394
Measuring engine speed....395
Measuring exhaust gas color....397
Adjusting valve clearance....399
Measuring compression pressure....401
Measuring blow-by pressure....404
Measuring engine oil pressure....405
Measuring intake air (boost) pressure....406
Handling fuel system equipment....408
Releasing residual pressure in fuel system....408
Measuring fuel pressure....409
Measuring fuel return rate and leakage....411
Bleeding air from fuel circuit....415
Testing leakage in fuel system....416
Handling reduced cylinder mode operation....417
Handling no-injection cranking operation....417
Handling controller voltage circuit....418
Check of muffler and muffler stack for looseness and damage....418
Check of muffler function....419
Check of installed condition of cylinder head and manifolds....419
Check of engine piping for damage and looseness....420
Testing and adjusting air conditioner compressor belt tension....420
Replacing alternator belt....421
120 Testing and adjusting, Part 2....424
Checking operating force of accelerator pedal....426
Checking directional lever....427
Testing and adjusting HST oil pressure....428
Testing clutch control pressure....432
Testing and adjusting steering wheel....433
Testing and adjusting steering oil pressure....435
Bleeding air from steering circuit....437
Testing hydraulic fan....438
Measuring brake pedal....440
Testing and adjusting brake pedal linkage....441
Measuring brake performance....442
Testing and adjusting accumulator charge pressure....443
Testing wheel brake oil pressure....445
Testing wear of brake disc....448
Bleeding air from wheel brake circuit....449
Releasing residual pressure in brake accumulator circuit....450
Testing parking brake performance....451
Testing and adjusting parking brake control cable....452
Measuring and adjusting work equipment control lever....453
Testing and adjusting work equipment hydraulic pressure....454
Testing work equipment PPC oil pressure....455
Bleeding air from hydraulic circuit....457
Releasing remaining pressure in hydraulic circuit....458
Testing and adjusting bucket positioner....459
Testing and adjusting of boom kick-out switch....460
Checking proximity switch operation pilot lamp....461
Procedure for testing diodes....462
Preparation work for troubleshooting for electric system....464
Starting KOMTRAX terminal operations....468
Indicator lamps of KOMTRAX terminal....472
130 Testing and adjusting, Part 3....476
Adjusting machine monitor....477
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor....478
Special functions of machine monitor (EMMS)....480
Pm clinic inspection chart....534
40 Troubleshooting....0
100 Failure code table and fuse locations....538
Failure codes table....539
Fuse locations....545
200 General information on troubleshooting....550
Points to remember when troubleshooting....551
Sequence of events in troubleshooting....552
Testing before troubleshooting....553
Classification and procedures of troubleshooting....554
Information contained in troubleshooting table....557
Connection table for connector pin numbers....559
T- branch box and T- branch adapter table....595
310 Troubleshooting by failure code (Display of code), Part 1....600
Failure code [2G40GZ] Brake: Oil pressure reduction....601
Failure code [6091NX] HST filter: Clogging....603
Failure code [989FN1] Travel speed: Overrun alarm....605
Failure code [AB00L6] Alternator R system: Hot short....607
Failure code [AB00MA] Alternator R system: Ground fault/Disconnection charge/Low charge voltage....609
Failure code [B@BAZG] Engine: Oil pressure reduction....611
Failure code [B@BCNS] Engine: Overheat....612
Failure code [B@BCZK] Engine: Low coolant level....613
Failure code [B@C6NS] Front brake: High oil temperature....615
Failure code [B@CRNS] HST: High oil temperature....616
320 Troubleshooting by failure code (Display of code), Part 2....618
Failure code [CA111] Abnormality in engine controller....620
Failure code [CA115] Engine Ne or Bkup speed sensor error....621
Failure code [CA122] Charge pressure sensor high error....623
Failure code [CA123] Charge pressure sensor low error....625
Failure code [CA131] Throttle sensor high error....627
Failure code [CA132] Throttle sensor low error....629
Failure code [CA144] Coolant sensor high error....631
Failure code [CA145] Coolant sensor low error....633
Failure code [CA153] Charge temperature sensor high error....635
Failure code [CA154] Charge temperature sensor low error....637
Failure code [CA155] Derating of speed by abnormally high charge temperature....639
Failure code [CA187] Sensor power supply 2 low error....641
Failure code [CA221] Atmospheric pressure sensor high error....643
Failure code [CA222] Atmospheric sensor low error....645
Failure code [CA227] Sensor power supply 2 high error....647
Failure code [CA234] Engine overspeed....648
Failure code [CA238] Ne speed sensor power supply error....649
Failure code [CA271] IMV (IMA) Short circuit....650
Failure code [CA272] IMV (IMA) Disconnection....651
Failure code [CA322] Injector #1 open/short error....653
Failure code [CA323] Injector #5 open/short error....655
Failure code [CA324] Injector #3 open/short error....657
Failure code [CA325] Injector #6 open/short error....659
Failure code [CA331] Injector #2 open/short error....661
Failure code [CA332] Injector #4 open/short error....663
Failure code [CA342] Calibration code inconsistency....665
Failure code [CA351] Injectors drive circuit error....667
Failure code [CA352] Sensor power supply 1 low error....669
Failure code [CA386] Sensor power supply 1 high error....671
330 Troubleshooting by failure code (Display of code), Part 3....674
Failure code [CA428] Abnormally high level in water sensor....677
Failure code [CA429] Abnormally low level in water sensor....679
Failure code [CA431] Idle validation switch error....681
Failure code [CA432] Idle validation action error....685
Failure code [CA435] Engine oil pressure switch error....689
Failure code [CA441] Battery voltage low error....690
Failure code [CA442] Battery voltage high error....693
Failure code [CA449] Common rail pressure high error 2....695
Failure code [CA451] Common rail pressure sensor high error....697
Failure code [CA452] Common rail pressure sensor low error....699
Failure code [CA488] Derating of torque by abnormally high charge temperature....701
Failure code [CA553] Common rail pressure high error 1....702
Failure code [CA559] Supply pump pressure very low error....703
Failure code [CA689] Engine Ne speed sensor error....705
Failure code [CA731] Engine Bkup speed sensor phase error....707
Failure code [CA757] All continuous data lost error....708
Failure code [CA778] Engine Bkup speed sensor error....711
Failure code [CA1633] KOMNET datalink timeout error....713
Failure code [CA2185] Throttle sensor supply voltage high error....717
Failure code [CA2186] Throttle sensor power supply low error....719
Failure code [CA2249] Supply pump pressure very low error 2....721
Failure code [CA2311] Abnormality in IMV (IMA) solenoid....723
Failure code [CA2555] Intake heater relay disconnection error....725
Failure code [CA2556] Intake heater relay short circuit error....727
340 Troubleshooting by failure code (Display of code), Part 4....730
Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short....731
Failure code [D192KY] ECSS solenoid relay: Hot short....733
Failure code [D1B0KA] HST safety relay: Disconnection....735
Failure code [D1B0KB] HST safety relay: Ground fault....737
Failure code [D1B0KY] HST safety relay: Hot short....739
Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection....741
Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection....743
Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection....745
Failure code [DAJ0KK] HST controller power supply: Low voltage....749
Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality....751
Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault....753
Failure code [DAJ1L6] HST controller main power line: Hot short....755
Failure code [DAJ2KK] Controller solenoid power supply: Low voltage....757
Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness....759
Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault....761
Failure code [DAJ5KX] Sensor 5V power supply: Out of output range....763
Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals....765
Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection....766
Failure code [DAJRMA] HST controller: Disagreement in option selection....772
350 Troubleshooting by failure code (Display of code), Part 5....774
Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line....776
Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality....781
Failure code [DD1NLD] Fan reverse switch signal: Abnormality....783
Failure code [DDB6KA] Parking brake switch A: Disconnection/Hot short....785
Failure code [DDB6KB] Parking brake switch B: Ground fault....787
Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble....789
Failure code [DDB6L0] Parking brake switch A: Ground fault....791
Failure code [DDB6L4] Parking brake switch B: Disconnection/Hot short....793
Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault....795
Failure code [DDD7KY] Travel speed control dial signal: Hot short....797
Failure code [DDE5MA] Emergency steering operation switch: Disconnection....799
Failure code [DDK3KA] Directional selector switch: Disconnection/Hot short....801
Failure code [DDK3KB] Directional selector switch: Ground fault....803
Failure code [DDK6KA] FNR lever: Disconnection/Ground fault....805
Failure code [DDK6KY] FNR lever: Hot short....809
Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering)....811
360 Troubleshooting by failure code (Display of code), Part 6....814
Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault....816
Failure code [DF10KB] Travel speed range selector switch: Hot short....819
Failure code [DGH1KX] HST oil temperature sensor: Ground fault....821
Failure code [DGR2KB] Brake oil temperature sensor: Ground fault....822
Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short....823
Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault....825
Failure code [DHH1KY] HST oil pressure sensor: Hot short....827
Failure code [DHTCL6] HST filter clogging sensor: Functional defect....829
Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short....831
Failure code [DLT3KX] Travel speed sensor B: Abnormality....833
Failure code [DLT4KX] Travel speed sensor A: Abnormality....837
Failure code [DLT4LC] Travel speed sensor A & B: Abnormality....839
Failure code [DV00KY] Alarm buzzer: Hot short....841
Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault....843
Failure code [DW26KY] Motor 2 solenoid: Hot short....845
Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short....847
Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault....849
370 Troubleshooting by failure code (Display of code), Part 7....852
Failure code [DX16KA] Fan EPC solenoid: Disconnection....853
Failure code [DX16KB] Fan EPC solenoid: Ground fault....854
Failure code [DX16KY] Fan EPC solenoid: Hot short....855
Failure code [DX19KA] Motor 1 solenoid: Disconnection....857
Failure code [DX19KB] Motor 1 solenoid: Ground fault....859
Failure code [DX19KY] Motor 1 solenoid: Hot short....861
Failure code [DX20KA] Clutch EPC solenoid: Disconnection....863
Failure code [DX20KB] Clutch EPC solenoid: Ground fault....865
Failure code [DX20KY] Clutch EPC solenoid: Hot short....867
Failure code [DXH7KB] Reverse solenoid: Ground fault....869
Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short....871
Failure code [DXH8KB] Forward solenoid: Ground fault....873
Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short....875
Failure code [J141N1] Steering pump: Overrun alarm....877
Failure code [M100N1] HST pump: Overrun alarm....877
Failure code [M400N1] Motor 1: Overrun alarm....878
400 Troubleshooting of electrical system (E-mode)....880
E-1 Engine does not start....882
E-2. Preheater does not operate normally....889
E-3 Defective boom kick-out function and cancellation....893
E-4 Defective bucket positioner function and cancellation....897
E-5 Defective lift arm FLOATING holding function and cancellation....901
E-6 Travel direction selection system does not function....905
E-7 Wiper does not operate....909
E-8 Windshield washer does not operate....913
E-9 Headlamp, clearance lamp and tail lamp do not light up or go off....917
E-10 Working lamp does not light up or go off....925
E-11 Turn signal lamp and hazard lamp do not light up or go off....930
E-12 Brake lamp does not light or it keeps lighting up....937
E-13 Backup lamp does not light or it keeps lighting up....939
E-14 Backup alarm does not sound or it keeps sounding....942
E-15 Horn does not sound or it keeps sounding....945
E-16 Alarm buzzer does not sound or it keeps sounding....947
E-17 Air conditioner does not operate or stop....949
E-18 The KOMTRAX system does not work properly....952
500 Troubleshooting of hydraulic and mechanical system (H-mode)....956
Method of using troubleshooting chart....958
Failure code and cause table....961
H-1 The machine does not start....963
H-2 The travel speed is slow....964
H-3 The traction force is weak....965
H-4 Engine stalls when traveling or engine speed drops excessively....966
H-5 The gear is not shifted....967
H-6 The steering wheel does not turn....968
H-7 The steering wheel is heavy....969
H-8 Steering wheel shakes or jerks....970
H-9 Machine deviates naturally to one side when traveling....970
H-10 The brake does not work or does not work well....971
H-11 The brake is not released or is dragged....972
H-12 The lift arm does not rise or lower....973
H-13 The lift arm moves slowly or the lift arm rising force is insufficient....974
H-14 When rising, the lift arm comes to move slowly at specific height....975
H-15 The lift arm cylinder cannot hold down the bucket (The bucket....975
H-16 Hydraulic drifts of the lift arm occur often....975
H-17 The lift arm wobbles during operation....975
H-18 When the control lever is switched from "HOLD" to "RAISE," the lift arm falls temporarily....976
H-19 The bucket does not tilt back....977
H-20 The bucket moves slowly or the tilting-back force is insufficient....978
H-21 The bucket comes to operate slowly in the midst of tilting-back....979
H-22 The bucket cylinder cannot hold down the bucket....979
H-23 Hydraulic drifts of the bucket occur often....979
H-24 The bucket wobbles during travel with load (The work equipment valve is set to "HOLD")....979
H-25 When the control lever is switched from "HOLD" to "TILT," the bucket falls temporarily....980
H-26 The control levers of the lift arm and bucket do not move smoothly and heavy....980
H-27 The ECSS does not operate and machine pitches and bounces....981
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)....982
600 Troubleshooting of engine (S-mode)....984
Method of using troubleshooting charts....985
S-1 Starting performance is poor....989
S-2 Engine does not start....990
S-3 Engine does not pick up smoothly....993
S-4 Engine stops during operations....994
S-5 Engine does not rotate smoothly....995
S-6 Engine lacks output (or lacks power)....996
S-7 Exhaust smoke is black (incomplete combustion)....997
S-8 Oil consumption is excessive (or exhaust smoke is blue)....998
S-9 Oil becomes contaminated quickly....999
S-10 Fuel consumption is excessive....1000
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)....1001
S-12 Oil pressure drops....1002
S-13 Oil level rises (Entry of coolant or fuel)....1003
S-14 Coolant temperature becomes too high (overheating)....1004
S-15 Abnormal noise is made....1005
S-16 Vibration is excessive....1006
50 Disassembly and assembly....0
100 General information on disassembly and assembly....1008
How to read this manual....1009
Coating materials list....1011
Special tool list....1014
Sketches of special tools....1018
200 Engine and cooling system....1028
Removal and installation of fuel supply pump assembly....1029
Removal and installation of fuel injector assembly....1031
Removal and installation of cylinder head assembly....1038
Removal and installation of engine hood assembly....1051
Removal and installation of radiator....1054
Removal and installation of air aftercooler....1057
Removal and installation of hydraulic oil cooler assembly....1059
Removal and installation of engine assembly....1061
Removal and installation of engine front oil seal assembly....1067
Removal and installation of engine rear oil seal assembly....1070
Removal and installation of cooling fan and fan motor assembly....1073
Removal and installation of fuel tank assembly....1076
310 Power train, Part 1....1080
Removal and installation of transfer assembly....1081
Disassembly and assembly of transfer assembly....1085
Removal and installation of parking brake assembly....1105
Disassembly and assembly of parking brake assembly....1107
320 Power train, Part 2....1114
Removal and installation of front axle assembly....1115
Removal and installation of rear axle assembly....1117
Disassembly and assembly of axle housing assembly....1120
Disassembly and assembly of differential assembly....1129
400 Undercarriage and frame....1158
Removal and installation of center hinge pin....1159
Removal and installation of counterweight....1169
500 Hydraulic system....1172
Removal and installation of HST pump and 4-gear pump assembly....1173
Disassembly and assembly of HST pump assembly....1177
Removal and installation of HST motor 1 assembly....1204
Removal and installation of HST motor 2 assembly....1206
Disassembly and assembly of HST motor assembly....1208
Removal and installation of work equipment control valve assembly....1224
Removal and installation of hydraulic tank....1226
Disassembly and assembly of hydraulic cylinder assembly....1228
600 Work equipment....1236
Removal and installation of work equipment assembly....1237
700 Cab and its attachments....1246
Removal and installation ofoperator's cab and floor frame assembly....1247
Removal and installation of operator's cab glass (Stuck glass)....1252
Removal and installation of air conditioner unit....1260
800 Electrical system....1268
Removal and installation of monitor panel....1269
Removal and installation of engine controller assembly....1271
Removal and installation of HST controller assembly....1272
Removal and installation of KOMTRAX terminal assembly....1273
90 Diagrams and drawings....0
100 Hydraulic diagrams and drawings....1276
Hydraulic circuit diagram....1278
200 Electrical diagrams and drawings....1282
Electrical circuit diagram....1284
Connector list and stereogram....1293
TEN00204-04 - Wheel Loader WA250-6 Operation & Maintenance Manual....1296
FOREWORD....1297
BEFORE READING THIS MANUAL....1298
SAFETY INFORMATION....1299
INTRODUCTION....1300
USE OF MACHINE....1300
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE....1300
VISIBILITY FROM OPERATOR'S SEAT....1300
NECESSARY INFORMATION....1301
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....1301
EPA REGULATIONS, ENGINE NUMBER PLATE....1301
POSITION OF SERVICE METER....1302
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....1302
CONTENTS....1303
SAFETY....1307
SAFETY....1308
SAFETY LABELS....1311
LOCATION OF SAFETY LABELS....1311
SAFETY LABELS....1312
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE....1318
PRECAUTIONS BEFORE STARTING OPERATION....1318
PREPARATIONS FOR SAFE OPERATION....1318
FIRE PREVENTION....1320
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE....1321
DO NOT GET CAUGHT IN ARTICULATING PORTION....1324
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES....1324
UNAUTHORIZED MODIFICATION....1324
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS....1324
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING....1325
PRECAUTIONS FOR OPERATION....1326
PRECAUTIONS FOR JOBSITE....1326
STARTING ENGINE....1328
OPERATION....1330
TRANSPORTATION....1337
TOWING....1338
PRECAUTIONS FOR MAINTENANCE....1339
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE....1339
PRECAUTIONS FOR INSPECTION AND MAINTENANCE....1344
TIRES....1349
OPERATION....1351
GENERAL VIEW....1352
GENERAL VIEW OF MACHINE....1352
GENERAL VIEW OF CONTROLS AND GAUGES....1353
EXPLANATION OF COMPONENTS....1355
MACHINE MONITOR....1355
SWITCHES....1392
CONTROL LEVERS, PEDALS....1406
STEERING TILT LOCK LEVER....1411
CAP AND COVER WITH LOCK....1411
FRAME LOCK BAR....1412
TOWING PIN....1413
GREASE PUMP....1413
OPENING, CLOSING CAB DOORS, WINDOWS....1414
FUSE....1418
SLOW BLOW FUSE....1420
POWER OUTLET....1421
STORAGE BOX....1421
AM/FM RADIO-CASSETTE STEREO....1422
AIR CONDITIONER....1430
HANDLING CAB WIPER....1437
OPERATION....1438
CHECK BEFORE STARTING ENGINE, ADJUST....1438
STARTING ENGINE....1456
CHECKS AFTER STARTING ENGINE....1460
OPERATIONS AND CHECKS AFTER STARTING ENGINE....1461
STOPPING ENGINE....1464
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE....1465
TURNING....1471
OPERATION OF WORK EQUIPMENT....1473
WORK POSSIBLE USING WHEEL LOADER....1475
PRECAUTIONS FOR OPERATION....1480
ADJUSTING WORK EQUIPMENT POSTURE....1482
PARKING MACHINE....1484
CHECKS AFTER COMPLETION OF OPERATION....1486
LOCKING....1486
HANDLING THE TIRES....1487
TRANSPORTATION....1489
TRANSPORTATION PROCEDURE....1489
LOADING, UNLOADING WORK WITH TRAILERS....1489
LIFTING MACHINE....1493
COLD WEATHER OPERATION....1495
PRECAUTIONS FOR LOW TEMPERATURE....1495
PRECAUTIONS AFTER COMPLETION OF WORK....1496
AFTER COLD WEATHER....1496
LONG-TERM STORAGE....1497
BEFORE STORAGE....1497
DURING STORAGE....1497
AFTER STORAGE....1497
TROUBLESHOOTING....1498
WHEN MACHINE RUNS OUT OF FUEL....1498
METHOD OF TOWING MACHINE....1498
IF BATTERY IS DISCHARGED....1500
OTHER TROUBLE....1503
MAINTENANCE....1509
GUIDES TO MAINTENANCE....1510
OUTLINES OF SERVICE....1512
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....1512
OUTLINE OF ELECTRIC SYSTEM....1515
WEAR PARTS....1516
WEAR PARTS LIST....1516
RECOMMENDED FUEL, COOLANT, AND LUBRICANT....1517
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....1518
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....1519
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....1520
TORQUE LIST....1520
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....1521
MAINTENANCE SCHEDULE CHART....1522
MAINTENANCE SCHEDULE CHART....1522
SERVICE PROCEDURE....1524
INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE)....1524
INITIAL 250 HOURS SERVICE....1524
INITIAL 1000 HOURS SERVICE....1524
WHEN REQUIRED....1525
CHECK BEFORE STARTING....1552
EVERY 50 HOURS SERVICE....1553
EVERY 100 HOURS SERVICE....1554
EVERY 250 HOURS SERVICE....1557
EVERY 500 HOURS SERVICE....1563
EVERY 1000 HOURS SERVICE....1567
EVERY 2000 HOURS SERVICE....1573
EVERY 4000 HOURS SERVICE....1580
EVERY 8000 HOURS SERVICE....1582
SPECIFICATIONS....1583
SPECIFICATIONS....1584
ATTACHMENTS, OPTIONS....1587
SELECTING BUCKET AND TIRES....1588
HANDLING HYDRAULIC QUICK COUPLER....1589
REMOVING ATTACHMENT....1589
INSTALLING ATTACHMENT....1591
METHOD OF USING 2 LEVERS....1593
EXPLANATION OF COMPONENTS....1593
HANDLING MACHINES EQUIPPED WITH KOMTRAX....1595
BASIC PRECAUTIONS....1595
INDEX....1597
TEN00259-04 - Wheel Loader WA250PZ-6 Operation & Maintenance Manual....1601
COVER....1601
FOREWORD....1602
BEFORE READING THIS MANUAL....1603
SAFETY INFORMATION....1604
INTRODUCTION....1605
USE OF MACHINE....1605
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE....1605
VISIBILITY FROM OPERATOR'S SEAT....1605
NECESSARY INFORMATION....1606
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....1606
EPA REGULATIONS, ENGINE NUMBER PLATE....1606
POSITION OF SERVICE METER....1607
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....1607
CONTENTS....1608
SAFETY....1612
SAFETY....1613
SAFETY LABELS....1616
LOCATION OF SAFETY LABELS....1616
SAFETY LABELS....1617
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE....1623
PRECAUTIONS BEFORE STARTING OPERATION....1623
PREPARATIONS FOR SAFE OPERATION....1623
FIRE PREVENTION....1625
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE....1626
DO NOT GET CAUGHT IN ARTICULATING PORTION....1629
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES....1629
UNAUTHORIZED MODIFICATION....1629
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS....1629
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING....1630
PRECAUTIONS FOR OPERATION....1631
PRECAUTIONS FOR JOBSITE....1631
STARTING ENGINE....1633
OPERATION....1635
TRANSPORTATION....1642
TOWING....1643
PRECAUTIONS FOR MAINTENANCE....1644
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE....1644
PRECAUTIONS FOR INSPECTION AND MAINTENANCE....1649
TIRES....1654
OPERATION....1656
GENERAL VIEW....1657
GENERAL VIEW OF MACHINE....1657
GENERAL VIEW OF CONTROLS AND GAUGES....1658
EXPLANATION OF COMPONENTS....1660
MACHINE MONITOR....1660
SWITCHES....1697
CONTROL LEVERS, PEDALS....1711
STEERING TILT LOCK LEVER....1716
CAP AND COVER WITH LOCK....1716
FRAME LOCK BAR....1717
TOWING PIN....1718
GREASE PUMP....1718
OPENING, CLOSING CAB DOORS, WINDOWS....1719
FUSE....1723
SLOW BLOW FUSE....1725
POWER OUTLET....1726
STORAGE BOX....1726
AM/FM RADIO-CASSETTE STEREO....1727
AIR CONDITIONER....1735
HANDLING CAB WIPER....1742
OPERATION....1743
CHECK BEFORE STARTING ENGINE, ADJUST....1743
STARTING ENGINE....1761
CHECKS AFTER STARTING ENGINE....1765
OPERATIONS AND CHECKS AFTER STARTING ENGINE....1766
STOPPING ENGINE....1769
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE....1770
TURNING....1776
OPERATION OF WORK EQUIPMENT....1778
HANDLING HYDRAULIC QUICK COUPLER....1780
WORK POSSIBLE USING WHEEL LOADER....1784
PRECAUTIONS FOR OPERATION....1789
ADJUSTING WORK EQUIPMENT POSTURE....1791
PARKING MACHINE....1794
CHECKS AFTER COMPLETION OF OPERATION....1796
LOCKING....1796
HANDLING THE TIRES....1797
TRANSPORTATION....1799
TRANSPORTATION PROCEDURE....1799
LOADING, UNLOADING WORK WITH TRAILERS....1799
LIFTING MACHINE....1803
COLD WEATHER OPERATION....1805
PRECAUTIONS FOR LOW TEMPERATURE....1805
PRECAUTIONS AFTER COMPLETION OF WORK....1806
AFTER COLD WEATHER....1806
LONG-TERM STORAGE....1807
BEFORE STORAGE....1807
DURING STORAGE....1807
AFTER STORAGE....1807
TROUBLESHOOTING....1808
WHEN MACHINE RUNS OUT OF FUEL....1808
METHOD OF TOWING MACHINE....1808
IF BATTERY IS DISCHARGED....1810
OTHER TROUBLE....1813
MAINTENANCE....1818
GUIDES TO MAINTENANCE....1819
OUTLINES OF SERVICE....1821
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....1821
OUTLINE OF ELECTRIC SYSTEM....1824
WEAR PARTS....1825
WEAR PARTS LIST....1825
RECOMMENDED FUEL, COOLANT, AND LUBRICANT....1826
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....1827
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....1828
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....1829
TORQUE LIST....1829
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....1830
MAINTENANCE SCHEDULE CHART....1831
MAINTENANCE SCHEDULE CHART....1831
SERVICE PROCEDURE....1833
INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE)....1833
INITIAL 250 HOURS SERVICE....1833
INITIAL 1000 HOURS SERVICE....1833
WHEN REQUIRED....1834
CHECK BEFORE STARTING....1860
EVERY 50 HOURS SERVICE....1861
EVERY 100 HOURS SERVICE....1862
EVERY 250 HOURS SERVICE....1865
EVERY 500 HOURS SERVICE....1871
EVERY 1000 HOURS SERVICE....1875
EVERY 2000 HOURS SERVICE....1881
EVERY 4000 HOURS SERVICE....1888
EVERY 8000 HOURS SERVICE....1890
SPECIFICATIONS....1892
SPECIFICATIONS....1893
ATTACHMENTS, OPTIONS....1896
SELECTING BUCKET AND TIRES....1897
HANDLING FORK TOOL....1898
EXPLANATION OF COMPONENTS....1898
OPERATION....1899
METHOD OF USING 3 LEVERS....1902
EXPLANATION OF COMPONENTS....1902
HANDLING MACHINES EQUIPPED WITH KOMTRAX....1904
BASIC PRECAUTIONS....1904
INDEX....1906
TEN00408-00 - Wheel Loader WA250PZ-6 Operation & Maintenance Manual....1910
COVER....1910
FOREWORD....1911
BEFORE READING THIS MANUAL....1912
SAFETY INFORMATION....1913
INTRODUCTION....1914
USE OF MACHINE....1914
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE....1914
VISIBILITY FROM OPERATOR'S SEAT....1914
NECESSARY INFORMATION....1915
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....1915
EPA REGULATIONS, ENGINE NUMBER PLATE....1915
POSITION OF SERVICE METER....1916
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....1916
CONTENTS....1917
SAFETY....1921
SAFETY....1922
SAFETY LABELS....1925
LOCATION OF SAFETY LABELS....1925
SAFETY LABELS....1926
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE....1932
PRECAUTIONS BEFORE STARTING OPERATION....1932
PREPARATIONS FOR SAFE OPERATION....1932
FIRE PREVENTION....1934
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE....1935
DO NOT GET CAUGHT IN ARTICULATING PORTION....1938
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES....1938
UNAUTHORIZED MODIFICATION....1938
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS....1938
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING....1939
PRECAUTIONS FOR OPERATION....1940
PRECAUTIONS FOR JOBSITE....1940
STARTING ENGINE....1942
OPERATION....1944
TRANSPORTATION....1951
TOWING....1952
PRECAUTIONS FOR MAINTENANCE....1953
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE....1953
PRECAUTIONS FOR INSPECTION AND MAINTENANCE....1958
TIRES....1963
OPERATION....1965
GENERAL VIEW....1966
GENERAL VIEW OF MACHINE....1966
GENERAL VIEW OF CONTROLS AND GAUGES....1967
EXPLANATION OF COMPONENTS....1969
MACHINE MONITOR....1969
SWITCHES....2006
CONTROL LEVERS, PEDALS....2020
STEERING TILT LOCK LEVER....2025
CAP AND COVER WITH LOCK....2025
FRAME LOCK BAR....2026
TOWING PIN....2027
GREASE PUMP....2027
OPENING, CLOSING CAB DOORS, WINDOWS....2028
FUSE....2032
SLOW BLOW FUSE....2034
POWER OUTLET....2035
STORAGE BOX....2035
AM/FM RADIO-CASSETTE STEREO....2036
AIR CONDITIONER....2044
HANDLING CAB WIPER....2051
OPERATION....2052
CHECK BEFORE STARTING ENGINE, ADJUST....2052
STARTING ENGINE....2070
CHECKS AFTER STARTING ENGINE....2074
OPERATIONS AND CHECKS AFTER STARTING ENGINE....2075
STOPPING ENGINE....2078
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE....2079
TURNING....2085
OPERATION OF WORK EQUIPMENT....2087
HANDLING HYDRAULIC QUICK COUPLER....2089
WORK POSSIBLE USING WHEEL LOADER....2093
PRECAUTIONS FOR OPERATION....2098
ADJUSTING WORK EQUIPMENT POSTURE....2100
PARKING MACHINE....2103
CHECKS AFTER COMPLETION OF OPERATION....2105
LOCKING....2105
HANDLING THE TIRES....2106
TRANSPORTATION....2108
TRANSPORTATION PROCEDURE....2108
LOADING, UNLOADING WORK WITH TRAILERS....2108
LIFTING MACHINE....2112
COLD WEATHER OPERATION....2114
PRECAUTIONS FOR LOW TEMPERATURE....2114
PRECAUTIONS AFTER COMPLETION OF WORK....2115
AFTER COLD WEATHER....2115
LONG-TERM STORAGE....2116
BEFORE STORAGE....2116
DURING STORAGE....2116
AFTER STORAGE....2116
TROUBLESHOOTING....2117
WHEN MACHINE RUNS OUT OF FUEL....2117
METHOD OF TOWING MACHINE....2117
IF BATTERY IS DISCHARGED....2119
OTHER TROUBLE....2122
MAINTENANCE....2127
GUIDES TO MAINTENANCE....2128
OUTLINES OF SERVICE....2130
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....2130
OUTLINE OF ELECTRIC SYSTEM....2133
WEAR PARTS....2134
WEAR PARTS LIST....2134
RECOMMENDED FUEL, COOLANT, AND LUBRICANT....2135
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....2136
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THANKOMATSU GENUINE OIL....2137
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....2138
TORQUE LIST....2138
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....2139
MAINTENANCE SCHEDULE CHART....2140
MAINTENANCE SCHEDULE CHART....2140
SERVICE PROCEDURE....2142
INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE)....2142
INITIAL 250 HOURS SERVICE....2142
INITIAL 1000 HOURS SERVICE....2142
WHEN REQUIRED....2143
CHECK BEFORE STARTING....2169
EVERY 50 HOURS SERVICE....2170
EVERY 100 HOURS SERVICE....2171
EVERY 250 HOURS SERVICE....2174
EVERY 500 HOURS SERVICE....2180
EVERY 1000 HOURS SERVICE....2184
EVERY 2000 HOURS SERVICE....2190
EVERY 4000 HOURS SERVICE....2197
EVERY 8000 HOURS SERVICE....2199
SPECIFICATIONS....2201
SPECIFICATIONS....2202
ATTACHMENTS, OPTIONS....2205
SELECTING BUCKET AND TIRES....2206
HANDLING FORK TOOL....2207
EXPLANATION OF COMPONENTS....2207
OPERATION....2208
METHOD OF USING 3 LEVERS....2211
EXPLANATION OF COMPONENTS....2211
HANDLING MACHINES EQUIPPED WITH KOMTRAX....2213
BASIC PRECAUTIONS....2213
INDEX....2215
TEN00455-01 - Wheel Loader WA250PZ-6 Operation & Maintenance Manual....2219
COVER....2219
FOREWORD....2220
BEFORE READING THIS MANUAL....2221
SAFETY INFORMATION....2222
INTRODUCTION....2223
USE OF MACHINE....2223
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE....2223
VISIBILITY FROM OPERATOR'S SEAT....2223
NECESSARY INFORMATION....2224
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....2224
EPA REGULATIONS, ENGINE NUMBER PLATE....2224
POSITION OF SERVICE METER....2225
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....2225
CONTENTS....2226
SAFETY....2230
SAFETY....2231
SAFETY LABELS....2234
LOCATION OF SAFETY LABELS....2234
SAFETY LABELS....2235
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE....2241
PRECAUTIONS BEFORE STARTING OPERATION....2241
PREPARATIONS FOR SAFE OPERATION....2241
FIRE PREVENTION....2243
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE....2244
DO NOT GET CAUGHT IN ARTICULATING PORTION....2247
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES....2247
UNAUTHORIZED MODIFICATION....2247
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS....2247
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING....2248
PRECAUTIONS FOR OPERATION....2249
PRECAUTIONS FOR JOBSITE....2249
STARTING ENGINE....2251
OPERATION....2253
TRANSPORTATION....2260
TOWING....2261
PRECAUTIONS FOR MAINTENANCE....2262
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE....2262
PRECAUTIONS FOR INSPECTION AND MAINTENANCE....2267
TIRES....2272
OPERATIONS....2274
GENERAL VIEW....2275
GENERAL VIEW OF MACHINE....2275
GENERAL VIEW OF CONTROLS AND GAUGES....2276
EXPLANATION OF COMPONENTS....2278
MACHINE MONITOR....2278
SWITCHES....2315
CONTROL LEVERS, PEDALS....2329
STEERING TILT LOCK LEVER....2334
CAP AND COVER WITH LOCK....2334
FRAME LOCK BAR....2335
TOWING PIN....2336
GREASE PUMP....2336
OPENING, CLOSING CAB DOORS, WINDOWS....2337
FUSE....2341
SLOW BLOW FUSE....2343
POWER OUTLET....2344
STORAGE BOX....2344
AM/FM RADIO-CASSETTE STEREO....2345
HANDLING CAB WIPER....2360
OPERATION....2361
CHECK BEFORE STARTING ENGINE, ADJUST....2361
STARTING ENGINE....2380
CHECKS AFTER STARTING ENGINE....2384
OPERATIONS AND CHECKS AFTER STARTING ENGINE....2385
STOPPING ENGINE....2388
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE....2389
TURNING....2395
OPERATION OF WORK EQUIPMENT....2397
HANDLING HYDRAULIC QUICK COUPLER....2399
WORK POSSIBLE USING WHEEL LOADER....2403
PRECAUTIONS FOR OPERATION....2408
ADJUSTING WORK EQUIPMENT POSTURE....2410
PARKING MACHINE....2413
CHECKS AFTER COMPLETION OF OPERATION....2415
LOCKING....2415
HANDLING THE TIRES....2416
TRANSPORTATION....2418
TRANSPORTATION PROCEDURE....2418
LOADING, UNLOADING WORK WITH TRAILERS....2418
LIFTING MACHINE....2422
COLD WEATHER OPERATION....2424
PRECAUTIONS FOR LOW TEMPERATURE....2424
PRECAUTIONS AFTER COMPLETION OF WORK....2425
AFTER COLD WEATHER....2425
LONG-TERM STORAGE....2426
BEFORE STORAGE....2426
DURING STORAGE....2426
AFTER STORAGE....2426
TROUBLESHOOTING....2427
WHEN MACHINE RUNS OUT OF FUEL....2427
METHOD OF TOWING MACHINE....2427
IF BATTERY IS DISCHARGED....2429
OTHER TROUBLE....2432
MAINTENANCE....2438
GUIDES TO MAINTENANCE....2439
OUTLINES OF SERVICE....2441
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....2441
OUTLINE OF ELECTRIC SYSTEM....2444
WEAR PARTS....2445
WEAR PARTS LIST....2445
RECOMMENDED FUEL, COOLANT, AND LUBRICANT....2446
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....2447
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....2448
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....2449
TORQUE LIST....2449
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....2450
MAINTENANCE SCHEDULE CHART....2451
MAINTENANCE SCHEDULE CHART....2451
SERVICE PROCEDURE....2453
INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE)....2453
INITIAL 250 HOURS SERVICE....2453
INITIAL 1000 HOURS SERVICE....2453
WHEN REQUIRED....2454
CHECK BEFORE STARTING....2480
EVERY 50 HOURS SERVICE....2481
EVERY 100 HOURS SERVICE....2482
EVERY 250 HOURS SERVICE....2485
EVERY 500 HOURS SERVICE....2491
EVERY 1000 HOURS SERVICE....2495
EVERY 2000 HOURS SERVICE....2501
EVERY 4000 HOURS SERVICE....2508
EVERY 8000 HOURS SERVICE....2510
SPECIFICATIONS....2512
SPECIFICATIONS....2513
ATTACHMENTS, OPTIONS....2516
SELECTING BUCKET AND TIRES....2517
HANDLING FORK TOOL....2518
EXPLANATION OF COMPONENTS....2518
OPERATION....2519
METHOD OF USING 3 LEVERS....2522
EXPLANATION OF COMPONENTS....2522
HANDLING MACHINES EQUIPPED WITH KOMTRAX....2524
BASIC PRECAUTIONS....2524
INDEX....2526
VEAM945101 - Wheel Loader WA250PZ-5 Operation & Maintenance Manual....2530
COVER....2530
FOREWORD....2532
Foreword....2533
Safety information....2535
Introduction....2537
Intended use....2537
Directions of machine....2537
Necessary information....2538
Machine serial No. plate and position....2538
Engine serial No. plate and position....2538
ROPS/FOPS-Cab serial no. plate....2539
Axle serial no. plate....2539
Transmission serial no. plate....2539
Seat operator serial no. plate....2539
Position of service meter....2540
Table to enter serial No. and distributor....2540
Contents....2541
Dimensions, weights and operating data....2547
WA250PZ-5: Dimensions, weights and operating data....2547
CE-conforming equipment....2548
CE-conforming equipment (pin on version)....2548
CE-conforming equipment (quick coupler version)....2548
Manufacturer-supplied CE-conforming equipment, according to document 421-93-H1900....2550
SAFETY....2554
Safety labels....2556
Location of safety labels....2556
Presentation of safety labels....2557
General precautions....2560
Safety rules....2560
Precautions for operation....2569
Starting engine....2569
Operation....2570
Transportation....2577
Battery....2578
Towing....2580
Precautions for maintenance....2581
Safety instructions....2581
Precautions with tires....2588
Handling tires....2588
Precautions when storing tires....2588
OPERATION....2590
General view....2592
General view of machine....2592
General view of controls and gauges....2593
Explanation of components....2595
Machine monitor....2595
Monitor system....2596
Types of warning....2597
Central warning lamp....2598
Character display portion....2599
Emergency stop item....2603
Caution items....2605
Warning/limit functions for travel speed....2607
Inspection and maintenance item....2608
Pilot display portion....2610
Meter display portion....2613
Other functions of machine monitor....2615
Switches....2619
Control levers, pedals....2627
Steering tilt lock lever....2630
Cap and cover with lock....2631
Safety bar....2632
Towing pin....2632
Grease pump....2632
Cab door inner lock....2633
Cab door open lock....2633
Cab window open lock cancel knob....2633
Fuse....2634
Fuse capacity and name of circuit....2634
Slow blow fuse....2635
Power outlet....2636
Air conditioner....2637
General locations and function of control panel....2637
Method of operation....2640
Precautions when using....2641
Handling cab wiper....2642
Preventing damage to wiper arm bracket....2642
Operation....2643
Check before starting engine, adjust....2643
Walk-around check....2643
Check before starting....2646
Adjustment....2651
Operations and checks before starting engine....2655
Starting engine....2657
Operations and checks after starting engine....2659
Breaking-in the machine....2659
Normal operation....2659
Stopping engine....2661
Moving the machine (Directional, speed), stopping the machine....2662
Moving the machine....2662
Changing direction....2664
Stopping the machine....2667
Turning....2668
Emergency steering....2668
Operation of work equipment....2669
Handling hydraulic quick coupler (option)....2670
REMOVING THE ATTACHMENT....2670
Installing the attachment....2671
Removal and installation of the attachment....2673
Precautions for use....2673
Precautions when removing the attachment....2673
Work possible using wheel loader....2674
Digging operations....2674
Leveling operations....2676
Pushing operation....2676
Load and carry operations....2676
Loading operations....2677
Precautions for operation....2679
Permissible water depth....2679
If wheel brake does not work....2679
Precautions when driving up or down slopes....2679
Adjusting work equipment posture....2680
Adjusting boom kickout....2680
Adjusting bucket positioner....2681
Adjusting fork positioner....2682
Bucket level indicator....2682
Parking machine....2683
Check after stopping engine....2685
Checks after completion of operation....2685
Locking....2685
Handling the tires....2686
Precautions when handling tires....2686
Tire pressure....2686
Precautions for using load and car method....2687
Transportation....2688
Transportation procedure....2688
Loading, unloading work with trailers....2688
Loading....2688
Securing machine....2689
Unloading....2690
Lifting machine....2691
Location of lifting position mark....2692
Lifting procedure....2693
Cold weather operation....2694
Precautions for low temperature....2694
Fuel and lubricants....2694
Coolant....2694
Battery....2695
Precautions after completion of work....2696
After cold weather....2696
Warming-up operation for steering hydraulic circuit in cold weather....2696
Long-term storage....2697
Before storage....2697
During storage....2697
After storage....2697
Troubleshooting....2698
When machine runs out of fuel....2698
Towing the machine....2698
When engine can be used....2699
When engine cannot be used....2699
If battery is discharged....2700
Removal and installation of battery....2700
Precautions for charging battery....2701
Starting engine with booster cable....2701
Other trouble....2703
Electrical system....2703
Chassis....2704
Engine....2706
MAINTENANCE....2708
Guides to maintenance....2709
Outlines of service....2711
Handling oil, fuel, coolant, grease and performing oil clinic....2711
Oil....2711
Fuel....2711
Coolant....2712
Grease....2712
Carrying out KOWA (Komatsu Oil Wear Analysis)....2712
Storing oil and fuel....2713
Filters....2714
Biodegradable hydraulic oil and lubricants....2714
Outline of electric system....2714
Wear parts....2715
Wear parts list....2715
Fuel, coolant and lubricants....2716
Lubrication chart....2717
Proper selection of fuel, coolant and lubricants....2718
Recommended brands, recommended quality for products other than komatsu genuine oil....2720
Standard tightening torques for bolts and nuts....2721
Torque list....2721
Periodic replacement of safety critical parts....2723
Safety critical parts....2723
Maintenance schedule chart....2725
Service schedule....2725
Service procedure....2727
Initial 50 hours service (only after the first 50 hours)....2727
Check for loose wheel hub bolts, tighten....2727
Initial 250 hours service (only after the first 250 hours)....2727
When required....2728
Check, clean, or replace air cleaner element....2728
Dust pre-extractor "Turbo II": check, clean....2731
Clean inside of cooling system....2732
Check oil level in transfer case, add oil....2735
Check axle oil level, add oil....2736
Clean axle case breather....2737
Clean air conditioner condenser....2737
Check window washing fluid level, add fluid....2738
Cleaning radiator fins using the reversible fan....2739
Clean radiator fins and cooler fins....2740
Clean transfer oil cooler fins....2741
Check electrical intake air heater....2741
Replace bolt on cutting edge....2741
Replace bucket teeth....2742
Check air conditioner....2743
Replace slow blow fuse....2744
Checking function of accumulator....2745
Selection and inspection of tires....2746
Check before starting....2748
Every 50 hours service....2749
Drain water, sediment from fuel tank....2749
Every 100 hours service....2750
Lubricate rear axle pivot pin....2750
Clean element in air conditioner fresh air filter....2750
Check oil level in hydraulic tank, add oil....2751
Every 250 hours service....2752
Check battery electrolyte level....2752
Check parking brake....2754
Check air conditioner compressor belt tension, adjust....2754
Check for loose wheel hub bolts, tighten....2755
Clean element in air conditioner recirculation filter....2756
Checking function of accumulator....2757
Lubricating....2758
Every 500 hours service....2759
Change oil in engine oil pan, replace engine oil filter cartridge....2759
Replace fuel filter cartridge....2760
Clean water separator strainer....2761
Every 1000 hours service....2762
Change oil in transfer case....2762
Clean transfer case breather....2763
Replace HST oil filter element....2764
Lubricating....2765
Check tightening parts of turbocharger....2765
Check play of turbocharger rotor....2765
Check alternator driving belt tension and replacement....2765
Every 2000 hours service....2766
Change oil in hydraulic tank, replace hydraulic filter element....2766
Replace hydraulic tank breather element....2767
Cleaning the strainer of the brake filter....2768
Change axle oil....2769
Replace element in air conditioner recirculation air filter, fresh air filter....2769
Check alternator, starting motor....2769
Check engine valve clearance, adjust....2769
Check brake disc wear....2770
Clean and check turbocharger....2770
Check vibration damper....2770
Every 4000 hours service....2771
Lubricating....2771
Check water pump....2771
TECHNICAL DATA....2772
Technical data....2773
Noise emission levels....2775
Vibration levels....2775
Operating condition:....2775
Guide to Reduce Vibration Levels on Machine....2775
ATTACHMENTS, OPTIONS....2778
Selecting bucket and tires....2779
Handling fork tool....2780
Explanation of components....2780
Work equipment lever....2780
Operation....2781
Loading operation....2781
Method of using 3 levers....2784
Explanation of components....2784
Lift arm control lever....2784
Bucket control lever....2785
Auxiliary control lever....2785
Directional selector switch....2785
Directional selector actuation switch....2786
Operation....2787
Using switch to change between forward and reverse....2787
Reversible fan....2789
Central lubrication system....2790
Operating the central lubrication system....2790
Display and control unit....2790
Led-display....2790
Pushbuttons....2791
Changing the lubrication interval times....2791
Handling machines equipped with KOMTRAX....2792
Basic precautions....2792
INDEX....2794
Index....2796
NOTES....2798
NOTES....2799
VEBM610101 - Wheel Loader WA250-6, WA250PZ-6 Shop Manual....2801
VEBM610101....2801
00 Index and foreword....2803
100 Index....2803
Composition of shop manual....2804
Table of contents....2806
200 Foreword and general information....2815
Safety notice....2816
How to read the shop manual....2821
Explanation of terms for maintenance standard....2823
Handling of electric equipment and hydraulic component....2825
Handling of connectors newly used for engines....2834
How to read electric wire code....2837
Precautions when carrying out operation....2840
Method of disassembling and connecting push-pull type coupler....2843
Standard tightening torque table....2846
Conversion table....2850
01 Specification....2855
100 Specification and technical data....2855
Specification dimension drawing....2857
Specifications....2858
Weight table....2862
Table of fuel, coolant and lubricants....2864
10 Structure, function and maintenance standard....2865
100 Engine and cooling system....2865
Engine mount and transfer mount....2866
Damper....2867
Cooling system....2868
Cooling system hydraulic piping diagram....2869
Cooling fan motor....2871
200 Power train....2879
Power train....2881
Power train system diagram....2882
Drive shaft....2884
HST hydraulic piping diagram....2885
HST pump....2886
HST motor....2894
Transfer....2900
Clutch solenoid valve....2911
Axle....2912
Differential....2914
Torque proportioning differential....2919
Limited slip differential....2922
Final drive....2926
300 Steering system....2931
Steering piping diagram....2933
Steering column....2934
Priority valve....2935
Orbit-roll valve....2938
2-way restrictor valve....2946
Cushion valve....2947
Steering cylinder....2948
Emergency steering piping diagram....2950
Emergency steering valve....2951
Steering relief valve....2954
400 Brake system....2955
Brake piping diagram....2957
Charge valve....2958
Brake valve....2962
Inching valve....2966
Accumulator (for brake)....2967
Slack adjuster....2968
Brake....2970
Parking brake control....2975
Parking brake....2976
500 Undercarriage and frame....2977
Axle mount and center hinge pin....2978
Tires....2983
600 Hydraulic system....2985
Work equipment hydraulic piping diagram....2986
Work equipment control lever linkage....2990
Hydraulic tank....2994
4-gear pump....2996
Work equipment control valve....2998
PPC valve....3023
Lock valve....3038
Accumulator (for PPC circuit)....3039
Bypass valve....3040
Quick coupler solenoid valve....3043
ECSS valve....3044
Accumulator (for ECSS)....3046
700 Work equipment....3047
Work equipment linkage....3048
Bucket....3052
Bucket positioner and boom kick-out....3056
Work equipment cylinder....3069
800 Cab and its attachments....3073
Cab....3075
Air conditioner....3076
910 Electrical system, Part 1....3089
Machine monitor system....3090
Machine monitor....3094
920 Electrical system, Part 2....3115
Electrical system (HST controller system)....3116
HST controller....3132
ECSS system....3134
KOMTRAX system....3136
Engine starting circuit....3138
Engine stopping circuit....3140
Preheating circuit....3141
Engine output derating function....3142
Automatic warm-up function....3142
Parking brake circuit....3143
Coupler plunger control system....3146
Multi-function knob....3147
Max. traction switch....3148
Sensor....3149
20 Standard value table....3155
100 Standard service value table....3155
Standard service value table for engine....3156
Standard service value table for chassis....3157
30 Testing and adjusting....3163
110 Testing and adjusting, Part 1....3163
Tools for testing, adjusting, and troubleshooting....3164
Measuring engine speed....3169
Measuring exhaust gas color....3171
Adjusting valve clearance....3173
Measuring compression pressure....3175
Measuring blow-by pressure....3178
Measuring engine oil pressure....3179
Measuring intake air (boost) pressure....3180
Handling fuel system equipment....3182
Releasing residual pressure in fuel system....3182
Measuring fuel pressure....3183
Measuring fuel return rate and leakage....3185
Bleeding air from fuel circuit....3189
Testing leakage in fuel system....3190
Handling reduced cylinder mode operation....3191
Handling no-injection cranking operation....3191
Handling controller voltage circuit....3192
Check of muffler and muffler stack for looseness and damage....3192
Check of muffler function....3193
Check of installed condition of cylinder head and manifolds....3193
Check of engine piping for damage and looseness....3194
Testing and adjusting air conditioner compressor belt tension....3194
Replacing alternator belt....3195
120 Testing and adjusting, Part 2....3197
Checking operating force of accelerator pedal....3199
Checking directional lever....3200
Testing and adjusting HST oil pressure....3201
Testing clutch control pressure....3205
Testing and adjusting steering wheel....3206
Testing and adjusting steering oil pressure....3208
Bleeding air from steering circuit....3210
Testing hydraulic fan....3211
Measuring brake pedal....3213
Testing and adjusting brake pedal linkage....3214
Measuring brake performance....3215
Testing and adjusting accumulator charge pressure....3216
Testing wheel brake oil pressure....3218
Testing wear of brake disc....3221
Bleeding air from wheel brake circuit....3222
Releasing residual pressure in brake accumulator circuit....3223
Testing parking brake performance....3224
Testing and adjusting parking brake control cable....3225
Measuring and adjusting work equipment control lever....3226
Testing and adjusting work equipment hydraulic pressure....3227
Testing work equipment PPC oil pressure....3228
Bleeding air from hydraulic circuit....3230
Releasing remaining pressure in hydraulic circuit....3231
Testing and adjusting bucket positioner....3232
Testing and adjusting of boom kick-out switch....3233
Checking proximity switch operation pilot lamp....3234
Procedure for testing diodes....3235
Preparation work for troubleshooting for electric system....3237
Starting KOMTRAX terminal operations....3241
Indicator lamps of KOMTRAX terminal....3245
130 Testing and adjusting, Part 3....3249
Adjusting machine monitor....3250
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor....3251
Special functions of machine monitor (EMMS)....3253
Pm clinic inspection chart....3307
40 Troubleshooting....3309
100 Failure code table and fuse locations....3309
Failure codes table....3310
Fuse locations....3316
200 General information on troubleshooting....3319
Points to remember when troubleshooting....3320
Sequence of events in troubleshooting....3321
Testing before troubleshooting....3322
Classification and procedures of troubleshooting....3323
Information contained in troubleshooting table....3326
Connection table for connector pin numbers....3328
T- branch box and T- branch adapter table....3363
310 Troubleshooting by failure code (Display of code), Part 1....3367
Failure code [2G40GZ] Brake: Oil pressure reduction....3368
Failure code [6091NX] HST filter: Clogging....3370
Failure code [989FN1] Travel speed: Overrun alarm....3372
Failure code [AB00L6] Alternator R system: Hot short....3374
Failure code [AB00MA] Alternator R system: Ground fault/Disconnection charge/Low charge voltage....3376
Failure code [B@BAZG] Engine: Oil pressure reduction....3378
Failure code [B@BCNS] Engine: Overheat....3379
Failure code [B@BCZK] Engine: Low coolant level....3380
Failure code [B@C6NS] Front brake: High oil temperature....3382
Failure code [B@CRNS] HST: High oil temperature....3383
320 Troubleshooting by failure code (Display of code), Part 2....3385
Failure code [CA111] Abnormality in engine controller....3387
Failure code [CA115] Engine Ne or Bkup speed sensor error....3388
Failure code [CA122] Charge pressure sensor high error....3390
Failure code [CA123] Charge pressure sensor low error....3392
Failure code [CA131] Throttle sensor high error....3394
Failure code [CA132] Throttle sensor low error....3396
Failure code [CA144] Coolant sensor high error....3398
Failure code [CA145] Coolant sensor low error....3400
Failure code [CA153] Charge temperature sensor high error....3402
Failure code [CA154] Charge temperature sensor low error....3404
Failure code [CA155] Derating of speed by abnormally high charge temperature....3406
Failure code [CA187] Sensor power supply 2 low error....3408
Failure code [CA221] Atmospheric pressure sensor high error....3410
Failure code [CA222] Atmospheric sensor low error....3412
Failure code [CA227] Sensor power supply 2 high error....3414
Failure code [CA234] Engine overspeed....3415
Failure code [CA238] Ne speed sensor power supply error....3416
Failure code [CA271] IMV (IMA) Short circuit....3417
Failure code [CA272] IMV (IMA) Disconnection....3418
Failure code [CA322] Injector #1 open/short error....3420
Failure code [CA323] Injector #5 open/short error....3422
Failure code [CA324] Injector #3 open/short error....3424
Failure code [CA325] Injector #6 open/short error....3426
Failure code [CA331] Injector #2 open/short error....3428
Failure code [CA332] Injector #4 open/short error....3430
Failure code [CA342] Calibration code inconsistency....3432
Failure code [CA351] Injectors drive circuit error....3434
Failure code [CA352] Sensor power supply 1 low error....3436
Failure code [CA386] Sensor power supply 1 high error....3438
330 Troubleshooting by failure code (Display of code), Part 3....3439
Failure code [CA428] Abnormally high level in water sensor....3442
Failure code [CA429] Abnormally low level in water sensor....3444
Failure code [CA431] Idle validation switch error....3446
Failure code [CA432] Idle validation action error....3450
Failure code [CA435] Engine oil pressure switch error....3454
Failure code [CA441] Battery voltage low error....3455
Failure code [CA442] Battery voltage high error....3458
Failure code [CA449] Common rail pressure high error 2....3460
Failure code [CA451] Common rail pressure sensor high error....3462
Failure code [CA452] Common rail pressure sensor low error....3464
Failure code [CA488] Derating of torque by abnormally high charge temperature....3466
Failure code [CA553] Common rail pressure high error 1....3467
Failure code [CA559] Supply pump pressure very low error....3468
Failure code [CA689] Engine Ne speed sensor error....3470
Failure code [CA731] Engine Bkup speed sensor phase error....3472
Failure code [CA757] All continuous data lost error....3473
Failure code [CA778] Engine Bkup speed sensor error....3476
Failure code [CA1633] KOMNET datalink timeout error....3478
Failure code [CA2185] Throttle sensor supply voltage high error....3482
Failure code [CA2186] Throttle sensor power supply low error....3484
Failure code [CA2249] Supply pump pressure very low error 2....3486
Failure code [CA2311] Abnormality in IMV (IMA) solenoid....3488
Failure code [CA2555] Intake heater relay disconnection error....3490
Failure code [CA2556] Intake heater relay short circuit error....3492
340 Troubleshooting by failure code (Display of code), Part 4....3495
Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short....3496
Failure code [D192KY] ECSS solenoid relay: Hot short....3498
Failure code [D1B0KA] HST safety relay: Disconnection....3500
Failure code [D1B0KB] HST safety relay: Ground fault....3502
Failure code [D1B0KY] HST safety relay: Hot short....3504
Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection....3506
Failure code [DAF3KK] UNSW power supply: Ground fault/ Disconnection....3508
Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection....3510
Failure code [DAJ0KK] HST controller power supply: Low voltage....3514
Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality....3516
Failure code [DAJ1L4] HST controller main power line: Disconnection/ Ground fault....3518
Failure code [DAJ1L6] HST controller main power line: Hot short....3520
Failure code [DAJ2KK] Controller solenoid power supply: Low voltage....3522
Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness....3524
Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault....3526
Failure code [DAJ5KX] Sensor 5V power supply: Out of output range....3528
Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals....3530
Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection....3531
Failure code [DAJRMA] HST controller: Disagreement in option selection....3537
350 Troubleshooting by failure code (Display of code), Part 5....3539
Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line....3541
Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality....3546
Failure code [DD1NLD] Fan reverse switch signal: Abnormality....3548
Failure code [DDB6KA] Parking brake switch A: Disconnection/Hot short....3550
Failure code [DDB6KB] Parking brake switch B: Ground fault....3552
Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble....3554
Failure code [DDB6L0] Parking brake switch A: Ground fault....3556
Failure code [DDB6L4] Parking brake switch B: Disconnection/Hot short....3558
Failure code [DDD7KX] Travel speed control dial signal: Disconnection/ Ground fault....3560
Failure code [DDD7KY] Travel speed control dial signal: Hot short....3562
Failure code [DDE5MA] Emergency steering operation switch: Disconnection....3564
Failure code [DDK3KA] Directional selector switch: Disconnection/Hot short....3566
Failure code [DDK3KB] Directional selector switch: Ground fault....3568
Failure code [DDK6KA] FNR lever: Disconnection/Ground fault....3570
Failure code [DDK6KY] FNR lever: Hot short....3574
Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering)....3576
360 Troubleshooting by failure code (Display of code), Part 6....3579
Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault....3581
Failure code [DF10KB] Travel speed range selector switch: Hot short....3584
Failure code [DGH1KX] HST oil temperature sensor: Ground fault....3586
Failure code [DGR2KB] Brake oil temperature sensor: Ground fault....3587
Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/ Hot short....3588
Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault....3590
Failure code [DHH1KY] HST oil pressure sensor: Hot short....3592
Failure code [DHTCL6] HST filter clogging sensor: Functional defect....3594
Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short....3596
Failure code [DLT3KX] Travel speed sensor B: Abnormality....3598
Failure code [DLT4KX] Travel speed sensor A: Abnormality....3602
Failure code [DLT4LC] Travel speed sensor A & B: Abnormality....3604
Failure code [DV00KY] Alarm buzzer: Hot short....3606
Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault....3608
Failure code [DW26KY] Motor 2 solenoid: Hot short....3610
Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short....3612
Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/ Ground fault....3614
370 Troubleshooting by failure code (Display of code), Part 7....3617
Failure code [DX16KA] Fan EPC solenoid: Disconnection....3618
Failure code [DX16KB] Fan EPC solenoid: Ground fault....3619
Failure code [DX16KY] Fan EPC solenoid: Hot short....3620
Failure code [DX19KA] Motor 1 solenoid: Disconnection....3622
Failure code [DX19KB] Motor 1 solenoid: Ground fault....3624
Failure code [DX19KY] Motor 1 solenoid: Hot short....3626
Failure code [DX20KA] Clutch EPC solenoid: Disconnection....3628
Failure code [DX20KB] Clutch EPC solenoid: Ground fault....3630
Failure code [DX20KY] Clutch EPC solenoid: Hot short....3632
Failure code [DXH7KB] Reverse solenoid: Ground fault....3634
Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short....3636
Failure code [DXH8KB] Forward solenoid: Ground fault....3638
Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short....3640
Failure code [J141N1] Steering pump: Overrun alarm....3642
Failure code [M100N1] HST pump: Overrun alarm....3642
Failure code [M400N1] Motor 1: Overrun alarm....3643
400 Troubleshooting of electrical system (E-mode)....3645
E-1 Engine does not start....3647
E-2. Preheater does not operate normally....3654
E-3 Defective boom kick-out function and cancellation....3658
E-4 Defective bucket positioner function and cancellation....3662
E-5 Defective lift arm FLOATING holding function and cancellation....3666
E-6 Travel direction selection system does not function....3670
E-7 Wiper does not operate....3674
E-8 Windshield washer does not operate....3678
E-9 Headlamp, clearance lamp and tail lamp do not light up or go off....3682
E-10 Working lamp does not light up or go off....3690
E-11 Turn signal lamp and hazard lamp do not light up or go off....3695
E-12 Brake lamp does not light or it keeps lighting up....3702
E-13 Backup lamp does not light or it keeps lighting up....3704
E-14 Backup alarm does not sound or it keeps sounding....3707
E-15 Horn does not sound or it keeps sounding....3710
E-16 Alarm buzzer does not sound or it keeps sounding....3712
E-17 Air conditioner does not operate or stop....3714
E-18 The KOMTRAX system does not work properly....3717
500 Troubleshooting of hydraulic and mechanical system (H-mode)....3721
Method of using troubleshooting chart....3723
Failure code and cause table....3726
H-1 The machine does not start....3728
H-2 The travel speed is slow....3729
H-3 The traction force is weak....3730
H-4 Engine stalls when traveling or engine speed drops excessively....3731
H-5 The gear is not shifted....3732
H-6 The steering wheel does not turn....3733
H-7 The steering wheel is heavy....3734
H-8 Steering wheel shakes or jerks....3735
H-9 Machine deviates naturally to one side when traveling....3735
H-10 The brake does not work or does not work well....3736
H-11 The brake is not released or is dragged....3737
H-12 The lift arm does not rise or lower....3738
H-13 The lift arm moves slowly or the lift arm rising force is insufficient....3739
H-14 When rising, the lift arm comes to move slowly at specific height....3740
H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air)....3740
H-16 Hydraulic drifts of the lift arm occur often....3740
H-17 The lift arm wobbles during operation....3740
H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily....3741
H-19 The bucket does not tilt back....3742
H-20 The bucket moves slowly or the tilting-back force is insufficient....3743
H-21 The bucket comes to operate slowly in the midst of tilting-back....3744
H-22 The bucket cylinder cannot hold down the bucket....3744
H-23 Hydraulic drifts of the bucket occur often....3744
H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”)....3744
H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily....3745
H-26 The control levers of the lift arm and bucket do not move smoothly and heavy....3745
H-27 The ECSS does not operate and machine pitches and bounces....3746
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)....3747
600 Troubleshooting of engine (S-mode)....3749
Method of using troubleshooting charts....3750
S-1 Starting performance is poor....3754
S-2 Engine does not start....3755
S-3 Engine does not pick up smoothly....3758
S-4 Engine stops during operations....3759
S-5 Engine does not rotate smoothly....3760
S-6 Engine lacks output (or lacks power)....3761
S-7 Exhaust smoke is black (incomplete combustion)....3762
S-8 Oil consumption is excessive (or exhaust smoke is blue)....3763
S-9 Oil becomes contaminated quickly....3764
S-10 Fuel consumption is excessive....3765
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)....3766
S-12 Oil pressure drops....3767
S-13 Oil level rises (Entry of coolant or fuel)....3768
S-14 Coolant temperature becomes too high (overheating)....3769
S-15 Abnormal noise is made....3770
S-16 Vibration is excessive....3771
50 Disassembly and assembly....3773
100 General information on disassembly and assembly....3773
How to read this manual....3774
Coating materials list....3776
Special tool list....3779
Sketches of special tools....3783
200 Engine and cooling system....3793
Removal and installation of fuel supply pump assembly....3794
Removal and installation of fuel injector assembly....3796
Removal and installation of cylinder head assembly....3803
Removal and installation of engine hood assembly....3816
Removal and installation of radiator....3819
Removal and installation of air aftercooler....3822
Removal and installation of hydraulic oil cooler assembly....3824
Removal and installation of engine assembly....3826
Removal and installation of engine front oil seal assembly....3832
Removal and installation of engine rear oil seal assembly....3835
Removal and installation of cooling fan and fan motor assembly....3838
Removal and installation of fuel tank assembly....3841
310 Power train, Part 1....3843
Removal and installation of transfer assembly....3844
Disassembly and assembly of transfer assembly....3848
Removal and installation of parking brake assembly....3868
Disassembly and assembly of parking brake assembly....3870
320 Power train, Part 2....3875
Removal and installation of front axle assembly....3876
Removal and installation of rear axle assembly....3878
Disassembly and assembly of axle housing assembly....3881
Disassembly and assembly of differential assembly....3890
400 Undercarriage and frame....3917
Removal and installation of center hinge pin....3918
Removal and installation of counterweight....3928
500 Hydraulic system....3931
Removal and installation of HST pump and 4-gear pump assembly....3932
Disassembly and assembly of HST pump assembly....3936
Removal and installation of HST motor 1 assembly....3963
Removal and installation of HST motor 2 assembly....3965
Disassembly and assembly of HST motor assembly....3967
Removal and installation of work equipment control valve assembly....3983
Removal and installation of hydraulic tank....3985
Disassembly and assembly of hydraulic cylinder assembly....3987
600 Work equipment....3993
Removal and installation of work equipment assembly....3994
700 Cab and its attachments....4001
Removal and installation of operator's cab and floor frame assembly....4002
Removal and installation of operator's cab glass (Stuck glass)....4007
Removal and installation of air conditioner unit....4015
800 Electrical system....4021
Removal and installation of monitor panel....4022
Removal and installation of engine controller assembly....4024
Removal and installation of HST controller assembly....4025
Removal and installation of KOMTRAX terminal assembly....4026
90 Diagrams and drawings....4027
100 Hydraulic diagrams and drawings....4027
Hydraulic circuit diagram WA250-6....4029
Hydraulic circuit diagram WA250PZ-6....4030
200 Electrical diagrams and drawings....4031
Electrical circuit diagram....4033
Electrical circuit diagram (1/9)....4033
Electrical circuit diagram (2/9)....4034
Electrical circuit diagram (3/9)....4035
Electrical circuit diagram (4/9)....4036
Electrical circuit diagram (5/9)....4037
Electrical circuit diagram (6/9)....4038
Electrical circuit diagram (7/9)....4039
Electrical circuit diagram (8/9)....4040
Electrical circuit diagram (9/9)....4041
Specific electrical circuit diagram (1/2) KOHAG Quick coupler version....4042
Specific electrical circuit diagram (2/2) KOHAG pinon version....4043
Connector list and stereogram....4044
VEBM945100 - Wheel Loader WA250PZ-5 Shop Manual....4045
VEBM945100 WA250PZ-5....4045
SAFETY....4051
FOREWORD....4053
01 GENERAL....4071
GENERAL ASSEMBLY DRAWINGS....4072
SPECIFICATIONS....4073
WEIGHT TABLE....4077
LIST OF LUBRICANT AND COOLANT....4079
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD....4081
ENGINE MOUNT AND TRANSFER MOUNT....4082
DAMPER....4083
COOLING SYSTEM....4084
POWER TRAIN....4085
POWER TRAIN SYSTEM DIAGRAM....4086
DRIVE SHAFT (PROPELLER SHAFT)....4088
HST HYDRAULIC PIPING DIAGRAM....4089
HST PUMP....4090
HIGH-PRESSURE RELIEF VALVE....4092
LOW-PRESSURE RELIEF VALVE....4094
HST CHARGE PUMP....4095
SPEED-RELATED VALVE (DA VALVE)....4096
HIGH-PRESSURE CUT-OFF VALVE....4097
HST MOTOR....4098
EP SERVO VALVE....4101
HA SERVO VALVE....4102
FORWARD-REVERSE SHUTTLE VALVE....4103
TRANSFER....4104
TRANSFER OIL COOLER....4115
CLUTCH SOLENOID VALVE....4116
AXLE....4117
DIFFERENTIAL....4120
LIMITED-SLIP DIFFERENTIAL....4126
Operation of limited-slip differential....4130
FINAL DRIVE....4132
AXLE MOUNTING AND CENTER HINGE PIN....4138
STEERING PIPING....4143
STEERING COLUMN....4144
PRIORITY VALVE....4145
ORBIT-ROLL VALVE....4148
2-WAY RESTRICTOR VALVE....4156
STEERING CYLINDER....4157
EMERGENCY STEERING PIPING....4159
EMERGENCY STEERING VALVE....4160
BRAKE PIPING....4163
BRAKE VALVE....4164
INCHING VALVE....4168
CHARGE VALVE....4170
ACCUMULATOR (FOR BRAKE)....4174
SLACK ADJUSTER....4175
BRAKE....4178
PARKING BRAKE CONTROL....4183
PARKING BRAKE....4184
HYDRAULIC PIPING....4186
WORK EQUIPMENT LEVER LINKAGE....4188
HYDRAULIC TANK....4192
4-GEAR PUMP UNIT....4194
ACCUMULATOR (FOR PPC CIRCUIT)....4196
LOCK VALVE....4197
BYPASS VALVE....4198
E.C.S.S. VALVE....4201
ACCUMULATOR (FOR E.C.S.S.)....4203
HYDRAULIC PIPING OF COOLING SYSTEM....4204
COOLING FAN MOTOR....4205
WORK EQUIPMENT CONTROL VALVE....4207
WORK EQUIPMENT PPC VALVE....4220
ATTACHMENT PPC VALVE (IF EQUIPPED)....4232
WORK EQUIPMENT LINKAGE....4236
BUCKET....4238
CONTROL OF BUCKET POSITIONER, BOOM KICK-OUT....4239
WORK EQUIPMENT CYLINDER....4249
AIR CONDITIONER....4251
MACHINE MONITORING SYSTEM....4252
MACHINE MONITOR....4262
LIST OF ITEMS DISPLAYED ON MONITOR....4263
ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)....4289
HST CONTROLLER....4293
FUNCTION OF SELECTING FORWARD-REVERSE SELECTOR SWITCH....4294
ENGINE START CIRCUIT....4296
ENGINE STOP CIRCUIT....4298
PREHEATING CIRCUIT....4299
(AUTOMATIC PREHEATING SYSTEM)....4299
PARKING BRAKE CIRCUIT....4300
ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM....4303
SENSORS....4304
20 TESTING AND ADJUSTING....4311
STANDARD VALUE TABLE FOR engine....4312
STANDARD VALUE TABLE FOR CHASSIS....4313
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING....4318
MEASURING ENGINE SPEED....4320
Measuring exhaust gas color....4321
ADJUSTING VALVE CLEARANCE....4322
MEASURING COMPRESSION PRESSURE....4324
MEASURING BLOW-BY PRESSURE....4325
TESTING AND ADJUSTING FUEL INJECTION TIMING....4326
MEASURING ENGINE OIL PRESSURE....4327
MEASURING, TESTING OPERATING FORCE OF ACCELERATOR PEDAL....4328
ADJUSTING ENGINE STOP SOLENOID....4330
ADJUSTING ENGINE SPEED SENSOR....4331
MEASURING DIRECTIONAL LEVER....4332
TESTING AND ADJUSTING HST OIL PRESSURE....4333
MEASURING CLUTCH CONTROL PRESSURER....4338
TESTING AND ADJUSTING STEERING WHEEL....4339
TESTING AND ADJUSTING STEERING OIL PRESSURE....4341
BLEEDING AIR FROM STEERING CIRCUIT....4342
TESTING HYDRAULIC FAN....4343
MEASURING BRAKE PEDAL....4344
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE....4345
MEASURING BRAKE PERFORMANCE....4346
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE....4347
MEASURING BRAKE OIL PRESSURE....4348
MEASURING WEAR OF BRAKE DISC....4350
BLEEDING AIR FROM BRAKE CIRCUIT....4351
MEASURING PARKING BRAKE PERFORMANCE....4352
TESTING AND ADJUSTING PARKING BRAKE LINKAGE....4353
MEASURING PARKING BRAKE RELEASE PRESSURE....4354
MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER....4355
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE....4356
TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE....4357
BLEEDING AIR....4359
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT....4360
TESTING AND ADJUSTING BUCKET POSITIONER....4361
TESTING AND ADJUSTING OF BOOM KICK-OUT....4362
CHECKING PROXIMITY SWITCH ACTUATION DISPLAY LAMP....4363
PROCEDURE FOR CHECKING DIODE....4364
special functions of machine monitor....4365
Flow of modes and functions....4366
Pm CLINIC INSPECTION CHART....4384
POINTS TO REMEMBER WHEN TROUBLESHOOTING....4388
SEQUENCE OF EVENTS IN TROUBLESHOOTING....4389
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE....4390
CHECK BEFORE TROUBLESHOOTING....4398
Categories, procedure, and method of using troubleshooting charts....4399
PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING No....4400
Connection table for connector pin numbers....4404
T-ADAPTER TABLE....4425
CONNECTOR TYPES AND MOUNTING LOCATIONS....4429
Connector layout drawing....4436
HST controller system diagram....4442
Before troubleshooting code display....4444
Before troubleshooting electrical system....4445
Information contained in troubuleshooting table....4446
Monitor system circuit diagram....4474
Before troubleshooting code display....4478
Before troubleshooting electrical system....4479
Information contained in troubuleshooting table....4480
Electrical system diagram....4530
Parking brake related diagram....4534
Before troubleshooting electrical system....4536
Information contained in troubuleshooting table....4538
Method of using troubleshooting chart....4598
Failure code and cause table....4600
Method of using troubleshooting charts....4622
30 DISASSEMBLY AND ASSEMBLY....4645
How to read this manual....4647
Precautions when performing operation....4649
Special tool list....4651
Sketches of special tools....4654
Removal, installation of fuel injection pump assembly....4660
Removal, installation of nozzle holder assembly....4664
Removal, installation of cylinder head assembly....4666
Removal, installation of engine assembly....4674
Removal, installation of radiator assembly....4681
Removal, installation of air aftercooler....4683
Removal, installation of hydraulic oil cooler assembly....4685
Removal, installation of cooling fan and fan motor assembly....4687
Removal, installation of fuel tank assembly....4689
Removal, installation of transfer....4691
Disassembly, assembly of transfer assembly....4694
Removal, installation of parking brake assembly....4714
Disassembly, assembly of parking brake assembly....4716
Removal, installation of front axle assembly....4721
Removal, installation of rear axle assembly....4723
Disassembly, assembly of axle housing assembly....4726
Disassembly, assembly of differential assembly....4735
Removal, installation of HST pump and 4-gear pump assembly....4761
Disassembly and assembly of HST pump assembly....4764
Removal, installation of HST motor 1 assembly....4790
Removal, installation of HST motor 2 assembly....4791
Disassembly and assembly of HST motor assembly....4792
Removal, installation of work equipment control valve assembly....4808
Removal, installation of travel damper valve assembly....4810
Removal, installation of hydraulic tank assembly....4812
Removal, installation of work equipment assembly....4814
Disassembly, assembly of hydraulic cylinder assembly....4821
Removal, installation of operator's cab assembly....4827
Removal, installation of operator's cab glass (Stuck glass)....4831
Removal, installation of center hinge pin....4839
Removal, installation of counterweight....4848
Removal, installation of air conditioner unit assembly....4850
Removal, installation of air conditioner compressor assembly....4852
Removal, installation of monitor panel....4853
90 OTHERS....4857
HYDRAULIC CIRCUIT DIAGRAM....4859
ELECTRICAL CIRCUIT DIAGRAM 1/4 (1/4)....4861
ELECTRICAL CIRCUIT DIAGRAM 1/4 (2/4)....4863
ELECTRICAL CIRCUIT DIAGRAM 1/4 (3/4)....4865
ELECTRICAL CIRCUIT DIAGRAM 1/4 (4/4)....4867
ELECTRICAL CIRCUIT DIAGRAM 2/4....4869
ELECTRICAL CIRCUIT DIAGRAM 3/4....4871
ELECTRICAL CIRCUIT DIAGRAM 4/4....4873
Komatsu Wheel Loaders WA250, WA250PZ Repair Service Manual
