Komatsu 75001 Shop Manual Download Page 1

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WHEEL LOADER

SEN03813-03

WA250

-6

WA250PZ

-6

SERIAL NUMBERS

WA250-

75001

WA250PZ- 75001

and up

Summary of Contents for 75001

Page 1: ...WHEEL LOADER SEN03813 03 WA250 6 WA250PZ 6 SERIAL NUMBERS WA250 75001 WA250PZ 75001 and up ...

Page 2: ...Z 6 00 100 1 SEN03822 03 WHEEL LOADER WA250 6 WA250PZ 6 Machine model Serial number WA250 6 75001 and up WA250PZ 6 75001 and up 00 Index and foreword 00 100 Index Composition of shop manual 2 Table of contents 4 ...

Page 3: ...own below and utilize them accord ingly Section Title Form Number Shop Manual contents binder binder label and tabs SEN03813 03 00 Index and foreword SEN03814 03 100 Index SEN03822 03 q 200 Foreword and general information SEN03823 01 01 Specification SEN03815 00 100 Specification and technical data SEN03824 00 10 Structure function and maintenance standard SEN03816 01 100 Engine and cooling syste...

Page 4: ...y of code Part 6 SEN03846 00 370 Troubleshooting by failure code Display of code Part 7 SEN03847 00 400 Troubleshooting of electrical system E mode SEN03848 00 500 Troubleshooting of hydraulic and mechanical system H mode SEN03849 00 600 Troubleshooting of engine S mode SEN03850 00 50 Disassembly and assembly SEN03820 02 100 General information on disassembly and assembly SEN03851 01 200 Engine an...

Page 5: ...a SEN03824 00 Specification dimension drawing 3 Specifications 4 Weight table 8 Table of fuel coolant and lubricants 10 10 Structure function and maintenance standard 100 Engine and cooling system SEN03825 00 Engine mount and transfer mount 2 Damper 3 Cooling system 4 Cooling system hydraulic piping diagram 5 Cooling fan motor 7 200 Power train SEN03826 00 Power train 3 Power train system diagram ...

Page 6: ...mulator for ECSS 62 700 Work equipment SEN03831 00 Work equipment linkage 2 Bucket 6 Bucket positioner and boom kick out 10 Work equipment cylinder 23 800 Cab and its attachments SEN03832 00 Cab 3 Air conditioner 4 910 Electrical system Part 1 SEN03833 01 Machine monitor system 2 Machine monitor 6 920 Electrical system Part 2 SEN03834 01 Electrical system HST controller system 2 HST controller 18 ...

Page 7: ...ting Part 2 SEN03837 01 Checking operating force of accelerator pedal 3 Checking directional lever 4 Testing and adjusting HST oil pressure 5 Testing clutch control pressure 9 Testing and adjusting steering wheel 10 Testing and adjusting steering oil pressure 12 Bleeding air from steering circuit 14 Testing hydraulic fan 15 Measuring brake pedal 17 Testing and adjusting brake pedal linkage 18 Meas...

Page 8: ...e code B CRNS HST High oil temperature 17 320 Troubleshooting by failure code Display of code Part 2 SEN03842 00 Failure code CA111 Abnormality in engine controller 3 Failure code CA115 Engine Ne or Bkup speed sensor error 4 Failure code CA122 Charge pressure sensor high error 6 Failure code CA123 Charge pressure sensor low error 8 Failure code CA131 Throttle sensor high error 10 Failure code CA13...

Page 9: ...code D192KY ECSS solenoid relay Hot short 4 Failure code D1B0KA HST safety relay Disconnection 6 Failure code D1B0KB HST safety relay Ground fault 8 Failure code D1B0KY HST safety relay Hot short 10 Failure code D5ZHL6 IGN C system Ground fault Disconnection 12 Failure code DAF3KK UNSW power supply Ground fault Disconnection 14 Failure code DAFRKR Machine monitor CAN NET Signal Disconnection 16 Fa...

Page 10: ... reverse solenoid circuit Disconnection Ground fault 36 370 Troubleshooting by failure code Display of code Part 7 SEN03847 00 Failure code DX16KA Fan EPC solenoid Disconnection 2 Failure code DX16KB Fan EPC solenoid Ground fault 3 Failure code DX16KY Fan EPC solenoid Hot short 4 Failure code DX19KA Motor 1 solenoid Disconnection 6 Failure code DX19KB Motor 1 solenoid Ground fault 8 Failure code D...

Page 11: ...porarily 21 H 19 The bucket does not tilt back 22 H 20 The bucket moves slowly or the tilting back force is insufficient 23 H 21 The bucket comes to operate slowly in the midst of tilting back 24 H 22 The bucket cylinder cannot hold down the bucket 24 H 23 Hydraulic drifts of the bucket occur often 24 H 24 The bucket wobbles during travel with load The work equipment valve is set to HOLD 24 H 25 W...

Page 12: ...ower train Part 2 SEN03854 00 Removal and installation of front axle assembly 2 Removal and installation of rear axle assembly 4 Disassembly and assembly of axle housing assembly 7 Disassembly and assembly of differential assembly 16 400 Undercarriage and frame SEN03855 00 Removal and installation of center hinge pin 2 Removal and installation of counterweight 12 500 Hydraulic system SEN03856 00 R...

Page 13: ...able of contents 100 Index 90 Diagrams and drawings 100 Hydraulic diagrams and drawings SEN03860 01 Hydraulic circuit diagram 3 200 Electrical diagrams and drawings SEN03861 01 Electrical circuit diagram 3 Connector list and stereogram 21 ...

Page 14: ...SEN03822 03 WA250 250PZ 6 00 100 13 Table of contents 100 Index ...

Page 16: ...n Safety notice 2 How to read the shop manual 7 Explanation of terms for maintenance standard 9 Handling of electric equipment and hydraulic component 11 Handling of connectors newly used for engines 20 How to read electric wire code 23 Precautions when carrying out operation 26 Method of disassembling and connecting push pull type coupler 29 Standard tightening torque table 32 Conversion table 36...

Page 17: ...y operation always wear safety shoes and helmet Do not wear loose work clothes or clothes with buttons missing q Always wear safety glasses when hit ting parts with a hammer q Always wear safety glasses when grinding parts with a grinder etc 4 When carrying out any operation with 2 or more workers always agree on the oper ating procedure before starting Always inform your fellow workers before sta...

Page 18: ...m damage Always use slings which have ample capacity and install them to proper places Operate the hoist or crane slowly to prevent the component from hitting any other part Do not work with any part still raised by the hoist or crane 6 When removing a cover which is under internal pressure or under pressure from a spring always leave 2 bolts in diagonal positions Loosen those bolts gradually and ...

Page 19: ...ropes form ing a wide hanging angle from the hook When hoisting a load with 2 or more ropes the force subjected to each rope will increase with the hanging angle The table below shows the variation of allow able load in kN kg when hoisting is made with 2 ropes each of which is allowed to sling up to 9 8 kN 1 000 kg vertically at various hanging angles When the 2 ropes sling a load vertically up to...

Page 20: ...t move the crane while the slung load is swinging 6 Do not raise or lower a load while the crane is moving longitudinally or laterally 7 Do not drag a sling 8 When lifting up a load stop it just after it leaves the ground and check safety and then lift it up 9 Consider the travel route in advance and lift up a load to a safe height 10 Place the control switch on a position where it will not be an ...

Page 21: ...refrigerant gas gets in your eyes or contacts your skin you may lose your sight and your skin may be frozen Accordingly put on safety glasses safety gloves and safety clothes when recover ing or adding the refrigerant Refrigerant gas must be recovered and added by a qualified person 2 Connection 1 When installing the air conditioner cir cuit hoses and tubes take care that dirt dust water etc will ...

Page 22: ...d of adjusting each part The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting 40 Troubleshooting This section explains how to find out failed parts and how to repair them The troubleshooting is divided by failure modes The S mode of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume In this ...

Page 23: ...manual the units are indicated with International System of units SI For reference con ventionally used Gravitational System of units is indicated in parentheses Symbol Item Remarks k Safety Special safety precautions are necessary when performing work a Caution Special technical precautions or other precautions for preserving stan dards are necessary when performing work 4 Weight Weight of parts ...

Page 24: ...ated q The above size set temporarily is called the standard size and the range of differ ence from the standard size is called the tolerance q The tolerance with the symbols of or is indicated on the right side of the standard size a The tolerance may be indicated in the text and a table as standard size upper limit of tolerance lower limit of tolerance Example 120 0 022 0 126 q Usually the size ...

Page 25: ...ft and check that the interference is in the standard range 4 Repair limit and allowable value or allow able dimension q The size of a part changes because of wear and deformation while it is used The limit of changed size is called the repair limit q If a part is worn to the repair limit it must be replaced or repaired q The performance and function of a prod uct lowers while it is used A value w...

Page 26: ...d in boxes or cases wiring harnesses are more likely to be affected by the direct effects of rain water heat or vibration Furthermore during inspection and repair operations they are frequently removed and installed again so they are likely to suffer deformation or damage For this reason it is necessary to be extremely careful when handling wiring harnesses 2 Main failures occurring in wiring harn...

Page 27: ...from entering but at the same time if water does enter it is difficult for it to be drained Therefore if water should get into the connector the pins will be short cir cuited by the water so if any water gets in immediately dry the connector or take other appropriate action before passing electricity through it 5 Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil...

Page 28: ... and pull the connec tors apart a Never pull with one hand 2 When removing from clips q Both of the connector and clip have stoppers which are engaged with each other when the connector is installed q When removing a connector from a clip pull the connector in a parallel direction to the clip for removing stop pers a If the connector is twisted up and down or to the left or right the housing may b...

Page 29: ...t be careful not to make it too hot as this will cause short circuits a If there is any damage or break age replace the connector 2 Fix the connector securely Align the position of the connector correctly and then insert it securely For connectors with the lock stopper push in the connector until the stop per clicks into position 3 Correct any protrusion of the boot and any misalignment of the wir...

Page 30: ...le connector 2 Connection Right of figure 1 Push in female connector 2 horizon tally until the lock clicks Arrow 1 2 Since locks a and b may not be set completely push in female connector 2 while moving it up and down until the locks are set normally Arrow 1 2 3 a Right of figure Lock a is pulled down not set completely and lock b is set completely 1 Male connector 2 Female connector a b Locks q D...

Page 31: ...ressed air there is the risk that oil in the air may cause defective contact so remove all oil and water from the com pressed air before blowing with air 2 Dry the inside of the connector with a dryer If water gets inside the connector use a dryer to dry the connector a Hot air from the dryer can be used but regulate the time that the hot air is used in order not to make the connector or related p...

Page 32: ...carrying out arc welding on the body disconnect all wiring harness con nectors connected to the controller Fit an arc welding ground close to the welding point 5 Points to remember when troubleshooting electric circuits 1 Always turn the power OFF before discon necting or connecting connectors 2 Before carrying out troubleshooting check that all the related connectors are properly inserted a Disco...

Page 33: ...o it is desirable to use unit exchange Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop and the perfor mance should be checked with special test equipment 3 Sealing openings After any piping or equipment is removed the openings should be sealed with caps tapes or vinyl bags to prevent any dirt or dust from entering If the opening i...

Page 34: ...ts and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil 6 Flushing operations After disassembling and assembling the equip ment or changing the oil use flushing oil to remove the contaminants sludge and old oil from the hydraulic circuit Normally flushing is carried out twice primary flushing is carried out with flushing oil and secondary flushing is carried ou...

Page 35: ...nsor of flywheel housing NE 95 170 12V140 engines Ambient pressure sensor PAMB 125 170 12V140 engines Disconnect connector 1 according to the fol lowing procedure 1 Slide lock L1 to the right 2 While pressing lock L2 pull out connec tor 1 toward you a Even if lock L2 is pressed connec tor 1 cannot be pulled out toward you if part A does not float In this case float part A with a small screw driver...

Page 36: ...ssing lock C pull out connector 3 in the direction of the arrow q 114 engine q 107 engine a If the lock is on the underside use flat head screwdriver 1 since you cannot insert your fingers 2 While pressing up lock C of the connec tor with flat head screwdriver 1 pull out connector 3 in the direction of the arrow q 107 114 engines Example Intake air pressure temperature sensor in intake manifold SU...

Page 37: ...TOMO 3 a Pull the connector straight up 4 Turn housing type Round green connector q 140 engine Example Intake air pressure sensor in intake mani fold CANNON 04 PIM etc 1 Disconnect connector 6 according to the following procedure 1 Turn housing H1 in the direction of the arrow a When connector is unlocked housing H1 becomes heavy to turn 2 Pull out housing H1 in the direction of the arrow a Housin...

Page 38: ...aving nomi nal No of 0 85 Indicates color of wire by color code Color codes are shown in Table 3 Indicates size of wire by nominal No Size Nominal No is shown in Table 2 Indicates type of wire by symbol Type symbol and material of wire are shown in Table 1 Since AV and AVS are classified by size nominal No they are not indi cated Table 1 Type Sym bol Material Using temperature range C Example of u...

Page 39: ... 1 29 1 96 2 09 3 08 3 30 5 23 d approx 1 0 1 2 1 5 1 9 1 9 2 3 2 4 3 0 Cov er D AVS Standard 2 0 2 2 2 5 2 9 2 9 3 5 3 6 AV Standard 4 6 AEX Standard 2 0 2 2 2 7 3 0 3 1 3 8 4 6 Nominal No 8 15 20 30 40 50 60 85 100 Conductor Number of strands Diam eter of strand 50 0 45 84 0 45 41 0 80 70 0 80 85 0 80 108 0 80 127 0 80 169 0 80 217 0 80 Sectional area mm2 7 95 13 36 20 61 35 19 42 73 54 29 63 84...

Page 40: ...Blue Red BrR Brown Red LW Blue White BrW Brown White LY Blue Yellow BrY Brown Yellow O Orange Ch Charcoal P Pink Dg Dark green R Red G Green RB Red Black GB Green Black RG Red Green GL Green Blue RL Red Blue Gr Gray RW Red White GR Green Red RY Red Yellow GW Green White Sb Sky Blue GY Green Yellow Y Yellow L Blue YB Yellow Black LB Blue Black YG Yellow Green Lg Light green YL Yellow Blue LgB Light...

Page 41: ...hen raising components be sure to use lifting equipment of ample strength q When using forcing screws to remove any components tighten the forcing screws uniformly in turn q Before removing any unit clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal a Precautions when handling piping during disassembly Fit the following plugs into the piping after di...

Page 42: ...lic cylinder 4 5 times stopping the cylinder 100 mm from the end of its stroke 3 Next operate the hydraulic cylinder 3 4 times to the end of its stroke 4 After doing this run the engine at normal speed a When using the machine for the first time after repair or long storage follow the same procedure 3 Precautions when completing the operation 1 Refilling with coolant oil and grease q If the coolan...

Page 43: ...ing parts for a crack and damage If any part is damaged replace it 2 Check the mounting bolts and nuts of the muffler exhaust pipe and their mounting parts for looseness If any bolt or nut is loosened retighten it 5 Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler If any abnormal sound is heard repair the muffler referring to Troubleshoo...

Page 44: ...er 1 and push hose joint 2 into mating adapter 3 Fig 1 a The adapter can be pushed in about 3 5 mm a Do not hold rubber cap portion 4 2 After hose joint 2 is pushed into adapter 3 press rubber cap portion 4 against adapter 3 until it clicks Fig 2 3 Hold hose adapter 1 or hose 5 and pull it out Fig 3 a Since some hydraulic oil flows out prepare an oil receiving container 2 Connection 1 Hold hose ad...

Page 45: ...ion ring 6 contacts contact surface a of the hexag onal portion at the male end Fig 6 2 While holding the condition of Step 1 turn lever 8 to the right clockwise Fig 7 3 While holding the condition of Steps 1 and 2 pull out whole body 7 to discon nect it Fig 8 2 Connection q Hold the tightening portion and push body 7 straight until sliding prevention ring 6 contacts contact surface a of the hexag...

Page 46: ... b of the hexag onal portion at the male end Fig 10 2 While holding the condition of Step 1 push cover 10 straight until it contacts contact surface b of the hexagonal por tion at the male end Fig 11 3 While holding the condition of Steps 1 and 2 pull out whole body 9 to discon nect it Fig 12 2 Connection q Hold the tightening portion and push body 9 straight until the sliding prevention ring cont...

Page 47: ...ones indicated in the table for bolts shown in Fig B Values of tightening torques shown in the table for Fig A are applied Thread diameter of bolt Width across flats Tightening torque mm mm Nm kgm 6 10 11 8 14 7 1 2 1 5 8 13 27 34 2 8 3 5 10 17 59 74 6 0 7 5 12 19 98 123 10 0 12 5 14 22 157 196 16 20 16 24 245 309 25 31 5 18 27 343 427 35 43 5 20 30 490 608 50 62 22 32 662 829 67 5 84 5 24 36 824 ...

Page 48: ...5 Nominal No Thread diameter Width across flats Tightening torque Nm kgm mm mm Range Target 02 14 Varies depending on type of connec tor 35 63 3 5 6 5 44 4 5 03 04 20 84 132 8 5 13 5 103 10 5 05 06 24 128 186 13 0 19 0 157 16 0 10 12 33 363 480 37 0 49 0 422 43 0 14 42 746 1 010 76 0 103 883 90 0 Nominal No Thread diameter Width across flats Tightening torque Nm kgm mm mm Range Target 08 8 14 5 88...

Page 49: ...of the 102 107 and 114 engine series to the torque below Nominal No of hose Width across flats Tightening torque Nm kgm Taper seal Face seal Range Target Thread size mm Nominal No Number of threads type of thread Thread diameter mm Reference 02 19 34 54 3 5 5 5 44 4 5 9 16 18UN 14 3 34 63 3 5 6 5 14 03 22 54 93 5 5 9 5 74 7 5 11 16 16UN 17 5 24 59 98 6 0 10 0 78 8 0 18 04 27 84 132 8 5 13 5 103 10...

Page 50: ...es Taper screws a Unless there are special instructions tighten the taper screws unit inch of the 102 107 and 114 engine series to the torque below Thread size Tightening torque mm Nm kgm 6 8 2 0 81 0 20 8 10 2 1 02 0 20 10 12 2 1 22 0 20 12 24 4 2 45 0 41 14 36 5 3 67 0 51 Tightening torque Material In cast iron or steel In aluminum Thread size inch Nm kgm Nm kgm 1 16 15 2 1 53 0 20 5 1 0 51 0 10...

Page 51: ... appear in the table so divide it by 10 move the decimal point one place to the left to convert it to 55 mm 2 Carry out the same procedure as above to convert 55 mm to 2 165 inches 3 The original value 550 mm was divided by 10 so multiply 2 165 inches by 10 move the decimal point one place to the right to return to the original value This gives 550 mm 21 65 inches Millimeters to inches B 1 mm 0 03...

Page 52: ... 55 72 75 74 96 77 16 79 37 81 57 83 78 85 98 40 88 18 90 39 92 59 94 80 97 00 99 21 101 41 103 62 105 82 108 03 50 110 23 112 44 114 64 116 85 119 05 121 25 123 46 125 66 127 87 130 07 60 132 28 134 48 136 69 138 89 141 10 143 30 145 51 147 71 149 91 152 12 70 154 32 156 53 158 73 160 94 163 14 165 35 167 55 169 76 171 96 174 17 80 176 37 178 57 180 78 182 98 185 19 187 39 189 60 191 80 194 01 19...

Page 53: ...7 151 9 159 1 166 4 173 6 180 8 188 1 195 3 202 5 209 8 30 217 0 224 2 231 5 238 7 245 9 253 2 260 4 267 6 274 9 282 1 40 289 3 296 6 303 8 311 0 318 3 325 5 332 7 340 0 347 2 354 4 50 361 7 368 9 376 1 383 4 390 6 397 8 405 1 412 3 419 5 426 8 60 434 0 441 2 448 5 455 7 462 9 470 2 477 4 484 6 491 8 499 1 70 506 3 513 5 520 8 528 0 535 2 542 5 549 7 556 9 564 2 571 4 80 578 6 585 9 593 1 600 3 60...

Page 54: ...1 408 100 1 422 1 437 1 451 1 465 1 479 1 493 1 508 1 522 1 536 1 550 110 1 565 1 579 1 593 1 607 1 621 1 636 1 650 1 664 1 678 1 693 120 1 707 1 721 1 735 1 749 1 764 1 778 1 792 1 806 1 821 1 835 130 1 849 1 863 1 877 1 892 1 906 1 920 1 934 1 949 1 963 1 977 140 1 991 2 005 2 020 2 034 2 048 2 062 2 077 2 091 2 105 2 119 150 2 134 2 148 2 162 2 176 2 190 2 205 2 219 2 233 2 247 2 262 160 2 276 ...

Page 55: ... 7 16 3 2 7 2 19 66 2 12 2 54 129 2 31 7 89 192 2 26 1 15 5 0 6 7 20 68 0 12 8 55 131 0 32 2 90 194 0 25 6 14 6 8 6 1 21 69 8 13 3 56 132 8 32 8 91 195 8 25 0 13 8 6 5 6 22 71 6 13 9 57 134 6 33 3 92 197 6 24 4 12 10 4 5 0 23 73 4 14 4 58 136 4 33 9 93 199 4 23 9 11 12 2 4 4 24 75 2 15 0 59 138 2 34 4 94 201 2 23 3 10 14 0 3 9 25 77 0 15 6 60 140 0 35 0 95 203 0 22 8 9 15 8 3 3 26 78 8 16 1 61 141...

Page 56: ...SEN03823 01 WA250 250PX 6 00 200 41 200 Foreword and general information Conversion table ...

Page 58: ...A250 6 WA250PZ 6 Machine model Serial number WA250 6 75001 and up WA250PZ 6 75001 and up 01 Specification 01 100 Specification and technical data Specification dimension drawing 3 Specifications 4 Weight table 8 Table of fuel coolant and lubricants 10 ...

Page 59: ...SEN03824 00 01 100 2 WA250 250PZ 6 100 Specification and technical data ...

Page 60: ...85 1 125 1 100 I Bucket dump angle max height degree 45 48 Min turning radius Bucket tip BOC tip mm 5 985 6 010 5 855 5 875 Center of outside tire mm 5 175 5 175 Permissible towing load kN kg 82 4 8 400 82 4 8 400 Travel speed 1st forward reverse km h 4 0 13 0 4 0 13 0 4 0 13 0 4 0 13 0 2nd forward reverse 13 0 13 0 13 0 13 0 3rd forward reverse 18 0 18 0 18 0 18 0 4th forward reverse 38 0 38 0 38...

Page 61: ...bility deg 25 25 Min turning radius center of outside tire mm 5 175 5 175 Turning radius cutting edge BOC tip SAE travel posture mm 5 985 6 010 5 855 5 875 Dimension Overall length with BOC mm 6 995 7 550 Overall width chassis mm 2 470 2 470 Bucket width with BOC mm 2 685 2 685 Overall height cab top mm 3 200 3 200 Overall height with bucket lifted up mm 5 065 5 265 Wheelbase mm 2 900 2 900 Tread ...

Page 62: ...is type piston motor Pump capacity cc rev 50 107 Transfer Counter shaft double acting planetary type spur gear constant mesh type switching between 2 power trains Reduction gear unit Spiral bevel gear type splash lubrication type Differential Straight bevel gear type torque proportioning Final drive Planetary gear single reduction type splash lubrication type Axle Drive wheel Front and rear wheel ...

Page 63: ...m3 rev 56 0 Work equipment pump Type Gear type Delivery cm3 rev 40 2 Brake and cooling fan pump Type Gear type Delivery cm3 rev 12 4 Transfer lubrication pump Type Gear type Delivery cm3 rev 12 4 Cylinder Steering cylinder Type Double acting piston type Cylinder bore mm 70 Piston rod outside diameter mm 40 Stroke mm 453 Max distance between centers of pins mm 1 271 Min distance between centers of ...

Page 64: ...istance between centers of pins mm 372 Control valve Work equipment control valve Type 2 spool type Set pressure MPa kg cm2 20 6 210 Steering valve Type Orbit roll type Set pressure MPa kg cm2 18 6 190 Motor Cooling fan motor Type Fixed displacement swash plate piston type with reversible valve and flow control valve Motor capacity cm3 rev 11 5 Work equipment Type of link Z bar link Parallel movem...

Page 65: ...e With torque proportioning differential With limited slip differential 555 559 555 559 Rear axle With torque proportioning differential With limited slip differential 492 496 492 496 Axle pivot Rear axle 79 79 Wheel 25 x 17 00 1 7 1 piece 130 130 Tire 20 5 25 12 PR 1 piece 147 147 Hydraulic tank excluding hydraulic oil 77 77 4 gear pump 21 21 Work equipment control valve 19 19 Work equipment PPC ...

Page 66: ...6 232 Bucket including BOC 2 3 m3 2 2 m3 967 892 Quick coupler 261 Coupler plunger assembly 4 Operator s cab including air conditioner and interior parts 800 800 Operator seat 41 41 Air conditioner unit 5 5 Battery 1 piece 30 30 a BOC Abbreviation for Bolt On Cutting edge Unit kg Machine model name WA250 6 WA250PZ 6 Serial No 75001 and up 75001 and up ...

Page 67: ...ants Table of fuel coolant and lubricants 1 a For details of notes Notes 1 and 2 in the table see Operation and Maintenance Manual Unit l Reservoir Specified capacity Refill capacity Engine oil pan 25 5 23 0 Transfer case 6 5 5 0 Hydraulic system 135 67 Axle front rear 18 18 Cooling system 22 Fuel tank 186 ...

Page 68: ...SEN03824 00 WA250 250PZ 6 01 100 11 100 Specification and technical data Table of fuel coolant and lubricants ...

Page 70: ...hine model Serial number WA250 6 75001 and up WA250PZ 6 75001 and up 10 Structure function and maintenance standard 10 100 Engine and cooling system Engine mount and transfer mount 2 Damper 3 Cooling system 4 Cooling system hydraulic piping diagram 5 Cooling fan motor 7 ...

Page 71: ...SEN03825 00 10 100 2 WA250 250PZ 6 100 Engine and cooling system Engine mount and transfer mount Engine mount and transfer mount 1 ...

Page 72: ...he torsional vibrations of the engine due to the fluctuations in torque q The power from the engine is transmitted to coupling 3 through flywheel 7 absorbing torsional vibrations on coupling 3 Then it is transmitted to HST pump through boss 4 Unit mm No Check item Criteria Remedy 1 Distance between HST pump installation surface and boss tip Standard size Repair limit Adjust 75 1 0 8 2 Wear on inte...

Page 73: ...iator 5 Aftercooler 6 Transfer oil cooler 7 Cooling fan 8 Cooling fan motor Specifications Radiator Oil cooler Aftercooler Core type AL WAVE 4 CF40 1 AL WAVE Fin pitch mm 3 5 2 3 5 2 4 0 2 Total heat dissipation area m2 29 86 4 15 x 2 10 87 Pressure valve cracking pressure kPa kg cm2 68 6 0 7 Vacuum valve cracking pressure kPa kg cm2 0 4 9 0 0 05 ...

Page 74: ...ydraulic piping diagram Cooling system hydraulic piping diagram 1 1 Cooling fan motor 2 Strainer 3 Hydraulic tank 4 Brake and cooling fan pump 5 Charge valve Outline q Cooling fan motor 1 installed in the machine rear side is driven by oil pressure from brake and cooling fan pump 4 ...

Page 75: ...SEN03825 00 10 100 6 WA250 250PZ 6 100 Engine and cooling system Cooling system hydraulic piping diagram ...

Page 76: ...pump through charge valve T To hydraulic tank through return filter TC To hydraulic tank 1 ER terminal 2 EF terminal 3 Solenoid proportional pilot valve 4 ON OFF pilot valve Specifications Type LMF16 Capacity 11 5 cm3 rev Rated speed 1 700 rpm Rated flow rate 19 6 l min Check valve cracking pressure 0 013 MPa 0 13 kg cm2 ...

Page 77: ...SEN03825 00 10 100 8 WA250 250PZ 6 100 Engine and cooling system Cooling fan motor ...

Page 78: ...oe 12 Retainer guide 13 Bearing 14 Oil seal 15 Flow control spool 16 Suction safety valve 17 Reversible spool Unit mm No Item Criteria Remedy 18 Spool return spring Standard size Repair limit If damaged or deformed replace spring Free length x Outside diameter Installed length Installed load Free length Installed load 44 84 x 12 33 58 8 N 6 kg 47 1 N 4 8 kg 19 Spool return spring 35 x 8 5 34 44 1 ...

Page 79: ... and bottom dead center of the stroke of piston 4 q The pressurized oil sent to one side of cylinder block 5 pushes piston 4 2 or 3 pistons q A single piston generates the force F1 F1 kg P kg cm2 x xD2 4 cm2 q This force works on thrust plate 2 q Since thrust plate 2 is fixed to the specific angle a to output shaft 1 the force is divided into components F2 and F3 q The radial component F3 generate...

Page 80: ...eration 1 When pump is started q The pressurized oil from the pump is supplied to port P increasing the MA side pressure q The starting torque is generated in the motor the motor starts revolution q The pressurized oil on motor outlet MB side of the motor returns through port T to the tank 2 When the pump is stopped q When the engine stops the input revolution of the pump becomes 0 rpm q The press...

Page 81: ...fan motor is heightened in some cases q Suction safety valve 1 is installed to protect the fan system circuit Operation q If the pressure in port P rises above the cracking pressure of suction safety valve 1 valve 2 of suction safety valve 1 opens to release the pressurized oil into port T q By this operation generation of abnormally high pressure in port P is prevented ...

Page 82: ...nk circuit q Spool 3 is pushed to the right by spring 4 q Port MA opens and pressurized oil flows in to revolve the motor in forward clockwise 2 When the ON OFF solenoid is energized q When ON OFF solenoid 1 is energized valve 2 is switched q The pressurized oil from the pump flows to spool chamber D through port C q The pressurized oil in chamber D com presses spring 4 q Spool 3 moves to the left...

Page 83: ...l valve the upstream pres sure of the orifice is conducted to the right side of spool 1 and the downstream pressure of the orifice is led to its left side q The differential pressure before and after ori fice E by the incoming flow rate to the motor works on spring 2 q In Fig 1 when the flow rate Q0 is increased beyond the differential pressure before and after spool 1 becomes larger than the inst...

Page 84: ...SEN03825 00 WA250 250PZ 6 10 100 15 100 Engine and cooling system Cooling fan motor ...

Page 86: ...01 and up 10 Structure function and maintenance standard 10 200 Power train Power train 3 Power train system diagram 4 Drive shaft 6 HST hydraulic piping diagram 7 HST pump 8 HST motor 16 Transfer 22 Clutch solenoid valve 33 Axle 34 Differential 36 Torque proportioning differential 41 Limited slip differential 44 Final drive 48 ...

Page 87: ...SEN03826 00 10 200 2 WA250 250PZ 6 200 Power train ...

Page 88: ...Z 6 10 200 3 200 Power train Power train Power train 1 1 Engine 2 Damper 3 HST pump 4 4 gear pump 5 High pressure hose 6 HST motor 1 7 HST motor 2 8 Transfer 9 Front drive shaft 10 Front axle 11 Rear drive shaft 12 Rear axle ...

Page 89: ...SEN03826 00 10 200 4 WA250 250PZ 6 200 Power train Power train system diagram Power train system diagram 1 ...

Page 90: ...discharge direction and discharged amount responding to inclination of the swash plate q HST motors 9 and 10 are installed on trans fer 12 and connected to HST pump 3 through high pressure hose 8 q The hydraulic power from HST pump 3 changes the rotating direction and speed of HST motors 9 and 10 to control the machine forward and reverse travel and travel speed q The power from HST motor 1 9 is t...

Page 91: ...front drive shaft 2 and rear drive shaft 4 q When the machine is articulated or when it receives traveling impacts or working impacts the distances between the transfer and the front and rear axles change The drive shafts absorb fluctuations in the angle and length with the universal joints and slip joint so that the power will be transmitted without damaging the parts even when the machine is exp...

Page 92: ...250 250PZ 6 10 200 7 200 Power train HST hydraulic piping diagram HST hydraulic piping diagram 1 1 Hydraulic tank 2 HST pump 3 HST drain oil filter 4 Clutch solenoid valve 5 HST oil filter 6 HST motor 1 7 HST motor 2 ...

Page 93: ...elief valve 6 Servo cylinder 7 High pressure relief valve 8 Control plate 9 Cylinder block 10 Piston 11 Swash plate Specifications Model name A4VG90DA Type Variable displacement swash plate type piston pump Theoretical delivery cc rev 0 90 High pressure relief valve set pressure MPa kg cm2 44 1 450 High pressure cutoff valve set pressure MPa kg cm2 Effective differential pressure 41 2 420 Low pres...

Page 94: ...s reciprocat ing movement of piston 10 The pumping action initiated by this reciprocating movement suctions or discharges the oil in cylinder block 9 continuously q The pumping action directs the oil flow in a cer tain definite direction so that it may flow to the HST motor q Reversing the inclination of swash plate 11 reverses the suction and discharge ports and as a result reversing the oil disc...

Page 95: ...installed on the HST pump If the oil pressure on the high pressure circuit side across the HST pump and HST motor goes beyond the set pressure it drains the pressure to the low pressure circuit side This valve sets the maximum pressure of the HST circuit in this manner to protect the circuit q If low level of the oil is detected in the circuit the valve conducts oil from the HST charge pump in ord...

Page 96: ...decreased q As the oil pressure in chamber B goes lower the orifice of main piston 5 is activated and differential pressure is generated in port A and chamber B q The oil pressure in port A pushes main piston 5 in the left direction relieving the abnormal pressure generated in port A to port C q As the oil pressure in port A goes lower than that in port C check spring 4 pushes back main piston 5 i...

Page 97: ... protect the circuit Operation q Port A is connected to the HST pump charge circuit and port B is connected to the drain circuit q As long as port A is below the set pressure oil does not flow to port B q If oil pressure in port A goes beyond the set pressure piston 3 is pushed in the right direc tion As a result the oil pressure in port A is released to port B and the oil pressure in port A is de...

Page 98: ...nction with the HST pump supplies oil to the HST speed related valve and the low pressure relief valve on the HST pump Specifications Function q This pump is connected to the HST pump drive shaft 5 with coupling 4 Pumping action is turned on as it is rotated q It contains pump gear 2 and crescent separa tor plate 8 to suction or delivery oil continu ously in the direction shown in the figure Type ...

Page 99: ...lve circuit respectively q The oil from the HST charge pump constantly flows to the low pressure relief valve circuit through port A orifice of pilot poppet 5 chamber B and port D q Orifice of pilot poppet 5 applies to the oil pressure from the HST charge pump As the result the differential pressure is generated in port A and chamber B q Oil pressure in port A pushes pilot poppet 5 in the left dir...

Page 100: ...ct the circuit Operation q Port A port B port Pc and port T are connected to the high pressure circuit in the reverse travel high pressure circuit in the for ward travel speed related valve circuit and drain circuit respectively q As oil pressure in A side goes high shuttle spool 7 is pushed down and closes the port B side circuit q Oil pressure on port A side pushes up piston 5 and at the same ti...

Page 101: ...block 4 Port plate 5 EP servo valve Specifications Model name A6VM107EP Type Variable displacement bent axis type piston motor Theoretical delivery cc rev 0 107 High pressure relief valve set pressure MPa kg cm2 44 1 450 High pressure cutoff valve set pressure MPa kg cm2 Effective differential pressure 41 2 420 Low pressure relief valve set pressure MPa kg cm2 2 45 25 ...

Page 102: ...onal shuttle valve Specifications Model name A6VM107HA Type Variable displacement bent axis type piston motor Theoretical delivery cc rev 50 107 High pressure relief valve set pressure MPa kg cm2 44 1 450 High pressure cutoff valve set pressure MPa kg cm2 Effective differential pressure 41 2 420 Low pressure relief valve set pressure MPa kg cm2 2 45 25 ...

Page 103: ...der block 3 having a certain angle to drive shaft 1 q As external load to the HST motor is increased servo valve 5 and directional shut tle valve 6 work to increase inclination of cyl inder block 3 and piston 2 reducing the revolving speed and increasing the torque Operation q Pressurized oil from the HST pump flows to the back side of piston 2 through the HST motor inlet port and is activated by ...

Page 104: ...or high pressure side circuit to the small diameter side S of servo cylinder 4 and releases the oil pressure on the large diameter side L to the tank motor housing As the result the servo cylinder 4 is moved toward the min side q When the current value given to motor 1 sole noid valve 1 is large when F1 F2 EP servo valve 2 conducts the oil pressure to the large diameter side L to move servo cylind...

Page 105: ...ssure on the large diameter side L to the tank motor housing Servo cylinder 3 moves toward the min side minimizing the motor displacement q If a large load is applied to the motor during for instance uphill travel HA servo valve 2 is switched to conduct the oil pressure from the directional shuttle valve to the large diameter side L As a result the difference in area between the large diameter sid...

Page 106: ...f the directional selec tor solenoid valve on the HST pump Above process reduces the decelerating impacts that results when the oil pressure is switched Operation q Directional selector solenoid valve 1 inter locks with the directional selector valve on the HST pump since it has received the signal that is corresponding to the directional signal to be sent to the directional selector solenoid valv...

Page 107: ...Z 6 200 Power train Transfer Transfer 1 a Clutch port b Lubrication inlet port c Lubrication suction port 1 HST motor 2 mounting section 2 HST motor 1 mounting section 3 Oil filler pipe 4 Transfer 5 Parking brake lever 6 Speed sensor ...

Page 108: ...3 Transfer clutch 4 Carrier 5 Ring gear number of teeth 80 6 Planetary pinion number of teeth 24 7 Planetary shaft 8 Motor 1 gear number of teeth 44 9 Sun gear number of teeth 28 10 Parking brake 11 Rear coupling 12 Output gear number of teeth 57 13 Spacer 14 Output shaft 15 Front coupling ...

Page 109: ...nput shaft bearing and ring gear middle 80 0 0 013 0 013 0 006 0 006 0 026 5 Clearance between input shaft and bearing rear 45 0 011 0 005 0 0 012 0 023 0 005 6 Clearance between input shaft bearing and carrier rear 75 0 0 013 0 013 0 006 0 006 0 026 7 Clearance between press fitting shaft and bearing 55 0 039 0 020 0 0 015 0 054 0 020 8 Clearance between press fitting shaft bearing and motor 1 ge...

Page 110: ...01 0 03 2 3 Thickness of seal ring 1 2 0 1 1 05 16 Inside diameter of seal ring contact surface 70 0 030 0 70 1 Width of seal ring groove 3 0 15 0 10 3 3 Width of seal ring 3 0 01 0 03 2 7 Thickness of seal ring 2 9 0 1 2 75 17 Inside diameter of seal ring contact surface 120 0 022 0 120 5 Width of seal ring groove 4 5 0 1 0 5 0 Width of seal ring 4 36 0 0 1 3 9 Thickness of seal ring 3 0 1 2 7 18...

Page 111: ...SEN03826 00 10 200 26 WA250 250PZ 6 200 Power train Transfer Output shaft ...

Page 112: ...ween oil seal and cage front 100 0 170 0 080 0 054 0 0 170 0 026 6 Clearance between dust seal and cage front 100 0 400 0 200 0 054 0 0 400 0 146 7 Clearance between oil seal and cage rear 100 0 170 0 080 0 054 0 0 170 0 026 8 Clearance between dust seal and cage rear 100 0 400 0 200 0 054 0 0 400 0 146 9 Clearance between output shaft and spacer 60 0 0 030 0 030 0 0 0 060 10 Inside diameter of co...

Page 113: ...SEN03826 00 10 200 28 WA250 250PZ 6 200 Power train Transfer ...

Page 114: ...it mm No Check item Criteria Remedy 5 Clearance between input shaft and bearing Standard size Tolerance Standard clearance Clearance limit Replace Shaft Hole 55 0 030 0 011 0 0 015 0 045 0 011 6 Clearance between input shaft bearing and cage 90 0 0 015 0 022 0 013 0 013 0 037 7 Backlash between motor 2 gear and output gear 0 170 0 453 ...

Page 115: ... fixed Clutch is disengaged released q The oil from the clutch solenoid valve is pres sure fed to the back side of piston 2 and pushes piston 2 in the left direction by com pressing spring 1 q Plates 3 and discs 4 are released from the frictional force setting ring gear 5 to the neu tral position q Wave spring 6 is assembled between plates 3 to accelerate return of piston 2 as the clutches are rel...

Page 116: ...peed mode Transfer clutch 1 is fixed to transmit power of both HST motor 1 2 and HST motor 2 3 Power of HST motor 1 2 Power of HST motor 2 3 O O Input shaft 4 O O O Sun gear 5 O O O Planetary pinion 6 O O O Carrier 7 O O O Motor 1 gear 8 Motor 2 gear 9 O O Output gear 10 i i O Output shaft 11 ...

Page 117: ...0 250PZ 6 200 Power train Transfer High speed mode Transfer clutch 1 is released and since HST motor 1 2 stops it transmits power of HST motor 2 3 alone Power of HST motor 2 3 O Motor 2 gear 9 O Output gear 10 O Output shaft 11 ...

Page 118: ...rge the transfer clutch drains oil pressure q As the current value of input signal becomes smaller oil pressure of the transfer clutch goes higher inversely proportional to the current value q If the current value of input signal is further lowered until the oil pressure of the transfer clutch reaches the oil pressure at which oil is pressure fed from the HST charge pump the oil pressure of the tr...

Page 119: ... Power train Axle Axle 1 Front axle 1 1 Differential 2 Final drive 3 Axle shaft 4 Axle housing 5 Wet multiple disc type brake 6 Coupling 7 Oil filler port and level plug 8 Drain plug 9 Brake oil port 10 Air bleeder 11 Oil temperature sensor ...

Page 120: ...Z 6 10 200 35 200 Power train Axle Rear axle 1 1 Differential 2 Final drive 3 Axle shaft 4 Axle housing 5 Wet multiple disc type brake 6 Coupling 7 Oil filler port and level plug 8 Drain plug 9 Brake oil port 10 Air bleeder ...

Page 121: ...250 250PZ 6 200 Power train Differential Differential 1 Front differential 1 1 Pinion number of teeth 9 2 Shaft 3 Bevel gear number of teeth 43 4 Sun gear shaft 5 Bevel pinion number of teeth 12 6 Side gear number of teeth 12 ...

Page 122: ...earance limit Replace Shaft Hole Outer race 112 713 0 025 0 0 004 0 029 0 054 0 004 Inner race 69 85 0 066 0 045 0 013 0 0 066 0 032 15 Clearance of bearing on pinion shaft gear side Outer race 130 0 0 018 0 062 0 074 0 074 0 044 Inner race 60 0 037 0 023 0 0 015 0 052 0 023 16 Clearance of bearing on pinion shaft coupling side Outer race 120 0 0 015 0 053 0 065 0 065 0 038 Inner race 55 0 039 0 0...

Page 123: ...00 38 WA250 250PZ 6 200 Power train Differential Rear differential 1 1 Pinion number of teeth 9 2 Shaft 3 Bevel gear number of teeth 43 4 Sun gear shaft 5 Bevel pinion number of teeth 12 6 Side gear number of teeth 12 ...

Page 124: ...erential side bearing Standard size Tolerance Standard clearance Clearance limit Replace Shaft Hole Outer race 112 713 0 0 018 0 004 0 029 0 029 0 014 Inner race 69 85 0 066 0 045 0 0 015 0 081 0 045 15 Clearance of bearing on pinion shaft gear side Outer race 130 0 0 018 0 023 0 063 0 063 0 005 Inner race 60 0 039 0 020 0 0 015 0 054 0 020 16 Clearance of bearing on pinion shaft coupling side Out...

Page 125: ...tary gear type and then transmitted to the axle shafts and wheels While machine is traveling straight q While the machine is traveling straight the right and left wheels rotate at the same speed Accordingly pinion 4 in the differential assembly does not rotate and the power of car rier 6 is transmitted through pinion 4 and side gear 3 to right and left sun gear shafts 2 evenly While machine is tur...

Page 126: ...nces under both tires are the same q When the road resistances under the both tires are the same distance a from pinion 4 to the meshing point of left side gear 7 and dis tance b to the meshing point of right side gear 3 are the same q Accordingly left traction force TL and right traction force TR are balanced Travel on soft ground When the road resis tances under both tires are different q When t...

Page 127: ...oes not run idle and the drive force is transmitted to both side gears and the tires do not slip until the ratio of a b becomes 1 1 38 or the difference between the road resistances under both tires becomes 38 q The lives of the tires are lengthened 20 30 and the working capacity is increased by the above effect ...

Page 128: ...SEN03826 00 WA250 250PZ 6 10 200 43 200 Power train Torque proportioning differential ...

Page 129: ... Power train Limited slip differential Limited slip differential 1 if equipped 1 Plate 2 Disc 3 Pinion number of teeth 12 4 Washer 5 Side gear number of teeth 24 6 Bevel pinion 7 Shaft 8 Pressure ring 9 Bevel gear number of teeth 43 10 Case ...

Page 130: ...0 04 0 03 2 45 13 Thicknesses of washer 2 0 05 1 8 14 Clearance between disc and plate total clearance on both sides 0 2 0 6 15 End play of side gear in axial direction one side 0 13 0 36 16 Backlash of case and plate 0 0 5 17 Backlash of side gear and disc 0 13 0 32 18 Clearance between spider and differential pinion Standard size Tolerance Standard clearance Clearance limit Shaft Hole 25 4 0 110...

Page 131: ...essure rings 8 that are facing each other q The power torque transmitted from pres sure rings 8 to shaft 7 is transmitted on the cam surfaces Force Fa to separate pressure rings 8 from each other is generated by incli nation of the cam surfaces in proportion to the transmitted torque q Separating load Fa acts on the brake on the back side of each side gear 5 to generate braking torque While machin...

Page 132: ...ntial starts working only as the sur plus portion of the drive force has exceeded the braking force Difference in wheel drive force by type of differ entials when either wheel slipped Torque proportioning differential q On a road where either wheel slips easily the drive force of the limited slip differential increases to 1 53 times of the torque propor tioning differential Conventional differenti...

Page 133: ...00 48 WA250 250PZ 6 200 Power train Final drive Final drive 1 Front final drive 1 1 Planetary gear number of teeth 26 2 Planetary carrier 3 Axle shaft 4 Ring gear number of teeth 69 5 Sun gear shaft number of teeth 15 ...

Page 134: ...030 0 100 0 0 100 0 070 8 Clearance between oil seal and housing Max 0 2 Adjust 9 Press fitting part of axle shaft seal Housing 155 0 400 0 200 0 063 0 0 400 0 137 Replace Shaft 115 0 0 054 0 200 0 400 0 400 0 146 10 Clearance of press fitting part of axle housing bearing Outer race 152 4 0 025 0 0 012 0 052 0 077 0 012 Inner race 92 075 0 073 0 051 0 025 0 0 073 0 026 11 Clearance of press fittin...

Page 135: ... 00 10 200 50 WA250 250PZ 6 200 Power train Final drive Rear final drive 1 1 Planetary gear number of teeth 26 2 Planetary carrier 3 Axle shaft 4 Ring gear number of teeth 69 5 Sun gear shaft number of teeth 15 ...

Page 136: ... 0 030 0 100 0 0 100 0 070 8 Clearance between oil seal and housing Max 0 2 Adjust 9 Press fitting part of axle shaft seal Housing 140 0 400 0 200 0 063 0 0 400 0 137 Replace Shaft 105 0 0 054 0 200 0 400 0 400 0 146 10 Clearance of press fitting part of axle housing bearing Outer race 130 0 0 025 0 028 0 068 0 068 0 003 Inner race 85 0 045 0 023 0 0 020 0 065 0 023 11 Clearance of press fitting p...

Page 137: ...ncrease the drive force q Ring gear 4 is press fitted to the axle housing and fixed with the pin q Speed of the power being transmitted from the differential through sun gear shaft 5 is reduced by the planetary gear unit to increase the drive force The increased drive force is transmitted through planetary carrier 2 and axle shaft 3 to the tire ...

Page 138: ...SEN03826 00 WA250 250PZ 6 10 200 53 200 Power train Final drive ...

Page 140: ...PZ 6 75001 and up 10 Structure function and maintenance standard 10 300 Steering system Steering piping diagram 3 Steering column 4 Priority valve 5 Orbit roll valve 8 2 way restrictor valve 16 Cushion valve 17 Steering cylinder 18 Emergency steering piping diagram 20 Emergency steering valve 21 Steering relief valve 24 ...

Page 141: ...SEN03827 01 10 300 2 WA250 250PZ 6 300 Steering system ...

Page 142: ... 3 300 Steering system Steering piping diagram Steering piping diagram 1 1 Steering cylinder right 2 Orbit roll valve 3 Hydraulic tank 4 Priority valve 5 Steering pump 6 2 way restrictor valve 7 Cushion valve 8 Steering cylinder left ...

Page 143: ... 1 1 Steering wheel 2 Steering column 3 Orbit roll valve 4 Steering tilt lock lever Unit mm No Check item Criteria Remedy 5 Clearance between steering shaft and column bushing Standard size Tolerance Standard clearance Clearance limit Replace Shaft Hole 19 0 0 08 0 15 0 05 0 05 0 23 0 4 ...

Page 144: ...aulic tank 1 Relief valve body 2 Spring seat 3 Spring 4 Poppet 5 Seat 6 Screen 7 Plug 8 Valve body 9 Spool 10 Spring 11 Plug Unit mm No Check item Criteria Remedy 12 Control spring Standard size Repair limit Replace Free length Installed length Installed load Free length Installed load 63 4 47 6 187 N 19 1 kg 63 4 1 187 14 7 N 19 1 1 5 kg 13 Relief spring 31 27 3 132 N 13 3 kg 132 14 7 N 13 3 1 5 ...

Page 145: ... steering wheel is at neutral position q When the engine is stopped spool 3 is pushed in the left direction by the repulsive force of spring 4 Thus port M and port N are fully opened and port M and port Q are closed q Starting the engine starts the steering pump rotation and the oil from the pump flows to port A of the Orbit roll valve through port M and port N q The oil that flew to chamber P thr...

Page 146: ...sion is determined by the dis placement in angle between the spool and sleeve on the Orbit roll valve namely the opening ratio of port A and port B And changing the operating distance of the steering wheel enables its stepless adjustment When steering cylinder is at stroke end q Trying to continuously turn the steering wheel after the steering cylinder has reached the stroke end increases oil pres...

Page 147: ... From steering pump L To steering cylinder R To steering cylinder LS To priority valve T To hydraulic tank 1 Gland 2 Valve body 3 Check valve 4 Gerotor 5 Spacer 6 Cover 7 Spacer 8 Drive shaft 9 Sleeve 10 Spool 11 Center pin 12 Centering spring 13 Anti cavitation valve 14 Overload relief valve ...

Page 148: ...tually when the oil is not supplied because of a trouble of the steer ing pump or engine Structure q Top A of spool 9 is connected to the drive shaft of the steering column and further con nected to sleeve 8 through center pin 7 which is not in contact with spool 9 while the steering wheel is at neutral and centering spring 2 q Top B of drive shaft 3 is engaged with cen ter pin 7 and united with s...

Page 149: ...SEN03827 01 10 300 10 WA250 250PZ 6 300 Steering system Orbit roll valve Operation When steering wheel is at neutral position ...

Page 150: ...eering circuit and port G to the L H steering circuit cut off the vertical grooves B C and D on spool 9 q Orifice b of port J to the priority valve is con nected to vertical groove B on spool 9 q Port K of sleeve 8 is connected to vertical groove M and port L on spool 9 q Due to connection and disconnection of the ports and vertical grooves the oil in the priority valve being set to the pilot pres...

Page 151: ...SEN03827 01 10 300 12 WA250 250PZ 6 300 Steering system Orbit roll valve When steering wheel is turned left ...

Page 152: ...sing vertical groove M and port L q Port F of the R H steering circuit is con nected to vertical groove D at the same time as port A and vertical groove B are con nected q Due to connection and disconnection of the ports and vertical grooves the oil from the pump flows from port A to vertical groove B then flows to port E starting rotation of the Gerotor The oil discharged from the Gerotor flows t...

Page 153: ... 7 are also connected and the oil form the pump flows in them Fig 2 shows the state that has resulted from turning the steering wheel by 90 continued for above condition Under this state ports 2 3 and 4 are in the suction state and connected to ports k a and c Ports 5 6 and 7 are in the discharge state and connected to ports d f and h q As shown above the ports in the discharge state of the Geroto...

Page 154: ...is placement a is generated between spool 9 and sleeve 8 As a result the ports of spool 9 and sleeve 8 are connected and the oil is sent to the steering cylinder When the steering wheel stops turning the Gerotor also stops turning Then the oil is not sent to the steering cylinder any more and its pressure rises To prevent this when the steering wheel stopped turning Gerotor is turned by the reac t...

Page 155: ... installed in the circuit near to the cylinder controls the move of the cylinder piston by giving pressure to the return oil Operation q When flowing in the left direction in the cylin der s forward move direction the oil pushes open poppet 3 and flows from orifice a and notch b of poppet 3 q When flowing in the right direction to the cylin der s return direction the oil conducted through orifice ...

Page 156: ...s poppet 4 of port A side then flows through the center groove of spool 8 up to port B opening pop pet 11 of port B side q At the same time the highly pressurized oil flows to the pressure chamber of plug 6 through orifice 5 of port A side Then over coming the port B side pressure and repul sive force of spring 7 it pushes spool 8 in the right direction cutting off the flow of oil from port A to p...

Page 157: ...andard clearance Clearance limit Replace Shaft Hole 40 0 0 025 0 180 0 042 0 042 0 205 2 Clearance between bushing in cylinder bottom frame connecting part and mounting pin 40 0 0 025 0 180 0 042 0 042 0 205 3 Connecting part of steering cylinder and front frame Width of boss Width of hinge Standard a b clearance 50 53 Max 0 5 after shim is adjusted 4 Connecting part of steering cylinder and rear ...

Page 158: ...bushing Standard size Tolerance Standard clearance Clearance limit Replace pin and bushing Shaft Hole 40 0 025 0 087 0 132 0 006 0 031 0 219 0 519 2 Clearance between piston rod supporting shaft and bushing 40 0 0 025 0 180 0 042 0 042 0 205 1 0 3 Clearance between cylinder bottom supporting shaft and bushing 40 0 0 025 0 180 0 042 0 042 0 205 1 0 ...

Page 159: ...gency steering piping diagram 1 if equipped 1 Steering pump 2 Priority valve 3 Orbit roll valve 4 Check valve 5 Emergency steering valve 6 HST motor 2 7 Pressure switch for detecting emergency steering operation 8 Steering relief valve 9 Pressure switch for detecting low oil pressure on steering ...

Page 160: ...ing valve Emergency steering valve 1 if equipped PP From steering pump A To HST motor 2 port A B To HST motor 2 port B Y To Orbit roll valve S From hydraulic tank G To pressure switch 1 Check valve body 2 Check valve 3 Valve body 4 Pressure reducing valve 5 Selector valve ...

Page 161: ...ormal q As long as the engine and steering pump are operating normally the oil being pressure fed from the steering pump flows to the Orbit roll valve enabling the steering q The oil from the steering pump flows to port PP pushes spool 1 in the left direction then cuts off the circuit from the HST motor to the Orbit roll valve ...

Page 162: ...n by the repul sive force of spring 2 q The high pressure side is selected for the oil from the HST pump at check valves 3 and 4 and the oil pressure is decreased to an appropriate level at pressure reducing valve 5 q De pressurized oil flows through port Y to the Orbit roll valve enabling the steering q If the oil in the HST circuit goes low because of flowing out to the steering circuit oil is s...

Page 163: ...rain S1 Steering pump oil pressure switch Low S2 Steering pump oil pressure switch Hi S3 Emergency steering oil pressure switch 1 Block 2 Relief valve 3 Orifice Outline q The steering relief valve is installed to the right side of the transmission and used to hold the steering oil pressure to the set pressure Set pressure 1 96 MPa 20 kg cm2 cracking pressure at 0 5 l min ...

Page 164: ...SEN03827 01 WA250 250PZ 6 10 300 25 300 Steering system Steering relief valve ...

Page 166: ...ial number WA250 6 75001 and up WA250PZ 6 75001 and up 10 Structure function and maintenance standard 10 400 Brake system Brake piping diagram 3 Charge valve 4 Brake valve 8 Inching valve 12 Accumulator for brake 13 Slack adjuster 14 Brake 16 Parking brake control 21 Parking brake 22 ...

Page 167: ...SEN03828 00 10 400 2 WA250 250PZ 6 400 Brake system ...

Page 168: ...tank 2 Brake valve 3 Brake and cooling fan pump 4 Rear brake 5 Accumulator for front side 6 Accumulator for rear side 7 Charge valve 8 Strainer 9 Slack adjuster for front left side 10 Front brake 11 Slack adjuster for front right side 12 Slack adjuster for rear right side 13 Slack adjuster for rear left side ...

Page 169: ...SEN03828 00 10 400 4 WA250 250PZ 6 400 Brake system Charge valve Charge valve 1 ...

Page 170: ...he pump Unit mm No Check item Criteria Remedy 7 Clearance between inverse shuttle valve and body Standard size Tolerance Standard clearance Clearance limit Replace Shaft Hole 12 0 006 0 014 0 011 0 0 006 0 025 0 029 8 Clearance between plunger and body 8 0 005 0 012 0 009 0 0 005 0 021 0 024 9 Clearance between unload valve and body 18 0 006 0 017 0 011 0 0 006 0 028 0 032 10 Inverse shuttle valve...

Page 171: ...ut in state q As the accumulator pressure goes low pres sure on port E goes low allowing plunger 1 to move in the right direction and unload relief valve 2 to close the drain circuit q Since the oil pressure in port F and the spring chamber of unload valve 3 increases unload valve 3 moves in the right direction q Port C and port B are opened conducting the oil from the pump to port B q As oil pres...

Page 172: ...lief valve 2 being pushed open q Since oil pressure in port F is decreased unload valve 3 moves in the left direction being subjected to the action of the oil from chamber B q Port C and port D are opened supplying most of the oil from the pump to the cooling fan motor through port P ports C and D and port A When the oil pressure from the pump went beyond the set pressure q As oil pressure in cham...

Page 173: ...l and body Standard size Tolerance Standard clearance Clearance limit Replace Shaft Hole 22 4 0 022 0 053 0 033 0 0 020 0 086 0 096 9 Clearance between inching valve guide and body 22 4 0 022 0 053 0 033 0 0 020 0 086 0 096 10 Clearance between inching valve spool and guide 12 0 050 0 093 0 050 0 0 050 0 143 0 157 11 Inching valve control spring Standard size Repair limit Free length Installed len...

Page 174: ...ion port Ta is closed and the oil from the pump activates the rear brake after being conducted through the accumulator port PA port A and rear brake piston q As spool 5 is pushed in the right direction spool 6 is also pushed in the right direction closing port Tb The oil from the pump flows through the accumulator port PB and port B to the front brake piston to activate the front brake When brake ...

Page 175: ...e d of spool 6 pushes back spool 6 in the left direction by the move distance of spool 5 As the result port PB and port B are disconnected q Since port Tb remains closed the oil con ducted to the brake piston is retained and the brake remains operable q The oil pressure of the rear brake circuit port A side is balanced with the brake pedal pressing effort and the oil pressure of the front brake ci...

Page 176: ...rt PA and port A are closed q At the same time oil in the rear brake piston is drained to the hydraulic tank through port A and port Ta releasing the rear brake q At the same time as spool 5 is moved in the left direction spool 6 is also pushed back in the left direction by the back pressure of the front brake piston and repulsive force of spring 7 As the result port PB and port B are closed q Oil...

Page 177: ...m HST pump port Y T2 To steering pump suction side 1 Brake pedal 2 Brake valve 3 Spool 4 Body Outline q The inching valve which is contained in brake valve 2 reduces the control oil pressure of the HST circuit responding to stroke S of spool 3 in order to reduce the capacity of the HST pump ...

Page 178: ... The space between cylinder 1 and free piston 2 is filled with nitrogen gas The nitrogen gas absorbs the hydraulic pulses generated by the hydrau lic pump and secures the braking force and operability when the engine is stopped by uti lizing its compressibility Specifications Gas used Nitrogen gas Amount of gas cc 500 Charge pressure MPa kg cm2 3 5 0 1 35 7 1 at 20 C Max pressure used MPa kg cm2 1...

Page 179: ... Standard size Tolerance Standard clearance Clearance limit Replace Shaft Hole 30 0 065 0 098 0 052 0 0 065 0 150 0 163 5 Clearance between check valve and body 10 0 013 0 028 0 015 0 0 013 0 043 0 048 6 Piston return spring Standard size Repair limit Free length Installed length Installed load Free length Installed load 87 5 48 2 11 8 N 1 2 kg 9 8 N 1 0 kg 7 Check valve return spring 21 7 19 25 5...

Page 180: ...the brake piston q The slack adjuster maintains the time lag up to activation of the brake constant by operating the brake using the oil being amassed between piston 1 and the brake piston q If the oil between piston 1 and brake piston goes low due to wear on the brake disc and like it pushes open check valve 2 to make up the deficit When brake is released q The oil being stopped between piston 1 ...

Page 181: ...28 00 10 400 16 WA250 250PZ 6 400 Brake system Brake Brake 1 Front brake 1 1 Differential housing 2 Bearing carrier 3 Piston 4 Spring 5 Inner ring 6 Sun gear shaft 7 Axle housing 8 Outer ring 9 Disc 2 pieces ...

Page 182: ...uck to its both sides and is installed between inner ring 5 and outer ring 8 and they are coupled together by the spline of sun gear shaft 6 Unit mm No Check item Criteria Remedy 10 Thickness of plate Standard size Tolerance Repair limit Replace 6 0 1 5 5 11 Thickness of brake disc 6 5 0 15 5 7 Depth of lining groove 0 8 min 0 4 Thickness of lining 1 0 0 8 min 12 Wear of disc contact surface of br...

Page 183: ...EN03828 00 10 400 18 WA250 250PZ 6 400 Brake system Brake Rear brake 1 1 Differential housing 2 Bearing carrier 3 Piston 4 Spring 5 Inner ring 6 Sun gear shaft 7 Axle housing 8 Outer ring 9 Disc 2 pieces ...

Page 184: ...ck to its both sides and is installed between inner ring 5 and outer ring 8 and they are coupled together by the spline of sun gear shaft 6 Unit mm No Check item Criteria Remedy 10 Thickness of plate Standard size Tolerance Repair limit Replace 6 0 1 5 5 11 Thickness of brake disc 6 5 0 15 5 7 Depth of lining groove 0 8 min 0 4 Thickness of lining 1 0 0 8 min 12 Wear of disc contact surface of bra...

Page 185: ...e the piston Accordingly disc 4 between piston 2 inner ring 3 and outer ring 5 is stopped and the brake is applied to the machine When brake is released q If the oil pressure is released piston 2 is returned to the original position by the return ing force of spring 8 and clearance is made between inner ring 3 and outer ring 5 and disc 4 becomes free The linings stuck to disc 4 have cross grooves ...

Page 186: ...rking brake lever 1 allows applying or releasing the parking brake q Pulling parking brake lever 1 on the opera tor s seat pulls up the multi disc brake lever 6 which is connected with control cable 4 applying the parking brake q Returning parking brake lever 1 to its original position pushes down the multi disc brake lever 6 which is connected with control cable 4 releasing the parking brake q As...

Page 187: ...n 4 and housing 2 that are connected to lever 1 moves on the slope of the piston groove responding to the pulling distance of the parking brake lever By this move of the ball piston 4 compresses plate 5 and disc 6 to each other thereby applying brake to output shaft 8 Unit mm No Check item Criteria Remedy 9 Thickness of plate Standard size Tolerance Repair limit Replace 2 6 0 06 2 5 Strain on plat...

Page 188: ...SEN03828 00 WA250 250PZ 6 10 400 23 400 Brake system Parking brake ...

Page 190: ...829 00 WHEEL LOADER WA250 6 WA250PZ 6 Machine model Serial number WA250 6 75001 and up WA250PZ 6 75001 and up 10 Structure function and maintenance standard 10 500 Undercarriage and frame Axle mount and center hinge pin 2 Tires 7 ...

Page 191: ...SEN03829 00 10 500 2 WA250 250PZ 6 500 Undercarriage and frame Axle mount and center hinge pin Axle mount and center hinge pin 1 a The following drawing shows WA250 6 ...

Page 192: ...hus it is fixed directly to front fame 5 with tension bolt 2 q Rear axle 3 is designed to sway at the center of rear frame 7 so that each tire may contact the ground surface even when the machine is traveling on soft ground q Front frame 5 and rear frame 7 are coupled by the center hinge pin 6 with the bearing between them The right and left steering cylin ders connect the front frame 5 and rear f...

Page 193: ...SEN03829 00 10 500 4 WA250 250PZ 6 500 Undercarriage and frame Axle mount and center hinge pin ...

Page 194: ... 0 027 0 057 0 143 7 Clearance between lower hinge pin and bearing 65 0 030 0 076 0 0 015 0 015 0 076 8 Clearance between front frame and lower hinge bearing 105 0 0 020 0 041 0 076 0 076 0 021 9 Clearance between rear frame and bushing 75 0 084 0 059 0 046 0 0 084 0 013 10 Clearance of press fitting part of lower hinge pin seal 80 0 260 0 160 0 046 0 0 260 0 114 11 Height of upper hinge spacer St...

Page 195: ...nce Repair limit Replace 10 0 0 15 2 Thickness of thrust washer 5 0 3 0 1 3 Clearance between shaft and hole on front support side Standard size Tolerance Standard clearance Clearance limit Shaft Hole 170 0 043 0 106 0 550 0 050 0 093 0 656 4 Clearance between shaft and hole on rear support side 170 0 043 0 106 0 550 0 050 0 093 0 656 5 Standard thickness of shim in thrust cap 0 2 ...

Page 196: ...and tread T are independent from each other Ground contact characteristics q Even if the tire is deformed by a load it does not move uselessly in ground contact and uni form ground contact surface is secured stably Deformation characteristics q Only side wall W is deformed as load is applied and tread T made of strong belts 2 keeps stability independently Bias tire Structure q The cords of carcass...

Page 198: ...re function and maintenance standard 10 600 Hydraulic system Work equipment hydraulic piping diagram 2 Work equipment control lever linkage 6 Hydraulic tank 10 4 gear pump 12 Work equipment control valve 14 PPC valve 39 Lock valve 54 Accumulator for PPC circuit 55 Bypass valve 56 Quick coupler solenoid valve 59 ECSS valve 60 Accumulator for ECSS 62 ...

Page 199: ...SEN03830 00 10 600 2 WA250 250PZ 6 600 Hydraulic system Work equipment hydraulic piping diagram Work equipment hydraulic piping diagram 1 WA250 6 ...

Page 200: ... valve 1 is filtered on the return filter on hydraulic tank 3 then is returned to hydraulic tank 3 q Operating the work equipment control lever operates the lift arm spool or bucket spool of work equipment PPC valve 4 The oil from work equipment PPC valve 4 operates respective spools of work equipment control valve 1 with its oil pressure then sends the oil pressure to lift cylinder 10 or bucket c...

Page 201: ...SEN03830 00 10 600 4 WA250 250PZ 6 600 Hydraulic system Work equipment hydraulic piping diagram WA250PZ 6 ...

Page 202: ...ve 2 is filtered on the return filter on hydraulic tank 5 then is returned to hydraulic tank 5 q Operating the work equipment control lever operates the lift arm spool or bucket spool of work equipment PPC valve 7 If operating the auxiliary control lever operates the spool of attachment PPC valve 6 The oil from work equipment PPC valve 7 or attachment PPC valve 6 operates respective spools of work...

Page 203: ...trol lever linkage Work equipment control lever linkage 1 WA250 6 Multi function mono lever type 1 Work equipment control lever 2 Directional selector switch 3 Wrist rest 4 Lock valve 5 Work equipment lock lever 6 Work equipment PPC valve 7 Wrist rest height adjustment lever ...

Page 204: ...lic system Work equipment control lever linkage WA250 6 2 lever type if equipped 1 Lift arm control lever 2 Bucket control lever 3 Wrist rest 4 Lock valve 5 Work equipment lock lever 6 Work equipment PPC valve 7 Wrist rest height adjustment lever ...

Page 205: ...ever linkage WA250PZ 6 Multi function mono lever type 1 Work equipment control lever 2 Auxiliary control lever 3 Directional selector switch 4 Wrist rest 5 Lock valve 6 Work equipment lock lever 7 Work equipment PPC valve 8 Attachment PPC valve 9 Wrist rest height adjustment lever ...

Page 206: ... control lever linkage WA250PZ 6 2 lever type if equipped 1 Lift arm control lever 2 Bucket control lever 3 Auxiliary control lever 4 Wrist rest 5 Lock valve 6 Work equipment lock lever 7 Attachment PPC valve 8 Work equipment PPC valve 9 Wrist rest height adjustment lever ...

Page 207: ...d breather 2 Return filter 3 Hydraulic tank 4 Drain plug 5 Sight gauge 6 Return filter bypass valve 7 Check valve Specifications Capacity of hydraulic tank l 96 Quantity of oil in hydraulic tank l 67 Set pressure of bypass valve MPa kg cm2 0 2 2 04 Cracking pressure of check valve MPa kg cm2 0 1 0 02 0 98 0 2 ...

Page 208: ...k pressure and the atmospheric pressure to prevent genera tion of the negative pressure set pressure of air intake valve 3 0 0 3 kPa 0 03 0 003 kg cm2 Prevention of pressure rise in tank q While the hydraulic circuit is in operation the oil level in the tank rises as the hydraulic cylin ders operate and the temperature rises Con sequently the pressure in the tank rises too If the pressure in the t...

Page 209: ... and transfer lubrication SAR 3 56 2 40 SBR 1 12 12 1 Steering pump 2 Work equipment pump 3 Brake and cooling fan pump 4 Transfer lubrication pump Outline q The 4 gear pump is installed on the HST pump The axial rotation drives this gear to supply pressurized oil to the steering work equipment brake cooling fan and transfer ...

Page 210: ...er of gear shaft SAR 3 56 0 083 0 144 0 20 SAR 2 40 0 071 0 121 SBR 1 12 0 068 0 115 SBR 1 12 7 Pin driven depth Type Standard size Allowance Repair limit SAR 3 56 13 0 0 5 SAR 2 40 12 SBR 1 12 10 SBR 1 12 7 0 5 0 8 Torque of spline rotating shaft 13 8 28 5 Nm 1 4 2 9 kgm Delivery Oil SAE10WCD Oil temperature 45 55 C Type Speed rpm Discharge pressure MPa kg cm2 Standard delivery l min Allowable de...

Page 211: ...SEN03830 00 10 600 14 WA250 250PZ 6 600 Hydraulic system Work equipment control valve Work equipment control valve 1 WA250 6 2 spool type ...

Page 212: ...cket cylinder head A2 To lift arm cylinder head B1 To bucket cylinder bottom B2 To lift arm cylinder bottom P From pump PA1 From work equipment PPC valve PA2 From work equipment PPC valve PB1 From work equipment PPC valve PB2 From work equipment PPC valve T To hydraulic tank TS To hydraulic tank ...

Page 213: ...SEN03830 00 10 600 16 WA250 250PZ 6 600 Hydraulic system Work equipment control valve ...

Page 214: ...d size Repair limit If damaged or deformed replace spring Free length x Outside diameter Installed length Installed load Free length Installed load 42 5 x 27 5 41 92 2 N 9 4 kg 73 8 N 7 52 kg 8 Spool return spring 56 9 x 26 3 55 3 88 3 N 9 0 kg 70 6 N 7 2 kg 9 Spool return spring 55 1 x 12 6 40 0 178 N 18 1 kg 142 N 14 5 kg 10 Spool return spring 42 x 27 5 41 72 6 N 7 4 kg 58 1 N 5 92 kg 11 Check ...

Page 215: ...SEN03830 00 10 600 18 WA250 250PZ 6 600 Hydraulic system Work equipment control valve WA250 6 3 spool type ...

Page 216: ... To lift arm cylinder head B1 To service actuator B2 To bucket cylinder bottom B3 To lift arm cylinder bottom P From pump PA1 To service PPC valve PA2 To work equipment PPC valve PA3 To work equipment PPC valve PB1 To service PPC valve PB2 To work equipment PPC valve PB3 To work equipment PPC valve T To hydraulic tank TS To hydraulic tank ...

Page 217: ...SEN03830 00 10 600 20 WA250 250PZ 6 600 Hydraulic system Work equipment control valve ...

Page 218: ... Standard size Repair limit If damaged or deformed replace spring Free length x Outside diameter Installed length Installed load Free length Installed load 42 5 x 27 5 41 92 2 N 9 4 kg 73 8 N 7 52 kg 9 Spool return spring 56 9 x 26 3 55 3 88 3 N 9 0 kg 70 6 N 7 2 kg 10 Spool return spring 55 1 x 12 6 40 0 178 N 18 1 kg 142 N 14 5 kg 11 Spool return spring 42 x 27 5 41 72 6 N 7 4 kg 58 1 N 5 92 kg ...

Page 219: ...SEN03830 00 10 600 22 WA250 250PZ 6 600 Hydraulic system Work equipment control valve WA250PZ 6 2 spool type ...

Page 220: ...e A1 To bucket cylinder head A2 To lift arm cylinder head B1 To bucket cylinder bottom B2 To lift arm cylinder bottom P From pump PA1 From work equipment PPC valve PA2 From work equipment PPC valve PB1 From work equipment PPC valve PB2 From work equipment PPC valve T To hydraulic tank ...

Page 221: ...SEN03830 00 10 600 24 WA250 250PZ 6 600 Hydraulic system Work equipment control valve ...

Page 222: ... size Repair limit If damaged or deformed replace spring Free length x Outside diameter Installed length Installed load Free length Installed load 42 5 x 27 5 41 92 2 N 9 4 kg 73 8 N 7 52 kg 8 Spool return spring 58 87 x 26 3 57 3 55 9 N 5 7 kg 45 1 N 4 6 kg 9 Spool return spring 53 35 x 12 38 5 110 8 N 11 3 kg 88 2 N 9 0 kg 10 Spool return spring 42 x 27 5 41 72 6 N 7 4 kg 58 1 N 5 92 kg 11 Check...

Page 223: ...SEN03830 00 10 600 26 WA250 250PZ 6 600 Hydraulic system Work equipment control valve WA250PZ 6 3 spool type ...

Page 224: ...er head A3 To lift arm cylinder head B1 To service actuator B2 To bucket cylinder bottom B3 To lift arm cylinder bottom P From pump PA1 To service PPC valve PA2 To work equipment PPC valve PA3 To work equipment PPC valve PB1 To service PPC valve PB2 To work equipment PPC valve PB3 To work equipment PPC valve T To hydraulic tank ...

Page 225: ...SEN03830 00 10 600 28 WA250 250PZ 6 600 Hydraulic system Work equipment control valve ...

Page 226: ... Standard size Repair limit If damaged or deformed replace spring Free length x Outside diameter Installed length Installed load Free length Installed load 42 5 x 27 5 41 92 2 N 9 4 kg 73 8 N 7 52 kg 9 Spool return spring 58 87 x 26 3 57 3 55 9 N 5 7 kg 45 1 N 4 6 kg 10 Spool return spring 53 35 x 12 38 5 110 8 N 11 3 kg 88 2 N 9 kg 11 Spool return spring 42 x 27 5 41 72 6 N 7 4 kg 58 1 N 5 92 kg ...

Page 227: ...hrough the orifice of main valve 1 Pilot pop pet 3 is contacted with valve seat 2 q As the pressurized oil in ports A and B reaches the set pressure of spring 4 pilot poppet 3 opens leading the pressurized oil in port B to port C through port D and pres sure in port B is decreased q As the pressure in port B goes low the orifice of main valve 1 generates differential pres sure between ports A and ...

Page 228: ...der circuit this valve works as a suction valve Operation 1 Operation as safety valve q Port A and port B are connected to the cyl inder circuit and drain circuit respectively q Pressurized oil in port A is conducted to port C through piston 1 hole Main valve 2 is contacted against the left side due to the rela tion d2 d3 q The relation between the size of cross sec tional diameters cross section ...

Page 229: ...because they are con nected to each other Suction valve 7 receives the pressurized oil by the difference in area between d4 and d1 q When the differential pressure between port B and port A increases beyond the set pres sure suction valve 7 moves to the right Thus the pressurized oil flows from port B to port A to prevent generation of negative pressure in port A Suction valve 1 Main poppet 2 Slee...

Page 230: ...ve And the maxi mum pressure is regulated by relief valve 2 q The bypass circuit is open since bucket spool 3 is at the neutral position Thus the pressur ized oil in port A flows to port B passing through in vicinity of the spool q The bypass circuit is open since lift arm spool 4 is at the neutral position Thus the pressur ized oil in port B enters port C of the drain circuit passing through in v...

Page 231: ...pressurized oil from pump 1 flows to the bypass circuit of lift arm spool 4 through the bypass circuit of bucket spool 3 q Since the bypass circuit is closed by the spool the pressurized oil from port B pushes open check valve 5 q The pressurized oil from port B flows to the cylinder bottom through port D q The pressurized oil on the cylinder head side returns to the hydraulic tank through port E ...

Page 232: ...surized oil from pump 1 flows to the bypass circuit of lift arm spool 4 through the bypass circuit of bucket spool 3 q Since the bypass circuit is closed by the spool the pressurized oil from port B pushes open check valve 5 q The pressurized oil from port B flows to the cylinder rod side through port E q The pressurized oil on the cylinder bottom side returns to the hydraulic tank through port D ...

Page 233: ...he bypass circuit of lift arm spool 4 through the bypass circuit of bucket spool 3 q Since the pressurized oil in the bypass circuit flows to the drain circuit by the spool check valve 5 cannot be pushed open q In addition the lift arm descends by its own weight since both the raise circuit D and lower circuit E of the lift arm cylinder are con nected to the drain circuit q As long as the bucket i...

Page 234: ...ol lever pulls out bucket spool 3 to set it to the tilt position q Since the bypass circuit is closed by the spool the pressurized oil from port A pushes open check valve 7 q The pressurized oil from port G flows to the cylinder bottom side q The pressurized oil on the cylinder rod side returns to the hydraulic tank through port H and drain port C Thus the bucket tilts ...

Page 235: ...ol lever pushes in bucket spool 3 to set it to the dump position q Since the bypass circuit is closed by the spool the pressurized oil from port A pushes open check valve 7 q The pressurized oil from port H flows to the cylinder rod side q The pressurized oil on the cylinder bottom side returns to the hydraulic tank through port G and drain port C Thus the bucket dumps ...

Page 236: ...valve PPC valve 1 a PPC Abbreviation for Proportional Pressure Control Work equipment PPC valve Mono lever type P From HST charge pump P1 To bucket valve tilt P2 To bucket valve dump P3 To lift arm valve raise P4 To lift arm valve lower float T To hydraulic tank ...

Page 237: ...N03830 00 10 600 40 WA250 250PZ 6 600 Hydraulic system PPC valve 1 Spool 2 Metering spring 3 Centering spring 4 Rod 5 Disc 6 Nut for connecting lever 7 Joint 8 Plate 9 Piston 10 Retainer 11 Body 12 Filter ...

Page 238: ... PB of the control valve bucket valve and ports P1 and P2 of the PPC valve are connected through fine control hole f of spool 1 to drain chamber D 2 Lift arm PPC valve q Ports PA and PB of the control valve lift arm valve and ports P3 and P4 of the PPC valve are connected through fine control hole f of spool 1 to drain chamber D ...

Page 239: ...rom pump pressure chamber PP and connected to drain chamber D almost simul taneously to release the pressure in port P1 q As a result spool 1 moves up and down to balance the force of metering spring 2 with the pressure in port P1 q The positional relationship between spool 1 and body 11 where fine control hole f is between drain chamber D and pump pres sure chamber PP does not change until retain...

Page 240: ...mp pressure is supplied until the pres sure in port P1 recovers to a pressure equiv alent to the position of the lever q When the control valve spool returns the pres surized oil in drain chamber D flows in through fine control hole f of the valve which is not in operation and flows through port P2 into chamber PA 4 When lever is operated to stroke end q Disc 5 and rod 4 push down piston 9 and ret...

Page 241: ...f the lever is released q At the same time the control valve is also moved to the float position to keep the lift arm in float condition 6 When float state of lift arm is reset q When returning disc 5 from the float posi tion the rod is pushed down with a force larger than absorptive power of the solenoid q The float state also can be reset and the lever can be returned to the neutral position by ...

Page 242: ...0PZ 6 10 600 45 600 Hydraulic system PPC valve 2 lever type if equipped P From HST charge pump P1 To bucket tilt valve P2 To lift arm LOWER FLOAT valve P3 To lift arm RAISE valve P4 To bucket DUMP valve T To hydraulic tank ...

Page 243: ...SEN03830 00 10 600 46 WA250 250PZ 6 600 Hydraulic system PPC valve 1 Spool 2 Metering spring 3 Centering spring 4 Rod 5 Lever 6 Ring 7 Plate 8 Piston 9 Retainer 10 Body 11 Filter ...

Page 244: ... PB of the control valve bucket valve and ports P1 and P4 of the PPC valve are connected through fine control hole f of spool 1 to drain chamber D 2 Lift arm PPC valve q Ports PA and PB of the control valve lift arm valve and ports P2 and P3 of the PPC valve are connected through fine control hole f of spool 1 to drain chamber D ...

Page 245: ...rom pump pressure chamber PP and connected to drain chamber D almost simul taneously to release the pressure in port P1 q As a result spool 1 moves up and down to balance the force of metering spring 2 with the pressure in port P1 q The positional relationship between spool 1 and body 10 where fine control hole f is between drain chamber D and pump pres sure chamber PP does not change until retain...

Page 246: ... pressure is supplied until the pres sure in port P1 recovers to a pressure equiv alent to the position of the lever q When the control valve spool returns the pres surized oil in drain chamber D flows in through fine control hole f of the valve which is not in operation and then flows through port P4 into chamber PA 4 When lever is operated to stroke end q Lever 5 and rod 4 push down piston 8 and...

Page 247: ...f the lever is released q At the same time the control valve is also moved to the float position to keep the lift arm in float condition 6 When float state of lift arm is reset q When returning lever 5 from the float posi tion the rod is pushed down with a force larger than absorptive power of the solenoid q The float state also can be reset and the lever can be returned to the neutral position by...

Page 248: ...SEN03830 00 WA250 250PZ 6 10 600 51 600 Hydraulic system PPC valve ...

Page 249: ...SEN03830 00 10 600 52 WA250 250PZ 6 600 Hydraulic system PPC valve Attachment PPC valve if equipped a For the details of operation see the paragraph of Work equipment PPC valve ...

Page 250: ...1 Spool 2 Piston 3 Lever 4 Plate 5 Retainer 6 Body 7 Filter Unit mm No Item Criteria Remedy 8 Centering spring Standard size Repair limit If damaged or deformed replace spring Free length x Outside diameter Installed length Installed load Free length Installed load 41 1 x 15 5 29 36 3 N 3 7 kg 29 0 N 2 96 kg 9 Metering spring 22 73 x 8 1 22 16 7 N 1 7 kg 13 3 N 1 36 kg ...

Page 251: ...4 Seat 5 Body Outline q The lock valve is installed between the HST charge pump and work equipment PPC valve As the work equipment lock lever is set to the Lock position this valve in conjunction with the work equipment lock lever cuts off the oil of the PPC circuit to disable the work equip ment operation ...

Page 252: ...e charge valve and work equipment PPC valve Even if the engine stops with the work equip ment raised the pressure of the compressed nitrogen gas in the accumulator applies the pilot oil pressure to the work equipment control valve so that the work equipment will lower by its weight Specifications Gas used Nitrogen gas Amount of gas cc 500 Charged pressure MPa kg cm2 1 18 0 2 0 12 2 0 at 80 C Max p...

Page 253: ...Hydraulic system Bypass valve Bypass valve 1 WA250PZ 6 PP From work equipment PPC valve port P4 T From work equipment PPC valve port P3 A To lift cylinder bottom side B To lift cylinder head side 1 Body 2 Plunger 3 Plug 4 Spool 5 Plug 6 Body ...

Page 254: ...alve operates the work equipment control valve and the oil from the work equipment pump flows to the lift cylinder bottom side q At this time the oil of the work equipment PPC valve flows to port T to push spool 1 to the left and closes ports A and B q The oil on the lift cylinder head side flows through the work equipment control valve into the hydraulic tank thus the lift arm rises ...

Page 255: ...s to port PP to push spool 1 to the right and opens ports A and B q When the lift arm is lowered a part of the oil on the lift cylinder bottom side flows through the work equipment control valve into the hydraulic tank A pressure higher than the pressure on the cylinder head side is generated on the cyl inder bottom side by the weight of the work equipment however q The hydraulic pressure generate...

Page 256: ...pment control valve port A2 A To coupler plunger head side B To coupler plunger bottom side 1 Body 2 Solenoid 3 Check valve 1 4 Check valve 2 Outline q When an attachment is installed or removed the quick coupler solenoid valve changes the oil flow for the coupler plunger electrically to extract or retract the coupler plunger and con nect or disconnect the attachment and quick coupler ...

Page 257: ...raulic system ECSS valve ECSS valve 1 if equipped a ECSS Abbreviation for Electronically Controlled Suspension System P From work equipment pump T To hydraulic tank A From lift cylinder bottom B From lift cylinder head SP To accumulator for ECSS ...

Page 258: ...SEN03830 00 WA250 250PZ 6 10 600 61 600 Hydraulic system ECSS valve 1 Main spool 2 Solenoid valve 3 Flow control valve 4 Shuttle valve 5 Charge valve ...

Page 259: ... circuit The space between cylinder 3 and free piston 4 is filled with nitrogen gas The nitrogen gas absorbs the oil pressure pulses generated on the lift cylinder bottom side during travel for higher travel performance and operating performance by utilizing its com pressibility Specifications Gas used Nitrogen gas Amount of gas cc 3 000 Charged pressure MPa kg cm2 2 0 0 1 20 1 at 20 C Max pressur...

Page 260: ...SEN03830 00 WA250 250PZ 6 10 600 63 600 Hydraulic system Accumulator for ECSS ...

Page 262: ...0 6 WA250PZ 6 Machine model Serial number WA250 6 75001 and up WA250PZ 6 75001 and up 10 Structure function and maintenance standard 10 700 Work equipment Work equipment linkage 2 Bucket 6 Bucket positioner and boom kick out 10 Work equipment cylinder 23 ...

Page 263: ...SEN03831 00 10 700 2 WA250 250PZ 6 700 Work equipment Work equipment linkage Work equipment linkage 1 WA250 6 ...

Page 264: ...6 0 090 0 207 0 120 0 156 0 297 1 0 13 Clearance between bushing and pin connecting lift cylinder rod and lift arm 75 0 030 0 076 0 174 0 100 0 130 0 250 1 0 14 Clearance between bushing and pin connecting lift cylinder bottom and frame 70 0 030 0 076 0 174 0 100 0 130 0 250 1 0 15 Connecting part of bucket cylinder and frame Width of boss Width of hinge Standard clearance Adjust shim so that clea...

Page 265: ...SEN03831 00 10 700 4 WA250 250PZ 6 700 Work equipment Work equipment linkage WA250PZ 6 ...

Page 266: ...6 0 090 0 207 0 120 0 156 0 297 1 0 14 Clearance between bushing and pin connecting lift cylinder rod and lift arm 75 0 030 0 076 0 174 0 100 0 130 0 250 1 0 15 Clearance between bushing and pin connecting lift cylinder bottom and frame 70 0 030 0 076 0 174 0 100 0 130 0 250 1 0 16 Connecting part of bucket cylinder and frame Width of boss Width of hinge Standard clearance Adjust shim so that clea...

Page 267: ...SEN03831 00 10 700 6 WA250 250PZ 6 700 Work equipment Bucket Bucket 1 WA250 6 1 Bucket 2 Bolt on cutting edge 3 Bucket teeth if equipped 4 Adapter if equipped ...

Page 268: ... Check item Criteria Remedy 5 Wear of cutting edge thickness Standard size Repair limit Reverse or replace 31 8 19 6 Wear of cutting edge length 90 5 7 Wear of bucket teeth Tooth 46 21 Replace Tip tooth 48 36 8 Clearance in adapter mounting parts Max 0 5 Adjust or replace ...

Page 269: ...SEN03831 00 10 700 8 WA250 250PZ 6 700 Work equipment Bucket WA250PZ 6 1 Bucket 2 Bolt on cutting edge 3 Bucket teeth if equipped 4 Adapter if equipped ...

Page 270: ... Check item Criteria Remedy 5 Wear of cutting edge thickness Standard size Repair limit Reverse or replace 31 8 19 6 Wear of cutting edge length 90 5 7 Wear of bucket teeth Tooth 46 21 Replace Tip tooth 48 36 8 Clearance in adapter mounting parts Max 0 5 Adjust or replace ...

Page 271: ...positioner and boom kick out 1 WA250 6 1 Bucket positioner proximity switch 2 Boom kick out proximity switch 3 Bar 4 Bucket cylinder 5 Lift arm 6 Plate Unit mm No Check item Criteria Remedy 7 Clearance on bucket positioner proximity switch 3 5 Adjust 8 Clearance on boom kick out proximity switch 3 5 ...

Page 272: ...e machine front side As bar 3 moves a specific distance proximity switch 1 detects that it is away from the sens ing face and returns the work equipment bucket control lever to hold position Boom kick out q The boom kick out is driven electrically As the lift arm is raised to an angle before reaching the maximum height the boom kick out returns the work equipment lift arm control lever from the ra...

Page 273: ...rox imity switch 1 turning on the proximity switch 1 lamp At this point bucket positioner relay 4 is ON and current flows to detent solenoid 6 of work equipment PPC valve 5 to energize the coil q Shifting work equipment bucket control lever 7 toward the tilt position moves spool 8 to the position of the arrow And spool is held there by the energized coil of detent solenoid 6 As a result work equip...

Page 274: ... OFF by alternator relay 11 Detent solenoid 6 circuit is turned off since L signal from alternator 10 is not sent to alter nator relay 11 as long as the engine is stopped As the result the work equipment bucket control lever 7 cannot be moved and held in the tilt position as long as bar 2 is positioned in sensing face of proximity switch 1 Function of proximity switch When object of sensing is ove...

Page 275: ...rning on the proximity switch 1 lamp At this point boom kick out relay 4 is ON and current flows to detent solenoid 6 of work equipment PPC valve 5 to energize the coil q Shifting work equipment lift arm control lever 7 toward the raise position moves spool 8 to the position of the arrow And spool is held there by the energized coil of detent solenoid 6 As a result work equipment lift arm control ...

Page 276: ...N or OFF by alternator relay 11 Detent solenoid 6 circuit is cut off since L sig nal from alternator 10 is not sent to alternator relay 11 as long as the engine is stopped As the result the work equipment lift arm control lever 7 cannot be moved and held in the raise position as long as plate 2 is posi tioned in sensing face of proximity switch 1 Function of proximity switch When object of sensing...

Page 277: ... 6 1 Fork positioner proximity switch 2 Bucket positioner proximity switch 3 Boom kick out proximity switch 4 Bar 5 Bucket cylinder 6 Lift arm 7 Plate Unit mm No Check item Criteria Remedy 8 Clearance on bucket positioner proximity switch 3 5 Adjust 9 Clearance on boom kick out proximity switch 3 5 ...

Page 278: ...ty switches 1 and 2 detect that it is away from the sensing face and return the work equip ment bucket or fork control lever to hold position q While the attachment selector switch of the right hand console is in the BUCKET posi tion proximity switch 2 operates While the former is in the FORK position proximity switch 1 operates Boom kick out q The boom kick out is driven electrically As the lift ...

Page 279: ...oner bar 2 moves on to the sensing face of prox imity switch 1 turning on the proximity switch 1 lamp At this point bucket positioner relay 4 is ON and current flows to detent solenoid 6 of work equipment PPC valve 5 to energize the coil q Shifting work equipment bucket control lever 7 toward the tilt position moves spool 8 to the position of the arrow And spool is held there by the energized coil...

Page 280: ... OFF by alternator relay 11 Detent solenoid 6 circuit is turned off since L signal from alternator 10 is not sent to alter nator relay 11 as long as the engine is stopped As the result the work equipment bucket control lever 7 cannot be moved and held in the tilt position as long as bar 2 is positioned in sensing face of proximity switch 1 Function of proximity switch When object of sensing is ove...

Page 281: ...rning on the proximity switch 1 lamp At this point boom kick out relay 4 is ON and current flows to detent solenoid 6 of work equipment PPC valve 5 to energize the coil q Shifting work equipment lift arm control lever 7 toward the raise position moves spool 8 to the position of the arrow And spool is held there by the energized coil of detent solenoid 6 As a result work equipment lift arm control ...

Page 282: ...N or OFF by alternator relay 11 Detent solenoid 6 circuit is cut off since L sig nal from alternator 10 is not sent to alternator relay 11 as long as the engine is stopped As the result the work equipment lift arm control lever 7 cannot be moved and held in the raise position as long as plate 2 is posi tioned in sensing face of proximity switch 1 Function of proximity switch When object of sensing...

Page 283: ...SEN03831 00 10 700 22 WA250 250PZ 6 700 Work equipment Bucket positioner and boom kick out ...

Page 284: ...Clearance limit Replace bushing Shaft Hole Lift 70 0 030 0 104 0 271 0 075 0 105 0 375 0 675 Bucket 75 0 030 0 104 0 291 0 077 0 107 0 395 0 695 2 Tightening torque of cylinder head Lift 1 030 103 Nm 105 10 5 kgm Retighten Tightening torque of cylinder head mounting bolt Bucket 250 24 5 Nm 25 5 2 5 kgm 3 Tightening torque of cylinder piston locknut Lift 3 970 397 Nm 405 40 5 kgm width across flats...

Page 285: ...SEN03831 00 10 700 24 WA250 250PZ 6 700 Work equipment Work equipment cylinder WA250PZ 6 Lift cylinder Bucket cylinder Coupler plunger ...

Page 286: ...9 0 011 0 153 0 453 2 Tightening torque of cylinder head Lift 1 030 103 Nm 105 10 5 kgm Retighten Tightening torque of cylinder head mounting bolt Bucket 343 34 5 Nm 35 3 5 kgm Tightening torque of cylinder head Coupler plunger 294 29 4 Nm 30 3 0 kgm 3 Tightening torque of cylinder piston locknut Lift 3 970 397 Nm 405 40 5 kgm width across flats 80 mm Tightening torque of cylinder piston Bucket 29...

Page 288: ...0 1 SEN03832 00 WHEEL LOADER WA250 6 WA250PZ 6 Machine model Serial number WA250 6 75001 and up WA250PZ 6 75001 and up 10 Structure function and maintenance standard 10 800 Cab and its attachments Cab 3 Air conditioner 4 ...

Page 289: ...SEN03832 00 10 800 2 WA250 250PZ 6 800 Cab and its attachments ...

Page 290: ...3 800 Cab and its attachments Cab Cab 1 1 Front working lamp 2 Radio antenna 3 Door left 4 Air conditioner external air filter 5 Front glass 6 Front wiper 7 KOMTRAX GPS antenna 8 KOMTRAX communication antenna 9 Door right 10 Rear wiper ...

Page 291: ...SEN03832 00 10 800 4 WA250 250PZ 6 800 Cab and its attachments Air conditioner Air conditioner 1 Air conditioner piping diagram 1 ...

Page 292: ...r 4 Receiver 5 Hot water return piping 6 Refrigerant piping 7 External air filter 8 Internal external air changeover damper 9 Blower unit 10 Air conditioner unit 11 Dual pressure switch 12 Air outlet duct 13 Cool and hot box if equipped 14 Internal air filter Specifications Refrigerant used R134a Refrigerant refilling level g 900 ...

Page 293: ...m Criteria Remedy 7 Air conditioner unit refrigerant inlet side 12 15 1 2 1 5 screw size M16 x 1 5 Retighten 8 Air conditioner unit refrigerant outlet side 30 35 3 1 3 6 screw size M24 x 1 5 9 Receiver refrigerant pipe set bolt 8 12 0 8 1 2 screw size M16 x 1 0 10 Compressor refrigerant piping lock bolt 20 25 2 0 2 6 screw size M8 x 1 25 11 Condenser refrigerant inlet side 20 25 2 0 2 6 screw size...

Page 294: ... and heater core 2 is synchronized with the blower and intake unit to generate cool and hot air q The temperature adjusting switch on the air conditioner panel controls air mix dampers 3 and 4 to adjust the spurting out temperature Cooler q The cooler circulates refrigerant through evap orator 1 to cause heat exchange dehumidifi cation and cooling q Air taken in by the blower and intake unit is co...

Page 295: ...coil As the relay coil is energized and the switch is turned ON the magnet clutch of the compressor is connected Air mix damper actuator q It starts the built in motor receiving signal cur rent from the air conditioner panel in order to open or close the air mix damper through the link mechanism q The motor rotating direction is determined as the air conditioner panel reads the position of the pot...

Page 296: ...ng the absorbed air to the evaporator and heater core Internal external air changeover damper actua tor q Receiving signal current from the air condi tioner panel it starts the built in motor to open or close the internal external air changeover damper through the link mechanism q The motor rotation direction is determined from the internal external air changeover switch on the air conditioner pan...

Page 297: ... tor to high pressure high temperature misty refrigerant so that it may be easily regenerated liquefied at normal temperature q Its built in magnet clutch turns on or off depending on the evaporator temperature and refrigerant pressure Specifications Number of cylinders Bore x Stroke mm 7 29 3 x 27 4 Piston capacity cc rev 129 2 Allowable maximum speed rpm 4 000 Refrigerant oil used Sanden SP 10 R...

Page 298: ...in crushes or is clogged with dusts heat exchange efficiency is degraded and complete liquefaction of refrigerant becomes unavail able As the result pressure in the refrigerant circulation circuit will be increased applying extra load to the engine or degrading the cool ing effect Thus care must be used in its han dling and daily inspection Specifications Fin pitch mm 1 5 Total heat dissipation ar...

Page 299: ...nser It is capable of completely liquefying the refrigerant even when bubbles are con tained in the refrigerant due to the condenser condition in heat dissipation q It eliminates foreign substances in the circula tion circuit and water content in the refrigerant by use of the built in filter and desiccating agent q Sight glass 1 allows inspecting flow of the refrigerant Specifications Effective cu...

Page 300: ...SEN03832 00 WA250 250PZ 6 10 800 13 800 Cab and its attachments Air conditioner ...

Page 301: ... Air conditioner When air conditioner switch is ON Turns ON air conditioner switch this lamp lights up No Switch name Function Operation 5 Internal external air changeover switch This switch is used to select either the circulation of internal air or introduction of external air pilot display on the display unit is switched depending on the switch setting Circulation of internal air I O Introducti...

Page 302: ...t 8 Night lamp signal Input 9 NC 10 NC 11 NC 12 NC 13 Day light sensor 2 Input 14 Day light sensor 1 Output JAE IL AG5 22P CN C47 Pin No Signal name Input and output signals 1 NC 2 NC 3 Blower motor relay Input 4 Internal external air changeover damper actuator output 1 Output 5 Internal external air changeover damper actuator output 2 Output 6 Mode selector actuator output 2 Output 7 Mode selecto...

Page 304: ...33 01 WHEEL LOADER WA250 6 WA250PZ 6 Machine model Serial number WA250 6 75001 and up WA250PZ 6 75001 and up 10 Structure function and maintenance standard 10 910 Electrical system Part 1 Machine monitor system 2 Machine monitor 6 ...

Page 305: ... state of the optional device selecting function q Travel speed or engine speed indication on the character display 2 Items displayed when abnormality is detected q Caution lamps q Action code while an action code is dis played if the machine monitor mode selector switch is pressed and released the failure code 6 digits is dis played 3 At the replacement period of a filter or oil the character dis...

Page 306: ...g cylinder having defective combustion by stopping fuel injection to each cylinder from the fuel injector 5 No injection cranking function Before restarting engine after a long term stor ing of the machine this function is used to lubricate the engine internally 6 Adjustment function Functions are provided to correct and adjust the installation errors and manufacturing dis persion of the sensors s...

Page 307: ...SEN03833 01 10 910 4 WA250 250PZ 6 910 Electrical system Part 1 Machine monitor system System circuit diagram 1 a Items marked with 1 in drawing may or may not installed ...

Page 308: ...SEN03833 01 WA250 250PZ 6 10 910 5 910 Electrical system Part 1 Machine monitor system ...

Page 309: ... HST oil filter clogging caution lamp 18 Air cleaner clogging caution lamp 1 19 Parking brake pilot lamp 20 Brake oil temperature caution lamp 21 Quick coupler operation pilot lamp 2 22 Cooling fan reverse rotation pilot lamp 23 Maintenance caution lamp 24 Parking brake reminder caution lamp 25 Battery charge circuit caution lamp 26 Steering oil pressure caution lamp 2 27 Emergency steering pilot ...

Page 310: ...ral warning lamp Display of message Central warning lamp 11 Central warning LED When error occurs E E E E E E E E Red Turned ON with errors E03 and E02 of each controller simultaneously displaying the message on the character display For other than above see Operating condition central warning lamp of other items Back light Back light LED When lamp switch is other than OFF White Gauges and meters ...

Page 311: ... gear speed is selected 0 0 Q Q Green Other symbols 6 8 Turn signal LED When turn signal lever and hazard lamp switch signal is input 0 0 Q Q Green Hazard lamp operates when starting switch is turned OFF 7 Head lamp high beam LED When head lamp is set to high beam when head lamp is ON and dimmer switch is ON 0 0 Q Q Blue 12 Brake oil pressure LED Normal oil pressure CLOSE Red Below set pressure OP...

Page 312: ... than below Red Error message is displayed on the character display as long as parking brake is left unapplied The alarm continues as long as starting switch is turned OFF This function can be enabled when MECHA is selected for 7 PKG BRAKE from the Option device selecting function of the machine monitor When parking brake is left unapplied CLOSE 0 0 w Q Q Remarks 25 Battery charge circuit LED Norm...

Page 313: ...on 0 0 A w Q A w Q 32 Economy operation LED Other than below 0 0 Green Economy mode operation 0 0 Q Q 34 S mode operation LED Other than below Green The lamp goes off when traction control is reset from max traction switch When traction control is reset with max traction switch the lamp is lit again when directional lever position is switched S mode operation is selected 0 0 Q Q 35 Traction contro...

Page 314: ...SEN03833 01 WA250 250PZ 6 10 910 11 910 Electrical system Part 1 Machine monitor Machine monitor operation switch 1 1 Machine monitor mode selector switch 1 2 Machine monitor mode selector switch 2 ...

Page 315: ... SW6 2 10 Spare dip switch SW6 3 11 Spare dip switch SW6 4 a It is prohibited to change setting of spare rotary switch and DIP switch Troubleshooting function 1 q The machine monitor monitors the input and output signals constantly for troubleshooting for the sys tem q If each controller detects abnormality by the self diagnosis abnormality information is forwarded to the machine monitor over the ...

Page 316: ... The range where operator is enabled to operate is within the portion of the Operator mode in the figure below a For the operating method in the operator mode see the Operation and maintenance manual 1 When an ID entered from the ID entry screen is once approved display changes directly to the Select function screen without displaying the ID entry screen until the starting switch is turned OFF ...

Page 317: ...and the menu of Engine speed display non display setting is set to rpm OFFoON in the Display of functions opened to the operator engine speed is displayed to the character display when the travel speed is displayed at the center of the monitor q When the engine speed is displayed at the center of the monitor travel speed is displayed to the charac ter display q Pressing the U switch changes the sc...

Page 318: ...me priority the item that occurred most recently will be displayed first Example of a failure code screen simultaneously occurring errors DX16KA B BCZK and CA431 1 The screen automatically returns to the Warning screen if the switch is not pressed more than 10 sec onds in the Normal screen display 2 The screen returns to the Warning screen if the switch is not pressed more than 30 seconds in the f...

Page 319: ...conds in the screen display of each menu q The language will be displayed as set in the Language selection function a See the Operation and maintenance manual for details of each menu 1 These menus are displayed when ADD is selected for 13 RPM SPEED item from the Optional device selecting function of the machine monitor 2 These menus are displayed when ADD is selected for 12 RPM OPT item from the ...

Page 320: ... monitor mode selector switches 1 and 2 and enter ID ID 6491 1 The cursor C is located at the highest order digit Pressing or switch changes the value of this digit in the range of 0 to 9 2 Press U switch at the target value to val idate it a The cursor moves to the 2nd digit position 3 Confirm the values for the 2nd digit and onward following the same procedure a If you have entered a wrong value...

Page 321: ...ing or switch on the menu screen switches individual menus of the service mode sequen tially and endlessly a Pressing U switch on the target menu screen changes the screen to the detailed screen of the same menu a Pressing t switch on the menu screen returns the screen to the 1st layer of the operator mode ...

Page 322: ...re history currently recorded max 20 histories to be stored q The history is used to check on the mechanical system failures of each controller saved in the machine monitor a For the operating procedure of this function see Special functions of machine monitor EMMS in Testing and adjusting Real time monitoring function REAL TIME MONITOR q This function is used to check on the input out put signals...

Page 323: ...stics is provided on user request These functions are also used when sensors valves and controllers are replaced or added a For the operating procedure of this function see Special functions of machine monitor EMMS in Testing and adjusting Maintenance monitoring function MAINTE NANCE MONITOR q This function is used for changing the filter and oil replacement timing and making ON OFF selection of t...

Page 324: ...ng or entering the serial number of machine Serial number of the set machine is used for controlling the machine a For the operating procedure of this function see Special functions of machine monitor EMMS in Testing and adjusting Model selection function MACHINE q This function is used for displaying or changing the setting of model information machine name a For the operating procedure of this f...

Page 325: ...supply 24 V I Constant power supply 24 V NSW power supply 24 V 6 SW power supply 24 V I Power supply 24 V SW power supply 24 V 7 SW power supply 24 V I Power supply 24 V SW power supply 24 V 8 NC 9 GND I GND GND 10 GND I GND GND 11 D_OUT_3 24 V sink 200 mA O A D O sink ECSS relay If equipped 12 D_OUT_2 24 V sink 200 mA O A D O sink Back up lamp 13 D_OUT_1 NC 14 D_OUT_0 24 V sink 200 mA O A D O sin...

Page 326: ...automatic reverse rotation switch automatic 15 NC 16 D_IN_13 NSW24 V 5 mA I C D I 24 V Turn signal lamp left 17 D_IN_15 NSW24 V 5 mA I C D I 24 V t switch 18 A_IN_0 0 30 V I H A I Alternator L signal AMP070 12P 1 CN L26 Pin No Specifications I O Group Form of use Signal name Remarks 1 D_IN_16 24 V GND 5 mA I D D I GND Brake oil pressure 2 NC 3 D_IN_20 24 V GND 5 mA I D D I GND air cleaner clogging...

Page 327: ...D switch 8 NC 9 GND O GND GND 10 D_IN_27 24 V GND 5 mA I E D I GND Coolant level 11 D_IN_29 24 V GND 5 mA I E D I GND engine oil level 12 NC 13 NC 14 D_IN_35 24 V GND 5 mA I F D I GND Parking brake left unapplied prevention dummy 15 D_IN_37 24 V GND 5 mA I G D I GND switch 16 D_IN_39 24 V GND 5 mA I G D I GND Operation of emergency steering If equipped 17 NC 18 NC AMP070 12P 2 CN L28 Pin No Specif...

Page 328: ...ifications I O Group Form of use Signal name Remarks 1 NC 2 NC 3 CAN I O P CAN CAN 4 NC 5 NC 6 GND O GND GND 7 NC 8 CAN I O P CAN CAN 9 NC 10 NC 11 NC 12 NC AMP070 14P CN L30 Pin No Specifications I O Group Form of use Signal name Remarks 1 NC 2 NC 3 NC 4 NC 5 NC 6 NC 7 NC 8 NC 9 NC 10 NC 11 NC 12 NC 13 NC 14 NC ...

Page 329: ...nect wiring harness on machine 6 NC Do not connect wiring harness on machine 7 NC Do not connect wiring harness on machine 8 NC Do not connect wiring harness on machine Switch No Specifications I O Group Form of use Signal name Remarks 1 16 Posi rotary switch 1 I spare 2 16 Posi rotary switch 2 I spare 3 16 Posi rotary switch 3 I spare 5 1 26 Posi DIP switch 1 I spare 2 26 Posi DIP switch 2 I spar...

Page 330: ...SEN03833 01 WA250 250PZ 6 10 910 27 910 Electrical system Part 1 Machine monitor ...

Page 332: ...rd 10 920 Electrical system Part 2 Electrical system HST controller system 2 HST controller 18 ECSS system 20 KOMTRAX system 22 Engine starting circuit 24 Engine stopping circuit 26 Preheating circuit 27 Engine output derating function 28 Automatic warm up function 28 Parking brake circuit 29 Coupler plunger control system 32 Multi function knob 33 Max traction switch 34 Sensor 35 ...

Page 333: ...ake lever bottom switch D o o D HST safety relay Sensor input Speed sensor A P o o C Throttle upper limit Eng_con CAN output Speed sensor B P o o C Throttle lower limit Eng_con HST oil pressure sensor A o o C Automatic warm up cancel Eng_con CAN input Engine speed Eng_con C o o C Monitor display information Eng_con Failure code real time monitor pilot lamp alarm buzzer etc Accelerator pedal angle ...

Page 334: ...ching modulation Relationship between accelerator pedal angle and travel speed A for switching HST motor 2 capacity Selected speed range Travel speed range km h Clutch solenoid output HST motor 1 solenoid output HST motor 2 solenoid output Variable shift control signal input voltage V 1st 0 13 depends on the variable shift control signal ON MAX MID Fixed to MAX ON 0 9 4 1 2nd 0 13 ON MAX MID Fixed...

Page 335: ...chine monitor may turn on at the same time As the directional lever is set to R reverse the HST controller activates the backup lamp relay to light the reverse lamp and sound the back up alarm 2 Speed range indicator The travel speed range selector switch position pilot lamp of the machine monitor displays the state of the travel speed range selector switch being sent to the HST controller Variabl...

Page 336: ...rough control of the drive force And by securing smooth start of the machine this function offers enhanced operating perfor mance q The S mode operation pilot lamp of the machine monitor remains lighted as long as the S mode opera tion is continued a The traction force control in the S mode is enabled when the directional lever is set to the forward posi tion and the machine is traveling forward o...

Page 337: ...position does not reduce the maximum traction force In this case the maximum traction force remains at the same level as when the traction control switch is set to the OFF position q As clockwise turning of the variable shift con trol switch 2 is continued the traction force approaches the maximum traction force being set from the Traction level selecting function of the machine monitor q It is po...

Page 338: ...long as the traction control or S mode is cancelled from the max traction switch the traction control operation pilot lamp or S mode operation pilot lamp of the machine monitor remains turned off a Holding down the max traction switch for a second or longer cancels the traction control or S mode as long as it is held down The traction control or S mode is restored at the moment the switch is relea...

Page 339: ...tch ing modulation Gear shift operation Behavior after gear shift Switch position before gear shift State of transfer clutch after gear shift Switch position after gear shift Actual speed range after gear shift Display of message Remarks 1st Connected 2nd 2nd Not displayed Gear shift available independent of traveling speed 3rd 3rd 4th 4th 2nd Connected 1st 1st Not displayed Gear shift available i...

Page 340: ...q This error state is reset as the travel speed goes below 39 5 km h or less a Above error message is not sent to KOMTRAX terminal Engine overrun prevention function q If the HST motor 2 capacity reaches its allowable rotating speed when the machine travels downhill at a high speed the HST pump and engine rotation becomes high speed This function prevents the HST motor 2 to overrun beyond the allo...

Page 341: ... as long as the low fuel consumption operation is continued q The economy operation pilot lamp lights up as the opening ratio of the accelerator pedal is maintained at less than 75 for 0 5 seconds or longer q The economy operation pilot lamp can be constantly turned off by selecting NO ADD for 4 ECO LAMP item from the Optional device selecting function of the machine monitor a For the setting proc...

Page 342: ...ing fan reverse solenoid valve relay 10 HST oil temperature sensor 11 Boost pressure and oil temperature sensor 12 Coolant temperature sensor 13 Engine speed sensor 14 Engine 15 Radiator Input and output signals HST controller a CAN signal b Cooling fan motor flow rate control signal c Cooling fan reverse signal Machine monitor d Cooling fan automatic reverse signal e Cooling fan manual reverse si...

Page 343: ...ller sends the signal current to the cooling fan motor flow rate control EPC valve in order to set the fan speed to a level suitable for the respective tempera ture levels and the engine speed Fan speed in accordance with temperature 1 The target fan speed is determined based on the coolant temperature HST oil temperature or boost air temperature data whichever is the highest 2 Within this range t...

Page 344: ...en turned ON again the control is implemented one more time if the control starting conditions are met The control derating of the minimum fan speed at start of engine is carried out if every condition in the fol lowing table is met 1 When the fan speed control conditions at low temperature are not applicable and the minimum boost air temperature is 20 C or above Point A Starting switch is turned ...

Page 345: ...irement 1 200 rpm is exempted when the HST oil temperature is 30 C or above 2 Overheat prevention function If overheat in the coolant temperature HST oil temperature or boost air temperature was recognized while the fan was rotating reverse the reverse rotation is forcibly stopped and the forward rotation is turned on in order to increase the air flow to the radiator 3 Fan speed during reverse rot...

Page 346: ...ttable for the reverse rotation duration by adjusting the items Adjustment of interval of fan automatic reverse operation and Adjustment of continuance of fan automatic reverse operation with the adjusting func tion of the machine monitor a For the adjustment procedure see Special functions of machine monitor EMMS in Testing and adjusting Condition 1 The fan reverse rotation switch is set to AUTO ...

Page 347: ...SEN03834 01 10 920 16 WA250 250PZ 6 920 Electrical system Part 2 Electrical system HST controller system System circuit diagram 1 a Items marked with 1 in drawing may or may not installed ...

Page 348: ...SEN03834 01 WA250 250PZ 6 10 920 17 920 Electrical system Part 2 Electrical system HST controller system ...

Page 349: ...wer holding relay Output 27 HST motor 2 solenoid relay Output 8 NC 28 CAN0_H Input Output 9 Clutch solenoid Output 29 Cooling fan motor flow rate control EPC Output 10 HST pump F solenoid Output 30 VIS solenoid power Input 11 VB controller power Input 31 GND controller GND 12 Starting switch ACC signal Input 32 GND sensor GND 13 Alternator L signal Input 33 HST oil pressure sensor Input 14 Directi...

Page 350: ...SEN03834 01 WA250 250PZ 6 10 920 19 920 Electrical system Part 2 HST controller ...

Page 351: ...al g ECSS cut off signal h ECSS cut off dummy signal Outline q When the machine travels at high speed the damping effect of the accumulator charged with high pressure gas and the automatic con trol of the lift cylinder circuit relief pressure under each travel condition damp the vertical movement of the work equipment and reduce rocking of the chassis As a result the operator comfort is improved s...

Page 352: ... A is obtained by deducting 1 km h from that available at the switching point B namely 4 7 km h a When tilting the bucket or lowering the lift arm turn OFF the ECSS operation signal to reset ECSS WA250PZ 6 a For the adjustment procedure see Special functions of machine monitor EMMS in Test ing and adjusting q The operating condition of PPC oil pressure switch is as follows ECSS switch Travel speed...

Page 353: ...operator is allowed to reference these information in the office and offer them to the cus tomer through various services a When offering the information to the customer it is required to separately implement the KOMTRAX system station opening procedure The information transmitted from the KOMTRAX terminal includes the following 1 Traveling map 2 Service meter 3 Position information 4 Error histor...

Page 354: ...nction q There are the LED lamp and the 7 segment indicator lamp in the display area and these lamps are used for the testing and the trouble shooting DEUTSCH 40P CN L80 Pin No Signal name Input Output signal Pin No Signal name Input Output signal 1 NC 21 Operation mode selection 1 Input 2 NC 22 Operation mode selection 2 Input 3 NC 23 NC 4 NC 24 NC 5 NC 25 NC 6 NC 26 NC 7 CAN0_L Input Output 27 S...

Page 355: ...ine controller cut out relay 19 CAN resistor 20 Directional selector switch operating switch 21 Directional selector switch Function 1 The neutral safety circuit is employed to secure safety when the engine is started q The engine can not be started while the directional lever is at any position other than N neutral q When the directional selector switch oper ating switch is turned ON the directio...

Page 356: ...N if both the directional lever and directional selec tor switch are at N neutral at this point the neutral safety relay is activated 3 When starting switch is set to START q As the starting switch is set to START the current flows through the starting switch terminal C KOMTRAX engine cut out relay and neutral safety relay to the starting motor safety relay to start the engine q When the direction...

Page 357: ...ne controller cut out relay work ing to maintain the current flow to the engine controller until its internal processing is com plete q As ACC signal is cut off the engine lowers its speed and stops At the same time the alter nator stops power generation stopping supply of the voltage from the alternator terminal L And the current from the starting switch termi nal BR is also stopped and the conta...

Page 358: ... q Setting the starting switch to ON lights the preheater pilot lamp of the machine monitor and starts preheating of intake air with the electrical intake air heater The engine controller sets the preheating dura tion referencing the intake air temperature being sent from the boost pressure sensor and temperature sensor q The pilot lamp remains turned on as long as preheating is continued Keep the...

Page 359: ...ed q If the coolant temperature is below 20 C at starting of the engine this function increases the low idle speed to 1 000 rpm The condition required for increasing the low idle speed depends on the coolant temperature as shown in the figure below The automatic warm up function is reset and the engine speed returns to 825 rpm as any of the fol lowing conditions is met Condition 1 The coolant temp...

Page 360: ... 1 1 Parking brake lever intermediate switch 2 Parking brake lever bottom switch 3 HST controller 4 Machine monitor 5 Alarm buzzer 6 HST controller power holding relay 7 HST safety relay 8 Clutch solenoid valve 9 HST motor 1 solenoid valve 10 HST pump forward solenoid valve 11 HST pump reverse solenoid valve ...

Page 361: ... is set to the mid position the bottom switch 2 is open but intermediate switch 1 is closed q The parking brake pilot lamp comes on only when the starting switch is ON q As bottom switch 2 opens the output to the forward and reverse solenoid valves of HST pump is stopped to prevent dragging of the parking brake And at the same time the directional lever and the directional selector switch are disa...

Page 362: ...comes on only when the starting switch is ON q The parking brake reminder caution lamp goes off independent of the given state q As bottom switch 2 opens the output to the forward and reverse solenoid valves of HST pump is stopped to prevent dragging of the parking brake And at the same time the directional lever and the directional selector switch are disabled to turn on the machine travel in bot...

Page 363: ...ion quick coupler sole noid valve 2 is energized If the work equipment bucket control lever is moved to the tilt side the oil flows into the head side of coupler plunger 3 Then coupler plunger 3 is retracted and the attachment and coupler are released When quick coupler attachment switch is in Connect position q If the quick coupler attachment switch 1 is set in the Connect position quick coupler ...

Page 364: ... 3 Option switch Reserved Function q Directional selector switch 1 is an alternate type Its control signal sent to the HST control ler causes switching between the forward and reverse travel q Max traction switch 2 and option switch 3 are momentary type Max traction switch 2 control signal sent to the HST controller can cels the traction control temporarily ...

Page 365: ...ness 2 Switch B yellow wiring harness 3 Spring 4 Wiring harness Function q These switches are installed on the knob of the work equipment lift arm control lever Switch A 1 functions as the max traction switch and switch B 2 does not function q Both of switch A 1 and switch B 2 are of momentary type that is their contacts are closed only while they are pressed ...

Page 366: ...Speed sensor 1 Hall IC 2 Circuit board 3 O ring 4 Housing 5 Heat shrink tube 6 Protective tube 7 Lead wire 8 Connector Function q The speed sensor is installed on the transfer case It generates two different types of pulses depending on the rotational direction and speed of the gear ...

Page 367: ...d on the motor 2 hydraulic piping and front axle respectively They generate the signal for the change in temperature as variation in the resistance of the thermistor HST oil pressure sensor Function q The HST oil pressure sensor is installed on the motor 2 solenoid block to measure the oil pressure in the HST circuit and generate the corresponding signal 1 Connector 2 Plug 3 Thermistor 1 Sensor 2 ...

Page 368: ...on the HST oil filter to monitor the oil pressure before and after the filter If the pressure goes beyond the specified level the switch is set to ON Coolant level sensor 1 Float 2 Sensor 3 Connector 4 Sub tank Function q This sensor is installed in the bulkhead As the coolant goes below the specified level the float moves down and the switch is set to OFF ...

Page 369: ... of the fuel tank The float moves up and down according to the fuel level The float moves the variable resistor through the arm The resistance changes according to the operat ing angle and signal voltage is generated from the source voltage according to the change of the resis tance 1 Connector 2 Float 3 Arm 4 Body 5 Spring 6 Contact 7 Spacer ...

Page 370: ...lerator pedal pressing angle Accelerator signal q Magnitude of the accelerator pedal displace ment being detected by the sensor is output in variable voltage from No 2 pin Idle validation signal q The sensor detects the accelerator pedal oper ation As the accelerator pedal is released it outputs the signal being entered to No 5 pin from No 4 pin And as the accelerator pedal is pressed it outputs t...

Page 371: ...sensed Boom kick out proximity switch Bucket positioner proximity switch 1 Switch 2 Locknut 3 Operation indication lamp 4 Connector Function q The boom kick out proximity switch is installed in the lift arm left side connecting part of the front frame And the bucket positioner proximity switch is installed on the bucket cylinder As long as the plate is positioned on the detector plane the switch l...

Page 372: ...SEN03834 01 WA250 250PZ 6 10 920 41 920 Electrical system Part 2 Sensor ...

Page 374: ... LOADER WA250 6 WA250PZ 6 Machine model Serial number WA250 6 75001 and up WA250PZ 6 75001 and up 20 Standard value table 20 100 Standard service value table Standard service value table for engine 2 Standard service value table for chassis 3 ...

Page 375: ...pera ture Within operating range At rated output Pollution level Max 12 22 At sudden acceleration Max 25 35 Valve clearance Normal temperature Intake valve mm 0 25 0 05 0 152 0 381 Exhaust valve 0 51 0 05 0 381 0 762 Blow by pressure At rated output Engine coolant temperature Within operating range kPa mmH2O Max 0 98 Max 100 1 96 200 Oil pressure At high idle Engine coolant tempera ture Within ope...

Page 376: ...8 4 9 0 8 0 5 15 7 1 6 Travel 1st 2nd Engine stopped deg 30 5 30 10 2nd 3rd 30 5 30 10 3rd 4th 30 5 30 10 Work equipment control lever Operating effort Lift arm Engine coolant tempera ture Operating range Engine speed Low idle Hydraulic oil temperature 60 80 C HOLD o RAISE N kg 14 7 4 9 0 1 5 0 5 0 29 4 3 RAISE o HOLD 18 6 4 9 0 1 9 0 5 0 35 3 3 6 HOLD o LOWER 12 3 4 9 0 1 25 0 5 0 25 7 2 6 LOWER ...

Page 377: ...utral α1 a For measuring posture see Fig A at end of this section Engine started α α1 α2 deg 45 2 stroke α 17 2 Brake pedal Operating effort Operating angle 20 Engine speed Low idle Hydraulic oil temperature Within operat ing range N kg 294 30 30 3 0 Min 238 Min 24 3 Operating angle Neutral α1 a For measuring posture see Fig B at end of this section Engine speed Low idle Hydraulic oil temperature ...

Page 378: ...Max 0 6 Max 6 Max 0 6 Max 6 Servo piston operating pres sure Hydraulic oil temperature 45 55 C Gear speed selector switch 1st Travel speed control dial 1 on Min side Directional lever Measure in both for ward and reverse position Measure while driving at full throttle Max speed 5 km h 2 6 0 2 0 26 5 2 0 2 6 0 2 26 5 2 Transfer Clutch control pressure Hydraulic oil temperature 45 55 C Directional l...

Page 379: ...he end of this section RAISE 1 Sec 5 9 0 5 Max 8 2 LOWER 3 4 0 5 Max 4 7 Bucket TILT 2 2 3 0 3 Max 3 8 DUMP 1 7 0 3 Max 2 5 TILT 3 1 4 0 3 Max 2 Hydraulic drift Lift arm cylinder Bucket no load Position of work equipment Lift arm and bucket in level position Engine stopped Hydraulic oil temperature 45 55 C Stop engine and leave for 5 minutes then measure for 15 minutes a For measuring posture see ...

Page 380: ...35 00 WA250 250PZ 6 20 100 7 100 Standard service value table Standard service value table for chassis Machine posture and procedure for performance measurement a Fig A a Fig B a Fig C a Fig D a Fig E a Fig F ...

Page 381: ...SEN03835 00 20 100 8 WA250 250PZ 6 100 Standard service value table Standard service value table for chassis a Fig G a Fig H a Fig J ...

Page 382: ...SEN03835 00 WA250 250PZ 6 20 100 9 100 Standard service value table Standard service value table for chassis ...

Page 384: ... 20 Measuring intake air boost pressure 21 Handling fuel system equipment 23 Releasing residual pressure in fuel system 23 Measuring fuel pressure 24 Measuring fuel return rate and leakage 26 Bleeding air from fuel circuit 30 Testing leakage in fuel system 31 Handling reduced cylinder mode operation 32 Handling no injection cranking operation 32 Handling controller voltage circuit 33 Check of muff...

Page 385: ...SEN03836 01 30 110 2 WA250 250PZ 6 110 Testing and adjusting Part 1 Replacing alternator belt 36 ...

Page 386: ...SEN03836 01 30 110 3 WA250 250PZ 6 110 Testing and adjusting Part 1 ...

Page 387: ...g intake air boost pressure F 1 799 101 5002 Hydraulic tester 1 2 799 201 2202 Boost gauge kit 1 101 200 kPa 760 1 500 mmHg Measuring fuel compression pressure G 1 799 101 5002 Hydraulic tester 1 Pressure gauge 2 5 6 40 60 MPa 25 60 400 600 kg cm2 790 261 1204 Digital hydraulic tester 1 Pressure gauge 60 MPa 600 kg cm2 2 6732 81 3170 Adapter 1 10 1 0 mm o R1 8 6215 81 9710 O ring 1 3 799 401 2320 ...

Page 388: ...alog hydraulic tester 1 Pressure gauge 2 5 6 40 60 MPa 25 60 400 600 kg cm2 790 261 1204 Digital hydraulic tester 1 Pressure gauge 60 MPa 600 kg cm2 Testing wheel brake oil pressure S 1 793 605 1001 Brake test kit 1 2 790 101 1430 Coupler 1 3 790 101 1102 Pump 1 4 790 301 1720 Adapter 1 20 1 5 mm o R1 8 5 799 101 5160 Nipple 1 6 799 401 2220 Hose 1 Length 5 m 7 790 261 1130 Coupling 1 Holding work...

Page 389: ...01 4220 T adapter 1 Controller 60 poles 799 601 4140 T adapter 1 Atmospheric pressure sensor 799 601 4340 T adapter 1 Pump actuator 799 601 4260 T adapter 1 Controller 4 poles 799 601 4190 T adapter 1 Common rail pressure sensor Diagnosis for chassis related controller sen sor actuator and har ness Z 799 601 2500 or 799 601 2700 or 799 601 2800 or 799 601 2900 or 799 601 7100 or 799 601 8000 T ada...

Page 390: ...70 1 For 070 12P 799 601 7530 Adapter for 070 1 For 070 14P 799 601 7540 Adapter for 070 1 For 070 18P 799 601 7550 Adapter for 070 1 For 070 20P 799 601 9000 or 799 601 9200 T adapter assembly 1 799 601 9020 Adapter for DT 1 For DT2P Incl in 799 601 4101 and 799 601 4201 799 601 9030 Adapter for DT 1 For DT3P 799 601 9040 Adapter for DT 1 For DT4P Incl in 799 601 4101 and 799 601 4201 799 601 905...

Page 391: ... Commercially available TORX wrench 1 3 26 mm TORX wrench KTC Q4T15 or equivalent Removal and installation of engine coolant temperature sensor Commercially available Socket 1 21 mm deep socket MITOLOY 4ML 21 or equivalent Applicable engine serial No 26500006 26530192 795T 981 1010 Socket 1 19 mm deep socket MITOLOY 4ML 19 or equivalent Applicable engine serial No 26530193 and up Testing and adjus...

Page 392: ...0 250PZ 6 30 110 9 110 Testing and adjusting Part 1 Sketches of special tools Sketches of special tools 1 Note Komatsu cannot accept any responsibility for special tools manufactured according to these sketches Socket ...

Page 393: ...1 ENG SPEED Engine speed 3 Start the engine set it in the measuring condition and measure the engine speed 2 Measuring HST stall speed 1 Referring to Special function of machine monitor select the real time monitoring function of the service mode 2 Select the two item simultaneous monitor ing 2 ITEMS and then enter the following code numbers directly a Monitoring items 1 Code No 01001 ENG SPEED En...

Page 394: ...ngine speed a Finish measurement in a short time so that the hydraulic oil temperature will not exceed 120 C 4 Measuring HST stall and hydraulic stall full stall speed 1 Set the machine monitor as in 2 Measur ing HST stall speed 2 Start the engine 3 Lower the bucket to near the ground then drive the machine forward and thrust the bucket into the stockpile of soil or rock portion a 4 While running ...

Page 395: ... handle of smoke checker A1 so that the filter paper will absorb the exhaust gas 5 Take out the filtering paper and compare it with the attached scale for judgement 6 Remove the measurement tool after the measurement and make sure that the machine is back to normal condition 2 Measuring with smoke meter A2 1 Insert the probe of smoke meter A2 in the outlet of the muffler exhaust pipe and fix it to...

Page 396: ...ting range 7 Accelerate the engine suddenly or run it at high idle and press the accelerator pedal of smoke meter A2 and collect the exhaust gas into the filter paper 8 Put the polluted filtering paper on non pol luted filtering paper more than 10 sheets in the filtering paper holder and read the indicated value 9 After finishing work remove the used instruments and return the removed parts ...

Page 397: ...thin the range of wide slit b when it is seen from the air conditioner compressor side a If you can see the yellow marks c of pro jection top a and the damper periphery you may set them to each other a After the above positioning the No 1 cyl inder or No 6 cylinder is not at the top dead center TDC Take care The cylin der is at 76 88 before the top dead cen ter 4 Check the movement of the rocker a...

Page 398: ... 10 tighten locknut 11 3 Locknut 24 4 Nm 2 45 0 41 kgm a After tightening the locknut check the valve clearance again 6 Rotate the crankshaft forward by 1 turn and set wide slit b to projection top a according to step 3 7 Adjust the other valve clearances according to steps 4 and 5 a If the valves marked with q in the valve arrangement drawing were adjusted in steps 4 and 5 adjust the valves marke...

Page 399: ...ove the wiring harnesses 3 Disconnect fuel high pressure tube 3 4 Loosen injector terminal nut 4 and remove the terminal from the injector 5 Set the cylinder to be checked to the compres sion top dead center a How to turn the crankshaft refer to Adjusting valve clearance a When the cylinder is at the compression top dead center the rocker arm of the cyl inder can be moved by the valve clear ance w...

Page 400: ...nt and that is dangerous Accordingly be sure to set the engine in the no injection cranking mode 16 Rotate the engine with the starting motor and measure the compression pressure a Read the gauge when its pointer is stabi lized 17 After finishing measurement remove the mea suring tools and return the removed parts a Install the injector and fuel high pressure tube according to the following proced...

Page 401: ...ten that on the common rail side 3 Sleeve nut 35 3 5 Nm 3 6 0 4 kgm 8 Connect the injector harness connector a After installing the rocker arm assembly adjust the valve clearance For details see Adjusting valve clearance 3 Rocker arm assembly mounting bolt 36 5 Nm 3 67 0 51 kgm a Tighten the injector terminal nut to the follow ing torque 3 Terminal nut 1 5 0 25 Nm 0 15 0 025 kgm a Tighten the head...

Page 402: ... While running the engine at HST stalling and hydraulic stalling and measure the blow by pressure a Do not keep stalling the HST for more than 20 seconds Take care that the HST oil temperature will not exceed 120 C a Normally the blow by pressure should be measured while the engine is operated at the rated output In the field however an approximate value can be obtained by HST stalling and hydraul...

Page 403: ...emove plug 1 from oil filter head 3 Install nipples E2 and E3 then connect hydraulic tester E4 1 MPa 10 kg cm2 4 Start the engine and heighten the coolant tem perature to the operating range 5 While running the engine at low idle and high idle measure the oil pressure 6 Remove the measurement tool after the mea surement and make sure that the machine is back to normal condition Symbol Part No Part...

Page 404: ...s sure when HST stalling and hydraulic stalling a Do not keep the HST stalled for more that 20 seconds so that the HST oil tempera ture will not exceed 120 C 2 Measurement with measuring tool 1 Open the engine right side cover 2 Remove air boost pressure pickup plug 1 R1 8 3 Install elbow 1 in hydraulic tester F1 and nipple 2 in boost gauge kit F2 and con nect pressure gauge 3 4 Start the engine a...

Page 405: ...e While running the engine at high idle stall the HST and hydraulic work equipment and measure the intake air pressure boost pressure a Do not keep stalling the HST for more than 20 seconds Take care that the HST oil temperature will not exceed 120 C 10 Remove the measurement tool after the measurement and make sure that the machine is back to normal condition ...

Page 406: ...ith highly efficient filtering performance to prevent mixing of foreign substances Thus substitut ing it with a non genuine filter could cause troubles in the fuel system It is strictly prohib ited to use such part Releasing residual pressure in fuel system 1 a Pressure is generated in the low pressure cir cuit and high pressure circuit of the fuel sys tem while the engine is running Low pressure ...

Page 407: ...raulic tester G1 and connect them to oil pressure gauge 2 a Use the oil pressure gauge of 2 5 MPa 25 kg cm2 3 Run the engine at low idle and measure the pressure in the fuel low pressure circuit a If the pressure in the fuel low pres sure circuit is in the following range it is normal k If the engine cannot be started you may measure the fuel pressure while rotating the engine with the starting mo...

Page 408: ...measurement remove the measuring tools and return the removed parts 3 Fuel pressure pickup plug 24 4 Nm 2 4 0 4 kgm 3 Measuring fuel negative pressure circuit pressure 1 Remove joint bolt 2 of fuel hose 1 between the prefilter and supply pump 2 Connect fuel hose 1 to supply pump 3 by tool G4 instead of joint bolt 2 a When installing tool G4 fit the gaskets to both sides of the fuel hose joint 3 To...

Page 409: ...nd in receiving pan 4 Crank the engine for 30 seconds and measure the delivery with measuring cyl inder H4 a Adjust the route of the test hose so that it will not slacken and put its end in receiving pan a Do not crank the engine for more than 30 seconds to protect the starting motor in any case other than this measurement a If the supply pump delivery is in the following standard range it is norm...

Page 410: ... low idle and measure the return rate in 25 seconds with measur ing cylinder H4 a If the return rate from the supply pump is in the following range it is normal k If the engine cannot be started you may measure the return rate while rotating the engine with the start ing motor Do not rotate for more than 25 seconds continuously however for protection of the start ing motor 6 After finishing measur...

Page 411: ... in 1 minute with measuring cylinder H4 a If the leakage from the pressure limiter is in the following range it is normal 6 After finishing measurement remove the measuring tools and return the removed parts 3 Joint bolt 24 4 Nm 2 4 0 4 kgm 4 Measuring return rate from injector a The leakage from the injector is measured while the return hose of the pressure lim iter is connected Accordingly befor...

Page 412: ...and measure the return rate in 1 minute with measuring cylinder H4 a If the return rate from the injector is in the following range it is normal k If the engine cannot be started you may measure the return rate while rotating the engine with the start ing motor Do not rotate for more than 20 seconds continuously however for protection of the start ing motor 5 After finishing measurement remove the...

Page 413: ... k Put chocks under the tires securely k When measuring check that there are no persons around the machine 1 Fill the fuel tank with fuel 2 Open the right side cover of the engine 3 Turn feed pump knob 1 to the left to pull it out and operate it forward and backward a Keep the operation of the knob until becomes hard to operate a The plug at the top of the fuel main filter does not need to be remo...

Page 414: ...ker for fuel leakage a If fuel leakage is recognized repeat the procedure from step 1 after repairing the leakage 4 Run the engine at low idle 5 Inspect the fuel piping and devices for fuel leakage a Check mainly around the high pressure circuit parts coated with the color checker for fuel leakage a If fuel leakage is recognized repeat the procedure from step 1 after repairing the leakage 6 Run th...

Page 415: ...ctive valve mechanism Moving valve system q Defect in electrical system 3 Since the common rail fuel injection system controls the injector of each cylinder electroni cally the operator can perform the reduced cyl inder mode operation easily with switches to find out a defective cylinder a The reduced cylinder mode operation is set from the service mode of the machine monitor For details see Speci...

Page 416: ...or connected to a connector between the engine controller and engine for troubleshooting do not start the engine a You may turn the starting switch to the OFF or ON position but must not turn it to the START position Check of muffler and muffler stack for looseness and damage 1 1 Check the muffler and muffler stack visually for a crack and damage If any part is damaged replace it 2 Check the mount...

Page 417: ...rence in sound from a new machine If it makes abnormal sound repair it referring to the Troubleshooting Volume Check of installed condition of cylinder head and manifolds 1 Check the installed condition of the cylinder head and air intake manifold and exhaust manifold If they are loosened retighten them a For the tightening torque see the Disassem bly and assembly volume ...

Page 418: ...r damage looseness of the mounting bolts and nuts and leakage of fuel through the joints If it is loosened or dam aged retighten or repair Testing and adjusting air condi tioner compressor belt tension 1 Testing q Press the middle point between air conditioner compressor pulley and drive pulley with a finger and measure deflection a of the belt a Pressing force Approx 98 N Approx 10 kg a Standard ...

Page 419: ... Apply wrench a to part A width across flats T 12 7 mm of tensioner assembly 1 and turn it in the arrow direction to decrease the tension of fan belt 2 k Make sure that the wrench a is secured at portion A before rotating it The spring of tensioner assembly 1 is strong If the wrench is loosely inserted the wrench may accidentally come off while being rotated and it is extremely dangerous k After r...

Page 420: ...SEN03836 01 WA250 250PZ 6 30 110 37 110 Testing and adjusting Part 1 Replacing alternator belt ...

Page 422: ...ing hydraulic fan 15 Measuring brake pedal 17 Testing and adjusting brake pedal linkage 18 Measuring brake performance 19 Testing and adjusting accumulator charge pressure 20 Testing wheel brake oil pressure 22 Testing wear of brake disc 25 Bleeding air from wheel brake circuit 26 Releasing residual pressure in brake accumulator circuit 27 Testing parking brake performance 28 Testing and adjusting...

Page 423: ... bucket positioner 36 Testing and adjusting of boom kick out switch 37 Checking proximity switch operation pilot lamp 38 Procedure for testing diodes 39 Preparation work for troubleshooting for electric system 41 Starting KOMTRAX terminal operations 45 Indicator lamps of KOMTRAX terminal 49 ...

Page 424: ...from the low idle position to the end of its travel high idle 3 Stop the engine 4 If the squeak noise is heard from accelerator pedal when checking lubricate from grease nipple 1 of roller shaft 2 Roller shaft Grease G2 LI a After greasing wipe off grease completely No grease is adhered on roller surface and roller sliding surface 5 After finishing the work remove the measuring instruments and ret...

Page 425: ...ush pull scale K1 or a spring balance to a point 10 mm from the tip of the directional lever then measure the operating effort when the lever is pulled in the direction of actuation a Carry out the measurement in each speed range Checking travel of directional lever 1 Stop the engine 2 Make mark a on the center of the knob of the directional lever then measure the travel with scale K2 when the lev...

Page 426: ...engine hood side cover 2 Install oil pressure gauge L 60 MPa 600 kg cm2 to pressure measurement nipple 1 q Nipple 1 For FORWARD circuit port MA q Nipple 2 For REVERSE circuit port MB a Install the oil pressure gauge L to nip ple 1 of the forward circuit 3 Measure the high pressure cut off oil pressure under the following conditions 1 Lower the bucket to near the ground then drive the machine forwa...

Page 427: ... Place the directional lever at N run the engine at high idle and measure the low pressure relief pressure 4 After finishing the work remove the measuring instruments and return the removed parts Testing servo piston control pressure DA pres sure 1 Remove floor frame cover 5 bottom left of operator s cab 2 Remove servo piston control pressure mea surement plug 6 DA pressure 10 mm P 1 25 mm 3 Insta...

Page 428: ...the brake pedal 4 After finishing the work remove the measuring instruments and return the removed parts Adjusting a The high pressure relief pressure is also the safety pressure of the main circuit so it cannot be measured Normally the cut off valve is actuated first so it does not rise to the safety valve set pressure Adjusting high pressure cut off valve a If the high pressure cut off pressure ...

Page 429: ...8 MPa 3 9 kg cm2 3 After adjusting tighten locknut 14 3 Locknut 69 6 Nm 7 1 kgm a After completion of adjustment repeat the measurement procedure to check the low pressure relief pressure again Adjusting DA valve a If the servo piston control pressure is not cor rect adjust the DA valve as follows 1 Remove the engine hood 2 Loosen locknut 17 of DA valve 16 then turn adjustment screw 18 to adjust a...

Page 430: ...lutch solenoid valve output pres sure clutch inlet pressure hose 2 then con nect hydraulic tester M1 6 MPa 60 kg cm2 and adapter M2 Hose size For 02 3 Set the speed selector switch to 3rd or 4th travel at a speed of at least 10 km h and mea sure the clutch inlet pressure clutch solenoid valve output pressure 4 After finishing the work remove the measuring instruments and return the removed parts S...

Page 431: ...becomes heavy when the steering valve lever starts to move Then measure the distance in a straight line between marks B and C Measuring operating force of steering wheel a Measurement conditions q Road surface Flat horizontal dry paved surface q Engine coolant temperature Within green range on engine coolant temperature gauge q Hydraulic oil temperature 45 55 C q Tire inflation pressure Specified ...

Page 432: ... 55 C q Tire inflation pressure Specified pressure q Engine speed Low idle and high idle 1 Start the engine a After starting the engine raise the bucket approx 400 mm and remove the frame lock bar 2 Operate the steering wheel to the end of its stroke to turn the machine to the left or right 3 Measure the time taken to operate the steering wheel to the end of the stroke to the right or left a Turn ...

Page 433: ...rame lock bar 1 to the frame 2 Remove oil pressure pickup plug 2 of the steering cylinder circuit 3 Fit a nipple P 3 to the steering circuit pressure measurement plug hole then install oil pres sure gauge P 1 P 2 40 MPa 400 kg cm2 4 Start the engine run the engine at high idle then turn the steering wheel to the left or right and measure the pressure when the relief valve is actuated Symbol Part N...

Page 434: ...w 6 to adjust a Turn the adjustment screw to adjust as fol lows q To INCREASE pressure turn CLOCKWISE q To DECREASE pressure turn COUNTERCLOCKWISE a Pressure adjustment for one turn of adjustment screw Approx 6 9 MPa 70 kg cm2 a Tool 1 for adjusting adjustment screw Size 7 32 inch hexagonal a Do not carry out any adjustment if the relief pressure cannot be measured accu rately 3 Adjustment screw 6...

Page 435: ...der have been removed and installed again 1 Start the engine and run at idle for approx 5 minutes 2 Run the engine at low idle and turn 4 5 times to the left and right a Operate the piston rod to approx 100 mm before the end of its stroke Be careful not to relieve the circuit 3 Repeat Step 2 with the engine at full throttle 4 Run the engine at low idle and operate the pis ton to the end of its str...

Page 436: ...ture 45 55 C a Test the fan in a place where the fan blade and probe will not be exposed to direct sunlight or strong light Testing fan speed 1 Open the radiator grill 2 Install stand 1 probe 2 and reflecting tape 3 in the tachometer kit Q1 3 Connect the cable of probe 2 to tachometer 4 Tachometer kit Q1 4 Start the engine run at high idle and measure the fan speed 5 After finishing the work remov...

Page 437: ...oil pressure 1 Open the radiator grill 2 Disconnect hose 1 install oil pressure gauge Q2 40 MPa 400 kg cm2 and adapter Q3 Hose size For 04 and connect hose 1 again 3 Start the engine and measure the fan drive oil pressure 4 After finishing the work remove the measuring instruments and return the removed parts ...

Page 438: ... engine coolant temperature gauge q Engine speed Low idle 1 Install push gauge 1 to the operator s foot a Set the push gauge at a point 150 mm from the fulcrum of the pedal 2 Start the engine and measure pedal angle α1 when running at low idle 3 Apply angle gauge 2 to the brake pedal and measure pressing angle α between pressing angles α1 and α2 α α1 α2 q Operating force at α2 196 N 20 kg ...

Page 439: ...distance of movement of rod 8 and check that clearance b is within the stan dard value Standard clearance b 0 0 3 mm a When doing this check that the brake pedal is in contact with the stopper Adjusting Adjusting link length a 1 Remove pin 5 and ball joint 3 then remove rod 1 2 Loosen locknut 4 then turn yoke 2 and ball joint 3 to adjust the length 3 After adjusting the length of link a connect it...

Page 440: ...ce 322 N 33 kg Measurement method 1 Start the engine and drive the machine 2 Set the speed selector switch to 4th and drive the machine 3 When the travel speed reaches 35 km h depress the left brake pedal with the specified operating force a Before carrying out this operation deter mine the run up path and the point for applying the brakes then apply the brakes when the machine reaches that point ...

Page 441: ...nt nipple and oil pressure gauge R 40 MPa 400 kg cm2 4 Measure the accumulator charge cut in pres sure Start the engine run the engine at low idle and measure the oil pressure when the brake pressure caution lamp on the monitor panel goes out q Cut in pressure MPa kg cm2 5 Measure the accumulator charge cut out pres sure a After the accumulator charge cut in is actuated measure the oil pressure wh...

Page 442: ...f valve accu mulator charge cut out valve 3 then turn adjustment screw 5 to adjust a Turn the adjustment screw to adjust as fol lows q To RAISE pressure turn CLOCK WISE q To LOWER pressure turn COUN TERCLOCKWISE a Pressure adjustment for one turn of adjustment screw 1 45 MPa 14 8 kg cm2 2 After adjusting tighten locknut 4 3 Locknut 11 8 16 7 Nm 1 2 1 7 kgm a After completion of adjustment repeat t...

Page 443: ... k When raising the lift arm to remove the inspection cover place a stand 1 under it to support securely Instead you may set stopper T to the lift arm cylinder to prevent the work equipment from lowering 2 Remove brake tube 2 of the measured side a The right side is shown as an example in the figure 3 Remove union 3 and install adapter S4 and nipple S5 a Use the O ring fitted to the union 4 Connec...

Page 444: ...SEN03837 01 WA250 250PZ 6 30 120 23 120 Testing and adjusting Part 2 Testing wheel brake oil pressure Composition and connection diagram of brake test kit S ...

Page 445: ...essurized for 5 min utes and check lowering of the pressure a If the hose is moved while the pressure is measured the pressure fluctuates Accordingly do not move the hose a After testing the pressure operate pump S3 to lower the pressure in brake test kit S1 and then remove brake test kit S1 a After finishing testing install the brake tube and bleed air from the brake circuit 8 After finishing the...

Page 446: ...e housing 2 While pressing the brake pedal insert testing gauge U in the inspection plug hole and pinch the inspection projection around piston 2 and plate 3 with the inspection gauge tip Reference Testing gauge U is component part of tool kit a If you can pinch the inspection projection around piston 2 and plate 3 with the inspection gauge tip the brake disc is worn more than the repair limit In ...

Page 447: ...the inspection cover place support stand 1 under the lift arm to support the lift arm securely or set stopper T to the lift arm cylinder to prevent the work equipment from falling 3 Connect hose 1 to bleeder screw 2 and place hose 1 in the oil receive pan a Work on the rear side similarly from under side of the machine 4 Press the brake pedal and then loosen bleeder screw 2 to bleed air a Return t...

Page 448: ...rcuit 1 k Before disconnecting any of the following brake accumulator circuits release resid ual pressure in that brake circuits q Piping between accumulator charge valve and brake accumulator q Piping between brake accumulator and brake valve on both sides 1 Stop the engine 2 Press the brake pedal at least 100 times to release the pressure from the brake accumula tor circuit ...

Page 449: ...eady for operation Measuring method 1 Start the engine and set the machine in the straight travel position and then drive up a slope of 1 5 gradient with no load in the bucket 2 Press the brake pedal to stop the machine set the directional lever in the N position and stop the engine 3 Pull the parking brake lever fully release the brake pedal gradually and check that the machine is kept stopped a ...

Page 450: ...the fixing parts are loosened tighten them and then perform the following adjustment Adjusting 1 Release the parking brake a Check that the pawl of the parking brake lever is at the lowest position 2 Loosen locknut 2 and remove clevis pin 3 3 Pull parking brake lever 4 on the transfer side in the release direction Add the play of the parking brake lever to the upper side how ever 4 Under the above...

Page 451: ...ol lever Install tool W1 to the work equipment control lever and secure it in position a Install tool W1 to the center of the knob a Operate the control lever at the same speed as for normal operations and measure the mini mum value for the effort needed to operate the knob Measuring travel of work equipment control lever Measure the travel at each position when operating the work equipment contro...

Page 452: ...lve is actuated Adjusting a Always stop the engine before adjusting the oil pressure k When carrying out the operation with the lift arm raised set support 1 or lift arm drop prevention stopper T in position before starting the operation 1 Remove front frame inspection cover 1 2 Remove cap nut 2 of relief valve 5 3 Loosen locknut 3 of relief valve 5 then turn adjustment screw 4 to adjust a Turn th...

Page 453: ...stall oil pressure gauge Y 6 MPa 60 kg cm2 3 Start the engine 4 Run the engine at high idle then operate the work equipment control lever and measure the oil pressure 5 After finishing the work remove the measuring instruments and return the removed parts Checking PPC valve output pressure 1 Remove the inspection cover 1 of the front frame k Except for measuring the oil pressure when carrying out ...

Page 454: ...ting work equipment PPC oil pressure 4 Operate the work equipment control lever at high idle and measure the oil pressure a A Bucket TILT B Bucket DUMP C Lift arm RAISE D Lift arm LOWER 5 After finishing the work remove the measuring instruments and return the removed parts ...

Page 455: ...tart the engine and run at idle for approx 5 minutes 2 Run the engine at low idle then raise and lower the lift arm 4 5 times in succession a Operate the piston rod to a point approx 100 mm before the end of its stroke Do not relieve the circuit under any circum stances 3 Run the engine at full throttle and repeat Step 2 After that run the engine at low idling and operate the piston rod to the end...

Page 456: ...lease all the remaining pressure Releasing remaining pressure in brake accumu lator circuit a If the piping between the ACC charge valve and brake accumulator between the ACC charge valve and parking brake valve and between the accumulator and brake valve is to be disconnected release the remaining pres sure from the circuit as follows 1 Stop the engine 2 Depress the brake pedal at least 100 times...

Page 457: ...surface of proximity switch 1 and detection bar 2 to the standard range with the shim and mounting bolt of the proximity switch bracket a Standard clearance a 3 5 mm a Adjust detection bar 2 with the shim so that clearance a will be in the standard range through the stroke of the detection bar 2 2 Adjusting installing position stopping position 1 Lower the bucket to the ground and set it to a desi...

Page 458: ...s be sure to apply the work equipment lock lever 2 Lower the lift arm and stop the engine 3 Align the marks and adjust the position of the plate so that the center of switch 1 is at the bottom of plate 2 then secure in position with bolt 3 4 Adjust the switch so that clearance a between the sensing surface of the switch and plate 2 is the standard value then secure in position 3 Switch mounting nu...

Page 459: ...amp to indicate its operating condition Use this pilot lamp when adjusting the proximity switch q A Operation pilot lamp Red Proximity switch Positional relationship between sensitive surface of proximity switch and sensing object Operation pilot lamp Remarks Bucket positioner Near ON Operates when center of switch is near Far OFF Boom kick out Near ON Operates when center of switch is far Far OFF...

Page 460: ...e diode as shown in the following figure 1 When using digital type circuit tester 1 Switch the testing mode to diode range and confirm the indicated value a Voltage of the battery inside is dis played with conventional circuit testers 2 Put the red probe of the test lead to the anode P of and the black probe to the cathode N of diode and confirm the indi cated value 3 Determine acceptability of th...

Page 461: ...athode N side of the diode and apply the black lead to the anode P side 3 Determine if a specific diode is good or no good by the way the pointer swings q With the connection 1 above the pointer is not moved It swings how ever when the connection 2 is employed Normal However magni tude of the pointer s move indicating the resistance value varies depend ing on the given tester model and the measure...

Page 462: ...ng pro cedure 1 Machine monitor 1 Disconnect the following connectors from cover 1 q Connector L06 Hazard switch q Connector L07 Front working lamp switch q Connector L08 Rear working lamp switch q Connector L09 ECSS switch If equipped q Connector L10 Machine monitor mode selector switch 1 q Connector L11 Machine monitor mode selector switch 2 a Pull the switch out of the cover and disconnect each...

Page 463: ...osis T adapters to HST connector of HST controller 2 3 KOMTRAX terminal 1 Open right door 1 and remove console cover 2 2 Connect diagnosis T adapter to connec tor L80 of KOMTRAX terminal 3 a If the connector cannot be discon nected and connected easily remove the KOMTRAX terminal a Since the connector is secured with screws loosen those screws before disconnecting a When connecting the connector a...

Page 464: ... IMV solenoid has a special locking mecha nism Disconnect it according to steps a b and connect it according to steps c d as shown below Disconnection a Unlock b Disconnect connector Connection c Connect connector d Lock 6 Common rail pressure sensor FUEL RAIL PRESS a Disconnection and connection of connector The connector of the common rail pres sure sensor has a special locking mecha nism Discon...

Page 465: ... Lock a Removal and installation of sensor A deep socket is necessary for removal and installation of the engine oil pressure switch See Testing adjusting Trouble shooting tools table 8 Ambient pressure sensor AMBAIR PRES SURE Engine Ne speed sensor CRANK SENSOR Engine Bkup speed sensor CAM SENSOR Engine oil pressure switch OIL PRESSURE SWITCH a Disconnection and connection of connectors The conne...

Page 466: ...e KOMTRAX terminal is ret rofitted a When retrofitting the KOMTRAX terminal after shipment retro fitted machine follow the steps below 1 Station opening check in machine side a Complete steps 3 to 5 within 60 sec onds If 60 seconds or above elapsed begin with step 1 again 1 Turn OFF the starting switch and then after making sure 5 seconds have elapsed proceed to the next step 2 Visually check that...

Page 467: ... Do not return the starting switch to OFF position 8 Turn the starting switch from ACC position to START position again and make sure that the engine starts 9 Make sure that the KOMTRAX terminal s indicator lamps are normally turned on a Move on to the next step if you can check that the display is Normal It takes from 90 seconds to 15 minutes before the display turns normal a If GPS position data...

Page 468: ...yed normally after 5 seconds elapsed a When Normal appears station opening check is completed a If Abnormal appears station open ing check does not end normally so you should perform the procedure above from step 1 again a If station opening check ends nor mally it should not be rechecked 12 When station opening check ended nor mally a communication with the KOMTRAX server starts automatically and...

Page 469: ...e that completed the station opening check in the machine side 1 Information model part number and serial number about the machine that completed the station opening check in the machine side 2 Part number and serial number of KOMTRAX terminal 3 Value of service meter when the KOMTRAX terminal was installed in 0 1 hours 2 The KOMTRAX operations administrator shall use a KOMTRAX client PC to regis ...

Page 470: ...s of KOMTRAX terminal 1 LED lamps for CPU 1 LED C1 State of R or ACC signal 2 LED C2 Starting output state 3 LED C3 State of S NET or C signal 4 LED C4 CAN state 5 LED C5 Download write state 6 LED C6 Download write state 7 segment and dot displays for CPU 7 7 segments Number of unsent mails 8 Dot GPS positioning state ...

Page 471: ...ED displays should be checked with the starting switch ON starting switch START or with the engine started 1 Blink types and blink times Fast blink Blinks in about 1 second cycle Slow blink Blinks in about 4 second cycle No LED Name function Display 1 Description 1 LED C1 States of starting switch ACC signal and alternator R signal ON Starting switch ACC signal ON Alternator R signal ON Fast blink...

Page 472: ...in an outdoor service area GPS positioning will fail in a weak signal or non service area No LED Name function Display 2 Description 7 7 segments Number of unsent mails satellite capture state 0 to 9 displayed The number indicates the number of unsent mails 10 or more unsent mails are indicated by 9 Light on indicates that the machine is in process of capturing the satellite 0 to 9 fast blink The ...

Page 474: ...r WA250 6 75001 and up WA250PZ 6 75001 and up 30 Testing and adjusting 30 130 Testing and adjusting Part 3 Adjusting machine monitor 2 Adjusting replaced reassembled or added sensor controller etc with machine monitor 3 Special functions of machine monitor EMMS 5 Pm clinic inspection chart 59 ...

Page 475: ...ng machine monitor 1 Layout of rotary switches SW1 SW2 and SW3 and DIP switches SW5 and SW6 q Do not change the setting of the rotary switches SW1 SW2 and SW3 and DIP switches SW5 and SW6 on the back side of the machine monitor q The switches shown in the figure are set as when the monitor is delivered ...

Page 476: ... parts is replaced or reassembled initialize the sensors solenoids etc with the machine monitor a Adjust the items in alphabetical order A with the machine monitor 1 Description No of Service mode in Special functions of machine monitor EMMS Replaced reassembled or added component or option Adjustment item Machine monitor A B C HST controller A B Change of tire size B Addition or removal of option...

Page 477: ...verse fan specification F Change continuance of fan automatic reverse operation Automatic reverse fan specification G Travel speed is indicated too quickly slowly H Turn engine speed travel speed on character display OFF J ECSS operates at high or low travel speed K Change display of major indication in engine speed 3 L Adjustment item Contents of change adjustment Description No 1 D Setting of op...

Page 478: ...nd adjusting Part 3 Special functions of machine monitor EMMS Special functions of machine monitor EMMS 1 a EMMS Equipment Management Monitoring System 1 Machine monitor mode change switch 1 2 Machine monitor mode change switch 2 3 Character display ...

Page 479: ... 2 Electrical system fault history display function 2 Traction level selection function 3 Mechanical system fault history display function 3 HST function selection function 4 Real time monitoring function 4 Odometer display function 5 Engine reduced cylinder function 5 Maintenance monitoring function 6 No injection cranking function 6 Telephone number input function 7 Adjustment function 7 Languag...

Page 480: ...ing and adjusting Part 3 Special functions of machine monitor EMMS Functions and flow of service mode Note Some items may not be used depending on the setting and specification although they are displayed on the monitor For details see the text ...

Page 481: ...SEN03838 00 30 130 8 WA250 250PZ 6 130 Testing and adjusting Part 3 Special functions of machine monitor EMMS ...

Page 482: ...SEN03838 00 WA250 250PZ 6 30 130 9 130 Testing and adjusting Part 3 Special functions of machine monitor EMMS ...

Page 483: ...vel selection function is displayed a If the traction control is turned ON with the traction control switch the traction can be set to 3 levels a For details see Operation and Mainte nance Manual Operation Other func tions of machine monitor a For items 3 and after display a desired screen with or switch on the Trac tion level selection function screen a Each time or switch is pressed the screen c...

Page 484: ...mber input function Telephone numbers are entered through the switch operation And modification or cancella tion of the phone numbers in the machine monitor is also available through the switch operation a When action code E03 is displayed a phone number is displayed along with CALL a For details see the Other functions of machine monitor of the Operation section in the Operation and maintenance m...

Page 485: ...nual 9 Travel speed engine speed display select ing function A unit to be used for the machine monitor speed display is selectable from km h and MPH It is also possible to turn on or off the dis play of the travel speed and engine speed a For details see the Other functions of machine monitor of the Operation section in the Operation and maintenance man ual 10 Travel speed engine speed display non...

Page 486: ...ter nately displayed a When action code E01 or E02 is dis played CALL Telephone number is not displayed a Action codes and actions alerted to operator Action code CALL Tele phone number Actions recommended to operator E01 Not displayed Do necessary testing and or servicing as the current work is over or at shift of the operator E02 Not displayed When an overrun related item is displayed Slow down ...

Page 487: ... If switch is pressed again after it was pressed to display every involved failure code the service meter display screen will be restored Pressing switch one more time dis plays the failure codes from the first If switch is not touched for 3 seconds the action code display screen is automat ically displayed a The service code display function displays the following information A Failure code locat...

Page 488: ...e value in the same order and then press U switch a When you have entered a wrong value to a position except the highest order digit move to the highest order digit using t switch to repeat the procedure from the first In this case values that had been entered remain as they are until modified When the cursor is at the highest order digit it can move to the higher layer using t switch 1 1 When the...

Page 489: ...When the normal screen Operator mode was inadvertently turned on repeat above steps from 1 input of the ID is not neces sary 2 When ending an operation completely Turn the starting switch off from the cur rent state 2 Electrical system fault history display func tion ELECTRIC FAULT The machine monitor records the past failures in the electric system as the failure codes The failure codes are displ...

Page 490: ...switch a The selected cursor will start flashing If YES is selected and t switch is pressed the information will be deleted If NO is selected and t switch is pressed deletion is cancelled and the Maintenance interval change item screen is restored a By default the cursor is set to NO cancel to prevent resetting error a Information of the currently occurring fail ure is not deletable 2 6 Deleting a...

Page 491: ...r B Failure code Location code in four digits Problem code in two digits C Number of occurrences number of occur rences of same code in past D Elapsed time 1 Elapsed time on service meter from the first occurrence E Elapsed time 2 Elapsed time on service meter from the last occurrence a The code of a failure currently occurring is indicated in flashing a For details of a displayed failure code see...

Page 492: ... E03 Electrical system CA115 Engine NE Bkup speed sensor Abnormality ENG E03 Electrical system CA122 Charge pressure sensor Abnormally high level ENG E03 Electrical system CA123 Charge pressure sensor Abnormally low level ENG E03 Electrical system CA131 Throttle sensor Abnormally high level ENG E03 Electrical system CA132 Throttle sensor Abnormally low level ENG E03 Electrical system CA144 Coolant...

Page 493: ...ve circuit Abnormality ENG E03 Electrical system CA352 Sensor power supply 1 Abnormally low level ENG E03 Electrical system CA386 Sensor power supply 1 Abnormally high level ENG E03 Electrical system CA428 Water sensor Abnormally high level ENG E01 Electrical system CA429 Water sensor Abnormally low level ENG E01 Electrical system CA431 Idle validation switch Abnormality ENG E01 Electrical system ...

Page 494: ...Intake air heater relay Disconnection ENG E01 Electrical system CA2556 Intake air heater relay Short circuit ENG E01 Electrical system D160KY Backup lamp buzzer relay Hot short MON E01 Electrical system D192KY ECSS solenoid relay Hot short MON E01 Electrical system D1B0KA HST safety relay Disconnection HST E03 Electrical system D1B0KB HST safety relay Ground fault HST E01 Electrical system D1B0KY ...

Page 495: ... fault HST E01 Electrical system DDB6KZ Parking brake switch or parking brake B reminder switch Trouble MON E03 Electrical system DDB6L0 Parking brake switch A Ground fault HST E01 Electrical system DDB6L4 Parking brake switch B Disconnection Hot short HST E03 Electrical system DDD7KX Travel speed control dial Disconnection Ground fault HST E01 Electrical system DDD7KY Travel speed control dial Ho...

Page 496: ...oid Disconnection Ground fault HST E01 Electrical system DW26KY Motor 2 solenoid Hot short HST E01 Electrical system DW7BKY Fan reverse solenoid circuit Hot short HST E01 Electrical system DW7BKZ Fan reverse solenoid circuit Disconnection Ground fault HST E01 Electrical system DX16KA Fan EPC solenoid Disconnection HST E01 Electrical system DX16KB Fan EPC solenoid Ground fault HST E01 Electrical sy...

Page 497: ...tion codes Action codes indicate what in displayed in the operator mode when a failure is detected a History classification History classification indicates in which system either electrical system or mechanical system in the fail ure history display function a failure has been recorded a Note Optional equipment is also included in table DXH8KB Forward solenoid Ground fault HST E03 Electrical syst...

Page 498: ...he menu Select REAL TIME MONITORING from the menu screen of Service mode 4 2 Displaying sub menu Press U switch while the menu is selected to display the sub menu initial screen 4 3 Selecting sub menu a Press or switch from the sub menu screen to display the sub menus endlessly in the following order a The sub menus are displayed in the field indicated with mark 1 MONITOR PANEL Machine monitor sys...

Page 499: ...t used a See the Real time monitoring code list for details 4 5 Setting 2 items simultaneous monitoring 1 Select 2 ITEMS from the sub menu screen 2 Press U switch while the sub menu is selected to display the monitoring code input screen 1 This cursor C is located at the high est order digit Pressing or switch changes the value of this digit in the range of 0 9 2 Press U switch when the intended v...

Page 500: ... while the monitoring is in progress holds the monitoring data and U mark starts flashing Pressing U switch again restores the active state 4 Display data for 2 items simultaneous monitoring a The 2 items simultaneous monitoring screen displays the following information A Monitoring code 1 1 Monitoring data 1 including the unit used B Monitoring code 2 2 Monitoring data 2 including the unit used a...

Page 501: ...1001 Engine speed ENG SPEED 0 4000 5 40012 Travel speed SPEED 0 0 50 0 6 04202 Fuel level FUEL SENSOR 0 100 7 04200 Fuel level FUEL SENSOR 0 00 5 00 8 04103 Coolant temperature COOLANT TEMP 40 210 9 04408 HST oil temperature HST OIL TEMP 24 131 10 04409 HST oil temperature HST OIL TEMP 0 00 5 00 11 30201 Front brake oil temperature F BRAKE OIL 24 131 12 30204 Front brake oil temperature F BRAKE OI...

Page 502: ...eed in each speed range Value of F1 R1 is speed when travel speed con trol dial is at min speed position 0 100 Depends on fuel level Gauge FULL 100 10 z 0 31 V Gauge 1 2 50 29 5 z 0 82 V Gauge 1 4 25 44 6 z 1 15 V Caution 62 z 1 47 V Gauge EMPTY 0 85 z 1 82 V V When sensor is disconnected has hot short Gauge EMPTY When sensor has ground fault Gauge FULL Depends on machine condition C C Engine cool...

Page 503: ...sure BOOM HEAD PRES 21 40600 Calibration pressure CAL PRESS 22 40800 Weight calculated by load meter MES LOAD 23 30802 Rotary switch setting condition SW1 SW2 SW3 F F F 24 30904 DIP switch setting condition SW5 1 SW5 2 ON OFF ON OFF 25 30905 DIP switch setting condition SW5 3 SW5 4 ON OFF ON OFF 26 30906 DIP switch setting condition SW6 1 SW6 2 ON OFF ON OFF 27 30907 DIP switch setting condition S...

Page 504: ... Unit 4 Remarks MPa a No use these items V MPa t Condition display a Do not move from initial position Condition display a Do not move from initial position Condition display a Do not move from initial position Condition display a Do not move from initial position Condition display a Do not move from initial position Condition display Condition display Condition display Condition display Condition...

Page 505: ...ing fan automatic reverse setting ON 24 V OFF OPEN D IN 10 D IN 11 D IN 12 Right winker Right winker lighting ON GND OFF OPEN D IN 13 Left winker Left winker lighting ON GND OFF OPEN D IN 14 U switch Pressing switch ON 24 V OFF OPEN D IN 15 t switch Pressing switch ON 24 V OFF OPEN 3 40902 D IN 16 Brake oil pressure Normal oil pressure ON GND OFF OPEN D IN 17 D IN 18 D IN 19 D IN 20 D IN 21 D IN 2...

Page 506: ...essing switch ON GND OFF OPEN D IN 38 switch Pressing switch ON GND OFF OPEN D IN 39 Low steering pressure Machine with optional emergency steering spec Oil pressure reduction ON GND OFF OPEN 6 40952 D OUT 0 Alarm buzzer Output ON ON 24 V OFF OPEN D OUT 1 D OUT 2 Backup alarm lamp relay Output ON ON 24 V OFF OPEN D OUT 3 ECSS solenoid relay Machine with optional ECSS spec Output ON ON 24 V OFF OPE...

Page 507: ...16 23 See separate table 8 41600 Engine mode ENGINE MODE 0 2 9 32600 HST oil pressure HST PRESS 0 0 500 0 10 32601 HST oil pressure HST PRESS 0 001 5 000 11 80000 Motor 1 output command value MOTOR SOL DIR 0 1000 12 8100 Clutch output command value CLUTCH SOL DIR 0 1000 13 41400 Fan output command value FAN EPC DIR 0 1000 14 93400 Fan reverse switch input FAN REVERSE SW 0 2 1 15 40013 Travel speed...

Page 508: ...gh pressure cutoff pressure 3 373 3 607 V Above 10 5 km h in 3rd or 4th gear speed 0 mA Other than above 100 600 mA Depends on control mA When clutch is engaged 670 mA When clutch is disengaged Above 10 5 km h in 3rd or 4th gear speed 0 mA mA 0 1000 mA Fan rotation direction is being reversed 800 mA Fan is rotating in reverse 0 mA mA Switch position forward 0 Switch position automatic reverse 2 Ma...

Page 509: ... Parking brake switch signal PARKING A B 11 00 10 01 23 04302 Alternator R voltage signal ALTERNATOR 0 0 30 0 24 99200 Travel speed control dial SPEED POT 0 0 50 0 25 99201 Travel speed control dial SPEED POT 0 001 5 000 26 80200 Traction level setting TRACTION 0 100 27 99101 Forward Reverse selector switch FNR signal MULTI FNR 100 010 001 28 99300 Machine status HST STATUS 0 6 29 99301 Clutch sta...

Page 510: ... When stopped When traction level A is set 84 When traction level B is set 74 When traction level C is set 64 Display is as shown at left regardless of traction control switch position 100 F 010 N 001 R ON OFF refers to each bit Condition display Stopped 0 Forward travel Directional lever in F 1 Reverse travel Directional lever in R 2 Forward travel lever in R 3 Reverse travel lever in F 4 Forward...

Page 511: ...tional switch selector switch Pressing switch ON 24 V OFF OPEN D IN 4 Traction control switch Pressing switch ON GND OFF OPEN D IN 5 D IN 6 D IN 7 2 40978 D OUT 0 D OUT 1 D OUT 2 D OUT 3 D OUT 4 D OUT 5 D OUT 6 D OUT 7 3 40979 D OUT 8 D OUT 9 D OUT 10 D OUT 11 D OUT 12 D OUT 13 D OUT 14 VIS Self holding relay Output ON ON GND OFF OPEN D OUT 15 HST safety relay Output ON ON GND OFF OPEN 4 40980 D O...

Page 512: ...9 9 kPa 13 36502 Boost pressure sensor voltage CHG PRESS A 0 00 5 00 V 14 18700 Engine output torque OUTPUT TORQUE 24000 24000 Nm 15 36700 Equivalent torque TORQUE RATIO 0 100 16 31706 Final accelerator position FINAL THROTTLE 0 100 17 37300 Momentary fuel consumption FUEL RATE 0 0 999 9 1 h 18 18600 Final injection volume command in weight INJECT COMMAND 0 1000 mg 19 36300 Final injection timing ...

Page 513: ... Service mode 2 Displaying sub menu Press U switch while the menu is selected to display the sub menu 3 Selecting a cylinder to be reduced Using or switch select a cylinder to be reduced from No 1 No 6 cylinders and then settle the selected cylinder using U switch a The cylinder to be reduced is selectable while the engine is run a Any number of cylinders can be reduced a single unit or two or mor...

Page 514: ...on cranking When a machine has been stored for a long time this function is used to lubricate the engine prior to its restart in order to prevent its wear or damages out of oil The no injection cranking must be set up while the engine is stopped 1 Selecting menu Display the NO INJECTION screen from menu screen of Service mode 2 Pressing U switch sets up the no injec tion cranking a If this screen ...

Page 515: ...ion is selected a The interval of the fan automatic reverse operation is adjustable in the range from 0 1 h 6 minutes to 200 h It must be set to at least twice the continuance of the fan automatic reverse operation however and cannot be set shorter than twice a When the machine is delivered the inter val of fan automatic reverse operation is set to 2 0 h a When the machine is delivered the con tin...

Page 516: ...stment of continuance of fan automatic reverse operation a This function is used to change the contin uance of the reverse operation when the fan automatic reverse operation is selected a The continuance of the fan automatic reverse operation is adjustable in the range from 0 5 minutes to 10 minutes It must be set to below 1 2 of the interval of the fan automatic reverse operation how ever and can...

Page 517: ...ift arm angle sensor upper Load meter specification a This item is not used 7 4 Adjustment of lift arm angle sensor lower Load meter specification a This item is not used 7 5 Adjustment of ECSS operation travel speed if equipped a This function is used to adjust the ECSS operation reset travel speed a The initial ECSS operation travel speed is 5 km h 3 1 MPH a The ECSS reset travel speed is the EC...

Page 518: ...adjusted to a minimum of 5 km h 3 1 MPH 7 If the operation travel speed is set to a desired value press t switch to finish setting 8 Maintenance monitoring function The maintenance function offers the following capabilities in the maintenance of filters and oils q Change of maintenance interval time q Selection between enabling or disabling timer by item q Setting of a default value q Selection be...

Page 519: ...tting range The entered interval time does not replace the cur rent value and the input screen will be restored a The shortest interval time value is 50 h a When you have entered a wrong value to a position except the highest order digit move to the highest order digit using t switch and repeat the procedure from the first In this case the value that had been entered remains as it is until modifie...

Page 520: ... is changed the timer remaining time is changed as shown below q Timer remaining time Interval time being set Elapsed time from the last replace ment 8 2 Selection between enabling or disabling timer by item 1 Pressing or switch from 8 1 3 Inter val time change screen displays the Selection between enabling or disabling timer by item screen a When Timer by item is enabled the order of display is O...

Page 521: ...witch from this state 4 Select YES or NO using or switch a The selected cursor will start flashing If YES is selected and t switch is pressed the change will be enabled If NO is selected and t switch is pressed the change will not be imple mented and the maintenance monitoring screen will be restored a By default the cursor is set to NO cancel to prevent resetting error a If the default value sett...

Page 522: ...S o ON screen a When U switch is pressed from the ALL ITEMS o OFF screen OFF will be is dis played in the upper space a When U switch is pressed from the ALL ITEMS o ON screen ON will be is dis played in the upper space 6 Select YES or NO using or switch a The selected cursor will start flashing If YES is selected and t switch is pressed the information will be deleted If NO is selected and t swit...

Page 523: ...ency This display is available only when the load meter is installed 1 Selecting menu Display the OPERATION INFO screen from the menu screen of Service mode 2 Press U switch to display the fuel con sumption ratio and average fuel consump tion screen 3 Using or switch select the item to be displayed from 1 4 on the fuel con sumption ratio and average fuel consump tion screen 1 Fuel consumption rati...

Page 524: ...st resetting q Upper limit Counting is stopped at 199999999 9 q Short ton or metric ton depends on optional setting a The lower column displays the load ing frequency from the last resetting q Upper limit Counting starts stopped at 65000 a Calculation is done only for the dura tion in which the engine is run and the optional device is used 4 Deleting display data a Data on screens 5 8 allow deleti...

Page 525: ...nges the value of this digit in the range of 0 9 7 Press U switch when the intended value appeared to specify it as the set value a The cursor moves to the 2nd digit 8 Set the values up to the lowest digit in the same order as above and then press U switch to settle a As the selection is settled the pre ceding screen is restored a If t switch is pressed before finish ing entering the cursor moves ...

Page 526: ...p to ADD normally NO ADD is selected ECO lamp in machine monitor is kept turned OFF 5 ECSS E C S S ADD ADD If not installed optionally select NO ADD 6 Reverse fan REVERSE FAN ADD ADD If fan reverse function is not installed select NO ADD 7 Parking brake PKG BRAKE MECHA MECHA If electric parking brake is installed select ELEC MECHA Mechanical ELEC Electric 9 Tire size correction TIRE SIZE 0 0 Keep ...

Page 527: ...xed to speedometer 5 Setting at previous ADD or initial setting 6 Travel speed rpm on character display Displayed Not displayed is displayed in operator mode 7 Travel speed rpm on character display Displayed Not displayed is not displayed in operator mode 8 Not displayed 9 Setting at previous ADD or initial setting ...

Page 528: ...g or settling the option set other items in order on the next 2 EMERG S T screen and the following screens 10 1 Option setting not setting selection a Among the items included in the list of installed optional devices and their setting the option setting not setting selection applies to the fol lowing items a If the options are not selected the option non selection screen NO ADD is displayed a If ...

Page 529: ...type is changed the oper ation acceptance tone peep sounds 10 4 Setting tire deflection option a Select 9 TIRE SIZE from the list of installed optional devices and their setting a Pressing U switch sequentially displays in the following order a The display progresses from 00 through 10 Pressing U switch at this point returns the display to 00 a As the display is switched the sound beep indicating ...

Page 530: ...Service mode 2 Press U switch to display the MACHINE No screen 3 Enter the serial number according to the following procedure a The cursor is positioned at the high est order digit 1 Pressing or switch increases or decreases the value at the cursor position Select a desired value using these switches 2 Press U switch to settle the selec tion a The cursor moves to the digit situated immediately on ...

Page 531: ...320 a If wrong model and tire are set machine does not work correctly a Press t switch when stopping the model selection a As the operation is stopped the sound beep indicating acceptance of the opera tion will be generated restoring the MACHINE screen 4 With the U switch settle the changed machine model and tire size a As the selection is settled the sound beep indicating acceptance of the opera ...

Page 532: ...sure SAE15W 40 High idle MPa kg cm2 Min 0 29 Min 3 0 0 25 2 5 Low idle Min 0 10 Min 1 0 0 07 0 7 a Before starting the inspection check that the machine does not move when the directional lever is placed in position k When measuring the transfer clutch control pressure carry out the measurement at a place where the machine can travel safety at a speed of more than 10 km h HST High pressure cut off...

Page 533: ...83 197 16 6 20 6 170 210 Brake Service brake Lining thick ness Front right mm 0 9 1 1 Max 0 6 Front left 0 9 1 1 Max 0 6 Rear right 0 9 1 1 Max 0 6 Rear left 0 9 1 1 Max 0 6 Work equipment Relief pressure Engine high idle Bucket relief MPa kg cm2 20 2 21 0 206 214 18 6 22 6 190 230 Lift arm speed Raising time sec 5 4 6 4 Max 8 2 Lowering time 2 9 3 9 Max 4 7 Bucket speed Dumping time 1 4 2 0 Max 2...

Page 534: ...SEN03838 00 WA250 250PZ 6 30 130 61 130 Testing and adjusting Part 3 Pm clinic inspection chart ...

Page 536: ...0 1 SEN03839 00 WHEEL LOADER WA250 6 WA250PZ 6 Machine model Serial number WA250 6 75001 and up WA250PZ 6 75001 and up 40 Troubleshooting 40 100 Failure code table and fuse locations Failure codes table 2 Fuse locations 8 ...

Page 537: ...ENG E03 Electrical system Troubleshoot ing by failure code Display of code Part 2 SEN03842 00 CA115 Engine NE Bkup speed sensor Abnormality ENG E03 Electrical system CA122 Charge pressure sensor Abnormally high level ENG E03 Electrical system CA123 Charge pressure sensor Abnormally low level ENG E03 Electrical system CA131 Throttle sensor Abnormally high level ENG E03 Electrical system CA132 Throt...

Page 538: ...ormality ENG E03 Electrical system CA352 Sensor power supply 1 Abnormally low level ENG E03 Electrical system CA386 Sensor power supply 1 Abnormally high level ENG E03 Electrical system CA428 Water sensor Abnormally high level ENG E01 Electrical system Troubleshoot ing by failure code Display of code Part 3 SEN03843 00 CA429 Water sensor Abnormally low level ENG E01 Electrical system CA431 Idle va...

Page 539: ... relay Disconnection ENG E01 Electrical system CA2556 Intake air heater relay Short circuit ENG E01 Electrical system D160KY Backup lamp buzzer relay Hot short MON E01 Electrical system Troubleshoot ing by failure code Display of code Part 4 SEN03844 00 D192KY ECSS solenoid relay Hot short MON E01 Electrical system D1B0KA HST safety relay Disconnection HST E03 Electrical system D1B0KB HST safety r...

Page 540: ...everse switch signal Abnormality HST E01 Electrical system DDB6KA Parking brake switch A Disconnection Hot short HST E01 Electrical system DDB6KB Parking brake switch B Ground fault HST E01 Electrical system DDB6KZ Parking brake switch or parking brake B reminder switch Trouble MON E03 Electrical system DDB6L0 Parking brake switch A Ground fault HST E01 Electrical system DDB6L4 Parking brake switc...

Page 541: ...y HST E03 Electrical system DLT4KX Travel speed sensor A Abnormality HST E03 Electrical system DLT4LC Travel speed sensor A B Abnormality HST E03 Electrical system DV00KY Alarm buzzer Hot short MON E01 Electrical system DW26KA Motor 2 solenoid Disconnection Ground fault HST E01 Electrical system DW26KY Motor 2 solenoid Hot short HST E01 Electrical system DW7BKY Fan reverse solenoid circuit Hot sho...

Page 542: ...electrical system or mechanical system in the fail ure history display function a failure has been recorded a Note Optional equipment is also included in table DX20KB Clutch solenoid Ground fault HST E03 Electrical system Troubleshoot ing by failure code Display of code Part 7 SEN03847 00 DX20KY Clutch solenoid Hot short HST E03 Electrical system DXH7KB Reverse solenoid Ground fault HST E03 Electr...

Page 543: ... box FS1 Optional devices are included Devices which are not set may be included Type of power supply Power source Fuse No Fuse capacity Destination of power Unswitched power supply Slow blow fuse 50 A 1 20A Starting switch B 2 10 A Hazard lamp 3 15 A HST controller 4 30 A Engine controller 5 10 A Machine monitor Tachograph Buzzer 6 10 A Radio Auto grease Room lamp 7 10 A Unswitched power supply f...

Page 544: ... 80A 1 20 A Air conditioner blower 2 5 A Air conditioner compressor 3 20 A Beacon Working lamp Front For addition Rotary lamp 4 20 A Glass heater 5 10 A Load meter air cleaner clogging relay 6 20 A Key ON power for optional device 7 10 A DC converter 8 10 A Parking brake Horn 9 10 A Air suspension seat 10 10 A Small lamp right 11 10 A Small lamp left 12 10 A Working lamp front 13 10 A Working lamp...

Page 545: ...te 2 on left side of engine compart ment and remove cover 3 Arrangement of slow blow fuse Type of power supply Power source Fuse capacity Destination of power Accessory power supply Battery 80 A Fuse box FS1 No 8 15 Fuse box FS2 No 1 15 120A Engine intake air heater relay Unswitched power supply Battery 50 A Fuse box FS1 No 1 7 ...

Page 546: ...SEN03839 00 WA250 250PZ 6 40 100 11 100 Failure code table and fuse locations Fuse locations ...

Page 548: ...ting 40 200 General information on troubleshooting Points to remember when troubleshooting 2 Sequence of events in troubleshooting 3 Testing before troubleshooting 4 Classification and procedures of troubleshooting 5 Information contained in troubleshooting table 8 Connection table for connector pin numbers 10 T branch box and T branch adapter table 46 ...

Page 549: ...a waste of manhours parts or oil or grease and at the same time will also lose the confidence of the user or operator For this reason when carrying out troubleshooting it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed pro cedure 2 Points to ask user or operator 1 Have any other problems occurred apart from the problem that has b...

Page 550: ...SEN03840 01 WA250 250PZ 6 40 200 3 200 General information on troubleshooting Sequence of events in troubleshooting Sequence of events in troubleshooting 1 ...

Page 551: ... or replace 13 Check of alternator terminal cables for looseness and corrosion Retighten or replace 14 Check of starting motor terminal cables for looseness and corrosion Retighten or replace 15 Check of operation of instruments Repair or replace Hydraulic and mechanical equipment 16 Check for abnormal noise and smell Repair 17 Check for oil leakage Repair 18 Bleeding air Bleed air 19 Check of eff...

Page 552: ...ed If an action code is not displayed on the machine monitor check for a failure code in the failure code dis play mode for the electrical system and the mechanical system of the machine monitor EMMS If a failure code is recorded carry out troubleshooting in Display of code according to that failure code a Each failure code flashes when the trouble corresponding to it is detected Even if a failure...

Page 553: ...is black Incomplete combustion S 7 12 Oil consumption is excessive or exhaust smoke is blue S 8 13 Oil becomes contaminated quickly S 9 14 Fuel consumption is excessive S 10 15 Oil is in coolant or coolant spurts back or coolant level goes down S 11 16 Oil pressure drops S 12 17 Oil level rises Entry of coolant or fuel S 13 18 Coolant temperature becomes too high overheating S 14 19 Abnormal noise...

Page 554: ... valve is set to HOLD H 24 47 When the control lever is switched from HOLD to TILT the bucket falls temporarily H 25 48 The control levers of the lift arm and bucket do not move smoothly and heavy H 26 49 The ECSS does not operate and machine pitches and bounces H 27 50 Fan revolution is abnormal Fan sound vibration is abnormally large or engine overheats H 28 51 Defective boom kick out function a...

Page 555: ...e cause is good Phenomenon of defective wiring harness Disconnection in wiring The connector connection is defective or the wiring harness is disconnected Grounding fault A harness not connected to ground earth circuit comes into contact with the ground earth circuit Hot short circuit A harness not connected to the power 24 V circuit comes into contact with the power 24 V circuit Short circuit A h...

Page 556: ... Related circuit diagram This is the excerpted circuit diagram related to trouble Connector No Indicates Model No of pins Color Connector No and pin No from each branching merging point Shows the ends of branch or source of merging within the parts of the same wiring harness Arrow io Roughly shows the location on the machine ...

Page 557: ... on troubleshooting Connection table for connector pin numbers Connection table for connector pin numbers Rev 2009 04 a The terms of male and female refer to the pins while the terms of male housing and female housing refer to the mating portion of the housing ...

Page 558: ...SEN03840 01 WA250 250PZ 6 40 200 11 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 559: ...SEN03840 01 40 200 12 WA250 250PZ 6 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 560: ...SEN03840 01 WA250 250PZ 6 40 200 13 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 561: ...SEN03840 01 40 200 14 WA250 250PZ 6 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 562: ...SEN03840 01 WA250 250PZ 6 40 200 15 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 563: ...SEN03840 01 40 200 16 WA250 250PZ 6 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 564: ...SEN03840 01 WA250 250PZ 6 40 200 17 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 565: ...SEN03840 01 40 200 18 WA250 250PZ 6 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 566: ...SEN03840 01 WA250 250PZ 6 40 200 19 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 567: ...SEN03840 01 40 200 20 WA250 250PZ 6 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 568: ...SEN03840 01 WA250 250PZ 6 40 200 21 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 569: ...SEN03840 01 40 200 22 WA250 250PZ 6 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 570: ...SEN03840 01 WA250 250PZ 6 40 200 23 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 571: ...SEN03840 01 40 200 24 WA250 250PZ 6 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 572: ...SEN03840 01 WA250 250PZ 6 40 200 25 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 573: ...SEN03840 01 40 200 26 WA250 250PZ 6 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 574: ...SEN03840 01 WA250 250PZ 6 40 200 27 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 575: ...SEN03840 01 40 200 28 WA250 250PZ 6 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 576: ...SEN03840 01 WA250 250PZ 6 40 200 29 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 577: ...SEN03840 01 40 200 30 WA250 250PZ 6 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 578: ...SEN03840 01 WA250 250PZ 6 40 200 31 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 579: ...SEN03840 01 40 200 32 WA250 250PZ 6 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 580: ...SEN03840 01 WA250 250PZ 6 40 200 33 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 581: ...SEN03840 01 40 200 34 WA250 250PZ 6 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 582: ...SEN03840 01 WA250 250PZ 6 40 200 35 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 583: ...SEN03840 01 40 200 36 WA250 250PZ 6 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 584: ...SEN03840 01 WA250 250PZ 6 40 200 37 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 585: ...SEN03840 01 40 200 38 WA250 250PZ 6 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 586: ...SEN03840 01 WA250 250PZ 6 40 200 39 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 587: ...SEN03840 01 40 200 40 WA250 250PZ 6 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 588: ...SEN03840 01 WA250 250PZ 6 40 200 41 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 589: ...SEN03840 01 40 200 42 WA250 250PZ 6 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 590: ...SEN03840 01 WA250 250PZ 6 40 200 43 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 591: ...SEN03840 01 40 200 44 WA250 250PZ 6 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 592: ...SEN03840 01 WA250 250PZ 6 40 200 45 200 General information on troubleshooting Connection table for connector pin numbers ...

Page 593: ...er for BENDIX MS 19 MS 19P q 799 601 2910 Adapter for BENDIX MS 14 MS 14P q 799 601 3470 Case q 799 601 2710 Adapter for MIC 5 MIC 5P q q q 799 601 2720 Adapter for MIC 13 MIC 13P q q q 799 601 2730 Adapter for MIC 17 MIC 17P q q q q q q 799 601 2740 Adapter for MIC 21 MIC 21P q q q q q q 799 601 2950 Adapter for MIC 9 MIC 9P q q q q 799 601 2750 Adapter for ECONO 2 ECONO2P q q 799 601 2760 Adapte...

Page 594: ...er for DTM 2 DTM2 q q 799 601 9020 Adapter for DT 2 DT2 q q q q 799 601 9030 Adapter for DT 3 DT3 q q 799 601 9040 Adapter for DT 4 DT4 q q q q 799 601 9050 Adapter for DT 6 DT6 q q 799 601 9060 Adapter for DT Gray 8 DT8GR q q 799 601 9070 Adapter for DT Black 8 DT8B q q 799 601 9080 Adapter for DT Green 8 DT8G q q 799 601 9090 Adapter for DT Brown 8 DT8BR q q 799 601 9110 Adapter for DT Gray 12 D...

Page 595: ... 799 601 4160 Adapter for engine CRI T3 Oil pressure switch 2 4160 q q 799 601 4180 Adapter for engine CRI T3 PEVA 3 4180 q q 799 601 4190 Socket for engine CRI T3 Commonrail pressure 3 1 2 3L q q 799 601 4230 Socket for engine CRI T3 Air intake pressure temperature 4 1 2 3 4C q q 799 601 4240 Socket for engine CRI T3 PAMB 3 1 2 3A q q 799 601 4250 Socket for engine CRI T3 PIM 3 1 2 3B q q 799 601...

Page 596: ...SEN03840 01 WA250 250PZ 6 40 200 49 200 General information on troubleshooting T branch box and T branch adapter table ...

Page 598: ...re code 6091NX HST filter Clogging 4 Failure code 989FN1 Travel speed Overrun alarm 6 Failure code AB00L6 Alternator R system Hot short 8 Failure code AB00MA Alternator R system Ground fault Disconnection charge Low charge voltage 10 Failure code B BAZG Engine Oil pressure reduction 12 Failure code B BCNS Engine Overheat 13 Failure code B BCZK Engine Low coolant level 14 Failure code B C6NS Front ...

Page 599: ...sensor can be checked with monitoring function Monitoring code MONITOR PANEL 40902 D IN 16 Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Brake oil pressure reduction System is normal aCarry out troubleshooting for hydraulic and mechanical systems 2 Defective brake oil pressure sensor Internal defect aPrepare with starting swit...

Page 600: ...SEN03841 00 WA250 250PZ 6 40 310 3 310 Troubleshooting by failure code Display of code Part 1 Failure code 2G40GZ Brake Oil pressure reduction Related circuit diagram ...

Page 601: ...Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Clogged HST oil filter System is normal aCheck HST oil filter directly 2 Defective HST oil filter clog ging sensor Internal defect aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON T13 Filter condition Resistance Between T13 ground ...

Page 602: ...SEN03841 00 WA250 250PZ 6 40 310 5 310 Troubleshooting by failure code Display of code Part 1 Failure code 6091NX HST filter Clogging ...

Page 603: ... that appears on machine If machine is used as it is brake etc may be damaged Related information If DW26KA or DW26KY is displayed carry out troubleshooting for it first Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Overrun System is normal when machine is used as it overruns by acceler ating on sharp downhill road etc aCheck ...

Page 604: ...SEN03841 00 WA250 250PZ 6 40 310 7 310 Troubleshooting by failure code Display of code Part 1 Failure code 989FN1 Travel speed Overrun alarm ...

Page 605: ...LTERNATOR R Method of reproducing failure code Turn the starting switch ON Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective alternator Internal trouble aPrepare with starting switch OFF then start engine and carry out troubleshooting Alternator Engine Voltage Wiring harness between E02 female 1 ground Running Throttle A...

Page 606: ...SEN03841 00 WA250 250PZ 6 40 310 9 310 Troubleshooting by failure code Display of code Part 1 Failure code AB00L6 Alternator R system Hot short Related circuit diagram ...

Page 607: ...Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 The battery is deteriorated The battery may be deteriorated Check it directly 2 Defective alternator Internal trouble aPrepare with starting switch OFF then start engine and carry out troubleshooting Alternator Engine Voltage Wiring harness between E02 female 1 ground Running Throt...

Page 608: ...841 00 WA250 250PZ 6 40 310 11 310 Troubleshooting by failure code Display of code Part 1 Failure code AB00MA Alternator R system Ground fault Disconnection charge Low charge voltage Related circuit diagram ...

Page 609: ... Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Low engine oil pressure When the system is normal Engine oil has potentially gone low Check the pressure and if it is below the specified level locate and eliminate the cause 2 Defective engine oil pressure switch Internal trouble aPrepare with starting switch OFF then start engin...

Page 610: ... on machine Engine output decreases Related information Engine coolant temperature can be checked with monitoring function Monitoring code ENGINE 04104 COOLANT TEMP C Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Engine coolant overheat when system is normal Engine coolant may be overheating Remove cause of overheat 2 Defectiv...

Page 611: ...rks on troubleshooting 1 Low radiator sub tank cool ant level System is normal aRadiator sub tank coolant level may be low Check and add cool ant if necessary 2 Defective radiator coolant level switch Internal defect aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON M05 male Sub tank coolant level Resistance Between 1 2 Above low level Normal Max 1...

Page 612: ...SEN03841 00 WA250 250PZ 6 40 310 15 310 Troubleshooting by failure code Display of code Part 1 Failure code B BCZK Engine Low coolant level Related circuit diagram ...

Page 613: ...sed as it is brake may be damaged Related information If temperature above 120 C is detected for 5 seconds continuously only caution lamp is turned ON as preliminary warning Brake oil temperature can be checked with monitoring function Monitoring code MONITOR PANEL 30201 F BRAKE OIL C Monitoring code MONITOR PANEL 30204 F BRAKE OIL V Possible causes and standard value in normal state Causes Standa...

Page 614: ...s hydraulic system equipments may be damaged Related information HST oil temperature can be checked with monitoring function Monitoring code MONITO PANEL 04408 HST OIL TEMP C Monitoring code MONITO PANEL 04409 HST OIL TEMP V Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 HST high oil temperature System is normal a HST oil may b...

Page 616: ...ensor high error 14 Failure code CA145 Coolant sensor low error 16 Failure code CA153 Charge temperature sensor high error 18 Failure code CA154 Charge temperature sensor low error 20 Failure code CA155 Derating of speed by abnormally high charge temperature 22 Failure code CA187 Sensor power supply 2 low error 24 Failure code CA221 Atmospheric pressure sensor high error 26 Failure code CA222 Atmo...

Page 617: ...ode CA325 Injector 6 open short error 42 Failure code CA331 Injector 2 open short error 44 Failure code CA332 Injector 4 open short error 46 Failure code CA342 Calibration code inconsistency 48 Failure code CA351 Injectors drive circuit error 50 Failure code CA352 Sensor power supply 1 low error 52 Failure code CA386 Sensor power supply 1 high error 54 ...

Page 618: ... of trouble Abnormality occurred in memory of engine controller or power supply circuit Action of controller Turns the centralized warning lamp and alarm buzzer ON Problem that appears on machine The engine does not start Related information Method of reproducing failure code Start engine Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troublesho...

Page 619: ...urred in signals of engine Ne speed sensor and engine Bkup speed sensor circuit Action of controller Turns the centralized warning lamp and alarm buzzer ON Problem that appears on machine Engine stops The engine does not start Related information Method of reproducing failure code Start engine Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troub...

Page 620: ...SEN03842 00 WA250 250PZ 6 40 320 5 320 Troubleshooting by failure code Display of code Part 2 Failure code CA115 Engine Ne or Bkup speed sensor error ...

Page 621: ...ctive boost pressure sensor and temperature sen sors pressure signal system Internal trouble aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting BOOST PRESS IMT Voltage Between 2 and 4 Voltage 4 75 5 25 V Voltage is measured with wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble ...

Page 622: ...SEN03842 00 WA250 250PZ 6 40 320 7 320 Troubleshooting by failure code Display of code Part 2 Failure code CA122 Charge pressure sensor high error Related circuit diagram ...

Page 623: ...st pressure sensor or temperature sen sor pressure signal circuit Internal trouble aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting BOOST PRESS IMT Voltage Between 2 and 4 Power supply 4 75 5 25 V Voltage is measured with wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and t...

Page 624: ...SEN03842 00 WA250 250PZ 6 40 320 9 320 Troubleshooting by failure code Display of code Part 2 Failure code CA123 Charge pressure sensor low error Related circuit diagram ...

Page 625: ... starting switch OFF then turn starting switch ON and carry out troubleshooting PD1 Accelerator pedal Voltage Between 1 and 3 All range Power supply 4 75 5 25 V Between 2 and 3 When released 0 50 0 80 V When pressed 3 70 4 00 V Sensor voltage is measured with wiring harness connected Accord ingly if voltage is abnormal check wiring harness and controller for another cause of trouble before judgmen...

Page 626: ...SEN03842 00 WA250 250PZ 6 40 320 11 320 Troubleshooting by failure code Display of code Part 2 Failure code CA131 Throttle sensor high error Related circuit diagram ...

Page 627: ...witch OFF then turn starting switch ON and carry out troubleshooting PD1 Accelerator pedal Voltage Between 1 and 3 All range Power supply 4 75 5 25 V Between 2 and 3 When released 0 50 0 80 V When pressed 3 70 4 00 V Sensor voltage is measured with wiring harness connected Accord ingly if voltage is abnormal check wiring harness and controller for another cause of trouble before judgment 3 Ground ...

Page 628: ...SEN03842 00 WA250 250PZ 6 40 320 13 320 Troubleshooting by failure code Display of code Part 2 Failure code CA132 Throttle sensor low error Related circuit diagram ...

Page 629: ...starting switch ON COOLANT TEMP male Coolant temperature Resistance Between A and B 0 C 30 37 kz 25 C 9 3 10 7 kz 50 C 3 2 3 8 kz 80 C 1 0 1 3 kz 95 C 700 800 z 2 Disconnection in wiring har ness Disconnection or defective contact in connector aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between EC1 female 15 COOLANT TEMP female...

Page 630: ...SEN03842 00 WA250 250PZ 6 40 320 15 320 Troubleshooting by failure code Display of code Part 2 Failure code CA144 Coolant sensor high error Related circuit diagram ...

Page 631: ...bleshooting 1 Defective coolant tempera ture sensor Internal trouble aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON COOLANT TEMP male Coolant temperature Resistance Between A and B 0 C 30 37 kz 25 C 9 3 10 7 kz 50 C 3 2 3 8 kz 80 C 1 0 1 3 kz 95 C 700 800 z Between B and ground All range Min 100 kz 2 Ground fault in wiring har ness Short circuit...

Page 632: ...alue in normal state Causes Standard value in normal state Remarks on troubleshooting 5 Defective engine controller a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON EC1 male Coolant temperature Resistance Between 15 and 38 0 C 30 37 kz 25 C 9 3 10 7 kz 50 C 3 2 3 8 kz 80 C 1 0 1 3 kz 95 C 700 800 z Between 15 and ground All range Min 100 kz ...

Page 633: ...e aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON BOOST PRESS IMT male Charge temperature Resistance Between 3 and 4 0 C 29 36 kz 25 C 9 11 kz 40 C 4 9 5 8 kz 100 C 600 700 z 2 Disconnection in wiring har ness Disconnection or defective contact in connector aPrepare with starting switch OFF then carry out troubleshooting without turning starting ...

Page 634: ...SEN03842 00 WA250 250PZ 6 40 320 19 320 Troubleshooting by failure code Display of code Part 2 Failure code CA153 Charge temperature sensor high error Related circuit diagram ...

Page 635: ...n normal state Remarks on troubleshooting 1 Defective temperature sig nal circuit of boost pressure sensor temperature sensor Internal trouble aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON BOOST PRESS IMT male Charge temperature Resistance Between 2 and 1 0 C 29 36 kz 25 C 9 11 kz 40 C 4 9 5 8 kz 100 C 600 700 z Between 2 and ground All range M...

Page 636: ... and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 5 Defective engine controller a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON EC1 female Charge temperature Resistance Between 23 and 47 0 C 29 36 kz 25 C 9 11 kz 40 C 4 9 5 8 kz 100 C 600 700 z Between 23 and ground All range Min 100 kz ...

Page 637: ... the charge temperature sensor boost temperature sensor can be checked with the monitoring function Code ENGINE 18500 CHG TEMP The input state voltage from the charge temperature sensor boost temperature sensor can be checked with the monitoring function Code ENGINE 18501 CHG TEMP Method of reproducing failure code Start engine Possible causes and standard value in normal state Causes Standard val...

Page 638: ...SEN03842 00 WA250 250PZ 6 40 320 23 320 Troubleshooting by failure code Display of code Part 2 Failure code CA155 Derating of speed by abnormally high charge temperature ...

Page 639: ...es Standard value in normal state Remarks on troubleshooting 1 Defective sensor or wiring harness aDisconnect connector with starting switch OFF then turn starting switch ON and carry out troubleshooting Disconnect devices at right in order If mark E of failure code dis appears after repro duction operation is conducted that device or wiring har ness has a defect in it Boost pressure temperature s...

Page 640: ...SEN03842 00 WA250 250PZ 6 40 320 25 320 Troubleshooting by failure code Display of code Part 2 Failure code CA187 Sensor power supply 2 low error Related circuit diagram ...

Page 641: ... pres sure sensor Internal trouble aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting AMBAIR PRESSURE Voltage Between 1 and 2 Power supply 4 75 5 25 V Voltage is measured with wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Hot short Short circuit with 5V 24V ...

Page 642: ...SEN03842 00 WA250 250PZ 6 40 320 27 320 Troubleshooting by failure code Display of code Part 2 Failure code CA221 Atmospheric pressure sensor high error Related circuit diagram ...

Page 643: ...nal trouble aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting AMBAIR PRESSURE Voltage Between 1 and 2 Power supply 4 75 5 25 V Voltage is measured with wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Ground fault in wiring har ness Short circuit with ground c...

Page 644: ...SEN03842 00 WA250 250PZ 6 40 320 29 320 Troubleshooting by failure code Display of code Part 2 Failure code CA222 Atmospheric sensor low error Related circuit diagram ...

Page 645: ...rns the centralized warning lamp and alarm buzzer ON Problem that appears on machine Engine output drops Related information Method of reproducing failure code Turn the starting switch ON Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective wiring harness connector Connecting parts among each sensor engine wiring harness an...

Page 646: ...buzzer ON Problem that appears on machine Engine speed fluctuates Related information Engine speed can be checked by monitoring function Code ENGINE 01001 ENG SPEED Method of reproducing failure code Start engine and running at high idle Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Use of improper fuel Check fuel used directl...

Page 647: ...lated information Method of reproducing failure code Turn the starting switch ON Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective sensor or wiring harness aDisconnect connector with starting switch OFF then turn starting switch ON and carry out troubleshooting Disconnect devices at right in order If failure code disappe...

Page 648: ...P3 PUMP REGULATOR male Resistance Between 1 and ground Min 100 kz 2 Ground fault in wiring har ness Short circuit with ground cir cuit a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between EC1 female 2 CP3 PUMP REGULATOR female 1 and ground Resis tance Min 100 kz 3 Short circuit in wiring har ness with another wiring harness a P...

Page 649: ...n carry out troubleshooting without turning starting switch ON Wiring harness between EC1 female 2 CP3 PUMP REGULATOR female 1 Resis tance Max 10 z Wiring harness between EC1 female 32 CP3 PUMP REGULATOR female 2 Resis tance Max 10 z 3 Hot short Short circuit with 24V circuit in wiring harness aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting Wiring harne...

Page 650: ...SEN03842 00 WA250 250PZ 6 40 320 35 320 Troubleshooting by failure code Display of code Part 2 Failure code CA272 IMV IMA Disconnection Related circuit diagram ...

Page 651: ...ing harness between EC1 female 53 INJ CYL 1 2 Resis tance Max 2 z 3 Ground fault in wiring har ness Contact with ground circuit aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between EC1 female 45 INJ CYL 1 1 and ground Resis tance Max 2 z 4 Short circuit in wiring har ness with another wiring harness aPrepare with starting switch...

Page 652: ...SEN03842 00 WA250 250PZ 6 40 320 37 320 Troubleshooting by failure code Display of code Part 2 Failure code CA322 Injector 1 open short error Related circuit diagram ...

Page 653: ...ing harness between EC1 female 60 INJ CYL 5 2 Resis tance Max 2 z 3 Ground fault in wiring har ness Contact with ground circuit aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between EC1 female 46 INJ CYL 5 1 and ground Resis tance Max 2 z 4 Short circuit in wiring har ness with another wiring harness aPrepare with starting switch...

Page 654: ...SEN03842 00 WA250 250PZ 6 40 320 39 320 Troubleshooting by failure code Display of code Part 2 Failure code CA323 Injector 5 open short error Related circuit diagram ...

Page 655: ...ing harness between EC1 female 55 INJ CYL 3 1 Resis tance Max 2 z 3 Ground fault in wiring har ness Contact with ground circuit aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between EC1 female 55 INJ CYL 3 1 and ground Resis tance Max 2 z 4 Short circuit in wiring har ness with another wiring harness aPrepare with starting switch...

Page 656: ...SEN03842 00 WA250 250PZ 6 40 320 41 320 Troubleshooting by failure code Display of code Part 2 Failure code CA324 Injector 3 open short error Related circuit diagram ...

Page 657: ...ing harness between EC1 female 59 INJ CYL 6 1 Resis tance Max 2 z 3 Ground fault in wiring har ness Contact with ground circuit aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between EC1 female 57 INJ CYL 6 2 and ground Resis tance Max 2 z 4 Short circuit in wiring har ness with another wiring harness aPrepare with starting switch...

Page 658: ...SEN03842 00 WA250 250PZ 6 40 320 43 320 Troubleshooting by failure code Display of code Part 2 Failure code CA325 Injector 6 open short error Related circuit diagram ...

Page 659: ...ing harness between EC1 female 51 INJ CYL 2 2 Resis tance Max 2 z 3 Ground fault in wiring har ness Contact with ground circuit aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between EC1 female 54 INJ CYL 2 1 and ground Resis tance Max 2 z 4 Short circuit in wiring har ness with another wiring harness aPrepare with starting switch...

Page 660: ...SEN03842 00 WA250 250PZ 6 40 320 45 320 Troubleshooting by failure code Display of code Part 2 Failure code CA331 Injector 2 open short error Related circuit diagram ...

Page 661: ...ing harness between EC1 female 58 INJ CYL 4 2 Resis tance Max 2 z 3 Ground fault in wiring har ness Contact with ground circuit aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between EC1 female 56 INJ CYL 4 1 and ground Resis tance Max 2 z 4 Short circuit in wiring har ness with another wiring harness aPrepare with starting switch...

Page 662: ...SEN03842 00 WA250 250PZ 6 40 320 47 320 Troubleshooting by failure code Display of code Part 2 Failure code CA332 Injector 4 open short error Related circuit diagram ...

Page 663: ...a Action of controller Turns the centralized warning lamp and alarm buzzer ON Problem that appears on machine Continues the normal operation Engine stops or does not start Related information Method of reproducing failure code Turn the starting switch ON Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defect in related system If...

Page 664: ...SEN03842 00 WA250 250PZ 6 40 320 49 320 Troubleshooting by failure code Display of code Part 2 Failure code CA342 Calibration code inconsistency ...

Page 665: ...arting switch ON L107 Male Resistance Between 1 and 2 200 400 z aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting When engine control cut out relay L107 is replaced with a relay of the same type if the condition becomes normal the engine control cut out relay 1 is defective 4 Defective engine control cut out relay L108 Internal dis connection or short cir...

Page 666: ...SEN03842 00 WA250 250PZ 6 40 320 51 320 Troubleshooting by failure code Display of code Part 2 Failure code CA351 Injectors drive circuit error Related circuit diagram ...

Page 667: ...tate Causes Standard value in normal state Remarks on troubleshooting 1 Defective sensor or wiring harness aDisconnect connector with starting switch OFF then turn starting switch ON and carry out troubleshooting Disconnect devices at right in order If failure code disappears after reproduction opera tion is conducted that device or wiring har ness has a defect in it Atmospheric pres sure sensor A...

Page 668: ...SEN03842 00 WA250 250PZ 6 40 320 53 320 Troubleshooting by failure code Display of code Part 2 Failure code CA352 Sensor power supply 1 low error Related circuit diagram ...

Page 669: ...hat appears on machine Starting performance is poor Engine output drops Related information Method of reproducing failure code Turn the starting switch ON Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective wiring harness connector Connecting parts among atmospheric pressure sensor engine wir ing harness and engine control...

Page 670: ...SEN03842 00 WA250 250PZ 6 40 320 55 320 Troubleshooting by failure code Display of code Part 2 Failure code CA386 Sensor power supply 1 high error ...

Page 672: ... Common rail pressure high error 2 22 Failure code CA451 Common rail pressure sensor high error 24 Failure code CA452 Common rail pressure sensor low error 26 Failure code CA488 Derating of torque by abnormally high charge temperature 28 Failure code CA553 Common rail pressure high error 1 29 Failure code CA559 Supply pump pressure very low error 30 Failure code CA689 Engine Ne speed sensor error ...

Page 673: ...30 Troubleshooting by failure code Display of code Part 3 Failure code CA2311 Abnormality in IMV IMA solenoid 50 Failure code CA2555 Intake heater relay disconnection error 52 Failure code CA2556 Intake heater relay short circuit error 54 ...

Page 674: ...SEN03843 00 WA250 250PZ 6 40 330 3 330 Troubleshooting by failure code Display of code Part 3 ...

Page 675: ...on in wiring har ness Disconnection or defective contact in connector aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between EC1 female 14 E42 male 1 Resis tance Max 10 z Wiring harness between EC1 female 47 E42 male 2 Resis tance Max 10 z 3 Short circuit in wiring har ness with another wiring harness aPrepare with starting switch...

Page 676: ...SEN03843 00 WA250 250PZ 6 40 330 5 330 Troubleshooting by failure code Display of code Part 3 Failure code CA428 Abnormally high level in water sensor Related circuit diagram ...

Page 677: ... and ground Min 100 kz 2 Ground fault in wiring har ness Contact with ground circuit aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between EC1 female 14 E42 male 1 and ground Resis tance Min 100 kz 3 Short circuit in wiring har ness with another wiring harness aPrepare with starting switch OFF then carry out troubleshooting witho...

Page 678: ...SEN03843 00 WA250 250PZ 6 40 330 7 330 Troubleshooting by failure code Display of code Part 3 Failure code CA429 Abnormally low level in water sensor Related circuit diagram ...

Page 679: ...ee Fig 1 Between 6 and 4 Signal 2 Sensor voltage is measured with wiring harness connected Accord ingly if voltage is abnormal check wiring harness and controller for another cause of trouble before judgment 2 Disconnection in wiring har ness Disconnection or defective contact in connector aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring ha...

Page 680: ...s among accelerator pedal engine unit wiring har ness and engine controller are suspected Inspect them directly Loose connector broken lock broken seal Corrosive bent broken forced in or extended pin Humidity in connector entry of dirt or dust poor insulation Possible causes and standard value in normal state 5 Defective engine controller a Prepare with starting switch OFF then carry out troublesh...

Page 681: ...CA431 Idle validation switch error Fig 1 Throttle Throttle sensor signal voltage Idle validation Idle validation switch signal voltage A Voltage when pedal opened 0 03 x Voltage when pedal pressed Voltage when pedal opened B Voltage when pedal opened 0 1 x Voltage when pedal pressed Voltage when pedal opened ...

Page 682: ...SEN03843 00 WA250 250PZ 6 40 330 11 330 Troubleshooting by failure code Display of code Part 3 Failure code CA431 Idle validation switch error ...

Page 683: ...validation switch 1 can be checked with the monitoring func tion Code ENGINE 18300 IVS 1 The input state ON OFF from the idle validation switch 2 can be checked with the monitoring func tion Code ENGINE 18301 IVS 2 The input state from throttle position sensor can be checked with the monitoring function Code ENGINE 31701 31707 THROTTLE POS Method of reproducing failure code Turn the starting switc...

Page 684: ...emale 9 EC2 female PD1 and 2 too is disconnected Resis tance Min 100 kz Wiring harness between EC2 female 21 EC2 female PD1 and 2 too is discon nected Resis tance Min 100 kz 4 Defective wiring harness connector Connecting parts among accelerator pedal engine unit wiring har ness and engine controller are suspected Inspect them directly Loose connector broken lock broken seal Corrosive bent broken ...

Page 685: ...SEN03843 00 40 330 14 WA250 250PZ 6 330 Troubleshooting by failure code Display of code Part 3 Failure code CA432 Idle validation action error Related circuit diagram ...

Page 686: ...CA432 Idle validation action error Fig 1 Throttle Throttle sensor signal voltage Idle validation Idle validation switch signal voltage A Voltage when pedal opened 0 03 x Voltage when pedal pressed Voltage when pedal opened B Voltage when pedal opened 0 1 x Voltage when pedal pressed Voltage when pedal opened ...

Page 687: ... OIL PRESSURE SWITCH male Resistance Between OIL PRESURE SWITCH male and body Max 10 z 2 Disconnection in wiring har ness Disconnection or defective contact in connector aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between EC1 female 17 OIL PRESSURE SWITCH female Resis tance Max 10 z 3 Short circuit in wiring har ness with anoth...

Page 688: ...cut out relay L107 Internal dis connection or short circuit a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON L107 Male Resistance Between 1 and 2 200 400 z a Prepare with starting switch OFF then turn starting switch ON and carry out troubleshooting When engine control cut out relay L107 is replaced with a relay of the same type if the condition ...

Page 689: ...ooting without turning starting switch ON Wiring harness among pins between EC3 female 3 4 EC3 female 1 2 With battery terminal disconnected Resis tance Min 100 kz Wiring harness among all pins between EC3 female 3 4 EC2 female With battery terminal disconnected Resis tance Min 100 kz Wiring harness among all pins between EC3 female 1 2 EC2 female With battery terminal disconnected Resis tance Min...

Page 690: ...SEN03843 00 WA250 250PZ 6 40 330 19 330 Troubleshooting by failure code Display of code Part 3 Failure code CA441 Battery voltage low error Related circuit diagram ...

Page 691: ... Method of reproducing failure code Turn the starting switch ON Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective battery voltage aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Battery Voltage Between and terminals Less than 32 V 2 Defective alternator aPrepare with st...

Page 692: ...SEN03843 00 WA250 250PZ 6 40 330 21 330 Troubleshooting by failure code Display of code Part 3 Failure code CA442 Battery voltage high error Related circuit diagram ...

Page 693: ...in normal state Remarks on troubleshooting 1 Defect in related system If another code is displayed carry out troubleshooting for it 2 Air in low pressure circuit Commingling of air with the low pressure circuit is suspected Inspect the circuit directly in the following procedure 1 Remove the pressure pickup plug outlet side of the fuel main fil ter 2 Operate the feed pump of the fuel pre filter 3 ...

Page 694: ...SEN03843 00 WA250 250PZ 6 40 330 23 330 Troubleshooting by failure code Display of code Part 3 Failure code CA449 Common rail pressure high error 2 ...

Page 695: ...first 2 Defective common rail pres sure sensor aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting FUEL RAIL PRESS Voltage Between 3 and 1 Power supply 4 75 5 25 V Voltage is measured with wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Hot short Short circuit ...

Page 696: ...SEN03843 00 WA250 250PZ 6 40 330 25 330 Troubleshooting by failure code Display of code Part 3 Failure code CA451 Common rail pressure sensor high error Related circuit diagram ...

Page 697: ...t 2 Defective common rail pres sure sensor aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting FUEL RAIL PRESS Voltage Between 3 and 1 Power supply 4 75 5 25 V Voltage is measured with wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Ground fault in wiring har n...

Page 698: ...SEN03843 00 WA250 250PZ 6 40 330 27 330 Troubleshooting by failure code Display of code Part 3 Failure code CA452 Common rail pressure sensor low error Related circuit diagram ...

Page 699: ...nput state boost temperature from the boost pressure and temperature sensors can be checked with the monitoring function Code ENGINE 18500 CHG TEMP The input state boost temperature sensor voltage from the boost pressure and temperature sen sors can be checked with the monitoring function Code ENGINE 18501 CHG TEMP Method of reproducing failure code Start engine Possible causes and standard value ...

Page 700: ... pressure from the common rail pressure sensor can be checked with the monitoring function Code ENGINE 36400 RAIL PRESS The input state voltage from the common rail pressure sensor can be checked with the monitoring function Code ENGINE 36402 RAIL PRESS Method of reproducing failure code Start engine Possible causes and standard value in normal state Causes Standard value in normal state Remarks o...

Page 701: ...akage to outside Inspect for fuel leakage directly visual inspection at engine low idle 2 Defective low pressure cir cuit device aFor check of pressure in fuel low pressure circuit see Testing and adjusting Testing fuel pressure Pressure in fuel low pressure circuit Cranking When starting is not available 0 3 1 1 MPa 3 1 11 3 kg cm2 At low idle When starting is available 0 5 1 3 MPa 5 1 13 3 kg cm...

Page 702: ...SEN03843 00 WA250 250PZ 6 40 330 31 330 Troubleshooting by failure code Display of code Part 3 Failure code CA559 Supply pump pressure very low error ...

Page 703: ...ck wiring harness and controller too for another cause of trouble and then judge 3 Broken engine Ne speed sensor or defective clear ance Inspect engine Ne speed sensor for breakage or clearance 4 Broken rotation sensing fly wheel Inspect it for breakage directly 5 Disconnection in wiring har ness Disconnection or defective contact in connector aPrepare with starting switch OFF then carry out troub...

Page 704: ...efective wiring harness connector Connecting parts among engine Ne speed sensor engine wiring harness and engine controller are suspected Inspect them directly Loose connector broken lock broken seal Corrosive bent broken forced in or extended pin Humidity in connector entry of dirt or dust poor insulation 10 Defective engine controller a Prepare with starting switch OFF then turn starting switch ...

Page 705: ...reakage directly 2 Broken engine Bkup speed sensor Inspect engine Bkup speed sensor for breakage directly 3 Defective broken mount of rotation sensing flywheel on crankshaft side Inspect it for defect or breakage according to the following proce dure 1 Set No 1 cylinder to compression top dead center align stamp ing mark 2 If tip of Ne speed sensor is aligned with center of oblong hole of rotation...

Page 706: ... broken the circuit probably has a grounding fault etc 5 Defective engine control cut out relay L107 Internal dis connection or short circuit a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON L107 male Resistance Between 1 and 2 200 400 z a Prepare with starting switch OFF then turn starting switch ON and carry out troubleshooting When engine cont...

Page 707: ...onnector Connecting parts among fuse No 4 of fuse box FS1 engine unit wiring harness and engine controller are suspected Inspect them directly Loose connector broken lock broken seal Corrosive bent broken forced in or extended pin Humidity in connector entry of dirt or dust poor insulation 9 Defective engine controller aPrepare with starting switch OFF then turn starting switch ON and carry out tr...

Page 708: ...SEN03843 00 WA250 250PZ 6 40 330 37 330 Troubleshooting by failure code Display of code Part 3 Failure code CA757 All continuous data lost error Related circuit diagram ...

Page 709: ...harness and controller too for another cause of trouble and then judge 3 Broken engine Bkup speed sensor or defective clear ance Inspect engine Bkup speed sensor directly for breakage or clear ance 4 Broken rotation sensing ring Inspect it for breakage directly 5 Disconnection in wiring har ness Disconnection or defective contact in connector aPrepare with starting switch OFF then carry out troubl...

Page 710: ...efective wiring harness connector Connecting parts among engine Bkup speed sensor engine wiring harness and engine controller are suspected Inspect them directly Loose connector broken lock broken seal Corrosive bent broken forced in or extended pin Humidity in connector entry of dirt or dust poor insulation 10 Defective engine controller a Prepare with starting switch OFF then turn starting switc...

Page 711: ...first Method of reproducing failure code Turn the starting switch ON Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective CAN end point resistance aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON CAN1 male Resistance Between A and B 110 140 z aPrepare with starting switch O...

Page 712: ... EC2 female 46 47 L29 female 3 8 and ground Resis tance Min 1 Mz Wiring harness between EC2 female 46 47 L72 female 22 32 and ground Resis tance Min 1 Mz Wiring harness between EC2 female 46 47 L80 female 7 8 and ground Resis tance Min 1 Mz Wiring harness between EC2 female 46 47 CAN1 female A B and ground Resis tance Min 1 Mz Wiring harness between EC2 female 46 47 CAN2 female A B and ground Resi...

Page 713: ...SEN03843 00 40 330 42 WA250 250PZ 6 330 Troubleshooting by failure code Display of code Part 3 Failure code CA1633 KOMNET datalink timeout error Related circuit diagram ...

Page 714: ...SEN03843 00 WA250 250PZ 6 40 330 43 330 Troubleshooting by failure code Display of code Part 3 Failure code CA1633 KOMNET datalink timeout error ...

Page 715: ...sible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Short circuit in wiring har ness with another wiring harness aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness among all pins between EC2 female 22 EC2 female PD1 and 2 too is disconnected Resis tance Min 100 kz Between ...

Page 716: ...SEN03843 00 WA250 250PZ 6 40 330 45 330 Troubleshooting by failure code Display of code Part 3 Failure code CA2185 Throttle sensor supply voltage high error Related circuit diagram ...

Page 717: ...te Remarks on troubleshooting 1 Ground fault in wiring har ness Contact with ground circuit aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between EC2 female 22 PD1 female 1 and ground Resis tance Min 100 kz 2 Short circuit in wiring har ness with another wiring harness aPrepare with starting switch OFF then carry out troubleshoot...

Page 718: ...SEN03843 00 WA250 250PZ 6 40 330 47 330 Troubleshooting by failure code Display of code Part 3 Failure code CA2186 Throttle sensor power supply low error Related circuit diagram ...

Page 719: ...ntralized warning lamp and alarm buzzer ON Problem that appears on machine Starting performance is poor Exhaust smoke is black Engine output lowers Related information The input state common rail pressure from the common rail pressure sensor can be checked with the monitoring function Code ENGINE 36400 RAIL PRESS The input state voltage from the common rail pressure sensor can be checked with the ...

Page 720: ...SEN03843 00 WA250 250PZ 6 40 330 49 330 Troubleshooting by failure code Display of code Part 3 Failure code CA2249 Supply pump pressure very low error 2 ...

Page 721: ...d 2 Max 5 z Between 1 and ground Min 100 kz 3 Disconnection in wiring har ness Disconnection or defective contact in connector aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between EC1 female 2 CP3 PUMP REGULATOR female 1 Resis tance Max 5 z Wiring harness between EC1 female 32 CP3 PUMP REGULATOR female 2 Resis tance Max 5 z 4 Gr...

Page 722: ...SEN03843 00 WA250 250PZ 6 40 330 51 330 Troubleshooting by failure code Display of code Part 3 Failure code CA2311 Abnormality in IMV IMA solenoid Related circuit diagram ...

Page 723: ... z aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting Test by replacing relay unit When heater relay is replaced with a relay of the same type if the condition becomes normal the heater relay is defective 2 Disconnection in wiring har ness Disconnection or defective contact in connector aPrepare with starting switch OFF then carry out troubleshooting witho...

Page 724: ...SEN03843 00 WA250 250PZ 6 40 330 53 330 Troubleshooting by failure code Display of code Part 3 Failure code CA2555 Intake heater relay disconnection error Related circuit diagram ...

Page 725: ... Between E06 and ground Resistance 300 600 z aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting Test by replacing relay unit When heater relay is replaced with a relay of the same type if the condition becomes normal the heater relay is defective 2 Ground fault in wiring har ness Contact with ground circuit aPrepare with starting switch OFF then carry out ...

Page 726: ...SEN03843 00 WA250 250PZ 6 40 330 55 330 Troubleshooting by failure code Display of code Part 3 Failure code CA2556 Intake heater relay short circuit error Related circuit diagram ...

Page 728: ...AN NET Signal Disconnection 16 Failure code DAJ0KK HST controller power supply Low voltage 20 Failure code DAJ0KT HST controller memory EEPROM Abnormality 22 Failure code DAJ1L4 HST controller main power line Disconnection Ground fault 24 Failure code DAJ1L6 HST controller main power line Hot short 26 Failure code DAJ2KK Controller solenoid power supply Low voltage 28 Failure code DAJ2L3 HST contr...

Page 729: ...ONITOR PANEL 40952 D OUT 0 Operating condition of ECSS can be checked with monitoring function Monitoring code MONITOR PANEL 40952 D OUT 3 Method of reproducing failure code Turn starting switch ON Set FNR directional lever or switch to R Reverse position Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective backup alarm lam...

Page 730: ...SEN03844 00 WA250 250PZ 6 40 340 3 340 Troubleshooting by failure code Display of code Part 4 Failure code D160KY Backup alarm lamp relay 1 circuit Hot short Related circuit diagram ...

Page 731: ... PANEL 40952 D OUT 2 Operating condition of alarm buzzer can be checked with monitoring function Monitoring code MONITOR PANEL 40952 D OUT 0 This fault is not detected if ECSS is not installed Method of reproducing failure code Travel at speed higher than 5 km h Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective ECSS sole...

Page 732: ...SEN03844 00 WA250 250PZ 6 40 340 5 340 Troubleshooting by failure code Display of code Part 4 Failure code D192KY ECSS solenoid relay Hot short Related circuit diagram ...

Page 733: ...andard value in normal state Remarks on troubleshooting 1 Defective HST safety relay Internal defect aPrepare with starting switch OFF then start engine and carry out troubleshooting Replace HST safety relay L111 with another relay Condition becomes normal Relay L111 is defective Condition does not become normal Relay L111 is normal aPrepare with starting switch OFF then carry out troubleshooting ...

Page 734: ...SEN03844 00 WA250 250PZ 6 40 340 7 340 Troubleshooting by failure code Display of code Part 4 Failure code D1B0KA HST safety relay Disconnection Related circuit diagram ...

Page 735: ...tput command values can be checked with monitoring function Motor 1 solenoid output HST 80000 MOTOR SOL DIR mA HST safety relay output HST 40979 D_OUT_15 ON OFF Clutch EPC solenoid output HST 80100 CLUTCH SOL DIR mA Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective HST safety relay Internal defect aPrepare with starting ...

Page 736: ...SEN03844 00 WA250 250PZ 6 40 340 9 340 Troubleshooting by failure code Display of code Part 4 Failure code D1B0KB HST safety relay Ground fault Related circuit diagram ...

Page 737: ... it first Following output command values can be checked with monitoring function Motor 1 solenoid output HST 80000 MOTOR SOL DIR mA HST safety relay output HST 40979 D_OUT_15 ON OFF Clutch EPC solenoid output HST 80100 CLUTCH SOL DIR mA Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective HST safety relay Internal defect a...

Page 738: ...SEN03844 00 WA250 250PZ 6 40 340 11 340 Troubleshooting by failure code Display of code Part 4 Failure code D1B0KY HST safety relay Hot short Related circuit diagram ...

Page 739: ...ard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective starting switch Internal defect aPrepare with starting switch OFF then turn starting switch to ON OFF START position and carry out troubleshooting L02 Starting switch position Voltage Between 3 ground START 20 30 V OFF ON Max 1 V 2 Disconnection in wiring har ness Disconnection in wiring or defec...

Page 740: ...SEN03844 00 WA250 250PZ 6 40 340 13 340 Troubleshooting by failure code Display of code Part 4 Failure code D5ZHL6 IGN C system Ground fault Disconnection Related circuit diagram ...

Page 741: ...oblem that appears on machine Service meter time gains or loses Odometer does not advance Fault history data is not saved Related information Method of reproducing failure code Turn starting switch ON Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Ground fault in wiring har ness Contact with GND cir cuit aPrepare with starting ...

Page 742: ...SEN03844 00 WA250 250PZ 6 40 340 15 340 Troubleshooting by failure code Display of code Part 4 Failure code DAF3KK UNSW power supply Ground fault Disconnection Related circuit diagram ...

Page 743: ...ormal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective CAN end point resistance aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON CAN1 male Resistance Between A and B 110 140 z aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON CAN2 male Resistance Between A and B 11...

Page 744: ...8 38 EC2 female 46 47 and ground Resis tance Min 1 Mz Wiring harness between HST female 28 38 C140 female 28 38 and ground Resis tance Min 1 Mz Wiring harness between HST female 28 38 CAN1 female A B and ground Resis tance Min 1 Mz Wiring harness between HST female 28 38 CAN2 female A B and ground Resis tance Min 1 Mz 4 Defective power supply cir cuit of machine monitor a Power supply circuit or g...

Page 745: ...SEN03844 00 40 340 18 WA250 250PZ 6 340 Troubleshooting by failure code Display of code Part 4 Failure code DAFRKR Machine monitor CAN NET Signal Disconnection Related circuit diagram ...

Page 746: ...SEN03844 00 WA250 250PZ 6 40 340 19 340 Troubleshooting by failure code Display of code Part 4 Failure code DAFRKR Machine monitor CAN NET Signal Disconnection ...

Page 747: ...vel in either direction Another trouble may be detected Related information If gear is set in neutral and engine is restarted while controller voltage is above 20 V system is reset Method of reproducing failure code Turn starting switch ON Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective Broken fuse Check fuse FS1 No 3 ...

Page 748: ...SEN03844 00 WA250 250PZ 6 40 340 21 340 Troubleshooting by failure code Display of code Part 4 Failure code DAJ0KK HST controller power supply Low voltage Related circuit diagram ...

Page 749: ... example shift down feel from 3rd or 4th gear speed may become bad Related information Method of reproducing failure code Turn starting switch ON Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective HST controller Carry out troubleshooting according to the following procedure 1 Change set information of HST controller Examp...

Page 750: ...SEN03844 00 WA250 250PZ 6 40 340 23 340 Troubleshooting by failure code Display of code Part 4 Failure code DAJ0KT HST controller memory EEPROM Abnormality ...

Page 751: ...hine monitor Starts starting key OFF processing earlier Problem that appears on machine Machine is not affected in particular Related information Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector aPrepare with starting switch OFF then carry...

Page 752: ...SEN03844 00 WA250 250PZ 6 40 340 25 340 Troubleshooting by failure code Display of code Part 4 Failure code DAJ1L4 HST controller main power line Disconnection Ground fault Related circuit diagram ...

Page 753: ...urned ON Problem that appears on machine Battery voltage may lower earlier Related information After error is detected it is displayed next time when starting switch is turned ON Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Hot short Contact with 24V circuit in wiring harness aPrepare with starting switch OFF then turn starti...

Page 754: ...SEN03844 00 WA250 250PZ 6 40 340 27 340 Troubleshooting by failure code Display of code Part 4 Failure code DAJ1L6 HST controller main power line Hot short Related circuit diagram ...

Page 755: ...Causes Standard value in normal state Remarks on troubleshooting 1 Defective VIS power supply holding relay Internal defect aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting Replace VIS power supply holding relay L102 with another relay Condition becomes normal Relay L102 is defective Condition does not become normal Relay L102 is normal aPrepare with sta...

Page 756: ...SEN03844 00 WA250 250PZ 6 40 340 29 340 Troubleshooting by failure code Display of code Part 4 Failure code DAJ2KK Controller solenoid power supply Low voltage Related circuit diagram ...

Page 757: ...hile fan is rotating in reverse peak pressure may occur Related information Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective VIS power supply holding relay Internal defect aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting Replace VIS power supply holding relay L102 with another...

Page 758: ...844 00 WA250 250PZ 6 40 340 31 340 Troubleshooting by failure code Display of code Part 4 Failure code DAJ2L3 HST controller load power supply holding line Hot short in wiring harness Related circuit diagram ...

Page 759: ...e in normal state Remarks on troubleshooting 1 Defective HST safety relay Internal defect aPrepare with starting switch OFF then turn starting switch ON and OFF wait for 30 seconds and turn it ON again and carry out troubleshooting Replace VIS power supply holding relay L102 with another relay Condition becomes normal Relay L102 is defective Condition does not become normal Relay L102 is normal aP...

Page 760: ...844 00 WA250 250PZ 6 40 340 33 340 Troubleshooting by failure code Display of code Part 4 Failure code DAJ2L4 HST controller load power supply holding line Disconnection Ground fault Related circuit diagram ...

Page 761: ...ard value in normal state Remarks on troubleshooting 1 Defective travel speed con trol dial defective speed range selector switch defec tive resistor defective travel speed sensor or defective HST pressure sensor aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Disconnect devices at right in order If failure code DAJ5KX lights up reset is indicate...

Page 762: ...SEN03844 00 WA250 250PZ 6 40 340 35 340 Troubleshooting by failure code Display of code Part 4 Failure code DAJ5KX Sensor 5V power supply Out of output range Related circuit diagram ...

Page 763: ...ore occurrence of the failure code is still used Turns the centralized warning lamp and alarm buzzer ON Does not display failure codes which may be false detected Problem that appears on machine Continuing the travel in this condition may damage the HST Related information Method of reproducing failure code Turn the starting switch ON Possible causes and standard value in normal state Causes Stand...

Page 764: ...h ON Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective CAN end point resistance a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON CAN1 male Resistance Between A and B 110 140 z a Prepare with starting switch OFF then carry out troubleshooting without turning starting swi...

Page 765: ... Mz Wiring harness between HST female 28 38 EC2 female 46 47 and ground Resis tance Min 1 Mz Wiring harness between HST female 28 38 C140 female 28 38 and ground Resis tance Min 1 Mz Wiring harness between HST female 28 38 CAN1 female A B and ground Resis tance Min 1 Mz Wiring harness between HST female 28 38 CAN2 female A B and ground Resis tance Min 1 Mz 4 Defective HST controller aCarry out tro...

Page 766: ...SEN03844 00 WA250 250PZ 6 40 340 39 340 Troubleshooting by failure code Display of code Part 4 Failure code DAJRKR HST controller CAN NET signal Disconnection Related circuit diagram ...

Page 767: ...ng harness L101 female 2 D07 female 1 T07 3 and ground Resis tance Min 1 Mz Between wiring harness L103 female 5 D08 female 1 T07 1 and ground Resis tance Min 1 Mz Between wiring harness L104 female 5 R59 female 1 and ground Resis tance Min 1 Mz Between wiring harness L63 female 5 1 HST female 25 and ground Resis tance Min 1 Mz Between wiring harness L15 female 3 D01 female 5 HST female 5 and grou...

Page 768: ... carry out troubleshooting Replace backup alarm lamp relay L126 with another relay If con dition becomes normal backup alarm lamp relay is defective f Defective directional pres sure selector solenoid Inter nal short circuit a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Between T07 male 3 T07 male 4 Resis tance 20 30 z g Defective motor 2 sole...

Page 769: ...0 42 WA250 250PZ 6 340 Troubleshooting by failure code Display of code Part 4 Failure code DAJRKR HST controller CAN NET signal Disconnection Related circuit diagram When HST controller power supply circuit is defective ...

Page 770: ...ed by itself Turns the centralized warning lamp and alarm buzzer ON Problem that appears on machine The option setting does not work normally Related information Method of reproducing failure code Turn the starting switch ON Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective option setting Set the option setting using the...

Page 772: ...KZ Parking brake switch bottom switch or parking brake reminder switch intermediate switch Trouble 16 Failure code DDB6L0 Parking brake switch A Ground fault 18 Failure code DDB6L4 Parking brake switch B Disconnection Hot short 20 Failure code DDD7KX Travel speed control dial signal Disconnection Ground fault 22 Failure code DDD7KY Travel speed control dial signal Hot short 24 Failure code DDE5MA ...

Page 773: ...SEN03845 00 40 350 2 WA250 250PZ 6 350 Troubleshooting by failure code Display of code Part 5 ...

Page 774: ...e engine stops Related information Method of reproducing failure code Turn the starting switch ON Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective CAN end point resistance a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON CAN1 male Resistance Between A B 110 140 z a Pre...

Page 775: ...iring harness between EC2 female 46 47 L29 female 3 8 and ground Resis tance Min 1 Mz Wiring harness between EC2 female 46 47 C140 female 28 38 and ground Resis tance Min 1 Mz Wiring harness between EC2 female 46 47 CAN1 female A B and ground Resis tance Min 1 Mz Wiring harness between EC2 female 46 47 CAN2 female A B and ground Resis tance Min 1 Mz 4 Defective power supply cir cuit of engine cont...

Page 776: ...SEN03845 00 WA250 250PZ 6 40 350 5 350 Troubleshooting by failure code Display of code Part 5 Failure code DB2RKR Engine controller CAN NET Disconnection in signal line Related circuit diagram ...

Page 777: ...ce Max 1 z Wiring harness between L02 female 2 EC2 female 39 Resis tance Max 1 z c Ground fault in wiring har ness Contact with GND cir cuit aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Between wiring harness fuse box FS1 No 4 fuse L107 female 3 L108 female 3 and ground Resis tance Min 1 Mz Between wiring harness L107 female 5 L108 female 5 EC...

Page 778: ...roller power supply circuit is defective Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting e Defective engine controller a Prepare with starting switch OFF then turn starting switch ON and carry out troubleshooting EC2 Voltage Between 33 ground Max 1 V Between 39 ground 20 30 V EC3 Voltage Between 3 4 ground 20 30 V Between 1 2 grou...

Page 779: ...itoring function Code HST 93400 FAN REVERSE SW Code MONITOR PANEL 40901 D IN 9 Method of reproducing failure code Turn starting switch ON Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective fan automatic reverse switch Internal short circuit aPrepare with starting switch OFF then carry out troubleshooting without turning s...

Page 780: ...SEN03845 00 WA250 250PZ 6 40 350 9 350 Troubleshooting by failure code Display of code Part 5 Failure code DD1NL4 Fan automatic reverse switch signal Abnormality Related circuit diagram ...

Page 781: ...ing function Code HST 93400 FAN REVERSE SW Code MONITOR PANEL 40900 D IN 1 Method of reproducing failure code Turn the starting switch ON Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective fan reverse switch Internal short circuit aPrepare with starting switch OFF then carry out troubleshooting without turning starting sw...

Page 782: ...SEN03845 00 WA250 250PZ 6 40 350 11 350 Troubleshooting by failure code Display of code Part 5 Failure code DD1NLD Fan reverse switch signal Abnormality Related circuit diagram ...

Page 783: ...causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective diode Internal defect aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON See Testing and adjusting Test procedure for diode Between D02 male 6 2 Continuity is secured Between D03 male 5 1 Continuity is secured 2 Disconnection in wir...

Page 784: ...SEN03845 00 WA250 250PZ 6 40 350 13 350 Troubleshooting by failure code Display of code Part 5 Failure code DDB6KA Parking brake switch A Disconnection Hot short Related circuit diagram ...

Page 785: ... HST controller recognition Monitoring code HST 99100 PARKING A B Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective diode Internal defect aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON See Testing and adjusting Test procedure for diode Between D02 male 7 3 Continuity i...

Page 786: ...SEN03845 00 WA250 250PZ 6 40 350 15 350 Troubleshooting by failure code Display of code Part 5 Failure code DDB6KB Parking brake switch B Ground fault Related circuit diagram ...

Page 787: ... OFF of parking brake indicator signal and reminder signal can be checked with monitoring function Monitoring code MONITOR PANEL 40903 D IN 26 28 Monitoring code MONITOR PANEL 40904 D IN 35 36 Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective diode Internal defect aPrepare with starting switch OFF then carry out troubles...

Page 788: ...0 250PZ 6 40 350 17 350 Troubleshooting by failure code Display of code Part 5 Failure code DDB6KZ Parking brake switch bottom switch or parking brake reminder switch intermediate switch Trouble Related circuit diagram ...

Page 789: ...IN 36 Parking brake switch A B HST controller recognition Monitoring code HST 99100 PARKING A B Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective diode Internal defect aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON See Testing and adjusting Test procedure for diode Bet...

Page 790: ...SEN03845 00 WA250 250PZ 6 40 350 19 350 Troubleshooting by failure code Display of code Part 5 Failure code DDB6L0 Parking brake switch A Ground fault Related circuit diagram ...

Page 791: ...B Recognition by machine monitor Monitoring code MONITOR PANEL 40903 D IN 26 and 40904 D IN 36 Parking brake switch A B HST controller recognition Monitoring code HST 99100 PARKING A B Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective diode Internal defect aPrepare with starting switch OFF then carry out troubleshooting ...

Page 792: ...SEN03845 00 WA250 250PZ 6 40 350 21 350 Troubleshooting by failure code Display of code Part 5 Failure code DDB6L4 Parking brake switch B Disconnection Hot short Related circuit diagram ...

Page 793: ...oubleshooting 1 Defective travel speed con trol dial Internal defect aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting Between L54 female A C Voltage 4 7 5 3 V Between L54 female B C Max speed side of dial Voltage 0 3 0 9 V Between L54 female B C Min speed side of dial Voltage 4 1 4 7 V 2 Disconnection in wiring har ness Disconnection in wiring or defecti...

Page 794: ...SEN03845 00 WA250 250PZ 6 40 350 23 350 Troubleshooting by failure code Display of code Part 5 Failure code DDD7KX Travel speed control dial signal Disconnection Ground fault Related circuit diagram ...

Page 795: ... aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting Between L54 female A C Voltage 4 7 5 3 V Between L54 female B C Max speed side of dial Voltage 0 3 0 9 V Between L54 female B C Min speed side of dial Voltage 4 1 4 7 V 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector aPrepare with starting switch OFF then carr...

Page 796: ...SEN03845 00 WA250 250PZ 6 40 350 25 350 Troubleshooting by failure code Display of code Part 5 Failure code DDD7KY Travel speed control dial signal Hot short Related circuit diagram ...

Page 797: ... function Monitoring code MONITOR PANEL 40904 D IN 39 Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective steering oil pres sure reduction switch Inter nal defect aPrepare with starting switch OFF then turn starting switch ON and start engine and carry out troubleshooting in each case F11 male Steering oil pressure Resista...

Page 798: ...SEN03845 00 WA250 250PZ 6 40 350 27 350 Troubleshooting by failure code Display of code Part 5 Failure code DDE5MA Emergency steering operation switch Disconnection Related circuit diagram ...

Page 799: ...ue in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective directional selec tor switch Internal disconnection or short circuit aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON L62 male Directional selector switch Resistance Between 1 2 F Forward Max 1 z Other than above Min 1 Mz Between 1 3 N Neutral Max 1 z O...

Page 800: ...SEN03845 00 WA250 250PZ 6 40 350 29 350 Troubleshooting by failure code Display of code Part 5 Failure code DDK3KA Directional selector switch Disconnection Hot short Related circuit diagram ...

Page 801: ...tate Causes Standard value in normal state Remarks on troubleshooting 1 Defective directional selec tor switch Internal disconnection or short circuit aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON L15 male Right FNR direc tional switch Resistance Between 1 2 F Forward Max 1 z Other than above Min 1 Mz Between 1 3 N Neutral Max 1 z Other than ab...

Page 802: ...SEN03845 00 WA250 250PZ 6 40 350 31 350 Troubleshooting by failure code Display of code Part 5 Failure code DDK3KB Directional selector switch Ground fault Related circuit diagram ...

Page 803: ...actuation switch Gear shift lever position lamp goes off Related information The input state ON OFF from the FNR directional lever switch can be checked with the monitoring function Code HST 40977 D IN 0 D IN 1 or D IN 2 Method of reproducing failure code Turn the starting switch ON and operate FNR directional lever Possible causes and standard value in normal state Causes Standard value in normal...

Page 804: ...L15 female 1 Resis tance Max 1 z Wiring harness between HST female 15 L15 female 4 Resis tance Max 1 z Wiring harness between HST female 5 L15 female 3 Resis tance Max 1 z Wiring harness between HST female 34 L15 female 2 Resis tance Max 1 z 6 Grounding fault in wiring har ness Contact with ground circuit a Prepare with starting switch OFF then carry out troubleshooting without turning starting sw...

Page 805: ...SEN03845 00 40 350 34 WA250 250PZ 6 350 Troubleshooting by failure code Display of code Part 5 Failure code DDK6KA FNR lever Disconnection Ground fault Related circuit diagram ...

Page 806: ...SEN03845 00 WA250 250PZ 6 40 350 35 350 Troubleshooting by failure code Display of code Part 5 Failure code DDK6KA FNR lever Disconnection Ground fault ...

Page 807: ...tional lever switch can be checked with the monitoring function Code HST 40977 D IN 0 D IN 1 or D IN 2 Method of reproducing failure code Turn the starting switch ON and operate FNR directional lever Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective FNR directional lever switch Internal short circuit aPrepare with starti...

Page 808: ...SEN03845 00 WA250 250PZ 6 40 350 37 350 Troubleshooting by failure code Display of code Part 5 Failure code DDK6KY FNR lever Hot short Related circuit diagram ...

Page 809: ...al state Causes Standard value in normal state Remarks on troubleshooting 1 Low steering oil pressure System is normal aCarry out troubleshooting for hydraulic and mechanical systems 2 Defective steering oil pres sure sensor switch Internal defect aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON F11 male Steering oil pressure Resistance Between 1 ...

Page 810: ...SEN03845 00 WA250 250PZ 6 40 350 39 350 Troubleshooting by failure code Display of code Part 5 Failure code DDS5L6 Steering Low oil pressure Operation of emergency steering Related circuit diagram ...

Page 812: ...ion Hot short 10 Failure code DHH1KX HST oil pressure sensor Disconnection Ground fault 12 Failure code DHH1KY HST oil pressure sensor Hot short 14 Failure code DHTCL6 HST filter clogging sensor Functional defect 16 Failure code DJF1KA Fuel level sensor Disconnection Hot short 18 Failure code DLT3KX Travel speed sensor B Abnormality 20 Failure code DLT4KX Travel speed sensor A Abnormality 24 Failu...

Page 813: ...SEN03846 00 40 360 2 WA250 250PZ 6 360 Troubleshooting by failure code Display of code Part 6 ...

Page 814: ...isplays range before error occurrence Once starting switch is turned OFF 4th gear is displayed Related information Method of reproducing failure code Turn starting switch ON Operate speed range selector switch Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective travel speed range selector switch Internal defect a Prepare w...

Page 815: ...Resis tance Max 1 z Wiring harness between L03 female 4 L70 female 8 Resis tance Max 1 z Wiring harness between HST female 22 L70 female 2 4 Resis tance Max 1 z 4 Ground fault in wiring har ness Contact with GND cir cuit aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Between wiring harness HST female 32 L70 female 7 and ground Resis tance Min 1 ...

Page 816: ...SEN03846 00 WA250 250PZ 6 40 360 5 360 Troubleshooting by failure code Display of code Part 6 Failure code DF10KA Travel speed range selector switch Disconnection Ground fault Related circuit diagram ...

Page 817: ...standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective travel speed range selector switch Internal defect aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON L03 female Switch position Resistance Between 1 2 2nd Max 1 z Other than above Min 1 Mz Between 1 3 1st Min 1 Mz 2nd Min 1 Mz 3rd Max 1 z 4th...

Page 818: ...e in normal state Remarks on troubleshooting 3 Hot short Contact with 24V circuit in wiring harness Between wiring harness L03 female 2 L70 female 1 and ground Voltage Max 1 V Between wiring harness L03 female 4 L70 female 8 and ground Voltage Max 1 V Wiring harness between HST female 22 L70 female 2 4 and ground Voltage Max 1 V 4 Defective HST controller HST Switch position Voltage Between 39 32 ...

Page 819: ...R PANEL 04408 HST OIL TEMP C Monitoring code MONITOR PANEL 04409 HST OIL TEMP V Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective HST oil tempera ture sensor Internal defect aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON T10 male HST oil temperature Resistance Between ...

Page 820: ...ode MONITOR PANEL 30201 F BRAKE OIL C Monitoring code MONITOR PANEL 30204 F BRAKE OIL V System resets itself after brake oil temperature reduces below 130 C Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Front brake overheat When system is normal Check for cause of overheat directly 2 Defective front brake axle oil temperature ...

Page 821: ...ure increases above 25 C Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective front brake axle oil temperature sensor Inter nal defect aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON F14 male Brake oil temperature Resistance Between 1 2 At 25 C 35 50 kz At 100 C 3 1 4 5 kz...

Page 822: ...SEN03846 00 WA250 250PZ 6 40 360 11 360 Troubleshooting by failure code Display of code Part 6 Failure code DGR2KZ Brake oil temperature sensor Disconnection Hot short Related circuit diagram ...

Page 823: ...HST 32600 HST PRESS MPa Monitoring code HST 32601 HST PRESS V Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective HST oil pressure sensor Internal defect aPrepare with starting switch OFF then turn starting twitch ON and carry out troubleshooting T11 Voltage Between C A 0 5 4 5 V Between B A 4 6 V 2 Disconnection in wiring...

Page 824: ...SEN03846 00 WA250 250PZ 6 40 360 13 360 Troubleshooting by failure code Display of code Part 6 Failure code DHH1KX HST oil pressure sensor Disconnection Ground fault Related circuit diagram ...

Page 825: ...olled with travel speed control dial however Related information If DAJ5KX is displayed carry out troubleshooting for it first Input state from HST oil pressure sensor can be checked with monitoring function Monitoring code HST 32600 HST PRESS MPa Monitoring code HST 32601 HST PRESS V Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshootin...

Page 826: ...SEN03846 00 WA250 250PZ 6 40 360 15 360 Troubleshooting by failure code Display of code Part 6 Failure code DHH1KY HST oil pressure sensor Hot short Related circuit diagram ...

Page 827: ...ut state ON OFF of HST filter clogging sensor can be checked with monitoring function Monitoring code MONITOR PANEL 40903 D IN 24 Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective HST filter clogging sensor Internal defect aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON...

Page 828: ...SEN03846 00 WA250 250PZ 6 40 360 17 360 Troubleshooting by failure code Display of code Part 6 Failure code DHTCL6 HST filter clogging sensor Functional defect ...

Page 829: ...oting 1 Defective fuel level sensor Internal defect aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON R21 male Fuel level Resistance Between 1 2 When full 7 11 z When 1 2 25 35 z When empty 60 95 z 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector aPrepare with starting switch OFF then carry out troublesh...

Page 830: ...SEN03846 00 WA250 250PZ 6 40 360 19 360 Troubleshooting by failure code Display of code Part 6 Failure code DJF1KA Fuel level sensor Disconnection Hot short Related circuit diagram ...

Page 831: ... T09 Voltage Between 1 2 4 7 5 3 V Between 2 ground Max 1 V aPrepare with starting switch OFF then start engine travel at con stant speed and carry out troubleshooting T09 Voltage Between 4 2 Below 1 V Above 4 V Changes at regular intervals 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector aPrepare with starting switch OFF then carry out troubleshooting ...

Page 832: ...lue in normal state Remarks on troubleshooting 5 Defective HST controller a Prepare with starting switch OFF then start engine and carry out troubleshooting without traveling HST Voltage Between 22 32 4 7 5 3 V Between 32 ground Max 1 V a Prepare with starting switch OFF then start engine travel at con stant speed and carry out troubleshooting HST Voltage Between 36 32 Below 1 V Above 4 V Changes ...

Page 833: ... not travel and carry out troubleshooting T09 Voltage Between 1 2 4 7 5 3 V Between 2 ground Max 1 V aPrepare with starting switch OFF then start engine travel at con stant speed and carry out troubleshooting T09 Voltage Between 3 2 Below 1 V Above 4 V Changes at regular intervals Between 4 2 Below 1 V Above 4 V Changes at regular intervals 7 Disconnection in wiring har ness Disconnection in wirin...

Page 834: ...Remarks on troubleshooting 10 Defective HST controller a Prepare with starting switch OFF then start engine and carry out troubleshooting without traveling HST Voltage Between 22 32 4 7 5 3 V Between 32 ground Max 1 V a Prepare with starting switch OFF then start engine travel at con stant speed and carry out troubleshooting HST Voltage Between 26 32 Below 1 V Above 4 V Changes at regular interval...

Page 835: ...ing T09 Voltage Between 1 2 4 7 5 3 V Between 2 ground Max 1 V aPrepare with starting switch OFF then start engine travel at con stant speed and carry out troubleshooting T09 Voltage Between 3 2 Below 1 V Above 4 V Changes at regular intervals 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector aPrepare with starting switch OFF then carry out troubleshooti...

Page 836: ... Standard value in normal state Remarks on troubleshooting 5 Defective HST controller a Prepare with starting switch OFF then start engine and carry out troubleshooting without traveling HST Voltage Between 22 32 4 7 5 3 V Between 32 ground Max 1 V a Prepare with starting switch OFF then start engine travel at con stant speed and carry out troubleshooting HST Voltage Between 26 32 Below 1 V Above ...

Page 837: ...g switch OFF then start engine travel at con stant speed and carry out troubleshooting T09 Voltage Between 3 2 Below 1 V Above 4 V Changes at regular intervals Between 4 2 Below 1 V Above 4 V Changes at regular intervals 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector aPrepare with starting switch OFF then carry out troubleshooting without turning star...

Page 838: ... Remarks on troubleshooting 5 Defective HST controller a Prepare with starting switch OFF then start engine and carry out troubleshooting without traveling HST Voltage Between 22 32 4 7 5 3 V Between 32 ground Max 1 V a Prepare with starting switch OFF then start engine travel at con stant speed and carry out troubleshooting HST Voltage Between 26 32 Below 1 V Above 4 V Changes at regular interval...

Page 839: ... 40925 D OUT 0 Output state ON OFF to backup alarm lamp relay can be checked with monitoring function Code MONITOR PANEL 40952 D OUT 2 Output state ON OFF to ECSS relay can be checked with monitoring function Code MONITOR PANEL 40952 D OUT 3 Method of reproducing failure code Turn the starting switch ON Possible causes and standard value in normal state Causes Standard value in normal state Remark...

Page 840: ...SEN03846 00 WA250 250PZ 6 40 360 29 360 Troubleshooting by failure code Display of code Part 6 Failure code DV00KY Alarm buzzer Hot short Related circuit diagram ...

Page 841: ...ch ON and carry out troubleshooting Replace motor 2 solenoid relay L103 with another relay Condition becomes normal Relay L103 is defective Condition does not become normal Relay L103 is normal aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Between L103 male 1 2 Resis tance 200 400 z 2 Defective VIS power supply holding relay Internal short circ...

Page 842: ...SEN03846 00 WA250 250PZ 6 40 360 31 360 Troubleshooting by failure code Display of code Part 6 Failure code DW26KA Motor 2 solenoid Disconnection Ground fault Related circuit diagram ...

Page 843: ...toring function Monitoring code HST 40980 D OUT 16 Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective motor 2 solenoid relay Internal defect aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting Replace motor 2 solenoid relay L103 with another relay Condition becomes normal Relay L10...

Page 844: ...SEN03846 00 WA250 250PZ 6 40 360 33 360 Troubleshooting by failure code Display of code Part 6 Failure code DW26KY Motor 2 solenoid Hot short Related circuit diagram ...

Page 845: ...ethod of reproducing failure code Start engine wait for at least 30 seconds and then press man ual reverse switch Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective fan reverse sole noid relay Internal defect aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting Replace fan reverse s...

Page 846: ...SEN03846 00 WA250 250PZ 6 40 360 35 360 Troubleshooting by failure code Display of code Part 6 Failure code DW7BKY Fan reverse solenoid circuit Hot short Related circuit diagram ...

Page 847: ...rry out troubleshooting Replace fan reverse solenoid relay L104 with another relay Condition becomes normal Relay L104 is defective Condition does not become normal Relay L104 is normal aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Between L104 male 1 2 Resis tance 200 400 z 2 Defective VIS power supply holding relay Internal short circuit aPre...

Page 848: ...SEN03846 00 WA250 250PZ 6 40 360 37 360 Troubleshooting by failure code Display of code Part 6 Failure code DW7BKZ Fan reverse solenoid circuit Disconnection Ground fault Related circuit diagram ...

Page 850: ...code DX19KB Motor 1 solenoid Ground fault 8 Failure code DX19KY Motor 1 solenoid Hot short 10 Failure code DX20KA Clutch EPC solenoid Disconnection 12 Failure code DX20KB Clutch EPC solenoid Ground fault 14 Failure code DX20KY Clutch EPC solenoid Hot short 16 Failure code DXH7KB Reverse solenoid Ground fault 18 Failure code DXH7KZ Reverse solenoid Disconnection Hot short 20 Failure code DXH8KB For...

Page 851: ... to the fan EPC solenoid can be checked with the monitoring function Code HST 41400 FAN EPC DIR Method of reproducing failure code Turn the starting switch ON Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective fan EPC solenoid Internal disconnection aPrepare with starting switch OFF then carry out troubleshooting without ...

Page 852: ...ate current to the fan EPC solenoid can be checked with the monitoring function Code HST 41400 FAN EPC DIR Method of reproducing failure code Turn the starting switch ON Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective fan EPC solenoid Internal short circuit a Prepare with starting switch OFF then carry out troubleshoot...

Page 853: ...ate current to the fan EPC solenoid can be checked with the monitoring function Code HST 41400 FAN EPC DIR Method of reproducing failure code Turn the starting switch ON Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective fan EPC solenoid Internal short circuit aPrepare with starting switch OFF then carry out troubleshooti...

Page 854: ...SEN03847 00 WA250 250PZ 6 40 370 5 370 Troubleshooting by failure code Display of code Part 7 Failure code DX16KY Fan EPC solenoid Hot short ...

Page 855: ...KY or DX20KY is also displayed carry out troubleshooting for it first Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective motor 1 solenoid Internal defect aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON T06 male Resistance Between 1 2 15 30 z Between 1 2 ground Min 1 Mz 2...

Page 856: ...SEN03847 00 WA250 250PZ 6 40 370 7 370 Troubleshooting by failure code Display of code Part 7 Failure code DX19KA Motor 1 solenoid Disconnection Related circuit diagram ...

Page 857: ...securely on slope machine moves down sud denly Related information Following output command values can be checked with monitoring function Motor 1 solenoid output HST 80000 MOTOR SOL DIR mA HST safety relay output HST 40979 D_OUT_15 ON OFF Clutch EPC solenoid output HST 80100 CLUTCH SOL DIR mA Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troub...

Page 858: ...SEN03847 00 WA250 250PZ 6 40 370 9 370 Troubleshooting by failure code Display of code Part 7 Failure code DX19KB Motor 1 solenoid Ground fault Related circuit diagram ...

Page 859: ...R mA HST safety relay output HST 40979 D_OUT_15 ON OFF Clutch EPC solenoid output HST 80100 CLUTCH SOL DIR mA DX19KA DX20KA or DX20KY may be also displayed depending on condition when error was detected Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective motor 1 solenoid Internal defect aPrepare with starting switch OFF th...

Page 860: ...SEN03847 00 WA250 250PZ 6 40 370 11 370 Troubleshooting by failure code Display of code Part 7 Failure code DX19KY Motor 1 solenoid Hot short Related circuit diagram ...

Page 861: ...R mA If failure code DX19KY or DX20KY is also displayed carry out troubleshooting for it first Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective clutch EPC sole noid Internal defect aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON T05 male Resistance Between 1 2 5 15 z B...

Page 862: ...SEN03847 00 WA250 250PZ 6 40 370 13 370 Troubleshooting by failure code Display of code Part 7 Failure code DX20KA Clutch EPC solenoid Disconnection Related circuit diagram ...

Page 863: ...ng parking brake securely on slope machine moves down sud denly Related information Following output command values can be checked with monitoring function Motor 1 solenoid output HST 80000 MOTOR SOL DIR mA HST safety relay output HST 40979 D_OUT_15 ON OFF Clutch EPC solenoid output HST 80100 CLUTCH SOL DIR mA Possible causes and standard value in normal state Causes Standard value in normal state...

Page 864: ...SEN03847 00 WA250 250PZ 6 40 370 15 370 Troubleshooting by failure code Display of code Part 7 Failure code DX20KB Clutch EPC solenoid Ground fault Related circuit diagram ...

Page 865: ... DIR mA HST safety relay output HST 40979 D_OUT_15 ON OFF Clutch EPC solenoid output HST 80100 CLUTCH SOL DIR mA DX19KA DX19KY or DX20KA may be also displayed depending on condition when error was detected Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective clutch EPC sole noid Internal defect aPrepare with starting switch...

Page 866: ...SEN03847 00 WA250 250PZ 6 40 370 17 370 Troubleshooting by failure code Display of code Part 7 Failure code DX20KY Clutch EPC solenoid Hot short Related circuit diagram ...

Page 867: ...ance Between 3 4 15 30 z Between 3 4 ground Min 1 Mz 2 Defective diode Internal defect aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON See Testing and adjusting Test procedure for diode Between T01B male 1 2 No continuity 3 Defective FR pressure select relay Internal defect aPrepare with starting switch OFF then start engine and carry out trouble...

Page 868: ...SEN03847 00 WA250 250PZ 6 40 370 19 370 Troubleshooting by failure code Display of code Part 7 Failure code DXH7KB Reverse solenoid Ground fault Related circuit diagram ...

Page 869: ... 30 z Between 3 4 ground Min 1 Mz 2 Defective diode Internal defect aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON See Testing and adjusting Test procedure for diode Between T01B male 2 1 No continuity 3 Defective FR pressure select relay Internal defect aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting...

Page 870: ...SEN03847 00 WA250 250PZ 6 40 370 21 370 Troubleshooting by failure code Display of code Part 7 Failure code DXH7KZ Reverse solenoid Disconnection Hot short Related circuit diagram ...

Page 871: ...Standard value in normal state Remarks on troubleshooting 1 Defective forward solenoid Internal defect aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON T01 male Resistance Between 1 2 15 30 z Between 1 2 ground Min 1 Mz 2 Defective diode Internal defect aPrepare with starting switch OFF then carry out troubleshooting without turning starting switc...

Page 872: ...SEN03847 00 WA250 250PZ 6 40 370 23 370 Troubleshooting by failure code Display of code Part 7 Failure code DXH8KB Forward solenoid Ground fault Related circuit diagram ...

Page 873: ...in normal state Remarks on troubleshooting 1 Defective forward solenoid Internal defect aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON T01 male Resistance Between 1 2 15 30 z Between 1 2 ground Min 1 Mz 2 Defective diode Internal defect aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON See Testin...

Page 874: ...SEN03847 00 WA250 250PZ 6 40 370 25 370 Troubleshooting by failure code Display of code Part 7 Failure code DXH8KZ Forward solenoid Disconnection Hot short Related circuit diagram ...

Page 875: ...esets itself Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Steering pump overrun aGive operator instructions to use engine in range where alarm is not turned ON Action code Failure code Trouble HST pump Overrun alarm HST controller system E02 M100N1 Contents of trouble HST pump speed exceeded alarm operation set value Action o...

Page 876: ...Action of controller Turns the centralized warning lamp and alarm buzzer ON Problem that appears on machine HST motor 1 may be broken If it is broken machine cannot travel Related information Advance alarm is turned ON before this code is displayed If HST motor 1 speed decreases below alarm reset value system resets itself Possible causes and standard value in normal state Causes Standard value in...

Page 878: ...ection selection system does not function 26 E 7 Wiper does not operate 30 E 8 Windshield washer does not operate 34 E 9 Headlamp clearance lamp and tail lamp do not light up or go off 38 E 10 Working lamp does not light up or go off 46 E 11 Turn signal lamp and hazard lamp do not light up or go off 51 E 12 Brake lamp does not light or it keeps lighting up 58 E 13 Backup lamp does not light or it ...

Page 879: ...SEN03848 00 40 400 2 WA250 250PZ 6 400 Troubleshooting of electrical system E mode ...

Page 880: ...ible when the starting switch is operated Starting switch operation in the order of OFF o ON o OFF 3 Defective fuse If the fuse is burn the circuit probably has a grounding fault etc See cause 18 4 Defective starting motor Internal trouble aPrepare with starting switch OFF with wiring harness connected then turn starting switch START and carry out troubleshooting Starting motor Voltage Between ter...

Page 881: ...with out turning starting switch ON D21 male Diode range Continuity Between 2 and 1 Measure at 2 in diode range Continue a Prepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON D22 male Diode range Continuity Between 2 and 1 Measure at 2 in diode range Continue 10 Defective diodes D01 Internal trouble a Prepare with starting switch OFF then carry out t...

Page 882: ...1 and 2 200 400 z aPrepare with starting switch OFF aCheck neutral safety relay unit Neutral safety relay L106 1 2 Resistance Between 3 5 When 24 V is applied When relay is ON Max 1 z Other than above When relay is OFF Min 1 Mz aPrepare with starting switch OFF then turn starting switch to START and carry out troubleshooting When neutral safety relay L106 is replaced with a relay of the same type ...

Page 883: ...lay is OFF Min 1 Mz a Prepare with starting switch OFF then turn starting switch to START and carry out troubleshooting When VIS power supply holding relay L102 is replaced with another relay if condition becomes normal VIS power supply holding relay is defective 18 Disconnection in wiring harness Disconnection in wiring harness or defective con tact a Prepare with starting switch OFF then carry o...

Page 884: ...g harness between L106 female 5 E01 female 1 and ground Resis tance Min 1 Mz Between wiring harness L02 female 2 L107 female 1 L108 female 1 and ground Resis tance Min 1 Mz Between wiring harness L02 female 4 EC2 female 2 and ground Resis tance Min 1 Mz Between wiring harness L15 female 3 L106 female 1 and ground Resis tance Min 1 Mz Between wiring harness L102 female 3 L15 female 1 and ground Res...

Page 885: ...SEN03848 00 40 400 8 WA250 250PZ 6 400 Troubleshooting of electrical system E mode E 1 Engine does not start Related circuit diagram ...

Page 886: ...SEN03848 00 WA250 250PZ 6 40 400 9 400 Troubleshooting of electrical system E mode E 1 Engine does not start ...

Page 887: ...ive intake air heater Internal defect aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Between E07B ground Resis tance 0 17 0 27 z 3 Defective diode E06A Internal defect aPrepare with starting switch OFF aReplace diode E06A Condition becomes normal Diode E06A is defective Condition does not become nor mal Diode E06A is normal aPrepare with startin...

Page 888: ...SEN03848 00 WA250 250PZ 6 40 400 11 400 Troubleshooting of electrical system E mode E 2 Preheater does not operate normally Related circuit diagram ...

Page 889: ...ct aTurn starting switch OFF and remove heater relay aCheck heater relay unit Heater relay E06 R90 Resistance Between E05 E07A When 24 V is applied When relay is ON Max 1 z Other than above When relay is OFF Min 1 Mz Between E06 R90 19 25 z 2 Ground fault in wiring harness Contact with GND circuit aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON B...

Page 890: ...SEN03848 00 WA250 250PZ 6 40 400 13 400 Troubleshooting of electrical system E mode E 2 Preheater does not operate normally ...

Page 891: ...ween L113 male 1 2 Resis tance Min 1 Mz 2 Defective detent active relay Internal trouble aPrepare with starting switch OFF aReplace detent active relay L115 with normal relay aOperate boom kick out with engine started Boom kick out function is normal Defective relay L115 Boom kick out does not function Relay L115 is normal aPrepare with starting switch OFF then carry out troubleshooting without tu...

Page 892: ...s not function 6 Wiring harness ground fault Contact with GND circuit a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between F04 female B and L113 female 2 and ground Resis tance Min 1 Mz Wiring harness between L113 female 5 and L36 female 1 and ground Resis tance Min 1 Mz a In this case the boom kick out detent does not function...

Page 893: ...in normal state Remarks on troubleshooting 7 Hot short circuiting between harnesses Contact with 24V circuit aPrepare with starting switch OFF then turn starting switch ON raise lift arm to the highest position kick out operated and carry out troubleshooting Wiring harness between F04 female B L113 female 2 and ground Voltage Max 1 V aIn this case boom kick out detent does not function lever retur...

Page 894: ...SEN03848 00 WA250 250PZ 6 40 400 17 400 Troubleshooting of electrical system E mode E 3 Defective boom kick out function and cancellation Related circuit diagram ...

Page 895: ...d 2 Resis tance 200 400 z aPrepare with starting switch OFF aSolid part check aApplies impressed voltage between L114 male 1 2 Between L114 male 3 and 5 Applies 24V impressed voltage between L114 male 1 2 Resis tance Max 1 z Does not apply voltage between L114 male 1 2 Resis tance Min 1 Mz 2 Defective detent active relay L113 aTurn starting switch OFF aReplace detent active relay L115 with normal ...

Page 896: ...ng harness discontinuity Disconnection or defective contact a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between F03 female A and fuse FS1 13 Resis tance Max 1 z Wiring harness between F03 female B and L114 female 2 Resis tance Max 1 z Wiring harness between F03 female C and ground Resis tance Max 1 z Wiring harness between L11...

Page 897: ...e 5 and ground Resis tance Min 1 Mz Wiring harness between L115 female 3 fuse FS1 13 and ground Resis tance Min 1 Mz Wiring harness between E02 female 1 L115 female 1 and ground Resis tance Min 1 Mz aIn this case the fuse is blown and no detents function lever returns to neutral 7 Hot short circuiting between harnesses aPrepare with starting switch OFF turn starting switch ON and carry out trouble...

Page 898: ...SEN03848 00 WA250 250PZ 6 40 400 21 400 Troubleshooting of electrical system E mode E 4 Defective bucket positioner function and cancellation Related circuit diagram ...

Page 899: ...Resis tance Min 1 Mz 2 Defective detent active relay Internal trouble aPrepare with starting switch OFF aReplace detent active relay L115 with normal relay aOperate lift arm FLOATING with engine started Lift arm FLOATING function is normal Defective relay L115 Lift arm FLOATING does not function Relay L115 is normal aPrepare with starting switch OFF then carry out troubleshooting without turning s...

Page 900: ... does not function 6 Wiring harness ground fault Contact with GND circuit a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between F04 female B and L113 female 2 and ground Resis tance Min 1 Mz Wiring harness between L113 female 5 and L35 female 1 and ground Resis tance Min 1 Mz a In this case the boom kick out detent does not func...

Page 901: ...ses Standard value in normal state Remarks on troubleshooting 7 Hot short circuiting between harnesses Contact with 24V circuit aPrepare with starting switch OFF then turn starting switch ON operate lift arm FLOATING and carry out troubleshooting Wiring harness between F04 female B L113 female 2 and ground Voltage Max 1 V aIn this case lift arm FLOATING detent does not function lever returns to ne...

Page 902: ...SEN03848 00 WA250 250PZ 6 40 400 25 400 Troubleshooting of electrical system E mode E 5 Defective lift arm FLOATING holding function and cancellation Related circuit diagram ...

Page 903: ...ed with indicator lamp or monitoring function of machine monitor Monitoring code HST 40977 D IN 0 D IN 1 D IN 2 Output state of directional solenoid FR output can be checked with monitoring function Monitoring code HST 40980 D OUT 18 D OUT 19 Possible causes and standard value in normal state Causes Standard value in normal state Remarks on troubleshooting 1 Defective parking brake bot tom switch ...

Page 904: ...SEN03848 00 WA250 250PZ 6 40 400 27 400 Troubleshooting of electrical system E mode E 6 Travel direction selection system does not function Related circuit diagram ...

Page 905: ...e forward solenoid Internal defect aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Between T01 male 1 2 Resis tance 30 60 z Between T01 male 1 2 ground Resis tance Min 1 Mz 2 Defective reverse solenoid Internal defect aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Between T01 male 3 4 Resis tan...

Page 906: ...SEN03848 00 WA250 250PZ 6 40 400 29 400 Troubleshooting of electrical system E mode E 6 Travel direction selection system does not function Related circuit diagram ...

Page 907: ...1 and ground Hi 20 30 V If wiper switch is turned OFF while wiper is operating voltage is applied between L57 5 and ground until wiper motor stops 3 Defective wiper timer relay Internal defect aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting L48 Front wiper switch Voltage Between 3 and ground Constant 20 30 V Between 4 and ground INT 20 30 V Between 2 an...

Page 908: ...le 7 fuse No 14 of fuse box FS1 circuit branch end Resis tance Max 1 z Wiring harness between L05 female 4 L57 female 1 Resis tance Max 1 z Wiring harness between L57 female 4 ground Resis tance Max 1 z 6 Grounding fault in wiring har ness Contact with ground circuit a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between L05 fema...

Page 909: ...20 30 V aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON L05 Rear wiper switch Resistance Between 7 and 9 ON Max 1 z Between 8 and 9 OFF Max 1 z Other than above Min 1 Mz 3 Disconnection in wiring har ness Disconnection or defective contact in connector aPrepare with starting switch OFF then carry out troubleshooting without turning starting switc...

Page 910: ...SEN03848 00 WA250 250PZ 6 40 400 33 400 Troubleshooting of electrical system E mode E 7 Wiper does not operate Related circuit diagram ...

Page 911: ...sher does not oper ate front washer motor is defective 2 Defective rear washer motor Internal defect B06 Rear wiper switch Voltage Resistance Between 1 ground Window washer operation position 20 30 V Between 2 ground Max 1 z If voltage and resistance are normal but rear washer does not oper ate rear washer motor is defective B07 Front wiper switch Voltage Resistance 3 Defective front wiper switch ...

Page 912: ...then carry out troubleshooting without turning starting switch ON Wiring harness between L05 female 6 B07 female 1 L48 female 2 Resis tance Max 1 z Wiring harness between L05 female 7 fuse No 14 of fuse box FS1 Resis tance Max 1 z Wiring harness between L05 female 10 B06 female 1 Resis tance Max 1 z Wiring harness between B07 female 2 B06 female 2 ground Resis tance Max 1 z 7 Ground fault in wirin...

Page 913: ...SEN03848 00 40 400 36 WA250 250PZ 6 400 Troubleshooting of electrical system E mode E 8 Windshield washer does not operate Related circuit diagram ...

Page 914: ...SEN03848 00 WA250 250PZ 6 40 400 37 400 Troubleshooting of electrical system E mode E 8 Windshield washer does not operate ...

Page 915: ...he input state ON OFF to the machine monitor from the lamp switch head lamp can be checked with the monitoring function Code MONITOR PANEL 40900 D IN 0 The input state ON OFF to the machine monitor from the dimmer switch high beam can be checked with the monitoring function Code MONITOR PANEL 40904 D IN 34 Possible causes and standard value in normal state Causes Standard value in normal state Rem...

Page 916: ...ing switch OFF then carry out troubleshooting without turning starting switch ON L120 male Resistance Between 1 and 2 200 400 z a Prepare with starting switch OFF then turn starting switch ON and carry out troubleshooting When headlamp relay L120 is replaced with a relay of the same type if the condition becomes normal the headlamp relay is defec tive 3 Defective headlamp relay right L119 a Prepar...

Page 917: ...with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between L04 female 2 L120 female 2 circuit branch end and ground Resis tance Min 1 Mz aCarry out above when left side does not go off Wiring harness between fuse No 8 of fuse box FS1 L120 female 1 3 and ground Resis tance Min 1 Mz Wiring harness between L120 female 5 L25 female 1 left FLH fema...

Page 918: ...troubleshooting 1 Broken bulb If a specific headlamp does not light up its bulb may be broken or may have a defective contact Check the bulb directly 2 Defective dimmer switch Internal trouble a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON L04 male Dimmer switch Resistance Between 5 and 3 Low Min 1 Mz High Max 1 z Between 4 and 3 Low Max 1 z Hi...

Page 919: ...shooting 1 Broken bulb If a specific headlamp does not light up its bulb may be broken or may have a defective contact Check the bulb directly 2 Defective dimmer switch Internal trouble aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON L04 male Dimmer switch Resistance Between 5 and 3 Low Min 1 Mz High Max 1 z Between 4 and 3 Low Max 1 z High Min 1...

Page 920: ... a relay of the same type if the condition becomes normal the small lamp relay is defec tive 4 Defective small lamp relay right L118 Internal trouble a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON L118 male Resistance Between 1 and 2 200 400 z a Prepare with starting switch OFF then turn starting switch ON and carry out troubleshooting When sma...

Page 921: ... above when left side does not go off Wiring harness between fuse No 11 of fuse box FS2 L118 female 1 3 and ground Resis tance Min 1 Mz aCarry out above when right side does not light Wiring harness between L117 female 5 FLC1 female A R22 female 6 and ground Resis tance Min 1 Mz Wiring harness between L118 female 5 FLC female A R23 female 6 and ground Resis tance Min 1 Mz 8 Hot short in wiring har...

Page 922: ...SEN03848 00 WA250 250PZ 6 40 400 45 400 Troubleshooting of electrical system E mode E 9 Headlamp clearance lamp and tail lamp do not light up or go off Related circuit diagram ...

Page 923: ...ooting without turning starting switch ON L122 male Resistance Between 1 and 2 200 400 z aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting When front working lamp relay L122 is replaced with a relay of the same type if the condition becomes normal the front working lamp relay is defective 4 Defective front working lamp switch Internal trouble aPrepare wit...

Page 924: ... 5 L122 female 1 and ground Resis tance Min 1 Mz Wiring harness between fuse No 12 of fuse box FS2 L07 female 6 L122 female 3 and ground Resis tance Min 1 Mz Wiring harness between L122 female 5 C04 female 1 C05 female 1 circuit branch end and ground Resis tance Min 1 Mz 7 Hot short in wiring harness Contact with 24V circuit a Prepare with starting switch OFF then turn starting switch ON and carry...

Page 925: ...starting switch ON L123 male Resistance Between 1 and 2 200 400 z aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting When rear working lamp relay L123 is replaced with a relay of the same type if the condition becomes normal the rear working lamp relay is defective 4 Defective rear working lamp switch Internal trouble aPrepare with starting switch OFF then...

Page 926: ...e 5 L123 female 1 and ground Resis tance Max 1 z Wiring harness between fuse No 13 of fuse box FS2 L08 female 6 L123 female 3 and ground Resis tance Max 1 z Wiring harness between L123 female 5 B01 female 1 B02 female 1 circuit branch end and ground Resis tance Max 1 z 7 Hot short in wiring harness Contact with 24V circuit a Prepare with starting switch OFF then turn starting switch ON and carry o...

Page 927: ...SEN03848 00 40 400 50 WA250 250PZ 6 400 Troubleshooting of electrical system E mode E 10 Working lamp does not light up or go off Related circuit diagram ...

Page 928: ...Defective hazard relay L125 Internal trouble a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON L125 male Resistance Between 1 and 2 200 400 z a Prepare with starting switch OFF then turn starting switch ON and carry out troubleshooting When hazard relay L125 is replaced with a relay of the same type if the condition becomes normal the hazard relay...

Page 929: ...h OFF then carry out troubleshooting without turning starting switch ON Wiring harness between L125 female 3 L49 female 3 and ground Resis tance Min 1 Mz Wiring harness between L49 female 4 L04 female 6 L124 female 1 3 and ground Resis tance Min 1 Mz Wiring harness between L04 female 7 R23 female 1 FLC left female C and ground Resis tance Min 1 Mz Wiring harness between L04 female 8 R22 female 1 F...

Page 930: ...le Turn signal lamp switch Resistance Between 6 and 7 Left Min 1 Mz Right Max 1 z Between 6 and 8 Left Max 1 z Right Min 1 Mz 3 Defective hazard relay L125 a Prepare with starting switch OFF then check relay unit Between L125 female 3 6 Resis tance Max 1 z 4 Disconnection in wiring har ness Disconnection or defective contact in connector a Prepare with starting switch OFF then carry out troublesho...

Page 931: ...ing switch OFF then carry out troubleshooting without turning starting switch ON L124 male Resistance Between 1 and 2 200 400 z aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting When hazard turn signal relay L124 is replaced with a relay of the same type if the condition becomes normal the hazard turn signal relay is defective 4 Defective hazard lamp swit...

Page 932: ...Mz Wiring harness between fuse No 2 of fuse box FS1 L06 female 6 and ground Resis tance Min 1 Mz Wiring harness between L125 female 1 L06 female 1 5 and ground Resis tance Min 1 Mz 7 Hot short in wiring harness Contact with 24V circuit a Prepare with starting switch OFF then turn starting switch ON and carry out troubleshooting When hot short resulted on the wiring harnesses of the following two c...

Page 933: ...SEN03848 00 40 400 56 WA250 250PZ 6 400 Troubleshooting of electrical system E mode E 11 Turn signal lamp and hazard lamp do not light up or go off Related circuit diagram ...

Page 934: ...SEN03848 00 WA250 250PZ 6 40 400 57 400 Troubleshooting of electrical system E mode E 11 Turn signal lamp and hazard lamp do not light up or go off ...

Page 935: ...p relay is defec tive 4 Defective brake lamp switch Internal trouble aPrepare with starting switch OFF then turn starting switch to START and carry out troubleshooting L34 male Brake pedal Resistance Between 1 and 2 Press Max 1 z Released Min 1 Mz Between 1 2 and ground Constant Min 1 Mz 5 Disconnection in wiring har ness Disconnection or defective contact in connector aPrepare with starting switc...

Page 936: ...e in normal state Causes Standard value in normal state Remarks on troubleshooting 7 Hot short in wiring harness Contact with 24V circuit a Prepare with starting switch OFF then turn starting switch ON and carry out troubleshooting Wiring harness between L34 female 2 L121 female 1 and ground Voltage Max 1 V Wiring harness between L121 female 5 R22 female 5 R23 female 5 and ground Voltage Max 1 V ...

Page 937: ...n carry out troubleshooting without turning starting switch ON L109 male Resistance Between 1 and 2 200 400 z aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting When backup lamp 1 relay L109 is replaced with a relay of the same type if the condition becomes normal the backup lamp 1 relay is defective 4 Defective backup lamp 2 relay L126 Internal disconnect...

Page 938: ...en fuse box FS1 No 14 L101 female 3 Resis tance Max 1 z Wiring harness between L101 female 4 R22 female 2 or R23 female 2 Resis tance Max 1 z Wiring harness between HST female 20 L101 female 5 Resis tance Max 1 z Wiring harness between L101 female 6 ground Resis tance Max 1 z Wiring harness between R22 female 4 ground Resis tance Max 1 z Wiring harness between R23 female 4 ground Resis tance Max 1...

Page 939: ...SEN03848 00 40 400 62 WA250 250PZ 6 400 Troubleshooting of electrical system E mode E 13 Backup lamp does not light or it keeps lighting up Related circuit diagram ...

Page 940: ...109 Internal trouble a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON L109 male Resistance Between 1 and 2 200 400 z a Prepare with starting switch OFF then turn starting switch ON and carry out troubleshooting When backup lamp 1 relay L109 is replaced with a relay of the same type if the condition becomes normal the backup lamp 1 relay is defect...

Page 941: ...se box FS1 No 14 L101 female 3 Resis tance Max 1 z Wiring harness between L101 female 4 B03 female 1 Resis tance Max 1 z Wiring harness between HST female 20 L101 female 5 Resis tance Max 1 z Wiring harness between L101 female 6 ground Resis tance Max 1 z Wiring harness between R22 female 4 ground Resis tance Max 1 z Wiring harness between R23 female 4 ground Resis tance Max 1 z Wiring harness bet...

Page 942: ...SEN03848 00 WA250 250PZ 6 40 400 65 400 Troubleshooting of electrical system E mode E 14 Backup alarm does not sound or it keeps sounding Related circuit diagram ...

Page 943: ... Internal trouble aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON L13 male Horn switch Resistance Between 1 and ground ON Max 1 z OFF Min 1 Mz 4 Defective horn Internal trouble aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting Disconnect connector and mea sure on female side F01 F02 Horn switch Voltage B...

Page 944: ...turning starting switch ON Wiring harness between fuse No 9 of fuse box FS2 L116 female 1 3 circuit branch end and ground Resis tance Min 1 Mz Wiring harness between L116 female 5 F01 female 1 F02 female 1 circuit branch end and ground Resis tance Min 1 Mz Wiring harness between L116 female 2 L13 female 1 and ground Resis tance Min 1 Mz 7 Hot short Contact with 24V circuit in wiring harness a Prep...

Page 945: ... with starting switch OFF then turn starting switch ON and carry out troubleshooting Remove the buzzer then connect 24 V to L46 male 1 and GND to L46 male 2 Alarm buzzer sounds Alarm buzzer is normal Alarm buzzer does not sound Defective alarm buzzer 3 Disconnection in wiring har ness Disconnection or defective contact in connector aPrepare with starting switch OFF then carry out troubleshooting w...

Page 946: ...SEN03848 00 WA250 250PZ 6 40 400 69 400 Troubleshooting of electrical system E mode E 16 Alarm buzzer does not sound or it keeps sounding Related circuit diagram ...

Page 947: ...tarting switch ON When fuse No 1 of fuse box FS2 is broken Wiring harness between fuse No 1 of fuse box A compressor clutch relay and ground Resis tance Min 1 Mz Wiring harness between compressor clutch relay E10 female 2 and ground Resis tance Min 1 Mz aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON When 5A fuse of the air conditioner unit main ...

Page 948: ...ine and ground ON 20 30 V OFF Max 1 V Blower OFF relay 5A fuse line of main cir cuit and ground ON 20 30 V OFF Max 1 V Pressure switch 5A fuse line of main circuit and ground ON 20 30 V OFF Max 1 V a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between fuse No 1 of fuse box FS2 blower OFF relay on the 15A fuse line Resis tance Ma...

Page 949: ...SEN03848 00 40 400 72 WA250 250PZ 6 400 Troubleshooting of electrical system E mode E 17 Air conditioner does not operate or stop Related circuit diagram ...

Page 950: ...n the starting switch ON then carry out troubleshooting LED 2 Normal state LED A2 ON 3 Defective starting switch ACC signal and alternator R signal aTurn the starting switch ON then start engine and carry out trou bleshooting LED 6 Normal state LED C1 ON aPrepare with starting switch OFF then start engine and carry out troubleshooting L80 Signal Voltage Between 36 and 37 38 Starting switch ACC 20 ...

Page 951: ...state Remarks on troubleshooting 6 Number of unsent mails a Turn the starting switch ON and carry out troubleshooting LED 12 Normal state 7 segments 0 9 7 Defective GPS positioning status a Turn the starting switch ON and carry out troubleshooting LED 13 Normal state Dot ON One or more minute may be taken until GPS positioning is com pleted after the starting switch was turned ON even in an outdoo...

Page 952: ... range lamp 3 LED A3 on communicating lamp 4 LED A4 internal transmission lamp 5 LED A5 internal reception lamp CPU LED 6 LED C1 R signal and ACC signal status 7 LED C2 engine control signal status 8 LED C3 C signal status 9 LED C4 CAN status 10 LED C5 download writing condition 11 LED C6 download writing condition 7 segments and dot for CPU 12 7 segments number of mails not yet sent 13 Dot GPS po...

Page 954: ... steering wheel is heavy 14 H 8 Steering wheel shakes or jerks 15 H 9 Machine deviates naturally to one side when traveling 15 H 10 The brake does not work or does not work well 16 H 11 The brake is not released or is dragged 17 H 12 The lift arm does not rise or lower 18 H 13 The lift arm moves slowly or the lift arm rising force is insufficient 19 H 14 When rising the lift arm comes to move slow...

Page 955: ...e bucket 24 H 23 Hydraulic drifts of the bucket occur often 24 H 24 The bucket wobbles during travel with load The work equipment valve is set to HOLD 24 H 25 When the control lever is switched from HOLD to TILT the bucket falls temporarily 25 H 26 The control levers of the lift arm and bucket do not move smoothly and heavy 25 H 27 The ECSS does not operate and machine pitches and bounces 26 H 28 ...

Page 956: ... items given under Checks before troubleshooting are checks that are particularly important to make about the condition of the machine before starting the actual troubleshooting Example Checks before starting troubleshoot ing q Is oil level and type of oil in hydraulic tank cor rect q Is there any oil leakage from steering valve or demand valve q Is steering linkage adjusted properly Step 3 Method...

Page 957: ...ses found in Step 2 and Step 4 there are common items Q marks on the line for each Diagnosis item and in the same Cause column as each other that have causes common with the problem items found in the troubleshooting in Step 1 and Step 3 a The items that are not common items that do not have Q marks in the same cause common as each other are probably not the cause so they can be eliminated The cau...

Page 958: ...SEN03849 00 WA250 250PZ 6 40 500 5 500 Troubleshooting of hydraulic and mechanical system H mode Method of using troubleshooting chart ...

Page 959: ...e steering wheel does not turn The steering wheel is heavy There is play in steering wheel or excessive shock Machine deviates naturally to one side when traveling Brake The brake does not work or does not work well The brake is not released or is dragged Work equipment system The lift arm does not rise or lower Q Q The lift arm moves slowly or the lift arm rising force is insufficient Q When the ...

Page 960: ...trictor valve Cushion valve ECSS solenoid valve Accumulator Fan pump Fan motor Charge valve Troubleshooting No Orbit roll Priority valve Relief valve Safety valve Brake disc and plate Brake piston Main relief valve Lift arm spool Bucket spool Suction and safety valve Suction valve Q Q Q H 1 HST related Q Q H 2 Q Q Q H 3 H 4 Q Q H 5 Q Q Q Q Q H 6 Steering wheel Q Q Q Q Q H 7 Q Q Q Q H 8 Q Q Q H 9 Q...

Page 961: ... any external oil leak found around the hydraulic piping pump and motor Cause Damper HST pump HST motor 2 HST motor 1 Others a b c d e f g h i j k l m n o Damper Pump body Piston pump end Pump body Charge pump end High pressure relief valve High pressure cut off valve Low pressure relief valve Charge relief valve DA valve Directional solenoid valve Motor body Motor body Inching valve Inching valve...

Page 962: ... a b c d e f g h i j k l m n o Pump body Piston pump end Pump body Charge pump end High pressure relief valve Low pressure relief valve Charge relief valve DA valve Directional solenoid valve Motor body Mode selector solenoid valve SOL a Angle stopper solenoid valve SOL b Motor body Angle stopper control solenoid valve Inching valve Inching valve linkage Clutch solenoid Clutch No Remedy Diagnosis ...

Page 963: ...alve High pressure cut off valve Motor body Motor body Inclination control solenoid valve Inching valve Inching valve linkage Clutch solenoid Clutch Transfer No Remedy Diagnosis E X E X E X E X E X E X E X A E X E X E X 1 The traction force is weak in both forward and reverse Q Q Q Q Q Q Q Q Q 2 The traction force is weak at forward Reverse is normal Q 3 The traction force is weak at reverse Forwa...

Page 964: ...here any problem before o Dirt in HST pump motor related equipment Inspection before diagnosis q Is the any external oil leak found around the hydraulic piping pump and motor Cause HST pump HST motor 2 Others a b c DA valve Inclination stopper solenoid valve SOL b Inclination control solenoid valve No Remedy Diagnosis E X E X E X 1 Engine stalls when traveling or engine speed drops excessively Q Q...

Page 965: ...peed range switch and the monitor display do not match check the electrical wiring a When the travel speed is slow carry out troubleshooting for H 2 first Cause HST motor 2 HST motor 1 Others a b c d Inclination stopper solenoid valve SOL b Inclination control solenoid valve Clutch solenoid Clutch No Remedy Diagnosis E X E X E X E X 1 The gear is not shifted Q Q Q Q ...

Page 966: ...ective seal Inspection before diagnosis q Are the oil level in the hydraulic tank and the oil type appropriate q Has the lock bar been removed from frame Cause Hydraulic pump Others a b c d e f Defective hydraulic pump or PTO Steering pump and switch pump Priority valve Orbit roll Internal defective steering cylinder Defective piston seal 2 way restrictor valve Emergency steering valve 1 Steering ...

Page 967: ...t of steering wheel and time taken to turn steering and check standard judgement value table to see if there is any abnormality Cause Hydraulic pump Valve Others a b c d e f The hydraulic pump is defective Internal defective steering cylinder Defective piston seal Priority valve Orbit roll internal defect Clogging of hydraulic oil return filter defective bypass valve Clogging of oil cooler The ste...

Page 968: ...ion pressure q Is the steering wheel play correct Check for abnormalities q Operate at a safe place and check how the steering wheel shakes and under what conditions a In cases where the steering wheel is heavy but does not shake go to H 7 The steering wheel is heavy Cause Valves Cylinder Valves a b c d Defect inside Orbit roll Defective 2 way restrictor valve Defect inside steering cylinder insid...

Page 969: ...ke lining in axle Mixing of air in brake circuit Defect inside brake valve Defective seal of accumulator piston insufficient gas pressure Defective operation of accumulator charge valve Defective brake pump For charge Defective brake linkage No Remedy Diagnosis E X E X X E X E X E X E X X E X A 1 When the brake pedal is stepped on only a little resistance is felt Q Q Q Q Q 2 When the brake pedal i...

Page 970: ...evel ground Cause a b c d Defective brake piston seal in axle Defective operation of brake piston in axle Defective slack adjuster Wear or abnormality of brake lining in axle No Remedy Diagnosis E X E X E X E X 1 The brake pedal is released but the brake is still applied Q Q Q Q 2 When the brake pedal is released oil is drained from the air bleeder the circuit oil pressure drops and the brake is r...

Page 971: ...ST pump PPC valve Work equip ment valve Cylinder a b c d e f g h i j Clogging of pump suction port or mixing of much air in oil Defective steering pump Defective work equipment pump Defective HST charge pump Defective operation of spool Defective low pressure relief valve Defective operation of spool Defective operation of main relief valve Breakage inside valve body Lift arm spool Damage of lift ...

Page 972: ...ion port or mixing of much air in oil Defective work equipment pump and steering pump Defective operation of spool Defective low pressure relief valve Defective operation of spool Defective operation or improper adjustment of main relief valve Wear or breakage inside valve body Lift arm spool Damage of lift arm cylinder piston seal No Remedy Diagnosis C E E X E X E X E X A X X E X 1 The bucket til...

Page 973: ...enly o Wastes pinched in valve or damage of parts q Have hydraulic drifts come to occur often gradually o Wear of parts Inspection before diagnosis q Is the lift arm spool at the neutral position o The spool detent is defective Diagnosis and Cause q Does any leaking noise occur inside the lift arm cylinder when hydraulic drift is measured o The cylin der packing is defective H 17 The lift arm wobb...

Page 974: ...ntrol lever is switched from HOLD to RAISE the lift arm falls temporarily 1 Check of Phenomenon q When the control lever is switched from HOLD to RAISE gradually at low idle of the engine the lift arm falls temporarily due to its own weight When the control lever is completely set to RAISE the lift arm returns to normal Cause q Improper adhesion of lift arm spool check valve of the work equipment ...

Page 975: ... mixing of much air in oil The steering pump is defective The hydraulic pump is defective The HST charge pump which is used as PPC pump too is defective Defective operation of spool The low pressure relief valve is defective The spool is defective Defective operation of main relief valve Breakage inside valve body Bucket spool Damage of bucket cylinder piston seal No Remedy Diagnosis C E E X E X X...

Page 976: ...he steering pump are defective Defective operation of spool Defective operation of low pressure relief valve Defective operation of spool Defective operation or improper adjustment of main relief valve Defective operation of safety valve With suction valve on bucket cylinder bottom side Wear or breakage inside valve body Bucket spool Damage of bucket cylinder piston seal No Remedy Diagnosis C E E ...

Page 977: ... drifts of the bucket occur often 1 Ask the operator about the following q Have hydraulic drifts come to occur often suddenly o Wastes pinched in valve or damage of parts q Have hydraulic drifts come to occur often gradually o Wear of parts Inspection before diagnosis q Is the bucket lever PPC valve at the neutral position o Seizure of link bushing or the spool detent is defective Check of Abnorma...

Page 978: ... weight When the control lever is completely set to TILT the bucket returns to normal Cause q Improper adhesion of bucket spool check valve of the work equipment valve H 26 The control levers of the lift arm and bucket do not move smoothly and heavy 1 Check of Abnormality q Refer to the criterion value table and check if the lever operating efforts are large practically Cause PPC valve a Defective...

Page 979: ...du ally o Wear of related device or defective seal Check before troubleshooting q Check that the hydraulic tank is filled with oil of a proper type up to a proper level q Check that the ECSS switch is set properly Cause Solenoid valve Accumulator Controller Sensor a b c d Malfunction of solenoid valve Gas leakage from accumulator or defective seal Malfunction of controller Defective travel speed s...

Page 980: ...eshooting q Check the level and type of the oil in the hydraulic tank q Check the hydraulic hoses pump and motor for oil leakage q Check the fan for damage Note If Lowering of engine performance is judged go to the troubleshooting for the engine system S mode Cause Tank to Pump Charge valve Fan motor Others a b c d e f g h i j k Clogging or sucked air on pump suction side Defective fan pump Malfun...

Page 982: ...ring operations 11 S 5 Engine does not rotate smoothly 12 S 6 Engine lacks output or lacks power 13 S 7 Exhaust smoke is black incomplete combustion 14 S 8 Oil consumption is excessive or exhaust smoke is blue 15 S 9 Oil becomes contaminated quickly 16 S 10 Fuel consumption is excessive 17 S 11 Oil is in coolant or coolant spurts back or coolant level goes down 18 S 12 Oil pressure drops 19 S 13 O...

Page 983: ...st probable one to make final confirmation according to the troubleshooting procedure Questions Items to be drawn from the user or operator They correspond to A and B in the chart on the right The items in A are basic ones The items in B can be drawn from the user or operator depending on their level Check items Items to be simply checked by the serviceman to narrow down causes They correspond to ...

Page 984: ... E Q or w E Causes to be referred to for questions and check items Q Causes related to questions and check items w Causes highly probable among ones marked with Q a When narrowing the causes apply the items marked with w before those marked with Q When narrowing the causes do not apply the items marked with E If no items have other marks and the causes cannot be narrowed however you may apply them...

Page 985: ...ts Example of troubleshooting Exhaust gas is black Let us assume that Clogged air cleaner is taken to be the cause of black exhaust gas 3 symptoms have causal relationship with this problem Color of exhaust gas gradually became black Power was lost gradu ally and Air cleaner clogging caution lamp is flashing ...

Page 986: ...f engine S mode Method of using troubleshooting charts If we look from these 3 symptoms to find the causes we find that there is a relationship with 5 causes Let us explain here the method of using this causal relationship to pinpoint the most probable cause ...

Page 987: ... added more frequently w When engine is preheated or when temperature is low preheating monitor does not indicate normally w During operation charge level monitor indicates abnormal charge w w Dust indicator is red w Air breather hole of fuel tank cap is clogged w Fuel is leaking from fuel piping w Q When priming pump is operated it makes no reaction or it is heavy w Q Starting motor cranks engine...

Page 988: ...hen starting switch is turned ON there is no operating sound from battery relay Q w Check items When starting switch is turned to START starting pinion does not move out Q Q w When starting switch is turned to START starting pinion moves out but Speed of rotation is low w Makes grating noise w w Soon disengages again w Makes rattling noise and does not turn Q Q Q Troubleshooting Inspect flywheel r...

Page 989: ...w w E Fuel other than specified one is used w Replacement of filters has not been carried out according to Operation and Maintenance Manual w E Q When fuel tank is inspected it is found to be empty w Air breather hole of fuel tank cap is clogged Q w Rust and water are found when fuel tank is drained Q E E E Check items When fuel filter is removed there is not fuel in it w w Fuel is leaking from fu...

Page 990: ... w w Oil must be added more frequently w When engine is preheated or when temperature is low preheating monitor does not indicate normally w Dust indicator is red w Air breather hole of fuel tank cap is clogged Q Rust and water are found when fuel tank is drained w Fuel is leaking from fuel piping w When priming pump is operated it makes no reaction or it is heavy w Q Starting motor cranks engine ...

Page 991: ... must be added more frequently w Dust indicator is red w Air breather hole of fuel tank cap is clogged w Rust and water are found when fuel tank is drained w Fuel is leaking from fuel piping w When priming pump is operated it makes no reaction or it is heavy w Q Check items When exhaust manifold is touched immediately after starting engine temperature of some cylinders is low Q w Color of exhaust ...

Page 992: ... Q There was hunting and engine stopped w Q Q Q Q Non specified fuel is being used Q Q Q Q Replacement of filters has not been carried out according to Operation and Maintenance Manual w w Fuel level monitor indicates low level w When fuel tank is inspected it is found to be empty w Air breather hole of fuel tank cap is clogged w Fuel is leaking from fuel piping w Check items Rust and water are fo...

Page 993: ...unting Occurs at a certain speed range Q Q Occurs at low idle Q Q Q Q Q Occurs even when speed is raised Q Q Q Occurs on slopes w Replacement of filters has not been carried out according to Operation and Maintenance Manual w When fuel tank is inspected it is found to be empty w Check items Air breather hole of fuel tank cap is clogged w Rust and water are found when fuel tank is drained Q Fuel is...

Page 994: ...tion and Maintenance Manual w w Oil must be added more frequently Q Q Dust indicator is red w w Air breather hole of fuel tank cap is clogged w w Fuel is leaking from fuel piping w Output becomes insufficient after short stop of operation w Check items Color of exhaust gas is Black w w Blue under light load w When exhaust manifold is touched immediately after starting engine temperature of some cy...

Page 995: ...used Q Q Oil must be added more frequently w Power was lost Suddenly w Q Q Q Gradually Q Q Q Q Dust indicator is red w Muffler is crushed w Air leaks between turbocharger and cylinder head clamp is loosened w Check items Engine is operated in low temperature mode at normal temperature Q Q Q When exhaust manifold is touched immediately after starting engine temperature of some cylinders is low Q w ...

Page 996: ...e of use of machine Operated for long period E E E E Oil consumption suddenly increased w Q Oil must be added more frequently w Q Oil becomes contaminated quickly Q Q w Outside of engine is dirty with oil w w w w w There are loose piping clamps in intake system w Check items Inside of turbocharger intake outlet pipe is dirty with oil w Inside of turbocharger exhaust outlet pipe is dirty with oil Q...

Page 997: ... Questions Confirm recent repair history Degree of use of machine Operated for long period E E E Non specified fuel is being used Q Q Oil must be added more frequently w Metal particles are found when oil filter is drained Q Q w Inside of exhaust pipe is dirty with oil w Engine oil temperature rises quickly w Check items Color of exhaust gas is Blue under light load w Black w Amount of blow by gas...

Page 998: ... E E E Condition of fuel consumption More than for other machines of same model Q Q Q Q Gradually increased Q Q Suddenly increased Q Q There is external leakage of fuel from engine w Combustion is irregular w Engine oil level rises and oil smells of diesel fuel w w Check items When exhaust manifold is touched immediately after starting engine temperature of some cylinders is low w Low idle speed i...

Page 999: ...r train oil cooler Questions Confirm recent repair history Degree of use of machine Operated for long period E E Oil level Suddenly rose Q Q Q Gradually rose Q Q Hard water is being used as coolant Q Q Oil level has risen and oil is milky Q Q w Check items There are excessive air bubbles in radiator coolant spurts back w Hydraulic oil or power train oil on applicable machine side is milky w When h...

Page 1000: ...is being used Q Q Replacement of filters has not been carried out according to Operation and Maintenance Manual w Oil pressure monitor Indicates pressure drop at low idle w Indicates pressure drop at low high idle Q w w w Q Indicates pressure drop on slopes w Sometimes indicates pressure drop w Q Oil level monitor indicates oil level drop w w Oil level in oil pan is low w Check items External hydr...

Page 1001: ...d E E E E Fuel must be added more frequently w w Coolant must be added more frequently Q Q There is oil in coolant Q Q Q Q w Oil smells of diesel fuel w w Oil is milky Q Q When engine is started drops of water come from muffler Q Check items When radiator cap is removed and engine is run at low idle an abnormal number of bubbles appears or coolant spurts back w Q Exhaust smoke is white Q Oil level...

Page 1002: ...es drop of coolant level Q w Engine oil level has risen oil is milky w w Q Fan belt tension is low w Check items When fan pulley is turned it has play w Milky oil is floating on coolant Q Q w There are excessive air bubbles in radiator coolant spurts back w When light bulb is held behind radiator core no light passes through w Radiator shroud inside of underguard are clogged with dirt or mud w w C...

Page 1003: ...cent repair history Degree of use of machine Operated for long period E Condition of abnormal noise Gradually occurred Q Q Suddenly occurred Q Q Q Non specified fuel is being used Q Oil must be added more frequently w Metal particles are found when oil filter is drained w w Air leaks between turbocharger and cylinder head w Check items When engine is cranked interference sound is generated around ...

Page 1004: ...arts in damper on applicable machine side Questions Confirm recent repair history Degree of use of machine Operated for long period E E E Condition of vibration Suddenly increased Q Q Gradually increased Q Q Q Non specified oil is being used Q Q Metal particles are found when oil filter is drained w w Metal particles are found when oil pan is drained w w Check items Oil pressure is low at low idle...

Page 1006: ...50PZ 6 Machine model Serial number WA250 6 75001 and up WA250PZ 6 75001 and up 50 Disassembly and assembly50 100 General information on disassembly and assembly How to read this manual 2 Coating materials list 4 Special tool list 7 Sketches of special tools 11 ...

Page 1007: ... Removal section contains procedures and precautions for implementing the work know how and the amount of oil or coolant to be drained q General tools that are necessary for removal are described as 1 2 etc and their part names part numbers and quantities are not described q Various symbols used in the Removal section are explained and listed below k This mark indicates safety related precau tions...

Page 1008: ...and that they can not be supplied from Komatsu in Japan i e locally made parts Disassembly q In Disassembly section the work procedures precautions and know how for carrying out those procedures and quantity of the oil and coolant drained are described q General tools that are necessary for disassem bly are described as 1 2 etc and their part names part numbers and quantities are not described q T...

Page 1009: ...735 790 129 9140 50 g Polyethylene container Quick setting adhesive Setting time Within 5 sec to 3 min Used mainly to stick metals rubbers plastics and woods Aron alpha 201 790 129 9130 2 g Polyethylene container Quick setting adhesive Quick setting type max strength is obtained after 30 minutes Used mainly to stick rubbers plastics and metals Loctite 648 50 79A 129 9110 50 cc Polyethylene contain...

Page 1010: ... 160LI SYGA 160CNLI SYG0 400LI A SYG0 160CNLI Various Various Feature Lithium grease with extreme pressure lubrication performance General purpose type Molybdenum disulfide grease LM G G2 M SYG2 400M SYG2 400M A SYGA 16CNM 400 g x 10 400 g x 20 16 kg Bellows type container Can Used for parts under heavy load Caution Do not apply grease to rolling bearings like swing circle bearings etc and spline ...

Page 1011: ...ture Adhesive SUNSTAR PENGUINE SEAL 580 SUPER S or W 417 926 3910 320 ml Polyethylene container Adhesive for cab glass S is used for high temperature season and W for low temperature season as adhesive for glass Using limit 4 months after date of manu facture Sika Japan Sikaflex 256HV 20Y 54 39850 310 ml Polyethylene container Used as adhesive for glass Using limit 6 months after date of manu fact...

Page 1012: ...ngine front oil seal assembly 6 790 331 1120 Wrench Angle q 1 Angle tightening of bolt 7 795 790 4510 Gauge q 1 Judgment of cylinder head bolt length Cooling fan assembly 8 791 415 2002 Remover t 1 Removal of cooling fan Transfer assembly and parking brake assembly D 1 790 201 2840 Spacer t 1 Press fitting of output shaft bearing 2 793T 417 1110 Push tool t 1 Q 3 790 101 5201 Push tool kit t 1 Pre...

Page 1013: ...01 5221 Grip 1 01010 51225 Bolt 1 6 790 101 3101 Bearing puller q 1 Removal of axle shaft bearing 7 790 101 3501 Gear puller q 1 Removal of ring gear 8 791T 465 1130 Push tool t 1 Q 790 201 2670 Plate t 1 9 799 501 1120 Pin t 1 Installation of planetary carrier roll pin 10 790 445 5980 Guide bar t 1 Removal and installation of pin ion gear shaft 11 Commercially available Dial gauge q 1 Measurement...

Page 1014: ...n J 1 793T 623 1170 Push tool t 1 Q Press fitting of bearing to front frame and upper hinge 2 791 830 1410 Push tool t 1 Press fitting of bearing to front frame and lower hinge 3 Commercially available Thickness gauge q 1 Measurement of clearance between front frame and retainer Piston pump and motor assembly S 1 790 201 2720 Push tool q 1 Disassembly assembly of pis ton pump and motor 2 790 201 2...

Page 1015: ...nder Q 1 Installation of piston ring 7 796 720 1670 Ring Lift Q 1 07281 01279 Clamp Lift Q 1 796 720 1680 Ring Bucket Q 1 07281 01589 Clamp Bucket Q 1 796 720 1740 Ring Steering Q 1 07281 00809 Clamp Steering Q 1 Operator s cab glass stuck glass X 1 1 793 498 1120 Clear plate t 2 Adjustment of clearance of win dow glass 2 793 498 1130 Plate t 2 3 793 498 1110 Magnet t 2 2 793 498 1210 Lifter Sucti...

Page 1016: ...ral information on disassembly and assembly Sketches of special tools Sketches of special tools 1 Note Komatsu cannot accept any responsibility for special tools manufactured according to these sketches D2 Push tool D4 Push tool 9JF00891 9JF00892 ...

Page 1017: ...Z 6 100 General information on disassembly and assembly Sketches of special tools Note Komatsu cannot accept any responsibility for special tools manufactured according to these sketches D14 Push tool H1 J1 Push tool COW16161 9JF00902 ...

Page 1018: ...00 13 100 General information on disassembly and assembly Sketches of special tools Note Komatsu cannot accept any responsibility for special tools manufactured according to these sketches H1 Push tool H1 Push tool 9JF00893 9JF00894 ...

Page 1019: ... 6 100 General information on disassembly and assembly Sketches of special tools Note Komatsu cannot accept any responsibility for special tools manufactured according to these sketches H2 Seal support H2 Seal support 9JF00896 9JF00895 ...

Page 1020: ...100 15 100 General information on disassembly and assembly Sketches of special tools Note Komatsu cannot accept any responsibility for special tools manufactured according to these sketches H3 Push tool H4 Holder 9JF00899 9JF00897 ...

Page 1021: ...PZ 6 100 General information on disassembly and assembly Sketches of special tools Note Komatsu cannot accept any responsibility for special tools manufactured according to these sketches H8 Push tool H16 Push tool COW16159 9JF00898 ...

Page 1022: ...0 100 17 100 General information on disassembly and assembly Sketches of special tools Note Komatsu cannot accept any responsibility for special tools manufactured according to these sketches H17 Push tool H18 Push tool 9JF00901 ...

Page 1023: ...8 WA250 250PZ 6 100 General information on disassembly and assembly Sketches of special tools Note Komatsu cannot accept any responsibility for special tools manufactured according to these sketches H22 Plate H23 Push tool ...

Page 1024: ...50 250PZ 6 50 100 19 100 General information on disassembly and assembly Sketches of special tools Note Komatsu cannot accept any responsibility for special tools manufactured according to these sketches H28 Push tool ...

Page 1026: ...tallation of cylinder head assembly 11 Removal and installation of engine hood assembly 24 Removal and installation of radiator 27 Removal and installation of air aftercooler 30 Removal and installation of hydraulic oil cooler assembly 32 Removal and installation of engine assembly 34 Removal and installation of engine front oil seal assembly 40 Removal and installation of engine rear oil seal ass...

Page 1027: ...el prefilter and bracket assembly 2 a Fix fuel prefilter and bracket assembly 2 to the machine with ropes 3 Disconnect wiring harness connector CN CP3 3 from fuel supply pump 4 4 Disconnect fuel filter hoses 5 and 6 from fuel supply pump 4 5 Disconnect fuel return hose 7 from fuel sup ply pump 4 a If mud is sticking lock L may become stiff Accordingly clean the connecting area a Press lock L from ...

Page 1028: ...gh pressure pipe is installed correctly and tighten the sleeve nut to the fol lowing torque 3 Sleeve nut 35 3 5 Nm 3 57 0 36 kgm k Be sure to use the genuine fuel high pressure pipe clamp and strictly observe the specified tightening torque 3 Install boot 9 a Direct the slit of the boot down a The boot is installed so that fuel will not spout over the hot parts of the engine and catch fire when it...

Page 1029: ...hood assembly 3 Lift off muffler 1 a Take care that the muffler will not interfere with water drain tube 2 4 Muffler assembly Approx 35 kg 4 Disconnect engine intake air heater wiring har ness terminal CN E07B 3 1 5 Remove clamp 4 and bracket 4a 2 6 Remove clamp 5 air hose 5a mounting bolt 6a and intake air inlet elbow 6 3 a Remove the engine intake air heater too 7 Remove 2 wiring harness clamps ...

Page 1030: ...er the starting motor and set tool A4 2 Rotate the crankshaft forward counter clockwise seeing from the flywheel side to set marks M1 and M2 Mark M1 Top of projection of front cover Mark M2 A wide slit on slitted revolution sensor disc at rear of crank shaft pulley Mark M3 Yellow paint on vibration damper on prolongation of wide slit M2 a Set the projection top of mark M1 within the wide slit M2 a...

Page 1031: ...d 16 Remove 12 crossheads 20 a Record the positions and shapes of holes a and b of each crosshead Reinstall each crosshead in the same direction 17 Remove retaining nuts 21 and 6 inlet connec tors 22 a Before removing clean the inlet connec tors carefully so that mud etc sticking around them will not enter their holes a Tool A5 is set for removal of inlet connec tor 22 See the special tools list 1...

Page 1032: ...d when it is removed Accordingly do not reuse the fuel hose but use new one when assembling again as a rule When replacing the fuel injector assembly with new one be sure to replace the inlet connector with new one too 1 Fuel injector assembly a Check that the fuel injector sleeve 23a is free from flaw and dirt 1 Fit O ring 26 and gasket 27 to fuel injector 23 2 Apply engine oil For details see Ta...

Page 1033: ...t and lubricants to O ring 29 of inlet connector 22 8 Insert inlet connector 22 perfectly while setting part B to the groove on the cylin der head side 9 Secure inlet connector 22 by tightening retaining nut 21 lightly 3 Retaining nut 21 15 5 Nm 1 5 0 5 kgm 10 Tighten 2 mounting bolts 25 of fuel injec tor 23 alternately 3 Fuel injector mounting bolt 25 8 0 0 8 Nm 0 8 0 08 kgm 11 Tighten retaining ...

Page 1034: ...he following faults replace it and fuel injector assembly together q There is a worn part or an uneven seat contact mark on sealing face e at the front end of the inlet connector a If high pressure fuel leaks through the inlet connector the seal face has fine streaks or cracks 2 Crosshead and rocker arm assembly 1 Install the crosshead and rocker arm a The shapes of holes a and b of each crosshead...

Page 1035: ...r seal end d at 2 mm from the end has stepped type wear which your nail can feel 1 Temporarily install fuel high pressure pipes 31 36 3 Sleeve nut 0 2 0 8 Nm 0 02 0 08 kgm 2 Tighten fuel high pressure pipes 31 36 in the following order 1 Tighten the cylinder head side of fuel high pressure pipes 31 and 36 2 Tighten the common rail side of fuel high pressure pipes 31 and 36 3 Tighten the cylinder h...

Page 1036: ...ant 6 Radiator Approx 22 l 2 Remove the engine hood assembly For details see Removal and installation of engine hood assembly 3 Lift off muffler 1 a Take care that the muffler will not interfere with water drain tube 2 4 Muffler assembly Approx 35 kg 4 Disconnect engine intake air heater wiring har ness terminal CN E07B 3 1 5 Remove clamp 4 and bracket 4a 2 6 Remove clamp 5 air hose 5a and intake ...

Page 1037: ...ant temperature sensor connector 18 18 Disconnect ambient air pressure sensor con nector 19 a Move the lock of ambient air pressure sensor connector 19 in the direction of the arrow and pull out the connector while pressing the claw 19 Disconnect intake air pressure sensor connec tor 20 20 Remove 2 wiring harness clamps 21 21 Disconnect wiring harness connector 22 a While pressing the lock of wiri...

Page 1038: ...igh pressure pipe 26 7 25 Remove 6 boots 27 8 26 Remove 6 high pressure pipes 28 9 a Loosen the sleeve nut on the common rail side of each high pressure pipe 27 Disconnect radiator upper hose 29 10 28 Disconnect air aftercooler upper hose 30 11 29 Disconnect heater hose 31 30 Disconnect corrosion resistor hose 32 31 Remove corrosion resistor and bracket assem bly 33 ...

Page 1039: ...dth across flats 12 7 mm of tensioner assembly 40 and turn it in the unwinding direction to decrease the tension of fan belt 41 k Set the wrench 1 securely to part A of tensioner assembly 40 before turn ing it The spring of tensioner assem bly 40 is strong If the wrench 1 is set incompletely and turned it comes off and that is very dangerous k After removing belt 41 return ten sioner assembly 40 s...

Page 1040: ...7 14 45 Remove 6 mounting nuts 48 and cylinder head cover 49 15 46 Position the crankshaft according to the follow ing procedure 1 Remove plug 50 under the starting motor and set tool A4 2 Rotate the crankshaft forward counter clockwise seeing from the flywheel side to set marks M1 and M2 Mark M1 Top of projection of front cover Mark M2 A wide slit on slitted revolution sensor disc at rear of cran...

Page 1041: ...ed 48 Remove 12 crossheads 54 a Record the positions and shapes of holes a and b of each crosshead Reinstall each crosshead in the same direction 49 Remove retaining nuts 55 and 6 inlet connec tors 56 a Before removing clean the inlet connec tors carefully so that mud etc sticking around them will not enter their holes a Tool A5 is set for removal of inlet connec tor 55 See the special tools list ...

Page 1042: ...sembly 57 52 Using tool A3 remove fuel injector assembly 57 a Take care that dirt and foreign matter will not enter the fuel injector assembly mounting area 53 Remove push rods 60 54 Remove 7 mounting bolts 61 and rocker housing 62 55 Remove 26 mounting bolts 63 and lift off cyl inder head assembly 64 4 Cylinder head assembly 75 kg 56 Remove cylinder head gasket 65 ...

Page 1043: ...a If a bolt is longer than the using limit replace it 2 Set cylinder head gasket 65 a Check that there is no dirt and foreign matter on the cylinder head mounting surface and in the cylinders a Check that the holes of the cylinder head gasket are matched to the holes of the cylinder head 3 Set cylinder head 64 on the cylinder block 4 Tighten 26 mounting bolts 63 2 3 turns with the fingers and then...

Page 1044: ...1 Fit O ring 66 and gasket 67 to fuel injector 57 2 Apply engine oil For details see Table of fuel coolant and lubricants to O ring 66 of fuel injector 57 and the mounting hole on the cylinder head side 3 While setting convex and concave parts A install holder 68 to fuel injector 57 4 Install rocker housing 62 3 Rocker housing mounting bolt 61 24 4 Nm 2 4 0 4 kgm 5 Install push rods 60 6 Insert fu...

Page 1045: ...ctly while setting part B to the groove on the cylin der head side 11 Secure inlet connector 56 by tightening retaining nut 55 lightly 3 Retaining nut 55 15 5 Nm 1 5 0 5 kgm 12 Tighten 2 mounting bolts 59 of fuel injec tor 57 alternately 3 Fuel injector mounting bolt 59 8 0 0 8 Nm 0 8 0 08 kgm 13 Tighten retaining nut 55 3 Retaining nut 55 50 5 Nm 5 1 0 5 kgm 14 Install the wiring harnesses to fue...

Page 1046: ...the following faults replace it and fuel injector assembly together q There is a worn part or an uneven seat contact mark on sealing face e at the front end of the inlet connector a If high pressure fuel leaks through the inlet connector the seal face has fine streaks or cracks 3 Crosshead and rocker arm assembly 1 Install the crosshead and rocker arm a The shapes of holes a and b of each crosshea...

Page 1047: ...2 mm from the end q Taper seal end d at 2 mm from the end has stepped type wear which your nail can feel 1 Temporarily install fuel high pressure pipes 73 78 3 Sleeve nut 0 2 0 8 Nm 0 02 0 08 kgm 2 Tighten fuel high pressure pipes 73 78 in the following order 1 Tighten the cylinder head side of fuel high pressure pipes 73 and 78 2 Tighten the common rail side of fuel high pressure pipes 73 and 78 ...

Page 1048: ...4 Nm 2 4 0 4 kgm in order 2nd time Tighten 1 12 to 53 6 Nm 5 4 0 6 kgm in order 3rd time Tighten only 1 4 to 53 6 Nm 5 4 0 6 kgm in order 14 3 Blow by duct mounting bolt 7 2 Nm 0 7 0 2 kgm 15 3 Cylinder head cover mounting nut 48 24 4 Nm 2 4 0 4 kgm q Bleeding air Bleed air from the fuel system For details see Testing and adjusting Bleeding air from fuel system q Refilling with coolant Add coolant...

Page 1049: ... under the tires k Disconnect the cable from the negative terminal of the battery 1 Open and fix right and left engine side covers 1 a Check that the covers are locked securely 2 Open radiator grille 2 3 Disconnect radiator overflow hose 3 4 Remove fuel prefilter and bracket assembly 4 a Disconnect water separator wiring har ness connector CN E42 fixed to the engine hood under the fuel prefilter a...

Page 1050: ... 11 from part a 9 Remove left cover 12a 10 Remove washer motor wiring harness clamp 12 11 Disconnect washer motor wiring harness con nector CN BL1 13 12 Remove 2 heat insulation sheet fixing plates 14 13 Disconnect rear combination lamp connector CN BR1 15 14 Remove hose 16 between the air cleaner and turbocharger 1 15 Remove exhaust pipe 18 ...

Page 1051: ...6 Remove 2 front mounting bolts 19 on each of the right and left sides 17 Remove 1 rear mounting bolt 20 on each of the right and left sides 18 Lift off engine hood assembly 21 4 Engine hood assembly 240 kg Installation q Carry out installation in the reverse order to removal 1 3 Hose clamp 10 5 0 5 Nm 1 07 0 05 kgm ...

Page 1052: ... high you may scald yourself with the hot cool ant Wait until the coolant is cooled and then drain the coolant 1 Loosen the radiator cap to drain the coolant 6 Radiator Approx 22 l 2 Open and fix right and left engine side covers 1 a Check that the covers are locked securely 3 Open radiator grille 2 4 Remove right and left stays 3 4 and 5 5 Remove 2 heat insulation plates 6 a Remove all the wiring...

Page 1053: ...r conditioner condenser 11 and air conditioner receiver tank 9 to the machine with ropes 11 Remove 4 mounting bolts 12 and bracket 13 12 Disconnect radiator lower hose 14 4 13 Remove 2 mounting bolts 15 and fix cooling fan and fan motor assembly 16 open a Check that the cooling fan and fan motor assembly is locked securely 14 Remove 4 mounting bolts 17 and plate 18 15 Remove the 2 mounting bolts a...

Page 1054: ...mp 8 8 0 5 Nm 0 9 0 05 kgm 3 3 Air conditioner receiver tank mounting U clamp 10 8 26 0 Nm 1 1 2 7 kgm 4 2 Radiator lower hose insertion area Gasket sealant THREEBOND 1206E or equivalent 3 Radiator lower hose clamp 8 8 0 5 Nm 0 9 0 05 kgm 5 a Fit grommet 23 to the mounting hole a Check that projection A of the radiator is fit ted to grommet a When installing the radiator set drain hose 24 in mount...

Page 1055: ...f the battery k If the radiator coolant temperature is high you may scald yourself with the hot cool ant Wait until the coolant is cooled and then drain the coolant 1 Loosen the radiator cap to drain the coolant 6 Radiator Approx 22 l 2 Remove the radiator For details see Removal and installation of radiator 3 Disconnect air aftercooler lower hose 1 1 a Since the air aftercooler upper hose was rem...

Page 1056: ...se clamp 8 8 0 5 Nm 0 9 0 05 kgm 2 a Fit grommet 4 to the mounting hole a Check that projection A of the radiator is fit ted to grommet 4 q Refilling with coolant Add coolant through the coolant filler to the specified level Run the engine to circulate the coolant through the system Then check the coolant level again 5 Total amount of coolant Approx 22 l For details see Table of fuel coolant and l...

Page 1057: ...he negative terminal of the battery k If the radiator coolant temperature is high you may scald yourself with the hot cool ant Wait until the coolant is cooled and then drain the coolant 1 Loosen the radiator cap to drain the coolant 6 Radiator Approx 22 l 2 Remove the radiator For details see Removal and installation of radiator 3 Disconnect hydraulic oil cooler upper hose 1 a Plug the disconnect...

Page 1058: ... the reverse order to removal q Refilling with oil Hydraulic tank Add oil through the oil filler to the specified level Run the engine to circulate the oil through the system Then check the oil level again 5 Hydraulic oil For details see Table of fuel coolant and lubricants Only necessary quantity q Refilling with coolant Add coolant through the coolant filler to the specified level Run the engine...

Page 1059: ... may scald yourself with the hot cool ant Wait until the coolant is cooled and then drain the coolant 1 Loosen the radiator cap to drain the coolant 6 Radiator Approx 22 l 2 Remove the engine hood For details see Removal and installation of engine hood 3 Remove muffler cover 1 a Remove the muffler cover since it will interfere with the engine slings wire ropes etc 4 Disconnect fuel prefilter wirin...

Page 1060: ...e hose clamp 12 14 Disconnect heater inlet hose 13 15 Remove engine wiring harness clamp 14 16 Remove 4 clamps 15 for the engine wiring harness and air conditioner piping 17 Disconnect engine intake air heater wiring har ness terminal CN E07B 16 2 18 Remove wiring harness clamps 17 and 18 19 Remove wiring harness connector mounting bolt 19 3 a Width across flats of hexagonal socket of mounting bol...

Page 1061: ...rness toward the frame so that it will not interfere with the other parts 23 Remove hose clamp 24 24 Disconnect fuel return hose 25 25 Remove 3 fan motor hose clamps 26 26 Remove 2 wiring harness clamps 27 27 Remove hose clamp 28 28 Remove 2 stays 29 on the right and left sides 29 Remove 2 heat insulation plates 30 30 Disconnect air aftercooler upper hose 31 4 31 Disconnect radiator upper hose 32 ...

Page 1062: ...e bars 1 and 2 over the frame Using lever blocks 3 and 4 sling HST pump assembly 36 temporarily 36 Remove 12 damper cover mounting bolts 37 9 a Do not remove HST pump mounting bolts 38 to disconnect the HST pump If the HST pump is disconnected from the engine assembly you cannot see if the gears are meshed when installing the engine assembly and the damper may be damaged consequently 37 Using the ...

Page 1063: ...nstallation q Carry out installation in the reverse order to removal 1 3 Engine ground cable mounting bolt 98 123 Nm 10 0 12 5 kgm 2 3 Wiring harness terminal CN E07B 16 4 0 0 6 Nm 0 41 0 06 kgm 3 3 Wiring harness connector mounting bolt 3 0 1 Nm 0 31 0 01 kgm 4 3 Air aftercooler upper hose clamp 10 5 0 5 Nm 1 07 0 05 kgm 5 2 Radiator upper hose Gasket sealant THREEBOND 1206E or equivalent 3 Radia...

Page 1064: ...lowing dimensions and lock the adjustment bolts Clearance a 2 mm Clearance b 2 mm 13 a When installing the engine assembly carefully set damper flange 43 to the gear of HST pump boss 44 a When installing the flange take care not to damage it q Bleeding air Bleed air from the fuel system For details see Testing and adjusting Bleeding air from fuel system q Refilling with coolant Add coolant through...

Page 1065: ...ground stop the engine apply the parking brake and put chocks under the tires k Disconnect the cable from the negative terminal of the battery 1 Open and fix right and left engine side covers 1 a Check that the covers are locked securely 2 Remove right and left stays 2 3 and 4 3 Remove 2 heat insulation plates 5 a Remove all the wiring harness clamps and hose clamps installed to heat insulation pl...

Page 1066: ...f fan belt 8 k Set the wrench 1 securely to part A of tensioner assembly 7 before turn ing it The spring of tensioner assem bly 7 is strong If the wrench 1 is set incompletely and turned it comes off and that is very dangerous k After removing belt 8 return ten sioner assembly 7 slowly and care fully k Take care not to catch your finger between the pulley and fan belt 8 dur ing work 6 Remove 6 mou...

Page 1067: ... of engine front oil seal 11 from cover 12 must be in the follow ing range q Projection x Max 0 38 mm q Facial runout TIR Total Indicator Reading y Max 0 25 mm 2 Vibration damper 1 Install vibration damper 10 to the crank shaft while setting the dowel hole of the former to dowel pin a of the latter 2 Tighten mounting bolts 9 according to the following procedure 1 Tighten the bolts to 55 5 Nm 5 6 0...

Page 1068: ... the radiator cap to drain the coolant 6 Radiator Approx 22 l 2 Remove the engine hood assembly For details see Removal and installation of engine hood assembly 3 Remove the engine assembly For details see Removal and installation of engine assembly 4 Remove 8 mounting bolts 1 and damper flange 2 1 5 Install eyebolt 1 to the damper mounting bolt hole and sling flywheel assembly 4 6 Remove the 2 fl...

Page 1069: ...rfaces to prevent oil leakage a When installing the engine rear oil seal do not apply oil or grease to the crankshaft and seal lip 2 Insert pilot 4 in crankshaft 6 and push engine rear oil seal 5 into flywheel housing 7 3 Push in engine rear oil seal 5 further and then pull out pilot 4 4 Using tool A2 install engine rear oil seal 5 to flywheel housing 7 a When installing engine rear oil seal 5 tak...

Page 1070: ...auge indicates the value at the start of rotation q Measuring facial runout a Facial runout Max 0 20 mm 1 Install the stand to dial gauge 6 and install them to flywheel housing 7 2 Set the dial gauge so that its probe will be perpendicular to end face c of the fly wheel near the periphery 3 Rotate the flywheel by 1 turn and measure the difference between the lowest and highest values indicated by ...

Page 1071: ...Open radiator grille 1 2 Remove 2 mounting bolts 2 and fix cooling fan and fan motor assembly 3 open a Check that the cooling fan and fan motor assembly is locked securely 3 Remove cover 4 4 Remove 3 fuel tank breather hose clamps 4a 5 Remove clip 4b and disconnect hose 4c from breather 4d 6 Remove breather 4d 7 Remove 2 wiring harness clamps 5 8 Disconnect wiring harness connectors CN R59 6 and C...

Page 1072: ... the periphery of the shroud 15 Using tool A8 remove cooling fan assembly 21 3 16 Remove fan guard 23 from shroud 22 17 Remove 2 mounting bolts 24 from each of the right and left sides to separate upper shroud 22a and lower shroud 22b from each other and remove fan assembly 25 a Since the inside of the shroud is fitted in the groove on the ring end of fan assem bly 25 fan assembly 25 cannot be rem...

Page 1073: ... 19 2 Mounting bolt 17 Adhesive LT 2 3 Mounting bolt 17 59 74 Nm 6 0 7 5 kgm 3 a Check that key 30 is fitted securely to the key way on the shaft of fan motor assembly 28 a When installing cooling fan assembly 21 set its key way to key 30 4 a Before installing fan motor assembly 28 add hydraulic oil for details see Table of fuel coolant and lubricants until it flows over plug 29 mounting hole and ...

Page 1074: ...the fuel from the fuel tank 6 Fuel tank Approx 186 l When full 2 Open and fix right and left engine side covers 1 a Check that the covers are locked securely 3 Open radiator grille 2 4 Remove the 2 mounting bolts and stopper bracket 3 5 Remove the 3 mounting bolts and cover 4 a Remove this cover since the fuel filler cap of the fuel tank will interfere with it 6 Remove 3 breather hose clamps 5a of...

Page 1075: ...ting bolts 14 on the right and left sides 1 15 Remove fuel tank rear mounting bolt 15 from the counterweight bottom 2 16 Lower transmission jack 1 gradually and remove fuel tank assembly 16 a Take care extremely that the fuel tank will not come off the transmission jack 4 Fuel tank assembly 90 kg excluding fuel Installation q Carry out installation in the reverse order to removal 1 2 3 Fuel tank m...

Page 1076: ...SEN03852 00 WA250 250PZ 6 50 200 51 200 Engine and cooling system Removal and installation of fuel tank assembly ...

Page 1078: ...250 6 75001 and up WA250PZ 6 75001 and up 50 Disassembly and assembly50 310 Power train Part 1 Removal and installation of transfer assembly 2 Disassembly and assembly of transfer assembly 6 Removal and installation of parking brake assembly 26 Disassembly and assembly of parking brake assembly 28 ...

Page 1079: ... blindness Therefore make sure to wear protec tive glasses when collecting or filling the refrigerant Collecting and filling work must be conducted by a qualified person k If the radiator coolant temperature is high you may scald yourself with the hot coolant when disconnecting the heater hoses and draining the coolant Wait until the coolant is cooled and then drain the coolant 1 Recover the refri...

Page 1080: ...ont drive shaft 9 from the trans fer 2 12 Remove rear drive shaft 10 3 13 Remove parking brake cable clamp and bracket assembly 11 in the left frame 14 Remove 2 hose clamps 12 in the right frame 15 Disconnect hydraulic oil cooler hose 13 from the hydraulic tank 16 Remove wiring harness clamp 14 in the left frame 17 Sling the transfer and HST motor assembly ...

Page 1081: ...ration a When connecting each refrigerant pipe apply compressor oil for new refrigerant R134a DENSO ND OIL8 or ZEXEL ZXL100PT equivalent to PAG46 to O ring 70 3 Threaded part of hose M16 1 5 12 15 Nm 1 2 1 5 kgm 3 Threaded part of hose M22 1 5 20 25 Nm 2 0 2 5 kgm 3 Threaded part of hose M24 1 5 30 35 Nm 3 0 3 5 kgm q Charging with refrigerant R134a Charge the air conditioner circuit with refriger...

Page 1082: ... oil through the oil filler to the specified level Run the engine to circulate the oil through the system Then check the oil level again 5 Hydraulic oil for details see Table of fuel coolant and lubricants Only necessary quantity q Refilling with coolant Add coolant through the coolant filler to the specified level Run the engine to circulate the coolant through the system Then check the coolant l...

Page 1083: ...model Sketch D 1 790 201 2840 Spacer t 1 2 793T 417 1110 Push tool t 1 Q 3 790 101 5201 Push took kit t 1 790 101 5311 Plate 1 790 101 5221 Grip 1 01010 51225 Bolt 1 4 793T 417 1120 Push tool t 1 Q 790 101 5221 Grip t 1 01010 81225 Bolt t 1 5 799 301 1500 Oil leak tester t 1 8 790 201 3260 Bolt 12 x 1 75 mm q 2 9 790 102 2900 Puller q 1 10 792 735 2420 Collar t 1 11 790 101 2501 Puller q 1 12 790 ...

Page 1084: ... 7 Remove the 6 mounting bolts and brake accumulator transfer oil filter bracket assembly 7 8 Disconnect suction hose 8 9 Remove pin 9a parking brake cable 9 and bracket 9b 10 Remove oil supply pipe 10 11 Remove the 4 mounting bolts and lift off HST motor 1 11 12 Remove the 4 mounting bolts and lift off HST motor 2 12 3 Parking brake assembly 1 Remove breather tube 13 2 Set the transfer assembly t...

Page 1085: ...or mounting section a Loosen the mounting bolts evenly and gradually release the belleville springs and then remove the cage q Free height of belleville springs 6 piece set 49 2 mm q Installed height of belleville springs 6 piece set 38 4 mm q Installed load of belleville springs 6 piece set 21 500 N 2 190 kg 2 Remove 6 belleville springs 19 a Check the directions of the belleville springs a The 1...

Page 1086: ...7 Clutch discs plates and springs 1 Remove 6 discs 22 7 plates 23 and 6 wave springs 24 2 Using bar 3 remove end plate 25 8 Coupling 1 Remove the mounting bolts and holder 58 2 Remove coupling 59 9 Cage assembly 1 Remove the mounting bolts Using tool D8 remove cage assembly 60 2 Remove shims 61 a Check the thickness and quantity of the shims AJF00418 AJF00420 AJF16148 AJF00437 AJF15394 AJF00439 ...

Page 1087: ...1 Remove spacer 62 11 Front case 1 Remove the mounting bolts Using tool D8 and bars 4 remove front case 63 12 Removal of HST motor 1 shaft and ring gear 1 Remove HST motor 1 shaft and ring gear assembly 28 13 Disassembly of HST motor 1 shaft and ring gear assembly 1 Using tool D9 remove bearing 27 2 Remove snap ring 29 and sun gear 30 AJF00449 AJF00450 AJF15395 9JF01027 9JF15396 AJF00425 ...

Page 1088: ...6 Remove snap ring 36 and bearing 37 14 Removal of carrier assembly 1 Using tool D11 remove carrier assembly 38 from the dowel pin of the HST motor 1 gear 15 Disassembly of carrier assembly 1 Press shaft 39 and remove ball 40 and pinion shaft 39 from carrier 41 a Keep the ball carefully 2 Remove 2 thrust washers 42 planetary gear 43 and bearing 44 at 3 places 16 Holder 1 Remove the mounting bolts ...

Page 1089: ...Disassembly of HST motor 2 gear and bear ing assembly 1 Using tool D9 and tool D12 remove 2 bearings 66 from HST motor 2 gear 65 19 Removal of output shaft and gear assembly 1 Remove 2 mounting bolts of cover 67 2 Remove output shaft and gear assembly 68 and cover 67 20 Disassembly of output shaft and gear assembly 1 Using tool D11 and tool D13 remove front bearing 69 2 Remove snap ring 70 and out...

Page 1090: ...d HST motor 1 gear and outer races 51 a If the claw of tool D15 is too thick to put it between the gear and case perform the following procedure 1 Screw 3 mounting bolts M12 35 mm 5 into the carrier mounting holes of HST motor 1 gear 51 by 15 mm 2 Using tool D15 3 claw puller remove bearing 50 and HST motor 1 gear and outer race 51 22 Disassembly of HST motor 1 gear and outer races 1 Using tool D1...

Page 1091: ...aft 49 2 Insert 2 tool D17 in the plug holes and hit them evenly to remove spacer 55 and bearing 56 from shaft 49 24 Rear case 1 Remove outer race 81 from rear case 80 25 Clutch housing 1 Using tool D18 remove clutch housing 26 and 3 pins 83 2 Remove snap ring 86 from clutch hous ing 26 3 Remove snap ring 57 9JF01037 9JF16146 AJF00906 9JF16147 ...

Page 1092: ...t rear bearing 72 to output shaft 73 until it stops a After press fitting the bearing apply power train oil for details see Table of fuel coolant and lubricants to it and rotate it 2 Install output gear 71 and snap ring 70 2 Spline of gear Grease LM G 3 Using tool D2 and the press press fit front bearing 69 a After press fitting the bearing apply power train oil for details see Table of fuel coola...

Page 1093: ...icants to them and rotate them 5 Installation of HST motor 2 gear and bear ing assembly 1 Install HST motor 2 gear and bearing assembly 64 6 Assembly of HST motor 1 gear and outer races 1 Install seal ring 85 to HST motor 1 gear 52 2 Seal ring Grease G2 LI 2 Install spacer 54 to HST motor 1 gear 52 3 Using tool D20 press fit 2 outer races 53 to HST motor 1 gear 52 7 Installation of HST motor 1 gea...

Page 1094: ...1 Install seal rings 46 and 47 to holder 45 2 Seal ring and O ring Grease G2 LI 2 Install holder 45 and tighten the mount ing bolts a Set the hole 2 mm in diameter g on the top of the holder horizontally Set it at 90 to the hole 4 5 mm in diame ter h on shaft 49 3 Mounting bolt 88 2 107 8 Nm 9 11 kgm 10 Assembly of carrier assembly 1 Set planetary gear 43 bearing 44 and 2 thrust washers 42 to carr...

Page 1095: ...owel pin of the HST motor 1 gear 12 Assembly of HST motor 1 shaft and ring gear assembly 1 Install bearing 37 to ring gear 32 and then install snap ring 36 2 Set ring gear 32 to HST motor 1 shaft 33 Using tool D19 and the press press fit bearing 37 3 Install spacer 35 and set bearing 34 4 Using tool D19 and the press press fit bearing 34 AJF00430 9JF01041 AJF00484 AJF16153 AJF00486 AJF15154 ...

Page 1096: ... the front case and rear case as an assembly a When installing the cases match the match marks on their tops to each other 1 Apply gasket sealant to the rear case according to the following procedure a Apply the gasket sealant to forcing screw contact part a similarly to the dimensions for a bolt hole a Apply the gasket sealant so that dimensions b and c will be the same respectively a Apply the g...

Page 1097: ... 2 Install clutch housing 26 and 3 pins 83 16 Clutch discs plates and springs 1 Install end plate 25 2 Install 6 discs 22 6 wave springs 24 and 7 plates 23 a Soak the discs in clean power train oil for details see Table of fuel coolant and lubricants for at least 2 minutes before installing them 17 Spacer and piston 1 Install the O ring and spacer 21 2 O ring Grease G2 LI AJF00907 AJF01036 AJF0090...

Page 1098: ...eds to be replaced replace all of the 6 springs as a set 19 Cage 1 Install cage 18 a Tighten the mounting bolts evenly and gradually q Installed load of belleville springs 6 piece set 21 500 N 2 190 kg 3 Mounting bolt 245 308 Nm 25 0 31 5 kgm 20 Operation test of transfer clutch 1 Using tool D5 apply air pressure to trans fer clutch disengagement port m a When the air pressure is applied if the tr...

Page 1099: ... Mounting bolt 98 123 Nm 10 0 12 5 kgm 23 Cage assembly 1 Press fit outer race 79 to cage 78 2 Using tools D3 and D4 press fit oil seal 77 and dust seal 76 to cage 78 2 Lips and clearances of oil seal and dust seal Silicone grease Three Bond 1855 or equivalent 24 Adjusting pre load on output shaft taper roller bearing 1 Install cage 78 without inserting any shim 3 Mounting bolt 4 80 0 98 Nm 0 5 0 ...

Page 1100: ...Nm 10 0 12 5 kgm 7 Install holder 58 and the holder mounting bolt to the output shaft 8 Set tool D23 to the holder mounting bolt and measure the rotating torque of the output shaft a Measure the rotating torque without installing the front and rear couplings q Rotating torque of output shaft 3 9 5 9 Nm 0 4 0 6 kgm 25 Coupling 1 Install coupling 59 on the cage side 2 Spline of coupling Molybdenum d...

Page 1101: ... LM G 3 Mounting bolt 245 309 Nm 25 0 31 5 kgm 2 Sling and install HST motor 1 11 a Do not apply molybdenum disulfide grease LM G to the HST motor 1 spline 3 Mounting bolt 245 309 Nm 25 0 31 5 kgm 3 Install oil supply pipe 10 4 Install parking brake cable 9 and bracket 9b a After inserting the cotter pin of park ing brake cable pin 9a open it to 180 to fix the cable pin 5 Insert suction hose 8 6 I...

Page 1102: ...3 4k CN T12 9 Connect the following wiring harnesses 4e CN T05 4f CN T18 4g CN T15A 10 Connect the following wiring harnesses to the brake accumulator 4a CN T11 4b CN T07 4c CN T06 4d CN T10 11 Install speed sensor 3 and bracket 2 12 Connect the speed sensor wiring harness connector 1 27 Adding transfer oil 5 Transfer case Approx 5 l For details see Table of fuel coolant and lubricants AJF00504 AJ...

Page 1103: ... put chocks under the tires k Disconnect the cable from the negative terminal of the battery 1 Drain the transfer oil 6 Transfer case Approx 5 l 2 Remove rear drive shaft 1 1 3 Turn parking brake lever 2 OFF 4 Pull out the cotter pin and remove pin 3 to disconnect parking brake cable 4 2 5 Disconnect suction hose 5 of transfer lubri cating oil pump 6 Remove the parking brake mounting bolts Using t...

Page 1104: ...ng bolts 2 Check that the lateral runout of the rear axle and transfer from each other is 3 mm or less 3 If the runout in 2 is 3 mm or larger adjust the transfer cushion and transfer mount to reduce the runout 2 a After installing the parking brake open cotter pin 3 to 180 to fix 3 a Using tool D8 install parking brake assembly 6 3 Parking brake mounting bolt 98 123 Nm 10 0 12 5 kgm q Refilling wi...

Page 1105: ...bolts 3 and 2 spac ers 4 a Since the spring tension is applied loosen the 2 clamping bolts evenly 2 Remove 5 plates 5 4 wave springs 6 and 4 discs 7 3 Cam plate 1 Remove cam plate 8 Symbol Part No Part name Necessity Q ty New Remodel Sketch D 3 790 101 5201 Push tool kit t 1 790 101 5311 Plate 1 790 101 5221 Grip 1 01010 51225 Bolt 1 4 793T 417 1120 Push tool t 1 Q 790 101 5221 Grip t 1 01010 8122...

Page 1106: ...Ball 1 Remove 6 balls 9 5 Lever 1 Remove the mounting bolt and lever 10 2 Remove lever 11 6 Pin 1 Remove pin 12 7 Dust seal and oil seal 1 Remove dust seal 13 and oil seal 14 8 Oil seal and bearings 1 Remove oil seal 15 2 Remove 2 bearings 16 from parking brake case 17 AJF00512 AJF00513 AJF00514 AJF00517 AJF00522 ...

Page 1107: ...Although the gasket is fitted to the park ing brake fitting face in the drawing per form the work without fitting the gasket 2 Oil seal and dust seal 1 Using tools D3 and D4 press fit oil seal 14 and dust seal 13 2 Lips and clearances of oil seal and dust seal Silicone grease Three Bond 1855 or equivalent 3 Pin 1 Install pin 12 a Install the pin with the grooved part outward a Check that dirt is n...

Page 1108: ...g to the ball grooves inside of parking brake housing cam plate discs and plates Perform the work with the gasket removed a Move cam plate 8 several times so that balls 9 will be fitted to grooves c of cam plate 8 a Check that the cam plate does not hitch on the housing 7 Plates disc and springs 1 Install 4 discs 7 4 wave springs 6 and 5 plates 5 a Soak the disc in clean power train oil for detail...

Page 1109: ...to press plate 5 too much and not to damage it a Press plate 5 until it is flush with the parking brake case a Move the lever and check that it returns normally 2 Clamping bolt Adhesive LT 2 3 Clamping bolt 19 6 27 4 Nm 2 0 2 8 kgm Perform the work with the gasket removed 8 Strainer 1 Install strainer 2 2 Install the O ring and cover 1 2 O ring Grease G2 LI 3 Mounting bolt 98 123 Nm 10 0 12 5 kgm ...

Page 1110: ...SEN03853 00 WA250 250PZ 6 50 310 33 310 Power train Part 1 Disassembly and assembly of parking brake assembly ...

Page 1112: ...250 6 75001 and up WA250PZ 6 75001 and up 50 Disassembly and assembly50 320 Power train Part 2 Removal and installation of front axle assembly 2 Removal and installation of rear axle assembly 4 Disassembly and assembly of axle housing assembly 7 Disassembly and assembly of differential assembly 16 ...

Page 1113: ... tires k Release the residual pressure in the brake accumulator circuit For details see Releasing remaining pressure in hydraulic circuit 1 Raise the chassis with the work equipment and set stands 1 under the frame in front of the front wheels to float the front of the chassis 2 Lift off the front wheel 1 1 a Lift off the front wheel on the other side similarly 4 Front wheel 1 side 280 kg 3 Remove...

Page 1114: ...ry out installation in the reverse order to removal 1 3 Front wheel mounting bolt 785 980 Nm 80 100 kgm 2 a When installing the drive shaft check that the key way of the spider cap is fitted to the key way of the mating yoke and then tighten the mounting bolts 3 Front drive shaft mounting bolt 59 74 Nm 6 0 7 5 kgm 3 3 Front axle mounting bolt 785 980 Nm 80 100 kgm q Bleeding air Bleed air from the...

Page 1115: ...rcuit For details see Releasing remaining pressure in hydraulic circuit 1 Raise the chassis with the work equipment and set stands 1 under the frame in front of the rear wheels to float the rear of the chassis 2 Support the counterweight on jack 2 3 Set blocks 3 between top of each side of the rear axle and the rear frame 4 Lift off the rear wheel 1 1 a Remove the right and left fenders a Lift off...

Page 1116: ... the rear axle with lever block 4 10 Sling rear axle assembly 7 temporarily sup port it on jack 5 and remove the mounting bolts of support 6 4 11 Pull out the rear axle assembly toward the rear of the chassis and disconnect it from the rear frame assembly a Take care not to damage dust seal 8 of rear frame 7 12 Lower the crane and jack 5 simultaneously to remove rear axle assembly 7 4 Rear axle as...

Page 1117: ... 3 mm If it is larger than 3 mm reduce it by moving the transfer mount a When installing the drive shaft check that the key way of the spider cap is fitted to the key way of the mating yoke and then tighten the mounting bolts 3 Rear drive shaft mounting bolt 59 74 Nm 6 0 7 5 kgm 3 2 Coupling mounting bolt Adhesive LT 2 3 Coupling mounting bolt 245 309 Nm 25 0 31 5 kgm 4 3 Support mounting bolt 785...

Page 1118: ...nd differential case so that the housing assemblies will not be mistaken 2 Remove axle housing assembly 1 3 Set axle housing assembly 1 with the planetary carrier side up Symbol Part No Part Name Necessity Q ty New Remodel Sketch H 1 793T 623 1170 Push tool t 1 Q 793T 422 1230 Push tool t 1 Q 793T 423 1110 Push tool t 1 Q 2 793T 422 1240 Seal support t 2 Q 793T 423 1120 Seal support t 2 Q 01016 50...

Page 1119: ...ing bolt 2 2 Remove planetary carrier assembly 3 3 Remove shim 4 a Check the thickness and quantity of the shims 5 Axle shaft 1 Sling axle housing assembly 5 about 20 mm 2 Apply tool H5 to the end of axle shaft 6 and drive out the shaft with a copper ham mer 2 a The bearing on the planetary carrier side will come off AJF00626 AJF00627 AJF00628 AJF00629 AJF16164 ...

Page 1120: ...f bearing 7 and sleeve 8a to hitch the claws of the puller 3 Install tool H6 to the bottom of the bearing and it securely 4 Install tool H6 to clearance b 5 Tighten the bolts of tool H6 to remove bearing 7 6 Remove oil seal 8 7 Axle housing 1 Using tool H7 pull up ring gear 9 and 3 pins 10 evenly to remove them from axle housing 11 a Install tool H8 to the bolt end of the tool H7 to adjust the hei...

Page 1121: ... drive in roll pin 15 of plan etary carrier 14 until it is in the range of shaft 16 a Take care not to drive in the roll pin too deep 2 Using tool H10 push out shaft 16 with a press 3 Pull roll pin 15 out of removed shaft 16 4 Remove pinion gear 17 bearings 18 and spacer 19 from planetary carrier 14 9JF00883 AJF16167 AJF16168 AJF00634 AJF00635 ...

Page 1122: ...eal 8 and the clear ance will be even 2 Axle shaft bearing 1 Erect axle shaft 6 on the block and fix it securely 2 Sling axle housing 11 vertically and then lower it slowly a Install the front axle matching it to the oil seal and insert the axle housing by utilizing its weight 2 Fitting part of oil seal and bearing front axle Axle oil AXO80 a After installing the housing leave tool H2 installed un...

Page 1123: ... it according to fol lowing steps 2 4 2 Hold 2 parts of axle shaft and housing assembly 5 and sling it by 20 30 mm as you installed the axle housing 3 Rotating axle shaft 6 hit the flange with a copper hammer in the direction of the arrow several times to drive out axle shaft 6 4 Adjust the turning force to the standard value according to step 1 5 Install planetary carrier 14 to the spline of axle...

Page 1124: ...fit shaft 16 to plan etary carrier 14 a When press fitting match pin holes f 2 Shaft Axle oil AXO80 a Matching the holes of shaft 16 and roll pin 15 drive roll pin 15 so that it will be flush with planetary carrier 14 4 Hit the end of shaft 16 and the differen tial side of gear 17 lightly to push back the bearing and check that the gear rotates smoothly 5 Ring gear 1 Install ring gear 9 to axle ho...

Page 1125: ...planetary car rier take care not to catch your fin gers in the gear 3 Tighten mounting bolt 2 a Degrease and clean the bolt hole of the axle shaft and mounting bolt 2 Mounting bolt Adhesive LT 2 3 Mounting bolt 490 608 Nm 50 62 kgm a Clean the shaft end and planetary carrier spline thoroughly before installing 4 Install tool H11 to axle housing 11 and measure the end play of the planetary car rier...

Page 1126: ... shims above 7 Axle housing assembly 1 Degrease and clean the mating faces of the axle housing and differential housing and apply gasket sealant all over them 2 Mating faces of housings Gasket sealant LOCTITE 515 or equivalent 2 Sling axle housing assembly 1 horizon tally and install it carefully matching it to the spline grooves of the sun gear shaft 3 Tighten the axle housing mounting bolts in t...

Page 1127: ...m rear axle support 7 Symbol Part No Part Name Necessity Q ty New Remodel Sketch H 13 799 301 1500 Oil leak tester t 1 14 797 101 1211 Wrench t 1 15 793 615 1100 Wrench t 1 16 793T 422 1220 Push tool t 1 Q 17 797T 423 1320 Push tool t 1 Q 18 792T 413 1130 Push tool t 1 Q 19 793 520 2202 Installer q 3 20 790 190 1500 Pump assembly t 1 21 799 101 5210 Nipple t 1 22 793T 422 1611 Plate t 1 Q 23 791T ...

Page 1128: ... dif ferent more or less from the shape of the actual cover 6 Differential assemblies 1 Place and stabilize differential assemblies 12 and 13 on blocks a 12 Front differential 13 Rear differential 7 Brakes a Remove both brakes according to the fol lowing procedure 1 Remove sun gear shafts 14 2 Remove 2 inside hexagon bolts 15 and outer plate 16 3 Remove 2 discs 17 1 plate 18 and 4 wave springs 19 ...

Page 1129: ...0 8 Top cover 1 Remove the mounting bolts and then remove top cover 21 using tool H24 9 Slack adjuster 1 Remove 2 slack adjusters 22 10 Removal of long cage assembly Only front differential 1 Remove coupling 23 a Remove the coupling protector only when it needs to be removed 2 Remove long cage assembly 24 11 Disassembly of long cage assembly Only front differential 1 Remove oil seal 25 2 Using too...

Page 1130: ...tool H24 remove front cage assembly 32 a Check the thickness and quantity of the shims 13 Removal of rear cage assembly For rear differential 1 Before removing cage assembly loosen the mounting bolts of coupling 41 2 Remove the mounting bolts Using tool H24 remove rear cage assembly 42 a Check the thickness and quantity of the shims 14 Disassembly of front cage assembly For front differential 1 Re...

Page 1131: ...ng protector only when it needs to be removed 2 Remove oil seal 82 3 For the further disassembly procedure for the rear cage assembly see steps 2 4 in 14 Disassembly of front cage assembly shown above 16 Bearing carriers 1 Sling differential carrier assembly 43 temporarily 2 Remove the mounting bolts and both bearing carriers 44 using tool H24 a Make marks on both bearing carriers so that they wil...

Page 1132: ... not damage the bearing of the dif ferential carrier assembly by hitting it against the differential case 18 Disassembly of standard differential carrier assembly a When keeping the parts on both sides make marks on them so that they will not be mistaken 1 Remove 12 mounting bolts 46 a Do not remove 4 mounting bolts 47 of spider shaft a 2 Remove case and bearing assembly 48 a Before disconnecting ...

Page 1133: ...washer 51 and side gear 52 5 Remove pinion gear assembly 53 6 Remove 4 spherical washers 54 and 4 pinion gears 55 from spider shaft 56 7 Remove side gear 57 8 Remove washer 58 9 Remove 4 mounting bolts and then remove bevel gear and bearing assembly 59 from case 60 AJF00552 AJF00554 AJF00553 AJF00555 AJF00556 AJF00557 ...

Page 1134: ...ifferential assembly disassemble it according to the following procedure a When keeping the parts on both sides make marks on them so that they will not be mistaken 1 Remove the 16 mounting bolts and bevel gear and bearing assembly 63 a Before disconnecting the bevel gear and bearing assembly make match marks on it and the case 2 Using tool H27 remove bearing 64 from bevel gear 65 3 Remove washer ...

Page 1135: ... Remove pressure ring 69 a Insert a finger in the hole on the side of the case to raise the pressure ring 6 Remove side gear 70 7 Remove pinion gear assembly 71 8 Remove 4 pinion gears 72 from spider shaft 73 9 Remove side gear 74 10 Remove pressure ring 75 AJF00563 AJF00564 AJF00565 AJF00566 AJF00568 AJF00567 ...

Page 1136: ...a Clean the all parts and check them for dirt or damage Coat their sliding surfaces with axle oil AXO80 before installing 1 Assembly of limited slip differential assem bly If equipped 1 Install bearing 79 to case 80 a Install the bearing by shrink fit at tem perature below 100 C or by using tool H28 and a press 2 Install washer 78 a Install the washer with the dimpled side in up AJF00570 AJF00571 ...

Page 1137: ...Before installing the discs and plates soak them in the axle oil AXO80 4 Install pressure ring 75 5 Install side gear 74 a Referring to step 10 below match the cut of the inside of the disc to the oil groove of the side gear 6 Install 4 pinion gears 72 to spider shaft 73 7 Install pinion gear assembly 71 AJF00570 AJF00567 AJF00568 AJF00566 AJF00565 ...

Page 1138: ...oak them in the axle oil AXO80 11 Selection of thickness of plate 1 Using tool H29 measure distance d between case 80 and plate 67 a Distance d is the clearance between the case and plate 2 Select the thickness of the plate so that distance d will be 0 2 0 6 mm a Replace the plates on both sides so that their thickness total of 2 pieces will be the same and assemble them according to the procedure...

Page 1139: ...axle oil AXO80 or grease thinly to it so that it will stuck to the bevel gear 14 Install bevel gear and bearing assembly 63 a Match the match marks made when the assembly was removed 2 Mounting bolt Adhesive LT 2 3 Mounting bolt 245 309 Nm 25 0 31 5 kgm 15 Adjust the clearance of the side gear in the axial direction 1 Measure clearance e between the side gear and washer through the shaft holes on ...

Page 1140: ...mble the limited slip differ ential again and perform 11 Selection of thickness of plate and 15 Adjust the clearance of the side gear in the axial direc tion 2 Assembly of standard differential carrier assembly 1 Install bearing 61 to bevel gear 62 a Install the bearing by shrink fit at tem perature below 100 C or by using tool H28 and a press 2 Install bevel gear and bearing assembly 59 to case 6...

Page 1141: ...re below 100 C or by using tool H28 and a press 9 Install washer 51 to case and bearing assembly 48 a Install the washer with the dimpled side up toward the side gear a Apply axle oil AXO80 or grease thinly to the washer and stick the washer to the case 10 Install case and bearing assembly 48 a Match the match marks made when the assembly was removed a Turn over the assembly and tighten the mounti...

Page 1142: ...both bearing carriers 44 a Install the shims of the thickness and quantity checked when disassem bled to each bearing carrier a Turning the bevel gear tighten the mounting bolts 2 Bearing Axle oil AXO80 3 Mounting bolt 98 123 Nm 10 0 12 5 kgm a Rotate the bearing several turns to spread axle oil AXO80 into it 4 Using tool H12 measure the starting torque of the bevel gear in the tangential directio...

Page 1143: ...nstall spacer 34 to pinion gear 36 4 Erect pinion gear assembly 81 and install cage assembly 88 5 Install bearing 37 to pinion gear assem bly 81 a Install the bearing by shrink fit at tem perature below 100 C or by using tool H17 and a press 6 Install holder 33 and nut 31 a Nut 31 should be used a brand new one 7 Using tool H14 See 12 Removal of front cage assembly tighten nut 31 to the specified ...

Page 1144: ... cage several turns to spread the axle oil to every part of the bearing and then measure the following q End play 0 0 162 mm q Starting torque at cage mounting hole A 0 60 8 N 0 6 2 kg a If the cage is heavy to rotate replace the bearing and then check the rota tion of the cage again 4 Remove coupling 41 Then using tool H18 press fit oil seal 82 2 Oil seal Grease G2 LI 5 Install coupling 41 and th...

Page 1145: ...ool H31 q Standard backlash 0 20 0 33 mm a Measure the backlash at 3 places on the periphery of the bevel gear and check that the dispersion of the mea sured values is 0 1 mm or less 2 If the measured backlash is out of the standard range adjust it by moving a part of the shims on either side to the opposite side a Do not change the total thickness of the shims on both sides a If the backlash is i...

Page 1146: ...nion a After adjusting the tooth contact check the backlash again 2 If the bevel pinion is too far from the bevel gear the tooth contact pattern is as fol lows In this case adjust the tooth contact according to the following procedure q Decrease the shims of the cage assembly on the bevel pinion side to move the cage assembly in the direc tion C q Adjust the shims on both sides of the bearing carr...

Page 1147: ... tooth contact pattern is as fol lows In this case adjust the tooth contact according to the following procedure q Increase the shims of the cage assembly on the bevel pinion side to move the cage assembly in the direc tion E q Adjust the shims on both sides of the bearing carrier to move bevel gear in the direction of F close to the bevel pinion a Do not change the total thickness of the shims on...

Page 1148: ...nge of h in the brake oil port 4 Install outer plate 16 and install 2 inside hexagon bolts 15 5 Install sun gear shaft 14 6 Install bleeder screw 100 7 Install tool H22 a You may install tool H22 when check ing for brake oil leakage a Be sure to fit the O ring to tool H22 3 Mounting bolt of tool H22 98 123 Nm 10 0 12 5 kgm 8 Set plate 1 equivalent to tool H19 Using tool H13 supply air into the bra...

Page 1149: ...d while the pres sure is measured the pressure fluctu ates Accordingly do not move the hose 4 Perform the high pressure brake oil leak age test a If oil leakage is not detected by the low pressure brake oil leakage test operate pump H20 to raise the pres sure to 4 410 kPa 45 kg cm2 a Leave the system at 4 410 kPa 45 kg cm2 for 5 minutes and check that the pressure does not drop more than 98 kPa 1 ...

Page 1150: ...ss fit bearing 30 to shaft 26 with a press a Direct the shield side of the bearing down 2 Using tool H33 press fit shaft and bearing assembly 91 to long cage 27 3 Install ring 29 and snap ring 28 4 Using tool H18 press fit oil seal 25 2 Oil seal Grease G2 LI 17 Installation of long cage assembly For only front differential 1 Sling and install long cage assembly 24 3 Mounting bolt 98 123 Nm 10 0 12...

Page 1151: ...Install the bushing with the chamfered part on the axle side and the slit at the side position a Install the packing with the lip on the outside of the rear axle support on the axle side 2 Sling and install rear axle support 7 3 Install thrust plate 6 and 2 thrust wash ers 5 a Clean the mating faces of the thrust plate and thrust washer thoroughly a Install thrust washer 5 with cham fered part h o...

Page 1152: ...st washer 5 with tool H34 at 4 places on the diagonal lines and obtain the average a Clean the contact face of the tool H34 depth micrometer thoroughly q Standard average value m Refer ence 19 65 20 00 mm 3 Calculate shim thickness t q Shim thickness t m k a Decide the number of the shims by the calculated shim thickness and the following table q Shim thickness 1 piece 0 2 mm 4 Install selected sh...

Page 1153: ...e and hose assembly 2 22 Axle housing 1 Install both axle housings 1 For details see Disassembly and assembly of axle housing assembly q Refilling with oil Axle housing Tighten the drain plug and add oil through the oil filler to the specified level 3 Drain plug 127 4 176 4 Nm 13 18 kgm 3 Oil filler plug 93 1 122 5 Nm 9 5 12 5 kgm 5 Axle oil Each of front and rear 18 l AXO80 AJF00527 ...

Page 1154: ...SEN03854 00 WA250 250PZ 6 50 320 43 320 Power train Part 2 Disassembly and assembly of differential assembly ...

Page 1156: ...ADER WA250 6 WA250PZ 6 Machine model Serial number WA250 6 75001 and up WA250PZ 6 75001 and up 50 Disassembly and assembly50 400 Undercarriage and frame Removal and installation of center hinge pin 2 Removal and installation of counterweight 12 ...

Page 1157: ...lling the refrigerant R134a a Never release the refrigerant R134a to the atmosphere k If the refrigerant R134a gets inside ones eyes it may cause blindness Therefore make sure to wear protec tive glasses when collecting or filling the refrigerant Collecting and filling work must be conducted by a qualified person k If the radiator coolant temperature is high you may scald yourself with the hot coo...

Page 1158: ...cket of the front frame 3 10 Remove 2 hose clamp bracket mounting bolts 4 from the front frame 11 Disconnect the PPC hoses 5 8 from the work equipment valve 4 12 Disconnect port P hose 9 and port T hose 10 a Since oil will leak through the discon nected hoses and tubes prepare oil receivers 13 Remove pins 11 from the bottom side of both steering cylinders 5 AJF00727 AJF00727 AJF00729 AJF00730 AJF0...

Page 1159: ...can pull out the pin easily and then remove upper hinge pin 16 and shims 17 8 a Check the thickness and quantity of the shims 4 Remove upper spacer 18 a The upper spacer may be removed after the front frame is disconnected 16 Disconnect the front frame and rear frame 9 1 Set hand lift truck 4 under bucket 19 2 Using a bar etc raise front frame assem bly 20 by 1 2 mm to move lower spacer 21 from re...

Page 1160: ...al 23 2 Remove retainer 24 and shims 25 a Check the thickness and quantity of the shims 3 Remove dust seal 26 from retainer 24 4 Remove bearing 27a and spacer 27b 18 Disassemble the upper hinge of the front frame 11 1 Remove lower spacer 28 2 Remove dust seal 29 3 Remove retainer 30 and shim 31 a Check the thickness and quantity of the shims 4 Remove dust seal 32 from retainer 30 AJF00737 AJF00739...

Page 1161: ...ach refrigerant pipe apply compressor oil for new refrigerant R134a DENSO ND OIL8 or ZEXEL ZXL100PT equivalent to PAG46 to O ring 70 3 Threaded part of hose M16 1 5 12 15 Nm 1 2 1 5 kgm 3 Threaded part of hose M22 1 5 20 25 Nm 2 0 2 5 kgm 3 Threaded part of hose M24 1 5 30 35 Nm 3 0 3 5 kgm q Charging with refrigerant R134a Charge the air conditioner circuit with refriger ant R134a a Charge capaci...

Page 1162: ...mble the upper hinge of the front frame 1 Using tool J1 press fit bearing 33a and spacer 33b to the front frame a Since the clearance of bearing 33a and spacer 33b is adjusted properly do not change their combination a Since bearing 33a and spacer 33b are an assembly always replace them as a set a Press fit bearing 33a and spacer 33b securely so that a clearance will not be made between the bearin...

Page 1163: ...s are inserted q Standard shim thickness 0 92 mm q Varieties of shim thickness 0 1 mm 0 2 mm 0 5 mm 1 0 mm 7 Insert selected shim 31 and tighten the 6 mounting bolts 3 Mounting bolt 98 123 Nm 10 0 12 5 kgm 3 Assemble the lower hinge of the front frame 1 Using tool J2 press fit bearing 27a and spacer 27b to the front frame a Since the clearance of bearing 27a and spacer 27b is adjusted properly do ...

Page 1164: ...e fitted with the lip in 2 Lip of dust seal Grease G2 LI 4 Tighten the 3 mounting bolts of retainer 24 evenly 3 Retainer mounting bolt 14 7 Nm 1 5 kgm 5 Measure the clearance between retainer 24 and front frame with tool J3 and then select shims so that the maximum clear ance will be less than 0 1 mm when the shims are inserted q Standard shim thickness 0 85 mm q Varieties of shim thickness 0 1 mm...

Page 1165: ...rame assembly by 1 2 mm with a large sized crane if available 3 Align the upper and lower pin holes a Using a hydraulic jack adjust the height of the front and rear frames and align the pin holes k When aligning the pin holes use a bar Never insert your fingers in the pin holes 4 Install upper spacer 18 a Install the spacer with the chamfered part on the bearing side 2 Upper spacer Lubricant conta...

Page 1166: ... 123 Nm 10 0 12 5 kgm 9 Install lock bolt 12 of lower hinge pin 13 a A clearance of 1 mm should be made at b between bushing 35 and lower hinge pin 13 q Refilling with oil Hydraulic tank Add oil through the oil filler to the specified level Run the engine to circulate the oil through the system Then check the oil level again 5 Hydraulic oil For details see Table of fuel coolant and lubricants Only...

Page 1167: ...e and put chocks under the tires 1 Disconnect battery negative terminal 1 from the right side and then disconnect battery terminal 2 2 Disconnect wiring connectors CN R23 3 and CN R24 4 3 Disconnect battery terminals 5 and 6 from the left side 4 Disconnect wiring connector CN R22 7 5 Open the engine left side cover and disconnect wiring connector CN BR1 8 6 Open the grille and sling it temporarily...

Page 1168: ... 11 temporarily and remove the mounting bolt and then remove counterweight 11 1 a When removing the counterweight insert bar 1 in its rear part to balance it 4 Counterweight and batteries both assembly 1 550 kg Installation q Carry out installation in the reverse order to removal 1 3 Mounting bolt 785 980 Nm 80 100 kgm AJF00931 ...

Page 1170: ... of HST pump and 4 gear pump assembly 2 Disassembly and assembly of HST pump assembly 6 Removal and installation of HST motor 1 assembly 33 Removal and installation of HST motor 2 assembly 35 Disassembly and assembly of HST motor assembly 37 Removal and installation of work equipment control valve assembly 53 Removal and installation of hydraulic tank 55 Disassembly and assembly of hydraulic cylin...

Page 1171: ... and filling work must be conducted by a qualified person k If the radiator coolant temperature is high you may scald yourself with the hot coolant when disconnecting the heater hoses and draining the cool ant Wait until the coolant is cooled and then drain the coolant 1 Recover the refrigerant R134a 1 2 Loosen the radiator cap to drain the coolant 6 Radiator 22 l 3 Remove the operator s cab and f...

Page 1172: ...cord the installed positions etc on them 6 Remove 2 hose clamps 18 7 Disconnect wiring harness connector 19 8 Remove wiring harness clamp 20 9 Sling HST pump and 4 gear pump assembly 21 10 Remove mounting bolts 22 and 23 4 Mounting bolt M12 22 4 pieces Mounting bolt M16 23 2 pieces 11 Lift off HST pump and gear pump assembly 21 a Since only 1 sling is installed to the flange side of the pump housi...

Page 1173: ...ump suction tube 11 Gasket sealant THREEBOND 1206E or equivalent 3 Hose clamp of steering pump suction tube 11 8 8 0 5 Nm 0 9 0 05 kgm 3 2 Insertion area of hydraulic tank return hose 17 Gasket sealant THREEBOND 1206E or equivalent 3 Clamp of hydraulic tank return hose 17 8 8 0 5 Nm 0 9 0 05 kgm 4 2 Mating face of HST pump and 4 gear pump assembly Gasket sealant LG 6 3 HST pump and 4 gear pump ass...

Page 1174: ...nd 4 gear pump assembly q Refilling with coolant Add coolant through the coolant filler to the specified level Run the engine to circulate the coolant through the system Then check the coolant level again 5 Total amount of coolant Approx 22 l For details see Table of fuel coolant and lubricants ...

Page 1175: ...emble the high pressure relief valve assemblies except the O rings and backup rings 2 Low pressure relief valve assembly 1 Remove low pressure relief valve assem bly 2 a Do not change adjustment screw 2 Disassemble the low pressure relief valve according to the following procedure if necessary a Before loosening the adjustment screw check the adjustment dimen sion 1 Remove spring 3 and spring seat...

Page 1176: ...re if necessary a Before loosening the adjustment screw check the adjustment dimen sion 1 Remove spring seat 10 and spring 11 from the pump case 2 Remove barrel assembly 12 from the pump case 3 Remove spring seat 13 and shuttle spool 15 from barrel 12 4 Remove spool 16 and piston 17 from barrel 12 5 Screw a bolt of M3 140 or longer one and pull valve seat 14 out of the pump case 6 Remove locknut 1...

Page 1177: ...lenoid valves 36 from for ward reverse solenoid valve assembly 34 a Remove cap 36B by turning it and remove coil 36A by pulling it from the solenoid valve and then remove the tube from the valve housing assembly 35 3 Disassemble the valve housing assembly 35 according to the following procedure 1 Remove 2 springs 37 and 2 collars 38 2 Remove piston 39 a Do not remove 4 plugs 41 and plug 42 from ho...

Page 1178: ... key 49 a Do not remove bearing metal 47 from flange 45 7 Port plate assembly 51 1 Mark the position angle of the indexing screw 50 m0 a Record setting measure angle 2 Set the indexing screw to disassembly position a 0 degree 3 Mark position of the port plate m1 4 Loosen port plate fixation 5 Lift off port plate assembly 51 and con trol plate 52 8 Cylinder block and piston assembly 54 1 Press cyli...

Page 1179: ...10 WA250 250PZ 6 500 Hydraulic system Disassembly and assembly of HST pump assembly 3 Remove cylinder block and piston assem bly 54 4 Disassemble cylinder block and piston assembly 54 according to the following procedure ...

Page 1180: ...ock 56 control plate 52 retainer guide 59 retainer 58 and shim 60 needs to be replaced replace the whole cylinder block since a dimension of shim 60 must be adjusted 5 Remove snap ring 63 from the cylin der block k Snap ring 63 will jump out Take care 6 Remove spring 62 and 2 shims 65 a Check of pistons q Check that there are no scratches or metal deposits on sliding surface b and there is no axia...

Page 1181: ...tc 2 Remove snap ring 67 3 Tighten screws 1 into the holes of shaft seal 68 blocked with rubber 4 Pull out shaft seal 68 with pliers 5 Remove snap ring 69 10 Drive shaft assembly 1 Remove drive shaft assembly 66 with plastic hammer strokes 2 Disassemble the drive shaft assembly according to the following procedure 1 Remove snap ring 70 2 Remove bearing 71 from drive shaft 72 a Check of drive shaft...

Page 1182: ...aring cups set 3 Remove wire 95 articulate pin 96 and bearing 74b from swivel cradle 73 a Check of cradle 76 q Sliding surface h free from scoring q Bearing surfaces j of cradle 76 4 Remove lever 75 from cradle 73 a Check of cradle lever 75 12 Servo cylinder assembly 1 Remove plugs 77 2 Remove joint pins 78 3 Mark positions m2 and m3 of the cov ers 80 and 81 note measure of zero position k 4 Loose...

Page 1183: ...ssembly 82 a Check of groove A 8 Disassemble the servo piston assembly 82 according to the following procedure a Disassemble either side first then disassemble the other side 1 Using tool S1 push collar 83 2 Break and remove plastic cap 86 Prepare new one for assembly 3 Remove ring 84 4 Remove snap ring 85 5 Remove collar 83 6 Remove large spring 87 and small spring 88 7 Remove collar 89 ...

Page 1184: ...dimension of ring 84 must be adjusted 13 Pump case 1 Remove guide ring 92 from servo cylin der mounting part 100 of pump case 2 Remove seal ring 93 and O ring 94 Assembly a Clean the all parts and remove burrs etc a Coat the rotary parts and sliding parts with engine oil for details see Table of fuel cool ant and lubricants before installing a If the tightening torque of a mounting bolt nut or plu...

Page 1185: ...collars 83 and 89 in engine oil for details see Table of fuel coolant and lubricants 2 Assemble the servo piston assembly according to the following procedure 1 Install rod 91 to piston 90 a Assemble either side first then assemble the other side 2 Install collar 89 3 Install small spring 88 and large spring 87 4 Install collar 83 5 Using tool S1 push collar 83 6 Install snap ring 85 7 Install rin...

Page 1186: ...ng cups 1 Insert bearing cup set 74a a Fit hole c of cup set 74a to the pin in the case 2 Swivel cradle 73 Assemble bearing 74b wire 95 lever 75 and articulating pin 96 to the cradle 76 a Completed cradle holding device 3 Insert completely swivel cradle 73 into housing a Assistance Devices e g clamp rub ber rings grease and string a Pay attention for correct seat of the swivel cradle 73 in the hou...

Page 1187: ...ring device dial gauge or depth measurement 5 q The measured values at the 2 points of P1 and P2 in the following figure must be the same 4 Fit joint pin 78 and plug 77 a Pinch wire 95 in pin 78 5 Make holding devices 6 2 pieces a Holding device 6 swivel cradle 6 Hold swivel 73 in position utilizing the seat screw k Do not use force 7 Install second holding device 6 diago nally and fix swivel 73 ...

Page 1188: ...tool S2 press fit bearing 71 to drive shaft 72 3 Install snap ring 70 4 Install drive shaft assembly 66 5 Install snap ring 69 a Before setting seal 68 perform the fol lowing procedures 6 Measure depth d1 to the groove bottom of snap ring 67 7 Make a mark of the insertion depth of push tool S3 finishing position m4 d1 on push tool S3 8 Using tool S3 press fit seal 68 a Threads of shaft M16 Thread ...

Page 1189: ...0 500 20 WA250 250PZ 6 500 Hydraulic system Disassembly and assembly of HST pump assembly 5 Cylinder block and piston assembly 1 Assemble the cylinder block and piston assembly according to the following pro cedure ...

Page 1190: ...56 con trol plate 52 retainer guide 59 retainer 58 and shim 60 needs to be replaced replace the whole cylin der block since a dimension of shim 60 must be adjusted 4 Install retainer guide 59 5 Install 9 pistons 57 to retainer 58 6 Install piston and retainer assembly to cylinder block 56 a Apply oil to piston and piston pad 2 Remove holding device 6 a Fit cylinder completely with pistons and reta...

Page 1191: ...ned in based on direction of rotation a Notch B is seen on one side a Indexing screw basic setting indexing screw 50 The end is eccentric Dimension m 29 0 75 mm 1 Press cylinder block 56 to the bottom 2 Screw in the indexing screw 50 a Groove in mounting position The groove is directed up in the fol lowing figure 3 Insert control plate 52 clockwise rota tion a Insert the control plate so that notc...

Page 1192: ...screwed opposite angle 3 Locking screw 50 observe adjusting measure the angle m0 8 Servo piston cover 1 Install servo piston covers 80 and 81 to both sides match mark positions m2 and m3 a Cover 80 will be removed because of fill ing oil 9 Charge pump assembly 44 1 Install wear plate 43 2 Install coupling 48 and key 49 a Bearing metal 47 is already in the flange 45 3 Install gear 46 to flange 45 4...

Page 1193: ...llowing procedure 1 Install plug 42 to housing 2 Threads of plug ThreeBond No 1305 2 Install 4 plugs 41 3 Plug 5 6 Nm 0 57 kgm 3 Install piston 39 4 Install 2 collars 38 and 2 springs 37 2 Install 2 solenoid valves 36 to valve housing assembly 35 a Fit the tube to the solenoid valve housing and install coil 36A and cap 36B 3 Install forward reverse solenoid valve assembly 34 3 Plug 9 8 Nm 1 kgm ...

Page 1194: ... and locknut 18 to holder 98 2 Install piston 17 and spool 16 to barrel 12 3 Install shuttle spool 15 valve seat 14 and spring seat 13 to barrel 12 4 Install barrel assembly 12 to the pump case 5 Install spring 11 and spring seat 10 to the pump case a Set the spring to the dimension mea sured before disassembly 2 Fit the O ring and install high pressure cut off valve assembly 9 a After installing ...

Page 1195: ...t 6 3 Install piston 5 4 Install spring seat 4 and spring 3 to the pump case 2 Fit the O ring and install low pressure relief valve assembly 2 3 Low pressure relief valve assem bly 70 Nm 7 14 kgm 14 High pressure relief valve assembly Fit the O ring and install 2 high pressure relief valve assemblies 1 3 High pressure relief valve assembly 200 10 Nm 20 39 1 02 kgm 15 Filling with oil a Remove serv...

Page 1196: ...ing a Observe the operating instructions before starting q Check the machine for remarkable faults q Do not operate the machine with defective instruments warning lights or control ele ments q All safety devices must be in a secure position q Do not carry with you movable objects or secure them to the machine q Keep oily and inflammable material away from the machine q Before entering the operator...

Page 1197: ...eas to DIN 912 socked head cap screws DIN 913 hexagon bolt or DIN 933 hexagon bolts with threads up to the head Thread Tensile strength class 8 8 10 9 12 9 Nm kgm Nm kgm Nm kgm M3 1 1 0 11 1 6 0 16 1 9 0 19 M4 3 1 0 32 4 5 0 46 5 3 0 54 M5 6 1 0 62 8 9 0 91 10 4 1 06 M6 10 4 1 06 15 5 1 58 18 1 84 M8 25 2 55 37 3 77 43 4 38 M10 51 5 20 75 7 65 87 8 87 M12 87 8 87 130 13 26 150 15 30 M14 140 14 28 ...

Page 1198: ...ing torque Nm kgm Nm kgm M8 x 1 5 0 51 G 1 8 A 10 1 02 M10 x 1 10 1 02 G 1 4 A 30 3 06 M12 x 1 5 20 2 04 G 3 8 A 35 3 57 M14 x 1 5 30 3 06 G 1 2 A 60 6 12 M16 x 1 5 35 3 57 G 3 4 A 90 9 18 M18 x 1 5 40 4 08 G 1 A 140 14 28 M20 x 1 5 50 5 10 G 11 4 A 240 24 47 M22 x 1 5 60 6 12 G 11 2 A 300 30 59 M26 x 1 5 70 7 14 M27 x 2 90 9 18 M30 x 1 5 100 10 20 M33 x 2 140 14 28 M42 x 2 240 24 47 M48 x 2 300 3...

Page 1199: ...d UNF UN threads to SAE J 514 Thread Tightening torque Thread Tightening torque Nm kgm Nm kgm 7 16 20UNF 15 1 53 M12 x 1 5 20 2 04 1 2 20UNF 20 2 04 M14 x 1 5 30 3 06 9 16 18UNF 25 2 55 M27 x 1 5 90 9 18 3 4 16UNF 72 7 34 7 8 14UN 127 12 95 11 16 12UN 147 14 99 13 16 12UN 173 17 64 15 16 12UN 198 20 19 15 8 12UN 320 32 63 17 8 12UN 390 39 77 ...

Page 1200: ...and assembly of HST pump assembly 3 SEAL LOCK sealing nuts Thread Tightening torque Nm kgm M6 10 1 02 M6 x 0 5 11 1 12 M8 22 2 24 M8 x 1 24 2 45 M10 40 4 08 M10 x 1 44 4 49 M12 69 7 04 M12 x 1 5 72 7 34 M14 110 11 22 M14 x 1 5 120 12 24 M16 170 17 34 M16 x 1 5 180 18 35 ...

Page 1201: ...embly and assembly of HST pump assembly 4 Oval head screw Oval head screw with inner TORX thread precoated with Precote 80 Thread Tensile strength class 10 9 11 9 Tightening torque Nm kgm Nm kgm M3 2 1 0 21 M4 4 7 0 48 M5 9 1 0 93 9 5 0 97 M6 15 8 1 61 M8 37 7 3 84 ...

Page 1202: ...rant R134a a Never release the refrigerant R134a to the atmosphere k If the refrigerant R134a gets inside ones eyes it may cause blindness Therefore make sure to wear protec tive glasses when collecting or filling the refrigerant Collecting and filling work must be conducted by a qualified person k If the radiator coolant temperature is high you may scald yourself with the hot coolant when disconn...

Page 1203: ... 3 Threaded part of hose M16 1 5 12 15 Nm 1 2 1 5 kgm 3 Threaded part of hose M22 1 5 20 25 Nm 2 0 2 5 kgm 3 Threaded part of hose M24 1 5 30 35 Nm 3 0 3 5 kgm q Charging with refrigerant R134a Charge the air conditioner circuit with refriger ant R134a a Charge capacity 1 200 50 g 2 3 Drive shaft mounting bolt 59 74 Nm 6 0 7 5 kgm 3 3 HST motor 1 assembly mounting bolt 245 309 Nm 25 0 31 5 kgm q R...

Page 1204: ...rant R134a a Never release the refrigerant R134a to the atmosphere k If the refrigerant R134a gets inside ones eyes it may cause blindness Therefore make sure to wear protec tive glasses when collecting or filling the refrigerant Collecting and filling work must be conducted by a qualified person k If the radiator coolant temperature is high you may scald yourself with the hot coolant when disconn...

Page 1205: ... 3 Threaded part of hose M16 1 5 12 15 Nm 1 2 1 5 kgm 3 Threaded part of hose M22 1 5 20 25 Nm 2 0 2 5 kgm 3 Threaded part of hose M24 1 5 30 35 Nm 3 0 3 5 kgm q Charging with refrigerant R134a Charge the air conditioner circuit with refriger ant R134a a Charge capacity 1 200 50 g 2 3 Drive shaft mounting bolt 59 74 Nm 6 0 7 5 kgm 3 3 HST motor 2 assembly mounting bolt 245 309 Nm 25 0 31 5 kgm q R...

Page 1206: ...Tighten screws 1 into the holes of shaft seal 4 blocked with rubber 4 Pull out shaft seal 4 with pliers 2 EP servo valve assembly and cover HST motor 1 1 Remove 4 mounting bolts and solenoid valve and housing assembly 5 a Take care of the spring which may jump out Symbol Part No Part name Necessity Q ty New Remodel Sketch S 4 02010 20783 Bolt q 1 5 790 201 2740 Push tool t 1 793T 417 1120 Push too...

Page 1207: ...noid and housing assembly 5 1 Remove caps 14 coil 15 and snap ring 16 of the solenoid in order 2 Remove spool 18 and bushing 19 from housing 13 3 Remove pin 20 a Do not remove nut 21 and screw 22 4 Remove plugs 24 from housing 13 a Do not remove plug 23 6 Cover 1 Remove cover 25 2 Remove plug 26 from cover 25 3 HA servo valve and forward reverse shuttle valve assembly and flushing valve assem bly ...

Page 1208: ...pring seat 29 and spring 30 from port plate 6 3 Remove spring seat 31 and spring 34 4 Disassemble 2 solenoids and housing assembly 27 1 Remove caps 36 and 37 coils 38 and 39 and bushing 40 of the solenoid in order a Disassemble the housing assembly according to the following procedure 2 Remove snap ring 43 control bush ing 44 and control piston 45 from housing 35 3 Remove pin 46 a Do not remove nu...

Page 1209: ...00 Hydraulic system Disassembly and assembly of HST motor assembly 4 Remove control piston 49 and spring 50 from housing 35 5 Remove plug 51 a Do not remove 5 plugs 52 5 Remove flushing valve assembly 53 from port plate 6 CJW12107 CJW12112 ...

Page 1210: ...assembly 6 Disassemble flushing valve assembly 53 according to the following procedure 1 Remove plug 54 2 Remove spring 55 plunger 56 ori fice 57 and snap ring 58 3 Remove 2 plugs 59 4 Remove spring 60 spring seat 61 and spool 62 5 Remove plug 63 6 Remove guide 64 orifice 65 and guide 66 CJW12164 ...

Page 1211: ...m Flow Rate Adjustment screw 67 3 Push piston 69 to set the angle of rotary group 70 to 0 4 Break and remove plastic cap 71 and check installed dimension b of Maximum Flow Rate Adjustment screw 96 5 Remove Maximum Flow Rate Adjustment screw 96 a Plastic cap 71 is used to prevent rusting Since a spare for it is not supplied apply paint or take another rust preventive measure after assem bling 6 Ins...

Page 1212: ...remove screw 76 rod 72 and piston 69 3 Screw a bolt of M4 and pull out valve guide 77 4 Remove poppet 78 5 Remove valve seat 79 a Check of port plate q Sliding surface and side guides free of scoring and no wear a Check of control plate Faces smooth and even free of cracks and scoring 6 Removal of shaft and rotary group assem bly 81 1 Remove O ring 75 2 Screw 2 in threaded pin into center pin d a ...

Page 1213: ...drive shaft a If a press is not available push the shaft end with tool 3 or 4 to remove rotary group assembly 81 a Check of housing q Sliding surface and slide guides free of scoring and no wear a Since shaft and bearing are used as an assembly do not remove the bear ing 7 Disassembly of rotary group assembly 70 1 Remove screw 2 2 Remove cylinder block 83 3 Remove shim 84 from cylinder block 83 CJ...

Page 1214: ...rm it up to max 120 C and remove with Torx tools 5 Remove 7 pistons 86 spring 87 and center pin 88 from shaft and bearing assembly 89 a Check of retaining ring 85 q No scoring and no evidence of wear a Check of piston and center pin q No scoring and no pittings a Do not disassemble the drive shaft and bearing assembly 89 If the drive shaft and bearing assembly is defective replace it whole CJW1201...

Page 1215: ...le The parts of this assembly cannot be supplied loose 1 Install 7 pistons 86 center pin 88 and spring 87 to the drive shaft and bearing assembly 89 2 Install retaining ring assembly 85 with the screw a For the tightening torque of the screw see Tightening torque table 3 Insert shim 84 center pin 88 and pis ton 86 in cylinder block 83 a Make sure all parts are fitted in cor rectly 4 Insert the pis...

Page 1216: ...gle to 0 degree 4 Remove screw 2 5 Install O ring 75 to the housing 3 Port plate assembly 6 1 Assemble port plate assembly 6 accord ing to the following procedure 1 Install valve seat 79 2 Install poppet 78 3 Install valve guide 77 a Piston 69 rod 72 and screw 76 are already in the port plate 6 4 Install piston 74 and bolt 73 5 Thinly apply grease to control plate 80 and then install it to the sli...

Page 1217: ...nd Maximum Flow Rate Adjustment screw 96 1 Remove screw 6 and set Maximum Flow Rate Adjustment screw 96 Dimension b is the value measured at the time of disassembly a When bolt is changed q Since the bolt is used to plug the hole simply do not replace it with long one 2 Swivel rotary group 70 to starting posi tion 3 Set Minimum Flow Rate Adjustment screw 67 to dimension a a Dimension a is importan...

Page 1218: ...Assemble the flushing valve assembly according to the following procedure 1 Install guide 66 orifice 65 and guide 64 3 Guide 66 3 Nm 0 31 kgm 3 Guide 64 8 Nm 0 81 kgm 2 Install plug 63 3 Plug 29 38 Nm 2 96 3 89 kgm 3 Install spool 62 spring seat 61 and spring 60 4 Install 2 plugs 59 3 Plug 40 Nm 4 1 kgm 5 Install snap ring 58 orifice 57 plunger 56 and spring 55 6 Install plug 54 3 Plug 50 Nm 5 1 k...

Page 1219: ...lug 51 to housing 35 2 Install spring 50 and control piston 49 to housing 35 a 5 plugs 52 are already in the hous ing 35 3 Install pin 46 4 Install control piston 45 and control bushing 44 5 Install snap ring 43 6 Install 2 solenoids to housing 35 a Install bushing 40 coils 39 and 38 and caps 37 and 36 of the solenoid in order 4 Install spring 34 and spring seat 31 to the port plate 5 Install spri...

Page 1220: ...or 1 1 Cover 1 Install plug 26 to cover 25 3 Plug 29 38 Nm 3 0 3 9 kgm 2 Install cover 25 3 Mounting bolt 39 49 Nm 4 0 5 0 kgm 2 Assemble housing assembly 5 according to the following procedure 1 Install plug 24 to housing 13 2 Install pin 20 3 Install bushing 19 and spool 18 to housing 13 a Plugs 23 are already in the housing 13 4 Install snap ring 16 coil 15 and cap 14 in order to housing assemb...

Page 1221: ...ic aggregates with medium before start up 9 Tightening torque table a If the tightening torque of a mounting bolt nut or plug is not shown in this manual see Disas sembly and assembly of HST pump assembly Tightening torque table 10 Before starting a Observe the operating instructions before starting q Check the machine for remarkable faults q Do not operate the machine with defective instruments w...

Page 1222: ...ft arm securely k Stop the engine and loosen the hydrau lic tank cap gradually to release the pressure in the tank k Operate the work equipment control lever 2 3 times to release the residual pressure in the work equipment circuit 3 Remove cover 2 on the work equipment con trol valve 4 Disconnect the following hoses and tubes from work equipment control valve assembly 2 1 a Plug the disconnected h...

Page 1223: ...6 Remove work equipment control valve assem bly 2 Installation q Carry out installation in the reverse order to removal 1 a Connect PPC hoses 5 6 11 and 12 according to their band colors as shown in the following table q Work equipment control lever specification Mono lever q Refilling with oil Hydraulic tank Add oil through the oil filler to the specified level Run the engine to circulate the oil...

Page 1224: ... lever 2 3 times to release the residual pressure in the work equipment circuit 1 Open and fix right engine side cover 1 a Check that the cover is locked securely 2 Remove right fender 2 4 Fender 25 kg 3 Remove covers 3 4 and 5 4 Remove hydraulic tank cover 6 k Loosen the hydraulic tank cap gradu ally to release the pressure in the hydraulic tank 5 Remove tube 7 between the hydraulic tank and hydr...

Page 1225: ...4 Hydraulic tank and ladder assembly 160 kg including hydraulic oil Installation q Carry out installation in the reverse order to removal 1 2 Insertion areas of suction hose 10 and return hose 11 Gasket sealant THREE BOND 1206E or equivalent 3 Clamps of suction hose 10 and return hose 11 8 8 0 5 Nm 0 9 0 05 kgm 2 3 Upper mounting bolt 18 of hydraulic tank 98 123 Nm 10 0 12 5 kgm 3 3 Lower mounting...

Page 1226: ...Part No Part Name Necessity Q ty New Remodel Sketch U 1 790 502 1003 Repair stand t 1 790 101 1102 Hydraulic pump t 1 2 790 102 2303 or 790 102 3802 Wrench assembly for lift and bucket t 1 3 790 302 1340 Socket for lift t 1 4 790 201 1702 Push tool kit t 1 790 101 5021 Grip 1 01010 50816 Bolt 1 790 201 1811 Push tool Lift 1 790 201 1821 Push tool Bucket 1 790 201 1741 Push tool Steering 1 5 790 20...

Page 1227: ...oil receiver 4 Piston and cylinder head Steering cylinder and lift cylinder 1 Set cylinder head and piston rod assembly 3 to tool U1 2 Using tool U3 remove nut 5 q Width across flats of nut Steering 46 mm q Width across flats of nut Lift 80 mm 3 Remove piston assembly 6 and cylinder head assembly 2 5 Piston and cylinder head Bucket cylinder 1 Set cylinder head and piston rod assembly 3 to tool U1 ...

Page 1228: ...ve O ring and backup ring 12 2 Remove snap ring 13 and dust seal 14 3 Remove rod packing 15 4 Remove bushing 16 Assembly a Take care not to damage the packings dust seals O rings etc a Do not insert each backup ring forcibly but warm it in water at 50 60 C and then insert it 1 Assembly of cylinder head assembly Steering cylinder assembly 1 Using tool U4 press fit bushing 16 2 Install rod packing 1...

Page 1229: ...tool U5 install dust seal 14 and secure it with snap ring 13 4 Install backup ring and O ring 12 3 Assembly of piston assembly Steering cyl inder assembly 1 Using tool U6 expand piston ring 10 a Set the tool to the piston ring and turn its handle by 8 10 turns to expand the piston ring 2 Remove piston ring 10 from tool U6 and install it to piston 8 3 Using tool U7 shrink piston ring 10 4 Install w...

Page 1230: ...sembly Bucket cylinder 1 Set piston rod 3 to tool U1 2 Install cylinder head assembly 2 3 Install piston assembly 6 4 Install 2 spacers 18 with 6 mounting bolts 2 Bolt mounting part of piston and mounting bolt Hardening acceler ator NIHON LOCTITE PRIMER T or equivalent a Apply the above primer first and then apply the following liquid adhesive 2 Bolt mounting part of piston Liquid adhesive LOCTITE...

Page 1231: ...g cylinder head and piston rod assem bly 3 and install cylinder 4 3 Install cylinder head assembly 2 to the cylinder 3 Cylinder head mounting bolt 250 24 5 Nm 25 5 2 5 kgm 4 Remove cylinder assembly 1 from tool U1 8 Bucket positioner Adjust the bucket positioner plate to the follow ing dimensions and tighten the bolts Dimension a 41 5 1 mm Dimension b 105 2 mm 9JF01064 9JF115389 ...

Page 1232: ...SEN03856 00 WA250 250PZ 6 50 500 63 500 Hydraulic system Disassembly and assembly of hydraulic cylinder assembly ...

Page 1234: ...0 1 SEN03857 01 WHEEL LOADER WA250 6 WA250PZ 6 Machine model Serial number WA250 6 75001 and up WA250PZ 6 75001 and up 50 Disassembly and assembly50 600 Work equipment Removal and installation of work equipment assembly 2 ...

Page 1235: ...ket link temporarily and remove bucket link pin 1 1 4 Bucket link 55 kg a Secure the bucket link to the bell crank with chains etc a Check the thickness and quantity of the shims 2 Remove bucket hinge mounting pin 2 2 k Never insert your fingers in the pin holes a Check the thickness and quantity of the shims 3 Move the machine to the rear and disconnect the bucket 4 Sling bucket cylinder assembly...

Page 1236: ... of the shims a When lowering the lift cylinder assembly put a block on the axle 4 Lift cylinder assembly 1 piece 110 kg 7 Disconnect boom positioner proximity switch connector CN F04 7 8 Remove boom kick out switch 8 5 9 Sling lift arm and bell crank and bucket link assembly 10 temporarily and pull out mount ing pin 11 6 a Check the thickness and quantity of the shims 10 Lift off lift arm and bel...

Page 1237: ...om the bell crank assembly 7 4 Bucket link assembly 30 kg 12 Sling bell crank assembly 14 temporarily and pull out mounting pin 15 13 Lift off bell crank assembly 14 4 Bell crank assembly 170 kg 14 Pull dust seal 17 and bushing 18 out of lift arm 16 8 15 Pull dust seal 19 and bushing 20 out of bell crank 14 8 16 Pull dust seal 21 and bushing 22 out of bucket link 12 8 CJW11355 CJW11356 CJW11357 CJ...

Page 1238: ...nces a on both sides will be the same q Clearance a On each side Max 1 5 mm q Varieties of shim thickness Only 1 5 mm 3 Install mounting pin 1 and lock it with bolt 24 k Never insert your fingers in the pin holes a Take care that the cord ring will not be caught 2 Procedure for installing bucket hinge pin 1 Operate the control lever to align the holes for bucket mounting pin 2 and install cord rin...

Page 1239: ...see Testing and adjusting Testing and adjusting bucket positioner 4 Procedure for installing lift cylinder pin on rod side k When starting the engine check that the directional lever is in neutral and the park ing brake is applied 1 Insert shims in clearance d q Clearance d On each side Max 1 5 mm q Varieties of shim thickness Only 1 5 mm 2 Install mounting pin 5 and lock it with bolt 28 k Never i...

Page 1240: ...side of bushing Lubricant containing molybde num disulfide LM P or equiva lent a After installing the pin supply grease con taining molybdenum disulfide 2 Grease Hyper White G2 T or equivalent 7 Procedure for installing bucket link pin 1 Insert shims so that clearances f on both sides will be even q Clearance f On each side Max 1 5 mm q Varieties of shim thickness Only 3 0 mm a Secure the bell cra...

Page 1241: ...ink 12 respec tively with hydraulic cylinder 3 etc and then install the dust seals 2 Bushing Grease G2 LI a Apply grease to the seal so that the seal will not be damaged a Press fit the dust seal with the lip out q Installed dimension g 0 25 0 80 mm q Installed dimension h 2 3 mm q Greasing Supply grease to each pin a Supply grease until it comes out of the joint 9JF01060 9JF01061 ...

Page 1242: ...SEN03857 01 WA250 250PZ 6 50 600 9 600 Work equipment Removal and installation of work equipment assembly ...

Page 1244: ...mber WA250 6 75001 and up WA250PZ 6 75001 and up 50 Disassembly and assembly50 700 Cab and its attachments Removal and installation of operator s cab and floor frame assembly 2 Removal and installation of operator s cab glass Stuck glass 7 Removal and installation of air conditioner unit 15 ...

Page 1245: ...may cause blindness Therefore make sure to wear protec tive glasses when collecting or filling the refrigerant Collecting and filling work must be conducted by a qualified person k If the radiator coolant temperature is high you may scald yourself with the hot coolant when disconnecting the heater hoses and draining the coolant Wait until the coolant is cooled and then drain the coolant a The oper...

Page 1246: ...ht q 16 P port hose Left lower q 17 R port hose Right lower q 18 L port hose Right upper q 13 T port hose Left upper Since hose 13 was disconnected in the previous step from the hydraulic tank it does not need to disconnect in this step a Plug the disconnected hoses to prevent oil leakage a Put tags to the disconnected hoses and record the installed positions etc on them 14 Open and fix left engin...

Page 1247: ...partment side 22 Disconnect air conditioner pipes 40 and 41 23 Disconnect heater hoses 42 and 43 from the engine side a Put tags to the disconnected hoses and pipes and record the installed positions etc on them 24 Remove air conditioner pipe clamps 44 and 45 from the lower left of the floor 25 Disconnect the following hoses from the top of the brake valve 3 q 47 A port hose q 48 B port hose q 49 ...

Page 1248: ... out grommet 58 and brake cable 59 together toward under the floor 32 Remove right and left front mount covers 60 33 Remove right and left rear fender brackets 61 34 Remove right and left front operator s cab mounting nuts 62 4 35 Remove right and left rear operator s cab mounting nuts 63 5 36 Lift off operator s cab and floor frame assembly 64 a Check that all the wiring and piping are disconnect...

Page 1249: ...rging with refrigerant R134a Charge the air conditioner circuit with refriger ant R134a a Charge capacity 1 200 50 g 2 Bleed air from the steering circuit For details see Testing and adjusting Bleeding air from steering circuit 3 Bleed air from the brake system For details see Testing and adjusting Bleeding air from brake cir cuit 4 3 Right and left front operator s cab mounting nuts 62 824 1 030 ...

Page 1250: ...ay cut the adhesive by the following method Insert a fine wire 2 piano wire etc in the adhesive and grip its both ends with priors 3 etc or hold them by winding them onto something and cut the adhesive with the wire a The broken window glass may be removed with knife 4 and a screwdriver If the screwdriver is applied directly to the normal window glass the glass will be broken a When using knife 4 ...

Page 1251: ...them for at least 5 minutes to dry 3 When the adhesive was removed with the scraper if any paint was flaked off coat the bare part with paint a If the glass is installed without repairing the bare part that part will be rusted a Do not apply paint to a part which will be coated with primer 4 Stick both sided adhesive tape 4 along the inside edge of the glass sticking section q Size of both sided a...

Page 1252: ...t to tools X1 1 and X1 2 and set them to the 2 lower places of the window glass sticking part of operator s cab 2 3 Using tool X2 suction cups place win dow glass 3 on tool X1 1 5 mm spacer and match it to the operator s cab 4 Check the clearance between window glass 3 and operator s cab 2 on both sides and adjust it evenly 5 Stick tape 6 between window glass 3 and operator s cab 2 and draw positi...

Page 1253: ...re respective brushes for the paint primer and glass primer 3 Evenly apply paint primer 7 to the parts on the outside of both sided adhesive tape on operator s cab 2 which will be coated with the adhesive 2 Paint primer SUNSTAR PAINT PRIMER 580 SUPRE a Do not apply the primer more than 2 times If it is applied more than 2 times its performance will be lowered a Parts to be coated with primer Apply...

Page 1254: ... Adhesive Summer SUNSTAR PENGUINE SEAL 580 SUPER S 2 Adhesive Winter SUNSTAR PENGUINE SEAL 580 SUPER W a The using limit of the adhesive is 4 months after the date of manufacture Do not use the adhesive after this limit a Keep the adhesive in a dark place where the temperature is below 25 C a Never heat the adhesive higher than 30 C a When reusing the adhesive remove the all hardened part from the...

Page 1255: ...a Apply adhesive 12 higher than both sided adhesive tape 4 a Apply the adhesive evenly 8 Install window glass 3 a If the glass is positioned wrongly the adhesive must be removed and cleaned and then the primer and adhesive must be applied again Accordingly position the glass carefully when sticking it 1 Similarly to step 1 match tools X1 1 X1 2 and X1 3 and set them to the 2 lower places of the wi...

Page 1256: ...degree that the window glass will be stuck to the both sided adhesive tape a Do not press the window glass to strongly 9 Cure the stuck window glass for a certain time a Curing time before removing tool X1 1 5 mm spacer at temperature of 20 C and humidity of 60 10 hours a Curing time before operating machine 1 day 10 If the front glass and both front glasses are replaced seal them 1 Stick masking ...

Page 1257: ...e of manufacture Do not use the caulking material after its usable period 2 Caulking material SUNSTAR PENGUINE SEAL NO 2505 3 Remove the caulking material projected from the joint with cardboard 8 etc 4 Remove the masking tapes from the win dow glass 11 Remove the primer and adhesive from the operator s cab and window glass a Using white gasoline wipe off the adhe sive before it is dried up a When...

Page 1258: ...herefore make sure to wear protec tive glasses when collecting or filling the refrigerant Collecting and filling work must be conducted by a qualified person k If the radiator coolant temperature is high you may scald yourself with the hot coolant when disconnecting the heater hoses and draining the cool ant Wait until the coolant is cooled and then drain the coolant 1 Recover the refrigerant R134...

Page 1259: ...ect the following connectors from the rear side 12 13 CN L30 14 CN L28 15 CN L27 16 CN L26 17 CN L25 18 CN L29 19 CN L24 a Take care not to strain the wiring since it is short 8 Remove monitor panel assembly 11 9 Disconnect wiper water hose 12 from the front outside of the cab 10 Remove wiper blades 13 11 Disconnect wiper water hose 14 from the inside of the cab 12 Disconnect wiper wiring harness ...

Page 1260: ...ng harness con nectors q 23 CN C50 q 24 CN C49 q 25 CN AL1 19 Remove air conditioner internal air filter case 26 20 Disconnect wiring harness connector 28 and fuse 29 21 Remove right cover 30 22 Disconnect heater hoses 32 and 33 and air conditioner pipes 34 and 35 at the lower right of air conditioner unit 31 a Plug the disconnected hoses and ports to prevent foreign matter from entering them 4 23...

Page 1261: ...ard a Check that all the wiring and piping are disconnected 26 Blower motor assembly 1 Remove side cover 39 and front cover 40 at the lower left of the operator s cab 2 Remove air conditioner external air filter case 41 3 Remove air conditioner external air duct 42 from the lower left of the floor 4 Remove the 5 mounting bolts and blower motor assembly 43 a Remove the 5 bolts indicated with the ar...

Page 1262: ... check that O ring 70 is fitted to it a Check O ring 70 for a flaw and deterioration a When connecting each refrigerant pipe apply compressor oil for new refrigerant R134a DENSO ND OIL8 or ZEXEL ZXL100PT equivalent to PAG46 to O ring 70 3 Threaded part of hose M16 1 5 12 15 Nm 1 2 1 5 kgm 3 Threaded part of hose M22 1 5 20 25 Nm 2 0 2 5 kgm 3 Threaded part of hose M24 1 5 30 35 Nm 3 0 3 5 kgm q Ch...

Page 1263: ...ng was disconnected to prevent entry of foreign matter until just before connecting the piping 2 O ring and threaded part Compressor oil for R134a SANDEN SP 10 3 Hose adapter mounting bolt 44 8 12 Nm 0 8 1 2 kgm q Refilling with coolant Add coolant through the coolant filler to the specified level Run the engine to circulate the coolant through the system Then check the coolant level again 5 Total...

Page 1264: ...SEN03858 00 WA250 250PZ 6 50 700 21 700 Cab and its attachments Removal and installation of air conditioner unit ...

Page 1266: ... 6 75001 and up WA250PZ 6 75001 and up 50 Disassembly and assembly50 800 Electrical system Removal and installation of monitor panel 2 Removal and installation of engine controller assembly 4 Removal and installation of HST controller assembly 5 Removal and installation of KOMTRAX terminal assembly 6 ...

Page 1267: ...tive terminal of the battery 1 Pull out each switch from panel cover 1 on the left side of the operator s seat and discon nect the following connectors q 2 CN L10 q 3 CN L11 q 4 CN L09 a Different specifications use different switches and connectors 2 Pull out each switch from panel cover 1 on the right side of the operator s seat and discon nect the following connectors q 5 CN L19 q 6 CN L07 q 7 ...

Page 1268: ... L30 q 14 CN L28 q 15 CN L27 q 16 CN L26 q 17 CN L25 q 18 CN L29 q 19 CN L24 a Take care not to strain the wiring since it is short 6 Remove monitor panel assembly 11 7 Remove bracket 20 from monitor panel assembly 11 Installation q Carry out installation in the reverse order to removal 1 3 Panel cover mounting bolt 1a 3 44 4 40 Nm 0 35 0 45 kgm 2 3 Monitor panel mounting bolts 9 and 10 2 75 3 53 ...

Page 1269: ...gine side cover 1 a Check that the cover is locked securely 2 Remove wiring harness clamp 2 3 Remove 2 wiring harness clamps 3 4 Remove 2 connector mounting bolts 4 1 a Width across flats of hexagonal socket of mounting bolt 4 mm 5 Disconnect connectors CN EC2 5 CN EC1 6 and CN EC3 7 6 Disconnect 5 mounting bolts 8 and engine controller assembly 9 2 Installation q Carry out installation in the rev...

Page 1270: ...round stop the engine apply the parking brake and put chocks under the tires k Disconnect the cable from the negative terminal of the battery 1 Slide the operator s seat to the forward end 2 Remove cover 1 from the rear of the opera tor s seat 3 Disconnect wiring harness connector CN HST 2 4 Remove HST controller 3 Installation q Carry out installation in the reverse order to removal a Before inst...

Page 1271: ...sconnect machine wiring harness connector CN L80 3 from KOMTRAX terminal assembly 2 a Disconnect the machine wiring harness first and then disconnect the antenna cables If the antenna cables are discon nected first an antenna cable disconnec tion error is saved in the KOMTRAX 1 a Remove CN L80 3 by loosening the hexagon socket head screw at its center 2 5 Disconnect antenna cable connectors 4 and ...

Page 1272: ...SEN03859 00 WA250 250PZ 6 50 800 7 800 Electrical system Removal and installation of KOMTRAX terminal assembly ...

Page 1274: ...90 100 1 SEN03860 01 WHEEL LOADER WA250 6 WA250PZ 6 Machine model Serial number WA250 6 75001 and up WA250PZ 6 75001 and up 90 Diagrams and drawings 90 100 Hydraulic diagrams and drawings Hydraulic circuit diagram 3 ...

Page 1275: ...SEN03860 01 90 100 2 WA250 250PZ 6 100 Hydraulic diagrams and drawings ...

Page 1276: ...EN03860 01 90 100 3 Hydraulic circuit diagram WA250 6 WA250 250PZ 6 Hydraulic circuit diagram 1 WA250 6 a This figure covers the equipment and devices that are unavailable as optional items in some areas ...

Page 1277: ...03860 01 90 100 5 Hydraulic circuit diagram WA250PZ 6 WA250 250PZ 6 Hydraulic circuit diagram 1 WA250PZ 6 a This figure covers the equipment and devices that are unavailable as optional items in some areas ...

Page 1278: ...SEN03860 01 WA250 250PZ 6 90 100 7 100 Hydraulic diagrams and drawings ...

Page 1280: ... 01 WHEEL LOADER WA250 6 WA250PZ 6 Machine model Serial number WA250 6 75001 and up WA250PZ 6 75001 and up 90 Diagrams and drawings 90 200 Electrical diagrams and drawings Electrical circuit diagram 3 Connector list and stereogram 21 ...

Page 1281: ...SEN03861 01 90 200 2 WA250 250PZ 6 200 Electrical diagrams and drawings ...

Page 1282: ...3 Electrical circuit diagram 1 9 WA250 250PZ 6 WA250 250PZ 6 Electrical circuit diagram 1 9 Electrical circuit diagram 1 a This figure covers the equipment and devices that are unavailable as optional items in some areas ...

Page 1283: ...3861 01 90 200 5 Electrical circuit diagram 2 9 WA250 250PZ 6 WA250 250PZ 6 Electrical circuit diagram 2 9 a This figure covers the equipment and devices that are unavailable as optional items in some areas ...

Page 1284: ...3861 01 90 200 7 Electrical circuit diagram 3 9 WA250 250PZ 6 WA250 250PZ 6 Electrical circuit diagram 3 9 a This figure covers the equipment and devices that are unavailable as optional items in some areas ...

Page 1285: ...3861 01 90 200 9 Electrical circuit diagram 4 9 WA250 250PZ 6 WA250 250PZ 6 Electrical circuit diagram 4 9 a This figure covers the equipment and devices that are unavailable as optional items in some areas ...

Page 1286: ...861 01 90 200 11 Electrical circuit diagram 5 9 WA250 250PZ 6 WA250 250PZ 6 Electrical circuit diagram 5 9 a This figure covers the equipment and devices that are unavailable as optional items in some areas ...

Page 1287: ...861 01 90 200 13 Electrical circuit diagram 6 9 WA250 250PZ 6 WA250 250PZ 6 Electrical circuit diagram 6 9 a This figure covers the equipment and devices that are unavailable as optional items in some areas ...

Page 1288: ...861 01 90 200 15 Electrical circuit diagram 7 9 WA250 250PZ 6 WA250 250PZ 6 Electrical circuit diagram 7 9 a This figure covers the equipment and devices that are unavailable as optional items in some areas ...

Page 1289: ...861 01 90 200 17 Electrical circuit diagram 8 9 WA250 250PZ 6 WA250 250PZ 6 Electrical circuit diagram 8 9 a This figure covers the equipment and devices that are unavailable as optional items in some areas ...

Page 1290: ...861 01 90 200 19 Electrical circuit diagram 9 9 WA250 250PZ 6 WA250 250PZ 6 Electrical circuit diagram 9 9 a This figure covers the equipment and devices that are unavailable as optional items in some areas ...

Page 1291: ...witch R 9 L03 DT T 4 Speed range selector switch R 8 L04 SWP 8 Combination lamp switch T 1 L05 S 10 Wiper switch front rear S 1 L06 SWP 6 Hazard switch R 6 L07 SWP 6 Front work lamp switch Q 5 L08 SWP 6 Rear work lamp switch R 6 L09 SWP 6 ECSS switch T 1 L10 SWP 6 Monitor 1 switch U 1 L11 SWP 6 Monitor 2 switch T 1 L13 DT T 2 Horn switch T 1 L15 DT T 4 FNR switch S 2 L16 SWP 6 Loadmeter A B If equ...

Page 1292: ...SEN03861 01 WA250 250PZ 6 90 200 23 200 Electrical diagrams and drawings ...

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