Komatsu WA250-6, WA250PZ-6 Wheel Loader Service Repair Manual - 75001 and up
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WHEEL LOADER
SEN03979-03
WA250
-6
WA250PZ
-6
SERIAL NUMBERS
WA250- 75001
WA250PZ- 75001
and up
WA250, 250PZ-6 00-100 1
SEN03988-03
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
SEN03988-03
00-100 2 WA250, 250PZ-6
Composition of shop manual
100 Index
Composition of shop manual 1
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs ..................................................................... SEN03979-03
00 Index and foreword .................................................................................................................... SEN03980-03
100 Index .................................................................................................................................. SEN03988-03 q
200 Foreword and general information ..................................................................................... SEN03989-01
01 Specification ............................................................................................................................... SEN03981-01
100 Specification and technical data......................................................................................... SEN03990-01
10 Structure, function and maintenance standard........................................................................... SEN03982-02
100 Engine and cooling system ................................................................................................ SEN03991-01
200 Power train ......................................................................................................................... SEN03992-01
300 Steering system ................................................................................................................. SEN03993-00
400 Brake system ..................................................................................................................... SEN03994-00
500 Undercarriage and frame ................................................................................................... SEN03995-00
600 Hydraulic system................................................................................................................ SEN03996-00
700 Work equipment ................................................................................................................. SEN03997-01
800 Cab and its attachments .................................................................................................... SEN03998-00
910 Electrical system, Part 1 .................................................................................................... SEN03999-00
920 Electrical system, Part 2 .................................................................................................... SEN04000-02
20 Standard value table................................................................................................................... SEN03983-01
100 Standard service value table .............................................................................................. SEN04001-01
30 Testing and adjusting ................................................................................................................. SEN03984-02
110 Testing and adjusting, Part 1.............................................................................................. SEN04002-01
120 Testing and adjusting, Part 2.............................................................................................. SEN04003-02 q
130 Testing and adjusting, Part 3.............................................................................................. SEN04004-01
SEN03988-03
WA250, 250PZ-6 00-100 3
Composition of shop manual
100 Index
40 Troubleshooting ..........................................................................................................................SEN03985-02
100 Failure code table and fuse locations .................................................................................SEN04005-02
200 General information on troubleshooting .............................................................................SEN04006-01
310 Troubleshooting by failure code (Display of code), Part 1 .................................................. SEN04007-01
320 Troubleshooting by failure code (Display of code), Part 2 .................................................. SEN04008-01
330 Troubleshooting by failure code (Display of code), Part 3 .................................................. SEN04009-02
340 Troubleshooting by failure code (Display of code), Part 4 .................................................. SEN04010-01
350 Troubleshooting by failure code (Display of code), Part 5 .................................................. SEN04011-01
360 Troubleshooting by failure code (Display of code), Part 6 .................................................. SEN04012-01
370 Troubleshooting by failure code (Display of code), Part 7 .................................................. SEN04013-00
400 Troubleshooting of electrical system (E-mode) ..................................................................SEN04014-01
500 Troubleshooting of hydraulic and mechanical system (H-mode)........................................SEN04015-01
600 Troubleshooting of engine (S-mode) ..................................................................................SEN04016-01
50 Disassembly and assembly ........................................................................................................ SEN03986-02
100 General information on disassembly and assembly ........................................................... SEN04017-01
200 Engine and cooling system ................................................................................................ SEN04018-02
310 Power train, Part 1..............................................................................................................SEN04019-00
320 Power train, Part 2..............................................................................................................SEN04020-00
400 Undercarriage and frame ................................................................................................... SEN04021-00
500 Hydraulic system ................................................................................................................SEN04022-01
600 Work equipment .................................................................................................................SEN04023-00
700 Cab and its attachments .....................................................................................................SEN04024-00
800 Electrical system ................................................................................................................SEN04025-00
90 Diagrams and drawings ..............................................................................................................SEN03987-01
100 Hydraulic diagrams and drawings ...................................................................................... SEN04026-01
200 Electrical diagrams and drawings....................................................................................... SEN04027-01
SEN03988-03
00-100 4 WA250, 250PZ-6
Table of contents
100 Index
Table of contents 1
00 Index and foreword
100 Index SEN03988-03
Composition of shop manual ......................................................................................................................... 2
Table of contents ........................................................................................................................................... 4
200 Foreword and general information SEN03989-01
Safety notice ................................................................................................................................................. 2
How to read the shop manual ....................................................................................................................... 7
Explanation of terms for maintenance standard............................................................................................ 9
Handling of electric equipment and hydraulic component ............................................................................. 11
Handling of connectors newly used for engines............................................................................................ 20
How to read electric wire code ...................................................................................................................... 23
Precautions when carrying out operation ...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler ................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
01 Specification
100 Specification and technical data SEN03990-01
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 SEN03991-01
Engine mount and transfer mount ................................................................................................................. 2
Damper ......................................................................................................................................................... 3
Cooling system.............................................................................................................................................. 4
Cooling system hydraulic piping diagram...................................................................................................... 5
Cooling fan motor .......................................................................................................................................... 7
200 Power train SEN03992-01
Power train .................................................................................................................................................... 3
Power train system diagram.......................................................................................................................... 4
Drive shaft ..................................................................................................................................................... 6
HST hydraulic piping diagram ....................................................................................................................... 7
HST pump ..................................................................................................................................................... 8
HST motor ..................................................................................................................................................... 16
Transfer ......................................................................................................................................................... 22
Clutch solenoid valve .................................................................................................................................... 33
Axle ............................................................................................................................................................... 34
Differential ..................................................................................................................................................... 36
Torque proportioning differential .................................................................................................................... 41
Limited slip differential ................................................................................................................................... 44
Final drive...................................................................................................................................................... 48
300 Steering system SEN03993-00
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
SEN03988-03
WA250, 250PZ-6 00-100 5
Table of contents
100 Index
400 Brake system SEN03994-00
Brake piping diagram..................................................................................................................................... 3
Charge valve ................................................................................................................................................. 4
Brake valve .................................................................................................................................................... 8
Inching valve.................................................................................................................................................. 12
Accumulator (for brake) ................................................................................................................................. 13
Slack adjuster ................................................................................................................................................ 14
Brake ............................................................................................................................................................. 16
Parking brake control ..................................................................................................................................... 21
Parking brake ................................................................................................................................................ 22
500 Undercarriage and frame SEN03995-00
Axle mount and center hinge pin ................................................................................................................... 2
Tires ............................................................................................................................................................... 7
600 Hydraulic system SEN03996-00
Work equipment hydraulic piping diagram .................................................................................................... 2
Work equipment control lever linkage ........................................................................................................... 6
Hydraulic tank ................................................................................................................................................ 12
4-gear pump .................................................................................................................................................. 14
Work equipment control valve ....................................................................................................................... 16
PPC valve ...................................................................................................................................................... 41
Lock valve...................................................................................................................................................... 56
Accumulator (for PPC circuit) ........................................................................................................................ 57
Bypass valve ................................................................................................................................................. 58
Quick coupler solenoid valve ......................................................................................................................... 61
ECSS valve ................................................................................................................................................... 62
Accumulator (for ECSS) ................................................................................................................................ 64
700 Work equipment SEN03997-01
Work equipment linkage ................................................................................................................................ 2
Bucket............................................................................................................................................................ 6
Bucket positioner and boom kick-out ............................................................................................................. 10
Work equipment cylinder ............................................................................................................................... 22
800 Cab and its attachments SEN03998-00
Cab ................................................................................................................................................................ 3
Air conditioner................................................................................................................................................ 4
910 Electrical system, Part 1 SEN03999-00
Machine monitor system................................................................................................................................ 2
Machine monitor ............................................................................................................................................ 6
920 Electrical system, Part 2 SEN04000-02
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
Max. traction switch ....................................................................................................................................... 33
Multi-function knob ........................................................................................................................................ 34
Sensor ........................................................................................................................................................... 35
20 Standard value table
100 Standard service value table SEN04001-01
Standard service value table for engine ........................................................................................................ 2
Standard service value table for chassis ....................................................................................................... 3
SEN03988-03
00-100 6 WA250, 250PZ-6
Table of contents
100 Index
30 Testing and adjusting
110 Testing and adjusting, Part 1 SEN04002-01
Tools for testing, adjusting, and troubleshooting ........................................................................................... 2
Measuring engine speed ............................................................................................................................... 7
Measuring exhaust gas color ........................................................................................................................ 9
Adjusting valve clearance ............................................................................................................................. 11
Measuring compression pressure ................................................................................................................. 13
Measuring blow-by pressure ......................................................................................................................... 16
Measuring engine oil pressure ...................................................................................................................... 17
Measuring intake air (boost) pressure........................................................................................................... 18
Handling fuel system equipment ................................................................................................................... 20
Releasing residual pressure in fuel system................................................................................................... 20
Measuring fuel pressure................................................................................................................................ 21
Measuring fuel return rate and leakage ........................................................................................................ 23
Bleeding air from fuel circuit .......................................................................................................................... 27
Checking leakage in fuel system................................................................................................................... 28
Handling cylinder cut-out mode operation..................................................................................................... 29
Handling no-injection cranking operation ...................................................................................................... 29
Handling controller voltage circuit ................................................................................................................. 30
Check of muffler and muffler stack for looseness and damage .................................................................... 30
Check of muffler function .............................................................................................................................. 31
Check of installed condition of cylinder head and manifolds......................................................................... 31
Check of engine piping for damage and looseness ...................................................................................... 32
Testing and adjusting air conditioner compressor belt tension...................................................................... 32
Replacing alternator belt ............................................................................................................................... 33
120 Testing and adjusting, Part 2 SEN04003-02
Checking operating force of accelerator pedal .............................................................................................. 3
Checking directional lever ............................................................................................................................. 4
Testing and adjusting HST oil pressure......................................................................................................... 5
Testing clutch control pressure...................................................................................................................... 9
Testing and adjusting steering wheel ............................................................................................................ 10
Testing and adjusting steering oil pressure ................................................................................................... 12
Bleeding air from steering circuit ................................................................................................................... 14
Testing hydraulic fan ..................................................................................................................................... 15
Measuring brake pedal .................................................................................................................................. 17
Testing and adjusting brake pedal linkage .................................................................................................... 18
Measuring brake performance ...................................................................................................................... 19
Testing and adjusting accumulator charge pressure ..................................................................................... 20
Testing wheel brake oil pressure ................................................................................................................... 22
Testing wear of brake disc............................................................................................................................. 25
Bleeding air from wheel brake circuit ............................................................................................................ 26
Releasing residual pressure in brake accumulator circuit ............................................................................. 27
Testing parking brake performance ............................................................................................................... 28
Testing and adjusting parking brake control cable ........................................................................................ 29
Measuring and adjusting work equipment control lever ................................................................................ 30
Testing and adjusting work equipment hydraulic pressure............................................................................ 31
Testing work equipment PPC oil pressure .................................................................................................... 32
Bleeding air from hydraulic circuit ................................................................................................................. 34
Releasing remaining pressure in hydraulic circuit ......................................................................................... 35
Testing and adjusting bucket positioner ........................................................................................................ 36
Testing and adjusting of boom kick-out switch .............................................................................................. 37
Checking proximity switch operation pilot lamp ............................................................................................ 38
Procedure for testing diodes ......................................................................................................................... 39
Preparation work for troubleshooting for electric system .............................................................................. 41
Starting KOMTRAX terminal operations........................................................................................................ 45
Indicator lamps of KOMTRAX terminal ......................................................................................................... 49
SEN03988-03
WA250, 250PZ-6 00-100 7
Table of contents
100 Index
130 Testing and adjusting, Part 3 SEN04004-01
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 .............................................................................................................................. 58
40 Troubleshooting
100 Failure code table and fuse locations SEN04005-02
Failure codes table ........................................................................................................................................ 2
Fuse locations ............................................................................................................................................... 8
200 General information on troubleshooting SEN04006-01
Points to remember when troubleshooting .................................................................................................... 2
Sequence of events in troubleshooting ......................................................................................................... 3
Testing before troubleshooting ...................................................................................................................... 4
Classification and procedures of troubleshooting .......................................................................................... 5
Information contained in troubleshooting table .............................................................................................. 8
Connection table for connector pin numbers ................................................................................................. 10
T- branch box and T- branch adapter table ................................................................................................... 46
310 Troubleshooting by failure code (Display of code), Part 1 SEN04007-01
Failure code [2G40ZG] Brake: Oil pressure reduction .................................................................................. 2
Failure code [6091NX] HST filter: Clogging................................................................................................... 4
Failure code [989FN1] Travel speed: Overrun alarm .................................................................................... 5
Failure code [AB00L6] Alternator R system: Hot short .................................................................................. 6
Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/Low charge voltage ................... 8
Failure code [B@BAZG] Engine: Oil pressure reduction............................................................................... 10
Failure code [B@BCNS] Engine: Overheat ................................................................................................... 11
Failure code [B@BCZK] Engine: Low coolant level ...................................................................................... 12
Failure code [B@C6NS] Front brake: High oil temperature .......................................................................... 14
Failure code [B@CRNS] HST: High oil temperature ..................................................................................... 15
320 Troubleshooting by failure code (Display of code), Part 2 SEN04008-01
Failure code [CA111] Abnormality in engine controller .................................................................................. 3
Failure code [CA115] Engine Ne or Bkup speed sensor error ....................................................................... 4
Failure code [CA122] Charge pressure sensor high error ............................................................................. 6
Failure code [CA123] Charge pressure sensor low error .............................................................................. 8
Failure code [CA131] Throttle sensor high error ........................................................................................... 10
Failure code [CA132] Throttle sensor low error ............................................................................................. 12
Failure code [CA144] Coolant sensor high error ........................................................................................... 14
Failure code [CA145] Coolant sensor low error............................................................................................. 16
Failure code [CA153] Charge temperature sensor high error ....................................................................... 18
Failure code [CA154] Charge temperature sensor low error ......................................................................... 20
Failure code [CA155] Derating of speed by abnormally high charge temperature ........................................ 22
Failure code [CA187] Sensor power supply 2 low error ................................................................................ 24
Failure code [CA221] Atmospheric pressure sensor high error..................................................................... 26
Failure code [CA222] Atmospheric sensor low error ..................................................................................... 28
Failure code [CA227] Sensor power supply 2 high error ............................................................................... 30
Failure code [CA234] Engine overspeed ....................................................................................................... 31
Failure code [CA238] Ne speed sensor power supply error .......................................................................... 32
Failure code [CA271] IMV (IMA) Short circuit ................................................................................................ 33
Failure code [CA272] IMV (IMA) Disconnection ............................................................................................ 34
Failure code [CA322] Injector #1 open/short error ........................................................................................ 36
Failure code [CA323] Injector #5 open/short error ........................................................................................ 38
Failure code [CA324] Injector #3 open/short error ........................................................................................ 40
Failure code [CA325] Injector #6 open/short error ........................................................................................ 42
Failure code [CA331] Injector #2 open/short error ........................................................................................ 44
Failure code [CA332] Injector #4 open/short error ........................................................................................ 46
Failure code [CA342] Calibration code inconsistency ................................................................................... 48
Failure code [CA351] Injectors drive circuit error .......................................................................................... 50
SEN03988-03
00-100 8 WA250, 250PZ-6
Table of contents
100 Index
Failure code [CA352] Sensor power supply 1 low error ................................................................................ 52
Failure code [CA386] Sensor power supply 1 high error .............................................................................. 54
330 Troubleshooting by failure code (Display of code), Part 3 SEN04009-02
Failure code [CA428] Abnormally high level in water sensor ........................................................................ 4
Failure code [CA429] Abnormally low level in water sensor ......................................................................... 6
Failure code [CA431] Idle validation switch error .......................................................................................... 8
Failure code [CA432] Idle validation action error .......................................................................................... 12
Failure code [CA435] Engine oil pressure switch error ................................................................................. 16
Failure code [CA441] Battery voltage low error ............................................................................................ 17
Failure code [CA442] Battery voltage high error ........................................................................................... 20
Failure code [CA449] Common rail pressure high error 2............................................................................. 22
Failure code [CA451] Common rail pressure sensor high error .................................................................... 24
Failure code [CA452] Common rail pressure sensor low error ..................................................................... 26
Failure code [CA488] Derating of torque by abnormally high charge temperature ....................................... 28
Failure code [CA553] Common rail pressure high error 1............................................................................. 29
Failure code [CA559] Supply pump pressure very low error......................................................................... 30
Failure code [CA689] Engine Ne speed sensor error ................................................................................... 32
Failure code [CA731] Engine Bkup speed sensor phase error ..................................................................... 34
Failure code [CA757] All continuous data lost error ...................................................................................... 35
Failure code [CA778] Engine Bkup speed sensor error ................................................................................ 38
Failure code [CA1633] KOMNET datalink timeout error ............................................................................... 40
Failure code [CA2185] Throttle sensor supply voltage high error ................................................................. 44
Failure code [CA2186] Throttle sensor power supply low error .................................................................... 46
Failure code [CA2249] Supply pump pressure very low error 2.................................................................... 48
Failure code [CA2311] Abnormality in IMV (IMA) solenoid ........................................................................... 50
Failure code [CA2555] Intake heater relay disconnection error .................................................................... 52
Failure code [CA2556] Intake heater relay short circuit error ........................................................................ 54
340 Troubleshooting by failure code (Display of code), Part 4 SEN04010-01
Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short ........................................................... 2
Failure code [D192KY] ECSS solenoid relay: Hot short ............................................................................... 4
Failure code [D1B0KA] HST safety relay: Disconnection ............................................................................. 6
Failure code [D1B0KB] HST safety relay: Ground fault ................................................................................ 8
Failure code [D1B0KY] HST safety relay: Hot short ..................................................................................... 10
Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection ............................................................. 12
Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection .................................................. 14
Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection ................................................ 16
Failure code [DAJ0KK] HST controller power supply: Low voltage .............................................................. 20
Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality .................................................... 22
Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault ................................... 24
Failure code [DAJ1L6] HST controller main power line: Hot short ................................................................ 26
Failure code [DAJ2KK] Controller solenoid power supply: Low voltage ....................................................... 28
Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness ............. 30
Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault ............ 32
Failure code [DAJ5KX] Sensor 5V power supply: Out of output range ......................................................... 34
Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals ............. 36
Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection ..................................................... 37
Failure code [DAJRMA] HST controller: Disagreement in option selection .................................................. 43
350 Troubleshooting by failure code (Display of code), Part 5 SEN04011-01
Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line ....................................... 2
Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality .................................................. 8
Failure code [DD1NLD] Fan reverse switch signal: Abnormality .................................................................. 10
Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short ........................................ 12
Failure code [DDB6KB] Parking brake indicator signal: Ground fault ........................................................... 14
Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch
(intermediate switch): Trouble ................................................................................................................. 16
Failure code [DDB6L0] Parking brake reminder signal: Ground fault ........................................................... 18
Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short ......................................... 20
Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault ................................. 22
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This Service Repair Manual is the ultimate guide for maintaining and repairing the Komatsu WA250-6, WA250PZ-6 Wheel Loader. It features high-quality diagrams and detailed instructions covering everything from the front bumper to the rear. Whether you're a professional mechanic or a DIY enthusiast, this manual is indispensable.
- File Format: PDF
- Compatibility: All Versions of Windows & Mac
- Language: English
- Requirements: Adobe Reader & Win
The manual covers the following models:
- WA250-6 Serial Number 75001 and up
- WA250PZ-6 Serial Number 75001 and up
Key contents of this Service Repair Manual include:
- Index and Foreword
- Specification
- Structure and Function
- Standard Value Table
- Testing and Adjusting
- Troubleshooting
- Disassembly and Assembly
- Maintenance Standard
- Diagrams and Drawings
All pages are printable, allowing you to have the necessary information at hand in your garage or workshop. By following the step-by-step instructions, you can save money by performing your own repairs. With instant access, there are no shipping costs or waiting for a CD to arrive. Upon secure payment processing, you will receive this manual instantly. We accept all major credit/debit cards and PayPal.
For more information, visit: Komatsu WA250-6 WA250PZ-6 Wheel Loader
