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SEN03979-00
WHEEL LOADER -6 WA250 WA250PZ -6 SERIAL NUMBERS
WA250- 75001 WA250PZ-75001
and up
SEN03988-00
WHEEL LOADER WA250-6 WA250PZ-6 Machine model
Serial number
WA250-6 WA250PZ-6
75001 and up 75001 and up
00 Index and foreword
00
100 Index Composition of shop manual .......................................................................................................................... 2 Table of contents ............................................................................................................................................. 4
WA250, 250PZ-6
00-100
1
SEN03988-00
100 Index Composition of shop manual
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 accordingly. Section Title
Form Number
Shop Manual, contents binder, binder label and tabs
SEN03979-00
00 Index and foreword 100 Index 200 Foreword and general information
SEN03980-00 SEN03988-00 SEN03989-00
01 Specification 100 Specification and technical data
SEN03981-00 SEN03990-00
10 Structure, function and maintenance standard 100 Engine and cooling system 200 Power train 300 Steering system 400 Brake system 500 Undercarriage and frame 600 Hydraulic system 700 Work equipment 800 Cab and its attachments 910 Electrical system, Part 1 920 Electrical system, Part 2
SEN03982-00 SEN03991-00 SEN03992-00 SEN03993-00 SEN03994-00 SEN03995-00 SEN03996-00 SEN03997-00 SEN03998-00 SEN03999-00 SEN04000-00
20 Standard value table 100 Standard service value table
SEN03983-00 SEN04001-00
30 Testing and adjusting 110 Testing and adjusting, Part 1 120 Testing and adjusting, Part 2 130 Testing and adjusting, Part 3
SEN03984-00 SEN04002-00 SEN04003-00 SEN04004-00
00-100
2
WA250, 250PZ-6
100 Index Composition of shop manual
SEN03988-00
40 Troubleshooting 100 Failure code table and fuse locations 200 General information on troubleshooting 310 Troubleshooting by failure code (Display of code), Part 1 320 Troubleshooting by failure code (Display of code), Part 2 330 Troubleshooting by failure code (Display of code), Part 3 340 Troubleshooting by failure code (Display of code), Part 4 350 Troubleshooting by failure code (Display of code), Part 5 360 Troubleshooting by failure code (Display of code), Part 6 370 Troubleshooting by failure code (Display of code), Part 7 400 Troubleshooting of electrical system (E-mode) 500 Troubleshooting of hydraulic and mechanical system (H-mode) 600 Troubleshooting of engine (S-mode)
SEN03985-00 SEN04005-00 SEN04006-00 SEN04007-00 SEN04008-00 SEN04009-00 SEN04010-00 SEN04011-00 SEN04012-00 SEN04013-00 SEN04014-00 SEN04015-00 SEN04016-00
50 Disassembly and assembly 100 General information on disassembly and assembly 200 Engine and cooling system 310 Power train, Part 1 320 Power train, Part 2 400 Undercarriage and frame 500 Hydraulic system 600 Work equipment 700 Cab and its attachments 800 Electrical system
SEN03986-00 SEN04017-00 SEN04018-00 SEN04019-00 SEN04020-00 SEN04021-00 SEN04022-00 SEN04023-00 SEN04024-00 SEN04025-00
90 Diagrams and drawings 100 Hydraulic diagrams and drawings 200 Electrical diagrams and drawings
SEN03987-00 SEN04026-00 SEN04027-00
WA250, 250PZ-6
00-100
3
SEN03988-00
Table of contents
100 Index Table of contents
1
00 Index and foreword 100 Index SEN03988-00 Composition of shop manual......................................................................................................................... 2 Table of contents ........................................................................................................................................... 4 200 Foreword and general information SEN03989-00 Safety notice ................................................................................................................................................. 2 How to read the shop manual ....................................................................................................................... 7 Explanation of terms for maintenance standard............................................................................................ 9 Handling of electric equipment and hydraulic component............................................................................. 11 Handling of connectors newly used for engines............................................................................................ 20 How to read electric wire code ...................................................................................................................... 23 Precautions when carrying out operation...................................................................................................... 26 Method of disassembling and connecting push-pull type coupler................................................................. 29 Standard tightening torque table ................................................................................................................... 32 Conversion table ........................................................................................................................................... 36 01 Specification 100 Specification and technical data SEN03990-00 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 SEN03991-00 Engine mount and transfer mount................................................................................................................. 2 Damper ......................................................................................................................................................... 3 Cooling system.............................................................................................................................................. 4 Cooling system hydraulic piping diagram...................................................................................................... 5 Cooling fan motor.......................................................................................................................................... 7 200 Power train SEN03992-00 Power train .................................................................................................................................................... 3 Power train system diagram.......................................................................................................................... 4 Drive shaft ..................................................................................................................................................... 6 HST hydraulic piping diagram ....................................................................................................................... 7 HST pump ..................................................................................................................................................... 8 HST motor..................................................................................................................................................... 16 Transfer......................................................................................................................................................... 22 Clutch solenoid valve .................................................................................................................................... 33 Axle ............................................................................................................................................................... 34 Differential ..................................................................................................................................................... 36 Torque proportioning differential.................................................................................................................... 41 Limited slip differential................................................................................................................................... 44 Final drive...................................................................................................................................................... 48 300 Steering system 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 00-100
4
WA250, 250PZ-6
100 Index Table of contents
SEN03988-00
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 SEN03997-00 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 SEN04000-00 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 SEN04001-00 Standard service value table for engine ........................................................................................................ 2 Standard service value table for chassis ....................................................................................................... 3 WA250, 250PZ-6
00-100
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SEN03988-00
100 Index Table of contents
30 Testing and adjusting 110 Testing and adjusting, Part 1 SEN04002-00 Tools for testing, adjusting, and troubleshooting ........................................................................................... 2 Measuring engine speed............................................................................................................................... 7 Measuring exhaust gas color ........................................................................................................................ 9 Adjusting valve clearance ............................................................................................................................. 11 Measuring compression pressure ................................................................................................................. 13 Measuring blow-by pressure ......................................................................................................................... 16 Measuring engine oil pressure ...................................................................................................................... 17 Measuring intake air (boost) pressure........................................................................................................... 18 Handling fuel system equipment ................................................................................................................... 20 Releasing residual pressure in fuel system................................................................................................... 20 Measuring fuel pressure................................................................................................................................ 21 Measuring fuel return rate and leakage ........................................................................................................ 23 Bleeding air from fuel circuit.......................................................................................................................... 27 Testing leakage in fuel system ...................................................................................................................... 28 Handling reduced cylinder mode operation................................................................................................... 29 Handling no-injection cranking operation ...................................................................................................... 29 Handling controller voltage circuit ................................................................................................................. 30 Check of muffler and muffler stack for looseness and damage .................................................................... 30 Check of muffler function .............................................................................................................................. 31 Check of installed condition of cylinder head and manifolds......................................................................... 31 Check of engine piping for damage and looseness ...................................................................................... 32 Testing and adjusting air conditioner compressor belt tension...................................................................... 32 Replacing alternator belt ............................................................................................................................... 33 120 Testing and adjusting, Part 2 SEN04003-00 Checking operating force of accelerator pedal.............................................................................................. 3 Checking directional lever ............................................................................................................................. 4 Testing and adjusting HST oil pressure......................................................................................................... 5 Testing clutch control pressure...................................................................................................................... 9 Testing and adjusting steering wheel ............................................................................................................ 10 Testing and adjusting steering oil pressure ................................................................................................... 12 Bleeding air from steering circuit................................................................................................................... 14 Testing hydraulic fan ..................................................................................................................................... 15 Measuring brake pedal.................................................................................................................................. 17 Testing and adjusting brake pedal linkage .................................................................................................... 18 Measuring brake performance ...................................................................................................................... 19 Testing and adjusting accumulator charge pressure..................................................................................... 20 Testing wheel brake oil pressure................................................................................................................... 22 Testing wear of brake disc............................................................................................................................. 25 Bleeding air from wheel brake circuit ............................................................................................................ 26 Releasing residual pressure in brake accumulator circuit............................................................................. 27 Testing parking brake performance............................................................................................................... 28 Testing and adjusting parking brake control cable ........................................................................................ 29 Measuring and adjusting work equipment control lever ................................................................................ 30 Testing and adjusting work equipment hydraulic pressure............................................................................ 31 Testing work equipment PPC oil pressure .................................................................................................... 32 Bleeding air from hydraulic circuit ................................................................................................................. 34 Releasing remaining pressure in hydraulic circuit......................................................................................... 35 Testing and adjusting bucket positioner ........................................................................................................ 36 Testing and adjusting of boom kick-out switch .............................................................................................. 37 Checking proximity switch operation pilot lamp ............................................................................................ 38 Procedure for testing diodes ......................................................................................................................... 39 Preparation work for troubleshooting for electric system .............................................................................. 41 Starting KOMTRAX terminal operations........................................................................................................ 45 Indicator lamps of KOMTRAX terminal ......................................................................................................... 49
00-100
6
WA250, 250PZ-6
100 Index Table of contents
SEN03988-00
130 Testing and adjusting, Part 3 SEN04004-00 Adjusting machine monitor ............................................................................................................................ 2 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ............................ 3 Special functions of machine monitor (EMMS).............................................................................................. 5 Pm clinic inspection chart .............................................................................................................................. 58 40 Troubleshooting 100 Failure code table and fuse locations SEN04005-00 Failure codes table ........................................................................................................................................ 2 Fuse locations ............................................................................................................................................... 8 200 General information on troubleshooting SEN04006-00 Points to remember when troubleshooting .................................................................................................... 2 Sequence of events in troubleshooting ......................................................................................................... 3 Testing before troubleshooting ...................................................................................................................... 4 Classification and procedures of troubleshooting.......................................................................................... 5 Information contained in troubleshooting table.............................................................................................. 8 Connection table for connector pin numbers................................................................................................. 10 T- branch box and T- branch adapter table ................................................................................................... 45 310 Troubleshooting by failure code (Display of code), Part 1 SEN04007-00 Failure code [2G40GZ] 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 charge/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 SEN04008-00 Failure code [CA111] Abnormality in engine controller .................................................................................. 3 Failure code [CA115] Engine Ne or Bkup speed sensor error....................................................................... 4 Failure code [CA122] Charge pressure sensor high error............................................................................. 6 Failure code [CA123] Charge pressure sensor low error .............................................................................. 8 Failure code [CA131] Throttle sensor high error ........................................................................................... 10 Failure code [CA132] Throttle sensor low error............................................................................................. 12 Failure code [CA144] Coolant sensor high error ........................................................................................... 14 Failure code [CA145] Coolant sensor low error............................................................................................. 16 Failure code [CA153] Charge temperature sensor high error ....................................................................... 18 Failure code [CA154] Charge temperature sensor low error......................................................................... 20 Failure code [CA155] Derating of speed by abnormally high charge temperature........................................ 22 Failure code [CA187] Sensor power supply 2 low error ................................................................................ 24 Failure code [CA221] Atmospheric pressure sensor high error..................................................................... 26 Failure code [CA222] Atmospheric sensor low error ..................................................................................... 28 Failure code [CA227] Sensor power supply 2 high error............................................................................... 30 Failure code [CA234] Engine overspeed....................................................................................................... 31 Failure code [CA238] Ne speed sensor power supply error.......................................................................... 32 Failure code [CA271] IMV (IMA) Short circuit................................................................................................ 33 Failure code [CA272] IMV (IMA) Disconnection ............................................................................................ 34 Failure code [CA322] Injector #1 open/short error ........................................................................................ 36 Failure code [CA323] Injector #5 open/short error ........................................................................................ 38 Failure code [CA324] Injector #3 open/short error ........................................................................................ 40 Failure code [CA325] Injector #6 open/short error ........................................................................................ 42 Failure code [CA331] Injector #2 open/short error ........................................................................................ 44 Failure code [CA332] Injector #4 open/short error ........................................................................................ 46 Failure code [CA342] Calibration code inconsistency ................................................................................... 48 Failure code [CA351] Injectors drive circuit error .......................................................................................... 50 WA250, 250PZ-6
00-100
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SEN03988-00
100 Index Table of contents
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 SEN04009-00 Failure code [CA428] Abnormally high level in water sensor........................................................................ 4 Failure code [CA429] Abnormally low level in water sensor ......................................................................... 6 Failure code [CA431] Idle validation switch error.......................................................................................... 8 Failure code [CA432] Idle validation action error .......................................................................................... 12 Failure code [CA435] Engine oil pressure switch error ................................................................................. 16 Failure code [CA441] Battery voltage low error ............................................................................................ 17 Failure code [CA442] Battery voltage high error ........................................................................................... 20 Failure code [CA449] Common rail pressure high error 2............................................................................. 22 Failure code [CA451] Common rail pressure sensor high error.................................................................... 24 Failure code [CA452] Common rail pressure sensor low error ..................................................................... 26 Failure code [CA488] Derating of torque by abnormally high charge temperature ....................................... 28 Failure code [CA553] Common rail pressure high error 1............................................................................. 29 Failure code [CA559] Supply pump pressure very low error......................................................................... 30 Failure code [CA689] Engine Ne speed sensor error ................................................................................... 32 Failure code [CA731] Engine Bkup speed sensor phase error ..................................................................... 34 Failure code [CA757] All continuous data lost error...................................................................................... 35 Failure code [CA778] Engine Bkup speed sensor error................................................................................ 38 Failure code [CA1633] KOMNET datalink timeout error ............................................................................... 40 Failure code [CA2185] Throttle sensor supply voltage high error ................................................................. 44 Failure code [CA2186] Throttle sensor power supply low error .................................................................... 46 Failure code [CA2249] Supply pump pressure very low error 2.................................................................... 48 Failure code [CA2311] Abnormality in IMV (IMA) solenoid ........................................................................... 50 Failure code [CA2555] Intake heater relay disconnection error .................................................................... 52 Failure code [CA2556] Intake heater relay short circuit error........................................................................ 54 340 Troubleshooting by failure code (Display of code), Part 4 SEN04010-00 Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short ........................................................... 2 Failure code [D192KY] ECSS solenoid relay: Hot short ............................................................................... 4 Failure code [D1B0KA] HST safety relay: Disconnection ............................................................................. 6 Failure code [D1B0KB] HST safety relay: Ground fault ................................................................................ 8 Failure code [D1B0KY] HST safety relay: Hot short ..................................................................................... 10 Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection ............................................................. 12 Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection.................................................. 14 Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection ................................................ 16 Failure code [DAJ0KK] HST controller power supply: Low voltage .............................................................. 20 Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality .................................................... 22 Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault ................................... 24 Failure code [DAJ1L6] HST controller main power line: Hot short................................................................ 26 Failure code [DAJ2KK] Controller solenoid power supply: Low voltage ....................................................... 28 Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness............. 30 Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault ............ 32 Failure code [DAJ5KX] Sensor 5V power supply: Out of output range......................................................... 34 Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals............. 36 Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection ..................................................... 37 Failure code [DAJRMA] HST controller: Disagreement in option selection .................................................. 43 350 Troubleshooting by failure code (Display of code), Part 5 SEN04011-00 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 switch A: Disconnection/Hot short ................................................... 12 Failure code [DDB6KB] Parking brake switch B: Ground fault...................................................................... 14 Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble................................................................................................................. 16 Failure code [DDB6L0] Parking brake switch A: Ground fault ...................................................................... 18 Failure code [DDB6L4] Parking brake switch B: Disconnection/Hot short .................................................... 20 Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault ................................. 22 00-100
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100 Index Table of contents
SEN03988-00
Failure code [DDD7KY] Travel speed control dial signal: Hot short .............................................................. 24 Failure code [DDE5MA] Emergency steering operation switch: Disconnection ............................................ 26 Failure code [DDK3KA] Directional selector switch: Disconnection/Hot short............................................... 28 Failure code [DDK3KB] Directional selector switch: Ground fault ................................................................. 30 Failure code [DDK6KA] FNR lever: Disconnection/Ground fault................................................................... 32 Failure code [DDK6KY] FNR lever: Hot short................................................................................................ 36 Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering) ................................ 38 360 Troubleshooting by failure code (Display of code), Part 6 SEN04012-00 Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault ............................ 2 Failure code [DF10KB] Travel speed range selector switch: Hot short ......................................................... 6 Failure code [DGH1KX] HST oil temperature sensor: Ground fault .............................................................. 8 Failure code [DGR2KB] Brake oil temperature sensor: Ground fault ............................................................ 9 Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short.......................................... 10 Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault ............................................ 12 Failure code [DHH1KY] HST oil pressure sensor: Hot short ......................................................................... 14 Failure code [DHTCL6] HST filter clogging sensor: Functional defect .......................................................... 16 Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short .............................................................. 18 Failure code [DLT3KX] Travel speed sensor B: Abnormality......................................................................... 20 Failure code [DLT4KX] Travel speed sensor A: Abnormality......................................................................... 24 Failure code [DLT4LC] Travel speed sensor A & B: Abnormality .................................................................. 26 Failure code [DV00KY] Alarm buzzer: Hot short ........................................................................................... 28 Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault ........................................................ 30 Failure code [DW26KY] Motor 2 solenoid: Hot short..................................................................................... 32 Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short ................................................................... 34 Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault ...................................... 36 370 Troubleshooting by failure code (Display of code), Part 7 SEN04013-00 Failure code [DX16KA] Fan EPC solenoid: Disconnection ........................................................................... 2 Failure code [DX16KB] Fan EPC solenoid: Ground fault .............................................................................. 3 Failure code [DX16KY] Fan EPC solenoid: Hot short ................................................................................... 4 Failure code [DX19KA] Motor 1 solenoid: Disconnection.............................................................................. 6 Failure code [DX19KB] Motor 1 solenoid: Ground fault................................................................................. 8 Failure code [DX19KY] Motor 1 solenoid: Hot short...................................................................................... 10 Failure code [DX20KA] Clutch EPC solenoid: Disconnection ....................................................................... 12 Failure code [DX20KB] Clutch EPC solenoid: Ground fault .......................................................................... 14 Failure code [DX20KY] Clutch EPC solenoid: Hot short ............................................................................... 16 Failure code [DXH7KB] Reverse solenoid: Ground fault............................................................................... 18 Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short............................................................. 20 Failure code [DXH8KB] Forward solenoid: Ground fault ............................................................................... 22 Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short............................................................. 24 Failure code [J141N1] Steering pump: Overrun alarm .................................................................................. 26 Failure code [M100N1] HST pump: Overrun alarm ....................................................................................... 26 Failure code [M400N1] Motor 1: Overrun alarm ............................................................................................ 27 400 Troubleshooting of electrical system (E-mode) SEN04014-00 E-1 Engine does not start .............................................................................................................................. 3 E-2 Preheater does not operate normally...................................................................................................... 10 E-3 Defective boom kick-out function and cancellation ................................................................................. 14 E-4 Defective bucket positioner function and cancellation ............................................................................ 18 E-5 Defective lift arm FLOATING holding function and cancellation ............................................................. 22 E-6 Travel direction selection system does not function................................................................................ 26 E-7 Wiper does not operate........................................................................................................................... 30 E-8 Windshield washer does not operate...................................................................................................... 34 E-9 Headlamp, clearance lamp and tail lamp do not light up or go off .......................................................... 38 E-10 Working lamp does not light up or go off............................................................................................... 46 E-11 Turn signal lamp and hazard lamp do not light up or go off .................................................................. 51 E-12 Brake lamp does not light or it keeps lighting up .................................................................................. 58 E-13 Backup lamp does not light or it keeps lighting up................................................................................ 60 E-14 Backup alarm does not sound or it keeps sounding ............................................................................. 63 E-15 Horn does not sound or it keeps sounding ........................................................................................... 66 WA250, 250PZ-6
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E-16 Alarm buzzer does not sound or it keeps sounding.............................................................................. 68 E-17 Air conditioner does not operate or stop............................................................................................... 70 E-18 The KOMTRAX system does not work properly................................................................................... 73 500 Troubleshooting of hydraulic and mechanical system (H-mode) SEN04015-00 Method of using troubleshooting chart .......................................................................................................... 3 Failure code and cause table ........................................................................................................................ 6 H-1 The machine does not start.................................................................................................................... 8 H-2 The travel speed is slow......................................................................................................................... 9 H-3 The traction force is weak ...................................................................................................................... 10 H-4 Engine stalls when traveling or engine speed drops excessively........................................................... 11 H-5 The gear is not shifted............................................................................................................................ 12 H-6 The steering wheel does not turn ........................................................................................................... 13 H-7 The steering wheel is heavy................................................................................................................... 14 H-8 Steering wheel shakes or jerks............................................................................................................... 15 H-9 Machine deviates naturally to one side when traveling .......................................................................... 15 H-10 The brake does not work or does not work well ................................................................................... 16 H-11 The brake is not released or is dragged ............................................................................................... 17 H-12 The lift arm does not rise or lower ........................................................................................................ 18 H-13 The lift arm moves slowly or the lift arm rising force is insufficient ....................................................... 19 H-14 When rising, the lift arm comes to move slowly at specific height........................................................ 20 H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air)................................... 20 H-16 Hydraulic drifts of the lift arm occur often ............................................................................................. 20 H-17 The lift arm wobbles during operation .................................................................................................. 20 H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily .................. 21 H-19 The bucket does not tilt back................................................................................................................ 22 H-20 The bucket moves slowly or the tilting-back force is insufficient .......................................................... 23 H-21 The bucket comes to operate slowly in the midst of tilting-back .......................................................... 24 H-22 The bucket cylinder cannot hold down the bucket ............................................................................... 24 H-23 Hydraulic drifts of the bucket occur often ............................................................................................. 24 H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”) ................. 24 H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily ...................... 25 H-26 The control levers of the lift arm and bucket do not move smoothly and heavy................................... 25 H-27 The ECSS does not operate and machine pitches and bounces......................................................... 26 H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) ................ 27 600 Troubleshooting of engine (S-mode) SEN04016-00 Method of using troubleshooting charts ........................................................................................................ 2 S-1 Starting performance is poor .................................................................................................................. 6 S-2 Engine does not start.............................................................................................................................. 7 S-3 Engine does not pick up smoothly.......................................................................................................... 10 S-4 Engine stops during operations .............................................................................................................. 11 S-5 Engine does not rotate smoothly ............................................................................................................ 12 S-6 Engine lacks output (or lacks power)...................................................................................................... 13 S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 14 S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 15 S-9 Oil becomes contaminated quickly ......................................................................................................... 16 S-10 Fuel consumption is excessive............................................................................................................. 17 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 18 S-12 Oil pressure drops ................................................................................................................................ 19 S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 20 S-14 Coolant temperature becomes too high (overheating) ......................................................................... 21 S-15 Abnormal noise is made ....................................................................................................................... 22 S-16 Vibration is excessive ........................................................................................................................... 23
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100 Index Table of contents
SEN03988-00
50 Disassembly and assembly 100 General information on disassembly and assembly SEN04017-00 How to read this manual................................................................................................................................ 2 Coating materials list ..................................................................................................................................... 4 Special tool list............................................................................................................................................... 7 Sketches of special tools ............................................................................................................................... 11 200 Engine and cooling system SEN04018-00 Removal and installation of fuel supply pump assembly ............................................................................... 2 Removal and installation of fuel injector assembly........................................................................................ 4 Removal and installation of cylinder head assembly..................................................................................... 11 Removal and installation of engine hood assembly ...................................................................................... 24 Removal and installation of radiator .............................................................................................................. 27 Removal and installation of air aftercooler..................................................................................................... 30 Removal and installation of hydraulic oil cooler assembly ............................................................................ 32 Removal and installation of engine assembly ............................................................................................... 34 Removal and installation of engine front oil seal assembly ........................................................................... 40 Removal and installation of engine rear oil seal assembly............................................................................ 43 Removal and installation of cooling fan and fan motor assembly.................................................................. 46 Removal and installation of fuel tank assembly............................................................................................. 49 310 Power train, Part 1 SEN04019-00 Removal and installation of transfer assembly .............................................................................................. 2 Disassembly and assembly of transfer assembly.......................................................................................... 6 Removal and installation of parking brake assembly..................................................................................... 26 Disassembly and assembly of parking brake assembly ................................................................................ 28 320 Power train, Part 2 SEN04020-00 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 SEN04021-00 Removal and installation of center hinge pin................................................................................................. 2 Removal and installation of counterweight .................................................................................................... 12 500 Hydraulic system SEN04022-00 Removal and installation of HST pump and 4-gear pump assembly............................................................. 2 Disassembly and assembly of HST pump assembly..................................................................................... 6 Removal and installation of HST motor 1 assembly...................................................................................... 33 Removal and installation of HST motor 2 assembly...................................................................................... 35 Disassembly and assembly of HST motor assembly .................................................................................... 37 Removal and installation of work equipment control valve assembly............................................................ 53 Removal and installation of hydraulic tank .................................................................................................... 55 Disassembly and assembly of hydraulic cylinder assembly .......................................................................... 57 600 Work equipment SEN04023-00 Removal and installation of work equipment assembly................................................................................. 2 700 Cab and its attachments SEN04024-00 Removal and installation of operator's cab and floor frame assembly .......................................................... 2 Removal and installation of operator's cab glass (Stuck glass)..................................................................... 7 Removal and installation of air conditioner unit ............................................................................................. 15 800 Electrical system SEN04025-00 Removal and installation of monitor panel..................................................................................................... 2 Removal and installation of engine controller assembly................................................................................ 4 Removal and installation of HST controller assembly ................................................................................... 5 Removal and installation of KOMTRAX terminal assembly........................................................................... 6
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SEN03988-00
100 Index Table of contents
90 Diagrams and drawings 100 Hydraulic diagrams and drawings SEN04026-00 Hydraulic circuit diagram............................................................................................................................... 3 200 Electrical diagrams and drawings SEN04027-00 Electrical circuit diagram ............................................................................................................................... 3 Connector list and stereogram ...................................................................................................................... 21
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100 Index Table of contents
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SEN03988-00
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SEN03988-00
WA250-6, WA250PZ-6 GALEO Wheel loader Form No. SEN03988-00
©2007 KOMATSU All Rights Reserved Printed in Japan 10-07 (01)
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SEN03989-00
WHEEL LOADER WA250-6 WA250PZ-6 Machine model
Serial number
WA250-6 WA250PZ-6
75001 and up 75001 and up
00 Index and foreword
00
200 Foreword and general information 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
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200 Foreword and general information Safety notice
SEN03989-00
Safety notice
(Rev. 2007/03)1
Important safety notice Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. 1.
General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. 1) Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting 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 operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
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8)
If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out weld in g wo rk , al way s wear wel din g gloves, apron, shielding goggles, cap and other clothes suited for welding work. Before starting work, warm up your body thoroughly to start work under good condition.
Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5
Prohibition of operation and handling by unlicensed workers
6 Safety check before starting work 7
Wearing protective goggles (for cleaning or grinding work)
8
Wearing shielding goggles and protectors (for welding work)
9 Good physical condition and preparation 10
2.
Precautions against work which you are not used to or you are used to too much
Preparations for work 1) Before adding oil or making any repairs, park the machine on hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
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200 Foreword and general information Safety notice
3) 4)
3.
When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the m a c h i n e . N e v e r j u m p o n o r o ff t h e machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from 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 alternately to release the pressure, and then remove the cover. 7) When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires.
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9) 10)
11)
12)
13) 14) 15)
16)
When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y installed. When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particul a r ly c a r e fu l t o c he c k t h a t t h e y ar e installed correctly. When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tools are correctly assembled. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
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SEN03989-00 4.
Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is seen well from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 7) Limit the hanging angle to 60°, as a rule. Do not sling a heavy load with ropes forming 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 allowable 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 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.
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When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.
11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.
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If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load slantingly. 13) When lifting down a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.
SEN03989-00 13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state. 14) If you find an obstacle around the hoist, stop the operation. 15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.
q
5.
6.
Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signs for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load slantingly. Do not 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 obstacle to work and passage. 11) After operating the hoist, do not swing the control switch. 12) Remember the position of the main switch so that you can turn off the power immediately in an emergency.
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7.
Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.
Wire ropes (Standard “Z” twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4
a
The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).
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200 Foreword and general information Safety notice
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1) Disconnection k Collect the air conditioner refrigerant (R134a) from the air conditioner circuit in advance. a Ask professional traders for collecting and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, when collecting or filling it, you must be qualified for handling the refrigerant and put on protective goggles. 2)
Connection 1] When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them. 2] When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints. 3] Check that each O-ring is not damaged or deteriorated. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, ZEXEL: ZXL100PG (equivalent to PAG46)) to its O-rings.
a
Example of O-ring (Fitted to every joint of hoses and tubes)
a
For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".
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How to read the shop manual q q q
1.
SEN03989-00
1
Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the engine volume of the engine model mounted on the machine. Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section explains the shop manuals list, table of contents, safety, and basic information. 01. Specification This section explains the specifications of the machine. 10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method 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 case, see the Chassis volume. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of reproducing, repairing, and replacing parts.
2.
Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.
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200 Foreword and general information How to read the shop manual
SEN03989-00 3.
4.
Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. q
Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. (Example: 00, 01, 02 …)
q
Revisions Revised brochures are shown in the shop manual composition table.
Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol
Item
k
Safety
a
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing work.
4
Weight
Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
3
Tightening torque
2
5.
Coat
5
Oil, coolant
6
Drain
Remarks Special safety precautions are necessary when performing work.
Places that require special attention for tightening torque during assembly. Places to be coated with adhesives, etc. during assembly. Places where oil, etc. must be added, and capacity. Places where oil, etc. must be drained, and quantity to be drained.
Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
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SEN03989-00
Explanation of terms for maintenance standard
1
The maintenance standard values necessary for judgment of products and parts are described by the following terms. 1.
Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another. q To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the “standard size” and the range of difference 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. q
Example: Standard size
Tolerance –0.022 –0.126
120 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 of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them
q
Example: Standard size 60
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Tolerance Shaft –0.030 –0.076
Hole +0.046 +0
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200 Foreword and general information Explanation of terms for maintenance standard
SEN03989-00 2.
Standard clearance and standard value The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the “standard value“, which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value.
5.
q
3.
4.
Standard interference q When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the “interference”. q The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard interference”. q After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range.
Clearance limit Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the “clearance limit”. q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired. q
6.
Interference limit The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “interference limit”. q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired. q
Repair limit and allowable value 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 must be replaced or repaired. q The performance and function of a product lowers while it is used. A value below which the product can be used without causing a problem is called the “allowable value”. q If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement. q
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SEN03989-00
Handling of electric equipment and hydraulic component
1
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil). Points to remember when handling electric equipment 1. Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted 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 harness 1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times. 2)
Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.
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SEN03989-00 3)
Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
4)
High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Accordingly, take care not to splash water over the connector. The connector is designed to prevent water 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-circuited 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 film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.
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3.
SEN03989-00
Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand. 2] q
When removing from clips 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 stoppers. a If the connector is twisted up and down or to the left or right, the housing may break.
3]
Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
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SEN03989-00 2)
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Connecting connectors 1] Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. a If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. a If there is any damage or breakage, 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 stopper clicks into position. 3] Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. q If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
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3)
Heavy duty wire connector (DT 8-pole, 12pole) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2). Connection (Right of figure) 1] Push in female connector (2) horizontally 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
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SEN03989-00 q
Disconnection
q
Connection (Example of incomplete setting of (a))
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SEN03989-00 4)
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200 Foreword and general information Handling of electric equipment and hydraulic component
Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1] Disconnect the connector and wipe off the water with a dry cloth. a If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oi l a nd wa ter fr om t he c om 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 parts too hot, as this will cause deformation or damage to the connector. 3] Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble.
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200 Foreword and general information Handling of electric equipment and hydraulic component
4.
Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller. 2) Do not place objects on top of the controller. 3) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 4) During rainy weather, do not leave the controller in a place where it is exposed to rain. 5) Do not place the controller on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 6) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors 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 disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit.
WA250, 250PZ-6
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200 Foreword and general information Handling of electric equipment and hydraulic component
Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. 1.
Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust.
2.
Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to check the performance after repairs, so 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 performance 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 is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal.
4.
Do not let any dirt or dust get in during refilling operations Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
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5.
Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants 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 equipment, 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 out with the specified hydraulic oil.
7.
Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.
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200 Foreword and general information Handling of connectors newly used for engines
SEN03989-00
Handling of connectors newly used for engines a
1.
Mainly, following engines are object for following connectors. q 107E-1 q 114E-3 q 125E-5 q 140E-5 q 170E-5 q 12V140E-3 Slide lock type (FRAMATOME-3, FRAMATOME-2) q 107 – 170, 12V140 engines q Various pressure sensors and NE speed sensor Examples) Intake air pressure in intake manifold: PIM (125, 170, 12V140 engines) Oil pressure sensor: POIL (125, 170, 12V140 engines) Oil pressure switch (107, 114 engines) Ne speed sensor of flywheel housing: NE (107 – 170, 12V140 engines) Ambient pressure sensor: PAMB (125, 170, 12V140 engines)
2.
1
Pull lock type (PACKARD-2) 107 – 170, 12V140 engine q Various temperature sensors Example) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc. Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.
q
Disconnect connector (1) according to the following procedure. 1) Slide lock (L1) to the right. 2) While pressing lock (L2), pull out connector (1) toward you. a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screwdriver while press lock (L2), and then pull out connector (1) toward you.
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200 Foreword and general information Handling of connectors newly used for engines
3.
SEN03989-00
Push lock type q 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the following procedure. 1) While pressing lock (C), pull out connector (3) in the direction of the arrow. q
q
114 engine
q
107, 114 engine Example) Intake air pressure/temperature sensor in intake manifold (SUMITOMO-04)
3)
While pressing lock (D), pull out connector (4) in the direction of the arrow.
107 engine
a
2)
If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.
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200 Foreword and general information Handling of connectors newly used for engines
SEN03989-00 q
4)
125 – 170, 12V140 engine While pressing lock (E) of the connector, pullout connector (5) in the direction of the arrow. Example) Fuel pressure in common rail: PFUEL etc. (AMP-3)
4.
Turn-housing type (Round green connector) 140 engine Example) Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.
q
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 Housing (H1) is left on the wiring harness side.
2)
Connect the connector according to the following procedure. 1] Insert the connector to the end, while setting its groove. 2] Turn housing (H1) in the direction of the arrow until it “clicks”.
Example) Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2)
Example) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up.
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200 Foreword and general information How to read electric wire code
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How to read electric wire code a
1
The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example: AEX
0.85
L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal 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 indicated.)
1.
Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1) Type
Symbol
Low-voltage wire for automobile
AV
Thin-cover low-voltage wire for automobile
AVS
Heat-resistant low-voltAEX age wire for automobile
WA250, 250PZ-6
Material Conductor Insulator Conductor
Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance
Insulator
Soft polyvinyl chloride
Conductor
Annealed copper for electric appliance Heat-resistant crosslinked polyethylene
Insulator
Using temperature range (°C)
Example of use General wiring (Nominal No. 5 and above)
–30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely –50 to +110 cold district, wiring at high-temperature place
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200 Foreword and general information How to read electric wire code
SEN03989-00 2.
Dimensions
(Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5 Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23 area (mm2) d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0 AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 – CovAV Standard – – – – – – – 4.6 er D AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.) AVS Standard CovAV Standard er D AEX Standard
8
15
20
30
40
50
60
85
100
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
3.7 – 5.5 5.3
4.8 – 7.0 7.0
6.0 – 8.2 8.2
8.0 – 10.8 10.8
8.6 – 11.4 11.4
9.8 – 13.0 13.0
10.4 – 13.6 13.6
12.0 – 16.0 16.0
13.6 – 17.6 17.6
108/0.80 127/0.80 169/0.80 217/0.80
“f” of nominal No. denotes flexible”.
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3.
SEN03989-00
Color codes table
(Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR
Color of wire Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red
Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW
Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example: “GW” means that the background is Green and marking is White. 4.
Types of circuits and color codes
(Table 4) Type of wire Charge Ground Start Light Instrument Signal Type of circuit Others
WA250, 250PZ-6
AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch
AEX
WG
–
–
–
–
–
–
–
–
–
–
–
–
–
–
RB YR GW LW BrW LgR
RY YB GR LR BrR LgY
RG YG GY LY BrY LgB
RL YL GB LB BrB LgW
–
–
–
–
–
–
–
–
–
–
– –
–
R B R D Y G L
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
YW GL
– – – –
Gr Br –
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200 Foreword and general information Precautions when carrying out operation
SEN03989-00
Precautions when carrying out operation
1
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. q q q q q q q q q q
a
Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. Precautions when handling piping during disassembly Fit the following plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes Nominal number 02 03 04 05 06 10 12 2)
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Sleeve nut (elbow end)
07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 07376-71034 07376-71234
02789-20210 02789-20315 02789-20422 02789-20522 02789-20628 07221-21034 07221-21234
Split flange type hoses and tubes Nominal number 04 05
3)
Plug (nut end)
Flange (hose end)
Sleeve head (tube end)
Split flange
07379-00400 07379-00500
07378-10400 07378-10500
07371-30400 07371-30500
If the part is not under hydraulic pressure, the following corks can be used. Nominal number
Part Number
06 08 10 12 14 16 18 20 22 24
07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430
D 6 8 10 12 14 16 18 20 22 24
27
07049-02734
27
26
Dimensions d L 5 8 6.5 11 8.5 12 10 15 11.5 18 13.5 20 15 22 17 25 18.5 28 20 30 22.5
34
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2. q q q q q q q q q q q q q
a
a 3.
SEN03989-00
Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1) Start the engine and run at low idle. 2) Operate the work equipment control lever to operate the hydraulic 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. When using the machine for the first time after repair or long storage, follow the same procedure. Precautions when completing the operation 1) Refilling with coolant, oil and grease q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again. q If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. q If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. a For details, see Testing and adjusting, “Bleeding air”. q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts. 2) Checking cylinder head and manifolds for looseness Check the cylinder head and intake and exhaust manifold for looseness. If any part is loosened, retighten it. q For the tightening torque, see “Disassembly and assembly”. 3) Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage. If any part is loosened or damaged, retighten or repair it. Cooling system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leakage. If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it.
WA250, 250PZ-6
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SEN03989-00 4)
5)
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200 Foreword and general information Precautions when carrying out operation
Checking muffler and exhaust pipe for damage and looseness 1] Visually check the muffler, exhaust pipe and their mounting 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. 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 “Troubleshooting” and “Disassembly and assembly”.
28
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200 Foreword and general information Method of disassembling and connecting push-pull type coupler
SEN03989-00
Method of disassembling and connecting push-pull type coupler k k
1
Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1 1.
Disconnection 1) Hold adapter (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 adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (Fig. 4) a Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
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200 Foreword and general information Method of disassembling and connecting push-pull type coupler
Type 2 1.
Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal 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 disconnect 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 hexagonal portion at the male end. (Fig. 9)
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SEN03989-00
Type 3 1.
Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal 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 portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect it. (Fig. 12)
2.
Connection q Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
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200 Foreword and general information Standard tightening torque table
SEN03989-00
Standard tightening torque table 1.
1
Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using torque wrench) a
The following table corresponds to the bolts in Fig. A.
Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 a
Tightening torque Nm 11.8 – 14.7 27 – 34 59 – 74 98 – 123 153 – 190 235 – 285 320 – 400 455 – 565 610 – 765 785 – 980 1,150 – 1,440 1,520 – 1,910 1,960 – 2,450 2,450 – 3,040 2,890 – 3,630
kgm 1.2 – 1.5 2.8 – 3.5 6.0 – 7.5 10.0 – 12.5 15.5 – 19.5 23.5 – 29.5 33.0 – 41.0 46.5 – 58.0 62.5 – 78.0 80.0 – 100.0 118 – 147 155 – 195 200 – 250 250 – 310 295 – 370
The following table corresponds to the bolts in Fig. B.
Thread diameter of bolt mm 6 8 10 12 a Fig. A
00-200
Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60
32
Width across flats mm 10 13 14 27
Tightening torque Nm kgm 5.9 – 9.8 0.6 – 1.0 13.7 – 23.5 1.4 – 2.4 34.3 – 46.1 3.5 – 4.7 74.5 – 90.2 7.6 – 9.2 a Fig. B
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200 Foreword and general information Standard tightening torque table
2.
Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below.
Thread diameter of bolt mm 10 12 16
3.
Width across flats mm 14 17 22
Tightening torque Nm 59 – 74 98 – 123 235 – 285
kgm 6.0 – 7.5 10.0 – 12.5 23.5 – 29.5
Table of tightening torques for O-ring boss piping joints a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Nominal No. 02 03,04 05,06 10,12 14
4.
SEN03989-00
Thread diameter mm 14 20 24 33 42
Width across flats mm
Tightening torque Nm {kgm} Range Target 35 – 63 { 3.5 – 6.5} 44 { 4.5} 84 – 132 { 8.5 – 13.5} 103 {10.5} Varies depending 157 {16.0} on type of connec- 128 – 186 {13.0 – 19.0} tor. 363 – 480 {37.0 – 49.0} 422 {43.0} 746 – 1,010 {76.0 – 103} 883 {90.0}
Table of tightening torques for O-ring boss plugs a Unless there are special instructions, tighten O-ring boss plugs to the torque below. Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52
Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52
WA250, 250PZ-6
Width across flats mm 14 17 19 22 24 27 30 32 32 – 36 – –
Tightening torque Nm {kgm} Range Target 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75} 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15} 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8} 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3} 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0} 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0} 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0} 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0} 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0} 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0} 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5} 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5} 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
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200 Foreword and general information Standard tightening torque table
SEN03989-00 5.
Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque Nm {kgm}
Nominal No. of hose
Width across flats
02
19 22 24 27 32 36 41 46 55
03 04 05 06 (10) (12) (14)
6.
Range 34 – 54 { 3.5 – 5.5} 34 – 63 { 3.5 – 6.5} 54 – 93 { 5.5 – 9.5} 59 – 98 { 6.0 – 10.0} 84 – 132 { 8.5 – 13.5} 128 – 186 {13.0 – 19.0} 177 – 245 {18.0 – 25.0} 177 – 245 {18.0 – 25.0} 197 – 294 {20.0 – 30.0} 246 – 343 {25.0 – 35.0}
Target
44 { 4.5} 74 { 7.5} 78 { 8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}
Thread size (mm) – 14 – 18 22 24 30 33 36 42
Face seal Nominal No. Thread diameNumber of ter (mm) (Refthreads, type of erence) thread 9/16-18UN 14.3 – – 11/16-16UN 17.5 – – 13/16-16UN 20.6 1-14UNS 25.4 1-3/16-12UN 30.2 – – – – – –
Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts) a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine series to the torque below. Tightening torque Bolts and nuts
Thread size mm 6 8 10 12 14
7.
Taper seal
Nm 10 ± 2 24 ± 4 43 ± 6 77 ± 12 —
kgm 1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22 —
Table of tightening torques for 102, 107 and 114 engine series (Eye joints) a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the torque below. Thread size mm 6 8 10 12 14
00-200
34
Tightening torque Nm 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5
kgm 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51
WA250, 250PZ-6
200 Foreword and general information Standard tightening torque table
8.
SEN03989-00
Table of tightening torques for 102, 107 and 114 engine series (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 inch 1/16 1/8 1/4 3/8 1/2 3/4 1
WA250, 250PZ-6
Tightening torque Nm 3±1 8±2 12 ± 2 15 ± 2 24 ± 4 36 ± 5 60 ± 9
kgm 0.31 ± 0.10 0.81 ± 0.20 1.22 ± 0.20 1.53 ± 0.20 2.45 ± 0.41 3.67 ± 0.51 6.12 ± 0.92
00-200
35
200 Foreword and general information Conversion table
SEN03989-00
Conversion table
1
Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimeters to inches 1.
Convert 55 mm into inches. 1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A). 2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). 3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2.
Convert 550 mm into inches. 1) The number 550 does not 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
(A)
00-200
(B)
0 10 20 30 40
0 0 0.394 0.787 1.181 1.575
1 0.039 0.433 0.827 1.220 1.614
2 0.079 0.472 0.866 1.260 1.654
3 0.118 0.512 0.906 1.299 1.693
4 0.157 0.551 0.945 1.339 1.732
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
36
5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740
6 0.236 0.630 1.024 1.417 1.811
1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
WA250, 250PZ-6
200 Foreword and general information Conversion table
SEN03989-00
Millimeters to inches 1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929
0 10 20 30 40
0 0 0.394 0.787 1.181 1.575
1 0.039 0.433 0.827 1.220 1.614
2 0.079 0.472 0.866 1.260 1.654
3 0.118 0.512 0.906 1.299 1.693
4 0.157 0.551 0.945 1.339 1.732
5 0.197 0.591 0.984 1.378 1.772
6 0.236 0.630 1.024 1.417 1.811
7 0.276 0.669 1.063 1.457 1.850
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
2.165 2.559 2.953 3.346 3.740
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
1 kg = 2.2046 lb 6 7 8 9 13.23 15.43 17.64 19.84 35.27 37.48 39.68 41.89 57.32 59.53 61.73 63.93 79.37 81.57 83.78 85.98 101.41 103.62 105.82 108.03
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
Kilogram to pound
0 10 20 30 40
0 0 22.05 44.09 66.14 88.18
1 2.20 24.25 46.30 68.34 90.39
2 4.41 26.46 48.50 70.55 92.59
3 6.61 28.66 50.71 72.75 94.80
4 8.82 30.86 51.91 74.96 97.00
5 11.02 33.07 55.12 77.16 99.21
50 60 70 80 90
110.23 132.28 154.32 176.37 198.42
112.44 134.48 156.53 178.57 200.62
114.64 136.69 158.73 180.78 202.83
116.85 138.89 160.94 182.98 205.03
119.05 141.10 163.14 185.19 207.24
121.25 143.30 165.35 187.39 209.44
0 10 20 30 40
0 1 2 0 0.264 0.528 2.642 2.906 3.170 5.283 5.548 5.812 7.925 8.189 8.454 10.567 10.831 11.095
3 0.793 3.434 6.076 8.718 11.359
4 1.057 3.698 6.340 8.982 11.624
1 l = 0.2642 U.S.Gal 5 6 7 8 9 1.321 1.585 1.849 2.113 2.378 3.963 4.227 4.491 4.755 5.019 6.604 6.869 7.133 7.397 7.661 9.246 9.510 9.774 10.039 10.303 11.888 12.152 12.416 12.680 12.944
50 60 70 80 90
13.209 15.850 18.492 21.134 23.775
14.001 16.643 19.285 21.926 24.568
14.265 16.907 19.549 22.190 24.832
14.529 17.171 19.813 22.455 25.096
123.46 145.51 167.55 189.60 211.64
125.66 147.71 169.76 191.80 213.85
127.87 149.91 171.96 194.01 216.05
130.07 152.12 174.17 196.21 218.26
Liters to U.S. Gallons
WA250, 250PZ-6
13.473 16.115 18.756 21.398 24.040
13.737 16.379 19.020 21.662 24.304
14.795 17.435 20.077 22.719 25.361
15.058 17.700 20.341 22.983 25.625
15.322 17.964 20.605 23.247 25.889
15.586 18.228 20.870 23.511 26.153
00-200
37
200 Foreword and general information Conversion table
SEN03989-00
Liters to U.K. Gallons 1 l = 0.21997 U.K.Gal 6 7 8 9 1.320 1.540 1.760 1.980 3.520 3.740 3.950 4.179 5.719 5.939 6.159 6.379 7.919 8.139 8.359 8.579 10.119 10.339 10.559 10.778
0 10 20 30 40
0 0 2.200 4.399 6.599 8.799
1 0.220 2.420 4.619 6.819 9.019
2 0.440 2.640 4.839 7.039 9.239
3 0.660 2.860 5.059 7.259 9.459
4 0.880 3.080 5.279 7.479 9.679
5 1.100 3.300 5.499 7.699 9.899
50 60 70 80 90
10.998 13.198 15.398 17.598 19.797
11.281 13.418 15.618 17.818 20.017
11.438 13.638 15.838 18.037 20.237
11.658 13.858 16.058 18.257 20.457
11.878 14.078 16.278 18.477 20.677
12.098 14.298 16.498 18.697 20.897
12.318 14.518 16.718 18.917 21.117
12.528 14.738 16.938 19.137 21.337
0 10 20 30 40
0 0 72.3 144.7 217.0 289.3
1 7.2 79.6 151.9 224.2 296.6
2 14.5 86.8 159.1 231.5 303.8
3 21.7 94.0 166.4 238.7 311.0
4 28.9 101.3 173.6 245.9 318.3
5 36.2 108.5 180.8 253.2 325.5
6 43.4 115.7 188.1 260.4 332.7
7 50.6 123.0 195.3 267.6 340.0
50 60 70 80 90
361.7 434.0 506.3 578.6 651.0
368.9 441.2 513.5 585.9 658.2
376.1 448.5 520.8 593.1 665.4
383.4 455.7 528.0 600.3 672.7
390.6 462.9 535.2 607.6 679.9
397.8 470.2 542.5 614.8 687.1
405.1 477.4 549.7 622.0 694.4
412.3 484.6 556.9 629.3 701.6
12.758 14.958 17.158 19.357 21.557
12.978 15.178 17.378 19.577 21.777
kgm to ft.lb 1 kgm = 7.233 ft.lb 8 9 57.9 65.1 130.2 137.4 202.5 209.8 274.9 282.1 347.2 354.4 419.5 491.8 564.2 636.5 708.8
426.8 499.1 571.4 643.7 716.1
100 110 120 130 140
723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 160 170 180 190
1084.9 1157.3 1129.6 1301.9 1374.3
00-200
38
1092.2 1164.5 1236.8 1309.2 1381.5
1099.4 1171.7 1244.1 1316.4 1388.7
1106.6 1179.0 1251.3 1323.6 1396.0
1113.9 1186.2 1258.5 1330.9 1403.2
1121.1 1193.4 1265.8 1338.1 1410.4
1128.3 1200.7 1273.0 1345.3 1417.7
1135.6 1207.9 1280.1 1352.6 1424.9
1142.8 1215.1 1287.5 1359.8 1432.1
1150.0 1222.4 1294.7 1367.0 1439.4
WA250, 250PZ-6
200 Foreword and general information Conversion table
SEN03989-00
kg/cm2 to lb/in2
0 10 20 30 40
0 0 142.2 284.5 426.7 568.9
1 14.2 156.5 298.7 440.9 583.2
2 28.4 170.7 312.9 455.1 597.4
3 42.7 184.9 327.1 469.4 611.6
4 56.9 199.1 341.4 483.6 625.8
5 71.1 213.4 355.6 497.8 640.1
6 85.3 227.6 369.8 512.0 654.3
1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9
50 60 70 80 90
711.2 853.4 995.6 1,138 1,280
725.4 867.6 1,010 1,152 1,294
739.6 881.8 1,024 1,166 1,309
753.8 896.1 1,038 1,181 1,323
768.1 910.3 1,053 1,195 1,337
782.3 924.5 1,067 1,209 1,351
796.5 938.7 1,081 1,223 1,365
810.7 953.0 1,095 1,237 1,380
825.0 967.2 1,109 1,252 1,394
839.2 981.4 1,124 1,266 1,408
100 110 120 130 140
1,422 1,565 1,707 1,849 1,991
1,437 1,579 1,721 1,863 2,005
1,451 1,593 1,735 1,877 2,020
1,465 1,607 1,749 1,892 2,034
1,479 1,621 1,764 1,906 2,048
1,493 1,636 1,778 1,920 2,062
1,508 1,650 1,792 1,934 2,077
1,522 1,664 1,806 1,949 2,091
1,536 1,678 1,821 1,963 2,105
1,550 1,693 1,835 1,977 2,119
150 160 170 180 190
2,134 2,276 2,418 2,560 2,702
2,148 2,290 2,432 2,574 2,717
2,162 2,304 2,446 2,589 2,731
2,176 2,318 2,460 2,603 2,745
2,190 2,333 2,475 2,617 2,759
2,205 2,347 2,489 2,631 2,773
2,219 2,361 2,503 2,646 2,788
2,233 2,375 2,518 2,660 2,802
2,247 2,389 2,532 2,674 2,816
2,262 2,404 2,546 2,688 2,830
200 210 220 230 240
2,845 2,987 3,129 3,271 3,414
2,859 3,001 3,143 3,286 3,428
2,873 3,015 3,158 3,300 3,442
2,887 3,030 3,172 3,314 3,456
2,901 3,044 3,186 3,328 3,470
2,916 3,058 3,200 3,343 3,485
2,930 3,072 3,214 3,357 3,499
2,944 3,086 3,229 3,371 3,513
2,958 3,101 3,243 3,385 3,527
2,973 3,115 3,257 3,399 3,542
WA250, 250PZ-6
00-200
39
200 Foreword and general information Conversion table
SEN03989-00 Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
°C
°F
°C
°F
°C
°F
°C
1°C = 33.8°F °F
–40.4 –37.2 –34.4 –31.7 –28.9
–40 –35 –30 –25 –20
–40.0 –31.0 –22.0 –13.0 –4.0
–11.7 –11.1 –10.6 –10.0 –9.4
11 12 13 14 15
51.8 53.6 55.4 57.2 59.0
7.8 8.3 8.9 9.4 10.0
46 47 48 49 50
114.8 116.6 118.4 120.2 122.0
27.2 27.8 28.3 28.9 29.4
81 82 83 84 85
177.8 179.6 181.4 183.2 185.0
–28.3 –27.8 –27.2 –26.7 –26.1
–19 –18 –17 –16 –15
–2.2 –0.4 1.4 3.2 5.0
–8.9 –8.3 –7.8 –7.2 –6.7
16 17 18 19 20
60.8 62.6 64.4 66.2 68.0
10.6 11.1 11.7 12.2 12.8
51 52 53 54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
–25.6 –25.0 –24.4 –23.9 –23.3
–14 –13 –12 –11 –10
6.8 8.6 10.4 12.2 14.0
–6.1 –5.6 –5.0 –4.4 –3.9
21 22 23 24 25
69.8 71.6 73.4 75.2 77.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 60
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
–22.8 –22.2 –21.7 –21.1 –20.6
–9 –8 –7 –6 –5
15.8 17.6 19.4 21.2 23.0
–3.3 –2.8 –2.2 –1.7 –1.1
26 27 28 29 30
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
–20.0 –19.4 –18.9 –18.3 –17.8
–4 –3 –2 –1 0
24.8 26.6 28.4 30.2 32.0
–0.6 0 0.6 1.1 1.7
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 67 68 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
–17.2 –16.7 –16.1 –15.6 –15.0
1 2 3 4 5
33.8 35.6 37.4 39.2 41.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
–14.4 –13.9 –13.3 –12.8 –12.2
6 7 8 9 10
42.8 44.6 46.4 48.2 50.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
00-200
40
WA250, 250PZ-6
200 Foreword and general information Conversion table
WA250, 250PZ-6
SEN03989-00
00-200
41
SEN03989-00
WA250-6, WA250PZ-6 GALEO Wheel loader Form No. SEN03989-00
©2007 KOMATSU All Rights Reserved Printed in Japan 10-07 (01)
00-200
42
SEN03990-00
WHEEL LOADER WA250-6 WA250PZ-6 Machine model
Serial number
WA250-6 WA250PZ-6
75001 and up 75001 and up
01 Specification
1
100 Specification and technical data Specification dimension drawing..................................................................................................................... 3 Specifications .................................................................................................................................................. 4 Weight table .................................................................................................................................................... 8 Table of fuel, coolant and lubricants.............................................................................................................. 10
WA250, 250PZ-6
01-100
1
SEN03990-00
01-100
2
100 Specification and technical data
WA250, 250PZ-6
100 Specification and technical data Specification dimension drawing
SEN03990-00
Specification dimension drawing
Item Machine weight (with BOC) Normal load
1
Unit
WA250-6
WA250PZ-6
kg
10,890
12,725
kN {kg}
36.1 {3,680}
34.5{3,520}
Bucket capacity (heaped, with BOC)
m3
2.3
2.2
Engine model
—
Komatsu SAA6D107E-1 Diesel engine
kW{HP}/rpm
103 {138}/2,000 104.1 {140}/2,000
Engine rated output • Net [ISO 9249/SAE J1349] (*1) • Gross [SAE J1955] (*2) A Overall length (with BOC)
mm
7,055
7,340
B Overall height
mm
3,130
3,200
C Overall height with bucket lifted up
mm
4,995
5,265
D Overall width
mm
2,375
2,470
E Minimum ground clearance
mm
395
465
F Bucket width G Dumping clearance (*3)
Bucket tip/BOC tip
H Dumping reach (*3)
Bucket tip/BOC tip
I
2,685
2,685
2,865/2,780
2,785/2,845
mm
1,015/1,055
1,125/1,100
degree
45
48
Bucket tip/BOC tip
mm
6,005/6,030
5,855/5,875
Center of outside tire
mm
5,175
5,175
Bucket dump angle (max. height) Min. turning radius
mm mm
Permissible towing load
kN {kg} 1st (forward/reverse)
Travel speed
2nd (forward/reverse) 3rd (forward/reverse) 4th (forward/reverse)
km/h
82.4 {8,400}
82.4 {8,400}
3.6 – 11.7/3.6 – 11.7
4.0 – 13.0/4.0 – 13.0
11.7/11.7
13.0/13.0
16.2/16.2
18.0/18.0
34.2/34.2
38.0/38.0
*1: *2: *3: a
Indicates the value at the lowest cooling fan speed. Indicates the value of the engine alone (without cooling fan). Indicates the value at the 45° bucket dump angle. The engine rated output is indicated in the net value and gross value. Gross denotes the rated output measured of an independent engine. While, net denotes the value measured of an engine under the condition essentially the same as that when it is installed on machine. a Following shows the rated output (net) at the maximum cooling fan speed. 100 kW {134 HP}/2,000 rpm a BOC: Abbreviation for Bolt-On Cutting edge
WA250, 250PZ-6
01-100
3
100 Specification and technical data Specifications
SEN03990-00
Specifications
1
Machine model name
Weight
Serial No.
75001 and up
75001 and up
kg
10,890
12,725
Machine weight (front wheel) in SAE travel posture
kg
4,410
5,670
Machine weight (rear wheel) in SAE posture
kg
6,480
7,055
Bucket capacity (heaped)
m3
2.3
2.2
kN {kg}
36.1 {3,680}
36.1 {3,680}
km/h
3.6 – 11.7 11.7 16.2 34.2
4.0 – 13.0 13.0 18.0 38.0
km/h
3.6 – 11.7 11.7 16.2 34.2
4.0 – 13.0 13.0 18.0 38.0
kN{kg}
109 {11,100} 109 {11,100}
98 {10,000} 98 {10,000}
Gradeability
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
6,005/6,030
5,855/5,875
Overall length (with BOC)
mm
7,055
7,550
Overall width (chassis)
mm
2,375
2,470
Bucket width (with BOC)
mm
2,685
2,685
Travel speed • Forward 1st • Forward 2nd • Forward 3rd • Forward 4th Performance
WA250PZ-6
Machine weight
Normal load
Dimension
WA250-6
• • • •
Reverse 1st Reverse 2nd Reverse 3rd Reverse 4th
Max. traction force • Forward • Reverse
Overall height (cab top)
mm
3,130
3,200
Overall height with bucket lifted up
mm
4,995
5,265
Wheelbase
mm
2,900
2,900
Tread
mm
1,930
1,930
Minimum ground clearance
mm
395
465
Max. hinge pin height
mm
3,725
3,965
Dumping clearance (*1) (cutting edge/BOC tip)
mm
2,865/2,780
2,785/2,845
Dumping reach (*1) (cutting edge/BOC tip)
mm
1,015/1,055
1,125/1,100
Steering angle
deg.
38 (frame stopper 40)
38 (frame stopper 40)
Bucket tilt angle (operating posture/max. height)
deg.
50/66
47/66
Bucket dump angle (max. height)
deg.
45
48
Digging depth, 10° (cutting edge/BOC tip)
mm
175/220
350/375
*1: Indicates the value at the 45° bucket dump angle. a BOC: Abbreviation for Bolt-On Cutting edge
01-100
4
WA250, 250PZ-6
100 Specification and technical data Specifications
Machine model name
WA250-6
WA250PZ-6
Serial No.
75001 and up
75001 and up
Model
SAA6D107E-1
Type
4-cycle, water-cooled, in-line 6-cylinder, direct injection type with turbocharger and air-cooled aftercooler
Cylinder bore x Cylinder stroke
mm
107 x 124
l {cc}
6.69 {6,690}
kW{HP}/rpm
103 {138}/2,000 104.1 {140}/2,000
Nm{kgm}/rpm
625 {63.7}/1,400
Min. fuel consumption
g/kWh {g/HPh}
218 {162}
Max. speed at no load
rpm
2,250
Min. speed at no load
rpm
825
Performance
Total piston displacement
Engine
SEN03990-00
Rated output • Net [ISO 9249/SAE J1349] (*1) • Gross [SAE J1995] (*2) Max. torque (*1)
Starting motor
24 V, 4.5 kW
Alternator
24 V, 60 A
Battery (*3)
12 V, 88 Ah x 2 pieces
HST pump • Type • Pump capacity
Variable displacement swash plate type piston pump cc/rev
0 – 90
HST motor 1 Power train
• Type • Pump capacity
Variable displacement bent axis type piston motor cc/rev
• Type • Pump capacity
Variable displacement bent axis type piston motor cc/rev
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
Drive wheel Axle
50 – 107 Counter-shaft double acting planetary type, spur gear constant-mesh type, switching between 2 power trains
Transfer
Front and rear wheel drive
Front axle
Fixed frame, semi-float type
Rear axle
Tire
0 – 107
HST motor 2
Center pin support type, semi-float type
Size
17.5–25–16PR
20.5–25–12PR
Rim size
25 x 14.00 SDC
25 x 17.00 – 1.7
300 {3.0} 300 {3.0}
280 {2.8} 280 {2.8}
Inflation pressure • Front wheel • Rear wheel
kPa {kg/cm2}
*1: *2: *3: a
Indicates the value at the lowest cooling fan speed. Indicates the value of the engine alone (without cooling fan). The battery capacity (Ah) is indicated in the 5-hour rate value. The engine rated output is indicated in the net value and gross value. Gross denotes the rated output measured of an independent engine. While, net denotes the value measured of an engine under the condition essentially the same as that when it is installed on machine. a Following shows the rated output (net) at the maximum cooling fan speed. 100 kW {134 HP}/2,000 rpm
WA250, 250PZ-6
01-100
5
100 Specification and technical data Specifications
SEN03990-00
Machine model name
WA250-6
WA250PZ-6
Serial No.
75001 and up
75001 and up
Main
Braking method
4-wheel brake, independent front and rear wheel brakes
Type of brake
Enclosed wet multiple disc type
Drive method
Hydraulic drive
Brake
Operating method
Foot-operated (with hydraulic booster)
Parking
Braking method
Transmission output shaft brake
Type of brake
Wet multiple disc type
Drive method
Mechanical type
Steering
Operating method
Manual lever type
Steering method
Articulated chassis type
Drive method
Hydraulic drive
Steering pump • Type
Hydraulic pump
• Delivery
Gear type cm /rev
56.0
3
Work equipment pump • Type • Delivery
Gear type cm /rev
40.2
3
Brake and cooling fan pump • Type • Delivery
Gear type cm /rev
12.4
3
Transfer lubrication pump • Type • Delivery
Gear type cm /rev
12.4
3
Hydraulic equipment
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 pins
mm
818
Lift cylinder
Cylinder
Type
Double-acting piston type
Cylinder bore
mm
130
Piston rod outside diameter
mm
70
Stroke
mm
717
Max. distance between centers of pins
mm
1,950.5
Min. distance between centers of pins
mm
1,233.5
Bucket cylinder
Type
01-100
6
Double-acting piston type
Double-acting piston type
Cylinder bore
mm
150
170
Piston rod outside diameter
mm
75
100
Stroke
mm
491
480
Max. distance between centers of pins
mm
1,545
1,815
Min. distance between centers of pins
mm
1,054
1,335
WA250, 250PZ-6
100 Specification and technical data Specifications
SEN03990-00
Machine model name
WA250-6
WA250PZ-6
Serial No.
75001 and up
75001 and up
Control valve
• Type • Set pressure
2-spool type MPa{kg/cm2}
• Type
Orbit-roll type MPa{kg/cm }
18.6 {190}
2
Cooling fan motor Fixed displacement, swash plate, piston type
• Type • Motor capacity
Work equipment
20.6 {210}
Steering valve • Set pressure
Motor
Hydraulic equipment
Work equipment control valve
Type of link Shape of bucket cutting edge
cm3/rev
11.5 Z-bar link
Parallel movement type Z-bar link
Straight cutting edge with BOC
Straight cutting edge with BOC
a BOC: Abbreviation for Bolt-On Cutting edge
WA250, 250PZ-6
01-100
7
100 Specification and technical data Weight table
SEN03990-00
Weight table k
1
This weight table is prepared for your reference when handling or transporting the components. Unit: kg Machine model name
WA250-6
WA250PZ-6
Serial No.
75001 and up
75001 and up
Engine (excluding coolant and oil)
590
590
Damper
3
3
Cooling assembly (excluding coolant and oil) • Radiator • Oil cooler • Aftercooler
69 10 9 10
69 10 9 10
Transfer oil cooler
3
3
Cooling fan motor
13
13
HST pump
60
60
HST motor 1
59
59
HST motor 2
59
59
Transfer
212
212
Front drive shaft
18
18
Rear drive shaft
4
4
Front axle • 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 14.00 SDC (1 piece) • 25 x 17.00 – 1.7 (1 piece)
96 —
— 130
Tire • 17.5–25–16 PR (1 piece) • 20.5–25–12 PR (1 piece)
115 —
— 147
Hydraulic tank (excluding hydraulic oil)
77
77
4-gear pump
21
21
Work equipment control valve • 2-spool valve • 3-spool valve
19 —
— 26
Work equipment PPC valve • Mono lever type • 2-lever type
3 —
— 4
Attachment PPC valve
—
1
Priority valve
6
6
Orbit-roll valve
7
7
Cushion valve
4
4
Charge valve
6
6
Brake valve
10
10
Steering cylinder assembly (1 piece)
18
18
Lift cylinder assembly (1 piece)
104
104
Bucket cylinder assembly
104
186
01-100
8
WA250, 250PZ-6
100 Specification and technical data Weight table
SEN03990-00
Unit: kg Machine model name
WA250-6
WA250PZ-6
Serial No.
75001 and up
75001 and up
Front frame
840
1,017
Rear frame
700
700
1,435
1,435
151
240
Counterweight Additional counterweight (1 piece) Engine hood (including side panel)
190
190
Fuel tank (excluding fuel)
100
100
Lift arm (including bushing)
715
907
Bucket link
28
66
Bell crank
166
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)
29
29
a BOC: Abbreviation for Bolt-On Cutting edge
WA250, 250PZ-6
01-100
9
100 Specification and technical data Table of fuel, coolant and lubricants
SEN03990-00
Table of fuel, coolant and lubricants a
1
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
—
01-100
10
WA250, 250PZ-6
100 Specification and technical data Table of fuel, coolant and lubricants
WA250, 250PZ-6
SEN03990-00
01-100
11
SEN03990-00
WA250-6, WA250PZ-6 GALEO Wheel loader Form No. SEN03990-00
©2007 KOMATSU All Rights Reserved Printed in Japan 10-07 (01)
01-100
12
SEN03991-00
WHEEL LOADER WA250-6 WA250PZ-6 Machine model
Serial number
WA250-6 WA250PZ-6
75001 and up 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
WA250, 250PZ-6
10-100
1
SEN03991-00
Engine mount and transfer mount
10-100
2
100 Engine and cooling system Engine mount and transfer mount
1
WA250, 250PZ-6
100 Engine and cooling system Damper
SEN03991-00
Damper
1
Unit: mm
No.
Check item
1
Distance between HST pump installation surface and boss tip
2
Wear on internal teeth of coupling (resin)
3. Coupling 4. Boss 5. HST pump input shaft 6. Cover 7. Flywheel
WA250, 250PZ-6
Criteria
Remedy
Standard size
Repair limit
75.1
±0.8 Repair limit: 1.0
Adjust Replace
Outline The damper protects the drive systems on and after the engine from torsional vibrations by reducing the 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). q
10-100
3
100 Engine and cooling system Cooling system
SEN03991-00
Cooling system
1
5. Aftercooler 6. Transfer oil cooler 7. Cooling fan 8. Cooling fan motor
1. Reservoir tank 2. Oil cooler 3. Radiator cap 4. Radiator 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
29.86
4.15 x 2
10.87
—
—
—
—
Total heat dissipation area (m2) Pressure valve cracking pressure (kPa {kg/cm2}) Vacuum valve cracking pressure (kPa {kg/cm2})
10-100
4
68.6 {0.7} 0 – 4.9 {0 – 0.05}
WA250, 250PZ-6
100 Engine and cooling system Cooling system hydraulic piping diagram
SEN03991-00
Cooling system hydraulic piping diagram
1. Cooling fan motor 2. Strainer 3. Hydraulic tank 4. Brake and cooling fan pump 5. Charge valve
WA250, 250PZ-6
1
Outline q Cooling fan motor (1) installed in the machine rear side is driven by oil pressure from brake and cooling fan pump (4).
10-100
5
SEN03991-00
10-100
6
100 Engine and cooling system Cooling system hydraulic piping diagram
WA250, 250PZ-6
100 Engine and cooling system Cooling fan motor
SEN03991-00
Cooling fan motor
1
Type: LMF16
P: From 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
WA250, 250PZ-6
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}
10-100
7
SEN03991-00
10-100
8
100 Engine and cooling system Cooling fan motor
WA250, 250PZ-6
100 Engine and cooling system Cooling fan motor
SEN03991-00
1. Output shaft 2. Case 3. Thrust plate 4. Shoe 5. Piston 6. Cylinder block 7. Valve plate 8. End cover 9. Bearing 10. Center spring 11. Retainer shoe 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
Standard size
18 Spool return spring
19 Spool return spring
WA250, 250PZ-6
Repair limit
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}
35 x 8.5
34
44.1 N {4.5 kg}
—
35.3 N {3.6 kg}
If damaged or deformed, replace spring
10-100
9
SEN03991-00
100 Engine and cooling system Cooling fan motor
1. Hydraulic motor Function q This hydraulic motor is called a swash platetype axial piston motor. It converts the energy of the pressurized oil sent from the hydraulic pump into rotary motion. Principle of operation q The pressurized oil from the hydraulic pump flows through valve plate (7) into cylinder block (5). q This pressurized oil can flow on only to one side of the (Y - Y) line connecting the top dead center 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) generates torque [T = F3 x ri] against the (Y - Y) line connecting the top dead center and bottom dead center. q The result of this torque [T = s (F3 x ri)] rotates cylinder block (5) through piston (4). q This cylinder block (5) is connected to output shaft (1) with the spline. q Output shaft (1) rotates to transmit the torque.
10-100
10
WA250, 250PZ-6
100 Engine and cooling system Cooling fan motor
SEN03991-00
2. Suction safety valve 1) Suction function Function q If the fan pump stops, the pressurized oil does not flow into the motor. q Since the motor continues revolution because of the force of inertia, however, the pressure on the outlet side of the motor rises. q When the pressurized oil stops flowing in from inlet port (P), suction safety valve (1) sucks in the pressurized oil on the outlet side and supplies it to port (MA) where there is not sufficient oil to prevent cavitation.
(2) When the pump is stopped q When the engine stops, the input revolution of the pump becomes 0 rpm. q The pressurized oil from the pump is not supplied to port (P). q As the pressurized oil is not supplied to (MA) side of the motor, the motor speed lowers gradually to stop. q If the motor shaft is revolved by the force of inertia while the oil flow in port (P) is reducing, the oil in port (T) on the outlet side is sent by suction safety valve (1) to (MA) side to prevent cavitation.
Operation (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.
WA250, 250PZ-6
10-100
11
SEN03991-00
100 Engine and cooling system Cooling fan motor
2) Safety function Function q When the engine is started, the pressure in port (P) of the 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.
10-100
12
WA250, 250PZ-6
100 Engine and cooling system Cooling fan motor
SEN03991-00
3. Operation of reversible valve 1) When the ON/OFF solenoid is de-energized q
q q q
When ON/OFF solenoid (1) is "de-energized", the pressurized oil from the pump is shut off by valve (2). Port (C) opens for the hydraulic tank circuit. Spool (3) is pushed to the right by spring (4). Port (MA) opens and pressurized oil flows in to revolve the motor in forward (clockwise).
WA250, 250PZ-6
2) When the ON/OFF solenoid is energized q q q q q
When ON/OFF solenoid (1) is "energized", valve (2) is switched. The pressurized oil from the pump flows to spool chamber (D) through port (C). The pressurized oil in chamber (D) compresses spring (4). Spool (3) moves to the left. Port (MB) opens and pressurized oil flows in to rotate the motor in reverse (counterclockwise).
10-100
13
SEN03991-00
100 Engine and cooling system Cooling fan motor
4. Flow control valve (continuously-variable type) Function This valve supplies the necessary pump delivery to the motor, and returns the excessive oil to the hydraulic tank. q
q q
q
The motor speed increases in proportion to the increase of the incoming oil (Q) as shown in Fig. 1. When the incoming flow rate is (Q1), motor speed becomes (B) rpm. In order to reduce noise and loss of the motor, this valve keeps the fan speed constant independent of the flow rate to the motor. Even if the flow rate is increased from (Q0) to (Q1), the valve maintains the motor speed constant between points (A) and (C).
Operation For the flow control valve, the upstream pressure 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 orifice (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 installed load of spring (2). q Spool (1) moves to the left and port (P) is connected to port (T). q The excessive oil in (Z) portion of Fig. 1 flows to the hydraulic tank through the flow control valve, and the motor speed is kept constant from (A) to (C). q This flow control valve is a continuously-variable type. q As shown in Fig. 2, it is possible to change the flow control valve continuously while maintaining the motor speed constant between (A') to ( C ') by c ha n g i n g t h e c o m m an d c u r r e n t between the motor speed (A) and (C). q
10-100
14
WA250, 250PZ-6
100 Engine and cooling system Cooling fan motor
WA250, 250PZ-6
SEN03991-00
10-100
15
SEN03991-00
WA250-6, WA250PZ-6 GALEO Wheel loader Form No. SEN03991-00
©2007 KOMATSU All Rights Reserved Printed in Japan 10-07 (01)
10-100
16
SEN03992-00
WHEEL LOADER WA250-6 WA250PZ-6 Machine model
Serial number
WA250-6 WA250PZ-6
75001 and up 75001 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
WA250, 250PZ-6
10-200
1
SEN03992-00
10-200
2
200 Power train
WA250, 250PZ-6
200 Power train Power train
SEN03992-00
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
WA250, 250PZ-6
10-200
3
SEN03992-00
Power train system diagram
10-200
4
200 Power train Power train system diagram
1
WA250, 250PZ-6
200 Power train Power train system diagram
1. Engine 2. Damper 3. HST pump 4. Steering pump 5. Work equipment pump 6. Brake and cooling fan pump 7. Transfer lubrication pump 8. High-pressure hose 9. HST motor 1 10. HST motor 2 11. Emergency steering valve (if equipped) 12. Transfer 13. Transfer clutch 14. Parking brake 15. Front drive shaft 16. Front axle 17. Differential 18. Wet multiple disc type brake 19. Final drive 20. Front tire 21. Rear drive shaft 22. Rear axle 23. Differential 24. Wet multiple disc type brake 25. Final drive 26. Rear tire
WA250, 250PZ-6
SEN03992-00 Outline q The power from engine (1) is transmitted to HST pump (3) after its torsional vibrations have been reduced with damper (2) installed on the flywheel. q The power from engine (1) is also transmitted to HST pump (3) and the HST charge pump being built in HST pump (3) as well as steering pump (4), work equipment pump (5), brake and cooling fan pump (6) and transfer lubrication pump (7) being connected to HST pump (3). q The directional selector valve and servo piston installed on HST pump (3) continuously modify the oil discharge direction and discharged amount responding to inclination of the swash plate. q HST motors (9) and (10) are installed on transfer (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 m oto rs (9) and (1 0) to cont ro l th e machine forward and reverse travel and travel speed. q The power from HST motor 1 (9) is transmitted to the output shaft through transfer clutch (13) in transfer (12). The power from HST motor 2 (10) is transmitted to the output shaft through the gear in transfer (12). q As the parking brake lever is operated, parking brake (14) being contained in the rear side of transfer (12) activates the wet multiple disc type brake to stop the machine. q The power to the front side is transmitted to front axle (16) through front drive shaft (15). The power to the rear side is transmitted to rear axle (22) through rear drive shaft (21). q Speed of the power transmitted to axles (16) and (22) is reduced on the pinion gear of differentials (17) and (23), then transmitted to the sun gear through the sun gear shaft. q Speed of the power transmitted to the sun gear is reduced on the planetary mechanism of final drives (19) and (25), then transmitted to tires (20) and (26) through the axle shaft and wheel.
10-200
5
SEN03992-00
Drive shaft
1. Front axle 2. Front drive shaft 3. Transfer 4. Rear drive shaft 5. Rear axle
10-200
6
200 Power train Drive shaft
1
Outline q The power from the transfer output shaft is transmitted to front axle (1) and rear axle (5) through 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 exposed to above impacts or changes in the component positions.
WA250, 250PZ-6
200 Power train HST hydraulic piping diagram
SEN03992-00
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
WA250, 250PZ-6
10-200
7
SEN03992-00
200 Power train HST pump
HST pump
1
a
HST: Abbreviation for HydroStatic Transmission
1. Directional selector solenoid valve 2. High-pressure cutoff valve 3. Speed-related valve (DA valve) 4. Charge pump 5. Low-pressure relief valve 6. Servo cylinder 7. High-pressure relief valve 8. Control plate 9. Cylinder block 10. Piston 11. Swash plate
10-200
8
Specifications Model name
A4VG90DA
Type
Variable displacement swash plate type piston pump
Theoretical delivery (cc/rev) High-pressure relief valve set pressure (MPa {kg/cm2}) High-pressure cutoff valve set pressure (MPa {kg/cm2}) Low-pressure relief valve set pressure (MPa {kg/cm2})
0 – 90 44.1 {450} Effective differential pressure 41.2 {420} 2.45 {25}
WA250, 250PZ-6
200 Power train HST pump
Operation Flow of power
q q
q
q
q q
The HST pump is installed on the damper of the engine flywheel. The power from the engine is transmitted to the HST pump through the flywheel and damper. The HST pump is equipped with directional selector solenoid valve (1) and servo cylinder (6). Driving the machine forward or reverse activates directional selector solenoid valve (1), tilting swash plate (11) and, as a result, causing the switch between the oil suction and discharge ports. The HST pump is built-in cylinder block and 9 pistons (10) rotate along with drive shaft (12). Tips of piston (10) slides on the swash plate surface of swash plate (11) that does not rotate.
WA250, 250PZ-6
SEN03992-00
Flow of oil
q
q
q
q q
q
Inclination of swash plate (11) starts reciprocating movement of piston (10). The pumping action initiated by this reciprocating movement suctions or discharges the oil in cylinder block (9) continuously. The pumping action directs the oil flow in a certain definite direction so that it may flow to the HST motor. Reversing the inclination of swash plate (11) reverses the suction and discharge ports and, as a result, reversing the oil discharging direction, too. Piston (10) does not stroke when swash plate (11) is at neutral, thus the oil is not discharged. Increasing or decreasing the inclination (angle) of swash plate (11) changes the stroke of piston (10), allowing to control the travel speed. If the amount of the oil in the low-pressure circuit (the oil to be returned from the motor to the pump) becomes insufficient due to leakage of oil in the HST pump, HST motor and control valve, the charge pump supplies the oil through speed-related valve (3) and the check valve on high-pressure relief valve (7).
10-200
9
SEN03992-00
High-pressure relief valve
1. Nut 2. Locknut 3. Poppet spring 4. Check spring 5. Main piston 6. Valve seat 7. Pilot poppet 8. Adjustment screw
10-200
10
200 Power train HST pump
1
Function q This valve is 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 order to protect cavitation.
WA250, 250PZ-6
200 Power train HST pump
SEN03992-00
Operation
q
q q q
Port (A) is connected to the high pressure circuit side of the HST pump, and ports (C) and (D) are connected to the low pressure circuit side of the pump. Oil fills up chamber (B) after flowing through the orifice of main piston (5). Pilot poppet (7) is seated on valve seat (6). If oil pressure in port (A) and chamber (B) goes beyond the set pressure, pilot poppet (7) is pushed in the left direction. As a result, the oil pressure in chamber (B) is released to port (C) through chamber (D) and the oil pressure in chamber (B) is decreased.
q
q
q
q
q
q
WA250, 250PZ-6
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). 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). As the oil pressure in port (A) goes lower than that in port (C), check spring (4) pushes back main piston (5) in the right direction. The oil in port (C) is conducted to port (A) through chamber (D) so that the oil level in port (A) may not go low. Increasing or decreasing the repulsive force of poppet spring (3) allows adjusting the set pressure. When increasing the set pressure, remove the nut to loosen the locknut and screw the adjustment screw. When decreasing, loosen the adjustment screw.
10-200
11
200 Power train HST pump
SEN03992-00
Low-pressure relief valve
1
q
When increasing the set pressure, loosen locknut (1) and screw adjustment screw (2). When decreasing, loosen the adjustment screw.
1. Locknut 2. Adjustment screw 3. Piston 4. Spring Function q This valve is installed on the HST pump. If the oil pressure on the low pressure circuit side across the HST pump and HST motor goes beyond the set pressure, it drains the oil to the hydraulic tank. This valve sets the oil pressure of the HST pump charge circuit in this manner to protect the circuit. Operation
q
q q
q
Port (A) is connected to the HST pump charge circuit and port (B) is connected to the drain circuit. As long as port (A) is below the set pressure, oil does not flow to port (B). If oil pressure in port (A) goes beyond the set pressure, piston (3) is pushed in the right direction. As a result, the oil pressure in port (A) is released to port (B) and the oil pressure in port (A) is decreased. Increasing or decreasing the repulsive force of spring (4) allows adjusting the set pressure.
10-200
12
WA250, 250PZ-6
200 Power train HST pump
SEN03992-00
HST charge pump
1. Cover bolt 2. Pump gear 3. Key 4. Coupling 5. Drive shaft 6. Plate 7. Charge pump cover 8. Crescent separator plate Outline q This pump is installed on the HST pump. It, working in conjunction with the HST pump, supplies oil to the HST speed-related valve and the low-pressure relief valve on the HST pump.
WA250, 250PZ-6
1
Specifications Type
Gear pump (inscription type)
Theoretical delivery (cc/rev)
19.6
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 separator plate (8) to suction or delivery oil continuously in the direction shown in the figure.
10-200
13
SEN03992-00
Speed-related valve (DA valve)
200 Power train HST pump
1
1. Locknut 2. Adjustment screw 3. Poppet spring 4. Spring seat 5. Pilot poppet Function q It diverges the oil from the HST charge pump into 2 parts. One part flows to the directional selector solenoid valve and other part flows to the low-pressure relief valve. Operation q Port (A), port (D) and port (C) are connected to the HST pump charge circuit, low-pressure relief valve circuit and directional selector solenoid valve 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 direction to flow the oil in chamber (B) to the directional selector solenoid valve circuit through port (C). q A set of pilot poppet (5) is consisted of poppet spring (3) and spring seat (4). q When decreasing the set pressure, loosen locknut (1) and screw adjustment screw (2). When increasing, loosen the adjustment screw.
10-200
14
WA250, 250PZ-6
200 Power train HST pump
SEN03992-00
High-pressure cutoff valve
1
1. Adjustment screw 2. Locknut 3. Spring 4. Spool 5. Piston 6. Barrel 7. Shuttle spool 8. Valve seat Function q This valve is 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 oil in the servo cylinder circuit to the hydraulic tank. This valve sets the maximum pressure of the HST pump circuit in this manner to protect 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 forward 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 time, pushes up spool (4), too, by compressing spring (3). q Port (Pc) and port (T) are opened, releasing abnormal pressure generated in port (Pc) to port (T). q As oil pressure in port (Pc) goes low, the swash plate angle of the HST pump is reduced. As a result, the pump delivery is reduced and the HST pump circuit is protected.
WA250, 250PZ-6
10-200
15
200 Power train HST motor
SEN03992-00
HST motor a
1
HST: Abbreviation for HydroStatic Transmission
HST motor 1
1. Drive shaft 2. Piston 3. Cylinder block 4. Port plate 5. EP servo valve
10-200
16
Specifications Model name Type
A6VM107EP Variable displacement bent axis type piston motor
Theoretical delivery 0 – 107 (cc/rev) High-pressure relief valve 44.1 {450} set pressure (MPa {kg/cm2}) High-pressure cutoff Effective differential pressure valve set pressure 41.2 {420} (MPa {kg/cm2}) Low-pressure relief valve 2.45 {25} set pressure (MPa {kg/cm2})
WA250, 250PZ-6
200 Power train HST motor
SEN03992-00
HST motor 2
1. Drive shaft 2. Piston 3. Cylinder block 4. Port plate 5. HA servo valve 6. Directional shuttle valve
WA250, 250PZ-6
Specifications Model name
A6VM107HA
Type
Variable displacement bent axis type piston motor
Theoretical delivery 50 – 107 (cc/rev) High-pressure relief valve set pressure 44.1 {450} (MPa {kg/cm2}) High-pressure cutoff Effective differential pressure valve set pressure 41.2 {420} (MPa {kg/cm2}) Low-pressure relief valve set pressure 2.45 {25} (MPa {kg/cm2})
10-200
17
SEN03992-00 Principle q It is assumed that the shaft of the disc is supported to enable free rotation of the disc. Force F being applied aslant to the disc is divided into force F1 orthogonal to the disc and force F2 that works in the circumferential direction of the disc. Force F1 pushes the disc in the axial direction and force F2 rotates the disc clockwise. q Also when force F' works on the disc instead of force F, it is likewise divided into force F1' and F2'. Force F2' rotates the disc counterclockwise.
200 Power train HST motor
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 inclination of piston (2) and cylinder block (3) as the rotating force of drive shaft (1). q As the HST motor is rotated forward or reverse, the oil in the high pressure circuit side is conducted to the directional shuttle valve (6). q As a large load is applied to the motor being connected to servo valve (5), the pressure difference is generated between the high pressure circuit side and directional shuttle valve (6), allowing the servo cylinder to increase inclination of cylinder block (3).
Structure q 7 pistons (2) are installed on the disc portion of drive shaft (1) like spherical joints. They are housed in cylinder 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 shuttle valve (6) work to increase inclination of cylinder block (3) and piston (2), reducing the revolving speed and increasing the torque.
10-200
18
WA250, 250PZ-6
200 Power train HST motor
SEN03992-00
EP servo valve
1. Motor 1 solenoid valve 2. EP servo valve 3. Spring 4. Servo cylinder Function q This valve is installed on the rear side of HST motor 1. It controls the motor displacement depending on the current value given to motor 1 solenoid valve (1).
WA250, 250PZ-6
1
Operation q Suction force F1 of motor 1 solenoid valve (1) and force F2 of spring (3) are applied to EP servo valve (2). q When the current value given to motor 1 solenoid valve (1) is small (when F1 < F2), EP servo valve (2) conducts the oil pressure on the motor 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 solenoid valve (1) is large (when F1 > F2), EP servo valve (2) conducts the oil pressure to the large diameter side (L) to move servo cylinder (4) toward the max side using the difference in area between the large diameter and small diameter side (S). q Magnitude of spring (3) force varies depending on the position of servo cylinder (4) (motor displacement). q The current value given to motor 1 solenoid valve (1) controls the motor displacement to the position where suction power F1 and spring force F2 balance.
10-200
19
SEN03992-00
HA servo valve
1. Motor 2 solenoid valve 2. HA servo valve 3. Servo cylinder Function q This valve is installed in the rear side of HST motor 2. In order to bring out the motor output corresponding to the external load to the motor, it controls the motor displacement using the oil pressure of the circuit being selected from the directional shuttle valve.
10-200
20
200 Power train HST motor
1
Operation q If the load to the motor is small, HA servo valve (2) conducts oil pressure to the small diameter side (S) through the directional shuttle valve and releases the oil pressure 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 side (L) and small diameter side (S) moves servo cylinder (3) toward the max side. The motor displacement becomes the maximum and generates large torque. q As motor 2 solenoid valve (1) is energized, HA servo valve (2) conducts the oil pressure from the directional shuttle valve to the large diameter side (L) independent of the magnitude of the load to the motor to set the motor displacement to the maximum.
WA250, 250PZ-6
200 Power train HST motor
SEN03992-00
Directional shuttle valve
1
1. Directional selector solenoid valve 2. Directional shuttle valve Function q This valve is installed in the rear side of HST motor 2. It controls the destination of the oil pressure to work on the HA servo valve referencing the incoming signal, which corresponds to the directional signal of the directional selector solenoid valve on the HST pump. Above process reduces the decelerating impacts that results when the oil pressure is switched. Operation Directional selector solenoid valve (1) interlocks 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 valve on the HST pump. q Directional shuttle valve (2) is activated by directional selector solenoid valve (1) and controls the destination of the oil pressure to work on the HA servo valve. q
WA250, 250PZ-6
10-200
21
SEN03992-00
Transfer
200 Power train 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
10-200
22
WA250, 250PZ-6
200 Power train Transfer
1. HST motor 1 2. Input shaft 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)
WA250, 250PZ-6
SEN03992-00
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
10-200
23
200 Power train Transfer
SEN03992-00 Input shaft
Unit: mm
No.
Check item
1
Clearance between input shaft and bearing (front)
Criteria Standard size
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
50
+0.011 –0.005
0 –0.012
–0.023 – 0.005
—
2
Clearance between input shaft bearing and cage (front)
80
0 –0.013
+0.013 –0.006
–0.006 – 0.026
—
3
Clearance between input shaft and bearing (middle)
50
+0.011 –0.005
0 –0.012
–0.023 – 0.005
—
4
Clearance between input 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 gear
100
0 –0.018
–0.016 –0.038
–0.038 – 0.002
—
9
Clearance between piston and spacer
177
–0.085 –0.125
+0.040 0
0.085 – 0.165
—
10 Clearance between piston and cage
222
–0.550 –0.650
+0.046 0
0.550 – 0.696
—
between clutch housing 11 Clearance and front case
200
+0.061 +0.015
+0.046 0
–0.061 – 0.031
—
10-200
24
Replace
WA250, 250PZ-6
200 Power train Transfer
SEN03992-00
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Tolerance
Repair limit
1.7
±0.05
1.6
Strain on separator plate
—
0.05
0.15
Thickness of friction plate
2.2
±0.08
1.8
Strain on friction plate
—
0.02
0.25
1,010 N {103 kg}
±101 N {±10.3 kg}
804 N {82 kg}
Inside diameter of seal ring contact surface
25
+0.021 0
25.1
Width of seal ring groove
2.5
+0.15 +0.10
2.7
Width of seal ring
2.5
–0.01 –0.03
2.3
Thickness of seal ring
1.2
±0.1
1.05
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
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
3
±0.1
2.7
Thickness of separator plate
12
13 of wave spring 14 Load (height: 2.2 mm)
15
16
17 Thickness of seal ring between sun gear and 18 Backlash planetary pinion
0.078 – 0.252
between planetary pinion 19 Backlash and ring gear
0.100 – 0.407
between motor 1 gear and 20 Backlash output gear
0.170 – 0.453
clearance of planetary gear — Side (on both sides)
WA250, 250PZ-6
Replace
0.35 – 0.80
10-200
25
SEN03992-00
200 Power train Transfer
Output shaft
10-200
26
WA250, 250PZ-6
200 Power train Transfer
SEN03992-00
Unit: mm
No. 1
Check item Clearance between output shaft and bearing (front)
Criteria Standard size
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
60
+0.030 +0.011
0 –0.015
–0.045 – –0.011
—
2
Clearance between output shaft bearing and cage (front)
110
0 –0.018
–0.015 –0.040
–0.040 – 0.003
—
3
Clearance between output shaft and bearing (rear)
65
+0.030 +0.011
0 –0.015
–0.045 – –0.011
—
4
Clearance between output shaft bearing and rear case (rear)
120
0 –0.018
–0.015 –0.040
–0.040 – 0.003
—
5
Clearance between 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
—
diameter of coupling oil seal 10 Inside contact surface (front) diameter of coupling oil seal 11 Inside contact surface (rear) between cage and front 12 Clearance case rotational torque of output 13 Free shaft
WA250, 250PZ-6
Standard size
Tolerance
Repair limit
75
0 –0.074
74.8
75
0 –0.074
74.8
Standard size
Standard clearance
Clearance limit
0.7
0.1 – 1.3
—
Replace
Adjust with shims
3.9 – 5.9 Nm {0.4 – 0.6 kgm}
10-200
27
SEN03992-00
10-200
28
200 Power train Transfer
WA250, 250PZ-6
200 Power train Transfer
SEN03992-00
1. HST motor 2 2. Motor 2 gear (number of teeth: 44) 3. Strainer 4. Drain plug Unit: mm
No.
Check item
5
Clearance between input shaft and bearing
6
Clearance between input shaft bearing and cage
7
Backlash between motor 2 gear and output gear
WA250, 250PZ-6
Criteria Standard size
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
55
+0.030 +0.011
0 –0.015
–0.045 – –0.011
—
90
0 –0.015
+0.022 –0.013
–0.013 – 0.037
—
Replace
0.170 – 0.453
10-200
29
200 Power train Transfer
SEN03992-00 Outline q The transfer is equipped with 2 HST motors. It selects a gear speed out of 1st - 4th speed both in the forward and reverse travels and transmits it to the output shaft. It changes the gear speed by varying output and revolving direction of the HST motors and combinations of the transfer clutches.
Operation of clutch Clutch is "engaged" (fixed)
Relation between transfer clutch and transfer clutch pressure at respective speed ranges Speed range 1st 2nd
3rd
4th
Transfer clutch
Transfer clutch pressure
Engaged OFF Engaged OFF Travel Travel Travel Travel speed speed speed speed 0 – A km/h A – 18 km/h 0 – A km/h A – 18 km/h Disengage OFF ON Engaged d Travel Travel Travel Travel speed speed speed speed 0 – A km/h A – 38 km/h 0 – A km/h A – 38 km/h Disengage OFF ON Engaged d
q
q
q
*1: The travel speeds listed above are the ones when the tires of the size 20.5-25 are worn. And value A varies depending on the opening ratio of the accelerator pedal.
As the oil from the clutch solenoid valve is cut off, piston (2) is pushed back in the right direction by the repulsive force of spring (1). Piston (2) compresses plates (3) and discs (4) and the rotation of discs (4) is stopped by the frictional force. As the internal teeth of disc (4) are meshed with the external teeth of ring gear (5), ring gear (5) is fixed.
Clutch is "disengaged" (released) Relationship between accelerator pedal angle and travel speed (A) for starting transfer clutch switching modulation Transfer clutch Engaged o Disengaged (B) Disengaged o Engaged (C)
Accelerator pedal angle (%) 0 – 65 65 – 90 90 – 100 8 km/h
8 – 10 km/h
10 km/h
7 km/h
7 – 9 km/h
9 km/h
q
q
q
10-200
30
The oil from the clutch solenoid valve is pressure-fed to the back side of piston (2), and pushes piston (2) in the left direction by compressing spring (1). Plates (3) and discs (4) are released from the frictional force, setting ring gear (5) to the neutral position. Wave spring (6) is assembled between plates (3) to accelerate return of piston (2) as the clutches are released. And at the same time, it helps smooth separation of plates (3) and discs (4) in order to prevent drag turning.
WA250, 250PZ-6
200 Power train Transfer
SEN03992-00
Power transmitting route Low speed 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) O Input shaft (4) O Sun gear (5) O Planetary pinion (6) O Carrier (7) O Motor 1 gear (8) O Output gear (10) O Output shaft (11)
WA250, 250PZ-6
i
Power of HST motor 2 (3) O O O O O O O O O Motor 2 gear (9) O i
10-200
31
SEN03992-00
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)
10-200
32
WA250, 250PZ-6
200 Power train Clutch solenoid valve
SEN03992-00
Clutch solenoid valve
P: From HST charge pump A: To transfer clutch T: To drain 1. Clutch solenoid valve 2. Plunger 3. Coil 4. Push pin 5. Spring 6. Spool 7. Body
WA250, 250PZ-6
1
Operation When the current value of input signal is large, 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 transfer clutch remains at this level even if the current value may be further decreased. q
10-200
33
SEN03992-00
200 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
10-200
34
WA250, 250PZ-6
200 Power train Axle
SEN03992-00
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
WA250, 250PZ-6
10-200
35
SEN03992-00
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)
10-200
36
WA250, 250PZ-6
200 Power train Differential
SEN03992-00
Unit: mm
No.
Check item
7
Starting torque of bevel gear
8
Thickness of pinion washer
9
Criteria
Remedy
88.2 – 205.8 Nm {0.9 – 2.1 kgm} (outside of bevel gear)
Adjust
Standard size
Tolerance
Repair limit
3
±0.08
2.8
2
±0.05
1.8
Thickness of side gear washer
of shim in differential 10 Thickness side bearing carrier (one side)
0.50 – 1.35
11 Backlash of bevel gear
0.20 – 0.33
Adjust
play of pinion 12 End (or starting torque)
0 – 0.162 (0 – 61 N {0 – 6.2 kg} (at cage bolt hole))
Replace
0.50 – 1.23
Adjust
of shim in differential 13 Thickness housing and cage assembly Standard size
Tolerance Shaft
Hole
Standard clearance
Clearance limit
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
—
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
—
Clearance of bearing on Outer race 16 pinion shaft coupling side Inner race
120
0 –0.015
–0.053 –0.065
–0.065 – –0.038
—
55
+0.039 +0.020
0 –0.015
–0.054 – –0.020
—
28
–0.06 –0.11
+0.10 +0.05
0.11 – 0.21
—
261
–0.110 –0.191
+0.081 0
0.110 – 0.272
—
241
–0.100 –0.172
+0.072 0
0.100 – 0.244
—
Outer race
110
0 –0.015
0 –0.035
–0.035 – 0.015
—
Inner race
50
+0.021 +0.002
0 –0.012
0.002 – 0.033
—
of differential 14 Clearance Outer race side bearing
of bearing on 15 Clearance pinion shaft gear side
between pinion gear and 17 Clearance spider Clearance in installation position of
18 differential housing piston
(between housing and piston) Clearance in installation position of
19 bearing carrier piston
(between piston and carrier)
Clearance between 20 drive shaft and cage bearing
WA250, 250PZ-6
Replace
Replace
10-200
37
SEN03992-00
Rear differential
200 Power train 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)
10-200
38
WA250, 250PZ-6
200 Power train Differential
SEN03992-00
Unit: mm
No.
Check item
7
Starting torque of bevel gear
8
Thickness of pinion washer
9
Criteria
Remedy
88.2 – 205.8 Nm {0.9 – 2.1 kgm} (outside of bevel gear)
Adjust
Standard size
Tolerance
Repair limit
3
±0.08
2.8
2
±0.05
1.8
Thickness of side gear washer
of shim in differential 10 Thickness side bearing carrier (one side)
0.50 – 1.35
11 Backlash of bevel gear
0.20 – 0.33
Adjust
play of pinion 12 End (or starting torque)
0 – 0.162 (0 – 61 N {0 – 6.2 kg} (at cage bolt hole))
Replace
0.50 – 1.23
Adjust
of shim in differential 13 Thickness housing and cage assembly Standard size
Tolerance Shaft
Hole
Standard clearance
Clearance limit
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
—
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
—
Clearance of bearing on Outer race 16 pinion shaft coupling side Inner race
120
0 –0.015
–0.041 –0.076
–0.076 – –0.026
—
55
+0.039 +0.020
0 –0.015
–0.054 – –0.020
—
25.18
–0.13 –0.18
+0.10 +0.05
0.180 – 0.280
—
261
–0.110 –0.191
+0.081 0
0.110 – 0.272
—
241
–0.100 –0.172
+0.072 0
0.100 – 0.244
—
of differential 14 Clearance Outer race side bearing
of bearing on 15 Clearance pinion shaft gear side
between pinion gear and 17 Clearance spider Clearance in installation position of
18 differential housing piston
(between housing and piston) Clearance in installation position of
19 bearing carrier piston
(between piston and carrier)
WA250, 250PZ-6
Replace
Replace
10-200
39
200 Power train Differential
SEN03992-00 Outline
q
q
q
While machine is traveling straight
The power from the engine is transmitted to the front and rear axles through the torque converter, transmission and drive shaft. In each axle, the direction of the power is changed by 90° and the speed is reduced by bevel pinion (1) and bevel gear (5). Then, the power is transmitted through pinion (4) to sun gear shafts (2). Speed of the power transmitted to the sun gear is further reduced by the final drive of the planetary gear type, and then transmitted to the axle shafts and wheels.
q
While machine is turning
q
10-200
40
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 carrier (6) is transmitted through pinion (4) and side gear (3) to right and left sun gear shafts (2) evenly.
While the machine is turning, the right and left wheels rotate at different speeds. Accordingly, pinion (4) and side gear (3) in the differential rotate and transmit the power of carrier (6) to sun gear shafts (2), depending on the difference in rotation speed between the right and left wheels.
WA250, 250PZ-6
200 Power train Torque proportioning differential
SEN03992-00
Torque proportioning differential Outline
1
Operation Straight travel (When the road resistances under both tires are the same)
q
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 distance (b) to the meshing point of right side gear (3) are the same. Accordingly, left traction force (TL) and right traction force (TR) are balanced.
Travel on soft ground (When the road resistances under both tires are different)
q
q
A 4-wheel-drive wheel loader, as a construction machine, must naturally work on places where the ground condition is bad. If its tires slip in such places, its function lowers and the lives of the tires are shortened. To solve this problem, the torque proportioning differential is used. Pinion (4) of this differential has an odd number of teeth. The meshing points of pinion (4) and side gears (3) change according to the difference of the road resistance. Consequently, the traction forces of the tires on both sides change.
q
q
WA250, 250PZ-6
When the tires slip on soft ground, the side gear of the tire on the less road resistance side turns forward. As a result, the meshing points of pinion (4) and the side gears change. If left side gear (7) turns forward a little, distance (a) from the pinion to the meshing point of the left side gear becomes longer than distance (b) to the meshing point of the right side gear, and then (a) and (b) are balanced at a point where (a) x (TL) = (b) x (TR). The ratio of (a) : (b) changes up to 1 : 1.38, depending on the meshing condition.
10-200
41
SEN03992-00 q
q
200 Power train Torque proportioning differential
Accordingly, the pinion does 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%. The lives of the tires are lengthened 20 - 30% and the working capacity is increased by the above effect.
10-200
42
WA250, 250PZ-6
200 Power train Torque proportioning differential
WA250, 250PZ-6
SEN03992-00
10-200
43
SEN03992-00
Limited slip differential
200 Power train 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
10-200
44
WA250, 250PZ-6
200 Power train Limited slip differential
SEN03992-00
Unit: mm
No.
Check item
Criteria Standard size
Remedy
Tolerance
Repair limit
±0.02
2.9
2.5
+0.04 –0.03
2.45
2
±0.05
1.8
3
11 Thickness of plate
3.1
12 Thickness of disc 13 Thicknesses of washer between disc and plate 14 Clearance (total clearance on both sides)
0.2 – 0.6
play of side gear in axial 15 End direction (one side)
16 Backlash of case and plate
0 – 0.5
17 Backlash of side gear and disc between spider and 18 Clearance differential pinion
WA250, 250PZ-6
Replace
0.13 – 0.36
0.13 – 0.32 Standard size 25.4
Tolerance Shaft
Hole
Standard clearance
Clearance limit
–0.110 –0.160
+0.05 0
0.110 – 0.210
—
10-200
45
200 Power train Limited slip differential
SEN03992-00 Operation of limited slip differential q The power from the transmission is transmitted through bevel gear (9), case (10), pressure ring (8), shaft (7), pinion (3) and side gear (5), and then divided to the right and left shafts. q The brake unit consisting of disc (2) and plate (1) is installed to the back side of side gear (5). It generates braking torque in proportion to the torque transmitted from pressure ring (8) to shaft (7). q Since the brake torque restricts the rotation of side gears (5) and case (10), right and left side gears (5) cannot rotate freely. Thus, the operation of the differential is restricted.
While machine is traveling straight When the drive forces of the right and left wheels are balanced [When the road conditions (coefficient of friction) under both wheels and the wheel loads are even, and the center of load is at the center of the bucket]
Mechanism of generation of braking torque by right and left side gears (5)
q
q
q
Shaft (7) is supported on the cam surfaces being provided on the surfaces of pressure rings (8) that are facing each other. The power (= torque) transmitted from pressure rings (8) to shaft (7) is transmitted on the cam surfaces. Force (Fa) to separate pressure rings (8) from each other is generated by inclination of the cam surfaces in proportion to the transmitted torque. Separating load (Fa) acts on the brake on the back side of each side gear (5) to generate braking torque.
10-200
46
q
The power from the transmission is distributed evenly by the differential gears to the right and left. Under this condition, the slip limits of the right and left wheels are the same. Accordingly, even if the power from the transmission may exceed the slip limits, both wheels slip and the differential does not work. No load is applied to the brake on the back side of the side gear.
WA250, 250PZ-6
200 Power train Limited slip differential
When the drive forces of the right and left wheels are unbalanced [When the road conditions (coefficient of friction) under both wheels and the wheel loads are uneven, and either wheel slips more easily] Example 1. When either wheel is on soft ground in digging work Example 2. When either wheel is on snow and the other one is on asphalt in snow removing work Example 3. When the right and left wheel loads are unbalanced in travel on a slope
SEN03992-00 Difference in wheel drive force by type of differentials when either wheel slipped Wheel drive force (drive force of slipping wheel is 1) Slipping wheel Locked wheel Total (ratio) Limited slip differential (if equipped) Torque proportioning differential (standard) Conventional differential
1
2.64
3.64 (1.53)
1
1.38
2.38 (1)
1
1
2 (0.84)
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 proportioning differential. Conventional differential (this is not applied with this machine.) q On a road where either wheel slips easily, the drive force of the limited slip differential increases to 1.82 times of the conventional differential. While machine is turning
q
q
The power from the transmission is evenly divided between the right and left by the differential gear. If, however, the divided drive force exceeds the wheel slip limit of the slip side, surplus of the driving force is transmitted to the opposite side (lock side) brake through the brake and case on the gear back side. Then the power is distributed to the lock side wheel. The differential starts working only as the surplus portion of the drive force has exceeded the braking force.
WA250, 250PZ-6
q
The same gears as that for the conventional differential are employed for the limited slip differential. Thus, they allow to smoothly generate a difference in rotation speed between the outer and inner wheels that is necessary for tuning.
10-200
47
SEN03992-00
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)
10-200
48
WA250, 250PZ-6
200 Power train Final drive
SEN03992-00
Unit: mm
No. 6
Check item
Criteria
Clearance between planetary gear bearing and shaft
7
Clearance between axle housing and ring gear
8
Clearance between oil seal and housing
9
Press fitting part of axle shaft seal
Standard size
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
33.338
+0.025 +0.013
+0.013 0
–0.025 – 0
—
298
+0.100 +0.030
+0.100 0
–0.100 – +0.070
—
Max. 0.2
Adjust
Housing
155
+0.400 +0.200
+0.063 0
–0.400 – –0.137
—
Shaft
115
0 –0.054
–0.200 –0.400
–0.400 – –0.146
—
Clearance of press 10 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
—
Clearance of press 11 fitting part of axle housing bearing
Outer race
130
0 –0.025
–0.038 –0.078
–0.078 – –0.013
—
Inner race
85
+0.035 +0.013
0 –0.020
–0.055 – –0.013
—
12 End play of axle shaft 13 Clearance of guide pin
a
Replace
0 – 0.1 12
+0.025 +0.007
+0.207 +0.145
Replace
Adjust 0.120 – 0.200
—
Replace
Starting force of axle housing, see "Disassembly and assembly of axle housing" in Disassembly and assembly.
WA250, 250PZ-6
10-200
49
SEN03992-00
Rear final drive
200 Power train 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)
10-200
50
WA250, 250PZ-6
200 Power train Final drive
SEN03992-00
Unit: mm
No. 6
Check item
Criteria
Clearance between planetary gear bearing and shaft
7
Clearance between axle housing and ring gear
8
Clearance between oil seal and housing
9
Press fitting part of axle shaft seal
Standard size
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
33.338
+0.025 +0.013
+0.013 0
–0.025 – 0
—
276
+0.100 +0.030
+0.100 0
–0.100 – +0.070
—
Max. 0.2
Adjust
Housing
140
+0.400 +0.200
+0.063 0
–0.400 – –0.137
—
Shaft
105
0 –0.054
–0.200 –0.400
–0.400 – –0.146
—
Clearance of press 10 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
—
Clearance of press 11 fitting part of axle housing bearing
Outer race
125
0 –0.018
–0.028 –0.068
–0.068 – –0.010
—
Inner race
80
+0.030 +0.011
0 –0.015
–0.045 – –0.011
—
12 End play of axle shaft 13 Clearance of guide pin
a
Replace
0 – 0.1 12
+0.025 +0.007
+0.207 +0.145
Replace
Adjust 0.120 – 0.200
—
Replace
Starting force of axle housing, see "Disassembly and assembly of axle housing" in Disassembly and assembly.
WA250, 250PZ-6
10-200
51
SEN03992-00
200 Power train Final drive
Outline
q
q q
The final drive finally reduces speed of the power from the engine to increase the drive force. Ring gear (4) is press fitted to the axle housing and fixed with the pin. 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.
10-200
52
WA250, 250PZ-6
200 Power train Final drive
WA250, 250PZ-6
SEN03992-00
10-200
53
SEN03992-00
WA250-6, WA250PZ-6 GALEO Wheel loader Form No. SEN03992-00
©2007 KOMATSU All Rights Reserved Printed in Japan 10-07 (01)
10-200
54
SEN03993-00
WHEEL LOADER WA250-6 WA250PZ-6 Machine model
Serial number
WA250-6 WA250PZ-6
75001 and up 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
WA250, 250PZ-6
10-300
1
SEN03993-00
10-300
2
300 Steering system
WA250, 250PZ-6
300 Steering system Steering piping diagram
SEN03993-00
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)
WA250, 250PZ-6
10-300
3
300 Steering system Steering column
SEN03993-00
Steering column
1
1. Steering wheel 2. Steering column 3. Orbit-roll valve 4. Steering tilt lock lever Unit: mm
No. 5
Check item Clearance between steering shaft and column bushing
10-300
4
Criteria Standard size 19
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
0 –0.08
+0.15 +0.05
0.05 – 0.23
0.4
Replace
WA250, 250PZ-6
300 Steering system Priority valve
SEN03993-00
Priority valve
1
P: From steering pump CF: To Orbit-roll valve EF: To work equipment control valve
LS: From Orbit-roll valve T: To hydraulic 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
Standard size
12 Control spring
13 Relief spring
WA250, 250PZ-6
Repair limit
Free length
Installed length
Installed load
63.4
47.6
187 N {19.1 kg}
63.4 ± 1
187 ± 14.7 N {19.1 ± 1.5 kg}
31
27.3
132 N {13.3 kg}
—
132 ± 14.7 N {13.3 ± 1.5 kg}
Free length Installed load Replace
10-300
5
300 Steering system Priority valve
SEN03993-00 Outline q The priority valve is installed between the steering pump and Orbit-roll valve and work equipment control valve. It diverges the oil from the steering pump to the steering circuit or work equipment circuit. It is also used for controlling the oil pressure from the priority valve to the Orbit-roll valve in order to protect the circuit. Set pressure: 18.6 MPa {190 kg/cm2}
Operation When steering wheel is at "neutral" position
q
q
q
q
q
10-300
6
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. 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). The oil that flew to chamber (P) through orifice (m) of spool (3) pushes spool (3) in the right direction by compressing spring (4). Port (M) and port (Q) are opened and port (M) and port (N) are almost closed to stabilize spool (3). Most of the oil from the pump flows to the work equipment circuit through port (Q).
WA250, 250PZ-6
300 Steering system Priority valve
When steering wheel is "turned left"
q
q
q
q
q
Turning the steering wheel left changes the angle between the sleeve and spool on the Orbit-roll valve, switching flow of the oil. (see "Orbit-roll valve".) Part of the oil from the pump that has flown to port (A) is then conducted to the R.H. steering cylinder through port (B) and Gerotor, and the remaining portion of the oil flows to chamber (R) through orifice (b) and port (J). Change in the angle between the sleeve and spool on the Orbit-roll valve generates a difference pressure between the oil pressure up to port (A) and that after port (B). Spool (3) stabilizes at a position where the difference pressure between that of up to port (A) and after port (B) [chamber (P) pressure chamber (R) pressure] is balanced with the repulsive force of spring (4). The ratio of diversion is determined by the displacement 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.
WA250, 250PZ-6
SEN03993-00 When steering cylinder is at stroke end
q
q
q
q
q
Trying to continuously turn the steering wheel after the steering cylinder has reached the stroke end increases oil pressure in port (S). As the oil pressure in port (S) goes beyond the set pressure of relief valve (10), the relief valve (10) releases the oil pressure in port (S) to the hydraulic tank through port (T). It generates differential pressure before and after orifice (r), breaking down the balance between the difference pressure up to port (A) and after port (B) and the repulsive force of spring (4). As a result, oil pressure up to port (A) becomes relatively higher. As port (A) oil pressure is increased, oil in chamber (P) pushes spool (3) in the right direction by compressing spring (4). Port (M) and port (N) are almost closed, and port (M) and port (N) are nearly fully opened to stabilize spool (3).
10-300
7
300 Steering system Orbit-roll valve
SEN03993-00
Orbit-roll valve
1
P: 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
10-300
8
WA250, 250PZ-6
300 Steering system Orbit-roll valve
Outline
q
q
The Orbit-roll valve is connected to the drive shaft of the steering column. It changes the oil flow from the steering pump to the right or left steering cylinder to decide the travel direction of the machine. The Orbit-roll valve is roughly divided into spool (9) and sleeve (8) that have rotary type direction selecting function and Gerotor (5) (combination of rotor (5a) and stator (5b)) that operates as a hydraulic motor during the normal steering operation and as a hand pump (the steering wheel's operating effort becomes too high to operate it actually) when the oil is not supplied because of a trouble of the steering pump or engine.
WA250, 250PZ-6
SEN03993-00 Structure
q
q
q
Top (A) of spool (9) is connected to the drive shaft of the steering column and further connected 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). Top (B) of drive shaft (3) is engaged with center pin (7) and united with sleeve (8) and the bottom is engaged with the spline of rotor (5a) of the Gerotor (5). 4 ports are provided on valve body (4). Each port is respectively connected to the pump circuit, tank circuit, L.H. steering circuit and R.H. steering circuit. And the ports of the pump side and tank side are connected by the check valve in the body. If the pump or engine fails, the oil can be sucked through this check valve directly from the tank side.
10-300
9
SEN03993-00
300 Steering system Orbit-roll valve
Operation When steering wheel is at "neutral" position
10-300
10
WA250, 250PZ-6
300 Steering system Orbit-roll valve
q
q
q q q
SEN03993-00
When the steering wheel is at "neutral" position, centering spring (2) sets center pin (7) to the center of the oblong hole on spool (9) and move of spool (9) and sleeve (8) is stopped. Port (A) from sleeve (8) pump, port (E) to the Gerotor, port (F) to the R.H. steering circuit and port (G) to the L.H. steering circuit cut off the vertical grooves (B), (C) and (D) on spool (9). Orifice (b) of port (J) to the priority valve is connected to vertical groove (B) on spool (9). Port (K) of sleeve (8) is connected to vertical groove (M) and port (L) on spool (9). Due to connection and disconnection of the ports and vertical grooves, the oil in the priority valve being set to the pilot pressure is conducted through port (J), orifice (b), vertical groove (M) and port (K), then drained from port (L) to the hydraulic tank.
WA250, 250PZ-6
10-300
11
SEN03993-00
300 Steering system Orbit-roll valve
When steering wheel is "turned left"
10-300
12
WA250, 250PZ-6
300 Steering system Orbit-roll valve
q
q
q
q
q
q
q
q
q
As the steering wheel is "turned left", spool (9) being connected to the drive shaft of the steering column is rotated counterclockwise. Since spool (9) and sleeve (8) are connected by centering spring(2), spool (9) compresses centering spring (2). An angular displacement corresponding to the amount of compression of centering spring (2) is generated between spool (9) and sleeve (8). Port (A) and vertical groove (B) are connected first being followed by the connection between vertical groove (B) and port (E), port (E) and vertical groove (C), and vertical groove (C) and port (G) to the L.H. steering circuit. Although the connection between vertical groove (B) and orifice (b) of port (J) to the priority valve is maintained, port (K) of sleeve (8) starts gradually closing vertical groove (M) and port (L). Port (F) of the R.H. steering circuit is connected to vertical groove (D) at the same time as port (A) and vertical groove (B) are connected. 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 to the L.H. steering cylinder head side through port (E), vertical groove (C) and port (G). Oil pressure of vertical groove (M) is transmitted to port (J) through orifice (b), then supplied from port (J) as the pilot pressure of the priority valve. The oil from the R.H. steering cylinder head is drained to the hydraulic tank through port (F), vertical groove (D) and port (H).
WA250, 250PZ-6
SEN03993-00 When steering wheel is at "stop" position q As operation of the steering wheel is stopped, angular displacement between spool (9) and sleeve (8) disappears and the steering wheel is returned to the neutral position by the repulsive force of centering spring (2).
10-300
13
300 Steering system Orbit-roll valve
SEN03993-00 Connection of hand pump and sleeve
q
q
Above figure shows the suction and discharge ports (P) of the Gerotor and connections with the sleeve ports. If the steering wheel is turned to the right, ports (a), (c), (e), (g), (i), and (k) will be connected to the pump side by the vertical grooves of the spool. Likewise, ports (b), (d), (f), (h), (j), and (l) are connected to the R.H. steering cylinder head side. Under the condition in Fig. 1, ports (1), (2) and (3) are in the discharge state of the Gerotor and connected to ports (l), (b), and (d) and the oil is sent to the steering cylinder. Ports (5), (6), and (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).
10-300
14
q
q
As shown above, the ports in the discharge state of the Gerotor are connected to the ports being connected to the steering cylinder. The ports in the suction state are connected to the pump circuit. The internal gear of the Gerotor advances by 1 tooth with every 1/7 turn of the steering wheel and discharges the oil from the pump according to the steering angle of the steering wheel. Accordingly, the discharge amount varies in proportion to the steering angle of the steering wheel.
WA250, 250PZ-6
300 Steering system Orbit-roll valve
SEN03993-00 Role of centering spring
q
q
WA250, 250PZ-6
Centering spring (2) is composed of 4 Xshaped leaf springs and 2 flat leaf springs and installed between spool (9) and sleeve (8) as shown in the figure. If the steering wheel is turned, spool (9) compresses centering spring (2) and angular displacement (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 reaction force of centering spring (2) by angular displacement (a) of spool (9) and sleeve (8) to return the steering wheel to the "neutral" position.
10-300
15
300 Steering system 2-way restrictor valve
SEN03993-00
2-way restrictor valve
1
1. Tube 2. Poppet 3. Body Function q In order to buffer the impacts resulting from the momentum of the machine when switching the steering, an orifice 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 cylinder's forward move direction), the oil pushes open poppet (3), and flows from orifice (a) and notch (b) of poppet (3).
10-300
16
q
When flowing in the right direction (to the cylinder's return direction), the oil conducted through orifice (a) of poppet (3) alone, thus the flow rate is restricted.
WA250, 250PZ-6
300 Steering system Cushion valve
SEN03993-00
Cushion valve
A: From steering cylinder left turning port B: From steering cylinder right turning port 1. Valve seat 2. Valve body 3. Spring 4. Poppet 5. Orifice 6. Plug 7. Spring 8. Spool 9. Plug 10. Spring 11. Poppet
WA250, 250PZ-6
1
Outline If sudden increase or bouncing occurs in oil pressure of the steering cylinder circuit, this valve mitigates the impacts by releasing the highly pressurized oil to instantly to other line.
q
Function q As highly pressurized oil rushed into port (A), it compresses spring (3) and opens poppet (4) of port (A) side, then flows through the center groove of spool (8) up to port (B) opening poppet (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 overcoming the port (B) side pressure and repulsive force of spring (7), it pushes spool (8) in the right direction, cutting off the flow of oil from port (A) to port (B). q Temporary flow of oil to the cushion valve works as cushioning effects in mitigating the steering impacts. After the operation of the cushion valve is completed, the steering functions as usual. q If the pressure change on the steering cylinder circuit is gradual, spool (8) cuts off the circuit before poppet (4) opens. Thus, the cushion valve remains inactivated.
10-300
17
300 Steering system Steering cylinder
SEN03993-00
Steering cylinder
1
Unit: mm
No. 1
Check item Clearance between bushing in cylinder rod frame connecting part and mounting pin
2
Clearance between bushing in cylinder bottom frame connecting part and mounting pin
3
Connecting part of steering cylinder and front frame
4
Connecting part of steering cylinder and rear frame
10-300
18
Criteria Standard size
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
40
0 –0.025
+0.180 +0.042
0.042 – 0.205
—
40
0 –0.025
+0.180 +0.042
0.042 – 0.205
—
Width of boss
Width of hinge
Standard (a + b) clearance
50
53
Max. 0.5 (after shim is adjusted)
50
53
Max. 0.5 (after shim is adjusted)
Replace
WA250, 250PZ-6
300 Steering system Steering cylinder
SEN03993-00
Unit: mm
No.
Check item
Criteria
Remedy
Shaft
Hole
Standard clearance
Clearance limit
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
1
Clearance between piston rod and bushing
WA250, 250PZ-6
Standard size
Tolerance
Replace pin and bushing
10-300
19
SEN03993-00
Emergency steering piping diagram
300 Steering system Emergency 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)
10-300
20
WA250, 250PZ-6
300 Steering system Emergency steering valve
SEN03993-00
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
WA250, 250PZ-6
1. Check valve body 2. Check valve 3. Valve body 4. Pressure reducing valve 5. Selector valve
10-300
21
SEN03993-00
300 Steering system Emergency steering valve
Operation When engine and steering pump are normal
q
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. 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.
10-300
22
WA250, 250PZ-6
300 Steering system Emergency steering valve
SEN03993-00
When engine or steering pump is abnormal
q
q
q q
a
If, during travel, the steering pump fails to supply sufficient amount of oil to the Orbit-roll valve due to a trouble on the engine or steering pump, discharge pressure of the steering pump goes low. As a result, spool (1) is pushed back in the right direction by the repulsive force of spring (2). 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). De-pressurized oil flows through port (Y) to the Orbit-roll valve, enabling the steering. If the oil in the HST circuit goes low because of flowing out to the steering circuit, oil is supplied to the HST circuit by check valves (6) and (7). Thanks to the function of check valves (3) and (4), the emergency steering system is operable both in the forward and reverse travel.
WA250, 250PZ-6
10-300
23
300 Steering system Steering relief valve
SEN03993-00
Steering relief valve
1
(if equipped)
P1: From steering pump P2: From emergency steering pump T: Drain S1: Steering pump oil pressure switch (Low) S2: Steering pump oil pressure switch (Hi) S3: Emergency steering oil pressure switch
Outline 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)
q
1. Block 2. Relief valve 3. Orifice
10-300
24
WA250, 250PZ-6
300 Steering system Steering relief valve
WA250, 250PZ-6
SEN03993-00
10-300
25
SEN03993-00
WA250-6, WA250PZ-6 GALEO Wheel loader Form No. SEN03993-00
©2007 KOMATSU All Rights Reserved Printed in Japan 10-07 (01)
10-300
26
SEN03994-00
WHEEL LOADER WA250-6 WA250PZ-6 Machine model
Serial number
WA250-6 WA250PZ-6
75001 and up 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
WA250, 250PZ-6
10-400
1
SEN03994-00
10-400
2
400 Brake system
WA250, 250PZ-6
400 Brake system Brake piping diagram
SEN03994-00
Brake piping diagram
1. Hydraulic 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
WA250, 250PZ-6
1
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)
10-400
3
SEN03994-00
Charge valve
10-400
4
400 Brake system Charge valve
1
WA250, 250PZ-6
400 Brake system Charge valve
SEN03994-00
P: From brake and cooling fan pump T: To hydraulic tank A: To cooling fan motor ACC1: To accumulator (rear side) ACC2: To accumulator (front side) S: Brake operation sensor port G: Gauge port 1. Valve body 2. Inverse shuttle valve 3. Plunger 4. Unload relief valve 5. Unload valve 6. Relief valve Unit: mm
No.
Check item
7
Clearance between inverse shuttle valve and body
Criteria Standard size
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
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
Standard size
Repair limit
Installed length
Installed load
Free length
Installed load
18.3
9.8 N {1.0 kg}
—
8.3 N {0.85 kg}
21.6 relief valve return spring 11 Unload (inside)
35.9
30.0
188 N {19.2 kg}
—
160 N {16.3 kg}
relief valve return spring 12 Unload (outside)
39.8
27.5
137 N {14.0 kg}
—
116 N {11.8 kg}
13 Unload valve return spring
51.6
45.0
49 N {5.0 kg}
—
42 N {4.3 kg}
14 Check valve return spring
11.5
9.0
4.9 N {0.5 kg}
—
4.2 N {0.43 kg}
10 Inverse shuttle valve return spring
Free length
Replace
Function q The charge valve maintains the oil pressure from the pump to the set pressure and accumulates it in the accumulator. q If the oil pressure from the pump goes beyond the relief valve s et pres sur e, this valve releases the oil pressure to the drain circuit in order to reduce the load to the pump.
WA250, 250PZ-6
10-400
5
400 Brake system Charge valve
SEN03994-00 Operation When oil is not supplied to accumulator (cut-out state)
q
q
q
q
Plunger (1) is moved in the left direction by the accumulator pressure, and maintains unload relief valve (2) being pushed open. The oil in the spring chamber of unload valve (3) is drained to the hydraulic tank through port (F), unload relief valve (2) and port (T). 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). 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 oil is supplied to accumulator 1. Cut-in state
q
q
q q
q
q
10-400
6
As the accumulator pressure goes low, pressure on port (E) goes low, allowing plunger (1) to move in the right direction and unload relief valve (2) to close the drain circuit. Since the oil pressure in port (F) and the spring chamber of unload valve (3) increases, unload valve (3) moves in the right direction. Port (C) and port (B) are opened, conducting the oil from the pump to port (B). As oil pressure in port (B) increases beyond the set pressure of check valve (4), check valve opens, allowing the oil to be supplied to the accumulator through port (E). The pressure for supplying oil to the accumulator depends on the set pressure of check valve (4). Amount of oil supplied to the accumulator is constant independent of the engine speed, thus surplus of the oil flows to the cooling fan motor through port (A). Inverse shuttle valve (5) supplies precedence to the accumulator of lower pressure when supplying oil.
WA250, 250PZ-6
400 Brake system Charge valve
2.
When pressure reaches cut-out pressure
q
As pressure in port (F) reaches the set pressure (cut-out pressure of unload relief valve (2)), oil in the spring chamber of unload valve (3) is drained to the hydraulic tank through port (F), unload relief valve (2) and port (T). Plunger (1) is moved in the left direction by the accumulator pressure, and maintains unload relief valve (2) being pushed open. 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). 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).
q
q
q
WA250, 250PZ-6
SEN03994-00
When the oil pressure from the pump went beyond the set pressure
q
As oil pressure in chamber (B) reaches the set pressure of relief valve (6), relief valve (6) is opened to drain the oil from the pump to the hydraulic tank through port (T). Above process protects the brake circuit by restricting its maximum pressure.
10-400
7
400 Brake system Brake valve
SEN03994-00
Brake valve
1
P1: From HST pump T1: To hydraulic tank T2: To steering pump (suction side) PA: From accumulator (rear side)
A: To Rear brake PB: From accumulator (front side) B: To front brake
1. Rod 2. Inching valve spool 3. Inching valve body 4. Brake valve spool (for rear)
5. Brake valve body (for rear) 6. Brake valve spool (for front) 7. Brake valve body (for front)
Unit: mm
No. 8 9
Check item Clearance between inching valve spool and body Clearance between inching valve guide and body
between inching valve 10 Clearance spool and guide
Criteria Standard size
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
22.4
–0.022 –0.053
+0.033 0
0.020 – 0.086
0.096
22.4
–0.022 –0.053
+0.033 0
0.020 – 0.086
0.096
12
–0.050 –0.093
+0.050 0
0.050 – 0.143
0.157
Standard size
Repair limit
Free length
Installed length
Installed load
Free length
Installed load
34.7
16.7
24.5 N {2.5 kg}
—
20.8 N {2.1 kg}
12 Brake valve control spring
35.6
24.0
113 N {11.5 kg}
—
96 N {9.8 kg}
13 Inching valve return spring
50.0
49.5
19.6 N {2.0 kg}
—
16.7 N {1.7 kg}
14 Brake valve return spring
114.9
52.4
147 N {15.0 kg}
—
125 N {12.7 kg}
11 Inching valve control spring
10-400
8
Replace
WA250, 250PZ-6
400 Brake system Brake valve
SEN03994-00
Outline q The brake valve is installed in the lower front side of the operator's seat. Pressing the brake pedal conducts oil to the brake piston, operating the brake. q The left side and right side brake pedals are mechanically interlocked. Pressing one of the pedals operates another pedal at the same time. q The brake valve contains the inching valve to regulate the control pressure of the HST pump. Operation When the brake pedal is pressed down
q
q
q
Brake pedal (1) pressing effort is transmitted to spool (5) through rod (2), spool (3) and spring (4). As spool (5) is pushed in the right direction, 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. 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.
WA250, 250PZ-6
When brake of one side is operated (when the other brake failed) q Even when only one side of the brakes remains operable due to, for instance, oil leak on the front or rear brake system, brake pedal (1) pressing effort moves in the right direction after being transmitted mechanically through spool (5) and spool (6). q Oil from the pump is conducted normally to the brake piston of the healthy system to enable stopping the machine as needed in order to ensure safety.
10-400
9
SEN03994-00
400 Brake system Brake valve
Balancing operation
q
q
q
q
q
q
q
As the rear brake piston is filled with oil and the oil pressure rises between port (PA) and port (A), the oil being conducted to chamber (E) through orifice (c) of spool (5) pushes spool (5) in the left direction resisting repulsive force of spring (4). As the result, port (PA) and port (A) are disconnected. Since port (Ta) remains closed, the oil conducted to the brake piston is retained and the brake remains operable. At the same time as spool (5) is moved to the left, the front brake piston is filled up with oil, increasing the oil pressure between port (PB) and port (B). Thus, the oil conducted to chamber (F) through orifice (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. Since port (Tb) remains closed, the oil conducted to the brake piston is retained and the brake remains operable. 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 circuit [port (B) side] is balanced with the oil pressure of the rear brake circuit [port (A) side]. As spools (5) and (6) are moved in the right direction to the stroke end, port (PA) and port (A) as well as port (PB) and port (B) are fully connected. As a result, oil pressure of the rear brake cir cuit and the front br ake circuit becomes equal to that from the pump. Braking force is adjustable by adjusting the brake pedal pressing effort until spools (5) and (6) are driven in the right direction to the stroke end.
10-400
10
WA250, 250PZ-6
400 Brake system Brake valve
SEN03994-00
When brake pedal is released
q q
q
q
q
Releasing brake pedal (1) releases the pedal pressing effort being applied to spool (5). Spool (5) is pushed back in the left direction by the back pressure of the rear brake piston and repulsive force of spring (7), and port (PA) and port (A) are closed. 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. 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. Oil in the front brake piston is drained to the hydraulic tank through port (B) and port (Tb), releasing the front brake.
WA250, 250PZ-6
10-400
11
SEN03994-00
Inching valve
P1: From HST pump port Y T2: To steering pump (suction side) 1. Brake pedal 2. Brake valve 3. Spool 4. Body
10-400
12
400 Brake system Inching valve
1
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.
WA250, 250PZ-6
400 Brake system Accumulator (for brake)
SEN03994-00
Accumulator (for brake)
1
1. Cylinder 2. Free piston Function q The accumulator is installed between the charge valve and brake valve. The space between cylinder (1) and free piston (2) is filled with nitrogen gas. The nitrogen gas absorbs the hydraulic pulses generated by the hydraulic pump and secures the braking force and operability when the engine is stopped by utilizing its compressibility. Specifications Gas used
WA250, 250PZ-6
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})
10 {102}
10-400
13
400 Brake system Slack adjuster
SEN03994-00
Slack adjuster
1
A: From brake valve B: To brake piston 1. Body 2. Check valve 3. Piston Unit: mm
No. 4 5
Check item Clearance between piston and body Clearance between check valve and body
Criteria Standard size
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
30
–0.065 –0.098
+0.052 0
0.065 – 0.150
0.163
10
–0.013 –0.028
+0.015 0
0.013 – 0.043
0.048
Standard size
6
7
Piston return spring
Check valve return spring
10-400
14
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}
21.7
19.25
53.9 N {5.5 kg}
—
46.1 N {4.7 kg}
Replace
WA250, 250PZ-6
400 Brake system Slack adjuster
SEN03994-00
Function q The slack adjuster is installed between the brake valve and brake piston. It maintains the time lag up to activation of the brake constant. Operation When brake is applied
q
q
q
The oil from the brake valve flows to port (A) and moves piston (1) in the right direction to activate the brake using the oil being amassed between piston (1) and the brake piston. The slack adjuster maintains the time lag up to activation of the brake constant by operating t he b r a k e u s i n g th e o i l b e i ng a m a s s e d between piston (1) and the brake piston. 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.
WA250, 250PZ-6
When brake is released
q
The oil being stopped between piston (1) and brake piston pushes back piston (1) in the left direction, allowing the oil, equivalent in the volume to piston (1) move distance, to return to the brake valve through port (A) then is drained to the hydraulic tank.
10-400
15
400 Brake system Brake
SEN03994-00
Brake Front brake
1 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)
10-400
16
WA250, 250PZ-6
400 Brake system Brake
SEN03994-00
Unit: mm
No.
Check item
10 Thickness of plate Thickness of brake disc
11 Depth of lining groove Thickness of lining of disc contact surface of 12 Wear brake outer ring
Criteria Tolerance
Repair limit
6
±0.1
5.5
6.5
±0.15
5.7
0.8 (min.)
—
0.4
1.0
0.8 (min.)
—
Standard size
Tolerance
Wear limit
19.0
±0.1
18.7
Installed height
Installed load
Installed load
6.5
2,253 N {230 kg}
1,800 N {184 kg}
Standard size of spring 13 Load (when 2 pieces are piled)
Remedy
Standard size
Replace
Repair limit
Outline q The front brake is a wet multiple disc type brake, which consists of piston (3), inner ring (5), disc (9), outer ring (8), and spring (4). q The brake cylinder consists of differential housing (1) and bearing carrier (2). And piston (3) is assembled to them. Inner ring (5) and outer ring (8) are coupled with the spline of differential housing (1). q Disc (9) has linings stuck 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).
WA250, 250PZ-6
10-400
17
SEN03994-00
Rear brake
400 Brake system 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)
10-400
18
WA250, 250PZ-6
400 Brake system Brake
SEN03994-00
Unit: mm
No.
Check item
10 Thickness of plate Thickness of brake disc
11 Depth of lining groove Thickness of lining of disc contact surface of 12 Wear brake outer ring
Criteria Tolerance
Repair limit
6
±0.1
5.5
6.5
±0.15
5.7
0.8 (min.)
—
0.4
1.0
0.8 (min.)
—
Standard size
Tolerance
Wear limit
19.0
±0.1
18.7
Installed height
Installed load
Installed load
6.5
2,253 N {230 kg}
1,800 N {184 kg}
Standard size of spring 13 Load (when 2 pieces are piled)
Remedy
Standard size
Replace
Repair limit
Outline q The rear brake is a wet multiple disc type brake, which consists of piston (3), inner ring (5), disc (9), outer ring (8), and spring (4). q The brake cylinder consists of differential housing (1) and bearing carrier (2). And piston (3) is assembled to them. Inner ring (5) and outer ring (8) are coupled with the spline of differential housing (1). q Disc (9) has linings stuck 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).
WA250, 250PZ-6
10-400
19
SEN03994-00
400 Brake system Brake
Operation When brake is operated
q
As the brake pedal is pressed, oil pressure (P) being supplied through the hydraulic tank, pump and brake charge valve to the brake cylinder acts on piston (2) in the brake cylinder to move 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 returning 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 on them. While disc (4) is rotating, oil flows in those grooves to cool the linings.
10-400
20
WA250, 250PZ-6
400 Brake system Parking brake control
SEN03994-00
Parking brake control
1. Parking brake lever 2. Parking brake lever bottom switch 3. Parking brake lever intermediate switch
1
4. Control cable 5. Transfer 6. Multi-disc brake lever
Outline q The parking brake is built in transfer (5). On this mechanical parking brake, operating the multi-disc brake lever (6) from parking brake lever (1) allows "applying" or "releasing" the parking brake. q Pulling parking brake lever (1) on the operator'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 long as the parking brake is "applied", current to the directional solenoid valve on the HST pump is cut off and the swash plate of the HST pump is maintained at the neutral position.
WA250, 250PZ-6
10-400
21
400 Brake system Parking brake
SEN03994-00
Parking brake
1
5. Plate 6. Disc 7. Wave spring 8. Output shaft
1. Lever 2. Housing 3. Ball 4. Piston
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Tolerance
Repair limit
2.6
±0.06
2.5
Strain on plate
—
0.05
0.1
Thickness of brake disc
2.2
±0.08
2.05
Strain on brake disc
—
0.02
0.25
1,010 N {103 kg}
±101 N {±10.3 kg}
858 N {87.6 kg}
Thickness of plate
9
Replace
10 of wave spring 11 Load (height: 2.2 mm)
Outline q This parking brake is a wet multiple disc type brake being operated mechanically to apply braking to output shaft (8). q Lever (1) is connected to the control cable. Ball (3) provided between piston (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).
10-400
22
WA250, 250PZ-6
400 Brake system Parking brake
WA250, 250PZ-6
SEN03994-00
10-400
23
SEN03994-00
WA250-6, WA250PZ-6 GALEO Wheel loader Form No. SEN03994-00
©2007 KOMATSU All Rights Reserved Printed in Japan 10-07 (01)
10-400
24
SEN03995-00
WHEEL LOADER WA250-6 WA250PZ-6 Machine model
Serial number
WA250-6 WA250PZ-6
75001 and up 75001 and up
10 Structure, function and maintenance standard
10
500 Undercarriage and frame Axle mount and center hinge pin .................................................................................................................... 2 Tires ................................................................................................................................................................ 7
WA250, 250PZ-6
10-500
1
SEN03995-00
Axle mount and center hinge pin a
500 Undercarriage and frame Axle mount and center hinge pin
1
The following drawing shows WA250-6.
10-500
2
WA250, 250PZ-6
500 Undercarriage and frame Axle mount and center hinge pin
1. 2. 3. 4. 5. 6. 7. 8.
Front axle Tension bolt Rear axle Frame lock bar Front frame Center hinge pin Rear frame Additional counterweight (WA250-6: if equipped) (WA250PZ-6: standard) 9. Counterweight
WA250, 250PZ-6
SEN03995-00 Outline q Front axle (1) receives the force during work directly. Thus, 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 cylinders connect the front frame (5) and rear frame (7). They adjust the bending angle or the turning radius of the frame according to move of the cylinder.
10-500
3
SEN03995-00
10-500
4
500 Undercarriage and frame Axle mount and center hinge pin
WA250, 250PZ-6
500 Undercarriage and frame Axle mount and center hinge pin
SEN03995-00
Unit: mm
No. 1
Check item Clearance between upper hinge pin and rear frame (small)
Criteria Tolerance
Standard size
Remedy
Shaft
Hole
Standard clearance
Clearance limit
65
–0.030 –0.049
+0.100 0
0.030 – 0.149
—
2
Clearance between upper hinge pin and spacer
65
–0.030 –0.049
+0.240 0
0.030 – 0.289
—
3
Clearance between upper hinge pin and bearing
65
–0.030 –0.049
0 –0.015
0.015 – 0.049
—
4
Clearance between upper hinge pin and rear frame (large)
80.5
–0.080 –0.180
±0.050
0.030 – 0.230
—
5
Clearance between front frame and upper hinge bearing
110
0 –0.020
–0.041 –0.076
–0.076 – –0.021
—
6
Clearance between lower hinge pin and rear frame bushing
65
–0.030 –0.076
+0.067 +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
—
80
+0.260 +0.160
+0.046 0
–0.260 – –0.114
—
of press fitting part of 10 Clearance lower hinge pin seal
11 Height of upper hinge spacer
Standard size
Tolerance
Repair limit
26
0 –0.25
—
thickness of shim 12 Standard between upper hinge and retainer
0.92
thickness of shim 13 Standard between upper hinge and retainer
1.45
thickness of shim 14 Standard between lower hinge and retainer
0.85
torque of upper hinge 15 Tightening retainer mounting bolt
torque of lower hinge 16 Tightening retainer mounting bolt
WA250, 250PZ-6
14.7 ± 1.5 Nm {1.5 ± 0.15 kgm} (when shim is adjusted)
Replace
Adjust
59 – 74 Nm {6.0 – 7.5 kgm} (final value) 14.7 ± 1.5 Nm {1.5 ± 0.15 kgm} (when shim is adjusted) 59 – 74 Nm {6.0 – 7.5 kgm} (final value)
10-500
5
500 Undercarriage and frame Axle mount and center hinge pin
SEN03995-00
Unit: mm
No.
Check item
1
Thickness of thrust plate
2
Thickness of thrust washer
3
Clearance between shaft and hole on front support side
4
Clearance between shaft and hole on rear support side
5
Standard thickness of shim in thrust cap
10-500
6
Criteria
Remedy
Standard size
Tolerance
Repair limit
10
0 –0.15
—
5
+0.3 –0.1
—
Standard size
Tolerance Shaft
Hole
Standard clearance
Clearance limit
170
–0.043 –0.106
+0.550 +0.050
0.093 – 0.656
—
170
–0.043 –0.106
+0.550 +0.050
0.093 – 0.656
—
0.2
Replace
—
WA250, 250PZ-6
500 Undercarriage and frame Tires
SEN03995-00
Tires
1
The radial tires (if equipped) of this machine have the following features. q High gripping force q Low fuel consumption q High operator comfort q Long life q Less frequency of burst q Less damages of machine q Less uneven wear q Less generation of heat Comparison of structures and characteristics of tires Radial tire
Bias tire
Structure q The cords of carcass (1) are arranged at right angles to the center line of tread (T) (radially). q Tread (T) is stabilized and protected by several strong belts (2). q Side wall (W) and tread (T) are independent from each other.
Structure q The cords of carcass (1) are arranged bias from the center line of tread (T). q Side wall (W) and tread (T) are integral.
Ground contact characteristics Even if the tire is deformed by a load, it does not move uselessly in ground contact and uniform ground contact surface is secured stably.
Ground contact characteristics If the tire is deformed by a load, the ground contact surface is also deformed, leading to wasteful moves. As a result, the ground contact surface becomes unstable.
q
q
Deformation characteristics q Only side wall (W) is deformed as load is applied and tread (T) made of strong belts (2) keeps stability independently.
Deformation characteristics q Side wall (W) which receives loads and tread (T) move as one unit.
WA250, 250PZ-6
10-500
7
SEN03995-00
WA250-6, WA250PZ-6 GALEO Wheel loader Form No. SEN03995-00
©2007 KOMATSU All Rights Reserved Printed in Japan 10-07 (01)
10-500
8
SEN03996-00
WHEEL LOADER WA250-6 WA250PZ-6 Machine model
Serial number
WA250-6 WA250PZ-6
75001 and up 75001 and up
10 Structure, function and maintenance standard
10
600 Hydraulic system 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
WA250, 250PZ-6
10-600
1
SEN03996-00
Work equipment hydraulic piping diagram
600 Hydraulic system Work equipment hydraulic piping diagram
1
WA250-6
10-600
2
WA250, 250PZ-6
600 Hydraulic system Work equipment hydraulic piping diagram
1. Work equipment control valve 2. Bucket cylinder 3. Hydraulic tank 4. Work equipment PPC valve 5. Lock valve 6. Oil cooler 7. Check valve 8. 4-gear pump • Steering pump • Work equipment pump • Brake and cooling fan pump • Transfer lubrication pump 9. Accumulator (for ECSS) (if equipped) 10. Lift cylinder 11. ECSS valve (if equipped) 12. Accumulator (for PPC circuit)
WA250, 250PZ-6
SEN03996-00 Outline q The hydraulic system is consisted of the HST, steering, work equipment, brake, cooling fan and transfer lubrication circuit. The work equipment circuit controls move of the lift arm and bucket. q The oil in hydraulic tank (3) is supplied to work equipment control valve (1) by work equipment pump of 4-gear pump (8). When each spool of the lift arm and bucket of work equipment control valve (1) is at the Hold position, the oil flows the drain circuit of work equipment control 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 cylinder (2) to operate the lift arm or bucket. q The maximum pressure in the hydraulic circuit is controlled with the relief valve in work equipment control valve (1). The bucket cylinder circuit is equipped with the safety-suction valve for protection of the circuit. q Accumulator (for PPC circuit) (12) is installed on the PPC pilot circuit so that the work equipment can be lowered to the ground even while the engine is stopped. q Hydraulic tank (3) is pressurized, enclosed, and equipped with the breather having the relief valve, which doubles the oil filler cap function. The breather applies pressure to the tank and, at the same time, prevents generation of negative pressure in the tank to prevent cavitation in the pump.
10-600
3
SEN03996-00
600 Hydraulic system Work equipment hydraulic piping diagram
WA250PZ-6
10-600
4
WA250, 250PZ-6
600 Hydraulic system Work equipment hydraulic piping diagram
1. Bypass valve (for lift arm circuit) 2. Work equipment control valve 3. Quick coupler solenoid valve 4. Bucket cylinder 5. Hydraulic tank 6. Work equipment PPC valve 7. Attachment PPC valve 8. Lock valve 9. Oil cooler 10. Check valve 11. 4-gear pump • Steering pump • Work equipment pump • Brake and cooling fan pump • Transfer lubrication pump 12. Accumulator (for ECSS) (if equipped) 13. Lift cylinder 14. ECSS valve (if equipped) 15. Coupler plunger 16. Accumulator (for PPC circuit)
WA250, 250PZ-6
SEN03996-00 Outline q The hydraulic system is consisted of the HST, steering, work equipment, brake, cooling fan and transfer lubrication circuit. The work equipment circuit controls move of the lift arm, bucket and attachment. q The oil in hydraulic tank (5) is supplied to work equipment control valve (2) by work equipment pump of 4-gear pump (11). When each spool of the lift arm, bucket and attachment of work equipment control valve (2) is at the Hold position, the oil flows the drain circuit of work equipment control valve (2), is filtered on the return filter on hydraulic tank (5), then is returned to hydraulic tank (5). q Operating the lift arm control lever or bucket control lever operates the lift arm spool or bucket spool of work equipment PPC valve (6). If operating the auxiliary control lever operates the spool of attachment PPC valve (7). The oil from work equipment PPC valve (6) or attachment PPC valve (7) operates respective spools of work equipment control valve (2) with its oil pressure, then sends the oil pressure to lift cylinder (13), bucket cylinder (4) or coupler plunger (15) to operate the lift arm, bucket or attachment. q The maximum pressure in the hydraulic circuit is controlled with the relief valve in work equipment control valve (2). The bucket cylinder circuit is equipped with the safety-suction valve for protection of the circuit. q Accumulator (for PPC circuit) (16) is installed on the PPC pilot circuit so that the work equipment can be lowered to the ground even while the engine is stopped. q Hydraulic tank (5) is pressurized, enclosed, and equipped with the breather having the relief valve, which doubles the oil filler cap function. The breather applies pressure to the tank and, at the same time, prevents generation of negative pressure in the tank to prevent cavitation in the pump.
10-600
5
SEN03996-00
Work equipment control lever linkage
600 Hydraulic system Work equipment control lever linkage
1
WA250-6 Mono-lever type
1. Work equipment control lever 2. Wrist rest 3. Lock valve 4. Work equipment lock lever 5. Work equipment PPC valve 6. Wrist rest height adjustment lever
10-600
6
WA250, 250PZ-6
600 Hydraulic system Work equipment control lever linkage
SEN03996-00
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
WA250, 250PZ-6
10-600
7
SEN03996-00
600 Hydraulic system Work equipment control lever linkage
WA250PZ-6 2-lever type
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
10-600
8
WA250, 250PZ-6
600 Hydraulic system Work equipment control lever linkage
SEN03996-00
WA250PZ-6 Multi-function mono-lever type (if equipped)
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
WA250, 250PZ-6
10-600
9
SEN03996-00
600 Hydraulic system Work equipment control lever linkage
WA250PZ-6 Mono-lever type (if equipped)
1. Auxiliary control lever 2. Work equipment control lever 3. Wrist rest 4. Lock valve 5. Work equipment lock lever 6. Work equipment PPC valve 7. Attachment PPC valve 8. Wrist rest height adjustment lever
10-600
10
WA250, 250PZ-6
600 Hydraulic system Work equipment control lever linkage
WA250, 250PZ-6
SEN03996-00
10-600
11
600 Hydraulic system Hydraulic tank
SEN03996-00
Hydraulic tank
1. Oil filler cap and breather 2. Return filter 3. Hydraulic tank 4. Drain plug 5. Sight gauge 6. Return filter bypass valve 7. Check valve
10-600
12
1
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}
WA250, 250PZ-6
600 Hydraulic system Hydraulic tank
Breather
SEN03996-00
1
1. Oil filler cap 2. Case 3. Lock-resetting knob 4. Sleeve 5. Poppet 6. Filter element Prevention of negative pressure in tank q Since the tank is pressurized and enclosed, if the oil level in it lowers, negative pressure is generated. At this time, sleeve (4) is opened by the differential pressure between the tank pressure and the atmospheric pressure to prevent generation 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 cylinders operate, and the temperature rises. Consequently, the pressure in the tank rises, too. If the pressure in the tank rises beyond the set level, poppet (5) is activated to release the pressure in the tank to prevent rise of pressure in the tank. (set pressure of exhaust valve: 0.1 ± 0.015 MPa {1.0 ± 0.15 kg/cm2})
WA250, 250PZ-6
10-600
13
600 Hydraulic system 4-gear pump
SEN03996-00
4-gear pump
1
(steering, work equipment, brake, cooling fan and transfer lubrication) SAR (3)56 + (2)40 + SB (1)12 + 12
1. Steering pump 2. Work equipment pump 3. Brake and cooling fan pump 4. Transfer lubrication pump
10-600
14
Outline 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.
q
WA250, 250PZ-6
600 Hydraulic system 4-gear pump
SEN03996-00
Unit: mm
No.
Check item
Criteria Type
Remedy
Standard clearance
Clearance limit
0.10 – 0.15
0.19
SAR(3)56
5
Side clearance
SAR(2)40 SBR(1)12 SBR(1)12
6
Clearance between inside diameter of plain bearing and outside diameter of gear shaft
SAR(3)56
0.083 – 0.144
SAR(2)40
0.071 – 0.121
SBR(1)12 SBR(1)12
7
8
Pin driven depth
Type
Standard size
SAR(3)56
13
SAR(2)40
12
SBR(1)12
10
SBR(1)12
7
Torque of spline rotating shaft
Delivery
Oil temperature: 45 – 55°C
Allowance 0 –0.5
Repair limit
—
+0.5 0
Speed (rpm)
Discharge pressure (MPa {kg/cm2})
SAR(3)56 SAR(2)40 SBR(1)12 SBR(1)12
WA250, 250PZ-6
Replace
13.8 – 28.5 Nm {1.4 – 2.9 kgm}
Type — Oil: SAE10WCD
0.20
0.068 – 0.115
2,500
20.6 {210} 2.9 {30}
Standard delivery (l/min)
Allowable delivery (l/min)
129
119
91
82
27
24
27
24
—
10-600
15
SEN03996-00
Work equipment control valve
600 Hydraulic system Work equipment control valve
1
WA250-6
2-spool type
10-600
16
WA250, 250PZ-6
600 Hydraulic system Work equipment control valve
SEN03996-00
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 TS: To hydraulic tank
WA250, 250PZ-6
10-600
17
SEN03996-00
10-600
18
600 Hydraulic system Work equipment control valve
WA250, 250PZ-6
600 Hydraulic system Work equipment control valve
SEN03996-00
1. Main relief valve 2. Bucket spool 3. Lift arm spool 4. Suction safety valve 5. Check valve 6. Suction valve Unit: mm
No.
Item
Criteria
Remedy
Standard size
7
Spool return spring
Repair limit
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 valve spring
39.5 x 11.2
25
29.4 N {3 kg}
—
23.5 N {2.4 kg}
WA250, 250PZ-6
If damaged or deformed, replace spring
10-600
19
SEN03996-00
600 Hydraulic system Work equipment control valve
WA250-6
3-spool type
10-600
20
WA250, 250PZ-6
600 Hydraulic system Work equipment control valve
SEN03996-00
A1: To service actuator A2: To bucket cylinder 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 TS: To hydraulic tank
WA250, 250PZ-6
10-600
21
SEN03996-00
10-600
22
600 Hydraulic system Work equipment control valve
WA250, 250PZ-6
600 Hydraulic system Work equipment control valve
SEN03996-00
1. Main relief valve 2. Service spool 3. Bucket spool 4. Lift arm spool 5. Suction safety valve 6. Check valve 7. Suction valve Unit: mm
No.
Item
Criteria
Remedy
Standard size
Repair limit
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}
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}
12 Check valve spring
39.5 x 11.2
25
29.4 N {3 kg}
—
23.5 N {2.4 kg}
8
9
Spool return spring
WA250, 250PZ-6
If damaged or deformed, replace spring
10-600
23
SEN03996-00
600 Hydraulic system Work equipment control valve
WA250PZ-6
2-spool type
10-600
24
WA250, 250PZ-6
600 Hydraulic system Work equipment control valve
SEN03996-00
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
WA250, 250PZ-6
10-600
25
SEN03996-00
10-600
26
600 Hydraulic system Work equipment control valve
WA250, 250PZ-6
600 Hydraulic system Work equipment control valve
SEN03996-00
1. Main relief valve 2. Bucket spool 3. Lift arm spool 4. Suction safety valve 5. Check valve 6. Suction valve Unit: mm
No.
Item
Criteria
Remedy
Standard size
7
Spool return spring
Repair limit
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 valve spring
39.5 x 11.2
25
29.4 N {3 kg}
—
23.5 N {2.4 kg}
WA250, 250PZ-6
If damaged or deformed, replace spring
10-600
27
SEN03996-00
600 Hydraulic system Work equipment control valve
WA250PZ-6
3-spool type
10-600
28
WA250, 250PZ-6
600 Hydraulic system Work equipment control valve
SEN03996-00
A1: To service actuator A2: To bucket cylinder 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
WA250, 250PZ-6
10-600
29
SEN03996-00
10-600
30
600 Hydraulic system Work equipment control valve
WA250, 250PZ-6
600 Hydraulic system Work equipment control valve
SEN03996-00
1. Main relief valve 2. Service spool 3. Bucket spool 4. Lift arm spool 5. Suction safety valve 6. Check valve 7. Suction valve Unit: mm
No.
Item
Criteria
Remedy
Standard size
Repair limit
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}
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}
12 Check valve spring
39.5 x 11.2
25
29.4 N {3 kg}
—
23.5 N {2.4 kg}
8
9
Spool return spring
Spool return spring
WA250, 250PZ-6
If damaged or deformed, replace spring
10-600
31
600 Hydraulic system Work equipment control valve
SEN03996-00
Relief valve 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 pressure in port (B) is decreased.
q
As the pressure in port (B) goes low, the orifice of main valve (1) generates differential pressure between ports (A) and (B). As a result, the main valve is pushed open, and pressurized oil in port (A) flows to the drain circuit through port (C) to release the abnormal pressure. Using the repulsive force of spring (4) can increase or decrease the set pressure. When increasing the set pressure, remove the cap nut to loosen the locknut and screw the adjustment screw (5). When decreasing, loosen the adjustment screw (5).
1. Main valve 2. Valve seat 3. Pilot poppet 4. Spring 5. Adjustment screw Function q This valve is installed in the inlet of the work equipment control valve. When the oil pressure increases beyond the specified level, it drains the oil to the hydraulic tank. Above process protects the work equipment circuit by restricting the maximum pressure.
q q
Operation Port (A) and port (C) are connected to the pump circuit and the drain circuit, respectively. Pressurized oil fills up port (B) after flowing through the orifice of main valve (1). Pilot poppet (3) is contacted with valve seat (2).
q
10-600
32
WA250, 250PZ-6
600 Hydraulic system Work equipment control valve
SEN03996-00
Suction safety valve
1. Piston 2. Main valve 3. Piston spring 4. Valve seat 5. Poppet 6. Poppet spring 7. Suction valve 8. Suction valve spring 9. Adjustment screw Function q This valve is installed in the bucket cylinder circuit of the work equipment control valve. When the bucket lever is set to the neutral position, if abnor mal pr ess ure is gener ated due to impacts to the cylinder, the abnormal pressure is relieved through this valve to protect the hydraulic equipment such as cylinder from damage. q And if negative pressure is generated in the cylinder circuit, this valve works as a suction valve. Operation
1. Operation as safety valve q q
q
q
If abnormal pressure is generated in port (A) and reaches the set pressure of spring (6), poppet (5) opens to drain the pressurized oil in port (C) through port (D) and outer circumference (a) of suction valve (7).
q
Opening of poppet (5) decreases the pressure in port (C), and piston (1) moves to the right. Piston (1) contacts the tip of poppet (5) and the pressurized oil is drained from port (D) through orifice (b).
Port (A) and port (B) are connected to the cylinder circuit and drain circuit, respectively. 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 relation (d2) < (d3). The relation between the size of cross sectional diameters (cross section areas) can be presented as (d5) > (d4) > (d1) > (d3) > (d2).
WA250, 250PZ-6
10-600
33
600 Hydraulic system Work equipment control valve
SEN03996-00 q
q
Since the pressure in port (C) is lower than that in port (A), main valve (2) moves to the right and the pressurized oil is conducted from port (A) to port (B) to prevent generation of abnormal pressure. Even if abnormal pressure is generated, suction valve (7) with the large cross sectional diameter remains not operated because of the relation (d1) < (d4).
Suction valve
1. Main poppet 2. Sleeve 3. Spring Function q This valve prevents to generate negative pressure on the circuit.
2. Operation as suction valve q
q
If negative pressure is generated on the cylinder circuit, negative pressure is set on both port (A) and port (C) because they are connected to each other. Suction valve ( 7) receives the pressurized oil by the difference in area between (d4) and (d1). When the differential pressure between port (B) and port (A) increases beyond the set pressure, 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).
10-600
34
Operation q If negative pressure is generated in port (A) (lift arm cylinder head) [if a pressure lower than that in the tank circuit port (B) is generated], main poppet (1) is opened by the difference in area between (d1) and (d2), and the pressurized oil flows to cylinder port (A) from tank port (B).
WA250, 250PZ-6
600 Hydraulic system Work equipment control valve
SEN03996-00
Operation of work equipment control valve 1. When lift arm and bucket spool are at the neutral position
Operation q The pressurized oil flows to port (A) through pump (1) and the priority valve. And the maximum pressure is regulated by relief valve (2). q The bypass circuit is open since bucket spool (3) is at the neutral position. Thus, the pressurized 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 pressurized oil in port (B) enters port (C) of the drain circuit passing through in vicinity of the spool, and returns to the hydraulic tank through the filter. WA250, 250PZ-6
10-600
35
SEN03996-00
600 Hydraulic system Work equipment control valve
2. When lift arm spool is at raise position
Operation q Pulling the work equipment control lever pulls out lift arm spool (4) to set it to the raise position. q The 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) and drain port (C). Thus, the lift arm is moved upward. 10-600
36
WA250, 250PZ-6
600 Hydraulic system Work equipment control valve
SEN03996-00
3. When lift arm spool is at lower position
Operation q Pushing the work equipment control lever pushes in lift arm spool (4) to set it to the lower position. q The 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 rod side through port (E). q The pressurized oil on the cylinder bottom side returns to the hydraulic tank through port (D) and drain port (C). Thus, the lift arm is moved downward. WA250, 250PZ-6
10-600
37
600 Hydraulic system Work equipment control valve
SEN03996-00
4. When lift arm spool is at float position
Operation q Pushing the work equipment control lever further from the lower position pushes in lift arm spool (4) to set it to the float position. q The 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 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 connected to the drain circuit.
10-600
38
q
As long as the bucket is contacting against the ground surface, the lift arm can be raised or lowered due to undulations on the ground surface.
WA250, 250PZ-6
600 Hydraulic system Work equipment control valve
SEN03996-00
5. When bucket spool is at tilt position
Operation q Pulling the work equipment control 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.
WA250, 250PZ-6
10-600
39
SEN03996-00
600 Hydraulic system Work equipment control valve
6. When bucket spool is at dump position
Operation q Pushing the work equipment control 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.
10-600
40
WA250, 250PZ-6
600 Hydraulic system PPC valve
SEN03996-00
PPC valve a
1
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)
WA250, 250PZ-6
P3: To lift arm valve (raise) P4: To lift arm valve (lower, float) T: To hydraulic tank
10-600
41
600 Hydraulic system PPC valve
SEN03996-00
1. Spool 2. Metering spring 3. Centering spring 4. Rod 5. Disc 6. Nut (for connecting lever)
10-600
42
7. Joint 8. Plate 9. Piston 10. Retainer 11. Body 12. Filter
WA250, 250PZ-6
600 Hydraulic system PPC valve
SEN03996-00
Operation 1. When in neutral 1) Bucket PPC valve q Ports (PA) and (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).
WA250, 250PZ-6
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).
10-600
43
SEN03996-00
600 Hydraulic system PPC valve
2. When in fine control mode (neutral o fine control) q If rod (4) and piston (9) are pushed by disc (5), retainer (10) is pushed and spool (1) is also pushed downward through metering spring (2). q When fine control hole (f) is shut off from drain chamber (D), almost simultaneously, it is connected to pump pressure chamber (PP). q The pilot pressurized oil from the HST charge pump flows through fine control hole (f) and port (P1) to port (PB). q If the pressure in port (P1) rises, spool (1) is pushed back and fine control hole (f) is disconnected from pump pressure chamber (PP) and connected to drain chamber (D) almost simultaneously 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 pressure chamber (PP)) does not change until retainer (10) comes in contact with spool (1). q Metering spring (2) is compressed in proportion to the stroke of the control lever. q Pressure in port (P1) also increases in proportion to the stroke of the control lever. q The control valve spool moves to a position where the pressure in chamber (PB) (equal to the pressure in port (P1)) is balanced with the force of the control valve spool return spring.
10-600
44
WA250, 250PZ-6
600 Hydraulic system PPC valve
3. When in fine control mode (when control lever is returned) q As disc (5) begins to return, the force of centering spring (3) and the pressure in port (P1) push up spool (1). q Because of this, fine control hole (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released. q If the pressure in port (P1) went abnormally low, spool (1) is pushed down by metering spring (2). q Fine control hole (f) is disconnected from drain chamber (D) and almost simultaneously connected to the pump pressure chamber (PP). q The pump pressure is supplied until the pressure in port (P1) recovers to a pressure equivalent to the position of the lever. q When the control valve spool returns, the pressurized 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).
WA250, 250PZ-6
SEN03996-00 4. When lever is operated to stroke end q Disc (5) and rod (4) push down piston (9) and retainer (10) pushes down spool (1). q Fine control hole (f) is disconnected from drain chamber (D) and connected to the pump pressure chamber (PP). q The pilot pressure oil from the HST charge pump flows through fine control hole (f) and port (P1) into chamber (PB) to push the control valve spool. q The oil returning from chamber (PA) flows through port (P2) and fine control hole (f') into drain chamber (D).
10-600
45
SEN03996-00
600 Hydraulic system PPC valve
5. When lift arm is "float" q If disc (5) pushes down rod (4) and piston (9) on port (P4) "lower" side, the detent starts operation before the stroke end. (the operating effort of the lever becomes heavy.) q If rod (4) is pushed down further, the detent operates to keep the lift arm in "float" state even if 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 When returning disc (5) from the "float" position, 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 turning off the current in the solenoid (deenergizing the solenoid). q
q
The lift arm raise and bucket tilt operations are carried out similarly to the above.
10-600
46
WA250, 250PZ-6
600 Hydraulic system PPC valve
SEN03996-00
2-lever type
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
WA250, 250PZ-6
10-600
47
600 Hydraulic system PPC valve
SEN03996-00
1. Spool 2. Metering spring 3. Centering spring 4. Rod 5. Lever 6. Ring
10-600
48
7. Plate 8. Piston 9. Retainer 10. Body 11. Filter
WA250, 250PZ-6
600 Hydraulic system PPC valve
SEN03996-00
Operation 1. When in neutral 1) Bucket PPC valve q Ports (PA) and (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).
WA250, 250PZ-6
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).
10-600
49
SEN03996-00
600 Hydraulic system PPC valve
2. When in fine control mode (neutral o fine control) q If rod (4) and piston (8) are pushed by lever (5), retainer (9) is pushed and spool (1) is also pushed downward through metering spring (2). q When fine control hole (f) is shut off from drain chamber (D), almost simultaneously, it is connected to pump pressure chamber (PP). q The pilot pressurized oil from the HST charge pump flows through fine control hole (f) and port (P1) to port (PB). q If the pressure in port (P1) rises, spool (1) is pushed back and fine control hole (f) is disconnected from pump pressure chamber (PP) and connected to drain chamber (D) almost simultaneously 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 pressure chamber (PP)) does not change until retainer (9) comes in contact with spool (1). q Metering spring (2) is compressed in proportion to the stroke of the control lever. q Pressure in port (P1) also increases in proportion to the stroke of the control lever. q The control valve spool moves to a position where the pressure in chamber (PB) (equal to the pressure in port (P1)) is balanced with the force of the control valve spool return spring.
10-600
50
WA250, 250PZ-6
600 Hydraulic system PPC valve
3. When in fine control mode (when control lever is returned) q If lever (5) begins to return, the force of centering spring (3) and the pressure in port (P1) push up spool (1). q Because of this, fine control hole (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released. q If the pressure in port (P1) went abnormally low, spool (1) is pushed down by metering spring (2). q Fine control hole (f) is disconnected from drain chamber (D) and almost simultaneously connected to the pump pressure chamber (PP). q The pump pressure is supplied until the pressure in port (P1) recovers to a pressure equivalent to the position of the lever. q When the control valve spool returns, the pressurized 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).
WA250, 250PZ-6
SEN03996-00 4. When lever is operated to stroke end q Lever (5) and rod (4) push down piston (8) and retainer (9) pushes down spool (1). q Fine control hole (f) is disconnected from drain chamber (D) and connected to the pump pressure chamber (PP). q The pilot pressure oil from the HST charge pump flows through fine control hole (f) and port (P1) into chamber (PB) to push the control valve spool. q The oil returning from chamber (PA) flows through port (P4) and fine control hole (f') into drain chamber (D).
10-600
51
SEN03996-00
600 Hydraulic system PPC valve
5. When lift arm is "float" q As lever (5) pushes down rod (4) and piston (8) on port (P3) "lower" side, the detent starts operation before the stroke end. (the operating effort of the lever becomes heavy.) q If rod (4) is pushed down further, the detent operates to keep the lift arm in "float" state even if 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 When returning lever (5) from the "float" position, 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 turning off the current in the solenoid (deenergizing the solenoid). q
q
The lift arm raise and bucket tilt operations are carried out similarly to the above.
10-600
52
WA250, 250PZ-6
600 Hydraulic system PPC valve
WA250, 250PZ-6
SEN03996-00
10-600
53
SEN03996-00
600 Hydraulic system PPC valve
Attachment PPC valve
a
For the details of operation, see the paragraph of "Work equipment PPC valve".
10-600
54
WA250, 250PZ-6
600 Hydraulic system PPC valve
SEN03996-00
P: From self pressure reducing valve P1: To attachment valve P2: To attachment valve T: To hydraulic tank 1. Spool 2. Piston 3. Lever 4. Plate 5. Retainer 6. Body 7. Filter Unit: mm
No.
Item
Criteria
Remedy
Standard size
8
9
Centering spring
Metering spring
WA250, 250PZ-6
Repair limit
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}
22.73 x 8.1
22
16.7 N {1.7 kg}
—
13.3 N {1.36 kg}
If damaged or deformed, replace spring
10-600
55
600 Hydraulic system Lock valve
SEN03996-00
Lock valve
1
1. Lever 2. End cap 3. Ball 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 equipment operation.
10-600
56
WA250, 250PZ-6
600 Hydraulic system Accumulator (for PPC circuit)
SEN03996-00
Accumulator (for PPC circuit)
1
1. Gas plug 2. Poppet 3. Holder 4. Bladder 5. Film 6. Shell 7. Oil port Outline q The accumulator is installed between the charge valve and work equipment PPC valve. Even if the engine stops with the work equipment 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
WA250, 250PZ-6
Nitrogen gas
Amount of gas (cc)
500
Charged pressure (MPa {kg/cm2})
1.18(+0.2/0) {12(+2/0)} (at 80°C)
Max. pressure used (MPa {kg/cm2})
3.92 {40}
10-600
57
600 Hydraulic system Bypass valve
SEN03996-00
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
10-600
58
1. Body 2. Plunger 3. Plug 4. Spool 5. Plug 6. Body
WA250, 250PZ-6
600 Hydraulic system Bypass valve
SEN03996-00
Operation When lift arm is "RAISE" operation
q
q
q
If the lift arm is "RAISE" operation, the oil of the work equipment PPC valve operates the work equipment control valve and the oil from the work equipment pump flows to the lift cylinder bottom side. 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). The oil on the lift cylinder head side flows through the work equipment control valve into the hydraulic tank, thus the lift arm rises.
WA250, 250PZ-6
10-600
59
SEN03996-00
600 Hydraulic system Bypass valve
When lift arm is "LOWER" operation
q
q
q
q
If the lift arm is "LOWER" operation, the oil of the work equipment PPC valve operates the work equipment control valve and the oil from the work equipment pump flows to the lift cylinder head side. At this time, the oil of the work equipment PPC valve flows to port (PP) to push spool (1) to the right and opens ports (A) and (B). 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 cylinder bottom side by the weight of the work equipment, however. The hydraulic pressure generated on the lift cylinder bottom side pushes up and opens check valve plunger (2) and flows through port (B) to the cylinder head side, thus the lift arm lowers smoothly.
10-600
60
WA250, 250PZ-6
600 Hydraulic system Quick coupler solenoid valve
SEN03996-00
Quick coupler solenoid valve
1
WA250PZ-6
P: From work equipment control valve port B2 T: To work equipment 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
WA250, 250PZ-6
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 connect or disconnect the attachment and quick coupler.
10-600
61
SEN03996-00
ECSS valve
600 Hydraulic system 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)
10-600
62
WA250, 250PZ-6
600 Hydraulic system ECSS valve
SEN03996-00
1. Main spool 2. Solenoid valve 3. Flow control valve 4. Shuttle valve 5. Charge valve
WA250, 250PZ-6
10-600
63
600 Hydraulic system Accumulator (for ECSS)
SEN03996-00
Accumulator (for ECSS)
1
(if equipped) 1. Valve 2. Top cover 3. Cylinder 4. Free piston Function The accumulator is installed to the lift cylinder bottom 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 compressibility.
q
Specifications
10-600
64
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. pressure used (MPa {kg/cm2})
20.6 {210}
WA250, 250PZ-6
600 Hydraulic system Accumulator (for ECSS)
WA250, 250PZ-6
SEN03996-00
10-600
65
SEN03996-00
WA250-6, WA250PZ-6 GALEO Wheel loader Form No. SEN03996-00
©2007 KOMATSU All Rights Reserved Printed in Japan 10-07 (01)
10-600
66
SEN03997-00
WHEEL LOADER WA250-6 WA250PZ-6 Machine model
Serial number
WA250-6 WA250PZ-6
75001 and up 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 .............................................................................................................................. 22
WA250, 250PZ-6
10-700
1
SEN03997-00
Work equipment linkage
700 Work equipment Work equipment linkage
1
WA250-6
10-700
2
WA250, 250PZ-6
700 Work equipment Work equipment linkage
SEN03997-00
1. Bucket 2. Bell crank 3. Bucket cylinder 4. Lift cylinder 5. Lift arm 6. Bucket link Unit: mm
No. 7
Check item
Criteria
Clearance between bushing and pin at each end of bucket link
Standard size
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
75
–0.030 –0.076
+0.174 +0.100
0.130 – 0.250
1.0
8
Clearance between bushing and pin connecting lift arm and bucket
75
–0.030 –0.076
+0.174 +0.100
0.130 – 0.250
1.0
9
Clearance between bushing and pin connecting lift arm and frame
75
–0.030 –0.076
+0.174 +0.100
0.130 – 0.250
1.0
85
–0.036 –0.090
+0.207 +0.120
0.156 – 0.297
1.0
11 connecting bucket cylinder rod and
85
–0.036 –0.090
+0.207 +0.120
0.156 – 0.297
1.0
between bushing and pin 12 Clearance connecting bell crank and lift arm
85
–0.036 –0.090
+0.207 +0.120
0.156 – 0.297
1.0
75
–0.030 –0.076
+0.174 +0.100
0.130 – 0.250
1.0
70
–0.030 –0.076
+0.174 +0.100
0.130 – 0.250
1.0
Clearance between bushing and pin
10 connecting bucket cylinder bottom and frame
Clearance between bushing and pin bell crank
Clearance between bushing and pin
13 connecting lift cylinder rod and lift arm
Clearance between bushing and pin
14 connecting lift cylinder bottom and frame
Width of boss Tolerance
Tolerance
Standard clearance
90
+0.8 0
93
±1.5
0.7 – 4.5
Left side
108
—
116
±1.5
6.5 – 9.5
Right side
108
—
111
±1.5
1.5 – 4.5 2.0 – 5.0
part of bucket cylinder 15 Connecting and frame
part of lift 16 Connecting arm and frame
Width of hinge Standard size
Standard size
Replace (Replace pin when it has scuff marks, too.)
Adjust shim so that clearance will be below 1.5 mm on each side
part of lift arm and 17 Connecting bucket
86
—
88
+3.0 0
part of bucket link and 18 Connecting bucket
85
±1.0
88
+3.0 0
2.0 – 7.0
part of lift cylinder and 19 Connecting frame
94
0 –0.5
98
±1.5
2.5 – 6.0
part of bell crank and 20 Connecting bucket link
85
±1.0
93
±1.5
5.5 – 10.5
part of bell crank and lift 21 Connecting arm
161
±1.5
164
±1.5
0 – 6.0
part of bucket cylinder 22 Connecting and bell crank
90
+0.8 0
93
±1.5
0.7 – 4.5
Replace
0.5 – 3.5
Adjust shim so that clearance will be below 1.5 mm on each side
part of lift arm and lift 23 Connecting cylinder
WA250, 250PZ-6
86
—
88
±1.5
10-700
3
SEN03997-00
700 Work equipment Work equipment linkage
WA250PZ-6
10-700
4
WA250, 250PZ-6
700 Work equipment Work equipment linkage
SEN03997-00
1. Bucket 2. Bell crank 3. Bucket cylinder 4. Lift cylinder 5. Lift arm 6. Bucket link 7. Quick coupler Unit: mm
No.
Check item
Criteria
Remedy
Shaft
Hole
Standard clearance
Clearance limit
75
–0.030 –0.076
+0.174 +0.100
0.130 – 0.250
1.0
Clearance between bushing and pin connecting lift arm and quick coupler
75
–0.030 –0.076
+0.174 +0.100
0.130 – 0.250
1.0
between bushing and pin 10 Clearance connecting lift arm and frame
75
–0.030 –0.076
+0.174 +0.100
0.130 – 0.250
1.0
110
–0.036 –0.090
+0.207 +0.120
0.156 – 0.297
1.0
12 connecting bucket cylinder rod and
110
–0.036 –0.090
+0.207 +0.120
0.156 – 0.297
1.0
between bushing and pin 13 Clearance connecting bell crank and lift arm
95
–0.036 –0.090
+0.207 +0.120
0.156 – 0.297
1.0
75
–0.030 –0.076
+0.174 +0.100
0.130 – 0.250
1.0
70
–0.030 –0.076
+0.174 +0.100
0.130 – 0.250
1.0
8
9
Clearance between bushing and pin at each end of bucket link
Clearance between bushing and pin
11 connecting bucket cylinder bottom and frame
Clearance between bushing and pin bell crank
Clearance between bushing and pin
14 connecting lift cylinder rod and lift arm
Clearance between bushing and pin
15 connecting lift cylinder bottom and frame
Standard size
Tolerance
Width of boss
Width of hinge
Replace (Replace pin when it has scuff marks, too.)
Tolerance
Standard size
Tolerance
Standard clearance
110
0 –0.5
114
±1.5
2.5 – 6.0
Left side
108
—
116
±1.5
6.5 – 9.5
Right side
108
—
111
±1.5
1.5 – 4.5
part of lift arm and quick 18 Connecting coupler
100
—
102
+1.5 0
2.0 – 3.5
part of bucket link and 19 Connecting quick coupler
100
±1.0
103
+1.5 0
2.0 – 5.5
part of lift cylinder and 20 Connecting frame
94
0 –0.5
98
±1.5
2.5 – 6.0
part of bell crank and 21 Connecting bucket link
100
±1.0
112
±1.5
9.5 – 14.5
part of bell crank and lift 22 Connecting arm
186
±0.5
189
±0.5
2.0 – 4.0
part of bucket cylinder 23 Connecting and bell crank
100
0 –0.5
112
±1.5
0.5 – 4.0
Replace
0.5 – 3.5
Adjust shim so that clearance will be below 1.5 mm on each side
part of bucket cylinder 16 Connecting and frame
part of lift 17 Connecting arm and frame
part of lift arm and lift 24 Connecting cylinder
WA250, 250PZ-6
Standard size
86
—
88
±1.5
Adjust shim so that clearance will be below 1.5 mm on each side
10-700
5
700 Work equipment Bucket
SEN03997-00
Bucket
1
WA250-6
1. Bucket 2. Bolt-on cutting edge
10-700
6
3. Bucket teeth (if equipped) 4. Adapter (if equipped)
WA250, 250PZ-6
700 Work equipment Bucket
SEN03997-00
Unit: mm
No. 5
Check item
Criteria Repair limit
31.8
19
90
5
Tooth
46
21
Tip tooth
48
36
Max. 0.5
—
Wear of cutting edge (thickness)
6
Wear of cutting edge (length)
7
Wear of bucket teeth
8
Reverse or replace
Replace
Clearance in adapter mounting parts
WA250, 250PZ-6
Remedy
Standard size
Adjust or replace
10-700
7
700 Work equipment Bucket
SEN03997-00 WA250PZ-6
1. Bucket 2. Bolt-on cutting edge
10-700
8
3. Bucket teeth (if equipped) 4. Adapter (if equipped)
WA250, 250PZ-6
700 Work equipment Bucket
SEN03997-00
Unit: mm
No. 5
Check item
Criteria Standard size
Repair limit
31.8
19
90
5
Tooth
46
21
Tip tooth
48
36
Max. 0.5
—
Wear of cutting edge (thickness)
6
Wear of cutting edge (length)
7
Wear of bucket teeth
8
Remedy
Replace
Clearance in adapter mounting parts
WA250, 250PZ-6
Reverse or replace
Adjust or replace
10-700
9
700 Work equipment Bucket positioner and boom kick-out
SEN03997-00
Bucket positioner and boom kick-out
1
WA250-6
1. Bucket positioner proximity switch 2. Boom kick-out proximity switch (if equipped) 3. Bar
4. Bucket cylinder 5. Lift arm 6. Plate (if equipped) Unit: mm
No.
Check item
Criteria
7
Clearance on bucket positioner proximity switch
3–5
8
Clearance on boom kick-out proximity switch
3–5
10-700
10
Remedy Adjust
WA250, 250PZ-6
700 Work equipment Bucket positioner and boom kick-out
SEN03997-00
Outline Bucket positioner q The bucket positioner is driven electrically. When the bucket is returned to an angle from the dump position to the tilt position, the bucket positioner returns the work equipment (bucket) control lever from the "tilt" position to the "hold" position to automatically stop the bucket at a proper digging angle. q Bar (3) is fixed to the rod side of bucket cylinder (4). And proximity switch (1) is fixed to the cylinder side. q Moving the work equipment (bucket) control lever from "dump" position to "tilt" position moves the rod of bucket cylinder (4) toward the machine front side. As bar (3) moves a specific distance, proximity switch (1) detects that it is away from the sensing face, and returns the work equipment (bucket) control lever to "hold" position. Boom kick-out (if equipped) 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 "raise" position to the "hold" position to stop the lift arm automatically at a desired height. q Plate (6) is fixed to lift arm (5). And proximity switch (2) is fixed to the front frame. q Moving the work equipment (lift arm) control lever from "lower" position to "raise" position moves lift arm (5) upward. As plate (6) moves a specific distance, proximity switch (2) detects that it is away from the sensing face, and returns the work equipment (lift arm) control lever to "hold" position.
WA250, 250PZ-6
10-700
11
700 Work equipment Bucket positioner and boom kick-out
SEN03997-00 Operation of proximity switch When bucket is tilted
q
While the bucket is dumped more than the position being set from the bucket positioner, bar (2) moves on to the sensing face of proximity 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.
10-700
12
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 equipment (bucket) control lever (7) is held at "tilt" position and the bucket tilts.
WA250, 250PZ-6
700 Work equipment Bucket positioner and boom kick-out
SEN03997-00 a
The power supply for detent solenoid (6) operation is turned "ON" or "OFF" by alternator relay (11). Detent solenoid (6) circuit is turned off since L signal from alternator (10) is not sent to alternator 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 over sensing face of proximity switch Lamp of proximity switch Bucket positioner relay Work equipment PPC valve detent solenoid circuit Work equipment PPC valve detent solenoid
Turned ON ON Power ON Energized
When object of sensing is apart from sensing face of proximity switch Lamp of proximity switch Bucket positioner relay Work equipment PPC valve detent solenoid circuit Work equipment PPC valve detent solenoid
q
Turned OFF OFF Power OFF De-energized
As the bucket is tilted and moved away from the position set by the positioner, in other words, as bar (2) moves away from the sensing face of proximity switch (1), the lamp of proximity switch (1) goes off and bucket positioner relay (4) is set to "OFF" state. Because of above, detent solenoid (6) circuit on work equipment PPC valve (5) is cut off and the coil is de-energized. Held bucket spool (8) receives the reaction force of spring (9) and returns work equipment (bucket) control lever (7) to "hold" position.
WA250, 250PZ-6
10-700
13
700 Work equipment Bucket positioner and boom kick-out
SEN03997-00 When lift arm is raised
q
While lift arm (3) is dumped beyond the position set from the boom kick-out, plate (2) moves on to the sensing face of proximity switch (1), turning 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.
10-700
14
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 lever (7) is held at "raise" position and lift arm (3) rises.
WA250, 250PZ-6
700 Work equipment Bucket positioner and boom kick-out
SEN03997-00 a
The power supply for detent solenoid (6) operation is turned "ON" or "OFF" by alternator relay (11). Detent solenoid (6) circuit is cut off since L signal 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 positioned in sensing face of proximity switch (1).
Function of proximity switch When object of sensing is apart from sensing face of proximity switch Lamp of proximity switch Boom kick-out relay Work equipment PPC valve detent solenoid circuit Work equipment PPC valve detent solenoid
Turned ON ON Power ON Energized
When object of sensing is over sensing face of proximity switch Lamp of proximity switch Boom kick-out relay Work equipment PPC valve detent solenoid circuit Work equipment PPC valve detent solenoid
q
Turned OFF OFF Power OFF De-energized
As lift arm (3) is raised and moved away from the position set by the boom kick-out, namely as plate (2) moves away from the sensing face of proximity switch (1), the lamp of proximity switch (1) lamp goes off and boom kick-out relay (4) is set to "OFF" state. Because of above, detent solenoid (6) circuit on work equipment PPC valve (5) is cut off and the coil is de-energized. Held lift arm spool (8) receives the reaction force of spring (9) and returns work equipment (lift arm) control lever (7) to the "hold" position.
WA250, 250PZ-6
10-700
15
700 Work equipment Bucket positioner and boom kick-out
SEN03997-00 WA250PZ-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
8
Clearance on bucket positioner proximity switch
3–5
9
Clearance on boom kick-out proximity switch
3–5
10-700
16
Remedy Adjust
WA250, 250PZ-6
700 Work equipment Bucket positioner and boom kick-out
SEN03997-00
Outline Bucket positioner or fork positioner q The bucket positioner is driven electrically. When the bucket or fork is returned to an angle from the dump position to the tilt position, the bucket positioner returns the work equipment (bucket or fork) control lever from the "tilt" position to the "hold" position to automatically stop the bucket or fork at a proper digging angle or lift angle. q Bar (4) is fixed to the rod side of bucket cylinder (5). And proximity switches (1) and (2) are fixed to the cylinder side. q Moving the work equipment (bucket or fork) control lever from "dump" position to "tilt" position moves the rod of bucket cylinder (5) toward the machine front side. As bar (4) moves a specific distance, proximity switches (1) and (2) detect that it is away from the sensing face, and return the work equipment (bucket or fork) control lever to "hold" position. q While the attachment selector switch of the right-hand console is in the "BUCKET" position, 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 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 "raise" position to the "hold" position to stop the lift arm automatically at a desired height. q Plate (7) is fixed to lift arm (6). And proximity switch (3) is fixed to the front frame. q Moving the work equipment (lift arm) control lever from "lower" position to "raise" position moves lift arm (6) upward. As plate (7) moves a specific distance, proximity switch (3) detects that it is away from the sensing face, and returns the work equipment (lift arm) control lever to "hold" position.
WA250, 250PZ-6
10-700
17
700 Work equipment Bucket positioner and boom kick-out
SEN03997-00 Operation of proximity switch
When bucket is tilted a The case when the attachment selector switch is in the "BUCKET" position is shown below.
q
While the bucket is dumped more than the position being set from the bucket positioner, bar (2) moves on to the sensing face of proximity 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.
10-700
18
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 equipment (bucket) control lever (7) is held at "tilt" position and the bucket tilts.
WA250, 250PZ-6
700 Work equipment Bucket positioner and boom kick-out
SEN03997-00 a
The power supply for detent solenoid (6) operation is turned "ON" or "OFF" by alternator relay (11). Detent solenoid (6) circuit is turned off since L signal from alternator (10) is not sent to alternator 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 over sensing face of proximity switch Lamp of proximity switch Bucket positioner relay Work equipment PPC valve detent solenoid circuit Work equipment PPC valve detent solenoid
Turned ON ON Power ON Energized
When object of sensing is apart from sensing face of proximity switch Lamp of proximity switch Bucket positioner relay Work equipment PPC valve detent solenoid circuit Work equipment PPC valve detent solenoid
q
Turned OFF OFF Power OFF De-energized
As the bucket is tilted and moved away from the position set by the positioner, in other words, as bar (2) moves away from the sensing face of proximity switch (1), the lamp of proximity switch (1) goes off and bucket positioner relay (4) is set to "OFF" state. Because of above, detent solenoid (6) circuit on work equipment PPC valve (5) is cut off and the coil is de-energized. Held bucket spool (8) receives the reaction force of spring (9) and returns work equipment (bucket) control lever (7) to "hold" position.
WA250, 250PZ-6
10-700
19
700 Work equipment Bucket positioner and boom kick-out
SEN03997-00 When lift arm is raised
q
While lift arm (3) is dumped beyond the position set from the boom kick-out, plate (2) moves on to the sensing face of proximity switch (1), turning 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.
10-700
20
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 lever (7) is held at "raise" position and lift arm (3) rises.
WA250, 250PZ-6
700 Work equipment Bucket positioner and boom kick-out
SEN03997-00 a
The power supply for detent solenoid (6) operation is turned "ON" or "OFF" by alternator relay (11). Detent solenoid (6) circuit is cut off since L signal 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 positioned in sensing face of proximity switch (1).
Function of proximity switch When object of sensing is apart from sensing face of proximity switch Lamp of proximity switch Boom kick-out relay Work equipment PPC valve detent solenoid circuit Work equipment PPC valve detent solenoid
Turned ON ON Power ON Energized
When object of sensing is over sensing face of proximity switch Lamp of proximity switch Boom kick-out relay Work equipment PPC valve detent solenoid circuit Work equipment PPC valve detent solenoid
q
Turned OFF OFF Power OFF De-energized
As lift arm (3) is raised and moved away from the position set by the boom kick-out, namely as plate (2) moves away from the sensing face of proximity switch (1), the lamp of proximity switch (1) lamp goes off and boom kick-out relay (4) is set to "OFF" state. Because of above, detent solenoid (6) circuit on work equipment PPC valve (5) is cut off and the coil is de-energized. Held lift arm spool (8) receives the reaction force of spring (9) and returns work equipment (lift arm) control lever (7) to the "hold" position.
WA250, 250PZ-6
10-700
21
700 Work equipment Work equipment cylinder
SEN03997-00
Work equipment cylinder
1
WA250-6 Lift cylinder
Bucket cylinder
Unit: mm No.
1
Check item
Clearance between piston rod and bushing
Tightening torque of cylinder head
2
3
Criteria Cylinder name
Standard size
Lift Bucket
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
70
–0.030 –0.104
+0.271 +0.075
0.105 – 0.375
0.675
75
–0.030 –0.104
+0.291 +0.077
0.107 – 0.395
0.695
Lift
1,030 ± 103 Nm {105 ± 10.5 kgm}
Tightening torque of cylinder head mounting bolt
Bucket
250 ± 24.5 Nm {25.5 ± 2.5 kgm}
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 lock bolt
Bucket
98 – 123 Nm {10 – 12.5 kgm}
10-700
22
Replace bushing
Retighten
WA250, 250PZ-6
700 Work equipment Work equipment cylinder
SEN03997-00
WA250PZ-6 Lift cylinder
Bucket cylinder
Unit: mm No.
1
Check item
Clearance between piston rod and bushing
Tightening torque of cylinder head
2
3
4
Criteria Cylinder name
Standard size
Lift Bucket
Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
70
–0.030 –0.104
+0.271 +0.075
0.105 – 0.375
0.675
100
–0.036 –0.090
+0.270 +0.060
0.096 – 0.360
0.660
Lift
1,030 ± 103 Nm {105 ± 10.5 kgm}
Tightening torque of cylinder head mounting bolt
Bucket
343 ± 34.5 Nm {35 ± 3.5 kgm}
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
294 ± 29.4 Nm {30 ± 3.0 kgm}
Tightening torque of cylinder piston lock screw
Bucket
58.8 – 73.5 Nm {6 – 7.5 kgm}
WA250, 250PZ-6
Replace bushing
Retighten
10-700
23
SEN03997-00
WA250-6, WA250PZ-6 GALEO Wheel loader Form No. SEN03997-00
©2007 KOMATSU All Rights Reserved Printed in Japan 10-07 (01)
10-700
24
SEN03998-00
WHEEL LOADER WA250-6 WA250PZ-6 Machine model
Serial number
WA250-6 WA250PZ-6
75001 and up 75001 and up
10 Structure, function and maintenance standard
10
800 Cab and its attachments Cab ................................................................................................................................................................. 3 Air conditioner ................................................................................................................................................. 4
WA250, 250PZ-6
10-800
1
SEN03998-00
10-800
2
800 Cab and its attachments
WA250, 250PZ-6
800 Cab and its attachments Cab
SEN03998-00
Cab
1
1. 2. 3. 4. 5. 6. 7.
Front working lamp Radio antenna Door (left) Air conditioner external air filter Front glass Front wiper KOMTRAX GPS antenna (WA250-6: if equipped) (WA250PZ-6: standard) 8. KOMTRAX communication antenna (WA250-6: if equipped) (WA250PZ-6: standard) 9. Door (right) 10. Rear wiper
WA250, 250PZ-6
10-800
3
SEN03998-00
800 Cab and its attachments Air conditioner
Air conditioner
1
Air conditioner piping diagram
1
10-800
4
WA250, 250PZ-6
800 Cab and its attachments Air conditioner
1. Hot water take-out piping 2. Compressor 3. Condenser 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
WA250, 250PZ-6
SEN03998-00 Specifications Refrigerant used
R134a
Refrigerant refilling level (g)
900
10-800
5
800 Cab and its attachments Air conditioner
SEN03998-00 Refrigerant circuit diagram
1. Engine 2. Compressor 3. Condenser 4. Receiver 5. Air conditioner unit 6. Dual pressure switch Table of tightening torque for refrigerant piping adapter Unit: Nm {kgm}
No.
Check item
7
Air conditioner unit refrigerant inlet side
8
Air conditioner unit refrigerant outlet side
9
Receiver refrigerant pipe set bolt
10 Compressor refrigerant piping lock bolt 11 Condenser refrigerant inlet side 12 Condenser refrigerant outlet side
10-800
6
Criteria
Remedy
12 – 15 {1.2 – 1.5} (screw size: M16 x 1.5) 30 – 35 {3.1 – 3.6} (screw size: M24 x 1.5) 8 – 12 {0.8 – 1.2} (screw size: M16 x 1.0) 20 – 25 {2.0 – 2.6} (screw size: M8 x 1.25) 20 – 25 {2.0 – 2.6} (screw size: M22 x 1.5) 12 – 15 {1.2 – 1.5} (screw size: M16 x 1.5)
Retighten
WA250, 250PZ-6
800 Cab and its attachments Air conditioner
SEN03998-00
Air conditioner unit
A: From receiver B: To compressor C: Hot water inlet D: Hot water outlet 1. Evaporator 2. Heater core 3. Air mix damper (upper) 4. Air mix damper (lower) 5. Expansion valve 6. Blower controller 7. Blower motor relay 8. Compressor clutch relay 9. Air mix damper actuator 10. Evaporator temperature sensor 11. Dual pressure switch
1
Outline q The vertical air conditioner unit on which evaporator (1) 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 The cooler circulates refrigerant through evaporator (1) to cause heat exchange (dehumidification and cooling). q Air taken in by the blower and intake unit is cooled with evaporator (1) and then blown out from the duct and grill. q
Heater q The heater circulates engine coolant in heater core (2) to cause heat exchange (heating). q Air taken in by the blower and intake unit is heated with heater core (2) and then blown out through the duct and grill.
WA250, 250PZ-6
10-800
7
SEN03998-00 Functions of major components Evaporator q Evaporator fin is cooled by the low-pressure, low-temperature refrigerant gas being sent from the expansion valve. Air from the blower motor is cooled and dehumidified when passing through the fin. Heater core q Fin of the heater core is heated by the hot water (cooling water) being sent from the engine. Air from the blower motor is heated as it passes through the fin. Expansion valve This valve converts high-pressure, high-temperature liquid refrigerant from the receiver to low-pressure, low-temperature misty refrigerant through the throttling function. It controls flow rate of refrigerant by changing level of throttling depending on the thermal load in the operator's cab.
q
Blower controller q It controls the blower motor speed receiving signal current from the air conditioner panel. Blower motor relay Signal current from the air conditioner panel controls the relay coil. As the relay coil is energized and the switch is turned "ON", power is supplied to the blower motor.
q
800 Cab and its attachments Air conditioner
Air mix damper actuator q It starts the built-in motor receiving signal current 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 potentiometer being built in the actuator. This reading is done as the target temperature is set from the temperature adjustment switch on the air conditioner panel. q Rotation of the motor is stopped as the contact, which is to move interlocked with the motor, moves away or signal current from the air conditioner panel is turned "OFF". Evaporator temperature sensor q In order to prevent freezing of the evaporator, it senses the evaporator temperature and sends necessary signals to the air conditioner panel. The signal sent to the air conditioner panel is used to control the compressor. As the result, temperature of the air blown out of the grill is adjusted depending on the volume of refrigerant circulated in the evaporator. Dual pressure switch q If abnormally low or high pressure was generated in the refrigerant circulation circuit, this switch releases the magnet clutch of the compressor to protect a series of cooler-related equipment.
Compressor clutch relay q Signal current from the air conditioner panel dual pressure switch is used for controlling the relay coil. As the relay coil is energized and the switch is turned "ON", the magnet clutch of the compressor is connected.
LA: 0.20 MPa {2 kg/cm2} LB: 0.02 MPa {0.2 kg/cm2} HA: 3.14 MPa {32 kg/cm2} HB: 0.59 MPa {6 kg/cm2}
10-800
8
WA250, 250PZ-6
800 Cab and its attachments Air conditioner
SEN03998-00
Blower and intake unit
1. Blower motor assembly 2. Internal/external air changeover damper actuator 3. Internal/external air changeover damper
1
Functions of major components Blower motor assembly q It suctions air by rotating the fin installed on the blower motor. And it is also used for sending the absorbed air to the evaporator and heater core. Internal/external air changeover damper actuator q Receiving signal current from the air conditioner 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 panel. q Rotation of the motor is stopped as the contact, which is to move interlocked with the motor, moves away or signal current from the air conditioner panel is turned "OFF".
WA250, 250PZ-6
10-800
9
SEN03998-00
800 Cab and its attachments Air conditioner
Compressor
1
A: From air conditioner unit B: To condenser
Function q Other than circulating the refrigerant, it compresses the refrigerant gas from the evaporator 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
10-800
10
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
Refrigerant oil refilling volume (cc)
135
WA250, 250PZ-6
800 Cab and its attachments Air conditioner
SEN03998-00
Condenser
A: From compressor B: To receiver
1
Function q It cools and liquefies the high-pressure and high-temperature misty refrigerant from the compressor. a
If the fin crushes or is clogged with dusts, heat exchange efficiency is degraded and complete liquefaction of refrigerant becomes unavailable. As the result, pressure in the refrigerant circulation circuit will be increased, applying extra load to the engine or degrading the cooling effect. Thus, care must be used in its handling and daily inspection.
Specifications
WA250, 250PZ-6
Fin pitch (mm)
1.5
Total heat dissipation area (m2)
6.55
Max. pressure used (MPa {kg/cm2})
3.6 {36}
10-800
11
800 Cab and its attachments Air conditioner
SEN03998-00
Receiver
A: From condenser B: To air conditioner unit 1. Sight glass
1
Function It is used to store liquefied high-pressure, hightemperature misty refrigerant from the condenser. It is capable of completely liquefying the refrigerant even when bubbles are contained in the refrigerant due to the condenser condition in heat dissipation. q It eliminates foreign substances in the circulation 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. q
Specifications
10-800
12
Effective cubic capacity (cm3)
578
Weight of desiccating agent (g)
300
WA250, 250PZ-6
800 Cab and its attachments Air conditioner
WA250, 250PZ-6
SEN03998-00
10-800
13
800 Cab and its attachments Air conditioner
SEN03998-00
Air conditioner panel
1
Display unit No.
Display category
Display items
Display range
Spurting out temperature
See above drawing
2
Air blasting volume
See above drawing
3
Circulation of internal air and introduction of external air
When circulating internal air and introducing external air
Air conditioner
When air conditioner switch is "ON"
1 Gauge
Pilot 4
Display method
Display Remarks color
All segments below applicable level come on (8-step display) All segments below applicable level come on (4-step display) The display indicates which is currently taking place - internal air circulation or external air introduction - responding to the operation of the internal/external air changeover switch.
Black
Liquid crystal
Turns "ON" air conditioner switch, this lamp lights up.
Switch block No.
Switch name
Function
Operation Circulation of internal air IO Introduction of external air OFF io ON
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)
6
Air conditioner switch
It turns on or off the cooling and the dehumidifying heating function.
7
Main power switch
8
Fan switch
9
Temperature adjusting switch
10-800
14
It turns on or off main power supply of the air conditioner. ON: Settings done during "OFF" are indicated on the display unit. OFF: Turns off the display unit lamp and stops the fan. It controls volume of air sent from the fan. (adjusted in 4 steps [LO, M1, M2 and HI]) It controls the spurting out temperature (8-step adjustment)
OFF io ON LO io HI Low temperature IO High temperature
WA250, 250PZ-6
800 Cab and its attachments Air conditioner
SEN03998-00
Outline q CPU (central processing unit) installed on the panel processes input signals from respective sensors and operation signals of the panel switches to display and output them. q The self-diagnosis function of CPU makes the troubleshooting easier. Input and output signals JAE IL-AG5-14P [CN-C48] Pin No.
Signal name
JAE IL-AG5-22P [CN-C47] Input and output signals
Pin No.
Input and output signals
Signal name
1
GND
—
1
NC
—
2
Sensor ground
—
2
NC
3
Internal/external air changeover damper actuator limiter
Input
3
Blower motor relay
4
External air temperature sensor
Input
4
Internal/external air changeover damper actuator output 1
Output
5
Evaporator temperature sensor
Input
5
Output
6
Internal air temperature sensor
Input
Internal/external air changeover damper actuator output 2
7
Starting switch (ON)
Input
6
Mode selector actuator output 2
Output
8
Night lamp signal
Input
7
Mode selector actuator output 1
Output
9
NC
—
8
Air mix damper actuator output 2
Output
10
NC
—
9
Air mix damper actuator output 1
Output
11
NC
—
10
Actuator potentiometer power supply (5 V)
—
— Input
12
NC
—
11
NC
—
13
Day light sensor 2
Input
12
NC
—
14
Day light sensor 1
Output
13
NC
—
WA250, 250PZ-6
14
NC
15
Magnet clutch
— Input
16
Air mix damper actuator limiter
Input
17
Mode selector actuator limiter
Input
18
Air mix damper actuator potentiometer
Input
19
Mode selector actuator potentiometer
Input
20
Blower gate
Input
21
Blower feedback
Input
22
Actuator potentiometer ground
—
10-800
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SEN03998-00
WA250-6, WA250PZ-6 GALEO Wheel loader Form No. SEN03998-00
©2007 KOMATSU All Rights Reserved Printed in Japan 10-07 (01)
10-800
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SEN03999-00
WHEEL LOADER WA250-6 WA250PZ-6 Machine model
Serial number
WA250-6 WA250PZ-6
75001 and up 75001 and up
10 Structure, function and maintenance standard
10
910 Electrical system, Part 1 Machine monitor system ................................................................................................................................. 2 Machine monitor ............................................................................................................................................. 6
WA250, 250PZ-6
10-910
1
910 Electrical system, Part 1 Machine monitor system
SEN03999-00
Machine monitor system Outline q In the machine monitor system, each controller on the network monitors controls the machine condition with the sensors installed to various parts of the machine, and then sends the result as network information to the machine monitor, which displays the information to notify the operator of the machine condition. q
The machine monitor displays the information in the operator mode or service mode.
q
The operator mode is used to display the information to the operator normally. The major functions used in the service mode are as follows.
1.
Items always displayed q Meters (speedometer or engine tachometer) q Gauges (engine coolant temperature gauge, HST oil temperature gauge and fuel gauge) q Pilot indicators q Service meter
q
2.
1
4.
In addition to the above, the following display, setting and adjustment functions are provided using the character display and the machine monitor mode selector switch, which is the operation switch of the character display. 1) Switching of traction level 2) Switching of HST reverse travel gear shifting pattern 3) Display the odometer 4) Resetting the filter or oil replacement time 5) Input the telephone number 6) Selecting the language 7) Adjusting the illuminance of nighttime light 8) Travel speed/engine speed display selecting function 9) Function for setting display/no-display of travel speed or engine speed to the character display
The following items are displayed according to the set state of the optional device selecting function. Travel speed or engine speed indication on the character display
Items displayed when abnormality is detected Caution lamps q Action code (while an action code is displayed, if the machine monitor mode selector switch (>) is pressed and released, the failure code (6 digits) is displayed.) q
3.
At the replacement period of a filter or oil, the character display displays that filter or oil. (maintenance monitoring function)
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WA250, 250PZ-6
910 Electrical system, Part 1 Machine monitor system
q
1.
The service mode function is provided for the ease of troubleshooting for the controllers on the network (including the machine monitor itself). The major functions used in this mode are as follows. Electrical system failure history display function The electrical system failures of each controller saved in the machine monitor are displayed. The information of those failures is also deleted with this function.
2.
Mechanical system failure history display function The mechanical system failures of each controller saved in the machine monitor are displayed.
3.
Real-time monitoring function The input and output signals recognized by each controller on the network are displayed in real time.
4.
Engine reduced-cylinder function This function is used for the purpose of specifying 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 storing 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 dispersion of the sensors, solenoid valves, etc. Function for changing control characteristics is provided on user request.
7.
Maintenance monitoring function Changes the filter or oil replacement time and makes ON/OFF selection of the function.
8.
Operating information display function Displays fuel consumption per operating hour.
WA250, 250PZ-6
SEN03999-00
9.
Optional device selecting function Verifies the installation of optional devices or changes their setting.
10. Machine serial number input function Enters the machine serial number to identify the machine. 11. Model selection function Enters the information of applicable model. 12. Initialize function Sets the machine monitor to the state set when the machine is delivered.
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SEN03999-00 System circuit diagram a
910 Electrical system, Part 1 Machine monitor system
1
Items marked with "*1" in drawing may or may not installed.
10-910
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WA250, 250PZ-6
910 Electrical system, Part 1 Machine monitor system
WA250, 250PZ-6
SEN03999-00
10-910
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910 Electrical system, Part 1 Machine monitor
SEN03999-00
Machine monitor
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
HST oil temperature gauge HST oil temperature caution lamp Engine coolant temperature gauge Engine coolant temperature caution lamp Speedometer or engine tachometer Turn signal pilot lamp (left) Head lamp high beam pilot lamp Turn signal pilot lamp (right) Fuel level caution lamp Fuel gauge Central warning lamp Brake oil pressure caution lamp Engine oil pressure caution lamp Water separator caution lamp Engine oil level caution lamp (*1) Radiator coolant level caution lamp HST oil filter clogging caution lamp Air cleaner clogging caution lamp (*1) Parking brake pilot lamp Brake oil temperature caution lamp
1
21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37.
Quick coupler operation pilot lamp (*2) Cooling fan reverse rotation pilot lamp Maintenance caution lamp Parking brake reminder caution lamp Battery charge circuit caution lamp Steering oil pressure caution lamp (*2) Emergency steering pilot lamp (*2) Meter display pilot lamp Character display portion Preheating pilot lamp Directional selector switch actuation pilot lamp (*2) Economy operation display lamp Shift hold pilot lamp (*1) S mode operation pilot lamp Traction control operation pilot lamp Travel speed range selector switch position pilot lamp Directional lever position pilot lamp
*1: Not used by this model *2: If equipped
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WA250, 250PZ-6
910 Electrical system, Part 1 Machine monitor
SEN03999-00
List of items displayed on monitor
1
Condition for judging that the engine is running: If 2 or more are met in the following 3 conditions, the engine is judged running when the abnormality in the CAN communication occurs and the charge level exceeds the specified level. 1. Turning "ON" of the starting switch is recorded (IGN-C signal was entered) 2. Charge level exceeds the specified value (the voltage reached 12 V once and remains 5 V or above after that) 3. Engine speed is 500 rpm or above Lamp
Lamp period
Alarm buzzer
Operating condition
Buzzer period
Priority
Period: 1,600 msec. ON: 800 msec. OFF: 800 msec. (duty 50%)
1
—
w: Intermittent sounds
Warning for dangerous condition (error or caution message is generated)
w: Flashing
Period: 1,600 msec. ON: 800 msec. OFF: 800 msec. (duty 50%)
A: Intermittent sounds
Period: 240 msec. Caution for erroneous operation (when an irregular ON: 80 msec. OFF: 160 msec. operation is done)
2
A: Intermittent
Period: 240 msec. ON: 80 msec. OFF: 160 msec.
E: Canceling sounds
Set cancellation such as ON: 1,000 msec. (1 time) calibration (inoperative state)
3
e: Completion sounds
ON: 100 msec. Completion of setting such as calibration (when normally OFF: 160 msec. ON: 100 msec. (1 time) ended)
4
— Back light
1 2
HST oil temperature
— — —
— — —
When lamp switch is other than "OFF"
— — —
— — —
Other than below
— — —
— — —
LED
LED
Pointer: Movement
Alarm: 105°C or above Caution lamp: LED When abnormality is detected (out of input signal range)
1
w Q
20
5
— — — DGH1KX — — — DGH1KX
Gauges and meters
9 10 Fuel level
WA250, 250PZ-6
— — —
— Q —
— Q —
When the sensor is disconnected or hot shortcircuited: Max When sensor was disconnected or hot shortcircuited: Min
Display color
White range: 50 – 102°C Red range: 102 – 135°C
w Q
Caution When abnormality is lamp: LED detected (high temperature)
— — —
CA144
— — —
CA144
When abnormality is detected (low temperature)
— — —
CA145
— — —
CA145
When engine speed display is selected
— — —
— — —
(selectable with the machine monitor setting)
When travel speed display is selected
— — —
— — —
— When a communication error is detected, the system displays "0".
Other than below
— — —
— — —
Pointer: Movement Travel speed
0
Q B@CRNS
— — —
Turned ON with errors (E03 and E02) of each controller, simultaneously displaying the message on the character display.
White range: 30 – 105°C Red range: 105 – 135°C
10
3
Q B@CRNS w Q
Remarks
Pointer: Movement Alarm: 105°C or above
Engine speed 5
Display of message
Red
For other than above, see "Operating condition, central warning lamp" of other items.
E
Q B@BCNS w Q
Q B@BCNS
Pointer: Movement Min. 62 z
10
1
— Q —
— Q —
When abnormality is Caution lamp: LED detected (input voltage is 4 V or above and no incoming IGN-C signal is detected)
10
2
— — —
DJF1KA — — —
When the sensor is disconnected or hot shortcircuited: Max When sensor was disconnected or hot shortcircuited: Min
Max: 10 z Min: 85 z Red
Engine coolant temperature
E E E
E E E
Alarm: 102°C or above 3 4
E
When error occurs
Other than below
Gauges and meters
Alarm buzzer
Reset
Operating condition
White
11 Central warning
Device
Red
Back light
Item
Engine is running
Red
Central warning lamp
No.
Operating condition Engine stopped Alarm buzzer
Category
Detection
Detecting time (sec)
Individual display Central warning lamp
—
Display of message
E: Separately set conditions
Individual display Central warning lamp
Q: ON
DJF1KA
When the sensor is grounded: Full When sensor was disconnected or hot shortcircuited: Empty
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910 Electrical system, Part 1 Machine monitor
SEN03999-00
— — —
— — —
Engine speed
When engine speed display is selected
0
0
— Q —
— Q —
When travel speed display is selected
0
0
— Q —
— Q —
LED
When F is selected (neutral safety is displayed as engine is stopped)
1
0
A Q
Q
— Q —
LED
When N is selected
0
0
— Q —
— Q —
LED
When R is selected (neutral safety is displayed as engine is stopped)
1
0
A Q
Q
— Q —
4
LED
When 4th gear speed is selected
0
0
— Q —
— Q —
3
LED
When 3rd gear speed is selected
0
0
— Q —
— Q —
2
LED
When 2nd gear speed is selected
0
0
— Q —
— Q —
1
LED
When 1st gear speed is selected
0
0
— Q —
— Q —
Display color
km/h or MPH (setting of a desired value is available from the machine monitor)
6 8
Turn signal
LED
When turn signal lever and hazard lamp switch signal is input
0
0
— Q —
— Q —
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 —
— — —
— — —
Normal oil pressure (CLOSE)
LED
oil 13 Engine pressure
LED
14 Water separator
LED
Radiator 16 coolant level
LED
1
1
— Q —
w Q
Q
Below set pressure (OPEN) (detect time continues) and after 30 seconds elapsed since engine was started (no detection time)
5
1
— — —
w Q
Q
Normal oil pressure (CLOSE)
— — —
— — —
Low oil pressure (OPEN)
w Q
Normal
— — —
Water mixing with fuel
— Q —
Normal coolant level (CLOSE)
— — —
Low coolant level (OPEN)
Red
oil 12 Brake pressure
Below set pressure (OPEN) (detection time continues) and 30 seconds after engine is started (no detection time)
30
1
Normal (OPEN)
oil filter 17 HST clogging
LED
Hazard lamp operates when starting switch is turned "OFF".
Blue
Travel speed 36 range selector switch position
When error occurs in communication, condition is held until starting switch is turned "OFF".
Clogging (CLOSE) (HST oil temperature 50°C or above and no abnormality detected)
10
When abnormality is detected (clogging was detected as engine was stopped)
3
2
Q B@BAZG w Q
2G40ZG
Q B@BAZG
— — — CA418
— Q —
CA418
— — —
— Q — B@BCZK — Q — B@BCZK — — —
— — —
— — —
— Q —
6091NX
Red
Items related to gear shifting
Green Green Green Green Green Green Orange Green
LED
Directional lever or N 37 directional selector switch position R
8
x 100 r/min (setting of a desired value is available from the machine monitor)
Red
28
Black
Converts travel speed pulse into travel distance
Displays various codes and items according to the machine condition and switch operation.
Green
Odometer
Remarks
Green
— — —
LCD
Display of message
Alarm buzzer
Individual display Central warning lamp
— — —
29
F
10-910
Display of message
Operates when charging normally at 1 : 1 to the clock time
Service meter
Travel speed
Other symbols
Individual display Central warning lamp
Operating condition
Reset
Device
Red
Unit
Item
Engine is running
Red
Character display
No.
Operating condition Engine stopped Alarm buzzer
Category
Detection
Detecting time (sec)
KEY — — — DHTCL6 — — — DHTCL6 OFF
WA250, 250PZ-6
910 Electrical system, Part 1 Machine monitor
SEN03999-00
— — —
— — —
— — —
A Q
— — —
— — — — Q —
23 Maintenance
brake 24 Parking reminder
LED
LED
5
5
— Q —
Temperature rise (1. or 2.) 1. Oil temperature 130°C or above 2. Oil temperature 125°C or above and travel speed 35 km/h or above
5
5
w Q
LED
Emergency 27 steering
WA250, 250PZ-6
— — — DGR2KZ — — — DGR2KZ
Other than below
— — —
0
0
A Q — Remarks A Q — Remarks
Normal
0
0
— — —
Reverse
0
0
— Q — Remarks — Q — Remarks
Selecting reverse rotation
0
0
— w —
— w —
Ordinary
— — —
— — —
30 hours or less before maintenance or maintenance time
— Q —
Other than below
— — —
0
0
Engine is running, alternator voltage is below the specified level, and no incoming ING-C is present.
30
When abnormality is detected (unmatched engine condition and the signal)
3
1
— Q —
Q
Remarks — — —
— — —
— — —
— — —
w Q
Q
— — —
— Q —
— Q —
3
(*) — — — 1
w — Q
0
0
— Q —
— Q —
— — —
— — —
0
w Q
LED Low oil pressure (CLOSE)
Error message is displayed on the character display when long as reverse rotation of fan is continued. "COOLING FAN REVERSE"
Message is simultaneously displayed on the character display. 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.
E
— — —
— — —
Low oil pressure (CLOSE)
Oil pressure normal (OPEN)
E
AB00L6 — — —
1
Alarm buzzer is sounded when connection of quick coupler is reset. Error message is simultaneously displayed on the character display. "PIN DISCONNECT"
— — —
Q
0.5
LED
w Q
To be released if the oil temperature is detected consecutively at lower than 125°C for 5 sec.
— — —
When quick coupler is disconnected
When parking brake is left unapplied (CLOSE)
Display color
Display of message
— — — DGR2KB — — — DGR2KB
When abnormality is detected (disconnection or hot short-circuit)
Oil pressure normal (OPEN) oil 26 Steering pressure
Q B@C6NS
When abnormality is detected (ground fault)
Normal voltage
25 Battery charge circuit
Q B@C6NS w Q
Red
Other symbols
LED
Temperature rise (oil temperature: Min. 120°C (alarm)
Q
Red
0
Orange
0
Red
Engine is running, parking brake operated and the directional lever is at any position other than "N"
Red
Released (CLOSE)
Red
Cooling fan 22 reverse rotation
LED
Alarm buzzer
— Q —
AB00MA
Red
coupler 21 Quick operation
LED
Individual display Central warning lamp
— Q —
Other than below
oil 20 Brake temperature
Display of message
Operation (OPEN)
Remarks
If abnormality is detected when starting switch is turned "ON", alarm is continued even after engine is started.
Judgment for Abnormal o Normal: 12 V or above Judgment for Normal o Abnormal: 5 V or below
Red
LED
Operating condition
Engine is running
This function can be enabled when "ADD" is selected for "2. EMERG S/T" from the "Optional device selecting function" of the machine monitor. *: The function is reset immediately when engine is stopped.
Green
19 Parking brake
Device
Individual display Central warning lamp
Item
Reset
No.
Operating condition Engine stopped Alarm buzzer
Category
Detection
Detecting time (sec)
This function can be enabled when "ADD" is selected for "2. EMERG S/T" from the "Optional device selecting function" of the machine monitor.
DDS5L6
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910 Electrical system, Part 1 Machine monitor
SEN03999-00
When directional lever is used Directional selector 31 switch actuation
LED
Other symbols
10-910
32 Economy operation
LED
mode 34 S operation
LED
Traction 35 control operation
LED
10
— Q —
— — —
— — —
When directional selector switch is used
0
0
— Q —
— Q —
Directional lever priority caution
0
0
A w
Q
A w
Q
Directional selector switch neutral caution
0
0
A w
Q
A w
Q
Other than below
0
0
— — —
— — —
Economy mode operation
0
0
— Q —
— Q —
— — —
— — —
— Q —
— Q —
— — —
— — —
— Q —
— Q —
Other than below S mode operation is selected
0
0
Other than below Traction control operation is turned on
0
0
Display color
Display of message
Alarm buzzer
— Q —
Red
0
Green
0
— — —
Remarks
This function can be enabled when "ADD" is selected for "3. EMERG S/T" from the "Optional device selecting function" of the machine monitor. Not to be displayed when error is made in communication.
Green
When preheater is turned on
— — —
Green
LED
Green
Other than below 30 Preheating
Engine is running Individual display Central warning lamp
Operating condition
Display of message
Device
Individual display Central warning lamp
Item
Reset
No.
Operating condition Engine stopped Alarm buzzer
Category
Detection
Detecting time (sec)
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.
WA250, 250PZ-6
910 Electrical system, Part 1 Machine monitor
SEN03999-00
Machine monitor operation switch
1
1. Machine monitor mode selector switch 1 2. Machine monitor mode selector switch 2
WA250, 250PZ-6
10-910
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SEN03999-00 Setting of machine monitor
910 Electrical system, Part 1 Machine monitor
1
1. Spare rotary switch (SW1) 2. Spare rotary switch (SW2) 3. Spare rotary switch (SW3) 4. Spare dip switch (SW5-1) 5. Spare dip switch (SW5-2) 6. Spare dip switch (SW5-3) 7. Spare dip switch (SW5-4) 8. Spare dip switch (SW6-1) 9. Spare dip switch (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 q q q
1
The machine monitor monitors the input and output signals constantly for troubleshooting for the system. If each controller detects abnormality by the self-diagnosis, abnormality information is forwarded to the machine monitor over the network. Abnormality information can be checked on the character display using the failure code display mode of the machine monitor.
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WA250, 250PZ-6
910 Electrical system, Part 1 Machine monitor
SEN03999-00
Character display function q q
a
1
Machine monitor display and setting can be changed by using the character display. The range where operator is enabled to operate is within the portion of the "Operator mode" in the figure below. 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".
WA250, 250PZ-6
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SEN03999-00
910 Electrical system, Part 1 Machine monitor
Operator mode functions
1
Self-check screen (0th layer) q Self-check is conducted for 3 seconds automatically when starting switch is turned to "ON". q During a self-check, entry through the machine monitor operating switch is not accepted. q After ending the self-check, the self-check screen automatically moves to 1st layer.
Normal screen (1st layer) q If the item of "13. RPM/SPEED" is set to "ADD" in the "Optional device selecting function" of machine monitor 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 character display. q Pressing the "U" switch changes the screen to the 2nd layer.
1. Engine speed display 2. Travel speed display A. In the case of "km/h" display B. In the case "MPH" display a
When "SI unit specification" is selected for the "Factory mode" from the machine monitor, the character display shows the engine speed in "rpm" and the monitor center display is fixed to the travel speed in "km/h".
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910 Electrical system, Part 1 Machine monitor
SEN03999-00
Failure code screen (1st layer) q Pressing the ">" switch while the Warning screen is on display changes display to the Failure code screen. q If multiple failure codes are present, pressing of the ">" switch sequentially displays them from the item of higher priority downward. If items have the same 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 seconds 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 failure code screen or if a new alarm is turned ON. *3: Pressing the ">" switch on the Normal screen before 10 seconds lapse changes display to the initial failure code screen.
WA250, 250PZ-6
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SEN03999-00
910 Electrical system, Part 1 Machine monitor
Display of functions opened to the operator (2nd layer or below) q Certain menus are not displayed unless the items in the "Optional device selecting function" of the machine monitor are set. q Pressing "U" switch allows selecting each menu. q For the 2nd layer down, the screen automatically returns to the screen of the 1st layer if the switch is not pressed more than 60 seconds 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 "Optional device selecting function" of the machine monitor. k
It is prohibited to select "ADD" for "12. RPM/OPT" from the "Optional device selecting function" of the machine monitor in the regions where the applicable law requires to display the travel speed.
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910 Electrical system, Part 1 Machine monitor
SEN03999-00
Service mode functions q q
Procedure for switching to Service Mode 1. Checking of the screen display Check that the character display is set to the 1st layer screen in the operator mode. 2.
1
The machine monitor is provided with service mode function for the ease of troubleshooting for the controllers on the network (including the machine monitor itself). Initial setting of the sensors and optional setting can be made in the service mode of the machine monitor.
3.
ID input and confirmation Operate the machine monitor mode selector switches 1 and 2 and enter ID. (ID: 6491)
Display of ID input initial screen Pressing " u " switch and "" switch signal j. "
