Komatsu WA250-1LC Wheel Loader Shop Manual CEBMW18020 – PDF DOWNLOAD
FILE DETAILS:
Komatsu WA250-1LC Wheel Loader Shop Manual CEBMW18020 – PDF DOWNLOAD
Language : English
Pages : 648
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WA250-1LC Wheel Loader Shop Manual CEBMW18020 – PDF DOWNLOAD
MACHINE MODEL SERIAL NUMBERS
WA25011 LC A65001 and up
GENERAL PRECAUTIONS :
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.
PREPARATIONS FOR WORK:
PRECAUTIONS DURING WORK :
TABLE OF CONTENTS:
Komatsu WA250-1LC Wheel Loader Shop Manual CEBMW18020 – PDF DOWNLOAD
MACHINE MODEL SERIAL NUMBERS
WA25011 LC A65001 and up
MAIN MENU 0
CONTENTS 5
10 ENGINE 19
12 TESTING AND ADJUSTING 19
STANDARD VALUE TABLE 21
ENGINE ON TEST BENCH 21
ENGINE ON CHASSIS 22
TOOL LIST 22
VALVE CLEARANCE 23
FUEL INJECTION TIMING 23
ENGINE OIL PRESSURE 24
ENGINE OIL TEMPERATURE 25
BLOW-BY PRESSURE 26
EXHAUST GAS COLOR 27
ACCELERATOR PEDAL 28
OPERATING FORCE 28
OPERATING ANGLE 29
13 DISASSEMBLY AND ASSEMBLY 31
NOZZLE HOLDER ASSEMBLY 32
REMOVAL 32
INSTALLATION 32
CYLINDER HEAD ASSEMBLY 33
REMOVAL 33
INSTALLATION 34
RADIATOR 35
REMOVAL 35
INSTALLATION 37
ENGINE 39
REMOVAL 39
INSTALLATION 44
FUEL TANK 48
REMOVAL 48
INSTALLATION 49
20 POWER TRAIN 52
21 STRUCTURE AND FUNCTION 52
GENERAL 54
HYDRAULIC CIRCUIT FOR POWER TRAIN 56
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN 57
TORQUE CONVERTER AND TRANSMISSION PIPING 58
TORQUE CONVERTER CHARGING PUMP 59
SPECIFICATIONS 59
OUTLINE 59
TORQUE CONVERTER 60
SPECIFICATIONS 60
OUTLINE 61
TORQUE CONVERTER OIL FILTER 62
TORQUE CONVERTER OIL COOLER AND RADIATOR 63
TORQUEFLOW TRANSMISSION 64
CLUTCH PACK 66
FORWARD AND REVERSE CLUTCH 66
1ST AND 3RD CLUTCH 66
2ND AND 4TH CLUTCH 67
OPERATION OF CLUTCH 68
FORWARD 1ST 69
FORWARD 2ND 70
FORWARD 3RD 71
FORWARD 4TH 72
REVERSE 1ST 73
TRANSMISSION CONTROL VALVE 74
TRANSMISSION SOLENOID VALVE 75
UPPER VALVE 76
LOWER VALVE 77
TORQUE CONVERTER OUTLET VALVE 78
PILOT REDUCING VALVE 79
TRANSMISSION SOLENOID VALVE 80
PRIORITY AND MAIN REGULATOR VALVE 81
MAIN REGULATOR VALVE 82
MODULATING RELIEF VALVE 83
ACCUMULATOR VALVE 83
QUICK RETURN VALVE 83
EMERGENCY MANUAL SPOOL 87
FORWARD 1ST 88
DIRECTIONAL SPOOL 89
FILL VALVE 90
PILOT OIL FILTER 92
DRIVE SHAFT 93
AXLE 94
FRONT 94
REAR 95
DIFFERENTIAL 96
FRONT 96
REAR 97
TORQUE PROPORTIONING 98
FINAL DRIVE 100
AXLE MOUNT 101
TIRE AND WHEEL 103
22 TESTING AND ADJUSTING 104
STANDARD VALUE TABLE 105
ENGINE STALL SPEED 106
OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION 108
SHIFT LEVER 111
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL 112
TIRE AND WHEEL 114
TROUBLESHOOTING 115
PREVENTING RECURRENCE OF TROUBLE 116
METHOD OF READING TROUBLESHOOTING TABLE 117
CHECKS BEFORE TROUBLESHOOTING 119
METHOD OF LOCATING MAIN PROBLEM POINTS WHEN TROUBLESHOOTING TRANSMISSION SYSTEM 120
TROUBLESHOOTING TABLE 121
TORQUE CONVERTER AND TRANSMISSION 121
1 Machine does not move off 121
2 Machine speed is low, thrust is weak, grade-ability falls off 123
3 Large shock when moving off or changing gear 125
4 Large time lag when moving off or changing gear 126
5 Oil temperature in torque converter is high 127
23 DISASSEMBLY AND ASSEMBLY 128
TORQUE CONVERTER CHARGING PUMP 130
REMOVAL 130
INSTALLATION 130
TRANSMISSION, TORQUE CONVERTER 131
REMOVAL 131
INSTALLATION 138
TORQUE CONVERTER 145
DISASSEMBLY 145
ASSEMBLY 148
TRANSMISSION 151
DISASSEMBLY 151
ASSEMBLY 158
CLUTCH PACK 170
DISASSEMBLY 170
FORWARD-REVERSE CLUTCH PACK 170
1ST -3RD SPEED CLUTCH PACK 173
2ND-4TH SPEED CLUTCH PACK 175
ASSEMBLY 177
FORWARD-REVERSE CLUTCH PACK 177
1ST-3RD SPEED CLUTCH PACK 182
2ND-4TH SPEED CLUTCH PACK 186
TRANSMISSION CONTROL VALVE 190
REMOVAL 190
INSTALLATION 191
TRANSMISSION SOLENOID VALVE 197
DISASSEMBLY 197
ASSEMBLY 197
DRIVE SHAFT 198
DISASSEMBLY 198
ASSEMBLY 200
FRONT AXLE 202
REMOVAL 202
INSTALLATION 204
REAR AXLE 206
REMOVAL 206
INSTALLATION 210
DIFFERENTIAL 215
DISASSEMBLY 215
ASSEMBLY 219
AXLE HOUSING 229
DISASSEMBLY 229
ASSEMBLY 233
24 MAINTENANCE STANDARD 240
ENGINE AND TRANSMISSION MOUNT 241
TORQUE CONVERTER CHARGING PUMP 242
TORQUE CONVERTER 243
TRANSMlSSlON 245
TRANSMISSION CLUTCH 249
UPPER VALVE 253
LOWER VALVE 255
SOLENOID VALVE 256
AXLE 257
DIFFERENTIAL 261
FINAL DRIVE 263
DRIVE SHAFT 264
AXLE MOUNT 265
40 STEERING SYSTEM 267
41 STRUCTURE AND FUNCTION 267
STEERING PIPING 268
HYDRAULIC CIRCUIT FOR STEERING 269
HYDRAULIC CIRCUIT DIAGRAM FOR STEERING 270
TWO-WAY RESTRICTOR VALVE 271
STEERING VALVE 272
CONNECTION OF HAND PUMP AND SLEEVE 278
PRIORITY VALVE 280
STEERING COLUMN 283
STEERING CYLINDER 284
CENTER HINGE PIN 285
42 TESTING AND ADJUSTING 287
STANDARD VALUE TABLE 288
TOOL LIST 288
STEERING WHEEL PLAY 289
OPERATING FORCE OF STEERING WHEEL 290
OPERATING TIME OF STEERING WHEEL 291
STEERING OIL PRESSURE 292
TROUBLESHOOTING 295
TROUBLESHOOTING TABLE 296
1 Steering wheel does not turn 296
2 Steering wheel is sluggish 297
3 Steering wheel moves unsteadily or is subjected to large shock 298
4 Machine tends to turn naturally in one particular direction when traveling 298
5 Left and right turning radii are different 298
43 DISASSEMBLY AND ASSEMBLY 299
STEERING VALVE 300
REMOVAL 300
INSTALLATION 302
DISASSEMBLY 304
ASSEMBLY 306
PRIORITY VALVE 308
REMOVAL 308
INSTALLATION 310
STEERING CYLINDER 312
REMOVAL 312
INSTALLATION 313
DISASSEMBLY 314
ASSEMBLY 316
CENTER HINGE PIN REMOVAL 319
REMOVAL 319
INSTALLATION 324
44 MAINTENANCE STANDARD 329
HYDRAULIC AND STEERING PUMP 330
STEERING CYLINDER MOUNT 331
CENTER HINGE PIN 332
STEERING COLUMN AND GEAR BOX 334
PRIORITY VALVE 335
50 BRAKE AND AIR SYSTEM 338
51 STRUCTURE AND FUNCTION 338
BRAKE PIPING 339
POWER MASTER CYLINDER 340
BRAKE 344
PARKING BRAKE CONTROL 346
PARKING BRAKE 347
OPERATION OF PARKING BRAKE 348
BRAKE CALIPER 349
52 TESTING AND ADJUSTING 350
STANDARD VALUE TABLE 351
TOOL LIST 352
MEASURING BRAKE PEDAL 353
BRAKE PEDAL LINKAGE 354
BRAKE PERFORMANCE 356
BRAKE PISTON LEAKAGE 357
BRAKE DISC WEAR 358
AIR BLEEDING FROM BRAKE CIRCUIT 359
PARKING BRAKE PERFORMANCE 360
PARKING BRAKE 361
CHECKING 361
ADJUSTING 362
MEASURING CLEARANCE 363
TROUBLESHOOTING 364
TROUBLESHOOTING TABLES 365
1 Brake is ineffective or not very effective 365
2 Brake cannot be released or drags 366
53 DISASSEMBLY AND ASSEMBLY 368
POWER MASTER CYLINDER 369
REMOVAL 369
INSTALLATION 370
DISASSEMBLY 371
ASSEMBLY 374
PARKING BRAKE 379
REMOVAL 379
lNSTALLATION 381
PARKING BRAKE PAD 383
REMOVAL 383
INSTALLATION 383
54 MAINTENANCE STANDARD 384
POWER MASTER CYLINDER 385
BRAKE 386
PARKING BRAKE 387
60 WORK EQUIPMENT SYSTEM 389
61 STRUCTURE AND FUNCTION 389
HYDRAULIC PIPING 390
HYDRAULIC CIRCUIT 391
HYDRAULIC CIRCUIT DIAGRAM 392
WORK EQUIPMENT LEVER LINKAGE 393
BUCKET LINKAGE 394
BUCKET POSITIONER AND BOOM KICK-OUT 396
HYDRAULIC TANK 398
OIL FILTER BYPASS VALVE 399
BREATHER 399
HYDRAULIC AND STEERING PUMPS 400
MAIN CONTROL VALVE 401
RELIEF VALVE 403
SAFElY VALVE W/SUCTION VALVE 404
As a safety valve 404
As a suction valve 405
SUCTION VALVE 405
LIFT AND DUMP SPOOLS AT “NEUTRAL POSITION” 406
LIFT SPOOL AT “RAISE POSITION” 407
LIFT SPOOL AT “LOWER POSITION” 408
LIFT SPOOL AT “FLOAT POSITION” 409
DUMP SPOOL AT “TILT BACK POSITION” 410
DUMP SPOOL AT DUMP “POSITION” 411
HYDRAULIC CYLINDER 412
62 TESTING AND ADJUSTING 413
STANDARD VALUE TABLE 415
DUMP AND LIFT CONTROL LEVERS 416
HYDRAULIC PRESSURE 419
LIFT ARM AND BUCKET 421
HYDRAULIC DRIFT OF LIFT ARM AND BUCKET 422
BUCKET POSITIONER 423
BOOM KICK-OUT 424
TROUBLESHOOTING 426
TROUBLESHOOTING TABLES 427
1 Lift arm does not rise 427
2 Lift arm moves slowly or does not have sufficient lifting power 428
3 Lift arm movement becomes slow after it reaches a certain height 429
4 Bucket cannot be held down with lift arm cylinder 429
5 Lift arm has large hydraulic drift 429
6 Lift arm movement is unsteady during work 429
7 Lift arm descends momentarily when control lever is shifted from “Hold to Raise” 429
8 Bucket does not tilt back 430
9 Bucket moves slowly or has insufficient tilt back power 431
10 Bucket movement becomes slow during tilt back 432
11 Bucket cannot be held down by the bucket cylinder 432
12 Bucket has large hydraulic drift 432
13 Bucket moves unsteadily when machine travels under load (Main control valve in “Hold”) 432
14 Bucket dumps momentarily when control lever is shifted from “Hold to Tilt back ” 432
15 Control levers of lift arm and dump move stiffly and sluggishly 433
63 DISASSEMBLY AND ASSEMBLY 435
HYDRAULIC TANK 437
REMOVAL 437
INSTALLATION 439
HYDRAULIC FILTER 441
REMOVAL 441
INSTALLATION 441
HYDRAULIC, STEERING PUMP 442
REMOVAL 442
INSTALLATION 443
MAIN CONTROL VALVE 444
REMOVAL 444
INSTALLATION 446
DISASSEMBLY 449
ASSEMBLY 449
DUMP CYLINDER 450
REMOVAL 450
INSTALLATION 452
DISASSEMBLY 453
ASSEMBLY 455
LIFT CYLINDER 457
REMOVAL 457
INSTALLATION 458
DISASSEMBLY 459
ASSEMBLY 461
WORK EQUIPMENT 463
REMOVAL 463
INSTALLATION 466
COUNTERWEIGHT 469
REMOVAL 469
INSTALLATION 469
64 STRUCTURE AND FUNCTION 471
HYDRAULIC AND STEERING PUMP 472
MAIN CONTROL VALVE 474
DUMP CYLINDER 476
LIFT CYLINDER 477
BUCKET LINKAGE 478
BUCKET POSITIONER AND BOOM KICK-OUT 481
BUCKET 482
80 ELECTRIC AND ELECTRONIC SYSTEM 484
81 STRUCTURE AND FUNCTION 484
ELECTRICAL WIRING CIRCUIT DlAGRAMS 485
ENGINE STARTING CIRCUIT 486
ENGINE STOP CIRCUIT 488
COMBINATION SWITCH 489
ELECTRICAL TRANSMISSION CONTROL 490
TRANSMISSION CUT-OFF SELECTOR SWITCH 491
NEUTRALIZER RELAY 492
ELECTRONIC VEHICLE MONITORING SYSTEM (RIMS) 493
MONITOR PANEL 494
INDICATION ON MONITOR PANEL 495
WIRING HARNESS 497
SENSORS 498
ENGINE OIL LEVEL SENSOR 499
COOLANT LEVEL SENSOR 499
BRAKE OIL LEVEL SENSOR 500
FUEL GAUGE SENSOR 501
COOLANT TEMPERATURE SENSOR 502
TORQUE CONVERTER OIL TEMPERATURE SENSOR 502
ENGINE OIL PRESSURE SENSOR 503
ROTATIONAL SPEED SENSOR 503
PROXIMITY SWITCH 504
82 TESTING AND ADJUSTING 508
ADJUSTING SPEEDOMETER MODULE 511
TROUBLESHOOTING 512
ELECTRICAL CIRCUIT SYSTEM 514
1 ENGINE STARTING CIRCUIT SYSTEM 514
2 ENGINE STOP CIRCUIT SYSTEM 515
3 TRANSMISSION CONTROL AND PARKING BRAKE SYSTEM 516
CONNECTION TABLE FOR CONNECTOR PIN NUMBER CONNECT1 517
PRECAUTION WHEN HANDLING CONNECTOR 522
METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART 524
ELECTRICAL SCHEMATIC 527
CHECKS BEFORE TROUBLESHOOTING 528
TROUBLESHOOTING CHARTS FOR ELECTRIC SYSTEM 530
POSITION OF CONNECTORS 531
E-1 ENGINE DOES NOT START 536
E-2 ENGINE DOES NOT STOP 537
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING 537
E-4 TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (TRANSMISSION CUT-OFF NORMAL) 538
E-5 MACHINE MOVES IN REVERSE BUT NOT IN FORWARD 538
E-6 MACHINE MOVES NEITHER IN FORWARD NOR REVERSE 539
E-7 MACHINE MOVES IN FORWARD BUT NOT IN REVERSE 541
E-8 MACHINE MOVES FORWARD EVEN WHEN 541
E-9 MACHINE MOVES IN REVERSE EVEN WHEN TRANSMISSION CONTROL LEVERS ARE IN NEUTRAL 542
E-10 MACHINE ALWAYS TRAVELS IN 2ND 542
E-11 TRANSMISSION DOES NOT CHANGE GEAR (But F-R changeable) 543
E-12 TRANSMISSION CANNOT BE CUT-OFF EVEN WHEN L H BRAKE PEDAL IS DEPRESSED WITH 544
E-13 TRANSMISSION DOES NOT RETURN TO NEUTRAL 545
TROUBLESHOOTING CHARTS FOR ELECTRONIC VEHICLE MONITORING SYSTEM 548
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS) SCHEMATIC 549
POSITION OF CONNECTORS 550
M-1 EVEN WHEN ENGINE IS STOPPED, (BRAKE OIL LEVEL) FLASHES 556
M-2 EVEN WHEN ENGINE IS STOPPED, (ENGINE OIL LEVEL) FLASHES 556
M-3 EVEN WHEN ENGINE IS STOPPED, (COOLANT LEVEL) FLASHES 557
M-4 (BATTERY CHARGE) FLASHES WHEN ENGINE IS RUNNING 557
M-5 (FUEL LEVEL) FLASHES 558
M-6 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, (BRAKE OIL LEVEL) 558
M-7 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, (ENGINE OIL PRESSURE) 558
M-8 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, (COOLANT LEVEL) 559
M-9 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, (BRAKE SERVO PRESSURE) 559
M-10 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, (COOLANT TEMPERATURE) 559
M-11 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, (TORQUE CONVERTER OIL TEMPERATURE) 560
M-12 (PARKING BRAKE) LIGHTS UP OR DOES NOT LIGHT UP 560
M-13 (WORKING LAMP) LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP 561
M-14 NOT USED 562
M-15 (FAILURE IN MAIN STEERING) LIGHTS UP OR DOES NOT LIGHT UP (IF EQUIPPED) 562
M-16 (EMERGENCY STEERING NORMAL) LIGHTS UP OR DOES NOT LIGHT UP (IF EQUIPPED) 563
M-17 (TRANSMISSION CUT-OFF) LIGHTS UP OR DOES NOT LIGHT UP 564
M-18 TURN SIGNAL LAMPS, HIGH BEAM LIGHT UP OR DO NOT LIGHT UP 565
M-19 SPEEDOMETER DISPLAY DOES NOT WORK 567
M-20 SERVICEMETER DOES NOT WORK NORMALLY 568
M-21 ALL OR PART OF MONITOR PANEL DOES NOT WORK 569
M-22 EVEN WHEN ENGINE IS STOPPED, (BATTERY CHARGE) FLASHES, OR (ENGINE OIL PRESSURE) FLASHES 570
M-23 NO LAMPS ON MONITOR LIGHT UP (IMMEDIATELY AFTER TURNING STARTING SWITCH TO ON, ENGINE STOPPED) 570
M-24 CENTRAL WARNING LAMP DOES NOT GO OUT 571
M-25 CENTRAL WARNING BUZZER DOES NOT STOP 571
M-26 NONE OF PANEL LAMPS ON MACHINE MONITOR LIGHT UP 572
M-27 SOME OF PANEL LAMPS ON MACHINE MONITOR DO NOT LIGHT UP 574
M-28 EMERGENCY ITEM IS FLASHING, BUT ALARM BUZZER DOES NOT SOUND 575
M-29 EMERGENCY ITEM OR NON-EMERGENCY ITEM IS FLASHING, BUT WARNING LAMP DOES NOT FLASH 575
M-30 ABNORMALITY IN (FUEL GAUGE) 576
M-31 ABNORMALITY IN (COOLANT TEMPERATURE GAUGE) 577
M-32 ABNORMALITY IN (TORQUE CONVERTER OIL TEMPERATURE GAUGE) 578
TABLE OF MONITOR REFERENCE VALUES 579
83 DISASSEMBLY AND ASSEMBLY 584
ELECTRONIC VECHICLE MONITOR SYSTEM (EVMS) 585
REMOVAL 585
INSTALLATION 586
90 OTHER 589
91 STRUCTURE AND FUNCTION 589
CAB 590
AIR CONDITIONER 592
PIPING, ENGINE TO HEATER CORE 592
PIPING, CONDENSER AND COMPRESSOR 593
ELECTRICAL DIAGRAM 594
AIR CONDITIONER UNIT 595
HEATING 595
COOLING 595
AIR CONDITIONER COMPRESSOR 596
AIR CONDITIONER CONDENSER 596
AIR CONDITIONER DRY RESERVOIR 597
93 DISASSEMBLY AND ASSEMBLY 599
CAB 600
REMOVAL 600
INSTALLATION 601
AIR CONDITIONER UNIT 602
REMOVAL 602
INSTALLATION 604
CONDENSER (AIR CONDITIONER) 606
REMOVAL 606
INSTALLATION 606
DRY RECEIVER (AIR CONDITIONER) 607
REMOVAL 607
INSTALLATION 607
COMPRESSOR (AIR CONDITIONER) 608
REMOVAL 608
INSTALLATION 608
97 GEAR PUMP 609
GENERAL 610
PRINCIPLE OF OPERATION 611
PRESSURE LOADED TYPE GEAR PUMP 614
FIXED SIDE PLATE TYPE GEAR PUMP 616
SA SERIES 617
STRUCTURE 617
TESTING AND ADJUSTING 621
DISASSEMBLY 624
ASSEMBLY 628
MAINTENANCE STANDARD 633
99 METRIC CONVERSIONS 635
S.V 14/12/24
