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KOMATSU WA250-5 WA250L-5 WA250PT-5 WA250PTL-5 WHEEL LOADER SHOP MANUAL SEBM033205 – PDF DOWNLOAD
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KOMATSU WA250-5 WA250L-5 WA250PT-5 WA250PTL-5 WHEEL LOADER SHOP MANUAL SEBM033205 – PDF DOWNLOAD
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WA250-5 70001 and up
WA250L-5 70001 and up
WA250PT-5 70001 and up
WA250PTL-5 70001 and up
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KOMATSU WA250-5 WA250L-5 WA250PT-5 WA250PTL-5 WHEEL LOADER SHOP MANUAL SEBM033205 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WA250-5 WA250L-5 WA250PT-5 WA250PTL-5 WHEEL LOADER SHOP MANUAL SEBM033205 – PDF DOWNLOAD
Language : English
Pages : 855
Downloadable : Yes
File Type : PDF
SERIAL NUMBERS
WA250-5 70001 and up
WA250L-5 70001 and up
WA250PT-5 70001 and up
WA250PTL-5 70001 and up
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU WA250-5 WA250L-5 WA250PT-5 WA250PTL-5 WHEEL LOADER SHOP MANUAL SEBM033205 – PDF DOWNLOAD
MAIN MENU............................................................................................................................................................................... 0 COVER................................................................................................................................................................................... 1 CONTENTS................................................................................................................................................................................ 2 SAFETY.................................................................................................................................................................................. 7 SAFETY NOTICE....................................................................................................................................................................... 7 FOREWORD................................................................................................................................................................................ 9 GENERAL............................................................................................................................................................................. 9 HOW TO READ THE SHOP MANUAL......................................................................................................................................................... 10 HOISTING INSTRUCTION................................................................................................................................................................ 11 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER.......................................................................................................................... 12 COATING MATERIALS................................................................................................................................................................... 14 STANDARD TIGHTENING TORQUE.......................................................................................................................................................... 16 ELECTRIC WIRE CODE.................................................................................................................................................................. 19 CONVERSION TABLE.................................................................................................................................................................... 20 UNITS............................................................................................................................................................................... 26 01 GENERAL.............................................................................................................................................................................. 27 GENERAL ASSEMBLY DRAWINGS........................................................................................................................................................... 28 SPECIFICATIONS...................................................................................................................................................................... 29 WEIGHT TABLE........................................................................................................................................................................ 33 LIST OF LUBRICANT AND COOLANT....................................................................................................................................................... 35 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD......................................................................................................................................... 36 ENGINE MOUNT AND TRANSFER MOUNT..................................................................................................................................................... 37 DAMPER.............................................................................................................................................................................. 38 COOLING SYSTEM...................................................................................................................................................................... 39 TRANSFER OIL COOLER................................................................................................................................................................. 40 POWER TRAIN......................................................................................................................................................................... 41 POWER TRAIN SYSTEM DIAGRAM.......................................................................................................................................................... 43 DRIVE SHAFT (PROPELLER SHAFT)....................................................................................................................................................... 45 HST HYDRAULIC PIPING DIAGRAM........................................................................................................................................................ 46 HST PUMP............................................................................................................................................................................ 47 HIGH-PRESSURE RELIEF VALVE.......................................................................................................................................................... 49 LOW-PRESSURE RELIEF VALVE........................................................................................................................................................... 51 HST CHARGE PUMP..................................................................................................................................................................... 52 SPEED-RELATED VALVE (DA VALVE)...................................................................................................................................................... 53 HIGH-PRESSURE CUT-OFF VALVE......................................................................................................................................................... 54 HST MOTOR........................................................................................................................................................................... 55 EP SERVO VALVE...................................................................................................................................................................... 58 HA SERVO VALVE...................................................................................................................................................................... 59 FORWARD-REVERSE SHUTTLE VALVE....................................................................................................................................................... 60 TRANSFER............................................................................................................................................................................ 61 CLUTCH SOLENOID VALVE............................................................................................................................................................... 72 AXLE................................................................................................................................................................................ 73 DIFFERENTIAL........................................................................................................................................................................ 75 LIMITED-SLIP DIFFERENTIAL........................................................................................................................................................... 81 FINAL DRIVE......................................................................................................................................................................... 87 AXLE MOUNTING AND CENTER HINGE PIN.................................................................................................................................................. 93 STEERING PIPING..................................................................................................................................................................... 98 STEERING COLUMN..................................................................................................................................................................... 99 PRIORITY VALVE......................................................................................................................................................................100 ORBIT-ROLL VALVE....................................................................................................................................................................103 2-WAY RESTRICTOR VALVE..............................................................................................................................................................111 CUSHION VALVE.......................................................................................................................................................................112 STEERING CYLINDER...................................................................................................................................................................113 EMERGENCY STEERING PIPING...........................................................................................................................................................115 EMERGENCY STEERING VALVE............................................................................................................................................................116 BRAKE PIPING........................................................................................................................................................................119 BRAKE VALVE.........................................................................................................................................................................120 INCHING VALVE.......................................................................................................................................................................124 CHARGE VALVE........................................................................................................................................................................125 ACCUMULATOR (FOR BRAKE).............................................................................................................................................................129 SLACK ADJUSTER......................................................................................................................................................................130 BRAKE...............................................................................................................................................................................133 PARKING BRAKE CONTROL...............................................................................................................................................................138 PARKING BRAKE.......................................................................................................................................................................139 HYDRAULIC PIPING....................................................................................................................................................................141 HYDRAULIC TANK......................................................................................................................................................................150 4-GEAR PUMP UNIT....................................................................................................................................................................152 ACCUMULATOR (FOR PPC CIRCUIT).......................................................................................................................................................154 LOCK VALVE..........................................................................................................................................................................155 BYPASS VALVE........................................................................................................................................................................156 QUICK COUPLER VALVE.................................................................................................................................................................162 E.C.S.S. VALVE......................................................................................................................................................................163 ACCUMULATOR (FOR E.C.S.S.)..........................................................................................................................................................165 HYDRAULIC PIPING OF COOLING SYSTEM..................................................................................................................................................166 COOLING FAN MOTOR...................................................................................................................................................................167 WORK EQUIPMENT CONTROL VALVE........................................................................................................................................................169 WORK EQUIPMENT PPC VALVE............................................................................................................................................................182 ATTACHMENT PPC VALVE (IF EQUIPPED)..................................................................................................................................................190 WORK EQUIPMENT LINKAGE..............................................................................................................................................................194 BUCKET..............................................................................................................................................................................198 CONTROL OF BUCKET POSITIONER, BOOM KICK-OUT, AND DUMP SPEED.........................................................................................................................200 WORK EQUIPMENT CYLINDER.............................................................................................................................................................215 AIR CONDITIONER (IF EQUIPPED).......................................................................................................................................................218 MACHINE MONITORING SYSTEM...........................................................................................................................................................219 MACHINE MONITOR.....................................................................................................................................................................229 LIST OF ITEMS DISPLAYED ON MONITOR..................................................................................................................................................230 ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)...........................................................................................................................................256 HST CONTROLLER......................................................................................................................................................................260 ENGINE START CIRCUIT................................................................................................................................................................261 ENGINE STOP CIRCUIT.................................................................................................................................................................263 PREHEATING CIRCUIT (AUTOMATIC PREHEATING SYSTEM)....................................................................................................................................264 PARKING BRAKE CIRCUIT...............................................................................................................................................................265 ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM.........................................................................................................................................268 SENSORS.............................................................................................................................................................................269 20 TESTING AND ADJUSTING................................................................................................................................................................275 STANDARD VALUE TABLE................................................................................................................................................................276 STANDARD VALUE TABLE FOR ENGINE.................................................................................................................................................276 STANDARD VALUE TABLE FOR CHASSIS................................................................................................................................................277 TESTING AND ADJUSTING...............................................................................................................................................................281 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...............................................................................................................................282 MEASURING ENGINE SPEED..........................................................................................................................................................284 MEASURING EXHAUST GAS COLOR.....................................................................................................................................................285 ADJUSTING VALVE CLEARANCE.......................................................................................................................................................286 MEASURING COMPRESSION PRESSURE..................................................................................................................................................288 MEASURING BLOW-BY PRESSURE......................................................................................................................................................289 TESTING AND ADJUSTING FUEL INJECTION TIMING.....................................................................................................................................290 MEASURING ENGINE OIL PRESSURE...................................................................................................................................................291 MEASURING, TESTING OPERATING FORCE OF ACCELERATOR PEDAL.........................................................................................................................292 ADJUSTING ENGINE STOP SOLENOID..................................................................................................................................................294 ADJUSTING ENGINE SPEED SENSOR...................................................................................................................................................295 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION...................................................................................................................295 MEASURING DIRECTIONAL LEVER.....................................................................................................................................................296 TESTING AND ADJUSTING HST OIL PRESSURE..........................................................................................................................................297 MEASURING CLUTCH CONTROL PRESSURE...............................................................................................................................................301 TESTING AND ADJUSTING STEERING WHEEL............................................................................................................................................302 TESTING AND ADJUSTING STEERING OIL PRESSURE.....................................................................................................................................304 BLEEDING AIR FROM STEERING CIRCUIT..............................................................................................................................................305 TESTING HYDRAULIC FAN...........................................................................................................................................................306 MEASURING BRAKE PEDAL...........................................................................................................................................................307 TESTING AND ADJUSTING BRAKE PEDAL LINKAGE.......................................................................................................................................308 MEASURING BRAKE PERFORMANCE.....................................................................................................................................................309 TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE...............................................................................................................................310 MEASURING BRAKE OIL PRESSURE....................................................................................................................................................311 MEASURING WEAR OF BRAKE DISC....................................................................................................................................................313 BLEEDING AIR FROM BRAKE CIRCUIT.................................................................................................................................................314 MEASURING PARKING BRAKE PERFORMANCE.............................................................................................................................................315 TESTING AND ADJUSTING PARKING BRAKE LINKAGE.....................................................................................................................................316 MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER............................................................................................................................318 TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE.........................................................................................................................319 TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE...........................................................................................................................320 BLEEDING AIR....................................................................................................................................................................322 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...............................................................................................................................323 TESTING AND ADJUSTING BUCKET POSITIONER.........................................................................................................................................324 TESTING AND ADJUSTING OF BOOM KICK-OUT..........................................................................................................................................325 CHECKING PROXIMITY SWITCH ACTUATION DISPLAY LAMP................................................................................................................................326 PROCEDURE FOR CHECKING DIODE....................................................................................................................................................327 SPECIAL FUNCTIONS OF MACHINE MONITOR............................................................................................................................................328 FLOW OF MODES AND FUNCTIONS.....................................................................................................................................................329 FAILURE CODE TABLE..............................................................................................................................................................337 PM CLINIC INSPECTION CHART......................................................................................................................................................347 TROUBLESHOOTING.....................................................................................................................................................................350 POINTS TO REMEMBER WHEN TROUBLESHOOTING.........................................................................................................................................351 SEQUENCE OF EVENTS IN TROUBLESHOOTING...........................................................................................................................................352 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE.......................................................................................................................................353 CHECK BEFORE TROUBLESHOOTING....................................................................................................................................................361 CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS...............................................................................................................362 PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO......................................................................................................................363 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS......................................................................................................................................367 T-ADAPTER TABLE.................................................................................................................................................................389 CONNECTOR TYPES AND MOUNTING LOCATIONS..........................................................................................................................................392 CONNECTOR LAYOUT DRAWING........................................................................................................................................................399 TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE).............................................................................................................................404 HST CONTROLLER SYSTEM DIAGRAM...............................................................................................................................................405 BEFORE TROUBLESHOOTING CODE DISPLAY.........................................................................................................................................407 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM....................................................................................................................................408 INFORMATION CONTAINED IN TROUBULESHOOTING TABLE.............................................................................................................................409 ERROR CODE [989F00] (HST MOTOR PROTECTION CAUTION (00)).....................................................................................................................411 ERROR CODE [DHH1KX] (HST OIL PRESSURE SENSOR INPUT SIGNAL OUTSIDE RANGE (KX))...............................................................................................412 ERROR CODE [DLE2LC] (ENGINE REVOLUTION SENSOR REVOLUTION SPEED SIGNAL MISMATCH (LC))........................................................................................414 ERROR CODE [DW26KZ] (MOTOR 2 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))........................................................................................415 ERROR CODE [DX19KZ] (MOTOR 1 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))........................................................................................417 ERROR CODE [DX20KZ] (CLUTCH SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ)).........................................................................................419 TROUBLESHOOTING CODE [HST-1] (DEFECTIVE HST CONTROLLLER POWER SOURCE (HST CONTROLLER DOES NOT FUNTION)).....................................................................421 TROUBLESHOOTING CODE [HST-2] (TRAVEL SPEED DOES NOT CHANGE).................................................................................................................423 TROUBLESHOOTING CODE [HST-3] HST OUTPUT CONTROL (TRACTION CONTROL) CANNOT BE CONTROLLED.....................................................................................426 TROUBLESHOOTING CODE [HST-4] (TRAVEL SPEED LIMIT CANNOT BE CHANGED WHEN GEAR SPEED SELECTOR SWITCH IS IN "1ST" POSITION)....................................................428 TROUBLESHOOTING CODE [HST-5] (TRAVEL SPEED IS NOT INCREASED)................................................................................................................430 TROUBLESHOOTING OF TRAVEL DAMPER SYSTEM (ECSS MODE) (IF EQUIPPED)...............................................................................................................432 RELATED ELECTRICAL CIRCUIT DIAGRAM..........................................................................................................................................433 ECSS-1 MALFUNCTION OF TRAVEL DAMPER.........................................................................................................................................434 TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE)....................................................................................................................................439 MONITOR SYSTEM CIRCUIT DIAGRAM..............................................................................................................................................440 BEFORE TROUBLESHOOTING CODE DISPLAY.........................................................................................................................................444 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM....................................................................................................................................445 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..............................................................................................................................446 ERROR CODE [15B0NX] (HST OIL FILTER CLOGGED (NX))...........................................................................................................................448 ERROR CODE [2G42ZG] (DECREASED BRAKE OIL PRESSURE (ZG)).....................................................................................................................449 ERROR CODE [989F00] (HST MOTOR PROTECTION CAUTION (00)).....................................................................................................................450 ERROR CODE [989FN1] (HST OVERRUNNING (N1))..................................................................................................................................451 ERROR CODE [AB00L6] (DEFECTIVE BATTERY CHARGING CIRCUIT (L6))...............................................................................................................452 ERROR CODE [AB00MA] (DEFECTIVE BATTERY CHARGING CIRCUIT (MA))...............................................................................................................453 ERROR CODE [B@BAZG] (DEGREASED ENGINE OIL PRESSURE (ZG))....................................................................................................................454 ERROR CODE [B@BCNS] (ENGINE WATER TEMPERATURE OVERHEATING (NS)).............................................................................................................455 ERROR CODE [B@BCZK] (ALARM INDICATING LOW COOLANT LEVEL (ZK))...............................................................................................................456 ERROR CODE [B@C7NS] (AXLE OIL TEMPERATURE OVERHEATING (NS)).................................................................................................................457 ERROR CODE [B@CRNS] (HST OIL TEMPERATURE OVERHEATING (NS))..................................................................................................................458 ERROR CODE [D5ZHL6] (STARTING SWITCH "C" (IGN "C") INPUT FAILURE (L6))......................................................................................................460 ERROR CODE [DAF0KT] (CONTROLLER INSIDE FAILURE (KT))........................................................................................................................462 ERROR CODE [DAJ0KR] (HST CONTROLLER COMMUNICATION FAILURE (KR)).............................................................................................................464 ERROR CODE [DD15LD] (MONITOR PANEL MODE SELECTOR SWITCH 1 [] (PANEL SWITCH 1) INPUT ERROR (LD)).............................................................................466 ERROR CODE [DD16LD] (MONITOR PANEL MODE SELECTOR SWITCH 1 [<>] (PANEL SWITCH 2) INPUT ERROR (LD))...........................................................................467 ERROR CODE [DD17LC] (MONITOR PANEL MODE SELECTOR SWITCH 2 [<] (PANEL SWITCH 3) INPUT ERROR (LD))............................................................................468 ERROR CODE [DD18LD] (MONITOR PANEL MODE SELECTOR SWITCH 2 [>] (PANEL SWITCH 4) INPUT ERROR (LD))............................................................................469 ERROR CODE [DDK3KB] (MULTIPLE DIRECTIONAL LEVER FR SIGNAL INPUT (KB)).......................................................................................................470 ERROR CODE [DDS5L6] (DECREASED STEERING OIL PRESSURE (L6))..................................................................................................................472 ERROR CODE [DGE2KX] (ENGINE WATER TEMPERATURE (HIGH TEMPERATUE) SENSOR SYSTEM FAILURE (KX)).................................................................................473 ERROR CODE [DGE3L6] (ENGINE WATER TEMPERATURE (LOW TEMPERATURE) SENSOR SYSTEM FAILURE (L6)).................................................................................474 ERROR CODE [DGH1KX] (HST OIL TEMPERATURE SENSOR SYSTEM FAILURE (KX))........................................................................................................475 ERROR CODE [DGR4KZ] (AXLE OIL TEMPERATURE SENSOR SYSTEM DISCONTINUITY (KA)).................................................................................................476 ERROR CODE [DGR4KX] (AXLE OIL TEMPERATURE SENSOR SYSTEM FAILURE (KX)).......................................................................................................477 ERROR CODE [DHE4L6] (ENGINE OIL PRESSURE SENSOR SYSTEM DISCONTINUITY (L6))..................................................................................................478 TROUBLESHOOTING CODE [MON-1] (THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT ON)...........................................................................................480 TROUBLESHOOTING CODE [MON-2] (THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT UP)..............................................................................................484 TROUBLESHOOTING CODE [MON-3] (THE ENGINE WATER TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP, OR AFTER THE ENGINE STARTS, THE ENGINE WATER TEMPERATURE GAUGE DOE NOT RISE).....485 TROUBLESHOOTING CODE [MON-4] (THE HST OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP, OR AFTER THE ENGINE STARTS, THE HST OIL TEMPERATURE GAUGE DOES NOT RISE.).............486 TROUBLESHOOTING CODE [MON-5] (THE FUEL LEVEL GAUGE DOES NOT RISE OR DECREASE.)..............................................................................................487 TROUBLESHOOTING CODE [MON-6] (THE RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP)....................................................................................488 TROUBLESHOOTING CODE [MON-7] (THE STEERING OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP).....................................................................................489 TROUBLESHOOTING CODE [MON-8] (THE EMERGENCY STEERING OIL PRESSURE INDICATOR LAMP DOES NOT LIGHT UP).........................................................................490 TROUBLESHOOTING CODE [MON-9] (INPUT FAILURE IN MONITOR PANEL MODE SLELECTOR SWITCH 1 [] (PANEL SWITCH 1)....................................................................491 TROUBLESHOOTING CODE [MON-10] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1 [<>] (PANEL SWITCH 2)).................................................................492 TROUBLESHOOTING CODE [MON-11] (INPUT FIALURE IN MONITOR PANEL MODE SELECTOR SWITCH 2 [<] (PANEL SWITCH 3))..................................................................493 TROUBLESHOOTING CODE [MON-12] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2 [>] (PANEL SWITCH 4))..................................................................494 TROUBLESHOOTING CODE [MON-13] (THE ALARM BUZZER DOES NOT SOUND OR STOP).....................................................................................................495 TROUBLESHOOTING CODE [MON-14] THE WIPER DOES NOT FUNCTION...................................................................................................................496 TROUBLESHOOTING CODE [MON-15] THE LAMPS DO NOT WORK PROPERLY................................................................................................................496 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...................................................................................................................................497 ELECTRICAL SYSTEM DIAGRAM...................................................................................................................................................498 PARKING BRAKE RELATED DIAGRAM...............................................................................................................................................502 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM....................................................................................................................................504 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..............................................................................................................................506 TROUBLESHOOTING CODE [E-1] (THE ENGINE DOES NOT START)......................................................................................................................508 TROUBLESHOOTING CODE [E-2] (THE ENGINE DOES NOT STOP).......................................................................................................................512 TROUBLESHOOTING CODE [E-3] (PREHEATING IS IMPOSSIBLE OR CONSTANT)...........................................................................................................514 TROUBLESHOOTING CODE [E-4] (THE PARKING BRAKE (MECHANICAL TYPE) DOES NOT FUNCTION)..........................................................................................518 TROUBLESHOOTING CODE [E-5] (DEFECTIVE BOOM KICK-OUT FUNCTION AND CANCELLATION)..............................................................................................525 TROUBLESHOOTING CODE [E-6] (DEFECTIVE BUCKET POSITIONER FUNCTION AND CANCELLATION)..........................................................................................528 TROUBLESHOOTING CODE [E-7] (DEFECTIVE LIFT ARM FLOATING HOLDING FUNCTION AND CANCELLATION)..................................................................................531 TROUBLESHOOTING CODE [E-8] (TRAVEK DIRECTION IS NOT CHANGED NORMALLY).......................................................................................................532 TROUBLESHOOTING CODE [E-9] (THE WIPER DOES NOT FUNCTION)....................................................................................................................538 TROUBLESHOOTING CODE [E-10] (THE WINDOW WASHER DOES NOT FUNCTION)...........................................................................................................544 TROUBLESHOOTING CODE [E-11] (LAMPS DO NOT WORK PROPERLY) ...................................................................................................................547 TROUBLESHOOTING CODE [E-12] (THE HORN DOES NOT SOUND).......................................................................................................................558 TROUBLESHOOTING CODE [E-13] (DEFECTIVE AIR CONDITIONER).....................................................................................................................560 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)........................................................................................................................573 METHOD OF USING TROUBLESHOOTING CHART.......................................................................................................................................574 FAILURE CODE AND CAUSE TABLE................................................................................................................................................576 H-1 THE MACHINE DOES NOT START..............................................................................................................................................578 H-2 THE TRAVEL SPEED IS SLOW................................................................................................................................................579 H-3 THE THRUSTING FORCE IS WEAK.............................................................................................................................................580 H-4 ENGINE STALLS WHEN TRAVELING OR ENGINE SPEED DROPS EXCESSIVELY..........................................................................................................581 H-5 THE GEAR IS NOT SHIFTED.................................................................................................................................................582 H-6 THE STEERING WHEEL DOES NOT TURN........................................................................................................................................583 H-7 THE STEERING WHEEL IS HEAVY.............................................................................................................................................584 H-8 STEERING WHEEL SHAKES OR JERKS..........................................................................................................................................585 H-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING...................................................................................................................585 H-10 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL..........................................................................................................................586 H-11 THE BRAKE IS NOT RELEASED OR IS DRAGGED................................................................................................................................587 H-12 THE LIFT ARM DOES NOT RISE OR LOWER....................................................................................................................................589 H-13 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT.................................................................................................590 H-14 WHEN RISING, THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT......................................................................................................591 H-15 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET (THE BUCKET RISES IN THE AIR)........................................................................................591 H-16 HYDRAULIC DRIFTS OF THE LIFT ARM OCCUR OFTEN...........................................................................................................................591 H-17 THE LIFT ARM WOBBLES DURING OPERATION..................................................................................................................................591 H-18 WHEN THE CONTROL LEVER IS SWITCHED FROM "HOLD" TO "RAISE", THE LIFT ARM FALLS TEMPORARILY..............................................................................592 H-19 THE BUCKET DOES NOT TILT BACK..........................................................................................................................................593 H-20 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT......................................................................................................594 H-21 THE BUCKET COMES TO OPERATE SLOWLY IN THE MIDST OF TILTING BACK........................................................................................................595 H-22 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET.......................................................................................................................595 H-23 HYDRAULIC DRIFTS OF BUCKET OCCUR OFTEN.................................................................................................................................595 H-24 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVE IS SET TO "HOLD".................................................................................596 H-25 WHEN THE CONTROL LEVER IS SWITCHED FROM "HOLD" TO "TILT," THE BUCKET FALLS TEMPORARILY.................................................................................596 H-26 THE CONTROL LEVERS OF THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY...........................................................................................596 H-27 THE TRAVEL DAMPER DOES NOT OPERATE AND MACHINE PITCHES AND BOUNCES.....................................................................................................597 TROUBLESHOOTING OF ENGINE (S MODE)..............................................................................................................................................598 METHOD OF USING TROUBLESHOOTING CHARTS......................................................................................................................................599 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...............................................................................................................603 S-2 ENGINE DOES NOT START...................................................................................................................................................605 (1) ENGINE DOES NOT TURN................................................................................................................................................605 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)............................................................................................606 (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)..........................................................................................607 S-3 ENGINE DOES NOT PICK UP SMOOLTHY (FOLLOW-UP IS POOR)....................................................................................................................608 S-4 ENGINE STOPS DURING OPERATIONS..........................................................................................................................................609 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...............................................................................................................................610 S-6 ENGINE LACK OUTPUT (OR LACKS POWER).....................................................................................................................................611 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)..........................................................................................................................612 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).................................................................................................................613 S-9 OIL BECOMES CONTAMINATED QUICKLY........................................................................................................................................614 S-10 FUEL CONSUMPTION IS EXCESSIVE..........................................................................................................................................615 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN................................................................................................616 S-12 OIL PRESSURE CAUTION LAMP LIGHT UP (DROP IN OIL PRESSURE)..............................................................................................................617 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)...................................................................................................................................618 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING).......................................................................................................................619 S-15 ABNORMAL NOISE IS MADE.................................................................................................................................................620 S-16 VIBRATION IS EXCESSIVE.................................................................................................................................................621 30 DISASSEMBLY AND ASSEMBLY.............................................................................................................................................................623 HOW TO READ THIS MANUAL.............................................................................................................................................................625 REMOVAL AND INSTALLATION OF ASSEMBLIES..........................................................................................................................................625 DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES..........................................................................................................................................626 PRECAUTIONS WHEN PERFORMING OPERATION...............................................................................................................................................627 SPECIAL TOOL LIST...................................................................................................................................................................629 SKETCHES OF SPECIAL TOOLS...........................................................................................................................................................632 REMOVAL, INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY...............................................................................................................................640 SPECIAL TOOLS...................................................................................................................................................................640 REMOVAL.........................................................................................................................................................................640 INSTALLATION....................................................................................................................................................................642 REMOVAL, INSTALLATION OF NOZZLE HOLDER ASSEMBLY.....................................................................................................................................644 SPECIAL TOOLS...................................................................................................................................................................644 REMOVAL.........................................................................................................................................................................644 INSTALLATION....................................................................................................................................................................645 REMOVAL, INSTALLATION OF CYLINDER HEAD ASSEMBLY.....................................................................................................................................646 SPECIAL TOOLS...................................................................................................................................................................646 REMOVAL.........................................................................................................................................................................646 INSTALLATION....................................................................................................................................................................651 REMOVAL, INSTALLATION OF ENGINE ASSEMBLY............................................................................................................................................654 REMOVAL.........................................................................................................................................................................654 INSTALLATION....................................................................................................................................................................659 REMOVAL, INSTALLATION OF RADIATOR ASSEMBLY..........................................................................................................................................661 REMOVAL.........................................................................................................................................................................661 INSTALLATION....................................................................................................................................................................662 REMOVAL, INSTALLATION OF AIR AFTERCOOLER............................................................................................................................................663 REMOVAL.........................................................................................................................................................................663 INSTALLATION....................................................................................................................................................................664 REMOVAL, INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY..............................................................................................................................665 REMOVAL.........................................................................................................................................................................665 INSTALLATION....................................................................................................................................................................666 REMOVAL, INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY.........................................................................................................................667 REMOVAL.........................................................................................................................................................................667 INSTALLATION....................................................................................................................................................................668 REMOVAL, INSTALLATION OF FUEL TANK ASSEMBLY.........................................................................................................................................669 REMOVAL.........................................................................................................................................................................669 INSTALLATION....................................................................................................................................................................670 REMOVAL, INSTALLATION OF TRANSFER...................................................................................................................................................671 REMOVAL.........................................................................................................................................................................671 INSTALLATION....................................................................................................................................................................673 DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY..........................................................................................................................................674 SPECIAL TOOLS...................................................................................................................................................................674 DISASSEMBLY.....................................................................................................................................................................674 ASSEMBLY........................................................................................................................................................................682 REMOVAL, INSTALLATION OF PARKING BRAKE ASSEMBLY.....................................................................................................................................694 REMOVAL.........................................................................................................................................................................694 INSTALLATION....................................................................................................................................................................695 DISASSEMBLY, ASSEMBLY OF PARKING BRAKE ASSEMBLY.....................................................................................................................................696 SPECIAL TOOLS...................................................................................................................................................................696 DISASSEMBLY.....................................................................................................................................................................696 ASSEMBLY........................................................................................................................................................................698 REMOVAL, INSTALLATION OF FRONT AXLE ASSEMBLY........................................................................................................................................701 REMOVAL.........................................................................................................................................................................701 INSTALLATION....................................................................................................................................................................702 REMOVAL, INSTALLATION OF REAR AXLE ASSEMBLY.........................................................................................................................................703 REMOVAL.........................................................................................................................................................................703 INSTALLATION....................................................................................................................................................................705 DISASSEMBLY, ASSEMBLY OF AXLE HOUSING ASSEMBLY......................................................................................................................................706 SPECIAL TOOLS...................................................................................................................................................................706 DISASSEMBLY.....................................................................................................................................................................706 ASSEMBLY........................................................................................................................................................................709 DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY......................................................................................................................................715 SPECIAL TOOLS...................................................................................................................................................................715 DISASSEMBLY.....................................................................................................................................................................715 ASSEMBLY........................................................................................................................................................................724 DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY.......................................................................................................................................741 SPECIAL TOOLS LIST..............................................................................................................................................................741 DISASSEMBLY.....................................................................................................................................................................741 ASSEMBLY........................................................................................................................................................................750 DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY......................................................................................................................................768 SPECIAL TOOLS LIST..............................................................................................................................................................768 DISASSEMBLY.....................................................................................................................................................................768 ASSEMBLY........................................................................................................................................................................777 REMOVAL, INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY......................................................................................................................784 REMOVAL.........................................................................................................................................................................784 INSTALLATION....................................................................................................................................................................785 REMOVAL, INSTALLATION OF TRAVEL DAMPER VALVE ASSEMBLY (IF EQUIPPED).................................................................................................................786 REMOVAL.........................................................................................................................................................................786 INSTALLATION....................................................................................................................................................................787 REMOVAL, INSTALLATION OF HYDRAULIC TANK ASSEMBLY....................................................................................................................................788 REMOVAL.........................................................................................................................................................................788 INSTALLATION....................................................................................................................................................................789 REMOVAL, INSTALLATION OF WORK EQUIPMENT ASSEMBLY....................................................................................................................................790 REMOVAL.........................................................................................................................................................................790 INSTALLATION....................................................................................................................................................................793 DISASSEMBLY, ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY................................................................................................................................797 SPECIAL TOOLS...................................................................................................................................................................797 DISASSEMBLY.....................................................................................................................................................................798 ASSEMBLY........................................................................................................................................................................801 REMOVAL, INSTALLATION OF OPERATOR'S CAB ASSEMBLY....................................................................................................................................806 REMOVAL.........................................................................................................................................................................806 INSTALLATION....................................................................................................................................................................809 REMOVAL, INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS).........................................................................................................................810 SPECIAL TOOLS...................................................................................................................................................................810 REMOVAL.........................................................................................................................................................................810 INSTALLATION....................................................................................................................................................................811 COATING MATERIALS...............................................................................................................................................................817 REMOVAL, INSTALLATION OF CENTER HINGE PIN...........................................................................................................................................818 REMOVAL.........................................................................................................................................................................818 INSTALLATION....................................................................................................................................................................822 REMOVAL, INSTALLATION OF COUNTERWEIGHT..............................................................................................................................................827 REMOVAL.........................................................................................................................................................................827 INSTALLATION....................................................................................................................................................................828 REMOVAL, INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY..............................................................................................................................829 SPECIAL TOOLS...................................................................................................................................................................829 REMOVAL.........................................................................................................................................................................829 INSTALLATION....................................................................................................................................................................830 REMOVAL, INSTALLATION OF AIR CONDITIONER COMPRESSOR, ASSEMBLY.......................................................................................................................831 SPECIAL TOOLS...................................................................................................................................................................831 REMOVAL.........................................................................................................................................................................831 INSTALLATION....................................................................................................................................................................831 REMOVAL, INSTALLATION OF MONITOR PANEL..............................................................................................................................................832 REMOVAL.........................................................................................................................................................................832 INSTALLATION....................................................................................................................................................................835 REMOVAL, INSTALLATION OF HST CONTROLLER ASSEMBLY....................................................................................................................................836 REMOVAL.........................................................................................................................................................................836 INSTALLATION....................................................................................................................................................................836 90 OTHERS ..............................................................................................................................................................................838 HYDRAULIC CIRCUIT DIAGRAM WA250-5...................................................................................................................................................840 HYDRAULIC CIRCUIT DIAGRA WA250PT-5..................................................................................................................................................841 ELECTRICAL CIRCUIT DIAGRAM 1/4 (1/4) (MACHINES EQUIPPED WITH ROPS CAB)..............................................................................................................842 ELECTRICAL CIRCUIT DIAGRAM 1/4 (2/4) (MACHINES EQUIPPED WITH ROPS CAB)..............................................................................................................843 ELECTRICAL CIRCUIT DIAGRAM 1/4 (3/4) (MACHINES EQUIPPED WITH ROPS CAB)..............................................................................................................844 ELECTRICAL CIRCUIT DIAGRAM 1/4 (4/4) (MACHINES EQUIPPED WITH ROPS CAB)..............................................................................................................845 ELECTRICAL CIRCUIT DIAGRAM 2/4 (MACHINES EQUIPPED WITH ROPS CAB)....................................................................................................................846 ELECTRICAL CIRCUIT DIAGRAM 3/4 (MACHINES EQUIPPED WITH ROPS CAB)....................................................................................................................847 ELECTRICAL CIRCUIT DIAGRAM 4/4 (MACHINES EQUIPPED WITH ROPS CAB)....................................................................................................................848 ELECTRICAL CIRCUIT DIAGRAM 1/4 (1/4) (MACHINES EQUIPPED WITH ROPS CANOPY)...........................................................................................................849 ELECTRICAL CIRCUIT DIAGRAM 1/4 (2/4) (MACHINES EQUIPPED WITH ROPS CANOPY)...........................................................................................................850 ELECTRICAL CIRCUIT DIAGRAM 1/4 (3/4) (MACHINES EQUIPPED WITH ROPS CANOPY)...........................................................................................................851 ELECTRICAL CIRCUIT DIAGRAM 1/4 (4/4) (MACHINES EQUIPPED WITH ROPS CANOPY)...........................................................................................................852 ELECTRICAL CIRCUIT DIAGRAM 2/4 (MACHINES EQUIPPED WITH ROPS CANOPY).................................................................................................................853 ELECTRICAL CIRCUIT DIAGRAM 3/4 (MACHINES EQUIPPED WITH ROPS CANOPY).................................................................................................................854 ELECTRICAL CIRCUIT DIAGRAM 4/4 (MACHINES EQUIPPED WITH ROPS CANOPY).................................................................................................................855
DESCRIPTION:
KOMATSU WA250-5 WA250L-5 WA250PT-5 WA250PTL-5 WHEEL LOADER SHOP MANUAL SEBM033205 – PDF DOWNLOAD
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This 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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
S.S 30/12/24
