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Komatsu WA250-5, WA250PT-5 Service Manual SEBM029702 PDF
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Description
KOMATSU WA250-5 WA250PT-5 SHOP MANUAL SEBM029702 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WA250-5 WA250PT-5 SHOP MANUAL SEBM029702 – PDF DOWNLOAD
Language : English
Pages : 815
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA250-5 WA250PT-5 SHOP MANUAL SEBM029702 – PDF DOWNLOAD
COVER................................................................................................................................................................................ 1 CONTENTS............................................................................................................................................................................. 2 01 GENERAL........................................................................................................................................................................... 27 GENERAL ASSEMBLY DRAWINGS........................................................................................................................................................ 28 SPECIFICATIONS................................................................................................................................................................... 29 WEIGHT TABLE..................................................................................................................................................................... 33 LIST OF LUBRICANT AND COOLANT.................................................................................................................................................... 35 10 STRUCTURE,FUNCTION AND MAINTENANCE STANDARD....................................................................................................................................... 37 ENGINE MOUNT AND TRANSFER MOUNT.................................................................................................................................................. 38 DAMPER........................................................................................................................................................................... 39 COOLING SYSTEM................................................................................................................................................................... 40 POWER TRAIN...................................................................................................................................................................... 41 POWER TRAIN SYSTEM DIAGRAM....................................................................................................................................................... 42 DRIVE SHAFT (PROPELLER SHAFT).................................................................................................................................................... 44 HST HYDRAULIC PIPING DIAGRAM..................................................................................................................................................... 45 HST PUMP......................................................................................................................................................................... 46 HIGH-PRESSURE RELIEF VALVE....................................................................................................................................................... 48 LOW-PRESSURE RELIEF VALVE........................................................................................................................................................ 50 HST CHARGE PUMP.................................................................................................................................................................. 51 SPEED-RELATED VALVE (DA VALVE)................................................................................................................................................... 52 HIGH-PRESSURE CUT-OFF VALVE...................................................................................................................................................... 53 HST MOTOR........................................................................................................................................................................ 54 EP SERVO VALVE................................................................................................................................................................... 57 HA SERVO VALVE................................................................................................................................................................... 58 FORWARD-REVERSE SHUTTLE VALVE.................................................................................................................................................... 59 TRANSFER......................................................................................................................................................................... 60 TRANSFER OIL COOLER.............................................................................................................................................................. 71 CLUTCH SOLENOID VALVE............................................................................................................................................................ 72 AXLE............................................................................................................................................................................. 73 DIFFERENTIAL..................................................................................................................................................................... 75 LIMITED-SLIP DIFFERENTIAL........................................................................................................................................................ 80 FINAL DRIVE...................................................................................................................................................................... 86 AXLE MOUNTING AND CENTER HINGE PIN............................................................................................................................................... 91 STEERING PIPING.................................................................................................................................................................. 96 STEERING COLUMN.................................................................................................................................................................. 97 PRIORITY VALVE................................................................................................................................................................... 98 ORBIT-ROLL VALVE.................................................................................................................................................................101 2-WAY RESTRICTOR VALVE...........................................................................................................................................................109 STEERING CYLINDER................................................................................................................................................................110 EMERGENCY STEERING PIPING........................................................................................................................................................112 EMERGENCY STEERING VALVE.........................................................................................................................................................113 BRAKE PIPING.....................................................................................................................................................................116 BRAKE VALVE......................................................................................................................................................................117 INCHING VALVE....................................................................................................................................................................121 CHARGE VALVE.....................................................................................................................................................................122 ACCUMULATOR (FOR BRAKE)..........................................................................................................................................................126 SLACK ADJUSTER...................................................................................................................................................................127 BRAKE............................................................................................................................................................................129 PARKING BRAKE CONTROL............................................................................................................................................................134 PARKING BRAKE....................................................................................................................................................................135 HYDRAULIC PIPING.................................................................................................................................................................136 WORK EQUIPMENT LEVER LINKAGE.....................................................................................................................................................140 HYDRAULIC TANK...................................................................................................................................................................144 4-GEAR PUMP UNIT.................................................................................................................................................................146 ACCUMULATOR (FOR PPC CIRCUIT)....................................................................................................................................................148 LOCK VALVE.......................................................................................................................................................................149 BYPASS VALVE.....................................................................................................................................................................150 QUICK COUPLER SOLENOID VALVE.....................................................................................................................................................156 E.C.S.S.VALVE....................................................................................................................................................................157 ACCUMULATOR (FOR E.C.S.S.).......................................................................................................................................................159 HYDRAULIC PIPING OF COOLING SYSTEM...............................................................................................................................................160 COOLING FAN MOTOR................................................................................................................................................................161 WORK EQUIPMENT CONTROL VALVE.....................................................................................................................................................163 WORK EQUIPMENT PPC VALVE.........................................................................................................................................................176 ATTACHMENT PPC VALVE (IF EQUIPPED)...............................................................................................................................................182 WORK EQUIPMENT LINKAGE...........................................................................................................................................................186 BUCKET...........................................................................................................................................................................190 CONTROL OF BUCKET POSITIONER,BOOM KICK-OUT,AND DUMP SPEED........................................................................................................................192 WORK EQUIPMENT CYLINDER..........................................................................................................................................................206 AIR CONDITIONER..................................................................................................................................................................209 MACHINE MONITORING SYSTEM........................................................................................................................................................210 MACHINE MONITOR..................................................................................................................................................................219 LIST OF ITEMS DISPLAYED ON MONITOR...............................................................................................................................................220 ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)........................................................................................................................................246 HST CONTROLLER...................................................................................................................................................................250 FUNCTION OF SELECTING FORWARD-REVERSE SELECTOR SWITCH............................................................................................................................251 ENGINE START CIRCUIT.............................................................................................................................................................253 ENGINE STOP CIRCUIT..............................................................................................................................................................255 PREHEATING CIRCUIT (AUTOMATIC PREHEATING SYSTEM).................................................................................................................................256 PARKING BRAKE CIRCUIT............................................................................................................................................................257 ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM......................................................................................................................................260 COUPLER PLUNGER CONTROL SYSTEM...................................................................................................................................................261 SENSORS..........................................................................................................................................................................262 20 TESTING AND ADJUSTING.............................................................................................................................................................268 STANDARD VALUE TABLE FOR ENGINE..................................................................................................................................................269 STANDARD VALUE TABLE FOR CHASSIS.................................................................................................................................................270 TESTING AND ADJUSTING............................................................................................................................................................274 TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING..............................................................................................................................275 MEASURING ENGINE SPEED.......................................................................................................................................................277 MEASURING EXHAUST GAS COLOR..................................................................................................................................................278 ADJUSTING VALVE CLEARANCE....................................................................................................................................................279 MEASURING COMPRESSION PRESSURE...............................................................................................................................................281 MEASURING BLOW-BY PRESSURE...................................................................................................................................................282 TESTING AND ADJUSTING FUEL INJECTION TIMING..................................................................................................................................283 MEASURING ENGINE OIL PRESSURE................................................................................................................................................284 MEASURING,TESTING OPERATION FORCE OF ACCELERATOR PEDAL.......................................................................................................................285 ADJUSTING ENGINE STOP SOLENOID...............................................................................................................................................287 ADJUSTING ENGINE SPEED SENSOR................................................................................................................................................288 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION................................................................................................................288 MEASURING DIRECTIONAL LEVER..................................................................................................................................................289 TESTING AND ADJUSTING HST OIL PRESSURE.......................................................................................................................................290 MEASURING CLUTCH CONTROL PRESSURER...........................................................................................................................................295 TESTING AND ADJUSTING STEERING WHEEL.........................................................................................................................................296 TESTING AND ADJUSTING STEERING OIL PRESSURE..................................................................................................................................298 BLEEDING AIR FROM STEERING CIRCUIT...........................................................................................................................................299 TESTING HYDRAULIC FAN........................................................................................................................................................300 MEASURING BRAKE PEDAL........................................................................................................................................................301 TESTING AND ADJUSTING BRAKE PEDAL LINKAGE....................................................................................................................................302 MEASURING BRAKE PERFORMANCE..................................................................................................................................................303 TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE............................................................................................................................304 MEASURING BRAKE OIL PRESSURER................................................................................................................................................305 MEASURING WEAR OF BRAKE DISC.................................................................................................................................................307 BLEEDING AIR FORM BRAKE CIRCUIT..............................................................................................................................................308 MEASURING PARKING BRAKE PERFORMANCE..........................................................................................................................................309 TESTING AND ADJUSTING PARKING BRAKE LINKAGE..................................................................................................................................310 MEASURING PARKING BRAKE RELEASE PRESSURE.....................................................................................................................................311 MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER.........................................................................................................................312 TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE......................................................................................................................313 TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE........................................................................................................................314 BLEEDING AIR.................................................................................................................................................................316 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT............................................................................................................................317 TESTING AND ADJUSTING BUCKET POSITIONER......................................................................................................................................318 TESTING AND ADJUSTING OF BOOM KICK-OUT.......................................................................................................................................319 CHECKING PROXIMITY SWITCH ACTUATION DISPLAY LAMP.............................................................................................................................320 PROCEDURE FOR CHECKING DIODE.................................................................................................................................................321 SPECIAL FUNCTIONS OF MACHINE MONITOR.........................................................................................................................................322 FLOW OF MODES AND FUNCTIONS..................................................................................................................................................323 PM CLINIC INSPECTION CHART...................................................................................................................................................341 TROUBLESHOOTING..................................................................................................................................................................343 POINTS TO REMEMBER WHEN TROUBLESHOOTING......................................................................................................................................344 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................................................................................345 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE....................................................................................................................................346 CHECK BEFORE TROUBLESHOOTING.................................................................................................................................................354 CATEGORIES,PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS..............................................................................................................355 PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO...................................................................................................................356 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...................................................................................................................................359 T-ADAPTER TABLE..............................................................................................................................................................380 CONNECTOR TYPES AND MOUNTING LOCATIONS.......................................................................................................................................383 CONNECTOR LAYOUT DRAWING.....................................................................................................................................................389 TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)..........................................................................................................................394 HST CONTROLLER SYSTEM DIAGRAM............................................................................................................................................395 BEFORE TROUBLESHOOTING CODE DISPLAY......................................................................................................................................397 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM.................................................................................................................................398 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...........................................................................................................................399 ERROR CODE [989F00](TRANSMISSION PROTECTION CAUTION(00)).................................................................................................................401 ERROR CODE [DHH1KX](HST OIL PRESSURE SENSOR INPUT SIGNAL OUTSIDE RANGE(KX))..............................................................................................402 ERROR CODE [DLE2LC](ENGINE REVOLUTION SENSOR REVOLUTION SPEED SIGNAL MISMATCH(LC)).......................................................................................404 ERROR CODE [DW26KZ](MOTOR 2 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING(KZ)).......................................................................................405 ERROR CODE [DX19KZ](MOTOR 1 SOLENOID SYSTEM DISCONTINUITY OR SHORT CIRCUITING(KZ)).......................................................................................408 ERROR CODE [DX20KZ](CLUTCH SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING(KZ))........................................................................................410 TROUBLESHOOTING CODE [HST-1](DEFECTIVE HST CONTROLLER POWER SOURCE(HST CONTROLLER DOES NOT FUNCTION))....................................................................412 TROUBLESHOOTING CODE [HST-2](TRAVEL SPEED DOES NOT SHIFTED)..............................................................................................................414 TROUBLESHOOTING CODE [HST-3](TRAVEL SPEED DOES NOT EXCESSIVE(DEFECTIVE SPEED SENSOR SYSTEM)).............................................................................417 TROUBLESHOOTING CODE [HST-4](TRAVEL SPEED CANNOT BE CONTROLLED WHEN THE TRAVEL SPEED SELECTOR SWITCH IS AT 1ST)..........................................................419 TROUBLESHOOTING CODE [HST-5] HST OUTPUT CONTROL(TRACTION CONTROL) CANNOT BE CONTROLLED...................................................................................421 TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)..........................................................................................................................423 MONITOR SYSTEM CIRCUIT DIAGRAM...........................................................................................................................................424 BEFORE TROUBLESHOOTING CODE DISPLAY......................................................................................................................................428 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM.................................................................................................................................429 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...........................................................................................................................430 ERROR CODE[15B0NX](HST OIL FILTER CLOGGED(NX))...........................................................................................................................432 ERROR CODE[2G42ZG](DECREASE ACCUMULATOR OIL PRESSURE(ZG))................................................................................................................433 ERROR CODE[989F00](TRANSMISSION PROTECTION CAUTION(00))..................................................................................................................434 ERROR CODE[989FN1](HST OVERRUNNING(N1))..................................................................................................................................435 ERROR CODE[AB00L6](DEFECTIVE BATTERY CHARGING CIRCUIT(L6))...............................................................................................................436 ERROR CODE[AB00MA](DEFECTIVE BATTERY CHARGING CIRCUIT(MA))...............................................................................................................437 ERROR CODE[B@BAZG](DEGREASED ENGINE OIL PRESSURE(ZG))....................................................................................................................438 ERROR CODE[B@BCNS](ENGINE WATER TEMPERATURE OVERHEATING(NS)).............................................................................................................439 ERROR CODE[B@BCZK](ALARM INDICATING LOW COOLANT LEVEL(ZK))...............................................................................................................440 ERROR CODE[B@C7NS](BRAKE COOLING OIL TEMPERATURE OVERHEATING(NS))........................................................................................................441 ERROR CODE[B@CRNS](HST OIL TEMPERATURE OVERHEATING(NS))..................................................................................................................442 ERROR CODE[D5ZHL6](STARTING SWITCH"C"(IGN"C")INPUT FAILURE(L6))..........................................................................................................443 ERROR CODE[DAF0KT](CONTROLLER INSIDE FAILURE(KT))........................................................................................................................445 ERROR CODE[DAJ0KR](HST CONTROLLER COMMUNICATION FAILURE(KR)).............................................................................................................446 ERROR CODE[DD15LD](MONITOR PANEL MODE SELECTOR SWITCH 1 [■](PANEL SWITCH 1)INPUT ERROR(LD))..............................................................................448 ERROR CODE[DD16LD](MONITOR PANEL MODE SELECTOR SWITCH 1 [◇](PANEL SWITCH 2)INPUT ERROR(LD))..............................................................................449 ERROR CODE[DD17LD](MONITOR PANEL MODE SELECTOR SWITCH 2 [<](PANEL SWITCH 3)INPUT ERROR(LD))..............................................................................450 ERROR CODE[DD18LD](MONITOR PANEL MODE SELECTOR SWITCH 2 [>](PANEL SWITCH 4)INPUT ERROR(LD))..............................................................................451 ERROR CODE[DDK3KB](MULTIPLE SHIFT LEVER FR SIGNAL INPUT(KB)).............................................................................................................452 ERROR CODE[DDS5L6](DECREASED STEERING OIL PRESSURE(L6))..................................................................................................................454 ERROR CODE[DGE2KX](ENGINE WATER TEMPERATURE(HIGH TEMPERATURE)SENSOR SYSTEM FAILURE(KX))..................................................................................455 ERROR CODE[DGE3L6](ENGINE WATER TEMPERATURE(LOW TEMPERATURE)SENSOR SYSTEM FAILURE(L6))...................................................................................456 ERROR CODE[DGH1KX](HST OIL TEMPERATURE SENSOR SYSTEM FAILURE(KX))........................................................................................................457 ERROR CODE[DGR1KX](BRAKE OIL TEMPERATURE SENSOR SYSTEM SHORT-CIRCUITING(KX)).............................................................................................458 ERROR CODE[DGR4KA](BRAKE OIL TEMPERATURE SENSOR SYSTEM DISCONTINUITY(KA))................................................................................................459 ERROR CODE[DHE4KA](ENGINE OIL PRESSURE SENSOR SYSTEM DISCONTINUITY(KA))..................................................................................................460 TROUBLESHOOTING CODE[MON-1](THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT ON)..........................................................................................461 TROUBLESHOOTING CODE[MON-2](THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON).......................................................................................464 TROUBLESHOOTING CODE[MON-3](THE ENGINE WATER TEMPERATURE CAUTION LAMP DOES NOT LIGHT NO,OR AFTER THE ENGINE STARTS,THE ENGINE WATER TEMPERATURE GAUGE DOES NOT RISE.)....465 TROUBLESHOOTING CODE[MON-4](THE HST OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT NO,OR AFTER THE ENGINE STARTS,THE HST OIL TEMPERATURE GAUGE DOES NOT RISE.)..............466 TROUBLESHOOTING CODE[MON-5](THE FUEL LEVEL GAUGE DOES NOT RISE OR DECREASE.).............................................................................................467 TROUBLESHOOTING CODE[MON-6](THE RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT ON)...................................................................................468 TROUBLESHOOTING CODE[MON-7](THE STEERING OIL PRESSURE CAUTION LAMP DOES NO LIGHT ON).....................................................................................469 TROUBLESHOOTING CODE[MON-8](THE EMERGENCY STEERING OIL PRESSURE INDICATOR LAMP DOES NOT LIGHT ON)........................................................................470 TROUBLESHOOTING CODE[MON-9](INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1 [■](PANEL SWITCH 1))...................................................................471 TROUBLESHOOTING CODE[MON-10](INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1 [◇](PANEL SWITCH 2))..................................................................472 TROUBLESHOOTING CODE[MON 11](INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2 [<](PANEL SWITCH 3))..................................................................473 TROUBLESHOOTING CODE[MON-12](INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2 [>](PANEL SWITCH 4))..................................................................474 TROUBLESHOOTING CODE[MON-13](THE ALARM BUZZER DOES NOT SOUND OR STOP)....................................................................................................475 TROUBLESHOOTING CODE[MON-14] THE WIPER DOES NOT FUNCTION.................................................................................................................476 TROUBLESHOOTING CODE[MON-15] THE LAMPS DO NOT WORK PROPERLY..............................................................................................................476 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)................................................................................................................................477 ELECTRICAL SYSTEM DIAGRAM................................................................................................................................................478 PARKING BRAKE RELATED DIAGRAM............................................................................................................................................481 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM.................................................................................................................................483 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...........................................................................................................................484 TROUBLESHOOTING CODE[E-1](THE ENGINE DOES NOT START).....................................................................................................................486 TROUBLESHOOTING CODE[E-2](THE ENGINE DOES NOT STOP)......................................................................................................................490 TROUBLESHOOTING CODE[E-3](PREHEATING IS IMPOSSIBLE OR CONSTANT)..........................................................................................................492 TROUBLESHOOTING CODE[E-4](THE PARKING BRAKE(MECHANICAL TYPE)DOES NOT FUNCTION)...........................................................................................496 TROUBLESHOOTING CODE[E-5](THE EMERGENCE BRAKE SYSTEM(ELECTRICAL TYPE)DOES NOT FUNCTION)..................................................................................501 TROUBLESHOOTING CODE[E-6](DEFECTIVE BOOM KICK-OUT FUNCTION AND CANCELLATION).............................................................................................502 TROUBLESHOOTING CODE[E-7](DEFECTIVE BUCKET LEVELER FUNCTION AND CANCELLATION)............................................................................................505 TROUBLESHOOTING CODE[E-8](DEFECTIVE LIFT ARM FLOATING HOLDING FUNCTION AND CANCELLATION).................................................................................508 TROUBLESHOOTING CODE[E-9](THE WIPER DOES NOT FUNCTION)...................................................................................................................509 TROUBLESHOOTING CODE[E-10](THE WINDOW WASHER DOES NOT FUNCTION)..........................................................................................................514 TROUBLESHOOTING CODE[E-11](LAMPS DO NOT WORK PROPERLY)...................................................................................................................517 TROUBLESHOOTING CODE[E-12](THE HORN DOES NOT SOUND)......................................................................................................................528 TROUBLESHOOTING CODE[E-13](DEFECTIVE THE AIR CONDITIONER)................................................................................................................530 TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM (H MODE)......................................................................................................................538 METHOD OF USING TROUBLESHOOTING CHART....................................................................................................................................539 FAILURE CODE AND CAUSE TABLE.............................................................................................................................................541 H-1 THE MACHINE DOES NOT START ..........................................................................................................................................543 H-2 THE TRAVEL SPEED IS SLOW.............................................................................................................................................544 H-3 THE THRUSTING FORCE IS WEAK..........................................................................................................................................545 H-4 ENGINE STALLS WHEN TRAVELING OR ENGINE SPEED DROPS EXCESSIVELY.......................................................................................................546 H-5 THE GEAR IS NOT SHIFTED..............................................................................................................................................547 H-6 THE STEERING WHEEL DOES NOT TURN.....................................................................................................................................548 H-7 THE STEERING WHEEL IS HEAVY..........................................................................................................................................549 H-8 STEERING WHEEL SHAKES OR JERKS.......................................................................................................................................550 H-9 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL........................................................................................................................551 H-10 THE BRAKE IS NOT RELEASED OR IS DRAGGED.............................................................................................................................552 H-11 THE PARKING BRAKE IS NOT WORK,RELEASED OR IS DRAGGED................................................................................................................553 H-12 THE LIFT ARM DOES NOT RISE OR LOWER.................................................................................................................................554 H-13 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT..............................................................................................555 H-14 WHEN RISING,THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT....................................................................................................556 H-15 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET(THE BUCKET RISES IN THE AIR)......................................................................................556 H-16 HYDRAULIC DRIFTS OF THE LIFT ARM OCCUR OFTEN........................................................................................................................556 H-17 THE LIFT ARM WOBBLES DURING OPERATION...............................................................................................................................556 H-18 WHEN THE CONTROL LEVER IS SWITCHED FORM"HOLD"TO"RAISE,"THE LIFT ARM FALLS TEMPORARILY...............................................................................557 H-19 THE BUCKET DOES NOT TILT BACK.......................................................................................................................................558 H-20 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT...................................................................................................559 H-21 THE BUCKET COMES TO OPERATE SLOWLY IN HE MIDST OF TILTING-BACK......................................................................................................560 H-22 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET.....................................................................................................................560 H-23 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN..........................................................................................................................560 H-24 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO(THE WORK EQUIPMENT VALVE IS SET TO "HOLD")..............................................................................561 H-25 WHEN THE CONTROL LEVER IS SWITCHED FORM"HOLD"TO"TILT,"THE BUCKET FALLS TEMPORARILY..................................................................................561 H-26 THE CONTROL LEVERS OF THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY........................................................................................561 TROUBLESHOOTING OF ENGINE (S MODE)...........................................................................................................................................562 METHOD OF USING TROUBLESHOOTING CHARTS...................................................................................................................................563 S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME).............................................................................................................567 S-2 ENGINE DOES NOT START................................................................................................................................................569 (1) ENGINE DOES NOT TURN.............................................................................................................................................569 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT(FUEL IS NOT BEING INJECTED)..........................................................................................570 (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED)........................................................................................571 S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR)..................................................................................................................572 S-4 ENGINE STOPS DURING OPERATIONS.......................................................................................................................................573 S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING).............................................................................................................................574 S-6 ENGINE LACKS OUTPUT(OR LACKS POWER)..................................................................................................................................575 S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)........................................................................................................................576 S-8 OIL CONSUMPTION IS EXCESSIVE(OR EXHAUST SMOKE IS BLUE)...............................................................................................................577 S-9 OIL BECOMES CONTAMINATED QUICKLY.....................................................................................................................................578 S-10 FUEL CONSUMPTION IS EXCESSIVE.......................................................................................................................................579 S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN...............................................................................................580 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP(DROP IN OIL PRESSURE)...........................................................................................................581 S-13 OIL LEVEL RISES(WATER,FUEL IN OIL)..................................................................................................................................582 S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING).....................................................................................................................583 S-15 ABNORMAL NOISE IS MADE..............................................................................................................................................584 S-16 VIBRATION IS EXCESSIVE..............................................................................................................................................585 30 DISASSEMBLY AND ASSEMBLY..........................................................................................................................................................586 HOW TO READ THIS MANUAL..........................................................................................................................................................588 REMOVAL AND INSTALLATION OF ASSEMBLIES.......................................................................................................................................588 DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES.......................................................................................................................................589 PRECAUTIONS WHEN PERFORMING OPERATION............................................................................................................................................590 SPECIAL TOOL LIST................................................................................................................................................................592 SKETCHES OF SPECIAL TOOLS........................................................................................................................................................595 REMOVAL,INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY.............................................................................................................................601 SPECIAL TOOLS................................................................................................................................................................601 REMOVAL......................................................................................................................................................................601 INSTALLATION.................................................................................................................................................................603 REMOVAL,INSTALLATION OF NOZZLE HOLDER ASSEMBLY...................................................................................................................................605 SPECIAL TOOLS................................................................................................................................................................605 REMOVAL......................................................................................................................................................................605 INSTALLATION.................................................................................................................................................................606 REMOVAL,INSTALLATION OF CYLINDER HEAD ASSEMBLY...................................................................................................................................607 SPECIAL TOOLS................................................................................................................................................................607 REMOVAL......................................................................................................................................................................607 INSTALLATION.................................................................................................................................................................612 REMOVAL,INSTALLATION OF ENGINE ASSEMBLY..........................................................................................................................................615 REMOVAL......................................................................................................................................................................615 INSTALLATION.................................................................................................................................................................620 REMOVAL,INSTALLATION OF RADIATOR ASSEMBLY........................................................................................................................................622 REMOVAL......................................................................................................................................................................622 INSTALLATION.................................................................................................................................................................623 REMOVAL,INSTALLATION OF AIR AFTERCOOLER..........................................................................................................................................624 REMOVAL......................................................................................................................................................................624 INSTALLATION.................................................................................................................................................................625 REMOVAL,INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY............................................................................................................................626 REMOVAL......................................................................................................................................................................626 INSTALLATION.................................................................................................................................................................627 REMOVAL,INSTALLATION OF COOLING FAN AND MOTOR ASSEMBLY...........................................................................................................................628 REMOVAL......................................................................................................................................................................628 INSTALLATION.................................................................................................................................................................629 REMOVAL,INSTALLATION OF FUEL TANK ASSEMBLY.......................................................................................................................................630 REMOVAL......................................................................................................................................................................630 INSTALLATION.................................................................................................................................................................631 REMOVAL,INSTALLATION OF TRANSFER.................................................................................................................................................632 REMOVAL......................................................................................................................................................................632 INSTALLATION.................................................................................................................................................................634 DISASSEMBLY,ASSEMBLY OF TRANSFER ASSEMBLY........................................................................................................................................635 SPECIAL TOOLS................................................................................................................................................................635 DISASSEMBLY..................................................................................................................................................................635 ASSEMBLY.....................................................................................................................................................................643 REMOVAL,INSTALLATION OF PARKING BRAKE ASSEMBLY...................................................................................................................................655 REMOVAL......................................................................................................................................................................655 INSTALLATION.................................................................................................................................................................656 DISASSEMBLY,ASSEMBLY OF PARKING BRAKE ASSEMBLY...................................................................................................................................657 SPECIAL TOOLS................................................................................................................................................................657 DISASSEMBLY..................................................................................................................................................................657 ASSEMBLY.....................................................................................................................................................................659 REMOVAL,INSTALLATION OF FRONT AXLE ASSEMBLY......................................................................................................................................662 REMOVAL......................................................................................................................................................................662 INSTALLATION.................................................................................................................................................................663 REMOVAL,INSTALLATION OF REAR AXLE ASSEMBLY.......................................................................................................................................664 REMOVAL......................................................................................................................................................................664 INSTALLATION.................................................................................................................................................................666 DISASSEMBLY,ASSEMBLY OF AXLE HOUSING ASSEMBLY....................................................................................................................................667 SPECIAL TOOLS................................................................................................................................................................667 DISASSEMBLY..................................................................................................................................................................667 ASSEMBLY.....................................................................................................................................................................670 DISASSEMBLY,ASSEMBLY OF DIFFERENTIAL ASSEMBLY....................................................................................................................................676 SPECIAL TOOLS................................................................................................................................................................676 DISASSEMBLY..................................................................................................................................................................676 ASSEMBLY.....................................................................................................................................................................685 REMOVAL,INSTALLATION OF HST PUMP AND 4-GEAR PUMP ASSEMBLY........................................................................................................................702 REMOVAL......................................................................................................................................................................702 INSTALLATION.................................................................................................................................................................704 DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY....................................................................................................................................705 DISASSEMBLY..................................................................................................................................................................705 ASSEMBLY.....................................................................................................................................................................714 REMOVAL,INSTALLATION OF HST MOTOR 1 ASSEMBLY.....................................................................................................................................731 REMOVAL......................................................................................................................................................................731 INSTALLATION.................................................................................................................................................................731 REMOVAL,INSTALLATION OF HST MOTOR 2 ASSEMBLY.....................................................................................................................................732 REMOVAL......................................................................................................................................................................732 INSTALLATION.................................................................................................................................................................732 DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY...................................................................................................................................733 DISASSEMBLY..................................................................................................................................................................733 ASSEMBLY.....................................................................................................................................................................741 REMOVAL,INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY....................................................................................................................749 REMOVAL......................................................................................................................................................................749 INSTALLATION.................................................................................................................................................................750 REMOVAL,INSTALLATION OF TRAVEL DAMPER VALVE ASSEMBLY.............................................................................................................................751 REMOVAL......................................................................................................................................................................751 INSTALLATION.................................................................................................................................................................752 REMOVAL,INSTALLATION OF HYDRAULIC TANK ASSEMBLY..................................................................................................................................753 REMOVAL......................................................................................................................................................................753 INSTALLATION.................................................................................................................................................................754 REMOVAL,INSTALLATION OF WORK EQUIPMENT ASSEMBLY .................................................................................................................................755 REMOVAL......................................................................................................................................................................755 INSTALLATION.................................................................................................................................................................758 DISASSEMBLY,ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY..............................................................................................................................762 SPECIAL TOOLS................................................................................................................................................................762 DISASSEMBLY..................................................................................................................................................................763 ASSEMBLY.....................................................................................................................................................................766 REMOVAL,INSTALLATION OF OPERATOR'S CAB ASSEMBLY..................................................................................................................................770 REMOVAL......................................................................................................................................................................770 INSTALLATION.................................................................................................................................................................773 REMOVAL,INSTALLATION OF OPERATOR'S CAB GLASS(STUCK GLASS)........................................................................................................................774 SPECIAL TOOLS................................................................................................................................................................774 REMOVAL......................................................................................................................................................................774 INSTALLATION.................................................................................................................................................................775 COATING MATERIALS............................................................................................................................................................781 REMOVAL,INSTALLATION OF CENTER HINGE PIN.........................................................................................................................................782 REMOVAL......................................................................................................................................................................782 INSTALLATION.................................................................................................................................................................786 REMOVAL,INSTALLATION OF COUNTERWEIGHT............................................................................................................................................791 REMOVAL......................................................................................................................................................................791 INSTALLATION.................................................................................................................................................................792 REMOVAL,INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY............................................................................................................................793 SPECIAL TOOLS................................................................................................................................................................793 REMOVAL......................................................................................................................................................................793 INSTALLATION.................................................................................................................................................................794 REMOVAL,INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY......................................................................................................................795 SPECIAL TOOLS................................................................................................................................................................795 REMOVAL......................................................................................................................................................................795 INSTALLATION.................................................................................................................................................................795 REMOVAL,INSTALLATION OF MONITOR PANEL............................................................................................................................................796 REMOVAL......................................................................................................................................................................796 INSTALLATION.................................................................................................................................................................798 90 OTHERS............................................................................................................................................................................799 HYDRAULIC CIRCUIT DIAGRAM WA250-5................................................................................................................................................800 HYDRAULIC CIRCUIT DIAGRAM WA250PT-5..............................................................................................................................................801 ELECTRICAL CIRCUIT DIAGRAM 1/4(1/4) (MACHINES EQUIPPED WITH ROPS CAB)............................................................................................................802 ELECTRICAL CIRCUIT DIAGRAM 1/4(2/4) (MACHINES EQUIPPED WITH ROPS CAB)............................................................................................................803 ELECTRICAL CIRCUIT DIAGRAM 1/4(3/4) (MACHINES EQUIPPED WITH ROPS CAB)............................................................................................................804 ELECTRICAL CIRCUIT DIAGRAM 1/4(4/4) (MACHINES EQUIPPED WITH ROPS CAB)............................................................................................................805 ELECTRICAL CIRCUIT DIAGRAM 2/4 (MACHINES EQUIPPED WITH ROPS CAB).................................................................................................................806 ELECTRICAL CIRCUIT DIAGRAM 3/4 (MACHINES EQUIPPED WITH ROPS CAB).................................................................................................................807 ELECTRICAL CIRCUIT DIAGRAM 4/4 (MACHINES EQUIPPED WITH ROPS CAB).................................................................................................................808 ELECTRICAL CIRCUIT DIAGRAM 1/4(1/4) (MACHINES EQUIPPED WITH ROPS CANOPY).........................................................................................................809 ELECTRICAL CIRCUIT DIAGRAM 1/4(2/4) (MACHINES EQUIPPED WITH ROPS CANOPY).........................................................................................................810 ELECTRICAL CIRCUIT DIAGRAM 1/4(3/4) (MACHINES EQUIPPED WITH ROPS CANOPY).........................................................................................................811 ELECTRICAL CIRCUIT DIAGRAM 1/4(4/4) (MACHINES EQUIPPED WITH ROPS CANOPY).........................................................................................................812 ELECTRICAL CIRCUIT DIAGRAM 2/4 (MACHINES EQUIPPED WITH ROPS CANPOY) .............................................................................................................813 ELECTRICAL CIRCUIT DIAGRAM 3/4 (MACHINES EQUIPPED WITH ROPS CANOPY)..............................................................................................................814 ELECTRICAL CIRCUIT DIAGRAM 4/4 (MACHINES EQUIPPED WITH ROPS CANOPY)..............................................................................................................815
DESCRIPTION:
KOMATSU WA250-5 WA250PT-5 SHOP MANUAL SEBM029702 – 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 29/12/24
