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KOMATSU WA250-5 WA250PT-5 SHOP MANUAL SEBM029702 – PDF DOWNLOAD
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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 : 839
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA250-5 WA250PT-5 SHOP MANUAL SEBM029702 – PDF DOWNLOAD
MAIN MENU................................................................................................................................................................................ 0 COVER.................................................................................................................................................................................... 1 CONTENTS................................................................................................................................................................................. 2 SAFETY................................................................................................................................................................................... 7 SAFETY NOTICE........................................................................................................................................................................ 7 FOREWARD................................................................................................................................................................................. 9 GENERAL.............................................................................................................................................................................. 9 HOW TO READ THE SHOP MANUAL.......................................................................................................................................................... 10 HOISTING INSTRUCTIONS................................................................................................................................................................ 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.......................................................................................................................................... 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......................................................................................................................................................................... 76 LIMITED-SLIP DIFFERENTIAL............................................................................................................................................................ 82 FINAL DRIVE.......................................................................................................................................................................... 88 AXLE MOUNTING AND CENTER HINGE PIN................................................................................................................................................... 94 STEERING PIPING...................................................................................................................................................................... 99 STEERING COLUMN......................................................................................................................................................................100 PRIORITY VALVE.......................................................................................................................................................................101 ORBIT ROLL VALVE.....................................................................................................................................................................104 2-WAY RESTRICTOR VALVE...............................................................................................................................................................112 STEERING CYLINDER....................................................................................................................................................................113 EMERGENCY STEERING PIPING............................................................................................................................................................115 EMERGENCY STEERING VALVE.............................................................................................................................................................116 BRAKE PIPING.........................................................................................................................................................................119 BRAKE VALVE..........................................................................................................................................................................120 INCHING VALVE........................................................................................................................................................................124 CHARGE VALVE.........................................................................................................................................................................126 ACCUMULATOR (FOR BRAKE)..............................................................................................................................................................130 SLACK ADJUSTER.......................................................................................................................................................................131 BRAKE................................................................................................................................................................................134 PARKING BRAKE CONTROL................................................................................................................................................................139 PARKING BRAKE........................................................................................................................................................................140 HYDRAULIC PIPING.....................................................................................................................................................................142 WORK EQUIPMENT LEVER LINKAGE.........................................................................................................................................................146 HYDRAULIC TANK.......................................................................................................................................................................150 4-GEAR PUMP UNIT.....................................................................................................................................................................152 ACCUMULATOR (FOR PPC CIRCUIT)........................................................................................................................................................154 LOCK VALVE...........................................................................................................................................................................155 BYPASS VALVE.........................................................................................................................................................................156 QUICK COUPLER SOLENOID 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)...................................................................................................................................................188 WORK EQUIPMENT LINKAGE...............................................................................................................................................................192 BUCKET...............................................................................................................................................................................196 CONTROL OF BUCKET POSITIONER, BOOM KICK-OUT, AND DUMP SPEED..........................................................................................................................198 WORK EQUIPMENT CYLINDER..............................................................................................................................................................212 AIR CONDITIONER......................................................................................................................................................................216 MACHINE MONITORING SYSTEM............................................................................................................................................................217 MACHINE MONITOR......................................................................................................................................................................227 LIST OF ITEMS DISPLAYED ON MONITOR...................................................................................................................................................228 ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)............................................................................................................................................254 HST CONTROLLER.......................................................................................................................................................................258 FUNCTION OF SELECTING FORWARD-REVERSE SELECTOR SWITCH................................................................................................................................259 ENGINE START CIRCUIT.................................................................................................................................................................261 ENGINE STOP CIRCUIT..................................................................................................................................................................263 PREHEATING CIRCUIT (AUTOMATIC PREHEATING SYSTEM).....................................................................................................................................264 PARKING BRAKE CIRCUIT................................................................................................................................................................265 ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM..........................................................................................................................................268 COUPLER PLUNGER CONTROL SYSTEM.......................................................................................................................................................269 SENSORS..............................................................................................................................................................................270 20 TESTING AND ADJUSTING.................................................................................................................................................................277 STANDARD VALUE TABLE FOR ENGINE......................................................................................................................................................278 STANDARD VALUE TABLE FOR CHASSIS.....................................................................................................................................................279 TESTING AND ADJUSTING................................................................................................................................................................283 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING.................................................................................................................................284 MEASURING ENGINE SPEED...........................................................................................................................................................286 MEASURING EXHAUST COLOR..........................................................................................................................................................287 ADJUSTING VALVE CLEARANCE........................................................................................................................................................288 MEASURING COMPRESSION PRESSURE...................................................................................................................................................290 MEASURING BLOW-BY PRESSURE.......................................................................................................................................................291 TESTING AND ADJUSTING FUEL INJECTION TIMING......................................................................................................................................292 MEASURING ENGINE OIL PRESSURE....................................................................................................................................................293 MEASURING, TESTING OPERATING FORCE OF ACCELERATOR PEDAL..........................................................................................................................294 ADJUSTING ENGINE STOP SOLENOID...................................................................................................................................................296 ADJUSTING ENGINE SPEED SENSOR....................................................................................................................................................297 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION....................................................................................................................297 MEASURING DIRECTIONAL LEVER......................................................................................................................................................298 TESTING AND ADJUSTING HST OIL PRESSURE...........................................................................................................................................299 MEASURING CLUTCH CONTROL PRESSURE................................................................................................................................................304 TESTING AND ADJUSTING STEERING WHEEL.............................................................................................................................................305 TESTING AND ADJUSTING STEERING OIL PRESSURE......................................................................................................................................307 BLEEDING AIR FROM STEERING CIRCUIT...............................................................................................................................................308 TESTING HYDRAULIC FAN............................................................................................................................................................309 MEASURING BRAKE PEDAL............................................................................................................................................................310 TESTING AND ADJUSTING BRAKE PEDAL LINKAGE........................................................................................................................................311 MEASURING BRAKE PERFORMANCE......................................................................................................................................................312 TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE................................................................................................................................313 MEASURING BRAKE OIL PRESSURE.....................................................................................................................................................314 MEASURING WEAR OF BRAKE DISC.....................................................................................................................................................316 BLEEDING AIR FROM BRAKE CIRCUIT..................................................................................................................................................317 MEASURING PARKING BRAKE PERFORMANCE..............................................................................................................................................318 TESTING AND ADJUSTING PARKING BRAKE LINKAGE......................................................................................................................................319 MEASURING PARKING BRAKE RELEASE PRESSURE.........................................................................................................................................320 MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER.............................................................................................................................321 TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE..........................................................................................................................322 TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE............................................................................................................................323 BLEEDING AIR.....................................................................................................................................................................325 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT................................................................................................................................326 TESTING AND ADJUSTING BUCKET POSITIONER..........................................................................................................................................327 TESTING AND ADJUSTING OF BOOM KICK-OUT...........................................................................................................................................328 CHECKING PROXIMITY SWITCH ACTUATION DISPLAY LAMP.................................................................................................................................329 PROCEDURE FOR CHECKING DIODE.....................................................................................................................................................330 SPECIAL FUNCTIONS OF MACHINE MONITOR.............................................................................................................................................331 FLOW MODES AND FUNCTIONS.........................................................................................................................................................332 PM CLINIC INSPECTION CHART.......................................................................................................................................................350 TROUBLESHOOTING......................................................................................................................................................................353 POINTS TO REMEMBER WHEN TROUBLESHOOTING..........................................................................................................................................354 SEQUENCE OF EVENTS IN TROUBLESHOOTING............................................................................................................................................355 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE........................................................................................................................................356 CHECK BEFORE TROUBLSHOOTING......................................................................................................................................................364 CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS................................................................................................................365 PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO.......................................................................................................................366 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.......................................................................................................................................370 T-ADAPTER TABLE..................................................................................................................................................................391 CONNECTOR TYPES AND MOUNTING LOCATIONS...........................................................................................................................................395 CONNECTOR LAYOUT DRAWING.........................................................................................................................................................402 TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)..............................................................................................................................407 HST CONTROLLER SYSTEM DIAGRAM................................................................................................................................................408 BEFORE TROUBLESHOOTING CODE DISPLAY..........................................................................................................................................410 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM.....................................................................................................................................411 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...............................................................................................................................412 ERROR CODE [989F00] (TRANSMISSION PROTECTION CAUTION (00))...................................................................................................................414 ERROR CODE [DHH1KX] (HST OIL PRESSURE SENSOR INPUT SIGNAL OUTSIDE RANGE (KX))................................................................................................415 ERROR CODE [DLE2LC] (ENGINE REVOLUTION SENSOR REVOLUTION SPEED SIGNAL MISMATCH (LC)).........................................................................................417 ERROR CODE [DW26KZ] (MOTOR 2 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ)).........................................................................................418 ERROR CODE [DX19KZ] (MOTOR 1 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ)).........................................................................................422 ERROR CODE [DX20KZ] (CLUTCH SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))..........................................................................................424 TROUBLESHOOTING CODE [HST-1] (DEFECTIVE HST CONTROLLER POWER SOURCE (HST CONTROLLER DOES NOT FUNCTION))......................................................................426 TROUBLESHOOTING CODE [HST-2] (TRAVEL SPEED DOES NOT SHIFTED).................................................................................................................428 TROUBLESHOOTING CODE [HST-3] (TRAVEL SPEED DOES NOT EXCESSIVE (DEFECTIVE SPEED SENSOR SYSTEM))...............................................................................432 TROUBLESHOOTING CODE [HST-4] (TRAVEL SPEED CANNOT BE CONTROLLED WHEN THE TRAVEL SPEED SELECTOR SWITCH IS AT 1ST).............................................................434 TROUBLESHOOTING CODE [HST-5] HST OUTPUT CONTROL (TRACTION CONTROL) CANNOT BE CONTROLLED......................................................................................436 TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)..............................................................................................................................439 MONITOR SYSTEM 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] (DECRESED ACCUMULATOR OIL PRESSURE (ZG)).................................................................................................................449 ERROR CODE [989F00] (TRANSMISSION 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] (DECREASED 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] (BRAKE COOLING 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 2 (PANEL SWITCH 2) INPUT ERROR (LD)).................................................................................467 ERROR CODE [DD17LD] (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 SHIFT LEVER FR SIGNAL INPUT (KB))..............................................................................................................470 ERROR CODE [DDS5L6] (DECREASED STEERING OIL PRESSURE (L6))...................................................................................................................472 ERROR CODE [DGE2KX] (ENGINE WATER TEMPERATURE (HIGH TEMPERATURE) 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 [DGR1KX] (BRAKE OIL TEMPERATURE SENSOR SYSTEM SHORT-CIRCUITING (KX))..............................................................................................476 ERROR CODE [DGR4KA] (BRAKE OIL TEMPERATURE SENSOR SYSTEM DISCONTINUITY (KA)).................................................................................................477 ERROR CODE [DHE4KA] (ENGINE OIL PRESSURE SENSOR SYSTEM DISCONTINUITY (KA))...................................................................................................478 TROUBLESHOOTING CODE [MON-1] (THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT ON)............................................................................................479 TROUBLESHOOTING CODE [MON-2] (THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON).........................................................................................482 TROUBLESHOOTING CODE [MON-3] (THE ENGINE WATER TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON, OR AFTER THE ENGINE STARTS, THE ENGINE WATER TEMPERATURE GAUGE DOES NOT RISE.)....483 TROUBLESHOOTING CODE [MON-4] (THE HST OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON, OR AFTER THE ENGINE STARTS, THE HST OIL TEMPERATURE GAUGE DOES NOT RISE.)..............484 TROUBLESHOOTING CODE [MON-5] (THE FUEL LEVEL GAUGE DOES NOT RISE OR DECREASE)................................................................................................485 TROUBLESHOOTING CODE [MON-6] (THE RADIATOR COOLANT LEVEL LAMP DOES NOT LIGHT ON).............................................................................................486 TROUBLESHOOTING CODE [MON-7] (THE STEERING OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON)......................................................................................487 TROUBLESHOOTING CODE [MON-8] (THE EMERGENCY STEERING OIL PRESSURE INDICATOR LAMP DOES NOT LIGHT ON)..........................................................................488 TROUBLESHOOTING CODE [MON-9] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1 (PANEL SWITCH 1))........................................................................489 TROUBLESHOOTING CODE [MON-10] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1 (PANEL SWITCH 2)).......................................................................490 TROUBLESHOOTING CODE [MON-11] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2 [<] (PANEL SWITCH 3))...................................................................491 TROUBLESHOOTING CODE [MON-12] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2 [>] (PANEL SWITCH 4))...................................................................492 TROUBLESHOOTING CODE [MON-13] (THE ALARM BUZZER DOES NOT SOUND OR STOP)......................................................................................................493 TROUBLESHOOTING CODE [MON-14] THE WIPER DOES NOT FUNCTION....................................................................................................................494 TROUBLESHOOTING CODE [MON-15] THE LAMPS DO NOT WORK PROPERLY.................................................................................................................494 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)....................................................................................................................................495 ELECTRICAL SYSTEM DIAGRAM....................................................................................................................................................496 PARKING BRAKE RELATED DIAGRAM................................................................................................................................................500 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM.....................................................................................................................................502 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...............................................................................................................................504 TROUBLESHOOTING CODE [E-1] (THE ENGINE DOES NOT START).......................................................................................................................506 TROUBLESHOOTING CODE [E-2] (THE ENGINE DOES NOT STOP)........................................................................................................................510 TROUBLESHOOTING CODE [E-3] (PREHEATING IS IMPOSSIBLE OR CONSTANT)............................................................................................................512 TROUBLESHOOTING CODE [E-4] (THE PARKING BRAKE (MECHANICAL TYPE) DOES NOT FUNCTION)...........................................................................................516 TROUBLESHOOTING CODE [E-5] (THE EMERGENCY BRAKE SYSTEM (ELECTRICAL TYPE) DOES NOT FUNCTION)..................................................................................522 TROUBLESHOOTING CODE [E-6] (DEFECTIVE BOOM KICK-OUT FUNCTION AND CANCELLATION)...............................................................................................523 TROUBLESHOOTING CODE [E-7] (DEFECTIVE BUCKET LEVELER FUNCTION AND CANCELLATION)..............................................................................................526 TROUBLESHOOTING CODE [E-8] (DEFECTIVE LIFT ARM FLOATING HOLDIING FUNCTION AND CANCELLATION)..................................................................................529 TROUBLESHOOTING CODE [E-9] (THE WIPER DOES NOT FUNCTION).....................................................................................................................530 TROUBLESHOOTING CODE [E-10] (THE WINDOW WASHER DOES NOT FUNCTION)............................................................................................................536 TROUBLESHOOTING CODE [E-11] (LAMPS DO NOT WORK PROPERLY).....................................................................................................................539 TROUBLESHOOTING CODE [E-12] (THE HORN DOES NOT SOUND)........................................................................................................................550 TROUBLESHOOTING CODE [E-13] (DEFECTIVE AIR CONDITIONER)......................................................................................................................552 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE).........................................................................................................................561 METHOD OF USING TROUBLESHOOTING CHART........................................................................................................................................562 FAILURE CODE AND CAUSE TABLE.................................................................................................................................................564 H-1 THE MACHINE DOES NOT START...............................................................................................................................................566 H-2 THE TRAVEL SPEED IS SLOW.................................................................................................................................................567 H-3 THE THRUSTING FORCE IS WEAK..............................................................................................................................................568 H-4 ENGINE STALLS WHEN TRAVELING OR ENGINE SPEED DROPS EXCESSIVELY...........................................................................................................569 H-5 THE GEAR IS NOT SHIFTED..................................................................................................................................................570 H-6 THE STEERING WHEEL DOES NOT TURN.........................................................................................................................................571 H-7 THE STEERING WHEEL IS HEAVY..............................................................................................................................................572 H-8 STEERING WHEEL SHAKES OR JERKS...........................................................................................................................................573 H-9 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL............................................................................................................................574 H-10 THE BRAKE IS NOT RELEASED OR IS DRAGGED.................................................................................................................................575 H-11 THE PARKING BRAKE IS NOT WORK, RELEASED OR IS DRAGGED...................................................................................................................576 H-12 THE LIFT ARM DOES NOT RISE OR LOWER.....................................................................................................................................577 H-13 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT..................................................................................................578 H-14 WHEN RISING, THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT.......................................................................................................579 H-15 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET (THE BUCKET RISES IN THE AIR).........................................................................................579 H-16 HYDRAULIC DRIFTS OF THE LIFT ARM OCCUR OFTEN............................................................................................................................579 H-17 THE LIFT ARM WOBBLES DURING OPERATION...................................................................................................................................579 H-18 WHEN THE CONTROL LEVER IS SWITCHED FROM "HOLD" TO "RAISE", THE LIFT ARM FALLS TEMPORARILY...............................................................................580 H-19 THE BUCKET DOES NOT TILT BACK...........................................................................................................................................581 H-20 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT.......................................................................................................582 H-21 THE BUCKET COMES TO OPERATE SLOWLY IN THE MIDST OF TILTING BACK.........................................................................................................583 H-22 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET.........................................................................................................................583 H-23 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN..............................................................................................................................583 H-24 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVE IS SET TO "HOLD").................................................................................584 H-25 WHEN THE CONTROL LEVER IS SWITCHED FROM "HOLD" TO "TILT", THE BUCKET FALLS TEMPORARILY..................................................................................584 H-26 THE CONTROL LEVERS OF THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY............................................................................................584 TROUBLESHOOTING OF ENGINE (S MODE)...............................................................................................................................................585 METHOD OF USING TROUBLESHOOTING CHARTS.......................................................................................................................................586 S-1 STARTING PERFORMANCE IS POOR (STARTING TIME ALWAYS TAKES TIME)...........................................................................................................590 S-2 ENGINE DOES NOT START....................................................................................................................................................592 (1) ENGINE DOES NOT TURN.................................................................................................................................................592 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED).............................................................................................593 (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...........................................................................................594 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW UP IS POOR).....................................................................................................................595 S-4 ENGINE STOPS DURING OPERATIONS...........................................................................................................................................596 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)................................................................................................................................597 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER).....................................................................................................................................598 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...........................................................................................................................599 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)..................................................................................................................600 S-9 OIL BECOMES CONTAMINATED QUICKLY.........................................................................................................................................601 S-10 FUEL CONSUMPTION IS EXCESSIVE...........................................................................................................................................602 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN.................................................................................................603 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)..............................................................................................................604 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)....................................................................................................................................605 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)........................................................................................................................606 S-15 ABNORMAL NOISE IS MADE..................................................................................................................................................607 S-16 VIBRATION IS EXCESSIVE..................................................................................................................................................608 30 DISASSEMBLY AND ASSEMBLY..............................................................................................................................................................609 HOW TO READ THIS MANUAL..............................................................................................................................................................611 REMOVAL AND INSTALLATION OF ASSEMBLIES...........................................................................................................................................611 DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES...........................................................................................................................................612 PRECAUTIONS WHEN PERFORMING OPERATION................................................................................................................................................613 SPECIAL TOOL LIST....................................................................................................................................................................615 SKETCHES OF SPECIAL TOOLS............................................................................................................................................................618 REMOVAL, INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY................................................................................................................................624 SPECIAL TOOLS....................................................................................................................................................................624 REMOVAL..........................................................................................................................................................................624 INSTALLATION.....................................................................................................................................................................626 REMOVAL, INSTALLATION OF NOZZLE HOLDER ASSEMBLY......................................................................................................................................628 SPECIAL TOOLS....................................................................................................................................................................628 REMOVAL..........................................................................................................................................................................628 INSTALLATION.....................................................................................................................................................................629 REMOVAL, INSTALLATION OF CYLINDER HEAD ASSEMBLY......................................................................................................................................630 SPECIAL TOOLS....................................................................................................................................................................630 REMOVAL..........................................................................................................................................................................630 INSTALLATION.....................................................................................................................................................................635 REMOVAL, INSTALLATION OF ENGINE ASSEMBLY.............................................................................................................................................638 REMOVAL..........................................................................................................................................................................638 INSTALLATION.....................................................................................................................................................................643 REMOVAL, INSTALLATION OF RADIATOR ASSEMBLY...........................................................................................................................................645 REMOVAL..........................................................................................................................................................................645 INSTALLATION.....................................................................................................................................................................646 REMOVAL, INSTALLATION OF AIR AFTERCOOLER.............................................................................................................................................647 REMOVAL..........................................................................................................................................................................647 INSTALLATION.....................................................................................................................................................................648 REMOVAL, INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY...............................................................................................................................649 REMOVAL..........................................................................................................................................................................649 INSTALLATION.....................................................................................................................................................................650 REMOVAL, INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY..........................................................................................................................651 REMOVAL..........................................................................................................................................................................651 INSTALLATION.....................................................................................................................................................................652 REMOVAL, INSTALLATION OF FUEL TANK ASSEMBLY..........................................................................................................................................653 REMOVAL..........................................................................................................................................................................653 INSTALLATION.....................................................................................................................................................................654 REMOVAL, INSTALLATION OF TRANSFER....................................................................................................................................................655 REMOVAL..........................................................................................................................................................................655 INSTALLATION.....................................................................................................................................................................657 DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY...........................................................................................................................................658 SPECIAL TOOLS....................................................................................................................................................................658 DISASSEMBLY......................................................................................................................................................................658 ASSEMBLY.........................................................................................................................................................................666 REMOVAL, INSTALLATION OF PARKING BRAKE ASSEMBLY......................................................................................................................................678 REMOVAL..........................................................................................................................................................................678 INSTALLATION.....................................................................................................................................................................679 DISASSEMBLY, ASSEMBLY OF PARKING BRAKE ASSEMBLY......................................................................................................................................680 SPECIAL TOOLS....................................................................................................................................................................680 DISASSEMBLY......................................................................................................................................................................680 ASSEMBLY.........................................................................................................................................................................682 REMOVAL, INSTALLATION OF FRONT AXLE ASSEMBLY.........................................................................................................................................685 REMOVAL..........................................................................................................................................................................685 INSTALLATION.....................................................................................................................................................................686 REMOVAL, INSTALLATION OF REAR AXLE ASSEMBLY..........................................................................................................................................687 REMOVAL..........................................................................................................................................................................687 INSTALLATION.....................................................................................................................................................................689 DISASSEMBLY, ASSEMBLY OF AXLE HOUSING ASSEMBLY.......................................................................................................................................690 SPECIAL TOOLS....................................................................................................................................................................690 DISASSEMBLY......................................................................................................................................................................690 ASSEMBLY.........................................................................................................................................................................693 DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY.......................................................................................................................................699 SPECIAL TOOLS....................................................................................................................................................................699 DISASSEMBLY......................................................................................................................................................................699 ASSEMBLY.........................................................................................................................................................................708 REMOVAL, INSTALLATION OF HST PUMP AND 4 GEAR PUMP ASSEMBLY...........................................................................................................................725 REMOVAL..........................................................................................................................................................................725 INSTALLATION.....................................................................................................................................................................727 DISASSEMBLY, ASSEMBLY OF HST PUMP ASSEMBLY...........................................................................................................................................728 DISASSEMBLY......................................................................................................................................................................728 ASSEMBLY.........................................................................................................................................................................737 REMOVAL, INSTALLATION OF HST MOTOR 1 ASSEMBLY........................................................................................................................................754 REMOVAL..........................................................................................................................................................................754 INSTALLATION.....................................................................................................................................................................754 REMOVAL, INSTALLATION OF HST MOTOR 2 ASSEMBLY........................................................................................................................................755 REMOVAL..........................................................................................................................................................................755 INSTALLATION.....................................................................................................................................................................755 DISASSEMBLY, ASSEMBLY OF HST MOTOR ASSEMBLY..........................................................................................................................................756 DISASSEMBLY......................................................................................................................................................................756 ASSEMBLY.........................................................................................................................................................................764 REMOVAL, INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY.......................................................................................................................772 REMOVAL..........................................................................................................................................................................772 INSTALLATION.....................................................................................................................................................................773 REMOVAL, INSTALLATION OF TRAVEL DAMPER VALVE ASSEMBLY................................................................................................................................774 REMOVAL..........................................................................................................................................................................774 INSTALLATION.....................................................................................................................................................................775 REMOVAL, INSTALLATION OF HYDRAULIC TANK ASSEMBLY.....................................................................................................................................776 REMOVAL..........................................................................................................................................................................776 INSTALLATION.....................................................................................................................................................................777 REMOVAL, INSTALLATION OF WORK EQUIPMENT ASSEMBLY.....................................................................................................................................778 REMOVAL..........................................................................................................................................................................778 INSTALLATION.....................................................................................................................................................................781 DISASSEMBLY, ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY.................................................................................................................................785 SPECIAL TOOLS....................................................................................................................................................................785 DISASSEMBLY......................................................................................................................................................................786 ASSEMBLY.........................................................................................................................................................................789 REMOVAL, INSTALLATION OF OPERATOR'S CAB ASSEMBLY.....................................................................................................................................793 REMOVAL..........................................................................................................................................................................793 INSTALLATION.....................................................................................................................................................................796 REMOVAL, INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)..........................................................................................................................797 SPECIAL TOOLS....................................................................................................................................................................797 REMOVAL..........................................................................................................................................................................797 INSTALLATION.....................................................................................................................................................................798 COATING MATERIALS................................................................................................................................................................804 REMOVAL, INSTALLATION OF CENTER HINGE PIN............................................................................................................................................805 REMOVAL..........................................................................................................................................................................805 INSTALLATION.....................................................................................................................................................................809 REMOVAL, INSTALLATION OF COUNTERWEIGHT...............................................................................................................................................814 REMOVAL..........................................................................................................................................................................814 INSTALLATION.....................................................................................................................................................................815 REMOVAL, INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY...............................................................................................................................816 SPECIAL TOOLS....................................................................................................................................................................816 REMOVAL..........................................................................................................................................................................816 INSTALLATION.....................................................................................................................................................................817 REMOVAL, INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY.........................................................................................................................818 SPECIAL TOOLS....................................................................................................................................................................818 REMOVAL..........................................................................................................................................................................818 INSTALLATION.....................................................................................................................................................................818 REMOVAL, INSTALLATION OF MONITOR PANEL...............................................................................................................................................819 REMOVAL..........................................................................................................................................................................819 INSTALLATION.....................................................................................................................................................................821 90 OTHERS................................................................................................................................................................................822 HYDRAULIC CIRCUIT DIAGRAM WA250-5....................................................................................................................................................823 HYDRAULIC CIRCUIT DIAGRAM WA250PT-5..................................................................................................................................................824 ELECTRICAL CIRCUIT DIAGRAM 1/4 (1/4).................................................................................................................................................825 ELECTRICAL CIRCUIT DIAGRAM 1/4 (2/4).................................................................................................................................................826 ELECTRICAL CIRCUIT DIAGRAM 1/4 (3/4).................................................................................................................................................827 ELECTRICAL CIRCUIT DIAGRAM 1/4 (4/4).................................................................................................................................................828 ELECTRICAL CIRCUIT DIAGRAM 2/4 ......................................................................................................................................................829 ELECTRICAL CIRCUIT DIAGRAM 3/4 ......................................................................................................................................................830 ELECTRICAL CIRCUIT DIAGRAM 4/4 ......................................................................................................................................................831 ELECTRICAL CIRCUIT DIAGRAM 1/4 (1/4) (MACHINES EQUIPPED WITH ROPS CANOPY)............................................................................................................832 ELECTRICAL CIRCUIT DIAGRAM 1/4 (2/4) (MACHINE EQUIPPED WITH ROPS CANOPY).............................................................................................................833 ELECTRICAL CIRCUIT DIAGRAM 1/4 (3/4) (MACHINES EQUIPPED WITH ROPS CANOPY)............................................................................................................834 ELECTRICAL CIRCUIT DIAGRAM 1/4 (4/4) (MACHINE EQUIPPED WITH ROPS CANOPY).............................................................................................................835 ELECTRICAL CIRCUIT DIAGRAM 2/4 (MACHINES EQUIPPED WITH ROPS CANOPY)..................................................................................................................836 ELECTRICAL CIRCUIT DIAGRAM 3/4 (MACHINES EQUIPPED WITH ROPS CANOPY)..................................................................................................................837 ELECTRICAL CIRCUIT DIAGRAM 4/4 (MACHINES EQUIPPED WITH ROPS CANOPY)..................................................................................................................838
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
