Komatsu WA250-1LC Wheel Loader Repair Manual CEBMW18020 PDF

Description

Komatsu WA250-1LC Wheel Loader Shop Manual CEBMW18020 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA250-1LC Wheel Loader Shop Manual CEBMW18020 – PDF DOWNLOAD

Language : English
Pages : 648
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu WA250-1LC Wheel Loader Shop Manual CEBMW18020 – PDF DOWNLOAD

SERIAL NUMBERS
A65001 and up

MAIN MENU 0
CONTENTS 5
10 ENGINE 19
12 TESTING AND ADJUSTING 19
STANDARD VALUE TABLE 21
ENGINE ON TEST BENCH 21
ENGINE ON CHASSIS 22
TOOL LIST 22
VALVE CLEARANCE 23
FUEL INJECTION TIMING 23
ENGINE OIL PRESSURE 24
ENGINE OIL TEMPERATURE 25
BLOW-BY PRESSURE 26
EXHAUST GAS COLOR 27
ACCELERATOR PEDAL 28
OPERATING FORCE 28
OPERATING ANGLE 29
13 DISASSEMBLY AND ASSEMBLY 31
NOZZLE HOLDER ASSEMBLY 32
REMOVAL 32
INSTALLATION 32
CYLINDER HEAD ASSEMBLY 33
REMOVAL 33
INSTALLATION 34
RADIATOR 35
REMOVAL 35
INSTALLATION 37
ENGINE 39
REMOVAL 39
INSTALLATION 44
FUEL TANK 48
REMOVAL 48
INSTALLATION 49
20 POWER TRAIN 52
21 STRUCTURE AND FUNCTION 52
GENERAL 54
HYDRAULIC CIRCUIT FOR POWER TRAIN 56
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN 57
TORQUE CONVERTER AND TRANSMISSION PIPING 58
TORQUE CONVERTER CHARGING PUMP 59
SPECIFICATIONS 59
OUTLINE 59
TORQUE CONVERTER 60
SPECIFICATIONS 60
OUTLINE 61
TORQUE CONVERTER OIL FILTER 62
TORQUE CONVERTER OIL COOLER AND RADIATOR 63
TORQUEFLOW TRANSMISSION 64
CLUTCH PACK 66
FORWARD AND REVERSE CLUTCH 66
1ST AND 3RD CLUTCH 66
2ND AND 4TH CLUTCH 67
OPERATION OF CLUTCH 68
FORWARD 1ST 69
FORWARD 2ND 70
FORWARD 3RD 71
FORWARD 4TH 72
REVERSE 1ST 73
TRANSMISSION CONTROL VALVE 74
TRANSMISSION SOLENOID VALVE 75
UPPER VALVE 76
LOWER VALVE 77
TORQUE CONVERTER OUTLET VALVE 78
PILOT REDUCING VALVE 79
TRANSMISSION SOLENOID VALVE 80
PRIORITY AND MAIN REGULATOR VALVE 81
MAIN REGULATOR VALVE 82
MODULATING RELIEF VALVE 83
ACCUMULATOR VALVE 83
QUICK RETURN VALVE 83
EMERGENCY MANUAL SPOOL 87
FORWARD 1ST 88
DIRECTIONAL SPOOL 89
FILL VALVE 90
PILOT OIL FILTER 92
DRIVE SHAFT 93
AXLE 94
FRONT 94
REAR 95
DIFFERENTIAL 96
FRONT 96
REAR 97
TORQUE PROPORTIONING 98
FINAL DRIVE100
AXLE MOUNT101
TIRE AND WHEEL103
22 TESTING AND ADJUSTING104
STANDARD VALUE TABLE105
ENGINE STALL SPEED106
OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION108
SHIFT LEVER111
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL112
TIRE AND WHEEL114
TROUBLESHOOTING115
PREVENTING RECURRENCE OF TROUBLE116
METHOD OF READING TROUBLESHOOTING TABLE117
CHECKS BEFORE TROUBLESHOOTING119
METHOD OF LOCATING MAIN PROBLEM POINTS WHEN TROUBLESHOOTING TRANSMISSION SYSTEM120
TROUBLESHOOTING TABLE121
TORQUE CONVERTER AND TRANSMISSION121
1 Machine does not move off121
2 Machine speed is low, thrust is weak, grade-ability falls off123
3 Large shock when moving off or changing gear125
4 Large time lag when moving off or changing gear126
5 Oil temperature in torque converter is high127
23 DISASSEMBLY AND ASSEMBLY128
TORQUE CONVERTER CHARGING PUMP130
REMOVAL130
INSTALLATION130
TRANSMISSION, TORQUE CONVERTER131
REMOVAL131
INSTALLATION138
TORQUE CONVERTER145
DISASSEMBLY145
ASSEMBLY148
TRANSMISSION151
DISASSEMBLY151
ASSEMBLY158
CLUTCH PACK170
DISASSEMBLY170
FORWARD-REVERSE CLUTCH PACK170
1ST -3RD SPEED CLUTCH PACK173
2ND-4TH SPEED CLUTCH PACK175
ASSEMBLY177
FORWARD-REVERSE CLUTCH PACK177
1ST-3RD SPEED CLUTCH PACK182
2ND-4TH SPEED CLUTCH PACK186
TRANSMISSION CONTROL VALVE190
REMOVAL190
INSTALLATION191
TRANSMISSION SOLENOID VALVE197
DISASSEMBLY197
ASSEMBLY197
DRIVE SHAFT198
DISASSEMBLY198
ASSEMBLY200
FRONT AXLE202
REMOVAL202
INSTALLATION204
REAR AXLE206
REMOVAL206
INSTALLATION210
DIFFERENTIAL215
DISASSEMBLY215
ASSEMBLY219
AXLE HOUSING229
DISASSEMBLY229
ASSEMBLY233
24 MAINTENANCE STANDARD240
ENGINE AND TRANSMISSION MOUNT241
TORQUE CONVERTER CHARGING PUMP242
TORQUE CONVERTER243
TRANSMlSSlON245
TRANSMISSION CLUTCH249
UPPER VALVE253
LOWER VALVE255
SOLENOID VALVE256
AXLE257
DIFFERENTIAL261
FINAL DRIVE263
DRIVE SHAFT264
AXLE MOUNT265
40 STEERING SYSTEM267
41 STRUCTURE AND FUNCTION267
STEERING PIPING268
HYDRAULIC CIRCUIT FOR STEERING269
HYDRAULIC CIRCUIT DIAGRAM FOR STEERING270
TWO-WAY RESTRICTOR VALVE271
STEERING VALVE272
CONNECTION OF HAND PUMP AND SLEEVE278
PRIORITY VALVE280
STEERING COLUMN283
STEERING CYLINDER284
CENTER HINGE PIN285
42 TESTING AND ADJUSTING287
STANDARD VALUE TABLE288
TOOL LIST288
STEERING WHEEL PLAY289
OPERATING FORCE OF STEERING WHEEL290
OPERATING TIME OF STEERING WHEEL291
STEERING OIL PRESSURE292
TROUBLESHOOTING295
TROUBLESHOOTING TABLE296
1 Steering wheel does not turn296
2 Steering wheel is sluggish297
3 Steering wheel moves unsteadily or is subjected to large shock298
4 Machine tends to turn naturally in one particular direction when traveling298
5 Left and right turning radii are different298
43 DISASSEMBLY AND ASSEMBLY299
STEERING VALVE300
REMOVAL300
INSTALLATION302
DISASSEMBLY304
ASSEMBLY306
PRIORITY VALVE308
REMOVAL308
INSTALLATION310
STEERING CYLINDER312
REMOVAL312
INSTALLATION313
DISASSEMBLY314
ASSEMBLY316
CENTER HINGE PIN REMOVAL319
REMOVAL319
INSTALLATION324
44 MAINTENANCE STANDARD329
HYDRAULIC AND STEERING PUMP330
STEERING CYLINDER MOUNT331
CENTER HINGE PIN332
STEERING COLUMN AND GEAR BOX334
PRIORITY VALVE335
50 BRAKE AND AIR SYSTEM338
51 STRUCTURE AND FUNCTION338
BRAKE PIPING339
POWER MASTER CYLINDER340
BRAKE344
PARKING BRAKE CONTROL346
PARKING BRAKE347
OPERATION OF PARKING BRAKE348
BRAKE CALIPER349
52 TESTING AND ADJUSTING350
STANDARD VALUE TABLE351
TOOL LIST352
MEASURING BRAKE PEDAL353
BRAKE PEDAL LINKAGE354
BRAKE PERFORMANCE356
BRAKE PISTON LEAKAGE357
BRAKE DISC WEAR358
AIR BLEEDING FROM BRAKE CIRCUIT359
PARKING BRAKE PERFORMANCE360
PARKING BRAKE361
CHECKING361
ADJUSTING362
MEASURING CLEARANCE363
TROUBLESHOOTING364
TROUBLESHOOTING TABLES365
1 Brake is ineffective or not very effective365
2 Brake cannot be released or drags366
53 DISASSEMBLY AND ASSEMBLY368
POWER MASTER CYLINDER369
REMOVAL369
INSTALLATION370
DISASSEMBLY371
ASSEMBLY374
PARKING BRAKE379
REMOVAL379
lNSTALLATION381
PARKING BRAKE PAD383
REMOVAL383
INSTALLATION383
54 MAINTENANCE STANDARD384
POWER MASTER CYLINDER385
BRAKE386
PARKING BRAKE387
60 WORK EQUIPMENT SYSTEM389
61 STRUCTURE AND FUNCTION389
HYDRAULIC PIPING390
HYDRAULIC CIRCUIT391
HYDRAULIC CIRCUIT DIAGRAM392
WORK EQUIPMENT LEVER LINKAGE393
BUCKET LINKAGE394
BUCKET POSITIONER AND BOOM KICK-OUT396
HYDRAULIC TANK398
OIL FILTER BYPASS VALVE399
BREATHER399
HYDRAULIC AND STEERING PUMPS400
MAIN CONTROL VALVE401
RELIEF VALVE403
SAFElY VALVE W/SUCTION VALVE404
As a safety valve404
As a suction valve405
SUCTION VALVE405
LIFT AND DUMP SPOOLS AT “NEUTRAL POSITION”406
LIFT SPOOL AT “RAISE POSITION”407
LIFT SPOOL AT “LOWER POSITION”408
LIFT SPOOL AT “FLOAT POSITION”409
DUMP SPOOL AT “TILT BACK POSITION”410
DUMP SPOOL AT DUMP “POSITION”411
HYDRAULIC CYLINDER412
62 TESTING AND ADJUSTING413
STANDARD VALUE TABLE415
DUMP AND LIFT CONTROL LEVERS416
HYDRAULIC PRESSURE419
LIFT ARM AND BUCKET421
HYDRAULIC DRIFT OF LIFT ARM AND BUCKET422
BUCKET POSITIONER423
BOOM KICK-OUT424
TROUBLESHOOTING426
TROUBLESHOOTING TABLES427
1 Lift arm does not rise427
2 Lift arm moves slowly or does not have sufficient lifting power428
3 Lift arm movement becomes slow after it reaches a certain height429
4 Bucket cannot be held down with lift arm cylinder429
5 Lift arm has large hydraulic drift429
6 Lift arm movement is unsteady during work429
7 Lift arm descends momentarily when control lever is shifted from “Hold to Raise”429
8 Bucket does not tilt back430
9 Bucket moves slowly or has insufficient tilt back power431
10 Bucket movement becomes slow during tilt back432
11 Bucket cannot be held down by the bucket cylinder432
12 Bucket has large hydraulic drift432
13 Bucket moves unsteadily when machine travels under load (Main control valve in “Hold”)432
14 Bucket dumps momentarily when control lever is shifted from “Hold to Tilt back”432
15 Control levers of lift arm and dump move stiffly and sluggishly433
63 DISASSEMBLY AND ASSEMBLY435
HYDRAULIC TANK437
REMOVAL437
INSTALLATION439
HYDRAULIC FILTER441
REMOVAL441
INSTALLATION441
HYDRAULIC, STEERING PUMP442
REMOVAL442
INSTALLATION443
MAIN CONTROL VALVE444
REMOVAL444
INSTALLATION446
DISASSEMBLY449
ASSEMBLY449
DUMP CYLINDER450
REMOVAL450
INSTALLATION452
DISASSEMBLY453
ASSEMBLY455
LIFT CYLINDER457
REMOVAL457
INSTALLATION458
DISASSEMBLY459
ASSEMBLY461
WORK EQUIPMENT463
REMOVAL463
INSTALLATION466
COUNTERWEIGHT469
REMOVAL469
INSTALLATION469
64 STRUCTURE AND FUNCTION471
HYDRAULIC AND STEERING PUMP472
MAIN CONTROL VALVE474
DUMP CYLINDER476
LIFT CYLINDER477
BUCKET LINKAGE478
BUCKET POSITIONER AND BOOM KICK-OUT481
BUCKET482
80 ELECTRIC AND ELECTRONIC SYSTEM484
81 STRUCTURE AND FUNCTION484
ELECTRICAL WIRING CIRCUIT DlAGRAMS485
ENGINE STARTING CIRCUIT486
ENGINE STOP CIRCUIT488
COMBINATION SWITCH489
ELECTRICAL TRANSMISSION CONTROL490
TRANSMISSION CUT-OFF SELECTOR SWITCH491
NEUTRALIZER RELAY492
ELECTRONIC VEHICLE MONITORING SYSTEM (RIMS)493
MONITOR PANEL494
INDICATION ON MONITOR PANEL495
WIRING HARNESS497
SENSORS498
ENGINE OIL LEVEL SENSOR499
COOLANT LEVEL SENSOR499
BRAKE OIL LEVEL SENSOR500
FUEL GAUGE SENSOR501
COOLANT TEMPERATURE SENSOR502
TORQUE CONVERTER OIL TEMPERATURE SENSOR502
ENGINE OIL PRESSURE SENSOR503
ROTATIONAL SPEED SENSOR503
PROXIMITY SWITCH504
82 TESTING AND ADJUSTING508
ADJUSTING SPEEDOMETER MODULE511
TROUBLESHOOTING512
ELECTRICAL CIRCUIT SYSTEM514
1 ENGINE STARTING CIRCUIT SYSTEM514
2 ENGINE STOP CIRCUIT SYSTEM515
3 TRANSMISSION CONTROL AND PARKING BRAKE SYSTEM516
CONNECTION TABLE FOR CONNECTOR PIN NUMBER CONNECT1517
PRECAUTION WHEN HANDLING CONNECTOR522
METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART524
ELECTRICAL SCHEMATIC527
CHECKS BEFORE TROUBLESHOOTING528
TROUBLESHOOTING CHARTS FOR ELECTRIC SYSTEM530
POSITION OF CONNECTORS531
E-1 ENGINE DOES NOT START536
E-2 ENGINE DOES NOT STOP537
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING537
E-4 TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (TRANSMISSION CUT-OFF NORMAL)538
E-5 MACHINE MOVES IN REVERSE BUT NOT IN FORWARD538
E-6 MACHINE MOVES NEITHER IN FORWARD NOR REVERSE539
E-7 MACHINE MOVES IN FORWARD BUT NOT IN REVERSE541
E-8 MACHINE MOVES FORWARD EVEN WHEN541
E-9 MACHINE MOVES IN REVERSE EVEN WHEN TRANSMISSION CONTROL LEVERS ARE IN NEUTRAL542
E-10 MACHINE ALWAYS TRAVELS IN 2ND542
E-11 TRANSMISSION DOES NOT CHANGE GEAR (But F-R changeable)543
E-12 TRANSMISSION CANNOT BE CUT-OFF EVEN WHEN LH BRAKE PEDAL IS DEPRESSED WITH544
E-13 TRANSMISSION DOES NOT RETURN TO NEUTRAL545
TROUBLESHOOTING CHARTS FOR ELECTRONIC VEHICLE MONITORING SYSTEM548
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS) SCHEMATIC549
POSITION OF CONNECTORS550
M-1 EVEN WHEN ENGINE IS STOPPED, (BRAKE OIL LEVEL) FLASHES556
M-2 EVEN WHEN ENGINE IS STOPPED, (ENGINE OIL LEVEL) FLASHES556
M-3 EVEN WHEN ENGINE IS STOPPED, (COOLANT LEVEL) FLASHES557
M-4 (BATTERY CHARGE) FLASHES WHEN ENGINE IS RUNNING557
M-5 (FUEL LEVEL) FLASHES558
M-6 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, (BRAKE OIL LEVEL)558
M-7 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, (ENGINE OIL PRESSURE)558
M-8 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, (COOLANT LEVEL) 559
M-9 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, (BRAKE SERVO PRESSURE)559
M-10 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, (COOLANT TEMPERATURE)559
M-11 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, (TORQUE CONVERTER OIL TEMPERATURE)560
M-12 (PARKING BRAKE) LIGHTS UP OR DOES NOT LIGHT UP560
M-13 (WORKING LAMP) LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP561
M-14 NOT USED562
M-15 (FAILURE IN MAIN STEERING) LIGHTS UP OR DOES NOT LIGHT UP (IF EQUIPPED)562
M-16 (EMERGENCY STEERING NORMAL) LIGHTS UP OR DOES NOT LIGHT UP (IF EQUIPPED)563
M-17 (TRANSMISSION CUT-OFF) LIGHTS UP OR DOES NOT LIGHT UP564
M-18 TURN SIGNAL LAMPS, HIGH BEAM LIGHT UP OR DO NOT LIGHT UP565
M-19 SPEEDOMETER DISPLAY DOES NOT WORK567
M-20 SERVICEMETER DOES NOT WORK NORMALLY568
M-21 ALL OR PART OF MONITOR PANEL DOES NOT WORK569
M-22 EVEN WHEN ENGINE IS STOPPED, (BATTERY CHARGE) FLASHES, OR (ENGINE OIL PRESSURE) FLASHES570
M-23 NO LAMPS ON MONITOR LIGHT UP (IMMEDIATELY AFTER TURNING STARTING SWITCH TO ON, ENGINE STOPPED)570
M-24 CENTRAL WARNING LAMP DOES NOT GO OUT571
M-25 CENTRAL WARNING BUZZER DOES NOT STOP571
M-26 NONE OF PANEL LAMPS ON MACHINE MONITOR LIGHT UP572
M-27 SOME OF PANEL LAMPS ON MACHINE MONITOR DO NOT LIGHT UP574
M-28 EMERGENCY ITEM IS FLASHING, BUT ALARM BUZZER DOES NOT SOUND575
M-29 EMERGENCY ITEM OR NON-EMERGENCY ITEM IS FLASHING, BUT WARNING LAMP DOES NOT FLASH575
M-30 ABNORMALITY IN (FUEL GAUGE)576
M-31 ABNORMALITY IN (COOLANT TEMPERATURE GAUGE)577
M-32 ABNORMALITY IN (TORQUE CONVERTER OIL TEMPERATURE GAUGE)578
TABLE OF MONITOR REFERENCE VALUES579
83 DISASSEMBLY AND ASSEMBLY584
ELECTRONIC VECHICLE MONITOR SYSTEM (EVMS)585
REMOVAL585
INSTALLATION586
90 OTHER589
91 STRUCTURE AND FUNCTION589
CAB590
AIR CONDITIONER592
PIPING, ENGINE TO HEATER CORE592
PIPING, CONDENSER AND COMPRESSOR593
ELECTRICAL DIAGRAM594
AIR CONDITIONER UNIT595
HEATING595
COOLING595
AIR CONDITIONER COMPRESSOR596
AIR CONDITIONER CONDENSER596
AIR CONDITIONER DRY RESERVOIR597
93 DISASSEMBLY AND ASSEMBLY599
CAB600
REMOVAL600
INSTALLATION601
AIR CONDITIONER UNIT602
REMOVAL602
INSTALLATION604
CONDENSER (AIR CONDITIONER)606
REMOVAL606
INSTALLATION606
DRY RECEIVER (AIR CONDITIONER)607
REMOVAL607
INSTALLATION607
COMPRESSOR (AIR CONDITIONER)608
REMOVAL608
INSTALLATION608
97 GEAR PUMP609
GENERAL610
PRINCIPLE OF OPERATION611
PRESSURE LOADED TYPE GEAR PUMP614
FIXED SIDE PLATE TYPE GEAR PUMP616
SA SERIES617
STRUCTURE617
TESTING AND ADJUSTING621
DISASSEMBLY624
ASSEMBLY628
MAINTENANCE STANDARD633
99 METRIC CONVERSIONS635

DESCRIPTION:

Komatsu WA250-1LC Wheel Loader Shop Manual CEBMW18020 – PDF DOWNLOAD

SERIAL NUMBERS
A65001 and up

G.B 13/12/24