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