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Komatsu WA250-5, WA250PT-5 Wheel Loader Shop Manual SEBM033208 – PDF DOWNLOAD
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Komatsu WA250-5, WA250PT-5 Wheel Loader Shop Manual
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WA250-5 70001 and up
WA250PT-5 70001 and up
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Description
Komatsu WA250-5, WA250PT-5 Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA250-5, WA250PT-5 Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA250-5, WA250PT-5
Serial Number: 70001 and up
Book Code: SEBM033208
Language: English
Pages: 832
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA250-5, WA250PT-5 Wheel Loader Shop Manual
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.
TABLE OF CONTENTS:
Komatsu WA250-5, WA250PT-5 Wheel Loader Shop Manual
COVER ................................................................................................................................................................................... 1 CONTENTS................................................................................................................................................................................. 2 01 GENERAL............................................................................................................................................................................... 27 GENERAL ASSEMBLY DRAWINGS............................................................................................................................................................ 28 SPECIFICATIONS....................................................................................................................................................................... 29 WEIGHT TABLE......................................................................................................................................................................... 33 LIST OF LUBRICANT AND COOLANT........................................................................................................................................................ 35 10 STRUCTURE,FUNCTION AND MAINTENANCE STANDARD........................................................................................................................................... 36 ENGINE MOUNT AND TRANSFER MOUNT...................................................................................................................................................... 37 DAMPER............................................................................................................................................................................... 38 COOLING SYSTEM....................................................................................................................................................................... 39 TRANSFER OIL COOLER.................................................................................................................................................................. 40 POWER TRAIN.......................................................................................................................................................................... 43 POWER TRAIN SYSTEM DIAGRAM........................................................................................................................................................... 44 DRIVE SHAFT (PROPELLER SHAFT)........................................................................................................................................................ 46 HST HYDRAULIC PIPING DIAGRAM......................................................................................................................................................... 47 HST PUMP............................................................................................................................................................................. 48 HIGH-PRESSURE RELIEF VALVE........................................................................................................................................................... 50 LOW-PRESSURE RELIEF VALVE............................................................................................................................................................ 52 HST CHARGE PUMP...................................................................................................................................................................... 53 SPEED-RELATED VALVE (DA VALVE)....................................................................................................................................................... 54 HIGH-PRESSURE CUT-OFF VALVE.......................................................................................................................................................... 55 HST MOTOR............................................................................................................................................................................ 56 EP SERVO VALVE....................................................................................................................................................................... 59 HA SERVO VALVE....................................................................................................................................................................... 60 FORWARD-REVERSE SHUTTLE VALVE........................................................................................................................................................ 61 TRANSFER............................................................................................................................................................................. 62 CLUTCH SOLENOID VALVE................................................................................................................................................................ 73 AXLE................................................................................................................................................................................. 74 DIFFERENTIAL......................................................................................................................................................................... 76 LIMITED-SLIP DIFFERENTIAL............................................................................................................................................................ 81 FINAL DRIVE.......................................................................................................................................................................... 87 AXLE MOUNTING AND CENTER HINGE PIN................................................................................................................................................... 92 STEERING PIPING...................................................................................................................................................................... 97 STEERING COLUMN...................................................................................................................................................................... 98 PRIORITY VALVE....................................................................................................................................................................... 99 ORBIT-ROLL VALVE.....................................................................................................................................................................102 2-WAY RESTRICTOR VALVE...............................................................................................................................................................110 CUSHION VALVE........................................................................................................................................................................111 STEERING CYLINDER....................................................................................................................................................................112 EMERGENCY STEERING PIPING............................................................................................................................................................114 EMERGENCY STEERING VALVE.............................................................................................................................................................115 BRAKE PIPING.........................................................................................................................................................................118 BRAKE VALVE..........................................................................................................................................................................119 INCHING VALVE........................................................................................................................................................................123 CHARGE VALVE.........................................................................................................................................................................124 ACCUMULATOR (FOR BRAKE)..............................................................................................................................................................128 SLACK ADJUSTER.......................................................................................................................................................................129 BRAKE................................................................................................................................................................................131 PARKING BRAKE CONTROL................................................................................................................................................................136 PARKING BRAKE........................................................................................................................................................................137 HYDRAULIC PIPING.....................................................................................................................................................................138 HYDRAULIC TANK.......................................................................................................................................................................142 4-GEAR PUMP UNIT.....................................................................................................................................................................148 ACCUMULATOR (FOR PPC CIRCUIT)........................................................................................................................................................150 LOCK VALVE...........................................................................................................................................................................151 BYPASS VALVE.........................................................................................................................................................................152 QUICK COUPLER VALVE..................................................................................................................................................................158 E.C.S.S. VALVE.......................................................................................................................................................................159 ACCUMULATOR (FOR E.C.S.S.)...........................................................................................................................................................161 HYDRAULIC PIPING OF COOLING SYSTEM...................................................................................................................................................162 COOLING FAN MOTOR....................................................................................................................................................................163 WORK EQUIPMENT CONTROL VALVE.........................................................................................................................................................165 WORK EQUIPMENT PPC VALVE.............................................................................................................................................................178 ATTACHMENT PPC VALVE (IF EQUIPPED)...................................................................................................................................................186 WORK EQUIPMENT LINKAGE...............................................................................................................................................................190 BUCKET...............................................................................................................................................................................194 CONTROL OF BUCKET POSITIONER, BOOM KICK-OUT, AND DUMP SPEED..........................................................................................................................196 WORK EQUIPMENT CYLINDER..............................................................................................................................................................210 AIR CONDITIONER (IF EQUIPPED)........................................................................................................................................................213 MACHINE MONITORING SYSTEM............................................................................................................................................................214 MACHINE MONITOR......................................................................................................................................................................223 LIST OF ITEMS DISPLAYED ON MONITOR...................................................................................................................................................224 ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)............................................................................................................................................250 HST CONTROLLER.......................................................................................................................................................................254 ENGINE START CIRCUIT.................................................................................................................................................................255 ENGINE STOP CIRCUIT..................................................................................................................................................................257 PREHEATING CIRCUIT (AUTOMATIC PREHEATING SYSTEM).....................................................................................................................................258 PARKING BRAKE CIRCUIT................................................................................................................................................................259 ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM..........................................................................................................................................262 SENSORS..............................................................................................................................................................................263 20 TESTING AND ADJUSTING.................................................................................................................................................................269 STANDARD VALUE TABLE FOR ENGINE......................................................................................................................................................270 STANDARD VALUE TABLE FOR CHASSIS.....................................................................................................................................................271 TESTING AND ADJUSTING................................................................................................................................................................275 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING................................................................................................................................276 MEASURING ENGINE SPEED...........................................................................................................................................................278 MEASURING EXHAUST GAS COLOR......................................................................................................................................................279 ADJUSTING VALVE CLEARANCE........................................................................................................................................................280 MEASURING COMPRESSION PRESSURE...................................................................................................................................................282 MEASURING BLOW-BY PRESSURE.......................................................................................................................................................283 TESTING AND ADJUSTING FUEL INJECTION TIMING......................................................................................................................................284 MEASURING ENGINE OIL PRESSURE....................................................................................................................................................285 MEASURING,TESTING OPERATING FORCE OF ACCELERATOR PEDAL...........................................................................................................................286 ADJUSTING ENGINE STOP SOLENOID...................................................................................................................................................288 ADJUSTING ENGINE SPEED SENSOR....................................................................................................................................................289 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION....................................................................................................................289 MEASURING DIRECTIONAL LEVER......................................................................................................................................................290 TESTING AND ADJUSTING HST OIL PRESSURE...........................................................................................................................................291 MEASURING CLUTCH CONTROL PRESSURE................................................................................................................................................295 TESTING AND ADJUSTING STEERING WHEEL.............................................................................................................................................296 TESTING AND ADJUSTING STEERING OIL PRESSURE......................................................................................................................................298 BLEEDING AIR FROM STEERING CIRCUIT...............................................................................................................................................299 TESTING HYDRAULIC FAN............................................................................................................................................................300 MEASURING BRAKE PEDAL............................................................................................................................................................301 TESTING AND ADJUSTING BRAKE PEDAL LINKAGE........................................................................................................................................302 MEASURING BRAKE PERFORMANCE......................................................................................................................................................303 TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE................................................................................................................................304 MEASURING BRAKE OIL PRESSURE.....................................................................................................................................................305 MEASURING WEAR OF BRAKE DISC.....................................................................................................................................................307 BLEEDING AIR FROM BRAKE CIRCUIT..................................................................................................................................................308 MEASURING PARKING BRAKE PERFORMANCE..............................................................................................................................................309 TESTING AND ADJUSTING PARKING BRAKE LINKAGE......................................................................................................................................310 MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL...................................................................................................................................312 TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE..........................................................................................................................313 TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE............................................................................................................................314 BLEEDING AIR.....................................................................................................................................................................316 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT................................................................................................................................317 TESTING AND ADJUSTING BUCKET POSITIONER..........................................................................................................................................318 TESTING AND ADJUSTING OF BOOM KICK-OUT...........................................................................................................................................319 CHECKING PROXIMITY SWITCH ACTUATION DISPLAY LAMP.................................................................................................................................320 PROCEDURE FOR CHECKING DIODE.....................................................................................................................................................321 SPECIAL FUNCTIONS OF MACHINE MONITOR.............................................................................................................................................322 FLOW OF MODES AND FUNCTIONS......................................................................................................................................................323 FAILURE CODE TABLE...............................................................................................................................................................331 PM CLINIC INSPECTION CHART.......................................................................................................................................................341 TROUBLESHOOTING......................................................................................................................................................................343 POINTS TO REMEMBER WHEN TROUBLESHOOTING..........................................................................................................................................344 SEQUENCE OF EVENTS IN TROUBLESHOOTING............................................................................................................................................345 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE........................................................................................................................................346 CHECK BEFORE TROUBLESHOOTING.....................................................................................................................................................354 CATEGORIES,PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS..................................................................................................................355 PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO.......................................................................................................................356 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.......................................................................................................................................359 T-ADAPTER TABLE..................................................................................................................................................................381 CONNECTOR TYPES AND MOUNTING LOCATIONS...........................................................................................................................................384 CONNECTOR LAYOUT DRAWING.........................................................................................................................................................390 TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)..............................................................................................................................395 HST CONTROLLER SYSTEM DIAGRAM................................................................................................................................................396 BEFORE TROUBLESHOOTING CODE DISPLAY..........................................................................................................................................398 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM.....................................................................................................................................399 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...............................................................................................................................400 ERROR CODE [989F00] (HST MOTOR PROTECTION CAUTION (00))......................................................................................................................402 ERROR CODE [DHH1KX] (HST OIL PRESSURE SENSOR INPUT SIGNAL OUTSIDE RANGE (KX))................................................................................................403 ERROR CODE [DLE2LC] (ENGINE REVOLUTION SENSOR REVOLUTION SPEED SIGNAL MISMATCH (LC)).........................................................................................405 ERROR CODE [DW26KZ] (MOTOR 2 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ)).........................................................................................406 ERROR CODE [DX19KZ] (MOTOR 1 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ)).........................................................................................408 ERROR CODE [DX20KZ] (CLUTCH SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))..........................................................................................410 TROUBLESHOOTING CODE [HST-1] (DEFECTIVE HST CONTROLLER POWER SOURCE (HST CONTROLLER DOES NOT FUNCTION))......................................................................412 TROUBLESHOOTING CODE [HST-2] (TRAVEL SPEED DOES NOT SHIFTED).................................................................................................................414 TROUBLESHOOTING CODE [HST-3] HST OUTPUT CONTROL (TRACTION CONTROL) CANNOT BE CONTROLLED......................................................................................417 TROUBLESHOOTING CODE [HST-4] (TRAVEL SPEED LIMIT CANNOT BE CHANGED WHEN GEAR SPEED SELECTOR SWITCH IS IN"1ST"POSITION).......................................................419 TROUBLESHOOTING CODE [HST-5] (TRAVEL SPEED IS NOT INCREASED).................................................................................................................421 TROUBLESHOOTING OF ECSS (ECSS MODE) (IF EQUIPPED)................................................................................................................................423 RELATED ELECTRICAL CIRCUIT DIAGRAM...........................................................................................................................................424 ECSS-1 MALFUNCTION OF ECSS...................................................................................................................................................425 TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE).....................................................................................................................................430 MONITOR SYSTEM CIRCUIT DIAGRAM...............................................................................................................................................431 BEFORE TROUBLESHOOTING CODE DISPLAY..........................................................................................................................................435 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM.....................................................................................................................................436 INFORMATION CONTANED IN TROUBLESHOOTING TABLE................................................................................................................................437 ERROR CODE [15B0NX] (HST OIL FILTER CLOGGED (NX))............................................................................................................................439 ERROR CODE [2G42ZG] (DECREASED BRAKE OIL PRESSURE (ZG))......................................................................................................................440 ERROR CODE [989F00] (HST MOTOR PROTECTION CAUTION (00))......................................................................................................................441 ERROR CODE [989FN1] (HST OVERRUNNING (N1))...................................................................................................................................442 ERROR CODE [AB00L6] (DEFECTIVE BATTERY CHARGING CIRCUIT (L6))................................................................................................................443 ERROR CODE [AB00MA] (DEFECTIVE BATTERY CHARGING CIRCUIT (MA))................................................................................................................444 ERROR CODE [B@BAZG] (DEGREASED ENGINE OIL PRESSURE (ZG)).....................................................................................................................445 ERROR CODE [B@BCNS] (ENGINE WATER TEMPERATURE OVERHEATING (NS))..............................................................................................................446 ERROR CODE [B@BCZK] (ALARM INDICATING LOW COOLANT LEVEL (ZK))................................................................................................................447 ERROR CODE [B@C7NS] (AXLE OIL TEMPERATURE OVERHEATING (NS))..................................................................................................................448 ERROR CODE [B@CRNS] (HST OIL TEMPERATURE OVERHEATING (NS))...................................................................................................................449 ERROR CODE [D5ZHL6] (STARTING SWITCH"C" (IGN"C") INPUT FAILURE (L6)).........................................................................................................450 ERROR CODE [DAF0KT] (CONTROLLER INSIDE FAILURE (KT)).........................................................................................................................452 ERROR CODE [DAJ0KR] (HST CONTROLLER COMMUNICATION FAILURE (KR))..............................................................................................................453 ERROE CODE [DD15LD] (MONITOR PANEL MODE SELECTOR SWITCH 1 [■] (PANEL SWITCH 1) INPUT ERROR (LD)).............................................................................455 ERROR CODE [DD16LD] (MONITOR PANEL MODE SELECTOR SWITCH 1 [◇] (PANEL SWITCH 2) INPUT ERROR (LD)).............................................................................456 ERROR CODE [DD17LD] (MONITOR PANEL MODE SELECTOR SWITCH 2 [<] (PANEL SWITCH 3) INPUT ERROR (LD)).............................................................................457 ERROR CODE [DD18LD] (MONITOR PANEL MODE SELECTOR SWITCH 2 [>] (PANEL SWITCH 4) INPUT ERROR (LD)).............................................................................458 ERROR CODE [DDK3KB] (MULTIPLE DIRECTIONAL LEVER FR SIGNAL INPUT (KB))........................................................................................................459 ERROR CODE [DDS5L6] (DECREASED STEERING OIL PRESSURE (L6))...................................................................................................................461 ERROR CODE [DGE2KX] (ENGINE WATER TEMPERATURE (HIGH TEMPERATURE) SENSOR SYSTEM FAILURE (KX)).................................................................................462 ERROR CODE [DGE3L6] (ENGINE WATER TEMPERATURE (LOW TEMPERATURE) SENSOR SYSTEM FAILURE (L6))..................................................................................463 ERROR CODE [DGH1KX] (HST OIL TEMPERATURE SENSOR SYSTEM FAILURE (KX)).........................................................................................................464 ERROR CODE [DGR4KA] (AXLE OIL TEMPERATURE SENSOR SYSTEM DISCONTINUITY (KA))..................................................................................................465 ERROR CODE [DGR4KX] (AXLE OIL TEMPERATURE SENSOR SYSTEM FAILURE (KX))........................................................................................................466 ERROR CODE [DHE4L6] (ENGINE OIL PRESSURE SENSOR SYSTEM DISCONTINUITY (L6))...................................................................................................467 TROUBLESHOOTING CODE [MON-1] (THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT ON)............................................................................................468 TROUBLESHOOTING CODE [MON-2] (THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON).........................................................................................472 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.)....473 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.)...............474 TROUBLESHOOTING CODE [MON-5] (THE FUEL LEVEL GAUGE DOES NOT RISE OR DECREASE.)...............................................................................................475 TROUBLESHOOTING CODE [MON-6] (THE RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT ON).....................................................................................476 TROUBLESHOOTING CODE [MON-7] (THE STEERING OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON)......................................................................................477 TROUBLESHOOTING CODE [MON-8] (THE EMERGENCY STEERING OIL PRESSURE INDICATOR LAMP DOES NOT LIGHT ON)..........................................................................478 TROUBLESHOOTING CODE [MON-9] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1 [■] (PANEL SWITCH 1))....................................................................479 TROUBLESHOOTING CODE [MON-10] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1 [◇] (PANEL SWITCH 2))...................................................................480 TROUBLESHOOTING CODE [MON-11] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2 [<] (PANEL SWITCH 3))...................................................................481 TROUBLESHOOTING CODE [MON-12] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2 [>] (PANEL SWITCH 4))...................................................................482 TROUBLESHOOTING CODE [MON-13] (THE ALARM BUZZER DOES NOT SOUND OR STOP)......................................................................................................483 TROUBLESHOOTING CODE [MON-14] THE WIPER DOES NOT FUNCTION....................................................................................................................484 TROUBLESHOOTING CODE [MON-15] THE LAMPS DO NOT WORK PROPERLY.................................................................................................................484 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)....................................................................................................................................485 ELECTRICAL SYSTEM DIAGRAM....................................................................................................................................................486 PARKING BRAKE RELATED DIAGRAM................................................................................................................................................489 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM.....................................................................................................................................491 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...............................................................................................................................492 TROUBLESHOOTING CODE [E-1] (THE ENGINE DOES NOT START).......................................................................................................................494 TROUBLESHOOTING CODE [E-2] (THE ENGINE DOES NOT STOP)........................................................................................................................498 TROUBLESHOOTING CODE [E-3] (PREHEATING IS IMPOSSIBLE OR CONSTANT)............................................................................................................500 TROUBLESHOOTING CODE [E-4] (THE PARKING BRAKE(MECHANICAL TYPE)DOES NOT FUNCTION).............................................................................................504 TROUBLESHOOTING CODE [E-5] (DEFECTIVE BOOM KICK-OUT FUNCTION AND CANCELLATION)...............................................................................................509 TROUBLESHOOTING CODE [E-6] (DEFECTIVE BUCKET POSITIONER FUNCTION AND CANCELLATION)...........................................................................................512 TROUBLESHOOTING CODE [E-7] (DEFECTIVE LIFT ARM FLOATING HOLDING FUNCTION AND CANCELLATION)...................................................................................515 TROUBLESHOOTING CODE [E-8] (TRAVEL DIRECTION IS NOT CHANGED NORMALLY)........................................................................................................516 TROUBLESHOOTING CODE [E-9] (THE WIPER DOES NOT FUNCTION).....................................................................................................................522 TROUBLESHOOTING CODE [E-10] (THE WINDOW WASHER DOES NOT FUNCTION)............................................................................................................527 TROUBLESHOOTING CODE [E-11] (LAMPS DO NOT WORK PROPERLY).....................................................................................................................530 TROUBLESHOOTING CODE [E-12] (THE HORN DOES NOT SOUND)........................................................................................................................541 TROUBLESHOOTING CODE [E-13] (DEFECTIVE THE AIR CONDITIONER)..................................................................................................................543 TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM (H MODE)..........................................................................................................................555 METHOD OF USING TROUBLESHOOTING CHART........................................................................................................................................556 FAILURE CODE AND CAUSE TABLE.................................................................................................................................................558 H-1 THE MACHINE DOES NOT START...............................................................................................................................................560 H-2 THE TRAVEL SPEED IS SLOW.................................................................................................................................................561 H-3 THE THRUSTING FORCE IS WEAK..............................................................................................................................................562 H-4 ENGINE STALLS WHEN TRAVELING OR ENGINE SPEED DROPS EXCESSIVELY...........................................................................................................563 H-5 THE GEAR IS NOT SHIFTED..................................................................................................................................................564 H-6 THE STEERING WHEEL DOES NOT TURN.........................................................................................................................................565 H-7 THE STEERING WHEEL IS HEAVY..............................................................................................................................................566 H-8 STEERING WHEEL SHAKES OR JERKS...........................................................................................................................................567 H-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING....................................................................................................................567 H-10 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL...........................................................................................................................568 H-11 THE BRAKE IS NOT RELEASED OR IS DRAGGED.................................................................................................................................569 H-12 THE LIFT ARM DOES NOT RISE OR LOWER.....................................................................................................................................570 H-13 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT..................................................................................................571 H-14 WHEN RISING, THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT.......................................................................................................572 H-15 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET (THE BUCKET RISES IN THE AIR).........................................................................................572 H-16 HYDRAULIC DRIFTS OF THE LIFT ARM OCCUR OFTEN............................................................................................................................572 H-17 THE LIFT ARM WOBBLES DURING OPERATION...................................................................................................................................572 H-18 WHEN THE CONTROL LEVER IS SWITCHED FROM"HOLD"TO "RAISE", THE LIFT ARM FALLS TEMPORARILY.................................................................................573 H-19 THE BUCKET DOES NOT TILT BACK...........................................................................................................................................574 H-20 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT.......................................................................................................575 H-21 THE BUCKET COMES TO OPERATE SLOWLY IN HE MIDST OF TILTING-BACK..........................................................................................................576 H-22 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET.........................................................................................................................576 H-23 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN..............................................................................................................................576 H-24 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO(THE WORK EQUIPMENT VALVE IS SET TO"HOLD")...................................................................................577 H-25 WHEN THE CONTROL LEVER IS SWITCHED FROM"HOLD"TO"TILT", THE BUCKET FALLS TEMPORARILY.....................................................................................577 H-26 THE CONTROL LEVERS OF THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY............................................................................................577 H-27 THE TRAVEL DAMPER DOES NOT OPERATE AND MACHINE PITCHES AND BOUNCES......................................................................................................578 TROUBLESHOOTING OF ENGINE (S MODE)...............................................................................................................................................579 METHOD OF USING TROUBLESHOOTING CHARTS.......................................................................................................................................580 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)................................................................................................................584 S-2 ENGINE DOES NOT START....................................................................................................................................................586 (1) ENGINE DOES NOT TURN.................................................................................................................................................586 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED).............................................................................................587 (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...........................................................................................588 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR).....................................................................................................................589 S-4 ENGINE STOPS DURING OPERATIONS...........................................................................................................................................590 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)................................................................................................................................591 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER).....................................................................................................................................592 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...........................................................................................................................593 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)..................................................................................................................594 S-9 OIL BECOMES CONTAMINATED QUICKLY.........................................................................................................................................595 S-10 FUEL CONSUMPTION IS EXCESSIVE...........................................................................................................................................596 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN.................................................................................................597 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)..............................................................................................................598 S-13 OIL LEVEL RISES (WATER,FUEL IN OIL).....................................................................................................................................599 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)........................................................................................................................600 S-15 ABNORMAL NOISE IS MADE..................................................................................................................................................601 S-16 VIBRATION IS EXCESSIVE..................................................................................................................................................602 30 DISASSEMBLY AND ASSEMBLY..............................................................................................................................................................603 HOW TO READ THIS MANUAL..............................................................................................................................................................605 REMOVAL AND INSTALLATION OF ASSEMBLIES...........................................................................................................................................605 DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES...........................................................................................................................................606 PRECAUTIONS WHEN PERFORMING OPERATION................................................................................................................................................607 SPECIAL TOOL LIST....................................................................................................................................................................609 SKETCHES OF SPECIAL TOOLS............................................................................................................................................................612 REMOVAL, INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY................................................................................................................................619 SPECIAL TOOLS....................................................................................................................................................................619 REMOVAL..........................................................................................................................................................................619 INSTALLATION.....................................................................................................................................................................621 REMOVAL, INSTALLATION OF NOZZLE HOLDER ASSEMBLY......................................................................................................................................623 SPECIAL TOOLS....................................................................................................................................................................623 REMOVAL..........................................................................................................................................................................623 INSTALLATION.....................................................................................................................................................................624 REMOVAL, INSTALLATION OF CYLINDER HEAD ASSEMBLY......................................................................................................................................625 SPECIAL TOOLS....................................................................................................................................................................625 REMOVAL..........................................................................................................................................................................625 INSTALLATION.....................................................................................................................................................................630 REMOVAL, INSTALLATION OF ENGINE ASSEMBLY.............................................................................................................................................633 REMOVAL..........................................................................................................................................................................633 INSTALLATION.....................................................................................................................................................................638 REMOVAL, INSTALLATION OF RADIATOR ASSEMBLY...........................................................................................................................................640 REMOVAL..........................................................................................................................................................................640 INSTALLATION.....................................................................................................................................................................641 REMOVAL, INSTALLATION OF AIR AFTERCOOLER.............................................................................................................................................642 REMOVAL..........................................................................................................................................................................642 INSTALLATION.....................................................................................................................................................................643 REMOVAL, INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY...............................................................................................................................644 REMOVAL .........................................................................................................................................................................644 INSTALLATION ....................................................................................................................................................................645 REMOVAL, INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY..........................................................................................................................646 REMOVAL..........................................................................................................................................................................646 INSTALLATION ....................................................................................................................................................................647 REMOVAL, INSTALLATION OF FUEL TANK ASSEMBLY..........................................................................................................................................648 REMOVAL..........................................................................................................................................................................648 INSTALLATION.....................................................................................................................................................................649 REMOVAL, INSTALLATION OF TRANSFER....................................................................................................................................................650 REMOVAL..........................................................................................................................................................................650 INSTALLATION.....................................................................................................................................................................652 DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY...........................................................................................................................................653 SPECIAL TOOLS....................................................................................................................................................................653 DISASSEMBLY......................................................................................................................................................................653 ASSEMBLY.........................................................................................................................................................................661 REMOVAL, INSTALLATION OF PARKING BRAKE ASSEMBLY......................................................................................................................................673 REMOVAL..........................................................................................................................................................................673 INSTALLATION.....................................................................................................................................................................674 DISASSEMBLY, ASSEMBLY OF PARKING BRAKE ASSEMBLY......................................................................................................................................675 SPECIAL TOOLS....................................................................................................................................................................675 DISASSEMBLY......................................................................................................................................................................675 ASSEMBLY.........................................................................................................................................................................677 REMOVAL, INSTALLATION OF FRONT AXLE ASSEMBLY.........................................................................................................................................680 REMOVAL..........................................................................................................................................................................680 INSTALLATION.....................................................................................................................................................................681 REMOVAL, INSTALLATION OF REAR AXLE ASSEMBLY..........................................................................................................................................682 REMOVAL..........................................................................................................................................................................682 INSTALLATION.....................................................................................................................................................................684 DISASSEMBLY, ASSEMBLY OF AXLE HOUSING ASSEMBLY.......................................................................................................................................685 SPECIAL TOOLS....................................................................................................................................................................685 DISASSEMBLY......................................................................................................................................................................685 ASSEMBLY.........................................................................................................................................................................688 DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY.......................................................................................................................................694 SPECIAL TOOLS....................................................................................................................................................................694 DISASSEMBLY......................................................................................................................................................................694 ASSEMBLY.........................................................................................................................................................................703 DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY........................................................................................................................................720 SPECIAL TOOLS LIST...............................................................................................................................................................720 DISASSEMBLY......................................................................................................................................................................720 ASSEMBLY.........................................................................................................................................................................729 DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY.......................................................................................................................................747 SPECIAL TOOLS LIST...............................................................................................................................................................747 DISASSEMBLY......................................................................................................................................................................747 ASSEMBLY.........................................................................................................................................................................756 REMOVAL, INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY.......................................................................................................................763 REMOVAL..........................................................................................................................................................................763 INSTALLATION.....................................................................................................................................................................764 REMOVAL, INSTALLATION OF TRAVEL DAMPER VALVE ASSEMBLY (IF EQUIPPED)..................................................................................................................765 REMOVAL..........................................................................................................................................................................765 INSTALLATION.....................................................................................................................................................................766 REMOVAL, INSTALLATION OF HYDRAULIC TANK ASSEMBLY.....................................................................................................................................767 REMOVAL..........................................................................................................................................................................767 INSTALLATION.....................................................................................................................................................................768 REMOVAL, INSTALLATION OF WORK EQUIPMENT ASSEMBLY.....................................................................................................................................769 REMOVAL..........................................................................................................................................................................769 INSTALLATION.....................................................................................................................................................................772 DISASSEMBLY, ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY.................................................................................................................................776 SPECIAL TOOLS....................................................................................................................................................................776 DISASSEMBLY......................................................................................................................................................................777 ASSEMBLY.........................................................................................................................................................................780 REMOVAL, INSTALLATION OF OPERATOR'S CAB ASSEMBLY.....................................................................................................................................785 REMOVAL..........................................................................................................................................................................785 INSTALLATION.....................................................................................................................................................................788 REMOVAL, INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)..........................................................................................................................789 SPECIAL TOOLS....................................................................................................................................................................789 REMOVAL..........................................................................................................................................................................789 INSTALLATION.....................................................................................................................................................................790 COATING MATERIALS................................................................................................................................................................796 REMOVAL, NSTALLATION OF CENTER HINGE PIN ............................................................................................................................................797 REMOVAL..........................................................................................................................................................................797 INSTALLATION.....................................................................................................................................................................801 REMOVAL, INSTALLATION OF COUNTERWEIGHT...............................................................................................................................................806 REMOVAL..........................................................................................................................................................................806 INSTALLATION ....................................................................................................................................................................807 REMOVAL, INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY...............................................................................................................................808 SPECIAL TOOLS....................................................................................................................................................................808 REMOVAL..........................................................................................................................................................................808 INSTALLATION.....................................................................................................................................................................809 REMOVAL, INSTALLATION OF CONDITIONER COMPRESSOR ASSEMBLY.............................................................................................................................810 SPECIAL TOOLS....................................................................................................................................................................810 REMOVAL..........................................................................................................................................................................810 INSTALLATION.....................................................................................................................................................................810 REMOVAL, INSTALLATION OF MONITOR PANEL...............................................................................................................................................811 REMOVAL..........................................................................................................................................................................811 INSTALLATION.....................................................................................................................................................................814 REMOVAL, INSTALLATION OF HST CONTROLLER ASSEMBLY.....................................................................................................................................815 REMOVAL..........................................................................................................................................................................815 INSTALLATION.....................................................................................................................................................................815 90 OTHERS................................................................................................................................................................................816 HYDRAULIC CIRCUIT DIAGRAM WA250-5....................................................................................................................................................817 HYDRAULIC CIRCUIT DIAGRAM WA250PT-5..................................................................................................................................................818 ELECTRICAL CIRCUIT DIAGRAM 1/4 (1/4) (MACHINES EQUIPPED WITH ROPS CAB)...............................................................................................................819 ELECTRICAL CIRCUIT DIAGRAM 1/4 (2/4) (MACHINES EQUIPPED WITH ROPS CAB)...............................................................................................................820 ELECTRICAL CRICUIT DIAGRAM 1/4 (3/4) (MACHINES EQUIPPED WITH ROPS CAB)...............................................................................................................821 ELECTRICAL CRICUIT DIAGRAM 1/4 (4/4) (MACHINES EQUIPPED WITH ROPS CAB)...............................................................................................................822 ELECTRICAL CIRCUIT DIAGRAM 2/4 (MACHINES EQUIPPED WITH ROPS CAB).....................................................................................................................823 ELECTRICAL CIRCUIT DIAGRAM 3/4 (MACHINES EQUIPPED WITH ROPS CAB).....................................................................................................................824 ELECTRICAL CIRCUIT DIAGRAM 4/4 (MACHINES EQUIPPED WITH ROPS CAB).....................................................................................................................825 ELECTRICAL CIRCUIT DIAGRAM 1/4 (1/4) (MACHINES EQUIPPED WITH ROPS CANOPY.............................................................................................................826 ELECTRICAL CIRCUIT DIAGRAM 1/4 (2/4) (MACHINES EQUIPPED WITH ROPS CANOPY)............................................................................................................827 ELECTRICAL CIRCUIT DIAGRAM 1/4 (3/4) (MACHINE EQUIPPED WITH ROPS CANOPY).............................................................................................................828 ELECTRICAL CIRCUIT DIAGRAM 1/4 (4/4) (MACHINE EQUIPPED WITH ROPS CANOPY).............................................................................................................829 ELECTRICAL CIRCUIT DIAGRAM 2/4 (MACHINES EQUIPPED WITH ROPS CANOPY)..................................................................................................................830 ELECTRICAL CIRCUIT DIAGRAM 3/4 (MACHINES EQUIPPED WITH ROPS CANOPY)..................................................................................................................831 ELECTRICAL CIRCUIT DIAGRAM 4/4 (MACHINES EQUIPPED WITH ROPS CANOPY)..................................................................................................................832
KOMATSU WA250-5, WA250PT-5 WHEEL LOADER SHOP MANUAL SEBM033208 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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