KOMATSU WA250-5H WA250PT-5H SERVICE REPAIR MANUAL (SN:WA250H50051 and up,WA250H60051and up) – PDF DOWNLOAD

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KOMATSU WA250-5H WA250PT-5H SERVICE REPAIR MANUAL (SN:WA250H50051 and up,WA250H60051and up)

KOMATSU WA250-5H WA250PT-5H SERVICE REPAIR MANUAL (SN:WA250H50051 AND UP,WA250H60051AND UP) – PDF DOWNLOAD:

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KOMATSU WA250-5H WA250PT-5H SERVICE REPAIR MANUAL (SN:WA250H50051 and up,WA250H60051and up)

• 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 WA250-5H WA250PT-5H SERVICE REPAIR MANUAL (SN:WA250H50051 and up,WA250H60051and up)

COVER.................................................................  1
FOREWORD..............................................................  9
01 GENERAL............................................................ 27
	GENERAL ASSEMBLY DRAWINGS......................................... 28
	SPECIFICATIONS.................................................... 29
	WEIGHT TABLE...................................................... 33
	LIST OF LUBRICANT AND COOLANT..................................... 35
10 STRUCTURE & FUNCTION............................................... 37
	ENGINE MOUNT AND TRANSFER MOUNT................................... 38
	DAMPER............................................................ 39
	COOLING SYSTEM.................................................... 40
	POWER TRAIN....................................................... 41
	POWER TRAIN SYSTEM DIAGRAM........................................ 42
	DRIVE SHAFT (PROPELLER SHAFT)..................................... 44
	HST HYDRAULIC PIPING DIAGRAM...................................... 45
	HST PUMP.......................................................... 46
	HIGH-PRESSURE RELIEF VALVE........................................ 48
	LOW-PRESSURE RELIEF VALVE......................................... 50
	HST CHARGE PUMP................................................... 51
	SPEED-RELATED VALVE (DA VALVE).................................... 52
	HIGH-PRESSURE CUT-OFF VALVE....................................... 53
	HST MOTOR......................................................... 54
	EP SERVO VALVE.................................................... 57
	HA SERVO VALVE.................................................... 58
	FORWARD-REVERSE SHUTTLE VALVE..................................... 59
	TRANSFER.......................................................... 60
	TRANSFER OIL COOLER............................................... 71
	CLUTCH SOLENOID VALVE............................................. 72
	AXLE.............................................................. 73
	DIFFERENTIAL...................................................... 76
	LIMITED-SLIP DIFFERENTIAL......................................... 82
	FINAL DRIVE....................................................... 88
	AXLE MOUNTING AND CENTER HINGE PIN................................ 94
	STEERING PIPING................................................... 99
	STEERING COLUMN...................................................100
	PRIORITY VALVE....................................................101
	ORBIT-ROLL VALVE..................................................104
	2-WAY RESTRICTOR VALVE............................................112
	STEERING CYLINDER.................................................113
	EMERGENCY STEERING PIPING.........................................115
	EMERGENCY STEERING VALVE..........................................116
	BRAKE PIPING......................................................119
	BRAKE VALVE.......................................................120
	INCHING VALVE.....................................................124
	CHARGE VALVE......................................................126
	ACCUMULATOR (FOR BRAKE)...........................................130
	SLACK ADJUSTER....................................................131
	BRAKE.............................................................134
	PARKING BRAKE CONTROL.............................................139
	PARKING BRAKE.....................................................140
	HYDRAULIC PIPING..................................................142
	WORK EQUIPMENT LEVER LINKAGE......................................146
	HYDRAULIC TANK....................................................150
	4-GEAR PUMP UNIT..................................................152
	ACCUMULATOR (FOR PPC CIRCUIT).....................................154
	LOCK VALVE........................................................155
	BYPASS VALVE......................................................156
	QUICK COUPLER VALVE...............................................162
	E.C.S.S. VALVE....................................................163
	ACCUMULATOR (FOR E.C.S.S.)........................................165
	HYDRAULIC PIPING OF COOLING SYSTEM................................166
	COOLING FAN MOTOR.................................................167
	WORK EQUIPMENT CONTROL VALVE......................................169
	WORK EQUIPMENT PPC VALVE..........................................182
	ATTACHMENT PPC VALVE (IF EQUIPPED)................................194
	WORK EQUIPMENT LINKAGE............................................198
	BUCKET............................................................202
	CONTROL OF BUCKET POSITIONER,.....................................204
	WORK EQUIPMENT CYLINDER...........................................218
	AIR CONDITIONER...................................................222
	MACHINE MONITORING SYSTEM.........................................223
	MACHINE MONITOR...................................................233
	LIST OF ITEMS DISPLAYED ON MONITOR................................234
	ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM).........................260
	HST CONTROLLER....................................................264
	FUNCTION OF SELECTING FORWARD-REVERSE SELECTOR SWITCH.............265
	ENGINE START CIRCUIT..............................................267
	ENGINE STOP CIRCUIT...............................................269
	PREHEATING CIRCUIT................................................270
	PARKING BRAKE CIRCUIT.............................................271
	ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM.......................274
	SENSORS...........................................................275
20 TESTING & ADJUSTING................................................281
	STANDARD VALUE TABLE FOR ENGINE...................................282
	STANDARD VALUE TABLE FOR CHASSIS..................................283
	TESTING AND ADJUSTING.............................................287
	TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.................288
	MEASURING ENGINE SPEED............................................290
	MEASURING EXHAUST GAS COLOR.......................................291
	ADJUSTING VALVE CLEARANCE.........................................292
	MEASURING COMPRESSION PRESSURE....................................294
	MEASURING BLOW-BY PRESSURE........................................295
	TESTING AND ADJUSTING FUEL INJECTION TIMING.......................296
	MEASURING ENGINE OIL PRESSURE.....................................297
	MEASURING, TESTING OPERATING FORCE OF ACCELERATOR PEDAL...........298
	ADJUSTING ENGINE STOP SOLENOID....................................300
	ADJUSTING ENGINE SPEED SENSOR.....................................301
	MEASURING DIRECTIONAL LEVER.......................................302
	TESTING AND ADJUSTING HST OIL PRESSURE............................303
	MEASURING CLUTCH CONTROL PRESSURER................................308
	TESTING AND ADJUSTING STEERING WHEEL..............................309
	TESTING AND ADJUSTING STEERING OIL PRESSURE.......................311
	BLEEDING AIR FROM STEERING CIRCUIT................................312
	TESTING HYDRAULIC FAN.............................................313
	MEASURING BRAKE PEDAL.............................................314
	TESTING AND ADJUSTING BRAKE PEDAL LINKAGE.........................315
	MEASURING BRAKE PERFORMANCE.......................................316
	TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE.................317
	MEASURING BRAKE OIL PRESSURER.....................................318
	MEASURING WEAR OF BRAKE DISC......................................320
	BLEEDING AIR FROM BRAKE CIRCUIT...................................321
	MEASURING PARKING BRAKE PERFORMANCE...............................322
	TESTING AND ADJUSTING PARKING BRAKE LINKAGE.......................323
	MEASURING PARKING BRAKE RELEASE PRESSURE..........................324
	MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER..............325
	TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE...........326
	TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE.............327
	BLEEDING AIR......................................................329
	RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT.................330
	TESTING AND ADJUSTING BUCKET POSITIONER...........................331
	TESTING AND ADJUSTING OF BOOM KICK-OUT............................332
	CHECKING PROXIMITY SWITCH ACTUATION DISPLAY LAMP..................333
	PROCEDURE FOR CHECKING DIODE......................................334
	SPECIAL FUNCTIONS OF MACHINE MONITOR..............................335
	FLOW OF MODES AND FUNCTIONS.......................................336
	PM CLINIC INSPECTION CHART........................................354
	TROUBLESHOOTING...................................................357
	TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)...............411
	TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)...............443
	TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE).....................499
	TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)..........569
	TROUBLESHOOTING OF ENGINE (S MODE)................................593
30 DISASSEMBLY & ASSEMBLY.............................................617
	HOW TO READ THIS MANUAL...........................................619
	PRECAUTIONS WHEN PERFORMING OPERATION.............................621
	SPECIAL TOOL LIST.................................................623
	SKETCHES OF SPECIAL TOOLS.........................................626
	REMOVAL, INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY.............632
	REMOVAL, INSTALLATION OF NOZZLE HOLDER ASSEMBLY...................636
	REMOVAL, INSTALLATION OF CYLINDER HEAD ASSEMBLY...................638
	REMOVAL, INSTALLATION OF ENGINE ASSEMBLY..........................646
	REMOVAL, INSTALLATION OF RADIATOR ASSEMBLY........................653
	REMOVAL, INSTALLATION OF AIR AFTERCOOLER..........................655
	REMOVAL, INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY............657
	REMOVAL, INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY.......659
	REMOVAL, INSTALLATION OF FUEL TANK ASSEMBLY.......................661
	REMOVAL, INSTALLATION OF TRANSFER.................................663
	DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY........................666
	REMOVAL, INSTALLATION OF PARKING BRAKE ASSEMBLY...................686
	DISASSEMBLY, ASSEMBLY OF PARKING BRAKE ASSEMBLY...................688
	REMOVAL, INSTALLATION OF FRONT AXLE ASSEMBLY......................693
	REMOVAL, INSTALLATION OF REAR AXLE ASSEMBLY.......................695
	DISASSEMBLY, ASSEMBLY OF AXLE HOUSING ASSEMBLY....................698
	DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY....................707
	REMOVAL, INSTALLATION OF HST PUMP AND 4-GEAR PUMP ASSEMBLY........733
	DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY.....................736
	REMOVAL, INSTALLATION OF HST MOTOR 1 ASSEMBLY.....................762
	REMOVAL, INSTALLATION OF HST MOTOR 2 ASSEMBLY.....................763
	DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY....................764
	REMOVAL, INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY....780
	REMOVAL, INSTALLATION OF TRAVEL DAMPER VALVE ASSEMBLY.............782
	REMOVAL, INSTALLATION OF HYDRAULIC TANK ASSEMBLY..................784
	REMOVAL, INSTALLATION OF WORK EQUIPMENT ASSEMBLY..................786
	DISASSEMBLY, ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY..............793
	REMOVAL, INSTALLATION OF OPERATOR'S CAB ASSEMBLY..................801
	REMOVAL, INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS).......805
	REMOVAL, INSTALLATION OF CENTER HINGE PIN.........................813
	REMOVAL, INSTALLATION OF COUNTERWEIGHT............................822
	REMOVAL, INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY............824
	REMOVAL, INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY......826
	REMOVAL, INSTALLATION OF MONITOR PANEL............................827
90 OTHERS.............................................................831

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