Komatsu WA250-5H, WA250PT-5H Wheel Loader Shop Manual VEBM230102 PDF

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Komatsu WA250-5H, WA250PT-5H Wheel Loader Shop Manual VEBM230102  – PDF DOWNLOAD

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Komatsu WA250-5H, WA250PT-5H Wheel Loader Shop Manual VEBM230102  – PDF DOWNLOAD

Language : English
Pages : 849
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu WA250-5H, WA250PT-5H Wheel Loader Shop Manual VEBM230102  – PDF DOWNLOAD

• MACHINE MODEL                        SERIAL NUMBER
  WA250-5H                                      WA250H50051 and up
  WA250PT-5H                                  WA250H60051 and 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

DESCRIPTION:

Komatsu WA250-5H, WA250PT-5H Wheel Loader Shop Manual VEBM230102  – PDF DOWNLOAD

• MACHINE MODEL                        SERIAL NUMBER
  WA250-5H                                      WA250H50051 and up
  WA250PT-5H                                  WA250H60051 and up

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.

G.B 25/12/24