KOMATSU WA250PZ-5 SHOP MANUAL VEBM945100 – PDF DOWNLOAD

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KOMATSU WA250PZ-5 SHOP MANUAL VEBM945100 – PDF DOWNLOAD

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KOMATSU WA250PZ-5 SHOP MANUAL VEBM945100 – PDF DOWNLOAD

Language : English
Pages : 830
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

KOMATSU WA250PZ-5 SHOP MANUAL VEBM945100 – PDF DOWNLOAD

VEBM945100 WA250PZ-5.....................................................  1
SAFETY...................................................................  7
FOREWORD.................................................................  9
01 GENERAL............................................................... 27
	GENERAL ASSEMBLY DRAWINGS............................................ 28
	SPECIFICATIONS....................................................... 29
	WEIGHT TABLE......................................................... 33
	LIST OF LUBRICANT AND COOLANT........................................ 35
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD.......................... 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
		Operation of limited-slip differential........................... 86
	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.........................................144
	HYDRAULIC TANK.......................................................148
	4-GEAR PUMP UNIT.....................................................150
	ACCUMULATOR (FOR PPC CIRCUIT)........................................152
	LOCK VALVE...........................................................153
	BYPASS VALVE.........................................................154
	E.C.S.S. VALVE.......................................................157
	ACCUMULATOR (FOR E.C.S.S.)...........................................159
	HYDRAULIC PIPING OF COOLING SYSTEM...................................160
	COOLING FAN MOTOR....................................................161
	WORK EQUIPMENT CONTROL VALVE.........................................163
	WORK EQUIPMENT PPC VALVE.............................................176
	ATTACHMENT PPC VALVE (IF EQUIPPED)...................................188
	WORK EQUIPMENT LINKAGE...............................................192
	BUCKET...............................................................194
	CONTROL OF BUCKET POSITIONER, BOOM KICK-OUT..........................195
	WORK EQUIPMENT CYLINDER..............................................205
	AIR CONDITIONER......................................................207
	MACHINE MONITORING SYSTEM............................................208
	MACHINE MONITOR......................................................218
	LIST OF ITEMS DISPLAYED ON MONITOR...................................219
	ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)............................245
	HST CONTROLLER.......................................................249
	FUNCTION OF SELECTING FORWARD-REVERSE SELECTOR SWITCH................250
	ENGINE START CIRCUIT.................................................252
	ENGINE STOP CIRCUIT..................................................254
	PREHEATING CIRCUIT...................................................255
	(AUTOMATIC PREHEATING SYSTEM)........................................255
	PARKING BRAKE CIRCUIT................................................256
	ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM..........................259
	SENSORS..............................................................260
20 TESTING AND ADJUSTING.................................................267
	STANDARD VALUE TABLE FOR engine......................................268
	STANDARD VALUE TABLE FOR CHASSIS.....................................269
	TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING....................274
	MEASURING ENGINE SPEED...............................................276
	Measuring exhaust gas color..........................................277
	ADJUSTING VALVE CLEARANCE............................................278
	MEASURING COMPRESSION PRESSURE.......................................280
	MEASURING BLOW-BY PRESSURE...........................................281
	TESTING AND ADJUSTING FUEL INJECTION TIMING..........................282
	MEASURING ENGINE OIL PRESSURE........................................283
	MEASURING, TESTING OPERATING FORCE OF ACCELERATOR PEDAL..............284
	ADJUSTING ENGINE STOP SOLENOID.......................................286
	ADJUSTING ENGINE SPEED SENSOR........................................287
	MEASURING DIRECTIONAL LEVER..........................................288
	TESTING AND ADJUSTING HST OIL PRESSURE...............................289
	MEASURING CLUTCH CONTROL PRESSURER...................................294
	TESTING AND ADJUSTING STEERING WHEEL.................................295
	TESTING AND ADJUSTING STEERING OIL PRESSURE..........................297
	BLEEDING AIR FROM STEERING CIRCUIT...................................298
	TESTING HYDRAULIC FAN................................................299
	MEASURING BRAKE PEDAL................................................300
	TESTING AND ADJUSTING BRAKE PEDAL LINKAGE............................301
	MEASURING BRAKE PERFORMANCE..........................................302
	TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE....................303
	MEASURING BRAKE OIL PRESSURE.........................................304
	MEASURING WEAR OF BRAKE DISC.........................................306
	BLEEDING AIR FROM BRAKE CIRCUIT......................................307
	MEASURING PARKING BRAKE PERFORMANCE..................................308
	TESTING AND ADJUSTING PARKING BRAKE LINKAGE..........................309
	MEASURING PARKING BRAKE RELEASE PRESSURE.............................310
	MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER.................311
	TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE..............312
	TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE................313
	BLEEDING AIR.........................................................315
	RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT....................316
	TESTING AND ADJUSTING BUCKET POSITIONER..............................317
	TESTING AND ADJUSTING OF BOOM KICK-OUT...............................318
	CHECKING PROXIMITY SWITCH ACTUATION DISPLAY LAMP.....................319
	PROCEDURE FOR CHECKING DIODE.........................................320
	special functions of machine monitor.................................321
	Flow of modes and functions..........................................322
	Pm CLINIC INSPECTION CHART...........................................340
	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...........................360
	T-ADAPTER TABLE......................................................381
	CONNECTOR TYPES AND MOUNTING LOCATIONS...............................385
	Connector layout drawing.............................................392
	HST controller system diagram........................................398
	Before troubleshooting code display..................................400
	Before troubleshooting electrical system.............................401
	Information contained in troubuleshooting table......................402
	Monitor system circuit diagram.......................................430
	Before troubleshooting code display..................................434
	Before troubleshooting electrical system.............................435
	Information contained in troubuleshooting table......................436
	Electrical system diagram............................................486
	Parking brake related diagram........................................490
	Before troubleshooting electrical system.............................492
	Information contained in troubuleshooting table......................494
	Method of using troubleshooting chart................................554
	Failure code and cause table.........................................556
	Method of using troubleshooting charts...............................578
30 DISASSEMBLY AND ASSEMBLY..............................................601
	How to read this manual..............................................603
	Precautions when performing operation................................605
	Special tool list....................................................607
	Sketches of special tools............................................610
	Removal, installation of fuel injection pump assembly................616
	Removal, installation of nozzle holder assembly......................620
	Removal, installation of cylinder head assembly......................622
	Removal, installation of engine assembly.............................630
	Removal, installation of radiator assembly...........................637
	Removal, installation of air aftercooler.............................639
	Removal, installation of hydraulic oil cooler assembly...............641
	Removal, installation of cooling fan and fan motor assembly..........643
	Removal, installation of fuel tank assembly..........................645
	Removal, installation of transfer....................................647
	Disassembly, assembly of transfer assembly...........................650
	Removal, installation of parking brake assembly......................670
	Disassembly, assembly of parking brake assembly......................672
	Removal, installation of front axle assembly.........................677
	Removal, installation of rear axle assembly..........................679
	Disassembly, assembly of axle housing assembly.......................682
	Disassembly, assembly of differential assembly.......................691
	Removal, installation of HST pump and 4-gear pump assembly...........717
	Disassembly and assembly of HST pump assembly........................720
	Removal, installation of HST motor 1 assembly........................746
	Removal, installation of HST motor 2 assembly........................747
	Disassembly and assembly of HST motor assembly.......................748
	Removal, installation of work equipment control valve assembly.......764
	Removal, installation of travel damper valve assembly................766
	Removal, installation of hydraulic tank assembly.....................768
	Removal, installation of work equipment assembly.....................770
	Disassembly, assembly of hydraulic cylinder assembly.................777
	Removal, installation of operator's cab assembly.....................783
	Removal, installation of operator's cab glass (Stuck glass)..........787
	Removal, installation of center hinge pin............................795
	Removal, installation of counterweight...............................804
	Removal, installation of air conditioner unit assembly...............806
	Removal, installation of air conditioner compressor assembly.........808
	Removal, installation of monitor panel...............................809
90 OTHERS................................................................813
	HYDRAULIC CIRCUIT DIAGRAM............................................815
	ELECTRICAL CIRCUIT DIAGRAM 1/4 (1/4).................................817
	ELECTRICAL CIRCUIT DIAGRAM 1/4 (2/4).................................819
	ELECTRICAL CIRCUIT DIAGRAM 1/4 (3/4).................................821
	ELECTRICAL CIRCUIT DIAGRAM 1/4 (4/4).................................823
	ELECTRICAL CIRCUIT DIAGRAM 2/4.......................................825
	ELECTRICAL CIRCUIT DIAGRAM 3/4.......................................827
	ELECTRICAL CIRCUIT DIAGRAM 4/4.......................................829

DESCRIPTION:

KOMATSU WA250PZ-5 SHOP MANUAL VEBM945100 – PDF DOWNLOAD

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.

S.S 26/12/24