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

Description

• Model List:
  • WA250-5H Wheel Loader
  • WA250PT-5H Wheel Loader

• 1. COVER
• 2. FOREWORD
• 3. GENERAL
• 3.1. GENERAL ASSEMBLY DRAWINGS
• 3.2. SPECIFICATIONS
• 3.3. WEIGHT TABLE
• 3.4. LIST OF LUBRICANT AND COOLANT
• 4. STRUCTURE FUNCTION
• 4.1. ENGINE MOUNT AND TRANSFER MOUNT
• 4.2. DAMPER
• 4.3. COOLING SYSTEM
• 4.4. POWER TRAIN
• 4.5. POWER TRAIN SYSTEM DIAGRAM
• 4.6. DRIVE SHAFT (PROPELLER SHAFT)
• 4.7. HST HYDRAULIC PIPING DIAGRAM
• 4.8. HST PUMP
• 4.9. HIGHPRESSURE RELIEF VALVE
• 4.10. LOWPRESSURE RELIEF VALVE
• 4.11. HST CHARGE PUMP
• 4.12. SPEEDRELATED VALVE (DA VALVE)
• 4.13. HIGHPRESSURE CUTOFF VALVE
• 4.14. HST MOTOR
• 4.15. EP SERVO VALVE
• 4.16. HA SERVO VALVE
• 4.17. FORWARDREVERSE SHUTTLE VALVE
• 4.18. TRANSFER
• 4.19. TRANSFER OIL COOLER
• 4.20. CLUTCH SOLENOID VALVE
• 4.21. AXLE
• 4.22. DIFFERENTIAL
• 4.23. LIMITEDSLIP DIFFERENTIAL
• 4.24. FINAL DRIVE
• 4.25. AXLE MOUNTING AND CENTER HINGE PIN
• 4.26. STEERING PIPING
• 4.27. STEERING COLUMN
• 4.28. PRIORITY VALVE
• 4.29. ORBITROLL VALVE
• 4.30. WAY RESTRICTOR VALVE
• 4.31. STEERING CYLINDER
• 4.32. EMERGENCY STEERING PIPING
• 4.33. EMERGENCY STEERING VALVE
• 4.34. BRAKE PIPING
• 4.35. BRAKE VALVE
• 4.36. INCHING VALVE
• 4.37. CHARGE VALVE
• 4.38. ACCUMULATOR (FOR BRAKE)
• 4.39. SLACK ADJUSTER
• 4.40. BRAKE
• 4.41. PARKING BRAKE CONTROL
• 4.42. PARKING BRAKE
• 4.43. HYDRAULIC PIPING
• 4.44. WORK EQUIPMENT LEVER LINKAGE
• 4.45. HYDRAULIC TANK
• 4.46. GEAR PUMP UNIT
• 4.47. ACCUMULATOR (FOR PPC CIRCUIT)
• 4.48. LOCK VALVE
• 4.49. BYPASS VALVE
• 4.50. QUICK COUPLER VALVE
• 4.51. VALVE
• 4.52. ACCUMULATOR (FOR E.C.S.S.)
• 4.53. HYDRAULIC PIPING OF COOLING SYSTEM
• 4.54. COOLING FAN MOTOR
• 4.55. WORK EQUIPMENT CONTROL VALVE
• 4.56. WORK EQUIPMENT PPC VALVE
• 4.57. ATTACHMENT PPC VALVE (IF EQUIPPED)
• 4.58. WORK EQUIPMENT LINKAGE
• 4.59. BUCKET
• 4.60. CONTROL OF BUCKET POSITIONER,
• 4.61. WORK EQUIPMENT CYLINDER
• 4.62. AIR CONDITIONER
• 4.63. MACHINE MONITORING SYSTEM
• 4.64. MACHINE MONITOR
• 4.65. LIST OF ITEMS DISPLAYED ON MONITOR
• 4.66. ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)
• 4.67. HST CONTROLLER
• 4.68. FUNCTION OF SELECTING FORWARDREVERSE SELECTOR SWITCH
• 4.69. ENGINE START CIRCUIT
• 4.70. ENGINE STOP CIRCUIT
• 4.71. PREHEATING CIRCUIT
• 4.72. PARKING BRAKE CIRCUIT
• 4.73. ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM
• 4.74. SENSORS
• 5. TESTING ADJUSTING
• 5.1. STANDARD VALUE TABLE FOR ENGINE
• 5.2. STANDARD VALUE TABLE FOR CHASSIS
• 5.3. TESTING AND ADJUSTING
• 5.4. TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
• 5.5. MEASURING ENGINE SPEED
• 5.6. MEASURING EXHAUST GAS COLOR
• 5.7. ADJUSTING VALVE CLEARANCE
• 5.8. MEASURING COMPRESSION PRESSURE
• 5.9. MEASURING BLOWBY PRESSURE
• 5.10. TESTING AND ADJUSTING FUEL INJECTION TIMING
• 5.11. MEASURING ENGINE OIL PRESSURE
• 5.12. MEASURING, TESTING OPERATING FORCE OF ACCELERATOR PEDAL
• 5.13. ADJUSTING ENGINE STOP SOLENOID
• 5.14. ADJUSTING ENGINE SPEED SENSOR
• 5.15. MEASURING DIRECTIONAL LEVER
• 5.16. TESTING AND ADJUSTING HST OIL PRESSURE
• 5.17. MEASURING CLUTCH CONTROL PRESSURER
• 5.18. TESTING AND ADJUSTING STEERING WHEEL
• 5.19. TESTING AND ADJUSTING STEERING OIL PRESSURE
• 5.20. BLEEDING AIR FROM STEERING CIRCUIT
• 5.21. TESTING HYDRAULIC FAN
• 5.22. MEASURING BRAKE PEDAL
• 5.23. TESTING AND ADJUSTING BRAKE PEDAL LINKAGE
• 5.24. MEASURING BRAKE PERFORMANCE
• 5.25. TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE
• 5.26. MEASURING BRAKE OIL PRESSURER
• 5.27. MEASURING WEAR OF BRAKE DISC
• 5.28. BLEEDING AIR FROM BRAKE CIRCUIT
• 5.29. MEASURING PARKING BRAKE PERFORMANCE
• 5.30. TESTING AND ADJUSTING PARKING BRAKE LINKAGE
• 5.31. MEASURING PARKING BRAKE RELEASE PRESSURE
• 5.32. MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER
• 5.33. TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE
• 5.34. TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE
• 5.35. BLEEDING AIR
• 5.36. RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
• 5.37. TESTING AND ADJUSTING BUCKET POSITIONER
• 5.38. TESTING AND ADJUSTING OF BOOM KICKOUT
• 5.39. CHECKING PROXIMITY SWITCH ACTUATION DISPLAY LAMP
• 5.40. PROCEDURE FOR CHECKING DIODE
• 5.41. SPECIAL FUNCTIONS OF MACHINE MONITOR
• 5.42. FLOW OF MODES AND FUNCTIONS
• 5.43. PM CLINIC INSPECTION CHART
• 5.44. TROUBLESHOOTING
• 5.45. TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)
• 5.46. TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)
• 5.47. TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
• 5.48. TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)
• 5.49. TROUBLESHOOTING OF ENGINE (S MODE)
• 6. DISASSEMBLY ASSEMBLY
• 6.1. HOW TO READ THIS MANUAL
• 6.2. PRECAUTIONS WHEN PERFORMING OPERATION
• 6.3. SPECIAL TOOL LIST
• 6.4. SKETCHES OF SPECIAL TOOLS
• 6.5. REMOVAL, INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY
• 6.6. REMOVAL, INSTALLATION OF NOZZLE HOLDER ASSEMBLY
• 6.7. REMOVAL, INSTALLATION OF CYLINDER HEAD ASSEMBLY
• 6.8. REMOVAL, INSTALLATION OF ENGINE ASSEMBLY
• 6.9. REMOVAL, INSTALLATION OF RADIATOR ASSEMBLY
• 6.10. REMOVAL, INSTALLATION OF AIR AFTERCOOLER
• 6.11. REMOVAL, INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY
• 6.12. REMOVAL, INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY
• 6.13. REMOVAL, INSTALLATION OF FUEL TANK ASSEMBLY
• 6.14. REMOVAL, INSTALLATION OF TRANSFER
• 6.15. DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY
• 6.16. REMOVAL, INSTALLATION OF PARKING BRAKE ASSEMBLY
• 6.17. DISASSEMBLY, ASSEMBLY OF PARKING BRAKE ASSEMBLY
• 6.18. REMOVAL, INSTALLATION OF FRONT AXLE ASSEMBLY
• 6.19. REMOVAL, INSTALLATION OF REAR AXLE ASSEMBLY
• 6.20. DISASSEMBLY, ASSEMBLY OF AXLE HOUSING ASSEMBLY
• 6.21. DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY
• 6.22. REMOVAL, INSTALLATION OF HST PUMP AND 4GEAR PUMP ASSEMBLY
• 6.23. DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
• 6.24. REMOVAL, INSTALLATION OF HST MOTOR 1 ASSEMBLY
• 6.25. REMOVAL, INSTALLATION OF HST MOTOR 2 ASSEMBLY
• 6.26. DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY
• 6.27. REMOVAL, INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY
• 6.28. REMOVAL, INSTALLATION OF TRAVEL DAMPER VALVE ASSEMBLY
• 6.29. REMOVAL, INSTALLATION OF HYDRAULIC TANK ASSEMBLY
• 6.30. REMOVAL, INSTALLATION OF WORK EQUIPMENT ASSEMBLY
• 6.31. DISASSEMBLY, ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
• 6.32. REMOVAL, INSTALLATION OF OPERATORS CAB ASSEMBLY
• 6.33. REMOVAL, INSTALLATION OF OPERATORS CAB GLASS (STUCK GLASS)
• 6.34. REMOVAL, INSTALLATION OF CENTER HINGE PIN
• 6.35. REMOVAL, INSTALLATION OF COUNTERWEIGHT
• 6.36. REMOVAL, INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY
• 6.37. REMOVAL, INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY
• 6.38. REMOVAL, INSTALLATION OF MONITOR PANEL
• 7. OTHERS