Komatsu WA250PZ-5 Wheel Loader Shop Manual VEBM945100

Description

• Model List:
  • WA250PZ-5 Wheel Loader

• 1. VEBM945100 WA250PZ5
• 2. SAFETY
• 3. FOREWORD
• 4. GENERAL
• 4.1. GENERAL ASSEMBLY DRAWINGS
• 4.2. SPECIFICATIONS
• 4.3. WEIGHT TABLE
• 4.4. LIST OF LUBRICANT AND COOLANT
• 5. STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
• 5.1. ENGINE MOUNT AND TRANSFER MOUNT
• 5.2. DAMPER
• 5.3. COOLING SYSTEM
• 5.4. POWER TRAIN
• 5.5. POWER TRAIN SYSTEM DIAGRAM
• 5.6. DRIVE SHAFT (PROPELLER SHAFT)
• 5.7. HST HYDRAULIC PIPING DIAGRAM
• 5.8. HST PUMP
• 5.9. HIGHPRESSURE RELIEF VALVE
• 5.10. LOWPRESSURE RELIEF VALVE
• 5.11. HST CHARGE PUMP
• 5.12. SPEEDRELATED VALVE (DA VALVE)
• 5.13. HIGHPRESSURE CUTOFF VALVE
• 5.14. HST MOTOR
• 5.15. EP SERVO VALVE
• 5.16. HA SERVO VALVE
• 5.17. FORWARDREVERSE SHUTTLE VALVE
• 5.18. TRANSFER
• 5.19. TRANSFER OIL COOLER
• 5.20. CLUTCH SOLENOID VALVE
• 5.21. AXLE
• 5.22. DIFFERENTIAL
• 5.23. LIMITEDSLIP DIFFERENTIAL
• 5.23.1. Operation of limitedslip differential
• 5.24. FINAL DRIVE
• 5.25. AXLE MOUNTING AND CENTER HINGE PIN
• 5.26. STEERING PIPING
• 5.27. STEERING COLUMN
• 5.28. PRIORITY VALVE
• 5.29. ORBITROLL VALVE
• 5.30. WAY RESTRICTOR VALVE
• 5.31. STEERING CYLINDER
• 5.32. EMERGENCY STEERING PIPING
• 5.33. EMERGENCY STEERING VALVE
• 5.34. BRAKE PIPING
• 5.35. BRAKE VALVE
• 5.36. INCHING VALVE
• 5.37. CHARGE VALVE
• 5.38. ACCUMULATOR (FOR BRAKE)
• 5.39. SLACK ADJUSTER
• 5.40. BRAKE
• 5.41. PARKING BRAKE CONTROL
• 5.42. PARKING BRAKE
• 5.43. HYDRAULIC PIPING
• 5.44. WORK EQUIPMENT LEVER LINKAGE
• 5.45. HYDRAULIC TANK
• 5.46. GEAR PUMP UNIT
• 5.47. ACCUMULATOR (FOR PPC CIRCUIT)
• 5.48. LOCK VALVE
• 5.49. BYPASS VALVE
• 5.50. VALVE
• 5.51. ACCUMULATOR (FOR E.C.S.S.)
• 5.52. HYDRAULIC PIPING OF COOLING SYSTEM
• 5.53. COOLING FAN MOTOR
• 5.54. WORK EQUIPMENT CONTROL VALVE
• 5.55. WORK EQUIPMENT PPC VALVE
• 5.56. ATTACHMENT PPC VALVE (IF EQUIPPED)
• 5.57. WORK EQUIPMENT LINKAGE
• 5.58. BUCKET
• 5.59. CONTROL OF BUCKET POSITIONER, BOOM KICKOUT
• 5.60. WORK EQUIPMENT CYLINDER
• 5.61. AIR CONDITIONER
• 5.62. MACHINE MONITORING SYSTEM
• 5.63. MACHINE MONITOR
• 5.64. LIST OF ITEMS DISPLAYED ON MONITOR
• 5.65. ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)
• 5.66. HST CONTROLLER
• 5.67. FUNCTION OF SELECTING FORWARDREVERSE SELECTOR SWITCH
• 5.68. ENGINE START CIRCUIT
• 5.69. ENGINE STOP CIRCUIT
• 5.70. PREHEATING CIRCUIT
• 5.71. (AUTOMATIC PREHEATING SYSTEM)
• 5.72. PARKING BRAKE CIRCUIT
• 5.73. ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM
• 5.74. SENSORS
• 6. TESTING AND ADJUSTING
• 6.1. STANDARD VALUE TABLE FOR engine
• 6.2. STANDARD VALUE TABLE FOR CHASSIS
• 6.3. TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
• 6.4. MEASURING ENGINE SPEED
• 6.5. Measuring exhaust gas color
• 6.6. ADJUSTING VALVE CLEARANCE
• 6.7. MEASURING COMPRESSION PRESSURE
• 6.8. MEASURING BLOWBY PRESSURE
• 6.9. TESTING AND ADJUSTING FUEL INJECTION TIMING
• 6.10. MEASURING ENGINE OIL PRESSURE
• 6.11. MEASURING, TESTING OPERATING FORCE OF ACCELERATOR PEDAL
• 6.12. ADJUSTING ENGINE STOP SOLENOID
• 6.13. ADJUSTING ENGINE SPEED SENSOR
• 6.14. MEASURING DIRECTIONAL LEVER
• 6.15. TESTING AND ADJUSTING HST OIL PRESSURE
• 6.16. MEASURING CLUTCH CONTROL PRESSURER
• 6.17. TESTING AND ADJUSTING STEERING WHEEL
• 6.18. TESTING AND ADJUSTING STEERING OIL PRESSURE
• 6.19. BLEEDING AIR FROM STEERING CIRCUIT
• 6.20. TESTING HYDRAULIC FAN
• 6.21. MEASURING BRAKE PEDAL
• 6.22. TESTING AND ADJUSTING BRAKE PEDAL LINKAGE
• 6.23. MEASURING BRAKE PERFORMANCE
• 6.24. TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE
• 6.25. MEASURING BRAKE OIL PRESSURE
• 6.26. MEASURING WEAR OF BRAKE DISC
• 6.27. BLEEDING AIR FROM BRAKE CIRCUIT
• 6.28. MEASURING PARKING BRAKE PERFORMANCE
• 6.29. TESTING AND ADJUSTING PARKING BRAKE LINKAGE
• 6.30. MEASURING PARKING BRAKE RELEASE PRESSURE
• 6.31. MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER
• 6.32. TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE
• 6.33. TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE
• 6.34. BLEEDING AIR
• 6.35. RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
• 6.36. TESTING AND ADJUSTING BUCKET POSITIONER
• 6.37. TESTING AND ADJUSTING OF BOOM KICKOUT
• 6.38. CHECKING PROXIMITY SWITCH ACTUATION DISPLAY LAMP
• 6.39. PROCEDURE FOR CHECKING DIODE
• 6.40. special functions of machine monitor
• 6.41. Flow of modes and functions
• 6.42. Pm CLINIC INSPECTION CHART
• 6.43. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 6.44. SEQUENCE OF EVENTS IN TROUBLESHOOTING
• 6.45. PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
• 6.46. CHECK BEFORE TROUBLESHOOTING
• 6.47. Categories, procedure, and method of using troubleshooting charts
• 6.48. PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING No.
• 6.49. Connection table for connector pin numbers
• 6.50. TADAPTER TABLE
• 6.51. CONNECTOR TYPES AND MOUNTING LOCATIONS
• 6.52. Connector layout drawing
• 6.53. HST controller system diagram
• 6.54. Before troubleshooting code display
• 6.55. Before troubleshooting electrical system
• 6.56. Information contained in troubuleshooting table
• 6.57. Monitor system circuit diagram
• 6.58. Before troubleshooting code display
• 6.59. Before troubleshooting electrical system
• 6.60. Information contained in troubuleshooting table
• 6.61. Electrical system diagram
• 6.62. Parking brake related diagram
• 6.63. Before troubleshooting electrical system
• 6.64. Information contained in troubuleshooting table
• 6.65. Method of using troubleshooting chart
• 6.66. Failure code and cause table
• 6.67. Method of using troubleshooting charts
• 7. DISASSEMBLY AND ASSEMBLY
• 7.1. How to read this manual
• 7.2. Precautions when performing operation
• 7.3. Special tool list
• 7.4. Sketches of special tools
• 7.5. Removal, installation of fuel injection pump assembly
• 7.6. Removal, installation of nozzle holder assembly
• 7.7. Removal, installation of cylinder head assembly
• 7.8. Removal, installation of engine assembly
• 7.9. Removal, installation of radiator assembly
• 7.10. Removal, installation of air aftercooler
• 7.11. Removal, installation of hydraulic oil cooler assembly
• 7.12. Removal, installation of cooling fan and fan motor assembly
• 7.13. Removal, installation of fuel tank assembly
• 7.14. Removal, installation of transfer
• 7.15. Disassembly, assembly of transfer assembly
• 7.16. Removal, installation of parking brake assembly
• 7.17. Disassembly, assembly of parking brake assembly
• 7.18. Removal, installation of front axle assembly
• 7.19. Removal, installation of rear axle assembly
• 7.20. Disassembly, assembly of axle housing assembly
• 7.21. Disassembly, assembly of differential assembly
• 7.22. Removal, installation of HST pump and 4gear pump assembly
• 7.23. Disassembly and assembly of HST pump assembly
• 7.24. Removal, installation of HST motor 1 assembly
• 7.25. Removal, installation of HST motor 2 assembly
• 7.26. Disassembly and assembly of HST motor assembly
• 7.27. Removal, installation of work equipment control valve assembly
• 7.28. Removal, installation of travel damper valve assembly
• 7.29. Removal, installation of hydraulic tank assembly
• 7.30. Removal, installation of work equipment assembly
• 7.31. Disassembly, assembly of hydraulic cylinder assembly
• 7.32. Removal, installation of operators cab assembly
• 7.33. Removal, installation of operators cab glass (Stuck glass)
• 7.34. Removal, installation of center hinge pin
• 7.35. Removal, installation of counterweight
• 7.36. Removal, installation of air conditioner unit assembly
• 7.37. Removal, installation of air conditioner compressor assembly
• 7.38. Removal, installation of monitor panel
• 8. OTHERS
• 8.1. HYDRAULIC CIRCUIT DIAGRAM
• 8.2. ELECTRICAL CIRCUIT DIAGRAM 1/4 (1/4)
• 8.3. ELECTRICAL CIRCUIT DIAGRAM 1/4 (2/4)
• 8.4. ELECTRICAL CIRCUIT DIAGRAM 1/4 (3/4)
• 8.5. ELECTRICAL CIRCUIT DIAGRAM 1/4 (4/4)
• 8.6. ELECTRICAL CIRCUIT DIAGRAM 2/4
• 8.7. ELECTRICAL CIRCUIT DIAGRAM 3/4
• 8.8. ELECTRICAL CIRCUIT DIAGRAM 4/4