Komatsu WA250-1LC Wheel Loader Shop Manual

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Komatsu WA250-1LC Wheel Loader Shop Manual (A65001 and up) – CEBMW18020

This complete service repair workshop manual PDF download for the Komatsu WA250-1LC Wheel Loader (SN: A65001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.

APPLICABLE MODELS :

Machine Model : WA250-1LC
Serial Numbers : A65001 and up

TABLE OF CONTENTS :

10 ENGINE
20 POWER TRAIN
40 STEERING SYSTEM
50 BRAKE AND AIR SYSTEM
60 WORK EQUIPMENT SYSTEM
80 ELECTRIC AND ELECTRONIC SYSTEM
90 OTHERS

– STRUCTURE AND FUNCTION
– TESTING AND ADJUSTING
– DISASSEMBLY AND ASSEMBLY
– MAINTENANCE STANDARD

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : CEBMW18020
Total Pages : 648

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10 ENGINE
12 TESTING AND ADJUSTING
STANDARD VALUE TABLE
ENGINE ON TEST BENCH
ENGINE ON CHASSIS
TOOL LIST
VALVE CLEARANCE
FUEL INJECTION TIMING
ENGINE OIL PRESSURE
ENGINE OIL TEMPERATURE
BLOW-BY PRESSURE
EXHAUST GAS COLOR
ACCELERATOR PEDAL
OPERATING FORCE
OPERATING ANGLE
13 DISASSEMBLY AND ASSEMBLY
NOZZLE HOLDER ASSEMBLY
REMOVAL
INSTALLATION
CYLINDER HEAD ASSEMBLY
REMOVAL
INSTALLATION
RADIATOR
REMOVAL
INSTALLATION
ENGINE
REMOVAL
INSTALLATION
FUEL TANK
REMOVAL
INSTALLATION

20 POWER TRAIN
21 STRUCTURE AND FUNCTION
GENERAL
HYDRAULIC CIRCUIT FOR POWER TRAIN
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN
TORQUE CONVERTER AND TRANSMISSION PIPING
TORQUE CONVERTER CHARGING PUMP
SPECIFICATIONS
OUTLINE
TORQUE CONVERTER
SPECIFICATIONS
OUTLINE
TORQUE CONVERTER OIL FILTER
TORQUE CONVERTER OIL COOLER AND RADIATOR
TORQUEFLOW TRANSMISSION
CLUTCH PACK
FORWARD AND REVERSE CLUTCH
1ST AND 3RD CLUTCH
2ND AND 4TH CLUTCH
OPERATION OF CLUTCH
FORWARD 1ST
FORWARD 2ND
FORWARD 3RD
FORWARD 4TH
REVERSE 1ST
TRANSMISSION CONTROL VALVE
TRANSMISSION SOLENOID VALVE
UPPER VALVE
LOWER VALVE
TORQUE CONVERTER OUTLET VALVE
PILOT REDUCING VALVE
TRANSMISSION SOLENOID VALVE
PRIORITY AND MAIN REGULATOR VALVE
MAIN REGULATOR VALVE
MODULATING RELIEF VALVE
ACCUMULATOR VALVE
QUICK RETURN VALVE
EMERGENCY MANUAL SPOOL
FORWARD 1ST
DIRECTIONAL SPOOL
FILL VALVE
PILOT OIL FILTER
DRIVE SHAFT
AXLE
FRONT
REAR
DIFFERENTIAL
FRONT
REAR
TORQUE PROPORTIONING
FINAL DRIVE
AXLE MOUNT
TIRE AND WHEEL
22 TESTING AND ADJUSTING
STANDARD VALUE TABLE
ENGINE STALL SPEED
OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION
SHIFT LEVER
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL
TIRE AND WHEEL
TROUBLESHOOTING
PREVENTING RECURRENCE OF TROUBLE
METHOD OF READING TROUBLESHOOTING TABLE
CHECKS BEFORE TROUBLESHOOTING
METHOD OF LOCATING MAIN PROBLEM POINTS WHEN TROUBLESHOOTING TRANSMISSION SYSTEM
TROUBLESHOOTING TABLE
TORQUE CONVERTER AND TRANSMISSION
1. Machine does not move off.
2. Machine speed is low, thrust is weak, grade-ability falls off.
3. Large shock when moving off or changing gear.
4. Large time lag when moving off or changing gear.
5. Oil temperature in torque converter is high.
23 DISASSEMBLY AND ASSEMBLY
TORQUE CONVERTER CHARGING PUMP
REMOVAL
INSTALLATION
TRANSMISSION, TORQUE CONVERTER
REMOVAL
INSTALLATION
TORQUE CONVERTER
DISASSEMBLY
ASSEMBLY
TRANSMISSION
DISASSEMBLY
ASSEMBLY
CLUTCH PACK
DISASSEMBLY
FORWARD-REVERSE CLUTCH PACK
1ST -3RD SPEED CLUTCH PACK
2ND-4TH SPEED CLUTCH PACK
ASSEMBLY
FORWARD-REVERSE CLUTCH PACK
1ST-3RD SPEED CLUTCH PACK
2ND-4TH SPEED CLUTCH PACK
TRANSMISSION CONTROL VALVE
REMOVAL
INSTALLATION
TRANSMISSION SOLENOID VALVE
DISASSEMBLY
ASSEMBLY
DRIVE SHAFT
DISASSEMBLY
ASSEMBLY
FRONT AXLE
REMOVAL
INSTALLATION
REAR AXLE
REMOVAL
INSTALLATION
DIFFERENTIAL
DISASSEMBLY
ASSEMBLY
AXLE HOUSING
DISASSEMBLY
ASSEMBLY
24 MAINTENANCE STANDARD
ENGINE AND TRANSMISSION MOUNT
TORQUE CONVERTER CHARGING PUMP
TORQUE CONVERTER
TRANSMlSSlON
TRANSMISSION CLUTCH
UPPER VALVE
LOWER VALVE
SOLENOID VALVE
AXLE
DIFFERENTIAL
FINAL DRIVE
DRIVE SHAFT
AXLE MOUNT

40 STEERING SYSTEM
41 STRUCTURE AND FUNCTION
STEERING PIPING
HYDRAULIC CIRCUIT FOR STEERING
HYDRAULIC CIRCUIT DIAGRAM FOR STEERING
TWO-WAY RESTRICTOR VALVE
STEERING VALVE
CONNECTION OF HAND PUMP AND SLEEVE
PRIORITY VALVE
STEERING COLUMN
STEERING CYLINDER
CENTER HINGE PIN
42 TESTING AND ADJUSTING
STANDARD VALUE TABLE
TOOL LIST
STEERING WHEEL PLAY
OPERATING FORCE OF STEERING WHEEL
OPERATING TIME OF STEERING WHEEL
STEERING OIL PRESSURE
TROUBLESHOOTING
TROUBLESHOOTING TABLE
1. Steering wheel does not turn.
2. Steering wheel is sluggish.
3. Steering wheel moves unsteadily or is subjected to large shock.
4. Machine tends to turn naturally in one particular direction when traveling.
5. Left and right turning radii are different.
43 DISASSEMBLY AND ASSEMBLY
STEERING VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
PRIORITY VALVE
REMOVAL
INSTALLATION
STEERING CYLINDER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
CENTER HINGE PIN REMOVAL
REMOVAL
INSTALLATION
44 MAINTENANCE STANDARD
HYDRAULIC AND STEERING PUMP
STEERING CYLINDER MOUNT
CENTER HINGE PIN
STEERING COLUMN AND GEAR BOX
PRIORITY VALVE

50 BRAKE AND AIR SYSTEM
51 STRUCTURE AND FUNCTION
BRAKE PIPING
POWER MASTER CYLINDER
BRAKE
PARKING BRAKE CONTROL
PARKING BRAKE
OPERATION OF PARKING BRAKE
BRAKE CALIPER
52 TESTING AND ADJUSTING
STANDARD VALUE TABLE
TOOL LIST
MEASURING BRAKE PEDAL
BRAKE PEDAL LINKAGE
BRAKE PERFORMANCE
BRAKE PISTON LEAKAGE
BRAKE DISC WEAR
AIR BLEEDING FROM BRAKE CIRCUIT
PARKING BRAKE PERFORMANCE
PARKING BRAKE
CHECKING
ADJUSTING
MEASURING CLEARANCE
TROUBLESHOOTING
TROUBLESHOOTING TABLES
1. Brake is ineffective or not very effective.
2. Brake cannot be released or drags.
53 DISASSEMBLY AND ASSEMBLY
POWER MASTER CYLINDER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
PARKING BRAKE
REMOVAL
lNSTALLATION
PARKING BRAKE PAD
REMOVAL
INSTALLATION
54 MAINTENANCE STANDARD
POWER MASTER CYLINDER
BRAKE
PARKING BRAKE

60 WORK EQUIPMENT SYSTEM
61 STRUCTURE AND FUNCTION
HYDRAULIC PIPING
HYDRAULIC CIRCUIT
HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIPMENT LEVER LINKAGE
BUCKET LINKAGE
BUCKET POSITIONER AND BOOM KICK-OUT
HYDRAULIC TANK
OIL FILTER BYPASS VALVE
BREATHER
HYDRAULIC AND STEERING PUMPS
MAIN CONTROL VALVE
RELIEF VALVE
SAFElY VALVE W/SUCTION VALVE
As a safety valve
As a suction valve
SUCTION VALVE
LIFT AND DUMP SPOOLS AT “NEUTRAL POSITION”
LIFT SPOOL AT “RAISE POSITION”
LIFT SPOOL AT “LOWER POSITION”
LIFT SPOOL AT “FLOAT POSITION”
DUMP SPOOL AT “TILT BACK POSITION”
DUMP SPOOL AT DUMP “POSITION”
HYDRAULIC CYLINDER
62 TESTING AND ADJUSTING
STANDARD VALUE TABLE
DUMP AND LIFT CONTROL LEVERS
HYDRAULIC PRESSURE
LIFT ARM AND BUCKET
HYDRAULIC DRIFT OF LIFT ARM AND BUCKET
BUCKET POSITIONER
BOOM KICK-OUT
TROUBLESHOOTING
TROUBLESHOOTING TABLES
1. Lift arm does not rise.
2. Lift arm moves slowly or does not have sufficient lifting power.
3. Lift arm movement becomes slow after it reaches a certain height.
4. Bucket cannot be held down with lift arm cylinder
5. Lift arm has large hydraulic drift.
6. Lift arm movement is unsteady during work.
7. Lift arm descends momentarily when control lever is shifted from “Hold to Raise”
8. Bucket does not tilt back.
9. Bucket moves slowly or has insufficient tilt back power.
10. Bucket movement becomes slow during tilt back.
11. Bucket cannot be held down by the bucket cylinder.
12. Bucket has large hydraulic drift.
13. Bucket moves unsteadily when machine travels under load. (Main control valve in “Hold”).
14. Bucket dumps momentarily when control lever is shifted from “Hold to Tilt back.”
15. Control levers of lift arm and dump move stiffly and sluggishly.
63 DISASSEMBLY AND ASSEMBLY
HYDRAULIC TANK
REMOVAL
INSTALLATION
HYDRAULIC FILTER
REMOVAL
INSTALLATION
HYDRAULIC, STEERING PUMP
REMOVAL
INSTALLATION
MAIN CONTROL VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
DUMP CYLINDER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
LIFT CYLINDER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
WORK EQUIPMENT
REMOVAL
INSTALLATION
COUNTERWEIGHT
REMOVAL
INSTALLATION
64 STRUCTURE AND FUNCTION
HYDRAULIC AND STEERING PUMP
MAIN CONTROL VALVE
DUMP CYLINDER
LIFT CYLINDER
BUCKET LINKAGE
BUCKET POSITIONER AND BOOM KICK-OUT
BUCKET

80 ELECTRIC AND ELECTRONIC SYSTEM
81 STRUCTURE AND FUNCTION
ELECTRICAL WIRING CIRCUIT DlAGRAMS
ENGINE STARTING CIRCUIT
ENGINE STOP CIRCUIT
COMBINATION SWITCH
ELECTRICAL TRANSMISSION CONTROL
TRANSMISSION CUT-OFF SELECTOR SWITCH
NEUTRALIZER RELAY
ELECTRONIC VEHICLE MONITORING SYSTEM (RIMS)
MONITOR PANEL
INDICATION ON MONITOR PANEL
WIRING HARNESS
SENSORS
ENGINE OIL LEVEL SENSOR
COOLANT LEVEL SENSOR
BRAKE OIL LEVEL SENSOR
FUEL GAUGE SENSOR
COOLANT TEMPERATURE SENSOR
TORQUE CONVERTER OIL TEMPERATURE SENSOR
ENGINE OIL PRESSURE SENSOR
ROTATIONAL SPEED SENSOR
PROXIMITY SWITCH
82 TESTING AND ADJUSTING
ADJUSTING SPEEDOMETER MODULE
TROUBLESHOOTING
ELECTRICAL CIRCUIT SYSTEM
1. ENGINE STARTING CIRCUIT SYSTEM
2. ENGINE STOP CIRCUIT SYSTEM
3. TRANSMISSION CONTROL AND PARKING BRAKE SYSTEM
CONNECTION TABLE FOR CONNECTOR PIN NUMBER CONNECT1
PRECAUTION WHEN HANDLING CONNECTOR
METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART
ELECTRICAL SCHEMATIC
CHECKS BEFORE TROUBLESHOOTING
TROUBLESHOOTING CHARTS FOR ELECTRIC SYSTEM
POSITION OF CONNECTORS
E-1 ENGINE DOES NOT START.
E-2 ENGINE DOES NOT STOP.
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING.
E-4 TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED. (TRANSMISSION CUT-OFF NORMAL)
E-5 MACHINE MOVES IN REVERSE BUT NOT IN FORWARD.
E-6 MACHINE MOVES NEITHER IN FORWARD NOR REVERSE.
E-7 MACHINE MOVES IN FORWARD BUT NOT IN REVERSE.
E-8 MACHINE MOVES FORWARD EVEN WHEN
E-9 MACHINE MOVES IN REVERSE EVEN WHEN TRANSMISSION CONTROL LEVERS ARE IN NEUTRAL.
E-10 MACHINE ALWAYS TRAVELS IN 2ND.
E-11 TRANSMISSION DOES NOT CHANGE GEAR (But F-R changeable).
E-12 TRANSMISSION CANNOT BE CUT-OFF EVEN WHEN L.H. BRAKE PEDAL IS DEPRESSED WITH
E-13 TRANSMISSION DOES NOT RETURN TO NEUTRAL.
TROUBLESHOOTING CHARTS FOR ELECTRONIC VEHICLE MONITORING SYSTEM
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS) SCHEMATIC
POSITION OF CONNECTORS
M-1 EVEN WHEN ENGINE IS STOPPED, (BRAKE OIL LEVEL) FLASHES.
M-2 EVEN WHEN ENGINE IS STOPPED, (ENGINE OIL LEVEL) FLASHES.
M-3 EVEN WHEN ENGINE IS STOPPED, (COOLANT LEVEL) FLASHES.
M-4 (BATTERY CHARGE) FLASHES WHEN ENGINE IS RUNNING.
M-5 (FUEL LEVEL) FLASHES.
M-6 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, (BRAKE OIL LEVEL)
M-7 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, (ENGINE OIL PRESSURE)
M-8 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, (COOLANT LEVEL)
M-9 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, (BRAKE SERVO PRESSURE)
M-10 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, (COOLANT TEMPERATURE)
M-11 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, (TORQUE CONVERTER OIL TEMPERATURE)
M-12 (PARKING BRAKE) LIGHTS UP OR DOES NOT LIGHT UP.
M-13 (WORKING LAMP) LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP.
M-14 NOT USED
M-15 (FAILURE IN MAIN STEERING) LIGHTS UP OR DOES NOT LIGHT UP (IF EQUIPPED).
M-16 (EMERGENCY STEERING NORMAL) LIGHTS UP OR DOES NOT LIGHT UP (IF EQUIPPED).
M-17 (TRANSMISSION CUT-OFF) LIGHTS UP OR DOES NOT LIGHT UP.
M-18 TURN SIGNAL LAMPS, HIGH BEAM LIGHT UP OR DO NOT LIGHT UP.
M-19 SPEEDOMETER DISPLAY DOES NOT WORK.
M-20 SERVICEMETER DOES NOT WORK NORMALLY.
M-21 ALL OR PART OF MONITOR PANEL DOES NOT WORK.
M-22 EVEN WHEN ENGINE IS STOPPED, (BATTERY CHARGE) FLASHES, OR (ENGINE OIL PRESSURE) FLASHES.
M-23 NO LAMPS ON MONITOR LIGHT UP (IMMEDIATELY AFTER TURNING STARTING SWITCH TO ON, ENGINE STOPPED).
M-24 CENTRAL WARNING LAMP DOES NOT GO OUT.
M-25 CENTRAL WARNING BUZZER DOES NOT STOP.
M-26 NONE OF PANEL LAMPS ON MACHINE MONITOR LIGHT UP.
M-27 SOME OF PANEL LAMPS ON MACHINE MONITOR DO NOT LIGHT UP.
M-28 EMERGENCY ITEM IS FLASHING, BUT ALARM BUZZER DOES NOT SOUND.
M-29 EMERGENCY ITEM OR NON-EMERGENCY ITEM IS FLASHING, BUT WARNING LAMP DOES NOT FLASH.
M-30 ABNORMALITY IN (FUEL GAUGE).
M-31 ABNORMALITY IN (COOLANT TEMPERATURE GAUGE).
M-32 ABNORMALITY IN (TORQUE CONVERTER OIL TEMPERATURE GAUGE).
TABLE OF MONITOR REFERENCE VALUES
83 DISASSEMBLY AND ASSEMBLY
ELECTRONIC VECHICLE MONITOR SYSTEM (EVMS)
REMOVAL
INSTALLATION

90 OTHER
91 STRUCTURE AND FUNCTION
CAB
AIR CONDITIONER
PIPING, ENGINE TO HEATER CORE
PIPING, CONDENSER AND COMPRESSOR
ELECTRICAL DIAGRAM
AIR CONDITIONER UNIT
HEATING
COOLING
AIR CONDITIONER COMPRESSOR
AIR CONDITIONER CONDENSER
AIR CONDITIONER DRY RESERVOIR
93 DISASSEMBLY AND ASSEMBLY
CAB
REMOVAL
INSTALLATION
AIR CONDITIONER UNIT
REMOVAL
INSTALLATION
CONDENSER (AIR CONDITIONER)
REMOVAL
INSTALLATION
DRY RECEIVER (AIR CONDITIONER)
REMOVAL
INSTALLATION
COMPRESSOR (AIR CONDITIONER)
REMOVAL
INSTALLATION
97 GEAR PUMP
GENERAL
PRINCIPLE OF OPERATION
PRESSURE LOADED TYPE GEAR PUMP
FIXED SIDE PLATE TYPE GEAR PUMP
SA SERIES
STRUCTURE
TESTING AND ADJUSTING
DISASSEMBLY
ASSEMBLY
MAINTENANCE STANDARD
99 METRIC CONVERSIONS

 

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Komatsu WA250-1LC Wheel Loader Shop Manual.pdf

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