Komatsu Wheel Loader WA250-5L WA250PT-5L service & repair manual

Description Komatsu Wheel Loader WA250-5L WA250PT-5L service & repair manual

Komatsu Wheel Loader - Waste Handler WA250-5L, WA250PT-5L pdf workshop service repair manual + operation & maintenance manual

Serial numbers:
WA250-5L A73001 and up
WA250PT-5L A79001 and up

MANUAL CONTENT:
GENERAL
SPECIFICATION
SYSTEM OPERATING PERAMETERS
WEIGHT TABLE
FUEL, COOLANT AND LUBRICANTS

STRUCTURE AND FUNCTION
ENGINE AND DRIVE SYSTEM MOUNTING
DRIVE SYSTEM DAMPER
COOLING SYSTEM
REVERSING FAN
PROPORTIONAL RELIEF VALVE
2-POSITION, 4-WAY SPOOL VALVE
FAN CONTROLLER
POWER TRAIN
POWER TRAIN SYSTEM DIAGRAM
DRIVE SHAFT
HST HYDRAULIC PIPING DIAGRAM
HST PUMP
HIGH-PRESSURE RELIEF VALVE
LOW-PRESSURE RELIEF VALVE
CHARGE PUMP
SPEED-RELATED VALVE (DA VALVE)
HIGH-PRESSURE CUT-OFF VALVE
HST MOTORS
EP SERVO VALVE
HA SERVO VALVE
FORWARD-REVERSE SHUTTLE VALVE
TRANSFER
INPUT SHAFT PORTION
OUTPUT SHAFT PORTION
CLUTCH OPERATION
TRANSFER OIL COOLER
CLUTCH SOLENOID VALVE
AXLES
FRONT AXLE
REAR AXLE
DIFFERENTIALS
FRONT DIFFERENTIAL
REAR DIFFERENTIAL
LIMITED-SLIP DIFFERENTIAL
FRONT
REAR
FINAL DRIVE
FRONT
REAR
AXLE MOUNTING AND CENTER HINGE CARIER
STEERING PIPING SYSTEM
STEERING COLUMN
PRIORITY VALVE
ORBIT-ROLL VALVE
STEERING WHEEL IN NEUTRAL
STEERING WHEEL TURNED (TURNING LEFT)
CONNECTION BETWEEN HAND PUMP AND SLEEVE
2-WAY RESTRICTOR VALVE
STEERING CYLINDER
EMERGENCY STEERING PIPING
EMERGENCY STEERING VALVE
BRAKE PIPING
BRAKE VALVE
INCHING VALVE
CHARGE VALVE
ACCUMULATOR (FOR BRAKE)
SLACK ADJUSTER
BRAKE
FRONT
REAR
PARKING BRAKE CONTROL
PARKING BRAKE
HYDRAULIC PIPING
WORK EQUIPMENT LEVER LINKAGE
MULTI-FUNCTION JOYSTICK TYPE
JOYSTICK TYPE (IF EQUIPPED)
MULTI-FUNCTION JOYSTICK TYPE
JOYSTICK TYPE (IF EQUIPPED)
HYDRAULIC TANK
BREATHER
PREVENTION OF NEGATIVE PRESSURE IN TANK
PREVENTION OF RISE OF PRESSURE IN TANK
4-GEAR PUMP UNIT
ACCUMULATOR (FOR PPC CIRCUIT)
LOCK VALVE
BY-PASS VALVE
WHEN LIFT ARM IS "RAISED"
WHEN LIFT ARM IS "LOWERED"
WHEN BUCKET IS "DUMP" IN FAST MODE (FROM TILT-BACK POSITION TO JUST BEFORE DUMP END)
WHEN BUCKET IS "DUMP" IN FAST MODE (FROM JUST BEFORE DUMP END TO DUMP END)
QUICK COUPLER SOLENOID VALVE
E.C.S.S. VALVE (IF EQUIPPED)
ACCUMULATOR (FOR E.C.S.S.) (IF EQUIPPED)
HYDRAULIC PIPING OF COOLING SYSTEM
COOLING FAN MOTOR
WORK EQUIPMENT CONTROL VALVE
2-SPOOL VALVE
3-SPOOL VALVE
RELIEF VALVE
SAFETY SUCTION VALVE
SUCTION VALVE
OPERATION OF THE WORK EQUIPMENT CONTROL VALVE
NEUTRAL POSITION OF THE LIFT ARM AND BUCKET SPOOLS
RAISE POSITION OF THE LIFT ARM SPOOL
LOWER POSITION OF THE LIFT ARM SPOOL
FLOAT POSITION OF THE LIFT ARM SPOOL
ROLL BACK POSITION OF THE BUCKET SPOOL
DUMP POSITION OF THE BUCKET SPOOL
WORK EQUIPMENT PPC VALVE
WHEN IN NEUTRAL
WHEN IN FINE CONTROL
WHEN LEVER IS OPERATED TO STROKE END
WHEN LIFT ARM IS FLOATED
WHEN FLOAT STATE OF LIFT ARM IS RESET
ATTACHMENT PPC VALVE (IF EQUIPPED)
AT THE NEUTRAL POSITION
AT THE FINE CONTROL POSITION
AT FULL STROKE
WORK EQUIPMENT LINKAGE
BUCKET
BUCKET POSITIONER, BOOM KICK-OUT, AND DUMP SPEED
BUCKET POSITIONER
BOOM KICK-OUT
OPERATION OF PROXIMITY SWITCH
BUCKET POSITIONER OR FORK POSITIONER
BOOM KICK-OUT
DUMP SPEED CONTROL
OPERATION OF PROXIMITY SWITCH
WORK EQUIPMENT CYLINDER
LIFT CYLINDER
LIFT CYLINDER
BUCKET CYLINDER
COUPLER PLUNGER
AIR CONDITIONER PIPING
MACHINE MONITORING SYSTEM
OUTLINE
NORMAL MODE
SERVICE MODE
SERVICE METER SETTING
INDIVIDUAL CIRCUIT DIAGRAMS OF THE MACHINE MONITOR
STARTING AND LIGHTING
POWER SUPPLY AND NETWORK
SENSING
HST SAFETY CONTROL
AUTOMATIC PREHEATING
POWER SUPPLY AND NETWORK
MACHINE MONITOR
LIST OF ITEMS DISPLAYED ON MONITOR
SERVICE MODE FUNCTIONS
OPERATING METHOD
ITEMS RELATED TO THE FAULT HISTORY OF ELECTRIC SYSTEM
ITEMS RELATED TO THE FAULT HISTORY OF MACHINE SYSTEM
REAL-TIME MONITOR FUNCTION
HOW TO INPUT INTERVAL
FUNCTION OF SELECTING OPTIONAL DEVICE
ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)
HST CONTROLLER
SELECTING FORWARD-REVERSE SELECTOR SWITCH
ENGINE STARTING CIRCUIT
ENGINE STOP CIRCUIT
PREHEATING CIRCUIT (AUTOMATIC PREHEAT SYSTEM)
PARKING BRAKE CIRCUIT
ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM
COUPLER PLUNGER CONTROL SYSTEM
SENSORS
ENGINE SPEED SENSOR
TRAVEL SPEED SENSOR
ENGINE OIL PRESSURE SENSOR
FUEL LEVEL SENSOR
COOLANT AND HST OIL TEMPERATURE SENSOR (FOR MONITOR)
COOLANT TEMPERATURE SENSOR (FOR PREHEATING)
AXLE OIL TEMPERATURE SENSOR
HST OIL PRESSURE SENSOR
STEERING AND EMERGENCY STEERING OIL PRESSURE SENSOR (IF EQUIPPED)
HST FILTER CLOGGING SENSOR
COOLANT LEVEL SENSOR
KOMTRAX SYSTEM
KOMTRAX TERMINAL SYSTEM
KOMTRAX TERMINAL
INPUT AND OUTPUT SIGNALS

TESTING, ADJUSTING AND TROUBLESHOOTING
STANDARD VALUE TABLE
ENGINE
CHASSIS
SPECIAL TOOLS
ENGINE COMPONENTS
MEASURING EXHAUST SMOKE
MEASURING EXHAUST TEMPERATURE
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING CRANCASE PRESSURE
MEASURING ENGINE OIL PRESSURE
MEASURING BOOST PRESSURE
MEASURING FUEL PRESSURE
ADJUSTING ENGINE SPEED SENSOR
BLEEDING AIR FROM FUEL SYSTEM
MEASURING ENGINE SPEED (LOW AND HIGH IDLE)
MEASURING HST STALL SPEED
MEASURING HYDRAULIC STALL
MEASURING FULL STALL SPEED
OPERATING FORCE OF ACCELERATOR PEDAL
TESTING OPERATING FORCE
OPERATING ANGLE OF PEDAL
ADJUSTING ENGINE STOP SOLENOID
ADJUSTING ENGINE SPEED SENSOR
REFRIGERANT COMPRESSOR BELT
MEASURING DIRECTIONAL LEVER EFFORT
HST OIL PRESSURE
MEASURING CLUTCH CONTROL PRESSURE
STEERING WHEEL
MEASURING STEERING WHEEL END PLAY
MEASURING OPERATING FORCE ON STEERING WHEEL
MEASURING OPERATING TIME FOR STEERING WHEEL
STEERING OIL PRESSURE
MEASURING MAIN RELIEF PRESSURE
ADJUSTING MAIN RELIEF PRESSURE
BLEEDING AIR FROM STEERING CIRCUIT
HYDRAULIC FAN
MEASURING FAN SPEED
MEASURING OIL PRESSURE
REVERSING FAN CONTROLLER, IF EQUIPPED
LED INDICATORS
MEASURING BRAKE PEDAL
BRAKE PEDAL LINKAGE
MEASURING BRAKE PERFORMANCE
ACCUMULATOR CHARGE PRESSURE
MEASURING BRAKE OIL PRESSURE
MEASURING WEAR OF BRAKE DISC
BLEEDING AIR FROM BRAKE CIRCUIT
MEASURING PARKING BRAKE PERFORMANCE
PARKING BRAKE LINKAGE
MEASURING PARKING BRAKE RELEASE PRESSURE
WORK EQUIPMENT CONTROL LEVER
WORK EQUIPMENT PRESSURE
WORK EQUIPMENT PPC OIL PRESSURE
TESTING AND ADJUSTING
BLEEDING AIR
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
BUCKET POSITIONER
BOOM KICK-OUT
TESTING
ADJUSTING
PROXIMITY SWITCH ACTUATION DISPLAY LAMP
PROCEDURE FOR CHECKING DIODE
SPECIAL FUNCTIONS OF MACHINE MONITOR
FLOW OF MODES AND FUNCTIONS
OPERATOR MODE
SERVICE MODE 1
SERVICE MODE 2
CHARACTER DISPLAY
OPERATING SWITCHES
OPERATOR MODE OPERATION AND DISPLAYS
FAILURE CODE TABLE
*SEPARATE TABLE: DETAILED PHENOMENA OF PROBLEM CODE (L*)
PROCEDURE FOR SWITCHING TO SERVICE MODE 1 AND SCREEN DISPLAY
REAL-TIME MONITORING ITEMS

TROUBLESHOOTING (GENERAL)
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT
HANDLING CONTROL BOX
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT
CHECKS BEFORE TROUBLESHOOTING
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS
PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
T-ADAPTER TABLE
CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR LAYOUT DRAWING
TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)
TROUBLESHOOTING OF HST MONITOR SYSTEM (HST MODE)
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE)
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)
TROUBLESHOOTING AIR CONDITIONING

TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM
POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL
USER CODE MEMORY RETENTION FUNCTION
HST CONTROLLER SYSTEM DIAGRAM
TROUBLESHOOTING CODE DISPLAY

TROUBLESHOOTING OF HST MONITOR SYSTEM (HST MODE)
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM
POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL
USER CODE MEMORY RETENTION FUNCTION
MONITOR SYSTEM CIRCUIT DIAGRAM
TROUBLESHOOTING CODE DISPLAY
ERROR CODE AND POSSIBLE CAUSE TABLE
FUSE SYSTEM CHECK
FUSE PANNEL CONNECTION TABLE
INFORMATION CONTAINED IN TESTING PROCEDURES
CODE KEY TABLE

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL
USER CODE MEMORY RETENTION FUNCTION
ELECTRICAL SYSTEM CIRCUIT DIAGRAM
FUSE SYSTEM CHECK
FUSE PANEL CONNECTION TABLE
INFORMATION CONTAINED IN TESTING PROCEDURES

TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE)

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)

TROUBLESHOOTING AIR CONDITIONING
AIR CONDITIONING SYSTEM
ENVIRONMENTAL IMPACT
OPERATOR CAB AIR CONDITIONING
PRINCIPLES OF REFRIGERATION
AIR CONDITIONING
THE ACT OF COOLING
THE REFRIGERATION CYCLE
AIR CONDITIONER SYSTEM COMPONENTS
COMPRESSOR (REFRIGERANT PUMP)
SERVICE VALVES
CONDENSER
RECEIVER-DRIER
THERMOSTATIC EXPANSION VALVE
EVAPORATOR
ELECTRICAL CIRCUIT
THERMOSTAT
COMPRESSOR CLUTCH
SAFETY SWITCHES
SYSTEM SERVICING
R-134A REFRIGERANT CONTAINERS
SERVICE TOOLS AND EQUIPMENT
RECOVERY/RECYCLE STATION
LEAK DETECTOR
SERVICE VALVES
VACUUM PUMP
MANIFOLD GAUGE SET
INSTALLING MANIFOLD GAUGE SET
PURGING AIR FROM SERVICE HOSES
ADDING REFRIGERANT TO THE SYSTEM (WITHOUT A CHARGING STATION)
STABILIZING THE AC SYSTEM
ADDING REFRIGERANT AND STABILIZING THE SYSTEM (WITH A RECOVERY/RECYCLING STATION)
RECOVERING AND RECYCLING THE REFRIGERANT
PERFORMING THE RECOVERY CYCLE
PERFORMING THE RECYCLING PROCEDURE
EVACUATING AND CHARGING THE AC SYSTEM
SYSTEM PERFORMANCE TEST
SYSTEM LEAK TESTING
ELECTRONIC LEAK DETECTOR
TRACER DYES
SOAP AND WATER
SYSTEM REPAIR
HOSES AND FITTINGS
LINES
EXPANSION VALVE
RECEIVER-DRIER
THERMOSTAT

DISASSEMBLY AND ASSEMBLY
REMOVAL AND INSTALLATION OF COMPONANTS
SPECIAL TOOLS
OVERHAUL OF COMPONANTS
PRECAUTIONS WHEN PERFORMING AN OPERATION
SKETCHES OF SPECIAL TOOLS
CONNECTOR REPAIR PROCEDURES
CONTACT TERMINAL REMOVAL (HD30 TYPE)
STRIPING INSULATION
CRIMPING CONTACT TERMINAL (HD30 TYPE)
INSERTION OF CONTACT TERMINAL (HD30 TYPE)
CONTACT TERMINAL REMOVAL (DT TYPE)
STRIPING INSULATION
CRIMPING CONTACT TERMINAL (DT TYPE)
INSERTION OF CONTACT TERMINAL (DT TYPE)
FUEL INJECTION PUMP ASSEMBLY
NOZZLE HOLDER ASSEMBLY
CYLINDER HEAD ASSEMBLY
ENGINE ASSEMBLY
RADIATOR ASSEMBLY
AIR AFTERCOOLER
HYDRAULIC OIL COOLER
COOLING FAN AND FAN MOTOR
FUEL TANK
TRANSFER
TRANSFER ASSEMBLY
PARKING BRAKE ASSEMBLY
FRONT AXLE ASSEMBLY
REAR AXLE ASSEMBLY
AXLE HOUSING ASSEMBLY
DIFFERENTIAL ASSEMBLY
HST PUMP AND 4-GEAR PUMP ASSEMBLY
HST PUMP ASSEMBLY
HST MOTOR 1 ASSEMBLY
HST MOTOR 2 ASSEMBLY
HST MOTOR ASSEMBLY
WORK EQUIPMENT CONTROL VALVE ASSEMBLY
TRAVEL DAMPER VALVE ASSEMBLY
HYDRAULIC TANK
WORK EQUIPMENT ASSEMBLY (Z-BAR LINKAGE)
BUCKET LINK PIN
BUCKET HINGE PIN
BUCKET CYLINDER PIN (ON ROD SIDE)
LIFT CYLINDER PIN (ON ROD SIDE)
LIFT ARM PIN (ON FRAME SIDE)
BUCKET LINK PIN
WORK EQUIPMENT ASSEMBLY (PARELLEL TOOL CARRIER)
BUCKET (TILT) CYLINDER
BOOM (LIFT) CYLINDER
BOOM AND PARALLEL TOOL LINKAGE
HYDRAULIC CYLINDER ASSEMBLY
OPERATORS CAB ASSEMBLY
OPERATORS CAB GLASS
COATING MATERIALS
CENTER HINGE PIN
COUNTERWEIGHT
AIR CONDITIONER UNIT ASSEMBLY
AIR CONDITIONER COMPRESSOR ASSEMBLY
MONITOR PANEL
KOMTRAX TERMINAL ASSEMBLY

OTHERS
HYDRAULIC CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM

Engine 6D102E-2 series workshop service repair manual