Komatsu Wheel Loader WA250-6 WA250PZ-6 service & repair manual

Description Komatsu Wheel Loader WA250-6 WA250PZ-6 service & repair manual

Komatsu Wheel Loader WA250-6, WA250PZ-6 pdf workshop service repair manual + operation & maintenance manual

Serial numbers:
WA250-6 75001 and up
WA250-6 A76001 and up
WA250PZ-6 75001 and up
WA250PZ-6 75160 and up
WA250PZ-6 H00051 and up

MANUAL CONTENT:
GENERAL
SPECIFICATIONS
Dimension Drawing
Specification Tables
WEIGHT TABLE
FUEL, COOLANT, AND LUBRICANTS

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Engine and Transmission Mounting
Damper
Cooling System
Cooling System Hydraulic Piping Diagram
Cooling Fan Motor
Hydraulic Motor
Suction Safety Valve
Operation of Reversible Valve
Flow Control Valve (Continuously Variable Type)
POWER TRAIN SYSTEM
Drive Line Components
System Diagram
Drive Shaft
HST Hydraulic Piping Diagram
HST Pump
Operation
High-Pressure Relief Valve
Low-pressure Relief Valve
HST Charge Pump
Speed-Related Valve (DA Valve)
High-Pressure Cutoff Valve
HST Motor
EP Servo Valve
HA Servo Valve
Directional Shuttle Valve
Transfer
Input Shaft
Output Shaft
Outline
Operation of Clutch
Power Transmitting Route
Clutch Solenoid Valve
DRIVE AXLE SYSTEM
Front and Rear Axles
Front Axle
Rear Axle
Differential
Front Differential
Rear Differential
Torque Proportioning Differential
Limited Slip Differential
Final Drive
Front Final Drive
Rear Final Drive
STEERING SYSTEM
Steering Piping Diagram
Steering Column
Priority Valve
Orbitrol Valve
Operation
Connection of Hand Pump and Sleeve
2-Way Restrictor Valve
Cushion Valve
Steering Cylinder
Emergency Steering Piping Diagram
Emergency Steering Valve
Steering Relief Valve
BRAKE SYSTEM
Brake Piping Diagram
Charge Valve
Brake Valve
Braking Operation
Inching Valve
Accumulator (for Brake)
Slack Adjuster
Brakes
Front Brake
Rear Brake
Parking Brake System
Brake Control
Parking Brake
UNDERCARRIAGE AND FRAME
Axle Mounting and Center Hinge Pin
Tires
Radial Tire
Bias Tire
HYDRAULIC SYSTEM
Work Equipment Hydraulic Piping Diagram
Work Equipment Control Lever Linkage
Mono-Lever Type
2-Lever Type
Hydraulic Tank
Breather
4-Gear Pump
Work Equipment Control Valve
2-Spool Type
MAINTENANCE STANDARD
3-Spool Type
Relief Valve
Safety-Suction Valve
Suction Valve
Operation of Work Equipment Control Valve
PPC Valve
Work Equipment PPC Valve
Attachment PPC Valve
Lock Valve
Accumulator (for PPC Circuit)
ECSS Valve
Accumulator (for ECSS)
Work Equipment
Work Equipment Linkage
Bucket
Bucket Positioner and Boom Kickout
Operation of Proximity Switch
Work Equipment Cylinders
Lift Cylinder
Bucket Cylinder
CAB ENVIRONMENT
Cab
Air Conditioner
Air Conditioner Piping Diagram
Refrigerant Circuit Diagram
Air Conditioner Unit
Blower and Intake Unit
Compressor
Condenser
Receiver
Air Conditioner Panel
ELECTRICAL SYSTEM
Machine Monitor System
System Circuit Diagram
Machine Monitor
Items Displayed on Monitor
Machine Monitor Operation Switches
Setting Machine Monitor
Troubleshooting Function
Character Display Function
Operator Mode Functions
Service Mode Functions
Input and Output Signals
Electrical System (HST Controller System)
Input and Output Signals Diagram
HST Controller Gear Shifting Control Function
HST Controller Protection Function
Cooling Fan Control Function
System Circuit Diagram
HST Controller
ECSS System
KOMTRAX System
KOMTRAX Terminal
Engine Starting Circuit
Engine Stopping Circuit
Preheating Circuit
Engine Output Lowering Function
Automatic Warm-up Function
Parking Brake Circuit
Max. Traction Switch
Multi-Function Knob
Modification of Multi-Function Lever
Sensors
Speed Sensor
HST Oil Temperature Sensor
Brake Oil Temperature Sensor
HST Oil Pressure Sensor
HST Oil FIlter Clogging Sensor
Coolant Lever Sensor
Fuel Level Sensor
Accelerator Pedal Sensor
Water-in-Fuel Sensor
Boom Kick-Out Proximity Switch
Bucket Positioner Proximity Switch

STANDARD VALUE TABLES
Standard Service Value Table for Engine
Standard Service Value Table for Chassis
MACHINE POSTURE

TESTING AND ADJUSTING
TOOLS
Tools for Testing, Adjusting, and Troubleshooting
ENGINE COMPONENTS
Engine Speed
Exhaust Gas Color
Using Handy Smoke Checker A1
Using Smoke Meter A2
Valve Clearance
Compression Pressure
Blow-By Pressure
Engine Oil Pressure
Intake Air (Boost) Pressure
Handling Cylinder Cut-Out Mode Operation
Handling No-Injection Cranking Operation
Handling Controller Voltage Circuit
FUEL SYSTEM
Handling Fuel System Equipment
Releasing Residual Pressure in Fuel System
Measuring Fuel Pressure
Measuring Fuel Return Rate and Leakage
Bleeding Air from Fuel Circuit
Testing Leakage in Fuel System
EXHAUST SYSTEM AND PIPING
Checking Muffler and Muffler Stack for Looseness and Damage
Checking Muffler Function
Checking Installed Condition of Cylinder Head and Manifolds
Checking Engine Piping for Damage and Looseness
BELTS
Air Conditioner Compressor Belt
Alternator Belt
ACCELERATOR PEDAL
Testing Operating Effort
Testing Operating Angle
DIRECTIONAL LEVER
Checking Operating Effort
Checking Travel
POWER TRAIN OIL PRESSURES
Testing HST Oil Pressure
High-Pressure Cutoff Oil Pressure
Low-Pressure Relief Pressure
Servo Piston Control Pressure (DA Pressure)
Servo Piston Actuating Pressure
Adjusting HST Oil Pressure
High-Pressure Cutoff Valve
Low-Pressure Relief Valve
DA Valve
Testing Clutch Control Pressure
STEERING SYSTEM
Steering Wheel
Measuring Play
Measuring Operating Effort
Measuring Operating Time
Steering Oil Pressure
Measuring Main Relief Pressure
Adjusting Main Relief Pressure
Bleeding Air From Steering Circuit
HYDRAULIC FAN
Fan Speed
Fan Drive Oil Pressure
BRAKE SYSTEM
Measuring Brake Pedal
Brake Pedal Linkage
Testing
Adjusting
Measuring Brake Performance
Accumulator Charge Pressure
Testing
Adjusting
Testing Wheel Brake Oil Pressure
Testing Wear of Brake Disc
Bleeding Air from Wheel Brake Circuit
Releasing Residual Pressure in Brake Accumulator Circuit
Testing Parking Brake Performance
Parking Brake Limit Switch
Testing
Adjusting
Parking Brake Control Cable
Testing
Adjusting
WORK EQUIPMENT
Control Lever
Measuring Operating Effort
Measuring Travel
Hydraulic Pressure
Measuring
Adjusting
PPC Oil Pressure
Testing PPC Valve Basic Pressure
Checking PPC Valve Output Pressure
Bleeding Air from Hydraulic Circuit
From Work Equipment PPC Circuit
Releasing Residual Pressure in Hydraulic Circuit
Between Hydraulic Cylinder and Control Valve
In Brake Accumulator Circuit
In PPC Accumulator Circuit
Bucket Positioner
Testing
Adjusting Clearance
Adjusting Installing Position (Stopping Position)
Boom Kickout Switch
Testing
Adjusting
Checking Proximity Switch Operation Pilot Lamp
ELECTRICAL SYSTEM TROUBLESHOOTING
Procedure for Testing Diodes
Using Digital-Type Circuit Tester
Using Analog-Type Circuit Tester
Preparation Work for Troubleshooting Electric System
Machine Monitor
HST Controller
KOMTRAX Terminal
Boost Pressure and Temperature Sensor (BOOST PRESS & IMT)
Supply Pump IMV Solenoid (FUEL REGULATOR)
Common Rail Pressure Sensor (FUEL RAIL PRESS)
Engine Coolant Temperature Sensor (COOLANT TEMP)
Ambient Temperature Sensor (AMBAIR PRESSURE)
Engine Ne Speed Sensor (CRANK SENSOR)
Engine Bkup Speed Sensor (CAM SENSOR)
Engine Oil Pressure Switch (OIL PRESSURE SWITCH)
KOMTRAX TERMINAL SYSTEM
Starting KOMTRAX Terminal Operations
Station Opening Check in Machine Side
Application for the Start of Use
KOMTRAX Terminal Indicator Lamps
MACHINE MONITOR SYSTEM
Adjusting Machine Monitor
Adjusting Replaced, Reassembled, or Added Sensor, Controller, Etc
Items to Be Set
Adjustment for Users Needs
Special Functions of Machine Monitor (EMSS)
Normal and Special Functions of Machine Monitor
Normal Functions: Operator Mode
Special Functions: Service Mode
Functions and Flow of Service Mode
Operator Mode
Service Meter Display Function
Traction Level Selection Function
HST Function Selection Function
Odometer Display Function
Maintenance Monitoring Function
Telephone Number Input Function
Language Selection Function
Monitor Brightness Adjustment Function
Travel Speed/Engine Speed Display Selecting Function
Travel Speed/Engine Speed Display/Non-Display Selecting Function
Action Code Display Function
Failure Code Display Function
Service Mode
Switching to Service Mode and Screen Display
Electrical System Fault History Display Function (ELECTRIC FAULT)
Mechanical System Fault History Display Function (MACHINE FAULT)
Failure Codes Table
Real-Time Monitoring Function (REAL-TIME MONITOR)
Real-Time Monitoring Codes Tables
Engine Reduced-Cylinder Function (CYLINDER CUT-OUT)
No-Injection Cranking Function
Adjustment Function (TUNING)
Maintenance Monitoring Function
Operating Information Display Function
Optional Device Selecting Function
Machine Serial Number Input Function
Model Selection Function (MACHINE WA***)
Initialize Function
PM CLINIC INSPECTION TABLES

TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PRECAUTIONS FOR MAINTENANCE
Precautions when Handling Electrical Equipment
Handling Electronic Control Unit
Points to Remember when Troubleshooting Electrical Circuits
ELECTRIC WIRE CODE
How to Read Electric Wire Code
Type, Symbol, and Material
Dimensions
Color Codes Table
Types of Circuits and Color Codes
HANDLING HYDRAULIC EQUIPMENT
CHECKS BEFORE TROUBLESHOOTING
Categories and Method of Using Troubleshooting Charts
Troubleshooting Individual Electrical Circuits
Chart Use
Chart Tips
Troubleshooting Individual Hydraulic Circuits
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

DISASSEMBLY AND ASSEMBLY
Removal and Installation of Assemblies
Disassembly and Assembly of Assemblies
COATING MATERIALS LIST
SPECIAL TOOLS LIST
SKETCHES OF SPECIAL TOOLS
CONNECTOR REPAIR PROCEDURES
Stripping Insulation
Wire Inspection
Contact Terminal Removal (HD30 Type)
Crimping Contact Terminal (HD30 Type)
Insertion Of Contact Terminal (HD30 Type)
Contact Terminal Removal (DT Type)
Crimping Contact Terminal (DT Type)
Insertion Of Contact Terminal (DT Type)
ENGINE AND COOLING SYSTEM

DIAGRAMS AND SCHEMATICS
HYDRAULIC SYSTEM
Hydraulic Circuit Diagram
ELECTRICAL SYSTEM
Machine Monitor System
HST Controller System Circuit Diagram
HST Controller System
Machine Monitor System (Lamp Related Items)
Machine Monitor System (Other than Lamp Related Items)
Engine Controller System
Electrical Circuit Diagram
Connector List and Sterograms
LUBRICATION SYSTEM
Automatic Greasing Circuit Diagram

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