KOMATSU WA250-1LC Wheel Loader Service Repair Manual + Operation & Maintenance Manual

CEBMWI 8020 SHOP MANUAL KOMKtkSU WA2504 LC WHEEL LOADER MACHINE MODEL SERIAL NUMBERS WA25011 LC A65001 and up It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision. FEB 92

PRODUCT PUBLICATIONS INFORMATION VARIOUS PRODUCT PARTS & SERVICE PUBLICATIONS ARE AVAILABLE TO ALL KOMATSU CONSTRUCTION EQUIPMENT OWNERS, INCLUDING OPERATION & MAINTENANCE MANUALS, PARTS BOOKS AND SHOP MANUALS. SPECIAL PUBLICATIONS SUCH AS SERVICETOOL, AIR CONDITIONING, ANDTURBOCHARGER SHOP MANUALS ARE ALSO AVAIlABLE AS WELL AS SELECTED OPERATION & MAINTENANCE AND SHOP MANUALS IN FOREIGN LANGUAGES. THE PUBLICATIONS LISTED BELOW ARE AVAILABLE FOR THIS PARTICULAR MACHINE(S). DESCRIPTION FORM NUMBER PARTS BOOK - PAPER: Engineand Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPBWl8021 PARTS BOOK - MICROFICHE: Engineand Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPMW18021 OPERATION & MAINTENANCE MANUAL: Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEAMW18020 SHOP MANUAL: Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine: CEBMW16020 Shop Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM61 OSMO Specification Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM61 OAR0 SAFETY MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1085 883 R3 PARTS AND SERVICE PUBLICATIONS CAN ONLY BE ACQUIRED BY AN AUTHORIZED KOMATSU DISTRIBUTOR, USING THE “REQUEST FOR LITERATURE” FORM KDC-EPS-05 SHOWN ON THE REVERSE SIDE OF THIS PAGE. PLEASE TEAR OUT THIS PAGE AND FILL IN ALL THE INFORMATION REQUESTED ON THE ORDER FORM! PUBINFl.KOM 011091

REoulslTloN FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS COMPLETE FORM AND RETURN TO - Komatsu America International Company 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186 Tel No. (847) 970-5887 SHIP TO c TYPE or PRINT ONLY . COMPANY NAME ATTN. PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE SERIAL NUMBER MUST BE SHOWN. QTY. PUBLICATION FORM NUMBER PARTS BooK PUBLICATION P-Paper DESCRIPTION MODEL NUMBER SERIAL NUMBER 1 M-Microfiche KDC9lD 081696 CURRENT PRICES WILL BE CHARGED

CONTENTS No. of page 10 ENGINE 12 TESTING AND ADJUSTING .................................................. 12-l 13 DISASSEMBLY AND ASSEMBLY .............................................. 13-1 20 POWER TRAIN 21 STRUCTURE AND FUNCTION ................................................ 21-l 22 TESTING AND ADJUSTING .................................................. 22-l 23 DISASSEMBLY AND ASSEMBLY .............................................. 23-l 24 MAINTENANCE STANDARD ................................................. 24-l 40 STEERING SYSTEM 41 STRUCTURE AND FUNCTION ................................................ 41-l 42 TESTING AND ADJUSTING .................................................. 42-l 43 DISASSEMBLY AND ASSEMBLY .............................................. 43-l 44 MAINTENANCESTANDARD ................................................. 44-l 50 BRAKE AND AIR SYSTEM 51 52 53 54 STRUCTURE AND FUNCTION ................................................ 51-l TESTING AND ADJUSTING .................................................. 52-1 DISASSEMBLY AND ASSEMBLY .............................................. 53-l MAINTENANCE STANDARD ................................................. 54-l 60 WORK EQUIPMENT SYSTEM 61 STRUCTURE AND FUNCTION ................................................ 61-l 62 TESTING AND ADJUSTING .................................................. 62-l 63 DISASSEMBLY AND ASSEMBLY .............................................. 63-l 64 MAINTENANCE STANDARD ................................................. 64-l 80 ELECTRIC AND ELECTRONIC SYSTEM 81 STRUCTURE AND FUNCTION ................................................ 81-l 82 TESTING AND ADJUSTING .................................................. 82-1 83 DISASSEMBLY AND ASSEMBLY .............................................. 83-l 90 OTHERS 91 93 97 99 STRUCTURE AND FUNCTION ................................................ 91-l DISASSEMBLY AND ASSEMBLY .............................................. 93-l GEAR PUMP ............................................................ 97-l METRIC CONVERSION TABLE ............................................... 99-l 00-l

SAFETY A WARNING! IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose. To prevent injury to workers, the symbol shown is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. SAFETY GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BE- FORE operating the machine. 1. 2. 3. 4. 5. 6. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. -Always wear safety glasses when hitting parts with a hammer. -Always wear safety glasses when grinding parts with a grinder, etc. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment. Keep all tools in good condition and learn the correct way to use them. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 00-2

SAFETY 13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (-) terminal first. 14. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts. 19. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts. l When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being oper- ated. 20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed. 21. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be partic- ularly careful to check that they are installed correctly. 22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. 00-3

FOREWORD This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into chapters for each main group of components; these chapters are further divided into the following sections. STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to ‘Causes” are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. 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HOW TO READ THE SERVICE MANUAL VOLUMES Service manuals are issued as a guide to carrying out repairs. They are two manuals for each machine, Chassis volume and Engine volume. These volumes are designed to avoid duplication of information. Therefore to deal with all repairs for any model, both chassis and engine volumes are needed. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to your distributors. Get the most up-to-date information before you start any work. FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number: Example 1 (Chassis volume): 10-3 Y Item number (10. Structure and Function) Consecutive page number for each item Example 2 (Engine volume): Refer to the pertinent engine manual. 3. Additional pages: Additional pages are indicated by a hyphen (-) and numbered after the page number. File as in the example. Example: 21-4 21-4-l 21-4 2 Added pages 21-5 REVISED EDITION MARK ([l] [2] [3] ....) When a manual is revised, an edition mark is recorded on the bottom outside corner of the pages. REVISIONS Revised pages are shown at the LIST OF RE- VISED PAGES on the between the title page and SAFETY page. SYMBOLS So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. Symbol 1 Item 1 Remarks A YY 4 * Special safety precautions are necessary when performing the work Safety Extra special safety precautions are necessary when performing the work because it is under internal pressure. Special technical precautions or other precautions for pre- Caution serving standards are necessary when performing the work. Weight of parts or systems. Caution necessary when Weight selecting hoisting wire or when working posture is important, etc. .f I Drain must be drained, and quan- tity to be drained. 00-5

HOISTING INSTRUCTIONS 1 Heavy parts (25 kg or more) must be lifted with a hoist etc. In the Disas- sembly and Assembly section, every part weighing 25 kg or more is indicated clearly with the symbol 1. If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: l Check for removal of all bolts fastening the part to the relative parts. l Check for existence of another part causing interface with the part to be removed. 2. Wire ropes 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard ‘7” or “s” tw_/&ropes without galvaniz- Rope diameter (mm) Allowable load (tons) 10.0 1.0 11.2 1.4 12.5 1.6 14.0 2.2 16.0 2.8 18.0 3.6 20.0 4.4 22.4 5.6 30.0 10.0 40.0 18.0 50.0 28.0 60.0 40.0 2) 00-6 The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used. Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion. 3) A 4) 100% 88% 79% 71% 41% Fso064 Do not sling a heavy load with one rope alone, but sling with two or more ropes sym- metrically wound on to the load. Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120” hanging angle. On the other hand, two ropes are subject to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150”. 300 800 SO’ 120" 150' Lifting angle : a FSO065

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KOMATSU WA250-1LC Wheel Loader Service Repair Manual + Operation & Maintenance Manual

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