WA250-3L WHEELLOADER
MACHINEMODELSERIALNUMBERS
WA250-3LA70001andup
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PRODUCTPUBLICATIONSINFORMATION
VARIOUSPRODUCTPARTS&SERVICEPUBLICATIONSAREAVAILABLETOALLKOMATSUCONSTRUCTION EQUIPMENTOWNERS,INCLUDINGOPERATION&MAINTENANCEMANUALS,PARTSBOOKSANDSHOP MANUALS.
SPECIALPUBLICATIONSSUCHASSERVICETOOL,AIRCONDITIONING,ANDTURBOCHARGERSHOPMANUALS AREALSOAVAILABLEASWELLASSELECTEDOPERATION&MAINTENANCEANDSHOPMANUALSIN FOREIGNLANGUAGES.
THEPUBLICATIONSLISTEDBELOWAREAVAILABLEFORTHISPARTICULARMACHINE(S).
COMPLETEFORM ANDRETURNTOKomatsuAmericaInternationalCompany
440NorthFairwayDrive
VernonHills,IL60061-8112U.S.A.
Attn:TechnicalPublications FaxNo.(847)970-4186
TelNo.(847)970-5887
SHIPTO
IMPORTANT-TOASSURESHIPMENTOFTHECORRECTPUBLICATION(S),THEMODELNUMBERANDMACHINE SERIALNUMBERMUSTBESHOWN. QTY.PUBLICATIONFORM
SAFETY
SAFETYNOTICE
IMPORTANTSAFETYNOTICE
Properserviceandrepairisextremelyimportantforthesafeoperationofyourmachine.Theserviceandrepair techniquesrecommendedanddescribedinthismanualarebotheffectiveandsafemethodsofoperation. Someoftheseoperationsrequiretheuseoftoolsspeciallydesignedforthepurpose.
Topreventinjurytoworkers,thesymbolsandareusedtomarksafetyprecautionsinthismanual.The cautionsaccompanyingthesesymbolsshouldalwaysbefollowedcarefully.Ifanydangeroussituationarises ormaypossiblyarise,firstconsidersafety,andtakethenecessaryactionstodealwiththesituation.
GENERALPRECAUTIONS
cleanandmakesurethatthereisnodirtoroilonthe
floor.Smokeonlyintheareasprovidedforsmoking.
Mistakesinoperationareextremelydangerous.ReadtheNeversmokewhileworking. OPERATION&MAINTENANCEMANUALcarefully BEFOREoperatingthemachine.
PREPARATIONSFORWORK
1.Beforecarryingoutanygreasingorrepairs,readall7.Beforeaddingoilormakingrepairs,parkthe theprecautionsgivenonthedecalswhicharefixedtomachineonhard,levelground,andblockthewheels themachine.ortrackstopreventthemachinefrommoving.
2.Whencarryingoutanyoperation,alwayswearsafety
8.Beforestartingwork,lowerblade,ripper,bucketor shoesandhelmet.Donotwearlooseworkclothes,anyotherworkequipmenttotheground.Ifthisisnot orclotheswithbuttonsmissing.possible,insertthesafetypinoruseblockstoprevent theworkequipmentfromfalling.Inaddition,be Alwayssure wearsafetyglasseswhenhittingpartswith ahammer.
Alwayswearsafetyglasseswhengrindingparts withagrinder,etc.
3.Ifweldingrepairsareneeded,alwayshaveatrained, experiencedweldercarryoutthework.When carryingoutweldingwork,alwayswearwelding gloves,apron,glasses,capandotherclothessuited forweldingwork.
4.Whencarryingoutanyoperationwithtwoormore workers,alwaysagreeontheoperatingprocedure beforestarting.Alwaysinformyourfellowworkers beforestartinganystepoftheoperation.Before startingwork,hangUNDERREPAIRsignsonthe controlsintheoperator'scompartment.
5.Keepalltoolsingoodconditionandlearnthecorrect waytousethem.
6.Decideaplaceintherepairworkshoptokeeptools andremovedparts.Alwayskeepthetoolsandparts intheircorrectplaces.Alwayskeeptheworkarea
tolockallthecontrolleversandhangwarningsigns onthem.
9.Whendisassemblingorassembling,supportthe machinewithblocks,jacksorstandsbeforestarting work.
10.Removeallmudandoilfromthestepsorother placesusedtogetonandoffthemachine.Always usethehandrails,laddersorstepswhengettingonor offthemachine.Neverjumponoroffthemachine. Ifitisimpossibletousethehandrails,laddersor steps,useastandtoprovidesafefooting.
PRECAUTIONSDURINGWORK
11.Whenremovingtheoilfillercap,drainplugor hydraulicpressuremeasuringplugs,loosenthem slowlytopreventtheoilfromspurtingout.Before disconnectingorremovingcomponentsoftheoil,
wateroraircircuits,firstremovethepressurecompletely18.Asageneralrule,donotusegasolinetowashparts. fromthecircuit.Inparticular,useonlytheminimumofgasolinewhen
12.Thewaterandoilinthecircuitsarehotwhenthe engineisstopped,sobecarefulnottogetburned.19.Besuretoassembleallpartsagainintheiroriginal Waitfortheoilandwatertocoolbeforecarryingoutplaces.Replaceanydamagedpartwithnewparts. anyworkontheoilorwatercircuits.
13.Beforestartingwork,removetheleadsfromthe battery.ALWAYSremovetheleadfromthenegative (-)terminalfirst.
14.Whenraisingheavycomponents,useahoistor crane.Checkthatthewirerope,chainsandhooks arefreefromdamage.Alwaysuseliftingequipment whichhasamplecapacity.Installthelifting equipmentatthecorrectplaces.Useahoistorcrane andoperateslowlytopreventthecomponentfrom hittinganyotherpart.Donotworkwithanypartstill raisedbythehoistorcrane.
15.Whenremovingcoverswhichareunderinternal pressureorunderpressurefromaspring,always leavetwoboltsinpositiononoppositesides.Slowly releasethepressure,thenslowlyloosentheboltsto remove.
16.Whenremovingcomponents,becarefulnottobreak ordamagethewiring,Damagedwiringmaycause electricalfires.
17.Whenremovingpiping,stopthefueloroilfrom spillingout.Ifanyfueloroildripsontothefloor,wipe itupimmediately.Fueloroilonthefloorcancause youtoslip,orcanevenstartfires.
washingelectricalparts. Wheninstallinghosesandwires,besurethat theywillnotbedamagedbycontactwithother partswhenthemachineisbeingoperated.
20.Wheninstallinghighpressurehoses,makesurethat theyarenottwisted.Damagedtubesaredangerous, sobeextremelycarefulwheninstallingtubesforhigh pressurecircuits.Alsocheckthatconnectingparts arecorrectlyinstalled.
21.Whenassemblingorinstallingparts,alwaysusethe specifiedtighteningtorques.Wheninstalling protectivepartssuchasguards,orpartswhich vibrateviolentlyorrotateathighspeed,be particularlycarefultocheckthattheyareinstalled correctly.
22.Whenaligningtwoholes,neverinsertyourfingersor hand.Becarefulnottogetyourfingerscaughtina hole.
23.Whenmeasuringhydraulicpressure,checkthatthe measuringtooliscorrectlyassembledbeforetaking anymeasurements.
24.Takecarewhenremovingorinstallingthetracksof track-typemachines.Whenremovingthetrack,the trackseparatessuddenly,soneverletanyonestand ateitherendofthetrack.
FOREWARD
GENERAL
Thisshopmanualhasbeenpreparedasanaidtoimprovethequalityofrepairsbygivingtheservicemananaccurate understandingoftheproductandbyshowinghimthecorrectwaytoperformrepairsandmakejudgements.Makesure youunderstandthecontentsofthismanualanduseittofulleffectateveryopportunity.
Thisshopmanualmainlycontainsthenecessarytechnicalinformationforoperationsperformedinaserviceworkshop. Foreaseofunderstanding,themanualisdividedintothefollowingsections.Thesesectionsarefurtherdividedintoeach maingroupofcomponents.
GENERAL
Thissectionliststhegeneralmachinedimensions,performancespecifications,componentweights,andfuel, coolantandlubricantspecificationcharts.
STRUCTUREANDFUNCTION
Thissectionexplainsthestructureandfunctionofeachcomponent.Itservesnotonlytogiveanunderstandingof thestructure,butalsoservesasreferencematerialfortroubleshooting.
TESTINGANDADJUSTING
Thissectionexplainscheckstobemadebeforeandafterperformingrepairs,aswellasadjustmentstobemade atcompletionofthechecksandrepairs.Troubleshootingchartscorrelating"Problems"to"Causes"arealso includedinthissection.
DISASSEMBLYANDASSEMBLY
Thissectionexplainstheordertobefollowedwhenremoving,installing,disassemblingorassemblingeach component,aswellasprecautionstobetakenfortheseoperations.
MAINTENANCESTANDARD
Thissectiongivesthejudgementstandardswheninspectingdisassembledparts.
NOTICE
Thespecificationscontainedinthisshopmanualaresubjecttochangeatanytimeandwithoutanyadvance notice.Contactyourdistributorforthelatestinformation.
HOWTOREADTHESHOPMANUAL
VOLUMESREVISEDEDITIONMARK
Shopmanualsareissuedasaguidetocarryingout repairs.Theyaredividedasfollows:
Chassisvolume:Issuedforeverymachinemodel
Enginevolume:Issuedforeachengineseries
Electricalvolume:Eachissuedasonetocoverall models
Attachmentvolume:Eachissuedasonetocoverall models
Thesevariousvolumesaredesignedtoavoidduplication ofinformation.Thereforetodealwithallrepairsforany model,itisnecessarythatchassis,engineelectricaland attachmentbeavailable.
DISTRIBUTIONANDUPDATING
Anyadditions,amendmentsorotherchangeswillbesent toyourdistributors.Getthemostup-to-dateinformation beforeyoustartanywork.
FILINGMETHOD
1.Seethepagenumberonthebottomofthepage.File thepagesincorrectorder.
2.Followingexamplesshowhowtoreadthepage number:
Example1(Chassisvolume): 10-3
Itemnumber(10.Structureand Function)
Consecutivepagenumberfor eachitem
Example2(Enginevolume): Refertothepertinentenginemanual.
3.Additionalpages:Additionalpagesareindicatedbya hyphen(-)andnumberedafterthepagenumber.File asintheexample.
Example: 10-4
10-4-1
Addedpages10-4-2 10-5
Whenamanualisrevised,aneditionmark(....)is recordedonthebottomoutsidecornerofthepages.
REVISIONS
RevisedpagesareshownattheLISTOFREVISED PAGESbetweenthetitlepageandSAFETYpage.
SYMBOLS
Sothattheshopmanualcanbeofamplepracticaluse, importantplacesforsafetyandqualityaremarkedwith thefollowingsymbols.
SymbolItemRemarks
Safety Specialsafetyprecautionsare necessarywhenperformingthe work.
Caution
Weight
Tightening torque
Specialtechnicalprecautionsor otherprecautionsforpreserving standardsarenecessarywhen performingthework.
Weightofpartsorsystems. Cautionnecessarywhenselecting hoistingwireorwhenworking postureisimportant,etc.
Placesthatrequirespecial attentionfortighteningtorque duringassembly.
CoatPlacestobecoatedwithadhesives andlubricantsetc.
Oil,water
Drain
Placeswhereoil,waterorfuel mustbeadded,andthecapacity.
Placeswhereoilorwatermustbe drained,andquantitytobe drained.
HOISTINGINSTRUCTIONS
HOISTING
Heavyparts(25kgormore)mustbeliftedwith ahoistetc.IntheDISASSEMBLYANDASSEMBLYsection,everypartweighing25kgormore isindicatedclearlywiththesymbol
Ifapartcannotbesmoothlyremovedfromthe machinebyhoisting,thefollowingchecksshouldbe made:
1)Checkforremovalofallboltsfasteningthepart totherelativeparts.
2)Checkforexistenceofanotherpartcausing interfacewiththeparttoberemoved.
WIREROPES
1)Useadequateropesdependingontheweightof partstobehoisted,referringtothetablebelow:
Wireropes (Standard"Z"or"S"twistropeswithoutgalvanizing Ropediameter(mm)Allowableload(tons)
3)Donotslingaheavyloadwithoneropealone,but slingwithtwoormoreropessymmetricallywound ontotheload.
Slingingwithoneropemaycauseturningof theloadduringhoisting,untwistingoftherope, orslippingoftheropefromitsoriginalwinding positionontheload,whichcanresultinadangerous accident.
4)Donotslingaheavyloadwithropesformingawide hanginganglefromthehook.Whenhoistingaload withtwoormoreropes,theforcesubjectedtoeach ropewillincreasewiththehangingangles.The tablebelowshowsthevariationofallowableload (kg)whenhoistingismadewithtworopes,eachof whichisallowedtoslingupto1000kgvertically,at varioushangingangles.Whentworopesslinga loadvertically,upto2000kgoftotalweightcanbe suspended.Thisweightbecomes1000kgwhen tworopesmakea120hangingangle.Onthe otherhand,tworopesaresubjecttoanexcessive forceaslargeas4000kgiftheyslinga2000kg loadataliftingangleof150
Theallowableloadvalueisestimatedtobe1/6or 1/7ofthebreakingstrengthoftheropeused.
2)Slingwireropesfromthemiddleportionofthe hook.Slingingneartheedgeofthehookmay causetheropetoslipoffthehookduringhoisting, andaseriousaccidentcanresult.Hookshave maximumstrengthatthemiddleportion.
COATINGMATERIALS
Therecommendedcoatingmaterialsprescribedintheshopmanualsarelistedbelow.
CategoryCodePartNo.QtyContainerMainapplications,features
LT-1A790-129-9030150gTube
Adhesive
Gasketsealant
Usedtopreventrubbergaskets,rubbercushionsandcorkplugsfrom comingout
LT-1B790-129-905020g(x2)Usedforplastics(exceptpolyethylene,polypropylene,
LT-209940-0003050g
Plastic container
Plastic
Usedinplacesrequiringanimmediatelyeffective,strongadhesive. tetrafluoroethylene,andvinylchloride),rubber,metalandnon-metal.
Features:Resistancetoheat,chemicals containerUsedforanti-looseningandsealantpurposesforboltsandplugs.
LT-3ofadhesiveandHardagtCan
790-129-9060SetAdh1kg hardeningagent500kg
LT-4790-129-9040250g
Usedasadhesiveorsealantformetal,glassorplastic.
Usedassealantformachined Plasticholes.container
cc---
LoctiteFeatures:Resistancetoheat,chemicals 648-50Usedatjointportionssubjecttohigh 79A-129-911050temperature.
LG-1790-129-9010200gTube
Usedasadhesiveorsealantforgasketsandpackingofpowertrain case,etc.
Features:Resistancetoheat
Usedassealantforflangesurfacesandboltsathightemperature
LG-3790-129-90701kgCanlocations;usedtopreventseizure.
Usedassealantforheatresistantgasketforathightemperature locationssuchasenginepre-combustionchamber,exhaustpipe.
Features:Resistancetowater,oil Usedassealantforflangesurface,thread.
LG-4790-129-9020200gTube
LG-5790-129-90801kg
Alsopossibletouseassealantforflangeswithlargeclearance.
Usedassealantformatingsurfacesoffinaldrivecase,transmission case.
PlasticUsedassealantforvariousthreads,pipejoints,flanges. containerUsedassealantfortaperedplugs,elbows,nipplesofhydraulicpiping.
LG-609940-00011250gTube
LG-709920-00150150gTube
Rustpreven-tion lubricant---09940-0005160gCan
Features:Siliconbased,resistanttoheat,cold.
Usedassealantforflangesurface,thread.
Usedassealantforoilpan,finaldrivecase,etc.
Usedassealantforflywheelhousing,intakemanifold,oilpan,
Features:Siliconbased,quickhardeningtype. thermostathousing,etc.
Usedaslubricantforslidingparts(topreventsqueaking).
Molybdenum disulfidelubricant---09940-00040200gTubeshrinkfitting.
Usedtopreventseizureorscuffingofthethreadwhenpressfittingor Usedaslubricantforlinkage,bearings,etc.
SYG-350Ll SYG-400Ll
LithiumgreaseG2-L1SYG-400Ll-AVariousVariousGeneralpurposetype
SYG-160Ll
SYGA-160CNLl
SSG2-400CA
SYG2-350CA
CalciumgreaseG2-CASYG2-400CA-AVariousVarious
SYG2-160CA
SYGA-16CNCA
Molybdenum400g disulfidegrease(10/case)---SYG2-400MBellowstype
Usedfornormaltemperature,lightloadbearingatplacesincontactwith waterorsteam.
Usedforplaceswithheavyload.
STANDARDTORQUEREQUIREMENTS
STANDARDTORQUEREQUIREMENTSOFBOLTSANDNUTS
Thefollowingchartsgivethestandardtorquesvaluesofboltsandnuts.Exceptionsaregiveninsectionsof DISASSEMBLYANDASSEMBLY
Thistorquetabledoesnotapplytotheboltswithwhichnylonpackingorothernon-ferrousmetalwashersareto beused,orwhichrequiretorquingtootherwisespecifiedvalues.