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KOMATSU AVANCE LOADER WA250-3 SHOP MANUAL SEBM005906 – PDF DOWNLOAD
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Description
KOMATSU AVANCE LOADER WA250-3 SHOP MANUAL SEBM005906 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU AVANCE LOADER WA250-3 SHOP MANUAL SEBM005906 – PDF DOWNLOAD
Language : English
Pages : 717
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU AVANCE LOADER WA250-3 SHOP MANUAL SEBM005906 – PDF DOWNLOAD
COVER...................................................................................................................................................................... 1 CONTENTS................................................................................................................................................................... 2 01 GENERAL................................................................................................................................................................. 26 GENERAL ASSENBLY DRAWING............................................................................................................................................... 27 SPECIFICATIONS......................................................................................................................................................... 29 WEIGHT TABLE........................................................................................................................................................... 32 LIST OF LUBRICANT AND WATER............................................................................................................................................ 34 10 STRUCTURE AND FUNCTION.................................................................................................................................................. 36 POWER TRAIN............................................................................................................................................................ 37 PATH OF POWER TRANSMISSOM.............................................................................................................................................. 38 TORQUE CONVERTER, TRANSMISSION PIPING.................................................................................................................................. 40 TORQUE CONVERTER,TRANSMISSION HYDRAULIC SISTEM DIAGRAM................................................................................................................. 41 TORQUE CONVERTER,TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM................................................................................................................ 42 TORQUE CONVERTER....................................................................................................................................................... 43 TORQUE CONVERTER OIL FILTER............................................................................................................................................ 45 TRANSMISSION........................................................................................................................................................... 46 TRANSMISSION CONTROL VALVE............................................................................................................................................. 57 DRIVE SHAFT............................................................................................................................................................ 78 AXLE................................................................................................................................................................... 79 FINAL DRIVE............................................................................................................................................................ 85 AXLE MOUNT............................................................................................................................................................. 86 CENTER HINGE PIN....................................................................................................................................................... 88 STEERING PIPING........................................................................................................................................................ 89 STEERING COLUMN........................................................................................................................................................ 90 PRIORITY VALVE......................................................................................................................................................... 91 STEERING VALVE (ORBIT-ROLL)............................................................................................................................................ 94 2-WAY RESTRICTOR VALVE.................................................................................................................................................102 BRAKE PIPING...........................................................................................................................................................103 POWER MASTER CYLINDER..................................................................................................................................................104 BRAKE..................................................................................................................................................................108 PARKING BRAKE CONTROL..................................................................................................................................................110 HYDRAULIC PIPING.......................................................................................................................................................112 STEERING, HYDRAULIC PUMP HYDRAULIC SYSTEM DIAGRAM......................................................................................................................114 STEERING,HYDRAULIC PUMP CIRCUIT DIAGRAM................................................................................................................................115 WORK EQUIPMENT CONTROL LEVER LINKAGE...................................................................................................................................116 HYDRAULIC TANK.........................................................................................................................................................117 WORK EQUIPMENT LINKAGE.................................................................................................................................................133 BUCKT..................................................................................................................................................................135 BUKKET POSITIONER AND BOOM KICKOUT.....................................................................................................................................136 CAB....................................................................................................................................................................140 MACHINE MOINTOR SISTEM.................................................................................................................................................141 MAIN MONITOR...........................................................................................................................................................142 MAINTENANCE MONITOR DISPLAY FUNCTION...................................................................................................................................147 SENSORS AND SWITCHES...................................................................................................................................................149 ENGINE STARTING CIRCUIT................................................................................................................................................154 ENGINE STOP CIRCUIT....................................................................................................................................................156 PREHEATING CIRCUIT.....................................................................................................................................................158 STARTING AID...........................................................................................................................................................160 ELECTRICAL TRANSMISSION CONTROL........................................................................................................................................161 COMBINATION SWITCH.....................................................................................................................................................162 TRANSMISSION CUT-OFF FUNCTION..........................................................................................................................................163 PARKING BRAKE NEUTRALIZER RELAY FUNCTION...............................................................................................................................165 KICK-DOWN SWITCH.......................................................................................................................................................166 KICK-DOWN ELECTRIC CIRCUIT DIAGRAM.....................................................................................................................................167 TRANSMISSION AUTO SHIFT CONTRCL SYSTEM (IF EQUIPPED)...................................................................................................................172 20 TESTING AND ADJUSTING...................................................................................................................................................180 STANDARD VALUE TABLE FOR ENGINE........................................................................................................................................181 STANDARD VALUE TABLE FOR CHASSIS.......................................................................................................................................183 STANDARD VALUE TABLE FOR ELECTRICAL PARTS..............................................................................................................................186 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING......................................................................................................................188 ADJUSTING VALUE CLEARANCE..............................................................................................................................................190 MEASURING COMPRESSION PRESSURE.........................................................................................................................................192 TESTING AND ADJUSTING FUEL INGECTION TIMING............................................................................................................................193 MEASURING EXHAUST COLOR................................................................................................................................................195 MEASURING BLOW-BY PRESSURE.............................................................................................................................................196 TESTING AND ADJUSTING FAN BELT TENSION.................................................................................................................................198 MEASURING ENGINE SPEED.................................................................................................................................................199 METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE...........................................................................................................................201 ADJUSTING ENGINE STOP SOLENOID.........................................................................................................................................203 MEASURING ENGINE OIL PRESSURE..........................................................................................................................................204 MEASURING INTAKE AIR PRESSURE (BOSST PRESSURE).........................................................................................................................205 MEASURING EXHAUST GAS TEMPERATURE......................................................................................................................................206 MEASURING ACCELERATOR PEDAL............................................................................................................................................207 MEASURING SHIFT LEVER..................................................................................................................................................209 MEASURING STALL SPEED..................................................................................................................................................210 MEASURING TORQUE CONVERTER,TRANSMISSION OIL PRESSURE...................................................................................................................212 METHOD OF OPERATING EMERGENCY MANUAL SPOOL.............................................................................................................................214 TESTING AND ADJUSTING STEERING WHEEL...................................................................................................................................216 MEASURING STEERING OIL PRESSURE........................................................................................................................................219 MEASURING BRAKE PEDAL..................................................................................................................................................221 TESTING AND ADJUSTING BRAKE PEDAL LINKAGE..............................................................................................................................222 MEASURING BRAKE PERFORMANCE............................................................................................................................................224 MEASURING BRAKE OIL PRESSURE...........................................................................................................................................225 MEASURING WEAR OF BRAKE DISC...........................................................................................................................................226 BLEEDING AIR FROM BRAKE SISTEM.........................................................................................................................................227 MEASURING PARKING BRAKE PERFORMANCE....................................................................................................................................228 TESTING AND ADJUSTING PARKING BRAKE LINKAGE............................................................................................................................229 TESTING PARKING BRAKE PISTON STROKE....................................................................................................................................230 MEASURING WEAR OF PARKING BRAKE DISC...................................................................................................................................231 MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER...................................................................................................................232 MEASURING STROKE F WORK EQUIPMENT VALVE SPOOL..........................................................................................................................235 MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE............................................................................................................................236 MEASURING WORK EQUIPMENT...............................................................................................................................................238 TESTING AND ADJUSTING BUCKET POSITIONER................................................................................................................................240 TESTING AND ADJUSTING BOOM KICK-OUT....................................................................................................................................241 ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)............................................................................................................................243 CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR..........................................................................................................................244 TROUBLESHOOTING........................................................................................................................................................245 POINTS TO REMEMBER WHEN TROUBLESHOOTING............................................................................................................................246 SEQUENCE OF EVENTS IN TROUBLESHOOTING..............................................................................................................................247 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE..........................................................................................................................248 HANDLING CONNECTORS................................................................................................................................................255 CHECKS BEOORE TROUBLESHOOTING......................................................................................................................................256 JUDGEMENT OF POWER TRAIN...........................................................................................................................................257 METHOD OF USING TROUBLESHOOTING CHARTS.............................................................................................................................258 CONNECTOR TYPES AND MOUNTING LOCATIONS.............................................................................................................................266 CONNECTOR PIN ARRANGEMENT DIAGRAM..................................................................................................................................267 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.........................................................................................................................270 TROUBLESHOOTING OF ENGINE (S6D95L) SYSTEM (SMODE)[SERIAL NO.53001-52999]...........................................................................................278 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)..................................................................................................279 S-2 ENGINE DOES NOT START .....................................................................................................................................280 (1) ENGINE DOES NOT TURN...................................................................................................................................280 (2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED).................................................................................281 (3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED................................................................................282 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR).......................................................................................................283 S-4 ENGINE STOPS DURING OPERATIONS.............................................................................................................................284 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)..................................................................................................................285 S-6 ENGINE LACKS OUTPUT (NO POWER).............................................................................................................................286 S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)...............................................................................................................287 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)......................................................................................................288 S-9 OIL BECOMES CONTAMINATED QUICKLY...........................................................................................................................289 S-10 FUEL CONSUMPTION IS EXCESSIVE.............................................................................................................................290 S-11 OIL IS COLLING WATER, OR WATER SPURTS BACKS, OR WATER LEVEL GOSE DOWN.....................................................................................291 S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)........................................................................................................292 S-13 OIL LEVEL RISES...........................................................................................................................................293 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)..........................................................................................................294 S-15 ABNORMAL NOISE IS MADE....................................................................................................................................295 S-16 VIBRATION IS EXCESSIVE....................................................................................................................................296 TROULESHOOTING OF ENGINE (S6D102E) SYSTEM (S MODE) [SERIAL NO.53001 AND UP]........................................................................................297 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)..................................................................................................298 S-2 ENGINE DOES NOT START......................................................................................................................................299 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR).......................................................................................................302 S-4 ENGINE STOPS DURING OPERATIONS.............................................................................................................................303 S-5 ENGINE DOSE NOT ROTATE SMOOTHLY (HUNTING)..................................................................................................................304 S-6 ENGINE LACKS OUTPUT (NO POWER).............................................................................................................................305 S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)...............................................................................................................306 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)......................................................................................................307 S-9 OIL BECOMES CONTAMINATED QUICKLY...........................................................................................................................308 S-10 FUEL CONSUMPTION IS EXCESSIVE.............................................................................................................................309 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN...................................................................................310 S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)........................................................................................................311 S-13 OIL LEVEL RISES...........................................................................................................................................312 S-14 WATER TEMPERATURE BECOME TOO HIGH (OVERHEATING)...........................................................................................................313 S-15 ABNORMAL NOISE IS MADE....................................................................................................................................314 S-16 VIBRATION IS EXCESSIVE....................................................................................................................................315 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (T MODE)......................................................................................316 POWEER TRAIN ..................................................................................................................................................317 T-1 MACHINE DOES NOT START.................................................................................................................................317 T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES...................................................................................319 T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR.................................................................................................321 T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR..............................................................................................322 T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH...............................................................................................................323 STEERING SYSTEM................................................................................................................................................324 T-6 STEERING WHEEL DOES NOT TURN...........................................................................................................................324 T-7 STEERING IS HEAVY......................................................................................................................................325 T-8 STEERING WHEEL SHAKES OR THERE EXCESSIVE SHOCK.........................................................................................................326 T-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING..................................................................................................326 BRAKE SYSTEM...................................................................................................................................................327 T-10 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR..........................................................................................................327 T-11 BRAKE IS NOT RELEASED, BRAKE DRAGS....................................................................................................................328 WORK EQUIPMENT.................................................................................................................................................329 T-12 BOOM DOES NOT RISE....................................................................................................................................329 T-13 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER.....................................................................................................330 T-14 WHEN MOON IS RAISED IT MOVES SLOWLY AT A CERTAIN HEIGHT...............................................................................................331 T-15 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS)............................................................................................331 T-16 EXCESSIVE HYDRAULIC DRIFT OF BOOM.....................................................................................................................331 T-17 BOOM SHAKES DURING OPERATION..........................................................................................................................332 T-18 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FORM HOLD TO RAISE..............................................................................332 T-19 BUCKET DOES NOT TILT BACK.............................................................................................................................333 T-20 BUCKET MOVEMENT IS SLOW OR TILT-LACKS POWER...........................................................................................................334 T-21 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION...............................................................................................335 T-22 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER..........................................................................................................335 T-23 EXCESSIVE HYDRAULIC DRIFT OF BUCKET...................................................................................................................335 T-24 BUCKET SHAKETS DURING LOADING OPERATION (MAIN CONTROL VALVE AT HOLD)..................................................................................336 T-25 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT.............................................................................336 T-26 BOOM, BUCKET CONTROL LEVERS ARE HEAVE OR NOT MOVE SMOOTHLY............................................................................................337 TROUBLESHOOTING OF ELECTRICAL SYSTEM FOR ENGINE, TRANMISSION (E MODE)..........................................................................................338 E-1 ENGINE DOES NOT START..................................................................................................................................339 (a) STARTING MOTOR DOES NOT TURN.......................................................................................................................339 1) CHECK STARTING CIRCUIT..........................................................................................................................339 2) CHECK BETWEEN BATTERY RELAY AND STARTING SWITCH.................................................................................................340 (b) STARTING MOTOR TURNS...............................................................................................................................341 E-2 ENGINE DOES NOT STOP...................................................................................................................................347 E-3 ENGIN STOPS WHEN MACHINE IS TRAVELLING.................................................................................................................348 E-4 TRAMISSION IS NOT SET TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (TRANSMISSION CUT-OFF IS NORMAL)........................................................349 E-5 TRAMISSION DOES NOT WORK NORMALLY......................................................................................................................350 (a) PROBLEM IN PARKING BRAKE, TRANSMISSION CUT-OFF SWITCH, NEUTRALIZER RELAY CIRCUIT...................................................................351 (b) DEFECTIVE CONTINUITY IN FORWARD SOLENOID CIRCUITY..................................................................................................353 (c) DEFECTIVE CONTINUITY IN REVERSE SOLENOID CIRCUIT...................................................................................................355 (d) CONTACT IS DIRECTIONAL CIRCUIT.....................................................................................................................357 1) FORWARD IS CONTINUOUS...........................................................................................................................357 2) REVERSE IS CONTINUOUS...........................................................................................................................359 (e) PROBLEM WITH SPEED SOLENOID OR ALWAYS STAYS IN 2ND.................................................................................................361 (f) CONTACT IN SPEED CIRCULT...........................................................................................................................363 1) BATTERY VOITAGE FORMED IN 1ST (SPEED) SOLENOID).................................................................................................363 2) BATTERY VOLTAGE FORMED IN 3RD (H-L) SOLENOLD....................................................................................................365 E-6 KICK-DOWN SWITCH DOES NOT WORK (USUAL F1-F4 SHIFTS NORMALLY)...........................................................................................367 E-7 KICK-DOWN IS ACTUATED ONLY WHEN KICK-DOWN SWITCH IS ON (SELF-HOLD FUNCTION OF KICK-DOWN SWITCH RETAY DOES NOT WORK)....................................369 E-8 KICK-DOWN IS NOT CANCELED..............................................................................................................................370 (a) KICK-DOWN IS NOT CANCELED WHEN DIRECTIONAL LEVER IS MOVED FROM FORWARD TO NEUTRAL OR REVERSE.......................................................370 (b) KICK-DOWN IS NOT CANCELED WHEN SPEED LEVER IS MOVED FROM 2ND TO OTHER SPEED RANGE..................................................................371 E-9 KICK-DOWN SWITCH IS WRONGLY ACTUATED WHEN TRAVELING IN F2..............................................................................................373 E-10 PREHEATING IS NOT CARRIED OUT.........................................................................................................................374 E-11 PREHEATING REMAINS ACTUATED...........................................................................................................................379 TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)................................................................................................................384 TROUBLE DATE DISPLY........................................................................................................................................386 TABLE OF ACTION CODES AND FAILURE CODES....................................................................................................................387 M-1 MAIN MONITOR DOES NOT WORK.............................................................................................................................388 M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP.........................................................389 M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY.............................................................................................................390 M-4 ABNORMALITY IN SHIFT INDICATOR.........................................................................................................................391 (a) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT F.....................................................................................................391 (b) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT R.....................................................................................................391 (c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS E WHEN DIRECTIONAL LEVER IS AT F...............................................391 (d) DOES NOT DISPLAY N EVEN DIRECTIONAL LEVER IS AT N AND DISPLAYS E WHEN DIRECTIONAL LEVER IS AT R....................................................392 (e) DOES NOT PLAY 1ST, 4TH.............................................................................................................................392 (f) DOES NOT DISPLAY 3RD, 4TH..........................................................................................................................392 (g) DOES NOT DISPLAY 2ND, 3RD .........................................................................................................................393 (h) DOES NOT DISPLAY 1ST, 2ND..........................................................................................................................393 M-5 HIGH BEAM DOES NOT LIGHT UP............................................................................................................................394 M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP..................................................................................................................395 (a) L.H. TURN SIGNAL DOES NOT LIAGT UP.................................................................................................................395 (b) R.N. TURN SINGNAL DOES NOT LIGHT UP................................................................................................................395 M-7 ABNORMALITY IN PARKING DISPLAY.........................................................................................................................396 (a) PARKING LAMP DOES NOT LIGHT UP.....................................................................................................................396 (b) PARKING LAMP STAYS LIGHTED UP......................................................................................................................396 M-8 ABNORMALITY IN PREHEATING SYSTEM.......................................................................................................................397 (a) DOES NOT CARRY OUT PREHEATING......................................................................................................................397 (b) ONLY MONITOR DISPLAY DOES NOT LIGHT UP.............................................................................................................398 (c) ALWAYS CARRIES OUT PREHEATING FOR 1 MINUTE.........................................................................................................398 (d) PREHEATING STAYS ON................................................................................................................................398 (e) PREHEATING TIME BECOMES SHORTER, OR IS UNSTABLE....................................................................................................399 M-9 NIGHT LIGHTING DOES NOT LIGHT UP.......................................................................................................................405 M-10 ABNORMALITY IN FRONT WORKING LAMP.....................................................................................................................406 (a) NEITHER MONITOR DISPLAY NOR FRONT WORKING LIGHT UP.................................................................................................406 (b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP.......................................................................................406 (c) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP...............................................................................................406 M-11 ABNORMALITY IN REAR WORKING LAMP......................................................................................................................407 (a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP.............................................................................................407 (b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP.......................................................................................407 (c) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP...............................................................................................407 M-12 ABNORMALITY IN TRANSMISSION CUT-OFF...................................................................................................................409 (a) WHEN MONITOR SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY IS NOT GIVEN..........................................................409 (b) MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION STAYS ON.............................................................................................409 (c) MONITOR DISPLAY LIGHTS UP BUT CUT-OFF FUNCTION IS NOT ACTUATED.....................................................................................410 M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING.........................................................................................................411 (a) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS(INTERMITTENTLY) EVEN WHEN DIRECTIONAL LEVER IS AT N, AND CAUTION LAMP FLASHES.........................411 (b) WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVEL IS AT POSITION OTHER THEN N....411 M-14 WHEN PARKING BRAKE DRAGGING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED.....................................412 (a) ACTUATED CONTINUOUSLY..............................................................................................................................412 (b) NOT ACTUATED.......................................................................................................................................412 M-15 ABNOMALITY IN BUZZER..................................................................................................................................413 (a) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS TURNED ON (DURING SELF-CHECK)........................................................................413 (b) BUZZER ALWAYS SOUNDS...............................................................................................................................413 M-16 CONDITION OF MONITOR OF SWITCHES IS NOT STORED IN MEMORY..............................................................................................414 M-17 ABNORMALITY IN FAILURE DISPLAY MODE...................................................................................................................415 (a) DOES NOT ENTER FAILURE DISPLAY MODE................................................................................................................415 (b) TIME FOR TIME ELAPSED SINCE FAILURE ON FAILURE DISPLAY MODE NOT ADVANCE............................................................................415 TROUBLESHING OF MAINTENANCE MONITOR SYSTEM(K MODE).............................................................................................................416 K-1 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS,MAINTENANCE MONITOR DOES NOT WORK.....................417 (a)ALL LUMPS ON MAINTENANCE MONITIOR DO NOT LIGHT UP FOR 3 SECONDS.....................................................................................417 (b)SOME LAMPS DO NOT LIGHT UP..........................................................................................................................418 K-2 WHEN STARTING SWITCH IS TURNED ON,ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT..........................................................418 K-3 WHEN ENGINE IS STARTING IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON(WITHIN 3 SECONDS),ALL LAMPS ON MAINTENANCE MONITOR DO NOT GO OUT................419 K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED),CHECK ITEMS FLASH...................................................................................420 (a) ENGINE OIL LEVEL DISPLAY FLASHES...................................................................................................................420 (b) ENGINE WATER LEVEL DISPLAY FLASHES.................................................................................................................421 (c) BRAKE OIL LEVEL DISPLAY FLASHES....................................................................................................................422 K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED),CAUTION ITEMS FLASH.................................................................................423 (a) ENGINE OIL PRESSURE DISPLAY FLASHES................................................................................................................423 (b)BATTERY CHARGE LEVEL DISPLAY FLASHES................................................................................................................424 K-6 CAUTION ITEMS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUND.............................................................................................425 K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT ALARM BUZZER SOUNDS....................................................................................426 K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP,CAUTION LAMP)DOES NOT LIGHT UP.................................................................427 (a)CHECK LAMP..........................................................................................................................................427 (b)CAUTION LAMP........................................................................................................................................427 K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT WARNING LAMP (CHECK LAMP) LIGHTS UP.........................................................428 (a) CHECK LAMP.........................................................................................................................................428 (b) CAUTION LAMP.......................................................................................................................................428 K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTEANCE MONITOR DOESNOT LIGHT UP).................................429 K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAYS LIGHTED UP................................................................430 K-12 SERVICE METER DOES NOT WORK...........................................................................................................................431 K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED..................................................................................................431 K-14 ABNORMALITY IN GAUGE ITEMS............................................................................................................................432 (a) ABNORMALITY IN FUEL GAUGE .........................................................................................................................432 (b) ABNORMALITY IN ENGINE WATER TEMPURATURE GAUGE......................................................................................................433 (c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE..............................................................................................434 30 DISASSEMBLY AND ASSEMBLY................................................................................................................................................435 METHOD OF USING MANUAL.................................................................................................................................................437 PRECAUTIONS WHEN CARRYING OUT OPERATION................................................................................................................................438 SPECIAL TOOL LIST......................................................................................................................................................440 STARTING MOTOR.........................................................................................................................................................442 REMOVAL AND INSTALLATION...........................................................................................................................................442 ALTERNATOR.............................................................................................................................................................443 REMOVAL AND INSTALLATION...........................................................................................................................................443 ENGINE OIL COOLER .....................................................................................................................................................445 REMOVAL AND INSTALLATION...........................................................................................................................................445 FUEL OF INJECTION PUMP.................................................................................................................................................447 REMOVAL............................................................................................................................................................447 INSTALLATION.......................................................................................................................................................448 WATER PUMP.............................................................................................................................................................454 REMOVAL AND INSTALLATION...........................................................................................................................................454 TURBOCHARGER...........................................................................................................................................................456 REMOVAL AND INSTALLATION...........................................................................................................................................456 NOZZLE HOLDER .........................................................................................................................................................458 REMOVAL AND INSTALLATION...........................................................................................................................................458 THERMOSTAT.............................................................................................................................................................461 REMOVAL AND INSTALLATION...........................................................................................................................................461 CYLINDER HEAD..........................................................................................................................................................463 REMOVAL............................................................................................................................................................463 INSTALLATION.......................................................................................................................................................465 RADIATOR ..............................................................................................................................................................475 REMOVAL............................................................................................................................................................475 INSTALLATION.......................................................................................................................................................478 RADIATOR, HYDRAULIC COOLER ............................................................................................................................................479 REMOVAL............................................................................................................................................................479 INSTALLATION.......................................................................................................................................................480 ENGINE.................................................................................................................................................................481 REMOVAL ...........................................................................................................................................................481 INSTALLATION.......................................................................................................................................................484 TORQUE CONVERTER CHARGING PUMP.........................................................................................................................................489 REMOVAL AND INSTALLATION...........................................................................................................................................489 TORQUE CONVERTER, TRANSMISSION.........................................................................................................................................490 REMOVAL............................................................................................................................................................490 INSTALLATION.......................................................................................................................................................499 TORQUE CONVERTER.......................................................................................................................................................501 DISASSEMBLY........................................................................................................................................................501 ASSEMBLY...........................................................................................................................................................503 TRANSMISSION ..........................................................................................................................................................505 DISASSEMBLY........................................................................................................................................................505 ASSEMBLY ..........................................................................................................................................................514 CLUTCH PACK ...........................................................................................................................................................527 DISASSEMBLY........................................................................................................................................................527 ASSEMBLY ..........................................................................................................................................................533 PARKING BRAKE..........................................................................................................................................................545 DISASSEMBLY........................................................................................................................................................545 ASSEMBLY ..........................................................................................................................................................547 TRANSMISSION CONTROL VLVE..............................................................................................................................................550 REMOVAL ...........................................................................................................................................................550 INSTALLATION.......................................................................................................................................................551 DISASSEMBLY........................................................................................................................................................552 ASSEMBLY ..........................................................................................................................................................554 TRANSMISSION SOLENOID VALVE............................................................................................................................................556 DISASSEMBLY AND ASSEMBLY...........................................................................................................................................556 ACCUMULATOR VALVE......................................................................................................................................................557 DISASSEMBLY AND ASSEMBLY...........................................................................................................................................557 DRIVE SHAFT............................................................................................................................................................559 DISASSEMBLY........................................................................................................................................................559 ASSEMBLY...........................................................................................................................................................561 FRONT AXLE.............................................................................................................................................................563 REMOVAL............................................................................................................................................................563 INSTALLATION.......................................................................................................................................................565 REAR AXLE..............................................................................................................................................................566 REMOVAL............................................................................................................................................................566 ASSEMBLY...........................................................................................................................................................570 DIFFERENTIAL...........................................................................................................................................................573 DISASSEMBLY........................................................................................................................................................573 ASSEMBLY...........................................................................................................................................................577 AXLE HOUSING...........................................................................................................................................................586 DISASSEMBLY........................................................................................................................................................586 ASSEMBLY...........................................................................................................................................................591 CENTER HINGE PIN.......................................................................................................................................................597 REMOVAL............................................................................................................................................................597 INSTALLATION.......................................................................................................................................................604 STEERING VALVE.........................................................................................................................................................607 REMOVAL ...........................................................................................................................................................607 INSTALLATION ......................................................................................................................................................609 DISASSEMBLY .......................................................................................................................................................610 ASEMBLY............................................................................................................................................................613 PRIORITY...............................................................................................................................................................618 REMOVAL ...........................................................................................................................................................618 INSTALLATION.......................................................................................................................................................619 STEERING CYLINDER......................................................................................................................................................620 REMOVAL AND INSTALLATION...........................................................................................................................................620 POWER MASTER CYLINDER .................................................................................................................................................621 REMOVAL ...........................................................................................................................................................621 INSTALLATION.......................................................................................................................................................622 DISASSEMBLY .......................................................................................................................................................623 ASSEMBLY ..........................................................................................................................................................626 PARKING BRAKE DISC.....................................................................................................................................................631 REMOVAL............................................................................................................................................................631 INSTALLATION.......................................................................................................................................................632 HYDRAULIC TANK ........................................................................................................................................................633 REMOVAL............................................................................................................................................................633 INSTALLATION.......................................................................................................................................................634 HYDRAULIC FILTER ......................................................................................................................................................635 REMOVAL AND INSTALLATION...........................................................................................................................................635 WORK EQUIPMENT, STEERING PUMP .........................................................................................................................................636 REMOVAL AND INSTALLATION...........................................................................................................................................636 MAIN CONTROL VALVE ....................................................................................................................................................637 REMOVAL ...........................................................................................................................................................637 INSTALLATION.......................................................................................................................................................638 DISASSEMBLY AND ASSEMBLY ..........................................................................................................................................639 BUCKET CYLINDER........................................................................................................................................................641 REMOVAL............................................................................................................................................................641 INSTALLATION.......................................................................................................................................................642 BOOM CYLINDER..........................................................................................................................................................643 REMOVAL............................................................................................................................................................643 INSTALLATION.......................................................................................................................................................644 HYDRAULIC CYLINDER.....................................................................................................................................................645 DISASSEMBLY........................................................................................................................................................645 ASSEMBLY ..........................................................................................................................................................647 WORK EQUIPMENT.........................................................................................................................................................649 REMOVAL............................................................................................................................................................649 INSTALLATION.......................................................................................................................................................652 COUNTERWEIGHT..........................................................................................................................................................654 REMOVAL AND INSTALLATION...........................................................................................................................................654 FUEL TANK..............................................................................................................................................................655 REMOVAL ...........................................................................................................................................................655 INSTALLATION.......................................................................................................................................................656 CAB ...................................................................................................................................................................657 REMOVAL............................................................................................................................................................657 INSTALLATION.......................................................................................................................................................658 MAIN MONITOR...........................................................................................................................................................659 REMOVAL............................................................................................................................................................659 INSTALLATION.......................................................................................................................................................660 MAINTENANCE MONITOR....................................................................................................................................................661 REMOVAL AND INSTALLATION...........................................................................................................................................661 AIR CONDITIONER UNIT...................................................................................................................................................662 REMOVAL............................................................................................................................................................662 INSTALLATION.......................................................................................................................................................667 AIR CONDITIONER CONDENSER..............................................................................................................................................668 REMOVAL............................................................................................................................................................668 INSTALLATION.......................................................................................................................................................669 DPY RECEIVER...........................................................................................................................................................670 REMOVAL AND INSTALLATION...........................................................................................................................................670 AIR CONDITIONER COMPRESSOR ............................................................................................................................................671 REMOVAL AND INSTALLATION...........................................................................................................................................671 40 MAINTENANCE STANDARD....................................................................................................................................................672 TRANSMISSION, ENGINE MOUNT.............................................................................................................................................673 TORQUE CONVERTER.......................................................................................................................................................675 TRANSMISSION...........................................................................................................................................................676 TRANSMISSION CONTROL VALVE.............................................................................................................................................682 ACCUMULATOR VALVE......................................................................................................................................................686 DRIVE SHAFT............................................................................................................................................................687 DIFFERENTIAL...........................................................................................................................................................688 FINAL DRIVE............................................................................................................................................................692 AXLE MOUNT.............................................................................................................................................................694 CENTER HINGE PIN.......................................................................................................................................................696 STEERING COLUMN .......................................................................................................................................................698 PRIORITY VALVE.........................................................................................................................................................699 MASTER CYLINDER........................................................................................................................................................700 BRAKE..................................................................................................................................................................701 PARKING BRAKE..........................................................................................................................................................702 MAIN CONTROL VALVE.....................................................................................................................................................703 HYDRAULIC CYLINDER.....................................................................................................................................................707 STEERING CYLINDER MOUNT................................................................................................................................................708 WORK EQUIPMENT LINKAGE.................................................................................................................................................709 BUCKET.................................................................................................................................................................711 BUCKET POSITIONER AND BOOM KICK-OUT....................................................................................................................................712 90 OTHERS..................................................................................................................................................................713 ELECTRICAL CIRCUIT DIAGRAM(1/2) (SERIAL NO.:50001-53000)...............................................................................................................714 ELECTRICAL CIRCUIT DIAGRAM(2/2) (SERIAL NO.:50001-53000)...............................................................................................................715 ELECTRICAL CIRCUIT DIAGRAM(1/2) (SERIAL NO.:53001 AND UP ).............................................................................................................716 ELECTRICAL CIRCUIT DIAGRAM(2/2) (SERIAL NO.:53001 AND UP)..............................................................................................................717
DESCRIPTION:
KOMATSU AVANCE LOADER WA250-3 SHOP MANUAL SEBM005906 – PDF DOWNLOAD
GENERAL
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 the following chapters; these chapters are further divided into the each main group of components.
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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
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” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together
S.S 22/12/24
