Komatsu Avance Loader WA250-3 Shop Manual SEBM005906 PDF

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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 : 724
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu Avance Loader WA250-3 Shop Manual SEBM005906 – PDF DOWNLOAD

• MACHINE MODEL            SERIAL NUMBER
  WA250-3                             50001 and up

MAIN MENU 0
CONTENTS . 2
SAFETY . 7
SAFETY NOTICE 7
FOREWORD . 9
GENERAL 9
HOW TO READ THE SHOP MANUAL 10
HOISTING INSTRUCTIONS 11
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER . 12
COATING MATERIALS 14
STANDARD TIGHTENING TORQUE . 16
ELECTRIC WIRE CODE . 19
CONVERSION TABLE . 20
UNITS 26
01 GENERAL . 22
GENERAL ASSEMBLY DRAWING 23
SPECIFICATIONS 28
WEIGHT TABLE 31
LIST OF LUBRICANT AND WATER . 33
10 STRUCTURE AND FUNCTION 35
POWER TRAIN . 36
PATH OF POWER TRANSMISSION 37
TORQUE CONVERTER, TRANSMISSION PIPING . 39
TORQUE CONVERTER, TRANSMISSION HYDRAULIC SYSTEM . 40
TORQUE CONVERTER, TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM . 41
TORQUE CONVERTER 42
TORQUE CONVERTER OIL FILTER . 44
TRANSMISSION 45
TRANSMISSION CONTROL VALVE 56
DRIVE SHAFT . 77
AXLE . 78
FINAL DRIVE . 84
AXLE MOUNT . 85
CENTER HINGE PIN 87
STEERING PIPING . 88
STEERING COLUMN 89
PRIORITY VALVE 90
STEERING VALVE (ORBIT-ROLL) . 93
2-WAY RESTRICTOR VALVE 101
BRAKE PIPING .102
POWER MASTER CYLINDER .103
BRAKE .107
PARKING BRAKE CONTROL 109
HYDRAULIC PIPING 111
STEERING, HYDRAULIC PUMP HYDRAULIC SYSTEM DIAGRAM .113
STEERING, HYDRAULIC PUMP HYDRAULIC CIRCUIT DIAGRAM .114
WORK EQUIPMENT CONTROL LEVER LINKAGE 115
HYDRAULIC TANK 116
MAIN CONTROL VALVE 119
WORK EQUIPMENT LINKAGE 132
BUCKET 134
BUCKET POSITIONER AND BOOM KICKOUT 135
CAB .139
MACHINE MONITOR SYSTEM 140
MAIN MONITOR 141
MAINTENANCE MONITOR DISPLAY FUNCTION 146
SENSORS AND SWITCHES 148
ENGINE STARTING CIRCUIT .153
ENGINE STOP CIRCUIT .155
PREHEATING CIRCUIT 157
STARTING AID 159
ELECTRICAL TRANSMISSION CONTROL .160
COMBINATION SWITCH 161
TRANSMISSION CUT-OFF FUNCTION .162
PARKING BRAKE NEUTRALIZER RELAY FUNCTION 164
KICK-DOWN SWITCH 165
KICK-DOWN ELECTRIC CIRCUIT DIAGRAM 166
TRANSMISSION AUTO SHIFT CONTROL SYSTEM (IF EQUIPPED) .171
20 TESTING AND ADJUSTING .179
STANDARD VALUE TABLE FOR ENGINE .180
STANDARD VALUE TABLE FOR CHASSIS 182
STANDARD VALUE TABLE FOR ELECTRICAL PARTS .185
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING .187
ADJUSTING VALVE CLEARANCE .189
MEASURING COMPRESSION PRESSURE .191
TESTING AND ADJUSTING FUEL INJECTION TIMING .192
MEASURING EXHAUST COLOR .194
MEASURING BLOW-BY PRESSURE 195
TESTING AND ADJUSTING FAN BELT TENSION 197
MEASURING ENGINE SPEED 198
METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE 200
ADJUSTING ENGINE STOP SOLENOID 202
MEASURING ENGINE OIL PRESSURE .203
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) 204
MEASURING EXHAUST GAS TEMPERATURE .205
MEASURING ACCELERATOR PEDAL 206
MEASURING SHIFT LEVER .208
MEASURING STALL SPEED .209
MEASURING TORQUE CONVERTER, TRANSMISSION OIL PRESSURE .211
METHOD OF OPERATING EMERGENCY MANUAL SPOOL 213
TESTING AND ADJUSTING STEERING WHEEL .215
MEASURING STEERING OIL PRESSURE .218
MEASURING BRAKE PEDAL .220
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE .221
MEASURING BRAKE PERFORMANCE .223
MEASURING BRAKE OIL PRESSURE 224
MEASURING WEAR OF BRAKE DISC 225
BLEEDING AIR FROM BRAKE SYSTEM .226
MEASURING PARKING BRAKE PERFORMANCE .227
TESTING AND ADJUSTING PARKING BRAKE LINKAGE .228
TESTING PARKING BRAKE PISTON STROKE .229
MEASURING WEAR OF PARKING BRAKE DISC 230
MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER 231
MEASURING STROKE OF WORK EQUIPMENT VALVE SPOOL 234
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE .235
MEASURING WORK EQUIPMENT 237
TESTING AND ADJUSTING BUCKET POSITIONER .239
TESTING AND ADJUSTING BOOM KICK-OUT .240
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE) .242
CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR .243
TROUBLESHOOTING 244
POINTS TO REMEMBER WHEN TROUBLESHOOTING .245
SEQUENCE OF EVENTS IN TROUBLESHOOTING .246
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE .247
HANDLING CONNECTORS .254
CHECKS BEFORE TROUBLESHOOTING .255
JUDGEMENT OF POWER TRAIN 256
METHOD OF USING TROUBLESHOOTING CHARTS 257
CONNECTOR TYPES AND MOUNTING LOCATIONS 265
CONNECTOR PIN ARRANGEMENT DIAGRAM 266
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS .269
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM .277
ENGINE START, STOP SYSTEM 277
PREHEATING SYSTEM 278
TRANSMISSION CONTROL, PARKING BRAKE SYSTEM .279
MACHINE MONITOR SYSTEM .280
TROUBLESHOOTING OF ENGINE (S6D95L) SYSTEM (S MODE) (SERIAL NO.50001-52999) .282
S-1 Starting performance is poor (Starting always takes time) 283
S-2 Engine does not start 284
(1) Engine does not turn .284
(2) Engine turns but no exhaust gas comes out (Fuel is not being injected) .285
(3) Exhaust gas comes out but engine does not start (Fuel is being injected) .286
S-3 Engine does not pick up smoothly (Follow-up is poor) 287
S-4 Engine stops during operations 288
S-5 Engine does not rotate smoothly (hunting) .289
S-6 Engine lacks output (no power) 290
S-7 Exhaust gas is black (incomplete combustion) 291
S-8 Oil consumption is excessive (or exhaust gas is blue) .292
S-9 Oil becomes contaminated quickly 293
S-10 Fuel consumption is excessive 294
S-11Oil is in cooling water, or water spurts back, or water level goes down 295
S-12 Oil pressure lamp lights up (drop in oil pressure) .296
S-13 Oil level rises 297
S-14 Water temperature becomes too high (overheating) 298
S-15 Abnormal noise is made .299
S-16 Vibration is excessive .300
TROUBLESHOOTING OF ENGINE (S6D102E) SYSTEM (S MODE) (SERIAL NO. 53001 AND UP) 301
S-1 Starting performance is poor (Starting always takes time) 302
S-2 Engine does not start .303
S-3 Engine does not pick up smoothly (Follow-up is poor) 306
S-4 Engine stops during operations 307
S-5 Engine does not rotate smoothly (hunting) .308
S-6 Engine lacks output (no power) 309
S-7 Exhaust gas is black (incomplete combustion) 310
S-8 Oil consumption is excessive (or exhaust gas is blue) .311
S-9 Oil becomes contaminated quickly 312
S-10 Fuel consumption is excessive 313
S-11 Oil is in cooling water, or water spurts back, or water level goes down .314
S-12 Oil pressure lamp lights up (drop in oil pressure) .315
S-13 Oil level rises 316
S-14 Water temperature becomes too high (overheating) 317
S-15 Abnormal noise is made .318
S-16 Vibration is excessive .319
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (T MODE) .320
POWER TRAIN 321
T-1 Machine does not start 321
T-2 Travel speed is slow, thrusting power is weak, lacks power on slopes .323
T-3 Excessive shock when starting machine or shifting gear 325
T-4 Excessive time lag when starting machine or shifting gear .326
T-5 Torque converter oil temperature is high 327
STEERING SYSTEM 328
T-6 Steering wheel does not turn 328
T-7 Steering is heavy .329
T-8 Steering wheel shakes or there is excessive shock .330
T-9 Machine deviates naturally to one side when traveling .330
BRAKE SYSTEM .331
T-10 Brakes do not work or braking effect is poor .331
T-11 Brake is not released, brake drags .332
WORK EQUIPMENT .333
T-12 Boom does not rise .333
T-13 Boom movement is slow or boom lacks lifting power 334
T-14 When boom is raised, it moves slowly at a certain height .335
T-15 Bucket cannot be pushed with boom cylinder (bucket floats) .335
T-16 Excessive hydraulic drift of boom .335
T-17 Boom shakes during operation .336
T-18 Boom drops momentarily when control lever is operated from HOLD to RAISE 336
T-19 Bucket does not tilt back 337
T-20 Bucket movement is slow or tilt-back lacks power .338
T-21 Bucket movement becomes slow during tilt-back operation 339
T-22 Bucket cannot be pushed with bucket cylinder .339
T-23 Excessive hydraulic drift of bucket 339
T-24 Bucket shakes during loading operation (Main control valve at HOLD) .340
T-25 Bucket dumps momentarily when control lever is operated from HOLD to TILT .340
T-26 Boom, bucket control levers are heavy or do not move smoothly 341
TROUBLESHOOTING OF ELECTRICAL SYSTEM FOR ENGINE, TRANSMISSION (E MODE) 342
E-1 Engine does not start .343
(a) Starting motor does not turn .343
1) Check starting circuit 343
2) Check between battery relay and starting switch .344
(b) Starting motor turns .345
E-2 Engine does not stop 351
E-3 Engine stops when machine is traveling 352
E-4 Transmission is not set to neutral when parking brake is applied (transmission cut-off is normal) 353
E-5 Transmission does not work normally .354
(a) Problem in parking brake, transmission cut-off switch, neutralizer relay circuit .355
(b) Defective continuity in FORWARD solenoid circuit .357
(c) Defective continuity in REVERSE solenoid circuit .359
(d) Contact in directional circuit .361
1) FORWARD is continuous .361
2) REVERSE is continuous .363
(e) Problem with speed solenoid or always stays in 2nd .365
(f) Contact in speed circuit .367
1) Battery voltage formed in 1st (speed) solenoid 367
2) Battery voltage formed in 3rd (H – L) solenoid 369
E-6 Kick-down switch does not work 371
E-7 Kick-down is actuated only when kick-down switch is ON 373
E-8 Kick-down is not canceled .374
(a) Kick-down is not canceled when directional lever is moved from FORWARD to NEUTRAL or REVERSE .374
(b) Kick-down is not canceled when speed lever is moved from 2nd to other speed range 375
E-9 Kick-down switch is wrongly actuated when traveling in F2 .377
E-10 Preheating 3 is not carried out .378
E-11 Preheating remains actuated .383
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE) .388
TROUBLE DATA DISPLAY 390
TABLE OF ACTION CODES AND FAILURE CODES .391
M-1 Main monitor does not work 392
M-2 When starting switch is turned ON and engine is started immediately, all lamps stay lighted up .393
M-3 Speedometer display does not work properly 394
M-4 Abnormality in shift indicator 395
(a) Stays at N even when directional lever is at F .395
(b) Stays at N even when directional lever is at R .395
(c) Does not display N even when directional lever is at N and displays E when directional lever is at F .395
(d) Does not display N even when directional lever is at N and displays E when directional lever is at R .396
(e) Does not display 1st, 4th 396
(f) Does not display 3rd, 4th 396
(g) Does not display 2nd, 3rd 397
(h) Does not display 1st. 2nd 397
M-5 High beam does not light up .398
M-6 Turn signal display does not light up .399
(a) L.H. turn signal does not light up .399
(b) R.H. turn signal does not light up .399
M-7 Abnormality in parking display 400
(a) Parking lamp does not light up .400
(b) Parking lamp stays lighted up 400
M-8 Abnormality in preheating system 401
(a) Does not carry out preheating 401
(1) Monitor display also does not light up .401
(2) Only monitor display lights up .401
(b) Only monitor display does not light up .402
(c) Always carries out preheating for 1 minute .402
(d) Preheating stays on 402
(e) Preheating time becomes shorter, or is unstable 403
M-9 Night lighting does not light up 409
M-10 Abnormality in front working lamp 410
(a) Neither monitor display nor front working lamp light up 410
(b) Working lamp lights up but monitor display does not light up .410
(c) Monitor lights up but working lamp does not light up .410
M-11 Abnormality in rear working lamp .411
(a) Neither monitor display nor rear working lamp light up .411
(b) Working lamp lights up but monitor display does not light up .411
(c) Monitor lights up but working lamp does not light up .411
M-12 Abnormality in transmission cut-off 413
(a) When monitor switch is pressed, cut-off function is not switched and display is not given 413
(b) Monitor display goes out but cut-off function stays on .413
(c) Monitor display lights up but cut-off function is not actuated .414
M-13 Abnormality in parking brake dragging warning 415
(a) When parking brake is applied, buzzer sounds (intermittently) even when directional lever is at N, and caution lamp flashes 415
(b) When parking brake is applied, buzzer does not sound and caution lamp does not light up even when directional lever is at 415
M-14 When parking brake dragging warning is given, buzzer and caution lamp are actuated continuously, or they are not actuated .416
(a) Actuated continuously 416
(b) Not actuated .416
M-15 Abnormality in buzzer 417
(a) Buzzer does not sound when starting switch is turned ON (during self-check) 417
(b) Buzzer always sounds .417
M-16 Condition of monitor switches is not stored in memory 418
M-17 Abnormality in failure display mode 419
(a) Does not enter failure display mode 419
(b) Time for time elapsed since failure on failure display mode does not advance .419
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE) 420
K-1 When starting switch is turned ON, all lamps on maintenance monitor do not light up for 3 sec, monitor does not work 421
(a) All lamps on maintenance monitor do not light up for 3 seconds .421
(b) Some lamps do not light up .422
K-2 When starting switch is turned ON, all lamps on maintenance monitor light up but do not go out .422
K-3 When engine is started immediately after starting switch is turned ON (within 3 seconds), all lamps on maintenance monitor do not go out 423
K-4 When starting switch is turned ON (engine stopped), CHECK items flash 424
(a) Engine oil level display flashes .424
(b) Engine water level display flashes .425
(c) Brake oil level display flashes 426
K-5 When starting switch is turned ON (engine started), CAUTION items flash 427
(a) Engine oil pressure display flashes 427
(b) Battery charge level display flashes .428
K-6 CAUTION items are flashing but alarm buzzer does not sound 429
K-7 There is no abnormality in monitor display but alarm buzzer sounds .430
K-8 CAUTION items are flashing but warning lamp (CHECK lamp, CAUTION lamp) does not light up .431
(a) CHECK lamp .431
(b) CAUTION lamp .431
K-9 There is no abnormality in maintenance monitor display but warning lamp (CHECK lamp, CAUTION lamp) lights up .432
(a) CHECK lamp .432
(b) CAUTION lamp .432
K-10 Night lighting does not light up when lamp switch is turned ON (only lighting of maintenance monitor does not light up) .433
K-11 Night lighting lights up even when lamp switch is OFF, night lighting stays lighted up 434
K-12 Service meter does not work 435
K-13 Service meter is running even when engine is stopped .435
K-14 Abnormality in gauge items .436
(a) Abnormality in fuel gauge 436
(b) Abnormality in engine water temperature gauge 437
(c) Abnormality in torque converter oil temperature gauge 438
30 DISASSEMBLY AND ASSEMBLY 439
METHOD OF USING MANUAL 441
PRECAUTIONS WHEN CARRYING OUT OPERATION .442
SPECIAL TOOL LIST .444
STARTING MOTOR .446
REMOVAL AND INSTALLATION 446
ALTERNATOR .447
REMOVAL AND INSTALLATION 447
ENGINE OIL COOLER .449
REMOVAL AND INSTALLATION .449
FUEL INJECTION PUMP 451
REMOVAL 451
INSTALLATION .452
WATER PUMP .458
REMOVAL AND INSTALLATION .458
TURBOCHARGER .460
REMOVAL AND INSTALLATION .460
NOZZLE HOLDER .462
REMOVAL AND INSTALLATION 462
THERMOSTAT .465
REMOVAL AND INSTALLATION .465
CYLINDER HEAD 467
REMOVAL 467
INSTALLATION .469
RADIATOR 479
REMOVAL 479
INSTALLATION .482
RADIATOR, HYDRAULIC COOLER .483
REMOVAL 483
INSTALLATION .484
ENGINE .485
REMOVAL 485
INSTALLATION .488
TORQUE CONVERTER CHARGING PUMP 493
REMOVAL AND INSTALLATION 493
TORQUE CONVERTER, TRANSMISSION .494
REMOVAL 494
INSTALLATION .503
TORQUE CONVERTER .505
DISASSEMBLY 505
ASSEMBLY 507
TRANSMISSION .509
DISASSEMBLY 509
ASSEMBLY 518
CLUTCH PACK .531
DISASSEMBLY 531
ASSEMBLY 537
PARKING BRAKE 549
DISASSEMBLY 549
ASSEMBLY 551
TRANSMISSION CONTROL VALVE 554
REMOVAL 554
INSTALLATION 555
DISASSEMBLY 556
ASSEMBLY 558
TRANSMISSION SOLENOID VALVE 560
DISASSEMBLY AND ASSEMBLY .560
ACCUMULATOR VALVE 561
DISASSEMBLY AND ASSEMBLY .561
DRIVE SHAFT 563
DISASSEMBLY .563
ASSEMBLY 565
FRONT AXLE .567
REMOVAL .567
INSTALLATION .569
REAR AXLE 570
REMOVAL 570
ASSEMBLY 574
DIFFERENTIAL .577
DISASSEMBLY .577
ASSEMBLY 581
AXLE HOUSING .590
DISASSEMBLY 590
ASSEMBLY .595
CENTER HINGE PIN 601
REMOVAL 601
INSTALLATION .608
STEERING VALVE 612
REMOVAL 612
INSTALLATION 614
DISASSEMBLY .615
ASSEMBLY 618
PRIORITY VALVE 623
REMOVAL 623
INSTALLATION 624
STEERING CYLINDER .625
REMOVAL AND INSTALLATION .625
POWER MASTER CYLINDER .626
REMOVAL 626
INSTALLATION 627
DISASSEMBLY .628
ASSEMBLY .631
PARKING BRAKE DISC 636
REMOVAL 636
INSTALLATION 637
HYDRAULIC TANK .638
REMOVAL 638
INSTALLATION 639
HYDRAULIC FILTER .640
REMOVAL AND INSTALLATION .640
WORK EQUIPMENT, STEERING PUMP .641
REMOVAL AND INSTALLATION .641
MAIN CONTROL VALVE .642
REMOVAL 642
INSTALLATION 643
DISASSEMBLY AND ASSEMBLY 644
BUCKET CYLINDER .646
REMOVAL 646
INSTALLATION .647
BOOM CYLINDER 648
REMOVAL 648
INSTALLATION .649
HYDRAULIC CYLINDER 650
DISASSEMBLY 650
ASSEMBLY 652
WORK EQUIPMENT .654
REMOVAL 654
INSTALLATION 657
COUNTERWEIGHT .659
REMOVAL AND INSTALLATION 659
FUEL TANK .660
REMOVAL 660
INSTALLATION 661
CAB 662
REMOVAL 662
INSTALLATION 663
MAIN MONITOR 664
REMOVAL 664
INSTALLATION .665
MAINTENANCE MONITOR 666
REMOVAL AND INSTALLATION .666
AIR CONDITIONER UNIT .667
REMOVAL 667
INSTALLATION .672
AIR CONDITIONER CONDENSER .673
REMOVAL 673
INSTALLATION 674
DRY RECEIVER .675
REMOVAL AND INSTALLATION .675
AIR CONDITIONER COMPRESSOR .676
REMOVAL AND INSTALLATION .676
40 MAINTENANCE STANDARD 677
TRANSMISSION, ENGINE MOUNT .678
TORQUE CONVERTER 680
TRANSMISSION .681
TRANSMISSION CONTROL VALVE 688
ACCUMULATOR VALVE .692
DRIVE SHAFT .693
DIFFERENTIAL 694
FINAL DRIVE .698
AXLE MOUNT .700
CENTER HINGE PIN 702
STEERING COLUMN .704
PRIORITY VALVE 705
MASTER CYLINDER .706
BRAKE 707
PARKING BRAKE .708
MAIN CONTROL VALVE 709
HYDRAULIC CYLINDER 713
STEERING CYLINDER MOUNT .714
WORK EQUIPMENT LINKAGE 715
BUCKET .717
BUCKET POSITIONER AND BOOM KICK-OUT 718
90 OTHERS 719
ELECTRICAL CIRCUIT DIAGRAM (1/2) (SERIAL NO.: 50001-53000) .720
ELECTRICAL CIRCUIT DIAGRAM (2/2) (SERIAL NO.: 50001-53000) .721
ELECTRICAL CIRCUIT DIAGRAM (1/2) (SERIAL NO.: 53001 AND UP) 722
ELECTRICAL CIRCUIT DIAGRAM (2/2) (SERIAL NO.: 53001 AND UP) 723

DESCRIPTION:

Komatsu Avance Loader WA250-3 Shop Manual SEBM005906 – PDF DOWNLOAD

• MACHINE MODEL            SERIAL NUMBER
  WA250-3                             50001 and up

G.B 23/12/24