Komatsu Avance Plus WA250-3MC Wheel Loader Shop Manual CEBM004602 – PDF

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Komatsu Avance Plus WA250-3MC Wheel Loader Shop Manual CEBM004602 – PDF DOWNLOAD

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Komatsu Avance Plus WA250-3MC Wheel Loader Shop Manual CEBM004602 – PDF DOWNLOAD

Language : English
Pages : 864
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu Avance Plus WA250-3MC Wheel Loader Shop Manual CEBM004602 – PDF DOWNLOAD

• SERIAL NUMBERS
• WA250-3MC A71001 and UP

MAIN MENU 0
COVER 1
CONTENTS 2
00 FORWARD 13
01 GENERAL 29
DIMENSIONAL DRAWING 30
GENERAL SPECIFICATIONS 31
WEIGHT TABLE 34
FUEL, COOLANT AND LUBRICANTS 35
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS 35
ENGINE OIL SPECIFICATIONS 36
NORMAL OPERATION 36
ARCTIC OPERATION 36
DIESEL FUEL SPECIFICATIONS 37
COOLANT SPECIFICATIONS 37
GENERAL 37
WATER 37
ANTIFREEZE 38
INHIBITORS/CONDITIONERS 38
10 STRUCTURE AND FUNCTION 43
POWER TRAIN 47
PATH OF POWER TRANSMISSION 48
TORQUE CONVERTER, TRANSMISSION PIPING 51
HYDRAULIC SYSTEM DIAGRAM 52
HYDRAULIC CIRCUIT DIAGRAM 53
TORQUE CONVERTER 54
TORQUE CONVERTER OIL FILTER 56
TRANSMISSION 57
CLUTCH 60
FORWARD, REVERSE CLUTCH 60
1ST, 3RD CLUTCH 61
2ND, 4TH CLUTCH 61
FORWARD 1ST 63
FORWARD 2ND 64
FORWARD 3RD 65
FORWARD 4TH 66
REVERSE 1ST 67
TRANSMISSION CONTROL VALVE 68
UPPER VALVE 69
LOWER VALVE 70
TRANSMISSION SOLENOID VALVE 71
TORQUE CONVERTER OUTLET PORT VALVE 72
PILOT REDUCING VALVE 73
TRANSMISSION SOLENOID VALVE 74
PRIORITY VALVE 75
MAIN REGULATOR VALVE 76
QUICK RETURN VALVE 77
MODULATION FILL VALVE 81
DIRECTIONAL SELECTOR SPOOL 83
EMERGENCY MANUAL SPOOL 84
OPERATION OF FORWARD 1ST 86
ACCUMULATOR VALVE 88
DRIVE SHAFT 90
AXLE 91
FRONT AXLE 91
REAR AXLE 92
AXLE MOUNT 94
DIFFERENTIAL 96
FRONT DIFFERENTIAL 96
REAR DIFFERENTIAL 97
TORQUE-PROPORTIONING DIFFERENTIAL 99
FINAL DRIVE 100
CENTER HINGE PIN 101
STEERING PIPING 102
STEERING COLUMN 103
PRIORITY VALVE 104
STEERING VALVE (ORBITAL) 107
CONNECTION BETWEEN HAND PUMP AND SLEEVE 114
2-WAY RESTRICTOR VALVE 116
BRAKE 117
BRAKE PIPING 117
POWER MASTER CYLINDER 118
BRAKE OFF 119
OIL PRESSURE STARTING TO RISE 119
PRESSURE RISING 120
RELIEF VALVE 120
ONE BRAKE LINE ACTUATED 121
BRAKE 122
PARKING BRAKE 124
PARKING BRAKE CONTROL 124
PARKING BRAKE 125
HYDRAULIC SYSTEM 126
STEERING AND HYDRAULIC PUMP 126
HYDRAULIC PIPING 127
HYDRAULIC SYSTEM DIAGRAM 128
HYDRAULIC CIRCUIT DIAGRAM 130
WORK EQUIPMENT LEVER LINKAGE 132
HYDRAULIC TANK 133
OIL FILTER BYPASS VALVE 134
BREATHER 135
PPC VALVE 137
OPERATION OF PPC VALVE 138
PPC RELIEF VALVE 141
ACCUMULATOR FOR PPC VALVE 142
MAIN CONTROL VALVE 144
2-SPOOL VALVE 144
3-SPOOL VALVE 146
RELIEF VALVE 148
SAFETY VALVE (WITH SUCTION) 149
SUCTION VALVE 150
MAIN CONTROL VALVE OPERATION 151
BOOM AND BUCKET SPOOLS AT NEUTRAL POSITION 151
BOOM SPOOL AT RAISE POSITION 152
BOOM SPOOL AT LOWER POSITION 153
BOOM SPOOL AT FLOAT POSITION 154
BUCKET SPOOL AT TILT BACK POSITION 155
BUCKET SPOOL AT DUMP POSITION 156
WORK EQUIPMENT 158
WORK EQUIPMENT LINKAGE 158
BUCKET 160
BUCKET POSITIONER AND BOOM KICK-OUT 161
BUCKET POSITIONER 162
BOOM KICK-OUT 162
PROXIMITY SWITCHES 164
ROPS CAB 166
AIR CONDITIONER PIPING 167
MACHINE MONITOR SYSTEM 168
MAIN MONITOR 169
MAIN MONITOR DISPLAY FUNCTION 170
PREHEATING OUTPUT FUNCTION 172
TROUBLE DATA DISPLAY MODE 173
MAINTENANCE MONITOR 174
MAINTENANCE MONITOR DISPLAY FUNCTION 174
TRANSMISSION AUTO-SHIFT CONTROL SYSTEM 178
SHIFT CONTROL SYSTEM FUNCTION 179
INPUT SIGNALS 179
OUTPUT SIGNALS 180
SHIFT CHARACTERISTICS 181
SAFETY FUNCTION 185
TROUBLESHOOTING 185
MODEL (ENGINE) SELECT SIGNAL 185
TRANSMISSION CONTROLLER 186
CONNECTOR SIGNALS 186
LED DISPLAY 187
ECSS 188
ECSS HYDRAULIC AND ELECTRICAL DIAGRAM 189
SENSORS AND SWITCHES 190
BRAKE OIL LEVEL SENSOR 190
RADIATOR WATER LEVEL 191
ENGINE OIL LEVEL SENSOR 191
FUEL LEVEL SENSOR 192
ENGINE WATER TEMPERATURE SENSOR 193
TORQUE CONVERTER OIL TEMPERATURE SENSOR 193
ENGINE SPEED SENSOR 194
ENGINE OIL PRESSURE SENSOR 194
ENGINE 195
ENGINE STARTING CIRCUIT 195
ENGINE STOP CIRCUIT 196
AUTOMATIC PREHEATING CIRCUIT 197
RIBBON HEATER 199
Q H S WATER TEMPERATURE SENSOR 199
HEATER RELAY 199
ELECTRICAL TRANSMISSION CONTROL 200
COMBINATION SWITCH 201
TRANSMISSION CUT-OFF FUNCTION 202
PARKING BRAKE NEUTRALIZER RELAY FUNCTION 204
KICK-DOWN SWITCH, HOLD SWITCH 205
KICK-DOWN SWITCH 205
KICK-DOWN ELECTRIC CIRCUIT DIAGRAM 206
KICK-DOWN SWITCH OPERATED 207
CANCELING ACTUATION OF KICK-DOWN SWITCH (CASE I) 208
CANCELLING ACTUATION OF KICK-DOWN SWITCH (CASE II) 209
CANCELLING ACTUATION OF KICK-DOWN SWITCH (CASE III) 210
ELECTRICAL WIRING DIAGRAM 211
ELECTRICAL WIRING DIAGRAM (1/6) 211
ELECTRICAL WIRING DIAGRAM (2/6) 213
ELECTRICAL WIRING DIAGRAM (3/6) 215
ELECTRICAL WIRING DIAGRAM (4/6) 217
ELECTRICAL WIRING DIAGRAM (5/6) 219
ELECTRICAL WIRING DIAGRAM (6/6) 221
20 TESTING, ADJUSTING AND TROUBLESHOOTING 223
STANDARD VALUE TABLE 227
ENGINE TABLE – IN CHASSIS 227
CHASSIS TABLE 228
SERVICE TOOLS TABLE 236
ENGINE 238
ADJUSTING ENGINE STOP MOTOR CABLE 238
ADJUSTING ENGINE STOP SOLENOID 238
MEASURING AND ADJUSTING VALVE CLEARANCE 238
MEASURING BLOW-BY PRESSURE 238
MEASURING COMPRESSION PRESSURE 238
MEASURING COOLANT TEMPERATURE 238
MEASURING ENGINE LUBRICATING OIL PRESSURE 238
MEASURING ENGINE SPEEDS 238
MEASURING EXHAUST COLOR 238
MEASURING EXHAUST GAS TEMPERATURE 238
MEASURING FUEL FILTER INLET RESTRICTION 238
TEST AND ADJUSTING FAN BELT TENSION 238
TEST AND ADJUSTING FUEL INJECTION TIMING 238
ACCELERATOR PEDAL 239
OPERATING FORCE 239
OPERATING ANGLE 240
SHIFT LEVER 241
OPERATING FORCE 241
TRAVEL 241
STALL SPEEDS 242
TORQUE CONVERTER STALL SPEED 242
HYDRAULIC STALL SPEED 243
FULL STALL SPEED 243
TORQUE CONVERTER 244
TRANSMISSION OIL PRESSURE 244
EMERGENCY MANUAL SPOOL 246
OPERATION 246
STEERING WHEEL 248
PLAY 248
OPERATING FORCE 248
OPERATING TIME 249
STEERING OIL PRESSURE 250
METHOD OF MEASURING MAIN RELIEF PRESSURE 250
METHOD OF ADJUSTING MAIN RELIEF PRESSURE 251
BRAKE 252
BRAKE PEDAL 252
OPERATING EFFORT 252
TRAVEL 252
BRAKE PEDAL LINKAGE 253
TESTING 253
ADJUSTING 253
BRAKE PERFORMANCE 255
BRAKE OIL PRESSURE 256
BRAKE DISC WEAR 257
BLEEDING AIR 258
PARKING BRAKE 259
PARKING BRAKE PERFORMANCE 259
PARKING BRAKE LINKAGE 260
PARKING BRAKE PISTON STROKE 261
PARKING BRAKE DISC WEAR 262
WORK EQUIPMENT 263
WORK EQUIPMENT CONTROL LEVER 263
PPC VALVE 264
MEASURING PRESSURE 264
WORK EQUIPMENT HYDRAULIC PRESSURE 266
WORK EQUIPMENT MEASUREMENT 268
WORK EQUIPMENT – HYDRAULIC DRIFT 269
BUCKET POSITIONER 270
BOOM KICK-OUT 271
MAIN MONITOR 273
FUEL LEVEL SENSOR 275
CHECKING FOR ABNORMALITY 275
TROUBLESHOOTING GENERAL 277
POINTS TO REMEMBER WHEN TROUBLESHOOTING 279
SEQUENCE OF EVENTS IN TROUBLESHOOTING 281
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 282
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT 282
HANDLING CONTROL BOX 287
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT 288
CHECKS BEFORE TROUBLESHOOTING 290
JUDGEMENT OF POWER TRAIN 291
PRECAUTIONS WHEN TROUBLESHOOTING 292
SAFETY 292
METHODS FOR TROUBLESHOOTING 292
PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING 294
PREVENTING RECURRENCE OF TROUBLE 295
HYDRAULIC EQUIPMENT 295
OIL CHECKS 295
CLEANING FRAGMENTS OF DAMAGED PARTS 295
METHOD OF USING TROUBLESHOOTING CHARTS 296
CATEGORY OF TROUBLESHOOTING CODE NUMBER 296
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE 296
METHOD OF USING MATRIX TROUBLESHOOTING TABLES 298
METHOD OF USING ENGINE RELATED CHARTS 300
TROUBLESHOOTING ELECTRICAL CONNECTORS 305
CONNECTOR TYPES 307
CONNECTOR PIN ARRANGEMENT 308
DIAGRAM (1/2) 308
DIAGRAM (2/2) 309
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 310
ELECTRICAL CIRCUIT DIAGRAMS 318
ENGINE START, STOP SYSTEM 318
PREHEATING SYSTEM 319
TRANSMISSION CONTROL, PARKING BRAKE SYSTEM 321
MACHINE MONITOR SYSTEM (1 of 2) 323
MACHINE MONITOR SYSTEM (2 of 2) 325
TROUBLESHOOTING SYSTEMS OF: 327
TROUBLESHOOTING OF TRANSMISSION CONGTROLLER SYSTEM (A-MODE) 327
OUTLINE 328
FUNCTION 328
TROUBLESHOOTING 328
FAILURE CODE TABLE 328
TABLE OF TROUBLESHOOTING MODES AND CAUSES 329
ELECTRICAL CIRCUIT DIAGRAM 330
A-1 TROUBLESHOOTING CODE [12] 332
F SOLENOID SIGNAL SYSTEM 332
A-2 TROUBLESHOOTING CODE [13] 333
R SOLENOID SIGNAL SYSTEM 333
A-3 TROUBLESHOOTING CODE [14] 334
ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM 334
A-4 TROUBLESHOOTING CODE [16] 335
ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM 335
A-5 TROUBLESHOOTING CODE [20] 336
ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM 336
A-6 TROUBLESHOOTING CODE [21] 337
ABNORMALITY IN SPEED LEVER SIGNAL SYSTEM 337
A-7 TROUBLESHOOTING CODE [22] 338
ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM 338
A-8 TROUBLESHOOTING CODE [23] 339
ABNORMALITY IN ENGINE SPEED SIGNAL SYSTEM 339
A-9 HOLD SWITCH SIGNAL SYSTEM 340
A-10 KICK-DOWN SWITCH SYSTEM 341
A-11 TRANSMISSION CUT-OUT SIGNAL SYSTEM 342
A-12 NEUTRALIZER RELAY SIGNAL SYSTEM 343
A-13 BUZZER SIGNAL SYSTEM 344
A-14 NETWORK SIGNAL SYSTEM 345
A-15 CONTROLLER POWER SOURCE SYSTEM 346
TROUBLESHOOTING ELECTRICALLY CONTROLLED SUSPENSION SYSTEM D MODE – (ECSS) 347
ECSS-ELECTRICAL/HYDRAULIC SCHEMATIC 348
ECSS-WORKING CHART 348
ECSS CIRCUIT – REMAINING PRESSURE REMOVAL 349
INSPECTION/ADJUSTMENT 349
TROUBLESHOOTING OF ELECTRICAL (E-MODE) 351
E-1 ENGINE DOES NOT START 352
(A) STARTING MOTOR DOES NOT TURN WHEN STARTING SWITCH IS TURNED TO START 352
(B) CHECK FUEL SHUT-OFF SOLENOID 354
E-2 ENGINE DOES NOT STOP 355
E-4 TRANSMISSION IS NOT SET TO NEUTRAL 356
WHEN PARKING BRAKE IS APPLIED (TRANSMISSION CUT-OFF IS NORMAL) 356
E-10 PREHEATING IS NOT CARRIED OUT 358
E-11 PREHEATING REMAINS ACTUATED 360
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K-MODE) 363
K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, 365
A ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS 365
B SOME LAMPS DO NOT LIGHT UP 366
K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP, BUT BO NOT GO OUT 366
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), ALL LAMPS 367
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) CHECK ITEMS FLASH 368
A ENGINE OIL LEVEL DISPLAY FLASHES 368
B ENGINE WATER LEVEL DISPLAY FLASHES 369
C BRAKE OIL LEVEL DISPLAY FLASHES 370
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH 371
A ENGINE OIL PRESSURE DISPLAY FLASHES 371
B BATTERY CHARGE LEVEL DISPLAY FLASHES 372
K-6 CAUTION ITEMS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUND 373
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT ALARM BUZZER SOUNDS 374
K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DO NOT LIGHT UP 375
A CHECK LAMP 375
B CAUTION LAMP 375
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DO NOT LIGHT UP 376
A CHECK LAMP 376
B CAUTION LAMP 376
K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE MONITOR 377
K-11 NIGHT LIGHTING IS ON EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAYS ON 378
K-12 SERVICE METER DOES NOT WORK 379
K-13 SERVICE METER IS RUNNING WITH ENGINE STOPPED 380
K-14 ABNORMALITY IN GAUGE ITEMS 381
A ABNORMALITY IN FUEL GAUGE 381
B ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE 382
C ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE 383
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M-MODE) 385
TROUBLE DATA DISPLAY 387
TABLE OF ACTION CODES AND FAILURES CODES 388
ACTION CODE TABLE 388
FAILURE CODE CHART 388
M-1 MAIN MONITOR DOES NOT WORK 389
M-2 WHEN STARTING SWITCH IS TURNED ON ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIT 390
M-3 SPEEDOMETER DISPLAYS DOES WORK PROPERLY 391
M-4 ABNORMALITY IN SHIFT INDICATOR 392
A STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT F 392
B STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT R 392
C DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N DISPLAYS E WHEN DIRECTIONAL LEVER IS AT F 392
D DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N DISPLAYS E WHEN DIRECTIONAL LEVER IS AT R 393
E DOES NOT DISPLAY 1ST, 4TH 393
F DOES NOT DISPLAY 3RD, 4TH 393
G DOES NOT DISPLAY 2ND, 3RD 394
H DOES NOT DISPLAY 1ST, 2ND 394
M-5 HIGH BEAM DOES NOT LIGHT UP 395
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP 396
A L H TURN SIGNAL DOES NOT LIGHT UP 396
B R H TURN SIGNAL DOES NOT LIGHT UP 396
M-7 ABNORMALITY IN PARKING DISPLAY 397
A PARKING LAMP DOES NOT LIGHT UP 397
B PARKING LAMP STAYS ON 397
M-8 ABNORMALITY IN PREHEATING SYSTEM 398
A DOES NOT CARRY OUT PREHEATING 398
B ONLY MONITOR DISPALY DOES NOT LIGHT UP 399
C ALWAYAS CARRIES OUT PREHEATING FOR 1 MINUTE 399
D PREHEATING STAYS ON 399
E PREHEATING TIME BECOMES SHORTER OR IS UNSTABLE 400
M-9 NIGHT LIGHTING DOES NOT LIGHT UP 402
M-10 ABNORMALITY IN FRONT WORKING LAMP 403
A NEITHER MONITOR DISPLAY, NOR FRONT WORKING LAMP LIGHT UP 403
B WORKING LAMP LIGHTS UP, BUT MONITOR DISPLAY DOES NOT LIGHT UP 403
C MONITOR LIGHTS UP, BUT WORKING LAMP DOES NOT LIGHT UP 403
M-11 ABNORMALITY IN REAR WORKING LAMP 404
A NEITHER MONITOR DISPLAY, NOR REAR WORKING LAMP LIGHT UP 404
B WORKING LAMP LIGHTS UP, BUT MONITOR DISPLAY DOES NOT LIGHT UP 404
C MONITOR LIGHTS UP, BUT WORKING LAMP DOES NOT LIGHT UP 404
M-12 ABNORMALITY IN TRNASMISSION CUT-OFF 406
A WHEN MONITOR SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT NOT SWITCHED AND DISPALY IS NOT GIVEN 406
B MONITOR DISPLAY GOES OUT, BUT CUT-OFF FUNCTION STAYS ON 406
C MONITOR DISPLAY LIGHTS UP, BUT CUT-OFF FUNCTION IS NOT ACTUATED 407
M-13 ABNORMALITY IN PARKING DRAGGING WARNING 408
A WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) EVEN WHEN DIRECTIONAL LEVER IS AT N AND CAUTION LAMP FLASHES 408
B WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT 408
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, 410
A ACTUATED CONTINUOUSLY 410
B NOT ACTUATED 410
M-15 ABNORMALITY IN BUZZER 411
A BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS TURNED ON (DURING SELF-CHECK) 411
B BUZZER ALWAYS SOUNDS 411
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY 412
M-17 ABNORMALITY IN FALIURE DISPLAY MODE 413
A DOES NOT ENTER FAILURE DISPLAY MODE 413
B TIME FOR TIME ELAPSED SINCE FAILURE ON FAILURE DISPLAY MODE DOES NOT ADVANCE 413
TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE) 414
S1 STARTING PERFORMANCE IS POOR 416
S2 ENGINE DOES NOT START 417
(1) ENGINE DOES NOT TURN 417
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT 418
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START 419
S-3 ENGINE DOES NOT PICK UP SMOOTHLY 420
S-4 ENGINE STOPS DURING OPERATIONS 421
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 422
S-6 ENGINE LACKS OUTPUT (NO POWER) 423
S-7 EXHAUST GAS IS BLACK 424
S-8 OIL CONSUMPTION IS EXCESSIVE 425
S-9 OIL BECOMES CONTAMINATED QUICKLY 426
S-10 FUEL CONSUMPTION IS EXCESSIVE 427
S-11 OIL IN COOLING WATER 428
S-12 OIL PRESSURE LAMP LIGHTS UP 429
S-13 OIL LEVEL RISES 430
S-14 WATER TEMPERATURE BECOMES TOO HIGH 431
S-15 ABNORMAL NOISE IS MADE 432
S-16 VIBRATION IS EXCESSIVE 433
TROUBLESHOOTING OF HYDRAULIC & MECHANICAL SYSTEMS (T-MODE) 434
POWER TRAIN 436
T-1 MACHINE DOES NOT START 436
T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES 437
T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR 439
T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR 440
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 441
STEERING SYSTEM 442
T-6 STEEERING WHEEL DOES NOT TURN 442
T-7 STEERING IS HEAVY 443
T-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK 444
T-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING 444
BRAKE SYSTEM 445
T-10 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR 445
T-11 BRAKE IS NOT RELEASED, BRAKE DRAGS 446
WORK EQUIPMENT 447
T-12 BOOM DOES NOT RISE 447
T-13 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER 448
T-14 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT 449
T-15 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS) 449
T-16 EXCESSIVE HYDRAULIC DRIFT OF BOOM 449
T-17 BOOM SHAKES DURING OPERATION 450
T-18 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE 450
T-19 BUCKET DOES NOT TILT BACK 451
T-20 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER 452
T-21 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION 453
T-22 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER 453
T-23 EXCESSIVE HYDRAULIC DRIFT OF BUCKET 453
T-24 BUCKET SHAKES DURING LOADING PERATION 454
T-25 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT 454
T-26 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY 455
TESTING, ADJUSTING AND TROUBLESHOOTING AIR CONDITIONER 456
SERVICE TOOLS 458
GAUGE MANIFOLD 458
STRUCTURE AND HANDLING OF GAUGE MANIFOLD 459
CHARGING HOSES 461
GAS LEAK DETECTOR 462
HALIDE TORCH LEAK DETECTOR 462
ELECTRIC LEAK TESTER 464
VALVE FOR SERVICE CANS 466
MAINTENANCE PROCEDURE 467
PRECAUTIONS WHEN REMOVING OR INSTALLING PIPING 467
PROHIBITED WORK 467
OTHER PRECAUTIONS 467
BLEEDING AIR FROM REFRIGERATION CIRCUIT 469
PURPOSE 469
CONNECTING GAUGE MANIFOLD 469
EVACUATION 470
AIR-TIGHTNESS CHECK 470
GAS-LEAK CHECK 471
EVACUATION (REPEATING) 471
CHARGING THE REFRIGERATION CIRCUIT WITH REFRIGERANT 472
CHARGING FROM THE HIGH-PRESSURE SIDE 472
CHARGING FROM THE LOW PRESSURE SIDE 473
WHEN THE AMBIENT TEMPERATURE IS LOW 474
WHEN THE AMBIENT TEMPERATURE IS HIGH 474
REPLACING SERVICE CANS 475
CHECKING THE AMOUNT OF REFRIGERANT 475
REMOVAL OF GAUGE MANIFOLD 477
DISCHARGING THE REFRIGERANT 477
DAILY CHECKS 478
CHECK REFRIGERANT LEVEL 478
CLEANING THE CONDENSER 478
CHECKING THE V-BELT 478
CHECKING OIL LEVEL 479
PROCEDURE FOR CHECKING 479
PROCEDURE FOR CHECKING OIL LEVEL 479
ADDING AND REMOVING OIL 480
ADDING OIL BY EVACUATION 480
TROUBLESHOOTING 481
VISUAL AND ACOUSTICAL CHECKS 481
DEFECTIVE COOLING 482
TROUBLESHOOTING TABLE 0
DEFECTIVE HEATING 486
TROUBLESHOOTING USING GAUGE MANIFOLD 487
PREPARATIONS BEFORE MEASURING 487
INSUFFICIENT REFRIGERANT 487
EXCESSIVE REFRIGERANT OR INSUFFICIENT COOLING OF CONDENSER 488
AIR INSIDE REFRIGERATION SYSTEM 489
MOISTURE IN REFRIGERATING SYSTEM 490
REFRIGERANT DOES NOT CIRCULATE 491
FAILURE OF EXPANSION VALVE (OPEN TO FAR), DEFECTIVE MOUNTING OF HEAT SENSING TUBE 492
DEFECTIVE COMPRESSION BY COMPRESSOR 493
30 DISASSEMBLY AND ASSEMBLY 494
METHOD OF USING MANUAL 498
PRECAUTIONS DURING OPERATION 499
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK 499
PRECAUTIONS WHEN CARRYING OUT INTSTALLATION WORK 500
PRECAUTIONS WHEN COMPLETING THE OPERATIONS 501
OTHER PRECAUTIONS 501
SPECIAL TOOL LIST 502
ENGINE 505
ALTERNATOR 505
CYLINDER HEAD 505
ENGINE OIL COOLER 505
FUEL INJECTION PUMP 505
NOZZLE HOLDER 505
STARTING MOTOR 505
THERMOSTAT 505
TURBOCHARGER 505
WATER PUMP 505
COVERS, LADDER AND ENGINE HOOD 506
REMOVAL 506
INSTALLATION 509
RADIATOR, HYDRAULIC COOLER 510
REMOVAL 510
INSTALLATION 511
MUFFER AND AIR CLEANER 512
REMOVAL 512
INSTALLATION 512
ENGINE 513
REMOVAL 513
INSTALLATION 516
TORQUE COVERTER CHARGING PUMP 517
REMOVAL 517
INSTALLATION 517
TORQUE COVERTER TRANSMISSION 518
REMOVAL 518
INSTALLATION 527
TORQUE COVERTER 529
DISASSEMBLY 529
ASSEMBLY 531
TRANSMISSION 533
DISASSEMBLY 533
ASSEMBLY 542
CLUTCH PACK 555
DISASSEMBLY 555
DISASSEMBLY OF FR CLUTCH PACK 555
DISASSEMBLY OF 1ST AND 3RD CLUTCH PACK 557
DISASSEMBLY OF 2ND AND 4TH CLUTCH PACK 559
ASSEMBLY 561
ASSEMBLY OF FORWARD, REVERSE CLUTCH PACK 561
ASSEMBLY OF 1ST AND 3RD CLUTCH PACK 565
ASSEMBLY OF 2ND AND 4TH CLUTCH PACK 569
PARKING BRAKE 573
DISASSEMBLY 573
ASSEMBLY 575
TRANSMISSION CONTROL VALVE 578
REMOVAL 578
INSTALLATION 580
DISASSEMBLY 581
ASSEMBLY 583
TRANSMISSION SOLENIOD VALVE 586
DISASSEMBLY 586
ASSEMBLY 587
ACCUMULATOR VALVE 588
DISASSEMBLY 588
ASSEMBLY 589
DRIVE SHAFT 590
DISASSEMBLY 590
ASSEMBLY 592
FRONT AXLE 594
REMOVAL 594
INSTALLATION 596
REAR AXLE 597
REMOVAL 597
INSTALLATION 601
DIFFERENTIAL 604
DISASSEMBLY 604
ASSEMBLY 608
AXLE HOUSING 617
DISASSEMBLY 590
ASSEMBLY 622
CENTER HINGE PIN 628
REMOVAL 628
INSTALLATION 635
STEERING VALVE 639
REMOVAL 639
INSTALLATION 641
DISASSEMBLY 642
DISASSEMBLY OF ROTOR 642
ASSEMBLY 645
ASSEMBLY OF CONTROL SIDE 645
ASSEMBLY OF ROTOR 647
PRIORITY VALVE 650
REMOVAL 650
INSTALLATION 651
STEERING CYLINDER 652
REMOVAL 652
INSTALLATION 653
POWER MASTER CYLINDER 654
REMOVAL 654
INSTALLATION 655
DISASSEMBLY 656
ASSEMBLY 659
PARKING BRAKE DISC 664
REMOVAL 664
INSTALLATION 665
HYDRAULIC TANK 666
REMOVAL 666
INSTALLATION 667
HYDRAULIC FILTER 668
REMOVAL 668
INSTALLATION 668
WORK EQUIPMENT 669
REMOVAL 669
INSTALLATION 670
MAIN CONTROL VALVE 671
REMOVAL 671
INSTALLATION 672
DISASSEMBLY 674
ASSEMBLY 676
HYDRAULIC LINES 677
PPC VALVE TO MAIN CONTROL VALVE 677
PPC VALVE 679
REMOVAL 679
INSTALLATION 680
CYLINDER 681
BUCKET CYLINDER 681
REMOVAL 681
INSTALLATION 682
BOOM CYLINDER 683
REMOVAL 683
INSTALLATION 684
HYDRAULIC CYLINDER 685
DISASSEMBLY 685
ASSEMBLY 687
WORK EQUIPMENT 690
REMOVAL 690
INSTALLATION 693
ECSS SYSTEM 695
ECSS CIRCUIT – REMAINING PRESSURE REMOVAL 695
ECSS SOLENOID VALVE 696
REMOVAL 696
INSTALLATION 696
ECSS CONTROL VALVE 697
REMOVAL 697
INSTALLATION 697
COUNTERWEIGHT 698
REMOVAL 698
INSTALLATION 698
FUEL TANK 699
REMOVAL 699
INSTALLATION 700
CAB (ROPS) 701
REMOVAL 701
INSTALLATION 702
MONITOR 703
MAIN MONITOR 703
REMOVAL 703
INSTALLATION 704
MAINTENANCE MONITOR 705
REMOVAL 705
INSTALLATION 705
AIR CONDITIONER 706
AIR CONDITIONER UNIT 706
REMOVAL 706
INSTALLATION 711
CONDENSER 712
REMOVAL 712
INSTALLATION 713
DRY RECIEVER 714
REMOVAL 714
INSTALLATION 715
COMPRESSOR 716
REMOVAL 716
INSTALLATION 717
40 MAINTENANCE STANDARD 767
TRANSMISSION, ENGINE MOUNT 768
TORQUE CONVERTER CHARGING PUMP 770
SAL (2) 32 + SAL (2) 25 770
TORQUE CONVERTER 772
TRANSMISSION 775
FORWARD, REVERSE CLUTCH 782
1ST, 3RD CLUTCH 784
2nd, 4th CLUTCH 786
TRANSMISSION CONTROL VALVE 788
UPPER VALVE 788
LOWER VALVE 792
SOLENOID VALVE 794
ACCUMULATOR VALVE 796
DRIVE SHAFTS 798
DIFFERENTIAL 800
FINAL DRIVE 806
AXLE MOUNT 808
CENTER HINGE PIN 810
STEERING COLUMN 812
PRIORITY VALVE 814
MASTER CYLINDER 816
BRAKE 818
PARKING BRAKE 820
HYDRAULIC PUMP 821
MAIN CONTROL VALVE 822
2-SPOOL VALVE 822
3-SPOOL VALVE 826
PPC VALVE 830
HYDRAULIC CYLINDER 832
STEERING CYLINDER MOUNT 834
WORK EQUIPMENT LINKAGE 836
BUCKET 840
BUCKET POSITIONER AND KICK-OUT 842
90 OTHERS 843
ELECTRICAL WIRING DIAGRAM (1/6) 845
ELECTRICAL WIRING DIAGRAM (2/6) 847
ELECTRICAL WIRING DIAGRAM (3/6) 849
ELECTRICAL WIRING DIAGRAM (4/6) 851
ELECTRICAL WIRING DIAGRAM (5/6) 853
ELECTRICAL WIRING DIAGRAM (6/6) 855
TRANSMISSION CONTROL, PARKING BRAKE SYSTEM 857
MACHINE MONITOR SYSTEM (1 OF 2) 859
MACHINE MONITOR SYSTEM (2 OF 2) 861

DESCRIPTION:

Komatsu Avance Plus WA250-3MC Wheel Loader Shop Manual CEBM004602 – PDF DOWNLOAD

• SERIAL NUMBERS
• WA250-3MC A71001 and UP

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 sections. These sections are further divided into each main
group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the
structure, but also serves as reference material for troubleshooting.
TESTING, ADJUSTING AND TROUBLESHOOTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion
of the checks and repairs. Troubleshooting charts correlating  Problems to Causes are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.

G.B  16/12/24