Komatsu Avance Plus WA250PT-3MC Parallel Tool Carrier Shop Manual PDF

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Komatsu Avance Plus WA250PT-3MC Parallel Tool Carrier Shop Manual CEBM004702  – PDF DOWNLOAD

FILE DETAILS:

Komatsu Avance Plus WA250PT-3MC Parallel Tool Carrier Shop Manual CEBM004702  – PDF DOWNLOAD

Language : English
Pages : 800
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu Avance Plus WA250PT-3MC Parallel Tool Carrier Shop Manual CEBM004702  – PDF DOWNLOAD

• SERIAL NUMBERS
• WA250PT-3MC – A78001 and UP

MAIN MENU 0
COVER 1
CONTENTS 2
00 FORWARD 13
SAFETY 13
SAFETY NOTICE 13
IMPORTANT SAFETY NOTICE 13
GENERAL PRECAUTIONS 13
PREPARATIONS FOR WORK 13
PRECAUTIONS DURING WORK 13
GENERAL 15
HOW TO READ THE SHOP MANUAL 16
VOLUMES 16
DISTRIBUTION AND UPDATING 16
FILING METHOD 16
REVISED EDITION MARK 16
REVISIONS 16
SYMBOLS 16
HOISTING INSTRUCTIONS 17
HOISTING 17
WIRE ROPES 17
COATING MATERIALS 18
STANDARD TIGHTENING TORQUE 20
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS 20
TIGHTENING TORQUE OF HOSE NUTS 21
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 21
TIGHTENING TORQUE FOR FLARED NUTS 21
ELECTRIC WIRE CODE 22
CLASSIFICATION BY THICKNESS 22
CLASSIFICATION BY COLOR AND CODE 22
CONVERSION TABLES 23
METHOD OF USING THE CONVERSION TABLE 23
01 GENERAL 29
SPECIFICATION DRAWING 30
WA250PT-3 (WITH BUCKET ATTACHMENT) 30
WA250PT-3 (WITH FORK ATTACHMENT) 32
SPECIFICATIONS 34
WA250PT-3 (MATERIAL HANDLING ARM) 36
WEIGHT TABLE 38
FUEL, COOLANT AND LUBRICANTS 39
ENGINE OIL SPECIFICATIONS 40
NORMAL OPERATION 40
ARCTIC OPERATION 40
DRIVE TRAIN, BRAKE AND HYDRAULIC SYSTEM OIL SPECIFICATIONS 41
FINAL DRIVE OIL SPECIFICATIONS 41
DRIVE AXLE OIL SPECIFICATIONS 41
DIESEL FUEL SPECIFICATIONS 41
COOLANT SPECIFICATIONS 42
SUPPLEMENTAL COOLANT ADDITIVES 44
COOLING SYSTEM TEST KIT 48
10 STRUCTURE AND FUNCTION 49
POWER TRAIN 53
PATH OF POWER TRANSMISSION 54
TORQUE CONVERTER AND TRANSMISSION PIPING 56
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM 57
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 58
TORQUE CONVERTER 59
TORQUE CONVERTER OIL FILTER 61
TRANSMISSION 63
CLUTCH 66
FORWARD, REVERSE CLUTCH 66
1ST, 3RD CLUTCH 67
2ND, 4TH CLUTCH 67
OPERATION OF CLUTCH 68
FORWARD 1ST 69
FORWARD 2ND 70
FORWARD 3RD 71
FORWARD 4TH 72
REVERSE 1ST 73
TRANSMISSION CONTROL VALVE 75
UPPER VALVE 76
LOWER VALVE 77
TRANSMISSION SOLENOID VALVE 78
TORQUE CONVERTER OUTLET PORT VALVE 79
PILOT REDUCING VALVE 80
TRANSMISSION SOLENOID VALVE 81
PRIORITY VALVE 82
MAIN REGULATOR VALVE 83
QUICK RETURN VALVE 84
MODULATION FILL VALVE 88
DIRECTIONAL SELECTOR SPOOL 90
EMERGENCY MANUAL SPOOL 91
DRIVE SHAFT 96
AXLE 97
FRONT AXLE 97
FRONT DIFFERENTIAL 98
REAR AXLE 99
REAR DIFFERENTIAL 100
TORQUE PROPORTIONING DIFFERENTIAL 102
FINAL DRIVE 103
AXLE MOUNT 104
FRONT AXLE 105
REAR AXLE 105
CENTER HINGE PIN 106
STEERING PIPING 107
STEERING COLUMN 108
PRIORITY VALVE 109
STEERING VALVE (ORBITAL) 112
CONNECTION BETWEEN HAND PUMP AND SLEEVE 118
2-WAY RESTRICTOR VALVE 120
BRAKE PIPING 121
POWER MASTER CYLINDER 122
BRAKE OFF 123
OIL PRESSURE STARTING TO RISE 123
PRESSURE RISING 124
RELIEF VALVE 124
ONE BRAKE LINE ACTUATED 125
BRAKE 126
OPERATION 127
PARKING BRAKE CONTROL 128
PARKING BRAKE 129
HYDRAULIC PIPING 130
STEERING, HYDRAULIC PUMP HYDRAULIC SYSTEM DIAGRAM 132
WORK EQUIPMENT LEVER LINKAGE 134
HYDRAULIC TANK 135
OIL FILTER BYPASS VALVE 136
BREATHER 137
PPC VALVE 138
OPERATION OF PPC VALVE 140
FUNCTION OF PPC VALVE 141
PPC RELIEF VALVE 143
ACCUMULATOR (FOR PPC VALVE) 144
MAIN CONTROL VALVE 145
3-SPOOL VALVE 145
RELIEF VALVE 147
SAFETY VALVE (WITH SUCTION) 148
SUCTION VALVE 149
BOOM AND BUCKET SPOOL AT “NEUTRAL” POSITION 150
BOOM SPOOL AT “RAISE” POSITION 151
BOOM SPOOL AT “LOWER” POSITION 152
BOOM SPOOL AT “FLOAT” POSITION 153
BUCKET SPOOL AT “TILT BACK” POSITION 154
BUCKET SPOOL AT “DUMP” POSITION – SLOW SPEED DUMP 155
BUCKET SPOOL AT “DUMP” POSITION – FAST SPEED DUMP 156
COUPLER PLUNGERS EXTENDED, COUPLER ATTACHED 157
COUPLER PLUNGERS RETRACTED, COUPLER REMOVAL 158
WORK EQUIPMENT LINKAGE 159
BUCKET 161
BUCKET POSITIONER AND BOOM KICK-OUT 162
BUCKET OR FORK POSITIONER 163
BOOM KICK-OUT 163
PROXIMITY SWITCH 165
OPERATION OF THE PROXIMITY SWITCH 167
ROPS CAB 168
AIR CONDITIONER 169
AIR CONDITIONER PIPING 169
MACHINE MONITOR SYSTEM 170
MAIN MONITOR 171
MAIN MONITOR DISPLAY FUNCTION 172
PREHEATING OUTPUT FUNCTION 174
MAINTENANCE MONITOR DISPLAY FUNCTION 176
TRANSMISSION AUTO-SHIFT CONTROL SYSTEM 179
SYSTEM 179
SHIFT CONTROL SYSTEM FUNCTION 180
INPUT SIGNALS 180
OUTPUT SIGNALS 180
SHIFT CHARACTERISTICS 181
SAFETY FUNCTION 184
TROUBLESHOOTING 185
MODEL (ENGINE) SELECT SIGNAL 185
TRANSMISSION CONTROLLER 186
LED DISPLAY 187
SENSORS AND SWITCHES 188
BRAKE OIL LEVEL SENSOR 188
RADIATOR WATER LEVEL 189
ENGINE OIL LEVEL SENSOR 189
FUEL LEVEL SENSOR 190
ENGINE COOLANT TEMPERATURE SENSOR 191
ENGINE SPEED SENSOR 192
ENGINE OIL PRESSURE SENSOR 192
ELECTRICAL WIRING DIAGRAM (1/7) 193
ELECTRICAL WIRING DIAGRAM (2/7) 195
ELECTRICAL WIRING DIAGRAM (3/7) 197
ELECTRICAL WIRING DIAGRAM (4/7) 199
ELECTRICAL WIRING DIAGRAM (5/7) 201
ELECTRICAL WIRING DIAGRAM (6/7) 203
ELECTRICAL WIRING DIAGRAM (7/7) 205
ENGINE STARTING CIRCUIT 207
ENGINE STOP CIRCUIT 208
AUTOMATIC PREHEATING CIRCUIT 209
RIBBON HEATER 211
Q H S WATER TEMPERATURE SENSOR 211
HEATER RELAY 211
ELECTRICAL TRANSMISSION CONTROL 212
COMBINATION SWITCH 213
TRANSMISSION CUT-OFF FUNCTION 214
PARKING BRAKE NEUTRALIZER RELAY FUNCTION 216
KICK DOWN, HOLD SWITCH 217
KICK-DOWN SWITCH 217
HOLD SWITCH 217
KICK DOWN ELECTRIC CIRCUIT DIAGRAM 218
DUMP SPEED SWITCH 223
QUICK COUPLER SWITCH 224
20 TESTING, ADJUSTING AND TROUBLESHOOTING 225
STANDARD VALUE TABLE 229
ENGINE TABLE – IN CHASSIS 229
CHASSIS TABLE 230
ELECTRICAL PARTS TABLE 235
SERVICE TOOLS TABLE 238
ENGINE 240
ADJUSTING ENGINE STOP MOTOR CABLE 240
ADJUSTING ENGINE STOP SOLENOID 240
MEASURING AND ADJUSTING VALVE CLEARANCE 240
MEASURING BLOW-BY PRESSURE 240
MEASURING COMPRESSION PRESSURE 240
MEASURING COOLANT TEMPERATURE 240
MEASURING ENGINE LUBRICATING OIL PRESSURE 240
MEASURING ENGINE SPEEDS 240
MEASURING EXHAUST COLOR 240
MEASURING EXHAUST GAS TEMPERATURE 240
MEASURING FUEL FILTER INLET RESTRICTION 240
TEST AND ADJUSTING FAN BELT TENSION 240
TEST AND ADJUSTING FUEL INJECTION TIMING 240
ACCELERATOR PEDAL 241
OPERATING FORCE 241
OPERATING ANGLE 242
SHIFT LEVER 243
OPERATING FORCE 243
TRAVEL 243
STALL SPEEDS 244
TORQUE CONVERTER STALL SPEED 244
HYDRAULIC STALL SPEED 245
FULL STALL SPEED 245
TORQUE CONVERTER 246
TRANSMISSION OIL PRESSURE 246
EMERGENCY MANUAL SPOOL 248
OPERATION 248
STEERING WHEEL 250
PLAY 250
OPERATING FORCE 250
OPERATING TIME 251
STEERING OIL PRESSURE 252
METHOD OF MEASURING MAIN RELIEF PRESSURE 252
METHOD OF ADJUSTING MAIN RELIEF PRESSURE 253
BRAKE 254
BRAKE PEDAL 254
OPERATING EFFORT 254
TRAVEL 254
BRAKE PEDAL LINKAGE 255
TESTING 255
ADJUSTING 255
BRAKE PERFORMANCE 257
BRAKE OIL PRESSURE 258
BRAKE DISC WEAR 259
BLEEDING AIR 260
PARKING BRAKE 261
PARKING BRAKE PERFORMANCE 261
PARKING BRAKE LINKAGE 262
PARKING BRAKE PISTON STROKE 263
PARKING BRAKE DISC WEAR 264
WORK EQUIPMENT 265
WORK EQUIPMENT CONTROL LEVER 265
PPC VALVE 266
MEASURING PRESSURE 266
HYDRAULIC PRESSURE 268
MEASUREMENT 271
HYDRAULIC DRIFT 272
BOOM KICK-OUT 273
BUCKET / FORK POSITIONER 274
MAIN MONITOR 276
FUEL LEVEL SENSOR 278
CHECKING FOR ABNORMALITY 278
TROUBLESHOOTING GENERAL 279
POINTS TO REMEMBER WHEN TROUBLESHOOTING 281
SEQUENCE OF EVENTS IN TROUBLESHOOTING 283
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 284
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT 284
HANDLING CONTROL BOX 289
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT 290
CHECKS BEFORE TROUBLESHOOTING 292
JUDGEMENT OF POWER TRAIN 293
PRECAUTIONS WHEN TROUBLESHOOTING 294
SAFETY 294
METHODS FOR TROUBLESHOOTING 294
PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING 296
PREVENTING RECURRENCE OF TROUBLE 297
HYDRAULIC EQUIPMENT 297
OIL CHECKS 297
CLEANING FRAGMENTS OF DAMAGED PARTS 297
METHOD OF USING TROUBLESHOOTING CHARTS 298
CATEGORY OF TROUBLESHOOTING CODE NUMBER 298
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE 298
METHOD OF USING MATRIX TROUBLESHOOTING TABLES 300
METHOD OF USING ENGINE RELATED CHARTS 302
TROUBLESHOOTING ELECTRICAL CONNECTORS 307
CONNECTOR TYPES 308
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 311
ELECTRICAL CIRCUIT DIAGRAMS 319
ENGINE START, STOP SYSTEM 319
PREHEATING SYSTEM 320
TRANSMISSION CONTROL, PARKING BRAKE SYSTEM 321
MACHINE MONITOR SYSTEM (1/2) 323
MACHINE MONITOR SYSTEM (2/2) 0
WORK EQUIPMENT DUMP SPEED AND QUICK COUPLER SYSTEM 0
TROUBLESHOOTING SYSTEMS OF A MODE – TRANSMISSION CONTROLLER SYSTEM 329
OUTLINE 330
FUNCTION 330
TROUBLESHOOTING 330
FAILURE CODE TABLE 330
TABLE OF TROUBLESHOOTING MODES AND CAUSES 331
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLER SYSTEM 332
A-1 TROUBLESHOOTING CODE [12] 334
F SOLENOID SIGNAL SYSTEM 334
A-2 TROUBLESHOOTING CODE [13] 335
R SOLENOID SIGNAL SYSTEM 335
A-3 TROUBLESHOOTING CODE [14] 336
ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM 336
A-4 TROUBLESHOOTING CODE [16] 337
ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM 337
A-5 TROUBLESHOOTING CODE [20] 338
ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM 338
A-6 TROUBLESHOOTING CODE [21] 339
ABNORMALITY IN SPEED LEVER SIGNAL SYSTEM 339
A-7 TROUBLESHOOTING CODE [22] 340
ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM 340
A-8 TROUBLESHOOTING CODE [23] 341
ABNORMALITY IN ENGINE SPEED SIGNAL SYSTEM 341
A-9 HOLD SWITCH SIGNAL SYSTEM 342
A-10 KICK-DOWN SWITCH SYSTEM 343
A-11 TRANSMISSION CUT-OUT SIGNAL SYSTEM 344
A-12 NEUTRALIZER RELAY SIGNAL SYSTEM 345
A-13 BUZZER SIGNAL SYSTEM 346
A-14 NETWORK SIGNAL SYSTEM 347
A-15 CONTROLLER POWER SOURCE SYSTEM 348
TROUBLESHOOTING ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM D MODE – (ECSS) 349
ECSS – ELECTRICAL/HYDRAULIC SCHEMATIC 350
ECSS – WORKING CHART 350
ECSS CIRCUIT – REMAINING PRESSURE REMOVAL 351
INSPECTION/ADJUSTMENT 351
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 353
E-1 ENGINE DOES NOT START 354
A STARTING MOTOR DOES NOT TURN WHEN STARTING SWITCYH IS TURNED TO START 354
B CHECK FUEL SHUT-OFF SOLENOID 356
E-2 ENGINE DOES NOT STOP 357
E-4 TRANSMISSION IS NOT SET UP TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (TRANSMISION CUT-OFF IS NORMAL) 358
E-10 PREHEATING IS NOT CARRIED OUT 360
E-11 PREHEATING REMAINS ACTUATED 362
E-12 ABNORMALITY IN QUICK COUPLER SYSTEM 364
E-13 ABNORMALITY IN TILT CYLINDER OPERATION 365
A ONLY SLOW DUMP SPEED IS AVAILABLE 365
B DUMP SPEED IS ERRATIC OR ONLY FAST DUMP SPEED IS AVAILABLE 366
C TILT BACK IS NOT AVAILABLE 367
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K-MODE) 369
K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DO 371
A ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS 371
B SOME LAMPS DO NOT LIGHT UP 372
K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP, BUT DO NOT GO OUT 372
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECS), ALL LAMPS ON MAINTENANCE MONITOR D 373
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) CHECK ITEMS FLASH 374
A ENGINE OIL LEVEL DISPLAY FLASHES 374
B ENGINE WATER LEVEL DISPLAY FLASHES 375
C BRAKE OIL LEVEL DISPLAY FLASHES 376
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH 377
A ENGINE OIL PRESSURE DISPLAY FLASHES 377
B BATTERY CHARGE LEVEL DISPLAY FLASHES 378
K-6 CAUTION ITEMS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUND 379
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT ALARM BUZZER SOUNDS 380
K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DO NOT LIGHT UP 381
A CHECK LAMP 381
B CAUTION LAMP 381
K-9 THERE IS NOT ABNORMALITY IN MAINTENANCE DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) LIGHTS UP 382
A CHECK LAMP 382
B CAUTION LAMP 382
K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENACE MONITOR DOES NOT LIGHT UP) 383
K-11 NIGHT LIGHING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAY LIT UP 384
K-12 SERVICE METER DOES NOT WORK 385
K-13 SERVICE METER IS RUNNING WITH ENGINE STOPPED 386
K-14 ABNORMALITY IN GAUGE ITEMS 387
A ABNORMALITY IN FUEL GAUGE 387
B ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE 388
C ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE 389
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M-MODE) 391
TROUBLE DATA DISPLAY 393
TABLE OF ACTION CODES AND FAILURE CODES 394
ACTION CODE TABLE 394
FAILURE CODE CHART 394
M-1 MAIN MONITOR DOES NOT WORK 395
M-2 WHEN STARING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIT 396
M-3 SPEEDOMETER DISPLAYS DOES NOT WORK PROPERLY 397
M-4 ABNORMALITY IN SHIFT INDICATOR 398
A STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT F 398
B STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT R 398
C DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS E WHEN DIRECTIONAL LEVER I 398
D DOES NOT DISPLAY N EVEN DIRECTIONAL LEVER IS AT N AND DISPLAYS E WHEN DIRECTIONAL LEVER IS AT R 399
E DOES NOT DISPLAY 1ST, 4TH 399
F DOES NOT DISPLAY 3RD, 4TH 399
G DOES NOT DISPLAY 2ND, 3RD 400
H DOES NOT DISPLAY 1ST, 2ND 400
M-5 HIGH BEAM DOES NOT LIGHT UP 401
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP 402
A L H TURN SIGNAL DOES NOT LIGHT UP 402
B R H TURN SIGNAL DOES NOT LIGHT UP 402
M-7 ABNORMALITY IN PARKING DISPLAY 403
A PARKING LAMP DOES NOT LIGHT UP 403
B PARKING LAMP STAYS ON 403
M-8 ABNORMALITY IN PREHEATING SYSTEM 404
A DOES NOT CARRY OUT PREHEATING 404
1 MONITOR DISPLAY ALSO DOES NOT LIGHT UP 404
2 ONLY MONITOR DISPLAY LIGHTS UP 404
B ONLY MONITOR DISPLAY DOES NOT LIGHT UP 405
C ALWAYS CARRIES OUT PREHEATING FOR 1 MINUTE 405
D PREHEATING STAYS ON 405
E PREHEATING TIME BECOMES SHORTER OR IS UNSTABLE 406
M-9 NIGHT LIGHTING DOES NOT LIGHT UP 408
M-10 ABNORMALITY IN FRONT WORKING LAMP 409
A NEITHER MONITOR DISPLAY, NOR FRONT WORKING LAMP LIGHT UP 409
B WORKING LAMP LIGHTS UP, BUT MONITOR DISPLAY DOES NOT LIGHT UP 409
C MONITOR LIGHTS UP, BUT WORKING LAMP DOES NOT LIGHT UP 409
M-11 ABNORMALITY IN REAR WORKING LAMP 410
A NEITHER MONITOR DISPLAY, NOR rear 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-12 ABNORMALITY IN TRANSMISSION CUT-OFF 412
A WHEN MONITOR SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY IS NOT GIVEN 412
B MONITOR DISPLAY GOES OUT, BUT CUT-OFF FUNCTION STAYS ON 412
C MONITOR DISPLAY LIGHTS UP, BUT CUT-OFF FUNCTION IS NOT ACTUATED 413
M-13 ABNORMALITY IN PARKING DRAGGING WARNING 414
A WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) EVEN WHEN DIRECTIONAL LEVER IS A 414
B WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN W 414
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOU 415
A ACTUATED CONTINUOUSLY 415
B NOT ACTUATED 415
M-15 ABNORMALITY IN BUZZER 416
A BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS TURNED ON (DURING SELF-CHECK) 416
B BUZZER ALWAYS SOUNDS 416
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY 417
M-17 ABNORMALITY IN FAILURE DISPLAY MODE 418
A DOES NOT ENTER FAILURE DISPLAY MODE 418
B TIME FOR TIME ELAPSED SINCE FAILURE ON FAILURE DISPLAY MODE DOES NOT ADVANCE 418
TROUBLESHOOTING SYSTEMS OF (S MODE) 419
S1 STARTING PERFORMANCE IS POOR 421
S2 ENGINE DOES NOT START 422
(1) ENGINE DOES NOT TURN 422
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT 423
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START 424
S-3 ENGINE DOES NOT PICK UP SMOOTHLY 425
S-4 ENGINE STOPS DURING OPERATIONS 426
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 427
S-6 ENGINE LACKS OUTPUT (NO POWER) 428
S-7 EXHAUST GAS IS BLACK 429
S-8 OIL CONSUMPTION IS EXCESSIVE 430
S-9 OIL BECOMES CONTAMINATED QUICKLY 431
S-10 FUEL CONSUMPTION IS EXCESSIVE 432
S-11 OIL IN COOLING WATER 433
S-12 OIL PRESSURE LAMP LIGHTS UP 434
S-13 OIL LEVEL RISES 435
S-14 WATER TEMPERATURE BECOMES TOO HIGH 436
S-15 ABNORMAL NOISE IS MADE 437
S-16 VIBRATION IS EXCESSIVE 460
TROUBLESHOOTING OF HYDRAULIC & MECHANICAL SYSTEM (T-MODE) 438
POWER TRAIN 440
T-1 MACHINE DOES NOT START 440
T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES 441
T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR 443
T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR 444
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 445
STEERING SYSTEM 446
T-6 STEERING WHEEL DOES NOT TURN 446
T-7 STEERING IS HEAVY 447
T-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK 448
T-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING 448
BRAKE SYSTEM 449
T-10 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR 449
T-11 BRAKE IS NOT RELEASED, BRAKE DRAGS 450
WORK EQUIPMENT 451
T-12 BOOM DOES NOT RISE 451
T-13 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER 452
T-14 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT 453
T-15 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS) 453
T-16 EXCESSIVE HYDRAULIC DRIFT OF BOOM 453
T-17 BOOM SHAKES DURING OPERATION 454
T-18 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE 454
T-19 BUCKET DOES NOT TILT BACK 455
T-20 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER 456
T-21 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION 457
T-22 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER 457
T-23 EXCESSIVE HYDRAULIC DRIFT OF BUCKET 457
T-24 BUCKET SHAKES DURING LOADING OPERATION 458
T-25 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT 458
T-26 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY 459
TROUBLESHOOTING SYSTEMS OF AIR CONDITIONER 461
SERVICE TOOLS 463
GAUGE MANIFOLD 463
STRUCTURE AND HANDLING OF GAUGE MANIFOLD 464
CHARGING HOSES 466
GAS LEAK DETECTOR 467
HALIDE TORCH LEAK DETECTOR 467
ELECTRIC LEAK TESTER 469
VALVE FOR SERVICE CANS 471
MAINTENANCE PROCEDURE 472
PRECAUTIONS WHEN REMOVING OR INSTALLING PIPING 472
PROHIBITED WORK 472
OTHER PRECAUTIONS 472
BLEEDING AIR FROM REFRIGERATION CIRCUIT 474
PURPOSE 474
CONNECTING GAUGE MANIFOLD 474
EVACUATION 475
AIR-TIGHTNESS CHECK 475
GAS-LEAK CHECK 476
EVACUATION (REPEATING) 476
CHARGING THE REFRIGERATION CIRCUIT WITH REFRIGERANT 477
CHARGING FROM THE HIGH-PRESSURE SIDE 477
CHARGING FROM THE LOW PRESSURE SIDE 478
WHEN THE AMBIENT TEMPERATURE IS LOW 479
WHEN THE AMBIENT TEMPERATURE IS HIGH 479
REPLACING SERVICE CANS 480
CHECKING THE AMOUNT OF REFRIGERANT 480
REMOVAL OF GAUGE MANIFOLD 482
DISCHARGING THE REFRIGERANT 482
DAILY CHECKS 483
CHECK REFRIGERANT LEVEL 483
CLEANING THE CONDENSER 483
CHECKING THE V-BELT 483
CHECKING OIL LEVEL 484
PROCEDURE FOR CHECKING 484
PROCEDURE FOR CHECKING OIL LEVEL 484
ADDING AND REMOVING OIL 485
ADDING OIL BY EVACUATION 485
TROUBLESHOOTING 486
VISUAL AND ACOUSTICAL CHECKS 486
DEFECTIVE COOLING 487
TROUBLESHOOTING TABLE 489
DEFECTIVE HEATING 491
TROUBLESHOOTING USING GAUGE MANIFOLD 492
PREPARATIONS BEFORE MEASURING 492
INSUFFICIENT REFRIGERANT 492
EXCESSIVE REFRIGERANT OR INSUFFICIENT COOLING OF CONDENSER 493
AIR INSIDE REFRIGERATION SYSTEM 494
MOISTURE IN REFRIGERATING SYSTEM 495
REFRIGERANT DOES NOT CIRCULATE 496
FAILURE OF EXPANSION VALVE (OPEN TO FAR), DEFECTIVE MOUNTING OF HEAT SENSING TUBE 497
DEFECTIVE COMPRESSION BY COMPRESSOR 498
30 DISASSEMBLY AND ASSEMBLY 499
METHOD OF USING MANUAL 503
PRECAUTIONS DURING OPERATION 504
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK 504
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK 505
PRECAUTIONS WHEN COMPLETING THE OPERATIONS 0
OTHER PRECAUTIONS 506
SPECIAL TOOL LIST 507
ENGINE 510
ALTERNATOR ASSEMBLY 510
CYLINDER HEAD ASSEMBLY 510
ENGINE OIL COOLER ASSEMBLY 510
FUEL INJECTION PUMP ASSEMBLY 510
NOZZLE HOLDER ASSEMBLY 510
STARTING MOTOR ASSEMBLY 510
THERMOSTAT ASSEMBLY 510
TURBOCHARGER ASSEMBLY 510
WATER PUMP ASSEMBLY 510
COVERS, LADDER AND ENGINE HOOD 511
REMOVAL 511
INSTALLATION 514
RADIATOR, HYDRAULIC COOLER ASSEMBLY 515
REMOVAL 515
INSTALLATION 0
MUFFER AND AIR CLEANER 517
REMOVAL 0
INSTALLATION 517
ENGINE ASSEMBLY 0
REMOVAL 518
INSTALLATION 521
TORQUE CONVERTER CHARGING PUMP 522
REMOVAL 522
INSTALLATION 522
TORQUE CONVERTER, TRANSMISSION 523
REMOVAL 0
INSTALLATION 532
TORQUE CONVERTER 534
DISASSEMBLY 534
ASSEMBLY 536
TRANSMISSION 538
DISASSEMBLY 538
ASSEMBLY 547
CLUTCH PACK 560
DISASSEMBLY 560
DISASSEMBLY OF FR CLUTCH PACK 560
DISASSEMBLY OF 1ST AND 3RD CLUTCH PACK 562
DISASSEMBLY OF 2ND AND 4TH CLUTCH PACK 0
ASSEMBLY 0
ASSEMBLY OF FORWARD, REVERSE CLUTCH PACK 566
ASSEMBLY OF 1ST AND 3RD CLUTCH PACK 570
ASSEMBLY OF 2ND AND 4TH CLUTCH PACK 0
PARKING BRAKE 578
DISASSEMBLY 578
ASSEMBLY 580
TRANSMISSION CONTROL VALVE 583
REMOVAL 583
INSTALLATION 585
DISASSEMBLY 586
ASSEMBLY 0
TRANSMISSION SOLENOID VALVE 591
DISASSEMBLY 591
ASSEMBLY 592
ACCUMULATOR VALVE 0
DISASSEMBLY 593
ASSEMBLY 0
DRIVE SHAFT 595
DISASSEMBLY 0
ASSEMBLY 0
FRONT AXLE 599
REMOVAL 0
INSTALLATION 601
REAR AXLE 0
REMOVAL 602
INSTALLATION 0
DIFFERENTIAL 609
DISASSEMBLY 609
ASSEMBLY 613
AXLE HOUSING 622
DISASSEMBLY 622
ASSEMBLY 627
CENTER HINGE PIN 633
REMOVAL 0
INSTALLATION 640
STEERING VALVE 0
REMOVAL 0
INSTALLATION 646
DISASSEMBLY 647
DISASSEMBLY OF ROTOR 0
ASSEMBLY 650
ASSEMBLY OF CONTROL SIDE 650
ASSEMBLY OF ROTOR 0
PRIORITY VALVE 655
REMOVAL 0
INSTALLATION 0
STEERING CYLINDER 0
REMOVAL 0
INSTALLATION 0
POWER MASTER CYLINDER 0
REMOVAL 659
INSTALLATION 660
DISASSEMBLY 661
ASSEMBLY 0
PARKING BRAKE DISC 669
REMOVAL 669
INSTALLATION 670
HYDRAULIC TANK 671
REMOVAL 671
INSTALLATION 672
HYDRAULIC FILTER 0
REMOVAL 0
INSTALLATION 0
WORK EQUIPMENT, STEERING PUMP 0
REMOVAL 674
INSTALLATION 675
MAIN CONTROL VALVE 0
REMOVAL 676
INSTALLATION 0
DISASSEMBLY 681
ASSEMBLY 683
PPC VALVE TO MAIN CONTROL VALVE HYDRAULIC LINES 0
PPC VALVE 686
REMOVAL 0
INSTALLATION 0
CYLINDER 688
BUCKET (TILT) CYLINDER 0
REMOVAL 688
INSTALLATION 689
BOOM (LIFT) CYLINDER 690
REMOVAL 690
INSTALLATION 692
HYDRAULIC CYLINDER 693
DISASSEMBLY 693
ASSEMBLY 695
BOOM AND PARALLEL TOOL LINKAGE 698
REMOVAL 698
INSTALLATION 0
ECSS SYSTEM 0
ECSS CIRCUIT – REMAINING PRESSURE REMOVAL 0
ECSS SOLENOID VALVE 0
REMOVAL 710
INSTALLATION 0
ECSS CONTROL VALVE 711
REMOVAL 711
INSTALLATION 0
COUNTERWEIGHT 0
REMOVAL 0
INSTALLATION 0
FUEL TANK 713
REMOVAL 713
INSTALLATION 0
CAB (ROPS) 0
REMOVAL 0
INSTALLATION 0
MAIN MONITOR 717
REMOVAL 717
INSTALLATION 0
MAINTENANCE MONITOR 719
REMOVAL 719
INSTALLATION 719
AIR CONDITIONER 0
AIR CONDITIONER UNIT 720
REMOVAL 720
INSTALLATION 725
CONDENSER 726
REMOVAL 726
INSTALLATION 727
DRY RECIEVER 728
REMOVAL 728
INSTALLATION 729
COMPRESSOR 730
REMOVAL 0
INSTALLATION 731
40 MAINTENANCE STANDARD 733
TRANSMISSION, ENGINE MOUNT 735
TORQUE CONVERTER CHARGING PUMP 736
TORQUE CONVERTER 737
TRANSMISSION 739
FORWARD, REVERSE CLUTCH 744
1ST, 3RD CLUTCH 745
2nd, 4th CLUTCH 746
TRANSMISSION CONTROL VALVE 748
UPPER VALVE 748
LOWER VALVE 750
SOLENOID VALVE 751
ACCUMULATOR VALVE 752
DRIVE SHAFT 753
DIFFERENTIAL 754
DIFFERENTIAL 756
FINAL DRIVE 758
AXLE MOUNT 760
CENTER HINGE PIN 762
STEERING COLUMN 764
PRIORITY VALVE 765
MASTER CYLINDER 766
BRAKE 767
PARKING BRAKE 768
HYDRAULIC PUMP 769
MAIN CONTROL VALVE 770
PILOT SOLENOID VALVE 772
PPC VALVE 773
HYDRAULIC CYLINDER 774
90 OTHERS 775
OPERATION OF THE PROXIMITY SWITCH 777
ELECTRICAL WIRING DIAGRAM (1/7) 779
ELECTRICAL WIRING DIAGRAM (2/7) 781
ELECTRICAL WIRING DIAGRAM (3/7) 783
ELECTRICAL WIRING DIAGRAM (4/7) 785
ELECTRICAL WIRING DIAGRAM (5/7) 787
ELECTRICAL WIRING DIAGRAM (6/7) 789
ELETRICAL WIRING DIAGRAM (7/7) 791
TRANSMISSION CONTROL, PARKING BRAKE SYSTEM 793
MACHINE MONITOR SYSTEM (1/2) 795
MACHINE MONITOR SYSTEM (2/2) 797

DESCRIPTION:

Komatsu Avance Plus WA250PT-3MC Parallel Tool Carrier Shop Manual CEBM004702  – PDF DOWNLOAD

• SERIAL NUMBERS
• WA250PT-3MC – A78001 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