Komatsu WA250-3 PARALLEL TOOL CARRIER Operation & Maintenance Manual

Starting from:
$40
Home
Komatsu WA250-3 PARALLEL TOOL CARRIER Operation & Maintenance Manual - PDF DOWNLOAD
Komatsu WA250-3 PARALLEL TOOL CARRIER Operation & Maintenance Manual

Description:

Komatsu WA250-3 PARALLEL TOOL CARRIER Operation & Maintenance Manual
This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel realize peak performance through effective, economical and safe machine operation and maintenance.
Keep this manual handy and have all personnel read it periodically. If this manual is lost or becomes dirty and can not be read, request a replacement manual from your local distributor. If you sell the machine, be sure to give this manual to the new owner. Continuing improvements in the design of this machine can lead to changes in detail, which may not be reflected in this manual.
Consult your local distributor or Komatsu America International Company for the latest available information on your machine or for questions regarding information in this manual
MAIN MENU........................................................................................  0
COVER............................................................................................  1
INTRODUCTION.....................................................................................  4
	1. FORWARD...................................................................................  5
	2. SAFETY INFORMATION........................................................................  6
	3. INTRODUCTION..............................................................................  7
		3.1 INTENDED USE.........................................................................  7
		3.2 FEATURES.............................................................................  7
		3.3 BREAKING IN A NEW MACHINE............................................................  7
	4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.............................  8
		4.1 MACHINE SERIAL NO. PLATE POSITION....................................................  8
		4.2 ENGINE SERIAL NO. PLATE POSITION.....................................................  8
		4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR............................................  8
	CONTENTS.....................................................................................  9
SAFETY........................................................................................... 15
	6. GENERAL PRECAUTIONS....................................................................... 16
	7. PRECAUTIONS DURING OPERATION.............................................................. 22
		7.1 BEFORE STARTING ENGINE............................................................... 22
		7.2 AFTER STARTING ENGINE................................................................ 25
		7.3 TRANSPORTATION....................................................................... 34
		7.4 BATTERY.............................................................................. 35
		7.5 TOWING............................................................................... 38
	8. PRECAUTIONS FOR MAINTENANCE............................................................... 39
		8.1 BEFORE CARRYING OUT MAINTENANCE...................................................... 39
		8.2 DURING MAINTENANCE................................................................... 44
		8.3 TIRES................................................................................ 49
	9. POSITION FOR ATTACHING SAFETY LABELS...................................................... 51
		9.1 POSTION FOR ATTACHING SAFETY LABELS.................................................. 51
OPERATION........................................................................................ 55
	10. GENERAL VIEW............................................................................. 56
		10.1 GENERAL VIEW OF MACHINE............................................................. 56
		10.2 GENERAL VIEW OF CONTROLS AND GAUGES................................................. 57
	11. EXPLANANTION OF COMPONENTS............................................................... 58
		11.1 METERS, LAMPS....................................................................... 58
			11.1.1 WARNING DISPLAYS.............................................................. 60
			11.1.2 METER DISPLAY PORTION......................................................... 64
		11.2 SWITCHES............................................................................ 68
		11.3 CONTROL LEVERS, PEDAL............................................................... 74
		11.4 STEERING COLUMN TILT LEVER.......................................................... 78
		11.5 CAP WITH LOCK....................................................................... 78
			11.5.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK................................... 78
		11.6 SAFETY BAR.......................................................................... 79
		11.7 TOWING PIN.......................................................................... 79
		11.8 GREASE PUMP CLAMP AND RUBBER RING................................................... 79
		11.9 BACKUP ALARM........................................................................ 80
		11.10 FUSE............................................................................... 81
			11.10.1 FUSE CAPACITY AND NAME OF CIRCUIT............................................ 81
		11.11 SLOW BLOW FUSE..................................................................... 82
		11.12 STORAGE PLACE FOR THIS MANUAL...................................................... 83
		11.13 AUXILIARY POWER SOURCE............................................................. 83
			11.13.1 FOR MACHINES EQUIPPED WITH ROPS CAB.......................................... 83
	12. CHECK BEFORE STARTING ENGINE............................................................. 84
		12.1 WALK AROUND CHECK................................................................... 84
		12.2 CHECK BEFORE STARTING............................................................... 87
			12.2.1 CHECK COOLANT LEVEL, ADD COOLANT.............................................. 87
			12.2.2 CHECK MONITOR PANEL........................................................... 87
			12.2.3 CHECK FUEL LEVEL, ADD FUEL.................................................... 88
			12.2.4 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL.................................... 88
			12.2.5 CHECK AND REFILL OF OIL IN BRAKE OIL TANK..................................... 89
			12.2.6 CHECK DUST INDICATOR.......................................................... 89
			12.2.7 CHECK ELECTRICAL WIRING....................................................... 90
			12.2.8 DRAIN THE WATER FROM THE FUEL WATER SEPARATOR................................. 91
			12.2.9 CHECK EFFECT OF PARKING BRAKE................................................. 91
			12.2.10 CHECK EFFECT OF WHEEL BRAKES................................................. 92
			12.2.11 CHECK SOUND OF HORN AND BACKUP ALARM......................................... 92
			12.2.12 CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE........................... 92
			12.2.13 CHECK ENGINE EXHAUST COLOR AND SOUND......................................... 92
			12.2.14 CHECK OPERATIONS OF GAUGES................................................... 92
			12.2.15 CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING.................... 92
			12.2.16 CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE................ 92
			12.2.17 CHECK LOCK OF CAB DOOR FOR MACHINES EQUIPPED WITH CAB........................ 92
		12.3 ADJUSMENT BEFORE OPERATION.......................................................... 93
			12.3.1 OPERATOR'S SEAT............................................................... 93
			12.3.2 ADJUST SEAT BELT.............................................................. 95
			12.3.3 ADJUST REAR VIEW MIRRORS...................................................... 96
		12.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE........................................ 97
		12.5 STARTING ENGINE..................................................................... 98
			12.5.1 NORMAL STARTING PROCEDURES IN COLD AND WARM CONDITIONS........................ 98
			12.5.2 STARTING PROCEDURES AFTER EXTENDED SHUTDOWN OR OIL CHANGE..................... 99
			12.5.3 STARTING PROCEDURES AFTER CHANGING FUEL FILTERS............................... 99
			12.5.4 STARTING PROCEDURES AFTER RUNNING OUT OF FUEL................................. 99
		12.6 OPERATIONS AND CHECKS AFTER STARTING ENGINE.........................................100
		12.7 MOVING MACHINE OFF..................................................................101
		12.8 CHANGING GEAR SPEED.................................................................103
		12.9 CHANGING DIRECTION..................................................................103
		12.10 TURNING............................................................................104
		12.11 STOPPING MACHINE...................................................................105
		12.12 OPERATION OF WORK EQUIPMENT (WITH BUCKET TOOL).....................................106
			12.12.1 LIFT ARM OPERATION (LEVER)...................................................106
			12.12.2 BUCKET OPERATION (LEVER).....................................................106
		12.13 OPERATAION OF WORK EQUIPMENT (WITH FORK TOOL)......................................107
			12.13.1 LIFT ARM OPERATION (LEVER....................................................107
			12.13.2 FORK OPERATION (LEVER).......................................................107
		12.14 OPERATION OF WORK EQUIPMENT (WITH MULTI-PURPOSE BUCKET TOOL).......................108
			12.14.1 LIFT ARM OPERATION (LEVER)...................................................108
			12.14.2 BUCKET OPERATION (LEVER).....................................................108
			12.14.3 AUXILIARY OPERATION (LEVER)..................................................109
			12.14.4 POSITION INDICATOR...........................................................109
		12.15 OPERATION OF WORK EQUIPMENT (WITH MATERIAL HANDLING ARM)...........................111
			12.15.1 LIFT ARM OPERATION (LEVER)...................................................111
		12.16 HYDRAULIC QUICK COUPLER............................................................112
			12.16.1 COUPLING THE ATTACHEMENT.....................................................112
			12.16.2 UNCOUPLING FROM THE ATTACHMENT...............................................113
			12.16.3 ATTACHMENTS REQUIRING HYDRAULIC POWER........................................114
		12.17 WORK POSSIBLE USING PARALLEL TOOL CARRIER..........................................115
			12.17.1 DIGGING OPERATIONS WITH ROCK PILES (GENERAL PURPOSE BUCKET)..................115
			12.17.2 DIGGING OPERATIONS ON LEVEL GROUND...........................................116
			12.17.3 LEVELING OPERATION...........................................................117
			12.17.4 PUSHING OPERATIONS...........................................................117
			12.17.5 LOAD AND CARRY OPERATIONS....................................................117
			12.17.6 LOADING OPERATIONS...........................................................118
			12.17.7 MULTI-PURPOSE BUCKET.........................................................119
			12.17.8 PALLET FORKS.................................................................124
			12.17.9 MATERIAL HANDLING ARM........................................................127
		12.18 PRECAUTIONS FOR OPERATION..........................................................128
			12.18.1 PERMISSIBLE WATER DEPTH......................................................128
			12.18.2 IF WHEEL BRAKE DOES NOT WORK.................................................128
			12.18.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...................................128
			12.18.4 PRECAUTIONS WHEN DRIVING MACHINE.............................................129
		12.19 ADJUSTING BOOM KICK-OUT POSITIONER.................................................130
			12.19.1 ADJUSTING BOOM KICK OUT......................................................130
			12.19.2 ADJUSTING BUCKET/FORK POSITIONER.............................................131
		12.20 PARKING MACHINE....................................................................132
		12.21 CHECKS AFTER COMPLETTION OF ENGINE OPERATION.......................................133
		12.22 STOPPING ENGINE....................................................................133
		12.23 CHECKS AFTER STOPPING ENGINE.......................................................134
		12.24 LOCKING............................................................................134
		12.25 HANDLING THE TIRES.................................................................135
			12.25.1 PRECAUTIONS WHEN HANDLING THE TIRES..........................................135
			12.25.2 TIRE PRESSURE................................................................135
	13. TRANSPORTATION...........................................................................137
		13.1 LOADING, UNLOADING WORK.............................................................137
		13.2 PRECAUTION FOR LOADING..............................................................138
		13.3 PRECAUTION FOR LIFTING UP THE VEHICLE...............................................138
			13.3.1 THE LOCATION OF DECALS REFERRING TO LIFTING POSITIONS.........................139
			13.3.2 WEIGHT LIST...................................................................139
			13.3.3 LIFTING PROCEDURE.............................................................140
	14. COLD WEATHER OPERATIONS..................................................................141
		14.1 PRECAUTIONS FOR LOW TEMPERATURE.....................................................141
			14.1.1 FUEL AND LUBRICANTS...........................................................141
			14.1.2 COOLANT.......................................................................141
			14.1.3 BATTERY.......................................................................142
		14.2 PRECAUTIONS FOR COMPLETION OF WORK..................................................143
		14.3 AFTER COLD WEATHER..................................................................143
	15. LONG TERM STORAGE........................................................................144
		15.1 BEFORE STORAGE......................................................................144
		15.2 DURING STORAGE......................................................................144
		15.3 AFTER STORAGE.......................................................................144
	16. TROUBLESHOOTING..........................................................................145
		16.1 WHEN MACHINE RUNS OUT OF FUEL.......................................................145
		16.2 TOWING THE MACHINE..................................................................146
			16.2.1 WHEN ENGINE CAN BE USED.......................................................148
			16.2.2 WHEN ENGINE CANNOT BE USED....................................................148
		16.3 IF BATTERY IS DISCHARGED............................................................149
			16.3.1 REMOVAL AND INSTALLATION OF BATTERY...........................................149
			16.3.2 PRECAUTION FOR CHARGING BATTERY...............................................150
			16.3.3 STARTING ENGINE WITH BOOSTER CABLE............................................151
		16.4 OTHER TROUBLE.......................................................................153
			16.4.1 ELECTRICAL SYSTEM.............................................................153
			16.4.2 CHASSIS.......................................................................154
			16.4.3 ENGINE........................................................................157
MAINTENANCE......................................................................................159
	17. GUIDES TO MAINTENANCE....................................................................160
	18. OUTLINES OF SERVICE......................................................................163
		18.1 OUTLINE OF OIL, FUEL, COOLANT.......................................................163
			18.1.1 OIL...........................................................................163
			18.1.2 FUEL..........................................................................163
			18.1.3 COOLANT.......................................................................164
			18.1.4 GREASE........................................................................165
			18.1.5 STORING OIL AND FUEL..........................................................165
			18.1.6 FILTERS.......................................................................165
		18.2 OUTLINE OF ELECTRICAL SYSTEM........................................................166
	19. WEAR PARTS LIST..........................................................................167
	20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.....................168
		20.1 ENGINE OIL SPECIFICATIONS...........................................................169
		20.2 DIESEL FUEL SPECIFICATIONS..........................................................170
		20.3 COOLANT SPECIFICATIONS..............................................................171
	21. STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS............................................177
		21.1 INTRODUCTION OF NECESSARY TOOLS.....................................................177
		21.2 TORQUE LIST.........................................................................178
	22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................................180
	23. MAINTENANCE SCHEDULE CHART...............................................................184
		23.1 MAINTENANCE SCHEDULE CHART..........................................................184
	24. SERVICE PROCEDURES.......................................................................188
		24.1 INITIAL 250 HOURS SERVICE...........................................................188
			24.1.1 REPLACE FUEL FILTERS..........................................................188
			24.1.2 REPLACE TRANSMISSION OIL FILTER ELEMENT.......................................188
			24.1.3 REPLACE HYDRAULIC TANK FILTER ELEMENT.........................................188
		24.2 WHEN REQUIRED.......................................................................189
			24.2.1 CHECK, CLEAN OR REPLACE AIR CLEANER ELEMENT...................................189
			24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL.........................................191
			24.2.3 CHECK AXLE OIL LEVEL, ADD OIL.................................................192
			24.2.4 CLEAN THE AXLE CASE BREATHER..................................................193
			24.2.5 CLEAN RADIATOR FINS...........................................................193
			24.2.6 REPLACE THE BOLT-ON CUTTING EDGES.............................................194
			24.2.7 REPLACE BUCKET TEETH (IF EQUIPPED)............................................195
			24.2.8 CHECK AIR CONDITIONER (IF EQUIPPED)...........................................196
			24.2.9 CHECK THE AIR CONDITIONER CONDENSER (IF EQUIPPED).............................197
			24.2.10 CHECK WINDOW WASHING FLUID...................................................197
			24.2.11 ADJUST PARKING BRAKE.........................................................198
			24.2.12 REPLACE SLOW BLOW FUSE.......................................................199
			24.2.13 CHECK AIR INTAKE HEATER......................................................199
		24.3 CHECK BEFORE STARTING...............................................................200
		24.4 EVERY 50 HOURS SERVICE..............................................................201
			24.4.1 CHECK THE TIRE INFLATION PRESSURE.............................................201
			24.4.2 DRAIN WATER, SEDIMENT FROM FUEL TANK..........................................201
		24.5 EVERY 100 HOURS OF SERVICE .........................................................202
			24.5.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL....................................202
			24.5.2 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER.............................203
			24.5.3 LUBRICATING...................................................................204
		24.6 EVERY 250 HOURS SERVICE.............................................................205
			24.6.1 CHANGE OIL IN ENGINE OIL PAN AND REPLACE ENGINE OIL FILTER....................205
			24.6.2 CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN.......................................206
			24.6.3 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER.........................206
			24.6.4 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.........................207
			24.6.5 CHECK BATTERY ELECTROLYTE LEVEL...............................................208
			24.6.6 CHECK AIR INTAKE SYSTEM.......................................................208
			24.6.7 LUBRICATING...................................................................209
		24.7 EVERY 500 HOURS SERVICE.............................................................210
			24.7.1 REPLACE FUEL FILTERS..........................................................210
			24.7.2 REPLACE TRANSMISSION OIL FILTER ELEMENT.......................................212
			24.7.3 LUBRICATE.....................................................................213
		24.8 EVERY 1000 HOURS SERVICE............................................................214
			24.8.1 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER...............................214
			24.8.2 CLEAN TRANSMISSION CASE BREATHER..............................................215
			24.8.3 LUBRICATE.....................................................................216
			24.8.4 ADJUST ENGINE VALVE LASH CLEARANCE............................................217
			24.8.5 CHECK FAN BELT TENSION........................................................218
			24.8.6 CHECK FAN BELT TENSIONER BEARING & FAN HUB BEARING & INSPECT FAN BELT.........218
		24.9 EVERY 2000 HOURS SERVICE............................................................219
			24.9.1 CHANGE OIL IN HYDRAULIC OIL TANK, REPLACE HYDRAULIC FILTER ELEMENT............219
			24.9.2 REPLACE HYDRAULIC TANK BREATHER ELEMENT.......................................221
			24.9.3 COOLING SYSTEM, REPLACE COOLANT AND FLUSH SYSTEM..............................222
			24.9.4 CHANGE AXLE OIL...............................................................225
			24.9.5 CHECK BRAKE DISC WEAR.........................................................226
			24.9.6 CHECK ALTERNATOR..............................................................226
			24.9.7 CHECK STARTER MOTOR...........................................................226
			24.9.8 CHECK VIBRATION DAMPER........................................................226
			24.9.9 REPLACE ELEMENT IN AIR COND. RECIRCULATION AIR FILTER AND FRESH AIR FILTER....226
			24.9.10 ADJUST ENGINE VALVE LASH CLEARANCE...........................................227
SPECIFICATIONS...................................................................................229
	25. SPECIFICATIONS...........................................................................230
OPTIONS, ATTACHMENTS.............................................................................237
	26. AVAILABLE ATTACHMENTS....................................................................238
	27. SELECTING ATTACHMENTS AND TIRES..........................................................239
	28. HEATER AND AIR CONDITIONING (IF EQUIPPED)................................................240
		28.1 GENERAL LOCATION AND FUNCTION OF CONTROL PANEL......................................240
		28.2 COOL BOX COMPARTMENT................................................................241
	29. HANDLING E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM)(IF EQUIPPED).................242
		29.1 STRUCTURE AND FUNCTION OF E.C.S.S...................................................242
		29.2 METHOD OF OPERATING E.C.S.S.........................................................243
		29.3 PRECAUTIONS WHEN OPERATING E.C.S.S..................................................243
		29.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR...............................................244
Screenshot Of The Manual:
