Komatsu WA250-3 wheel Loader Operation & Maintenance Manual PDF DOWNLOAD

Komatsu WA250-3 Wheel Loader Operation & Maintenance Manual

Description:

Komatsu WA250-3 Wheel Loader 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

Table Of Contents:

Komatsu WA250-3 Wheel Loader Operation & Maintenance Manual

MAIN MENU........................................................................................  0
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
	5. CONTENTS..................................................................................  9
SAFETY........................................................................................... 14
	6. GENERAL PRECAUTIONS....................................................................... 15
	7. PRECAUTIONS DURING OPERATION.............................................................. 21
		7.1 BEFORE STARTING ENGINE............................................................... 21
		7.2 AFTER STARTING ENGINE................................................................ 24
		7.3 TRANSPORTATION....................................................................... 33
		7.4 BATTERY.............................................................................. 34
		7.5 TOWING............................................................................... 37
	8. PRECAUTIONS FOR MAINTENANCE............................................................... 38
		8.1 BEFORE CARRYING OUT MAINTENANCE...................................................... 38
		8.2 DURING MAINTENANCE................................................................... 43
		8.3 TIRES................................................................................ 48
	9. POSITION FOR ATTACHING SAFETY LABELS...................................................... 50
		9.1 POSITION FOR ATTACHING SAFETY LABELS................................................. 50
OPERATION........................................................................................ 54
	10. GENERAL VIEW............................................................................. 55
		10.1 GENERAL VIEW OF MACHINE............................................................. 55
		10.2 GENERAL VIEW OF CONTROLS AND GAUGES................................................. 56
	11. EXPLANATION OF COMPONENTS................................................................ 57
		11.1 METER, LAMPS........................................................................ 57
			11.1.1 WARNING DISPLAYS.............................................................. 59
			11.1.2 METER DISPLAY PORTION......................................................... 63
		11.2 SWITCHES............................................................................ 67
		11.3 CONTROL LEVERS, PEDAL............................................................... 72
		11.4 STEERING COLUMN TILT LEVER.......................................................... 76
		11.5 CAP WITH LOCK....................................................................... 76
			11.5.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK................................... 76
		11.6 SAFETY BAR.......................................................................... 77
		11.7 TOWING PIN.......................................................................... 77
		11.8 GREASE PUMP CLAMP AND RUBBER RING................................................... 77
		11.9 BACKUP ALARM........................................................................ 78
		11.10 FUSE............................................................................... 79
			11.10.1 FUSE CAPACITY AND NAME OF CIRCUIT............................................ 79
		11.11 SLOW BLOW FUSE..................................................................... 80
		11.12 STORAGE PLACE FOR THIS MANUAL...................................................... 81
		11.13 AUXILIARY POWER SOURCE............................................................. 81
			11.13.1 FOR MACHINES EQUIPPED WITH ROPS CAB.......................................... 81
	12. CHECK BEFORE STARTING ENGINE............................................................. 82
		12.1 WALK AROUND CHECK................................................................... 82
		12.2 CHECK BEFORE STARTING............................................................... 85
			12.2.1 CHECK COOLANT LEVEL, ADD COOLANT.............................................. 85
			12.2.2 CHECK MONITOR PANEL........................................................... 85
			12.2.3 CHECK FUEL LEVEL, ADD FUEL.................................................... 86
			12.2.4 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL.................................... 86
			12.2.5 CHECK AND REFILL OF OIL IN BRAKE OIL TANK..................................... 87
			12.2.6 CHECK DUST INDICATOR.......................................................... 87
			12.2.7 CHECK ELECTRICAL WIRING....................................................... 88
			12.2.8 DRAIN THE WATER FROM THE FUEL-WATER SEPARATOR................................. 89
			12.2.9 CHECK EFFECT OF PARKING BRAKE................................................. 89
			12.2.10 CHECK EFFECT OF WHEEL BRAKES................................................. 90
			12.2.11 CHECK SOUND OF HORN AND BACKUP ALARM......................................... 90
			12.2.12 CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE........................... 90
			12.2.13 CHECK ENGINE EXHAUST COLOR AND SOUND......................................... 90
			12.2.14 CHECK OPERATIONS OF GAUGES................................................... 90
			12.2.15 CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING.................... 90
			12.2.16 CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE................ 90
			12.2.17 CHECK LOCK OF CAB DOOR FOR MACHINES EQUIPPED WITH CAB........................ 90
		12.3 ADJUSTMENT BEFORE OPERATION......................................................... 91
			12.3.1 OPERATOR'S SEAT............................................................... 91
			12.3.2 ADJUST SEAT BELT.............................................................. 93
			12.3.3 ADJUST REAR VEIW MIRRORS...................................................... 94
		12.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE........................................ 95
		12.5 STARTING ENGINE..................................................................... 96
			12.5.1 NORMAL STARTING PROCEDURES IN COLD AND WARM CONDITIONS........................ 96
			12.5.2 STARTING PROCEDURES AFTER EXTENDED SHUTDOWN OR OIL CHANGE..................... 97
			12.5.3 STARTING PROCEDURES AFTER CHANGING FUEL FILTERS............................... 97
			12.5.4 STARTING PROCEDURES AFTER RUNNING OUT OF FUEL................................. 97
		12.6 OPERATIONS AND CHECKS AFTER STARTING ENGINE......................................... 98
		12.7 MOVING MACHINE OFF.................................................................. 99
		12.8 CHANGING GEAR SPEED.................................................................101
		12.9 CHANGING DIRECTION..................................................................101
		12.10 TURNING............................................................................102
		12.11 STOPPING MACHINE...................................................................103
		12.12 OPERATION OF WORK EQUIPMENT........................................................104
		12.13 WORK POSSIBLE USING WHEEL LOADER...................................................105
			12.13.1 DIGGING OPERATIONS WITH ROCK PILES...........................................105
			12.13.2 DIGGING OPERATIONS ON LEVEL GROUND...........................................106
			12.13.3 LEVELING OPERATION...........................................................107
			12.13.4 PUSHING OPERATIONS...........................................................107
			12.13.5 LOAD AND CARRY OPERATIONS....................................................107
			12.13.6 LOADING OPERATIONS...........................................................108
		12.14 PRECAUTIONS FOR OPERATION..........................................................109
			12.14.1 PERMISSIBLE WATER DEPTH......................................................109
			12.14.2 IF WHEEL BRAKE DOES NOT WORK.................................................109
			12.14.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...................................109
			12.14.4 PRECAUTIONS WHEN DRIVING MACHINE.............................................110
		12.15 ADJUSTING WORK EQUIPMENT POSTURE...................................................111
			12.15.1 ADJUSTING BOOM KICKOUT.......................................................111
			12.15.2 ADJUSTING BUCKET POSITIONER..................................................112
			12.15.3 BUCKET LEVEL INDICATOR.......................................................112
		12.16 PARKING MACHINE....................................................................113
		12.17 CHECKS AFTER COMPLETION OF ENGINE OPERATION........................................114
		12.18 STOPPING ENGINE....................................................................114
		12.19 CHECKS AFTER STOPPING ENGINE.......................................................115
		12.20 LOCKING............................................................................115
		12.21 HANDLING THE TIRES.................................................................116
			12.21.1 PRECAUTIONS WHEN HANDLING THE TIRES..........................................116
			12.21.2 TIRE PRESSURE................................................................116
	13. TRANSPORTATION...........................................................................118
		13.1 LOADING, UNLOADING WORK.............................................................118
		13.2 PRECAUTION FOR LOADING..............................................................119
		13.3 PRECAUTION FOR LIFTING UP THE VEHICLE...............................................119
			13.3.1 THE LOCATION OF DECALS REFERRING TO LIFTING POSITIONS.........................120
			13.3.2 WEIGHT LIST...................................................................120
			13.3.3 LIFTING PROCEDURE.............................................................121
	14. COLD WEATHER OPERATIONS..................................................................122
		14.1 PRECAUTIONS FOR LOW TEMPERATURE.....................................................122
			14.1.1 FUEL AND LUBRICANTS...........................................................122
			14.1.2 COOLANT.......................................................................122
			14.1.3 BATTERY.......................................................................123
		14.2 PRECAUTIONS AFTER COMPLETION OF WORK................................................124
		14.3 AFTER COLD WEATHER..................................................................124
	15. LONG TERM STORAGE........................................................................125
		15.1 BEFORE STORAGE......................................................................125
		15.2 DURING STORAGE......................................................................125
		15.3 AFTER STORAGE.......................................................................125
	16. TROUBLESHOOTING..........................................................................126
		16.1 WHEN MACHINE RUNS OUT OF FUEL.......................................................126
		16.2 TOWING THE MACHINE..................................................................127
			16.2.1 WHEN ENGINE CAN BE USED.......................................................129
			16.2.2 WHEN ENGINE CANNOT BE USED....................................................129
		16.3 IF BATTERY IS DISCHARGED............................................................130
			16.3.1 REMOVAL AND INSTALLATION OF BATTERY...........................................130
			16.3.2 PRECAUTIONS FOR CHARGING BATTERY..............................................131
			16.3.3 STARTING ENGINE WITH BOOSTER CABLE............................................132
		16.4 OTHER TROUBLE.......................................................................134
			16.4.1 ELECTRICAL SYSTEM.............................................................134
			16.4.2 CHASSIS.......................................................................135
			16.4.3 ENGINE........................................................................138
MAINTENANCE......................................................................................140
	17. GUIDES TO MAINTENANCE....................................................................141
	18. OUTLINES OF SERVICE......................................................................144
		18.1 OUTLINE OF OIL, FUEL, COOLANT.......................................................144
			18.1.1 OIL...........................................................................144
			18.1.2 FUEL..........................................................................144
			18.1.3 COOLANT.......................................................................145
			18.1.4 GREASE........................................................................146
			18.1.5 STORING OIL AND FUEL..........................................................146
			18.1.6 FILTERS.......................................................................146
		18.2 OUTLINE OF ELECTRIC SYSTEM..........................................................147
	19. WEAR PARTS LIST..........................................................................148
	20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.....................149
		20.1 ENGINE OIL SPECIFICATIONS...........................................................150
		20.2 DIESEL FUEL SPECIFICATIONS..........................................................150
		20.3 COOLANT SPECIFICATIONS..............................................................152
	21. STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS............................................158
		21.1 INTRODUCTION OF NECESSARY TOOLS.....................................................158
		21.2 TORQUE LIST.........................................................................159
	22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................................160
	23. MAINTENANCE SCHEDULE CHART...............................................................164
		23.1 MAINTENANCE SCHEDULE CHART..........................................................164
	24. SERVICE PROCEDURES.......................................................................168
		24.1 INITIAL 250 HOURS SERVICE...........................................................168
			24.1.1 REPLACE FUEL FILTERS..........................................................168
			24.1.2 REPLACE TRANSMISSION OIL FILTER ELEMENT.......................................168
			24.1.3 REPLACE HYDRAULIC TANK FILTER ELEMENT.........................................168
		24.2 WHEN REQUIRED.......................................................................169
			24.2.1 CHECK, CLEAN OR REPLACE AIR CLEANER ELEMENT...................................169
			24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL.........................................171
			24.2.3 CHECK AXLE OIL LEVEL , ADD OIL................................................172
			24.2.4 CLEAN THE AXLE CASE BREATHER..................................................173
			24.2.5 CLEAN RADIATOR FINS...........................................................173
			24.2.6 REPLACE THE BOLT-ON CUTTING EDGES.............................................174
			24.2.7 REPLACE BUCKET TEETH (IF EQUIPPED)............................................175
			24.2.8 CHECK AIR CONDITIONER (IF EQUIPPED)...........................................176
			24.2.9 CHECK THE AIR CONDITIONER CONDENSER (IF EQUIPPED).............................177
			24.2.10 CHECK WINDOW WASHING FLUID...................................................177
			24.2.11 ADJUST PARKING BRAKE.........................................................178
			24.2.12 REPLACE SLOW BLOW FUSE.......................................................179
			24.2.13 CHECK AIR INTAKE HEATER......................................................179
		24.3 CHECK BEFORE STARTING...............................................................180
		24.4 EVERY 50 HOURS SERVICE..............................................................181
			24.4.1 CHECK THE TIRE INFLATION PRESSURE.............................................181
			24.4.2 DRAIN WATER, SEDIMENT FROM FUEL TANK..........................................181
		24.5 EVERY 100 HOURS SERVICE.............................................................182
			24.5.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL....................................182
			24.5.2 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER.............................183
			24.5.3 LUBRICATING...................................................................184
		24.6 EVERY 250 HOURS SERVICE.............................................................185
			24.6.1 CHANGE OIL IN ENGINE OIL PAN AND REPLACE ENGINE OIL FILTER....................185
			24.6.2 CHECK FOR LOOSE WHEEL HUB NUTS. TIGHTEN.......................................186
			24.6.3 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER.........................186
			24.6.4 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.........................187
			24.6.5 CHECK BATTERY ELECTROLYTE LEVEL...............................................188
			24.6.6 CHECK AIR INTAKE SYSTEM.......................................................188
			24.6.7 LUBRICATING...................................................................189
		24.7 EVERY 500 HOURS SERVICE.............................................................190
			24.7.1 REPLACE FUEL FILTERS..........................................................190
			24.7.2 REPLACE TRANSMISSION OIL FILTER ELEMENT.......................................192
			24.7.3 LUBRICATE.....................................................................193
		24.8 EVERY 1000 HOURS SERVICE............................................................194
			24.8.1 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER...............................194
			24.8.2 CLEAN TRANSMISSION CASE BREATHER..............................................195
			24.8.3 LUBRICATE.....................................................................196
			24.8.4 ADJUST ENGINE VALVE LASH CLEARANCE............................................197
			24.8.5 CHECK FAN BELT TENSION........................................................198
			24.8.6 CHECK FAN BELT TENSIONER BEARING & FAN HUB BEARING & INSPECT FAN BELT.........198
		24.9 EVERY 2000 HOURS SERVICE............................................................199
			24.9.1 CHANGE OIL IN HYDRAULIC OIL TANK, REPLACE HYDRAULIC FILTER ELEMENT............199
			24.9.2 REPLACE HYDRAULIC TANK BREATHER ELEMENT.......................................201
			24.9.3 COOLING SYSTEM, REPLACE COOLANT AND FLUSH THE SYSTEM..........................202
			24.9.4 CHANGE AXLE OIL...............................................................205
			24.9.5 CHECK BRAKE DISC WEAR.........................................................206
			24.9.6 CHECK ALTERNATOR..............................................................206
			24.9.7 CHECK STARTER MOTOR...........................................................206
			24.9.8 CHECK VIBRATION DAMPER........................................................206
			24.9.9 REPLACE ELEMENT IN AIR COND. RECIRCULATION AIR FILTER AND FRESH AIR FILTER....206
			24.9.10 ADJUST ENGINE VALVE LASH CLEARANCE...........................................207
SPECIFICATIONS...................................................................................209
	25. SPECIFICATIONS...........................................................................210
OPTIONS,  ATTACHMENTS............................................................................212
	26. AVAILABLE ATTACHMENTS....................................................................213
	27. SELECTING BUCKETS AND TIRES..............................................................214
	28. HEATER AND AIR CONDITIONING (IF EQUIPPED)................................................215
		28.1 GENERAL LOCATION AND FUNCTION OF CONTROL PANEL......................................215
		28.2 COOL BOX COMPARTMENT................................................................216
	29. HANDLING E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM) (IF EQUIPPED)................217
		29.1 STRUCTURE AND FUNCTION OF E.C.S.S...................................................217
		29.2 METHOD OF OPERATING E.C.S.S.........................................................218
		29.3 PRECAUTIONS WHEN OPERATING E.C.S.S..................................................218
		29.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR...............................................219

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