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KOMATSU GALEO WA200-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:65629 and up) KOMATSU WA200-5 – PDF DOWNLOAD
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- KOMATSU GALEO WA200-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:65629 and up
- PUBLICATION NUMBER:TEN00151-00
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Description
KOMATSU GALEO WA200-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:65629 and up) KOMATSU WA200-5
KOMATSU GALEO WA200-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:65629 AND UP) KOMATSU WA200-5 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU GALEO WA200-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:65629 and up) KOMATSU WA200-5
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance.
TABLE OF CONTENTS:
KOMATSU GALEO WA200-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:65629 and up) KOMATSU WA200-5
COVER............................................................................................ 1 FOREWORD......................................................................................... 2 FOREWORD..................................................................................... 3 SAFETY INFORMATION........................................................................... 6 INTRODUCTION................................................................................. 8 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE............................................. 8 NECESSARY INFORMATION........................................................................ 9 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE............................. 9 ENGINE SERIAL NO. PLATE.................................................................. 9 POSITION OF SERVICE METER................................................................ 10 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................................................ 10 CONTENTS......................................................................................... 11 SAFETY........................................................................................... 14 SAFETY....................................................................................... 15 SAFETY LABELS................................................................................ 18 LOCATION OF SAFETY LABELS................................................................ 18 SAFETY LABELS............................................................................ 19 GENERAL PRECAUTIONS.......................................................................... 24 SAFETY RULES............................................................................. 24 IF ABNORMALITIES ARE FOUND............................................................... 24 CLOTHING AND PERSONAL PROTECTIVE ITEMS................................................... 24 FIRE EXTINGUISHER AND FIRST AID KIT...................................................... 24 SAFETY FEATURES.......................................................................... 24 KEEP MACHINE CLEAN....................................................................... 25 INSIDE OPERATOR'S COMPARTMENT............................................................ 25 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT........................................... 25 HANDRAILS AND STEPS...................................................................... 26 MOUNTING AND DISMOUNTING................................................................. 27 NO PEOPLE ON ATTACHMENTS................................................................. 27 DO NOT GET CAUGHT IN ARTICULATED PORTION................................................. 27 PREVENTION OF BURNS...................................................................... 27 FIRE PREVENTION.......................................................................... 28 ACTION IF FIRE OCCURS.................................................................... 29 WINDOW WASHER LIQUID..................................................................... 29 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)............................. 29 PRECAUTIONS FOR ATTACHMENTS, OPTIONS..................................................... 29 UNAUTHORIZED MODIFICATION................................................................ 29 SAFETY AT WORKSITE....................................................................... 30 WORKING ON LOOSE GROUND.................................................................. 30 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES................................................... 30 ENSURE GOOD VISIBILITY................................................................... 31 VENTILATION FOR ENCLOSED AREAS........................................................... 31 CHECKING SIGNALMAN'S SIGNALS AND SIGNS................................................... 31 EMERGENCY EXIT FROM OPERATOR'S CAB....................................................... 31 BE CAREFUL ABOUT ASBESTOS DUST........................................................... 32 PRECAUTIONS FOR OPERATION.................................................................... 33 STARTING ENGINE.......................................................................... 33 CHECKS BEFORE STARTING ENGINE........................................................ 33 PRECAUTIONS WHEN STARTING............................................................ 33 PRECAUTIONS IN COLD AREAS............................................................ 34 OPERATION................................................................................ 35 CHECKS BEFORE OPERATION.............................................................. 35 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE..................................... 35 PRECAUTIONS WHEN TRAVELING........................................................... 36 TRAVELING ON SLOPES.................................................................. 37 PROHIBITED OPERATIONS................................................................ 38 PRECAUTIONS WHEN OPERATING........................................................... 38 METHODS OF USING BRAKE............................................................... 39 OPERATE CAREFULLY ON SNOW............................................................ 39 PARKING MACHINE...................................................................... 40 TRANSPORTATION........................................................................... 41 LOADING AND UNLOADING................................................................ 41 SHIPPING............................................................................. 41 BATTERY.................................................................................. 42 BATTERY HAZARD PREVENTION............................................................ 42 STARTING WITH BOOSTER CABLES......................................................... 43 TOWING................................................................................... 44 WHEN TOWING.......................................................................... 44 PRECAUTIONS FOR MAINTENANCE.................................................................. 45 WARNING TAG.............................................................................. 45 KEEP WORK PLACE CLEAN AND TIDY........................................................... 45 APPOINT LEADER WHEN WORKING WITH OTHERS.................................................. 45 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE.............................................. 46 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING....................................... 47 INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF............................. 47 PROPER TOOLS............................................................................. 48 ACCUMULATOR.............................................................................. 48 PERSONNEL................................................................................ 48 ATTACHMENTS.............................................................................. 48 WORK UNDER THE MACHINE................................................................... 49 NOISE.................................................................................... 49 PRECAUTIONS WHEN USING HAMMER............................................................ 49 REPAIR WELDING........................................................................... 49 REMOVING BATTERY TERMINAL................................................................ 49 PRECAUTIONS WITH HIGH-PRESSURE OIL....................................................... 50 HANDLING HIGH-PRESSURE HOSES............................................................. 50 WASTE MATERIALS.......................................................................... 50 MAINTENANCE OF AIR CONDITIONER........................................................... 50 COMPRESSED AIR........................................................................... 51 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................................ 51 PRECAUTIONS WITH TIRES....................................................................... 52 HANDLING TIRES........................................................................... 52 PRECAUTIONS WHEN STORING TIRES........................................................... 52 OPERATION........................................................................................ 53 GENERAL VIEW................................................................................. 54 GENERAL VIEW OF MACHINE.................................................................. 54 GENERAL VIEW OF CONTROLS AND GAUGES...................................................... 55 EXPLANATION OF COMPONENTS.................................................................... 57 MACHINE MONITOR.......................................................................... 57 SWITCHES................................................................................. 83 CONTROL LEVERS, PEDALS................................................................... 90 STEERING TILT LOCK LEVER................................................................. 94 CAP AND COVER WITH LOCK.................................................................. 94 FRAME LOCK BAR........................................................................... 95 TOWING PIN............................................................................... 96 GREASE PUMP.............................................................................. 96 CAB DOOR INNER LOCK...................................................................... 96 CAB DOOR OPEN LOCK....................................................................... 97 CAB WINDOW OPEN LOCK CANCEL KNOB......................................................... 97 FUSE..................................................................................... 97 SLOW BLOW FUSE........................................................................... 99 POWER OUTLET............................................................................. 99 STORAGE BOX.............................................................................. 99 AM/FM RADIO..............................................................................100 AM/FM RADIO-CASSETTE STEREO..............................................................106 AIR CONDITIONER..........................................................................114 HANDLING CAB WIPER.......................................................................119 OPERATION....................................................................................120 CHECK BEFORE STARTING ENGINE, ADJUST.....................................................120 STARTING ENGINE..........................................................................136 OPERATIONS AND CHECKS AFTER STARTING ENGINE..............................................138 STOPPING ENGINE..........................................................................140 MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE............................141 TURNING..................................................................................145 OPERATION OF WORK EQUIPMENT..............................................................147 WORK POSSIBLE USING WHEEL LOADER.........................................................149 PRECAUTIONS FOR OPERATION................................................................154 ADJUSTING WORK EQUIPMENT POSTURE.........................................................156 PARKING MACHINE..........................................................................158 CHECKS AFTER COMPLETION OF OPERATION.....................................................160 LOCKING..................................................................................160 HANDLING THE TIRES.......................................................................161 TRANSPORTATION...............................................................................163 TRANSPORTATION PROCEDURE.................................................................163 LOADING, UNLOADING WORK WITH TRAILERS....................................................163 LIFTING MACHINE..........................................................................167 COLD WEATHER OPERATION.......................................................................169 PRECAUTIONS FOR LOW TEMPERATURE..........................................................169 PRECAUTIONS AFTER COMPLETION OF WORK.....................................................170 AFTER COLD WEATHER.......................................................................170 WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER......................171 LONG-TERM STORAGE............................................................................172 BEFORE STORAGE...........................................................................172 DURING STORAGE...........................................................................172 AFTER STORAGE............................................................................172 TROUBLESHOOTING..............................................................................173 WHEN MACHINE RUNS OUT OF FUEL............................................................173 METHOD OF TOWING MACHINE.................................................................173 IF BATTERY IS DISCHARGED.................................................................175 OTHER TROUBLE............................................................................178 MAINTENANCE......................................................................................183 GUIDES TO MAINTENANCE........................................................................184 OUTLINES OF SERVICE..........................................................................186 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...................................186 OUTLINE OF ELECTRIC SYSTEM...............................................................189 WEAR PARTS...................................................................................190 WEAR PARTS LIST..........................................................................190 RECOMMENDED FUEL, COOLANT, AND LUBRICANT.....................................................191 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.....................192 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....193 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...............................................194 TORQUE LIST..............................................................................194 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................195 MAINTENANCE SCHEDULE CHART...................................................................196 MAINTENANCE SCHEDULE CHART...............................................................196 SERVICE PROCEDURE............................................................................198 INITIAL 250 HOURS SERVICE................................................................198 WHEN REQUIRED............................................................................199 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT.........................................199 CLEAN INSIDE OF COOLING SYSTEM.......................................................202 CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL............................................205 CHECK AXLE OIL LEVEL, ADD OIL........................................................206 CLEAN AXLE CASE BREATHER.............................................................207 CLEAN AIR CONDITIONER CONDENSER......................................................208 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID..........................................208 CLEAN RADIATOR FINS AND COOLER FINS..................................................209 CHECK ELECTRICAL INTAKE AIR HEATER...................................................209 TURN, REPLACE BOLT-ON CUTTING EDGE...................................................210 REPLACE BUCKET TEETH.................................................................211 CHECK AIR CONDITIONER................................................................213 REPLACE SLOW BLOW FUSE...............................................................214 CHECKING FUNCTION OF ACCUMULATOR.....................................................215 SELECTION AND INSPECTION OF TIRES....................................................216 CHECK BEFORE STARTING....................................................................218 EVERY 50 HOURS SERVICE...................................................................219 DRAIN WATER, SEDIMENT FROM FUEL TANK.................................................219 EVERY 100 HOURS SERVICE..................................................................220 LUBRICATE REAR AXLE PIVOT PIN........................................................220 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER....................................220 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...........................................221 EVERY 250 HOURS SERVICE..................................................................222 CHECK BATTERY ELECTROLYTE LEVEL......................................................222 CHECK PARKING BRAKE..................................................................224 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST................................224 CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN.............................................225 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER................................226 CHECKING FUNCTION OF ACCUMULATOR.....................................................226 LUBRICATING..........................................................................227 EVERY 500 HOURS SERVICE..................................................................228 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....................228 REPLACE FUEL FILTER CARTRIDGE........................................................229 REPLACEMENT OF FILTER CARTRIDGE FOR POOR-QUALITY FUEL................................230 CLEAN WATER SEPARATOR STRAINER.......................................................231 EVERY 1000 HOURS SERVICE.................................................................232 CHANGE OIL IN TRANSFER CASE..........................................................232 CLEAN TRANSFER CASE BREATHER.........................................................233 REPLACE HST OIL FILTER ELEMENT.......................................................234 REPLACE CORROSION RESISTOR CARTRIDGE.................................................235 LUBRICATING..........................................................................235 CHECK TIGHTENING PARTS OF TURBOCHARGER...............................................235 CHECK PLAY OF TURBOCHARGER ROTOR.....................................................235 CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT................................236 EVERY 2000 HOURS SERVICE.................................................................237 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT.......................237 REPLACE HYDRAULIC TANK BREATHER ELEMENT..............................................238 CHANGE AXLE OIL......................................................................239 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER........239 CLEAN BRAKE CIRCUIT STRAINER.........................................................240 CHECK BRAKE DISC WEAR................................................................241 CHECKING FUNCTION OF ACCUMULATOR.....................................................242 CHECK ALTERNATOR, STARTING MOTOR.....................................................242 CHECK ENGINE VALVE CLEARANCE, ADJUST.................................................242 CLEAN AND CHECK TURBOCHARGER.........................................................242 CHECK VIBRATION DAMPER...............................................................242 EVERY 4000 HOURS SERVICE.................................................................243 LUBRICATING..........................................................................243 CHECK WATER PUMP.....................................................................243 SPECIFICATIONS...................................................................................244 SPECIFICATIONS...............................................................................245 ATTACHMENTS, OPTIONS.............................................................................247 SELECTING BUCKET AND TIRES...................................................................248 HANDLING BATTERY DISCONNECTOR SWITCH.........................................................249 EXPLANATION OF COMPONENTS................................................................249 HANDLING.................................................................................249 INDEX............................................................................................250
PLEASE NOTE:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
