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KOMATSU GALEO WA200PTL-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:65001 & UP) – PDF DOWNLOAD
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- KOMATSU GALEO WA200PTL-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:65001 & UP
- PUBLICATION NUMBER:TEN00082-00
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Description
KOMATSU GALEO WA200PTL-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:65001 & UP)
KOMATSU GALEO WA200PTL-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:65001 & UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU GALEO WA200PTL-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:65001 & UP)
- 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.
- Before beginning operation or maintenance, operators and maintenance personnel must always observe the following points. Read this manual thoroughly and understand its contents fully. Read the safety messages and safety labels given in this manual carefully so that they should be understood fully. Keep this manual at the storage location for the Operation and Maintenance Manual given below so that all personnel involved in working on the machine can consult it periodically.
- In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu distributor to obtain a new copy. When you sell the machine, make sure that this manual should be provided to the new owner together with the machine.
TABLE OF CONTENTS:
KOMATSU GALEO WA200PTL-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:65001 & UP)
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, OPIONS.................................................... 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................................................................. 92 STEERING TILT LOCK LEVER............................................................... 96 CAP AND COVER WITH LOCK................................................................ 96 FRAME LOCK BAR......................................................................... 97 TOWING PIN............................................................................. 98 GREASE PUMP............................................................................ 98 CAB DOOR INNER LOCK.................................................................... 98 CAB DOOR OPEN LOCK..................................................................... 99 CAB WINDOW OPEN LOCK CANCEL KNOB....................................................... 99 FUSE................................................................................... 99 SLOW BLOW FUSE.........................................................................101 POWER OUTLET...........................................................................101 STORAGE BOX............................................................................101 AM/FM RADIO-CASSETTE STEREO............................................................102 AIR CONDITIONER........................................................................110 HANDLING CAB WIPER.....................................................................115 OPERATION..................................................................................116 CHECK BEFORE STARTING ENGINE, ADJUST...................................................116 STARTING ENGINE........................................................................131 OPERATIONS AND CHECKS AFTER STARTING ENGINE............................................133 STOPPING ENGINE........................................................................135 MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE..........................136 TURNING................................................................................141 OPERATION OF WORK EQUIPMENT............................................................143 HANDLING HYDRAULIC QUICK COUPLER.......................................................145 WORK POSSIBLE USING WHEEL LOADER.......................................................149 PRECAUTIONS FOR OPERATION..............................................................154 ADJUSTING WORK EQUIPMENT POSTURE.......................................................156 PARKING MACHINE........................................................................160 CHECKS AFTER COMPLETION OF OPERATION...................................................162 LOCKING................................................................................162 HANDLING THE TIRES.....................................................................163 TRANSPORTATION.............................................................................165 TRANSPORTATION PROCEDURE...............................................................165 LOADING, UNLOADING WORK WITH TRAILERS..................................................165 LIFTING MACHINE........................................................................169 COLD WEATHER OPERATION.....................................................................171 PRECAUTIONS FOR LOW TEMPERATURE........................................................171 PRECAUTIONS AFTER COMPLETION OF WORK...................................................172 AFTER COLD WEATHER.....................................................................172 WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER....................173 LONG-TERM STORAGE..........................................................................174 BEFORE STORAGE.........................................................................174 DURING STORAGE.........................................................................174 AFTER STORAGE..........................................................................174 TROUBLESHOOTING............................................................................175 WHEN MACHINE RUNS OUT OF FUEL..........................................................175 METHOD OF TOWING MACHINE...............................................................175 IF BATTERY IS DISCHARGED...............................................................177 OTHER TROUBLE..........................................................................180 MAINTENANCE....................................................................................185 GUIDES TO MAINTENANCE......................................................................186 OUTLINES OF SERVICE........................................................................188 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................188 OUTLINE OF ELECTRIC SYSTEM.............................................................191 WEAR PARTS.................................................................................192 WEAR PARTS LIST........................................................................192 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................193 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...................194 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....195 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.............................................196 TORQUE LIST............................................................................196 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..............................................197 MAINTENANCE SCHEDULE CHART.................................................................198 MAINTENANCE SCHEDULE CHART.............................................................198 SERVICE PROCEDURE..........................................................................200 INITIAL 250 HOURS SERVICE..............................................................200 WHEN REQUIRED..........................................................................201 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT.......................................201 CLEAN INSIDE OF COOLING SYSTEM.....................................................204 CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL..........................................207 CHECK AXLE OIL LEVEL, ADD OIL......................................................208 CLEAN AXLE CASE BREATHER...........................................................209 CLEAN AIR CONDITIONER CONDENSER....................................................210 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID........................................210 CLEAN RADIATOR FINS AND COOLER FINS................................................211 CLEAN TRANSFER OIL COOLER FINS.....................................................211 CHECK ELECTRICAL INTAKE AIR HEATER.................................................211 TURN, REPLACE BOLT-ON CUTTING EDGE.................................................212 REPLACE BUCKET TEETH...............................................................213 CHECK AIR CONDITIONER..............................................................214 REPLACE SLOW BLOW FUSE.............................................................215 CHECKING FUNCTION OF ACCUMULATOR...................................................216 SELECTION AND INSPECTION OF TIRES..................................................217 CHECK BEFORE STARTING..................................................................219 EVERY 50 HOURS SERVICE.................................................................220 DRAIN WATER, SEDIMENT FROM FUEL TANK...............................................220 EVERY 100 HOURS SERVICE................................................................221 LUBRICATE REAR AXLE PIVOT PIN......................................................221 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER..................................221 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL.........................................222 EVERY 250 HOURS SERVICE................................................................223 CHECK BATTERY ELECTROLYTE LEVEL....................................................223 CHECK PARKING BRAKE................................................................225 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST..............................225 CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN...........................................226 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER..............................227 CHECKING FUNCTION OF ACCUMULATOR...................................................227 LUBRICATING........................................................................228 EVERY 500 HOURS SERVICE................................................................229 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..................229 REPLACE FUEL FILTER CARTRIDGE......................................................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 LUBRICATING........................................................................235 CHECK TIGHTENING PARTS OF TURBOCHARGER.............................................235 CHECK PLAY OF TURBOCHARGER ROTOR...................................................235 CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT..............................235 EVERY 2000 HOURS SERVICE...............................................................236 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT.....................236 REPLACE HYDRAULIC TANK BREATHER ELEMENT............................................237 CHECK AXLE OIL.....................................................................238 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER......238 CLEAN BRAKE CIRCUIT STRAINER.......................................................239 CHECK BRAKE DISC WEAR..............................................................240 CHECKING FUNCTION OF ACCUMULATOR...................................................241 CHECK ALTERNATOR, STARTING MOTOR...................................................241 CHECK ENGINE VALVE CLEARANCE, ADJUST...............................................241 CLEAN AND CHECK TURBOCHARGER.......................................................241 CHECK VIBRATION DAMPER.............................................................241 EVERY 4000 HOURS SERVICE...............................................................242 LUBRICATING........................................................................242 CHECK WATER PUMP...................................................................242 SPECIFICATIONS.................................................................................243 SPECIFICATIONS.............................................................................244 ATTACHMENTS, OPTIONS...........................................................................246 SELECTING BUCKET AND TIRES.................................................................247 HANDLING FORK TOOL.........................................................................248 EXPLANATION OF COMPONENTS..............................................................248 OPERATION..............................................................................249 INDEX..........................................................................................252
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