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KOMATSU GALEO WA250-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:72302 & UP) KOMATSU WA250-5 – PDF DOWNLOAD
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- KOMATSU GALEO WA250-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:72302 & UP
- PUBLICATION NUMBER:TEN00215-00
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Description
KOMATSU GALEO WA250-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:72302 & UP) KOMATSU WA250-5
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KOMATSU GALEO WA250-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:72302 & UP) KOMATSU WA250-5 – PDF DOWNLOAD:
TABLE OF CONTENTS:
KOMATSU GALEO WA250-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:72302 & UP) KOMATSU WA250-5
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...................................................................................... 54 GENERAL VIEW............................................................................... 55 GENERAL VIEW OF MACHINE................................................................ 55 GENERAL VIEW OF CONTROLS AND GAUGES.................................................... 56 EXPLANATION OF COMPONENTS.................................................................. 58 MACHINE MONITOR........................................................................ 58 SWITCHES............................................................................... 84 CONTROL LEVERS, PEDALS................................................................. 91 STEERING TILT LOCK LEVER............................................................... 95 CAP AND COVER WITH LOCK................................................................ 95 FRAME LOCK BAR......................................................................... 96 TOWING PIN............................................................................. 97 GREASE PUMP............................................................................ 97 CAB DOOR INNER LOCK.................................................................... 97 CAB DOOR OPEN LOCK..................................................................... 98 CAB WINDOW OPEN LOCK CANCEL KNOB....................................................... 98 FUSE................................................................................... 98 SLOW BLOW FUSE.........................................................................100 POWER OUTLET...........................................................................100 STORAGE BOX............................................................................100 AM/FM RADIO............................................................................101 AM/FM RADIO-CASSETTE STEREO............................................................107 AIR CONDITIONER........................................................................115 HANDLING CAB WIPER.....................................................................120 HANDLING MACHINES EQUIPPED WITH KOMTRAX................................................121 OPERATION..................................................................................122 CHECK BEFORE STARTING ENGINE, ADJUST...................................................122 STARTING ENGINE........................................................................137 OPERATIONS AND CHECKS AFTER STARTING ENGINE............................................139 STOPPING ENGINE........................................................................141 MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE..........................142 TURNING................................................................................146 OPERATION OF WORK EQUIPMENT............................................................148 WORK POSSIBLE USING WHEEL LOADER.......................................................150 PRECAUTIONS FOR OPERATION..............................................................155 ADJUSTING WORK EQUIPMENT POSTURE.......................................................157 PARKING MACHINE........................................................................159 CHECKS AFTER COMPLETION OF OPERATION...................................................161 LOCKING................................................................................161 HANDLING THE TIRES.....................................................................162 TRANSPORTATION.............................................................................164 TRANSPORTATION PROCEDURE...............................................................164 LOADING, UNLOADING WORK WITH TRAILERS..................................................164 LIFTING MACHINE........................................................................168 COLD WEATHER OPERATION.....................................................................170 PRECAUTIONS FOR LOW TEMPERATURE........................................................170 PRECAUTIONS AFTER COMPLETION OF WORK...................................................171 AFTER COLD WEATHER.....................................................................171 WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER....................172 LONG-TERM STORAGE..........................................................................173 BEFORE STORAGE.........................................................................173 DURING STORAGE.........................................................................173 AFTER STORAGE..........................................................................173 TROUBLESHOOTING............................................................................174 WHEN MACHINE RUNS OUT OF FUEL..........................................................174 METHOD OF TOWING MACHINE...............................................................174 IF BATTERY IS DISCHARGED...............................................................176 OTHER TROUBLE..........................................................................179 MAINTENANCE....................................................................................184 GUIDES TO MAINTENANCE......................................................................185 OUTLINES OF SERVICE........................................................................187 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................187 OUTLINE OF ELECTRIC SYSTEM.............................................................190 WEAR PARTS.................................................................................191 WEAR PARTS LIST........................................................................191 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................192 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...................193 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....194 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.............................................195 TORQUE LIST............................................................................195 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..............................................196 MAINTENANCE SCHEDULE CHART.................................................................197 MAINTENANCE SCHEDULE CHART.............................................................197 SERVICE PROCEDURE..........................................................................199 INITIAL 250 HOURS SERVICE..............................................................199 WHEN REQUIRED..........................................................................200 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT.......................................200 CLEAN INSIDE OF COOLING SYSTEM.....................................................203 CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL..........................................206 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 CHECK ELECTRICAL INTAKE AIR HEATER.................................................211 TURN, REPLACE BOLT-ON CUTTING EDGE.................................................212 REPLACE BUCKET TEETH...............................................................213 CHECK AIR CONDITIONER..............................................................215 REPLACE SLOW BLOW FUSE.............................................................216 CHECKING FUNCTION OF ACCUMULATOR...................................................217 SELECTION AND INSPECTION OF TIRES..................................................218 CHECK BEFORE STARTING..................................................................220 EVERY 50 HOURS SERVICE.................................................................221 DRAIN WATER, SEDIMENT FROM FUEL TANK...............................................221 EVERY 100 HOURS SERVICE................................................................222 LUBRICATE REAR AXLE PIVOT PIN......................................................222 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER..................................222 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL.........................................223 EVERY 250 HOURS SERVICE................................................................224 CHECK BATTERY ELECTROLYTE LEVEL....................................................224 CHECK PARKING BRAKE................................................................226 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST..............................226 CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN...........................................227 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER..............................228 CHECKING FUNCTION OF ACCUMULATOR...................................................228 LUBRICATING........................................................................229 EVERY 500 HOURS SERVICE................................................................230 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..................230 REPLACE FUEL FILTER CARTRIDGE......................................................231 REPLACEMENT OF FILTER CARTRIDGE FOR POOR-QUALITY FUEL..............................232 CLEAN WATER SEPARATOR STRAINER.....................................................233 EVERY 1000 HOURS SERVICE...............................................................234 CHANGE OIL IN TRANSFER CASE........................................................234 CLEAN TRANSFER CASE BREATHER.......................................................235 REPLACE HST OIL FILTER ELEMENT.....................................................236 REPLACE CORROSION RESISTOR CARTRIDGE...............................................237 LUBRICATING........................................................................237 CHECK TIGHTENING PARTS OF TURBOCHARGER.............................................237 CHECK PLAY OF TURBOCHARGER ROTOR...................................................237 CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT..............................238 EVERY 2000 HOURS SERVICE...............................................................239 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT.....................239 REPLACE HYDRAULIC TANK BREATHER ELEMENT............................................240 CHANGE AXLE OIL....................................................................241 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER......241 CLEAN BRAKE CIRCUIT STRAINER.......................................................242 CHECK BRAKE DISC WEAR..............................................................243 CHECKING FUNCTION OF ACCUMULATOR...................................................244 CHECK ALTERNATOR, STARTING MOTOR...................................................244 CHECK ENGINE VALVE CLEARANCE, ADJUST...............................................244 CLEAN AND CHECK TURBOCHARGER.......................................................244 CHECK VIBRATION DAMPER.............................................................244 EVERY 4000 HOURS SERVICE...............................................................245 LUBRICATING........................................................................245 CHECK WATER PUMP...................................................................245 SPECIFICATIONS.................................................................................246 SPECIFICATIONS.............................................................................247 ATTACHMENTS, OPTIONS...........................................................................248 SELECTING BUCKET AND TIRES.................................................................249 INDEX..........................................................................................250
DESCRIPTION:
KOMATSU GALEO WA250-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:72302 & UP) KOMATSU WA250-5
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
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