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KOMATSU GALEO WA250PT-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:70001 & UP) – PDF DOWNLOAD
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- KOMATSU GALEO WA250PT-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:70001 & UP
- PUBLICATION NUMBER:TEN00085-00
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Description
KOMATSU GALEO WA250PT-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:70001 & UP)
KOMATSU GALEO WA250PT-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:70001 & UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU GALEO WA250PT-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:70001 & 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 WA250PT-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:70001 & 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........................................................................ 23 SAFETY RULES........................................................................... 23 IF ABNORMALITIES ARE FOUND............................................................. 23 CLOTHING AND PERSONAL PROTECTIVE ITEMS................................................. 23 FIRE EXTINGUISHER AND FIRST AID KIT.................................................... 23 SAFETY FEATURES........................................................................ 23 KEEP MACHINE CLEAN..................................................................... 24 INSIDE OPERATOR'S COMPARTMENT.......................................................... 24 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT......................................... 24 HANDRAILS AND STEPS.................................................................... 25 MOUNTING AND DISMOUNTING............................................................... 26 NO PEOPLE ON ATTACHMENTS............................................................... 26 DO NOT GET CAUGHT IN ARTICULATED PORTION............................................... 26 PREVENTION OF BURNS.................................................................... 26 FIRE PREVENTION........................................................................ 27 ACTION IF FIRE OCCURS.................................................................. 28 WINDOW WASHER LIQUID................................................................... 28 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)........................... 28 PRECAUTIONS FOR ATTACHMENTS, OPTIONS................................................... 28 UNAUTHORIZED MODIFICATION.............................................................. 28 SAFETY AT WORKSITE..................................................................... 29 WORKING ON LOOSE GROUND................................................................ 29 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES................................................. 29 ENSURE GOOD VISIBILITY................................................................. 30 VENTILATION FOR ENCLOSED AREAS......................................................... 30 CHECKING SIGNALMAN'S SIGNALS AND SIGNS................................................. 30 EMERGENCY EXIT FROM OPERATOR'S CAB..................................................... 30 BE CAREFUL ABOUT ASBESTOS DUST......................................................... 31 PRECAUTIONS FOR OPERATION.................................................................. 32 STARTING ENGINE........................................................................ 32 CHECKS BEFORE STARTING ENGINE...................................................... 32 PRECAUTIONS WHEN STARTING.......................................................... 32 PRECAUTIONS IN COLD AREAS.......................................................... 33 OPERATION.............................................................................. 34 CHECKS BEFORE OPERATION............................................................ 34 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE................................... 34 PRECAUTIONS WHEN TRAVELING......................................................... 35 TRAVELING ON SLOPES................................................................ 36 PROHIBITED OPERATIONS.............................................................. 37 PRECAUTIONS WHEN OPERATING......................................................... 37 METHODS OF USING BRAKE............................................................. 38 OPERATE CAREFULLY ON SNOW.......................................................... 38 PARKING MACHINE.................................................................... 39 TRANSPORTATION......................................................................... 40 LOADING AND UNLOADING.............................................................. 40 SHIPPING........................................................................... 40 BATTERY................................................................................ 41 BATTERY HAZARD PREVENTION.......................................................... 41 STARTING WITH BOOSTER CABLES....................................................... 42 TOWING................................................................................. 43 WHEN TOWING........................................................................ 43 PRECAUTIONS FOR MAINTENANCE................................................................ 44 WARNING TAG............................................................................ 44 KEEP WORK PLACE CLEAN AND TIDY......................................................... 44 APPOINT LEADER WHEN WORKING WITH OTHERS................................................ 44 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE............................................ 45 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING..................................... 46 INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF........................... 46 PROPER TOOLS........................................................................... 47 ACCUMULATOR............................................................................ 47 PERSONNEL.............................................................................. 47 ATTACHMENTS............................................................................ 47 WORK UNDER THE MACHINE................................................................. 48 NOISE.................................................................................. 48 PRECAUTIONS WHEN USING HAMMER.......................................................... 48 REPAIR WELDING......................................................................... 48 REMOVING BATTERY TERMINAL.............................................................. 48 PRECAUTIONS WITH HIGH-PRESSURE OIL..................................................... 49 HANDLING HIGH-PRESSURE HOSES........................................................... 49 WASTE MATERIALS........................................................................ 49 MAINTENANCE OF AIR CONDITIONER......................................................... 49 COMPRESSED AIR......................................................................... 50 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.......................................... 50 PRECAUTIONS WITH TIRES..................................................................... 51 HANDLING TIRES......................................................................... 51 PRECAUTIONS WHEN STORING TIRES......................................................... 51 OPERATION...................................................................................... 52 GENERAL VIEW............................................................................... 53 GENERAL VIEW OF MACHINE................................................................ 53 GENERAL VIEW OF CONTROLS AND GAUGES.................................................... 54 EXPLANATION OF COMPONENTS.................................................................. 56 MACHINE MONITOR........................................................................ 56 SWITCHES............................................................................... 82 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........................................................................135 OPERATIONS AND CHECKS AFTER STARTING ENGINE............................................137 STOPPING ENGINE........................................................................139 MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE..........................140 TURNING................................................................................144 OPERATION OF WORK EQUIPMENT............................................................146 HANDLING HYDRAULIC QUICK COUPLER.......................................................148 WORK POSSIBLE USING WHEEL LOADER.......................................................151 PRECAUTIONS FOR OPERATION..............................................................156 ADJUSTING WORK EQUIPMENT POSTURE.......................................................158 PARKING MACHINE........................................................................162 CHECKS AFTER COMPLETION OF OPERATION...................................................164 LOCKING................................................................................164 HANDLING THE TIRES.....................................................................165 TRANSPORTATION.............................................................................167 TRANSPORTATION PROCEDURE...............................................................167 LOADING, UNLOADING WORK WITH TRAILERS..................................................167 LIFTING MACHINE........................................................................171 COLD WEATHER OPERATION.....................................................................173 PRECAUTIONS FOR LOW TEMPERATURE........................................................173 PRECAUTIONS AFTER COMPLETION OF WORK...................................................174 AFTER COLD WEATHER.....................................................................174 WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER....................175 LONG-TERM STORAGE..........................................................................176 BEFORE STORAGE.........................................................................176 DURING STORAGE.........................................................................176 AFTER STORAGE..........................................................................176 TROUBLESHOOTING............................................................................177 WHEN MACHINE RUNS OUT OF FUEL..........................................................177 METHOD OF TOWING MACHINE...............................................................177 IF BATTERY IS DISCHARGED...............................................................179 OTHER TROUBLE..........................................................................182 MAINTENANCE....................................................................................187 GUIDES TO MAINTENANCE......................................................................188 OUTLINES OF SERVICE........................................................................190 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................190 OUTLINE OF ELECTRIC SYSTEM.............................................................193 WEAR PARTS.................................................................................194 WEAR PARTS LIST........................................................................194 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................195 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...................196 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....197 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.............................................198 TORQUE LIST............................................................................198 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..............................................199 MAINTENANCE SCHEDULE CHART.................................................................200 MAINTENANCE SCHEDULE CHART.............................................................200 SERVICE PROCEDURE..........................................................................202 INITIAL 250 HOURS SERVICE..............................................................202 WHEN REQUIRED..........................................................................203 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT.......................................203 CLEAN INSIDE OF COOLING SYSTEM.....................................................206 CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL..........................................209 CHECK AXLE OIL LEVEL, ADD OIL......................................................210 CLEAN AXLE CASE BREATHER...........................................................211 CLEAN AIR CONDITIONER CONDENSER....................................................212 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID........................................212 CLEAN RADIATOR FINS AND COOLER FINS................................................213 CLEAN TRANSFER OIL COOLER FINS.....................................................213 CHECK ELECTRICAL INTAKE AIR HEATER.................................................213 TURN, REPLACE BOLT-ON CUTTING EDGE.................................................214 REPLACE BUCKET TEETH...............................................................215 CHECK AIR CONDITIONER..............................................................217 REPLACE SLOW BLOW FUSE.............................................................218 CHECKING FUNCTION OF ACCUMULATOR...................................................219 SELECTION AND INSPECTION OF TIRES..................................................220 CHECK BEFORE STARTING..................................................................222 EVERY 50 HOURS SERVICE.................................................................223 DRAIN WATER, SEDIMENT FROM FUEL TANK...............................................223 EVERY 100 HOURS SERVICE................................................................224 LUBRICATE REAR AXLE PIVOT PIN......................................................224 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER..................................224 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL.........................................225 EVERY 250 HOURS SERVICE................................................................226 CHECK BATTERY ELECTROLYTE LEVEL....................................................226 CHECK PARKING BRAKE................................................................228 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST..............................228 CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN...........................................229 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER..............................230 CHECKING FUNCTION OF ACCUMULATOR...................................................230 LUBRICATING........................................................................231 EVERY 500 HOURS SERVICE................................................................232 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..................232 REPLACE FUEL FILTER CARTRIDGE......................................................233 REPLACEMENT OF FILTER CARTRIDGE FOR POOR-QUALITY FUEL..............................234 CLEAN WATER SEPARATOR STRAINER.....................................................235 EVERY 1000 HOURS SERVICE...............................................................236 CHANGE OIL IN TRANSFER CASE........................................................236 CLEAN TRANSFER CASE BREATHER.......................................................237 REPLACE HST OIL FILTER ELEMENT.....................................................238 REPLACE CORROSION RESISTOR CARTRIDGE...............................................239 LUBRICATING........................................................................239 CHECK TIGHTENING PARTS OF TURBOCHARGER.............................................239 CHECK PLAY OF TURBOCHARGER ROTOR...................................................239 CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT..............................240 EVERY 2000 HOURS SERVICE...............................................................241 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT.....................241 REPLACE HYDRAULIC TANK BREATHER ELEMENT............................................242 CHANGE AXLE OIL....................................................................243 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER......243 CLEAN BRAKE CIRCUIT STRAINER.......................................................244 CHECK BRAKE DISC WEAR..............................................................245 CHECKING FUNCTION OF ACCUMULATOR...................................................246 CHECK ALTERNATOR, STARTING MOTOR...................................................246 CHECK ENGINE VALVE CLEARANCE, ADJUST...............................................246 CLEAN AND CHECK TURBOCHARGER.......................................................246 CHECK VIBRATION DAMPER.............................................................246 EVERY 4000 HOURS SERVICE...............................................................247 LUBRICATING........................................................................247 CHECK WATER PUMP...................................................................247 SPECIFICATIONS.................................................................................248 SPECIFICATIONS.............................................................................249 ATTACHMENTS, OPTIONS...........................................................................250 SELECTING BUCKET AND TIRES.................................................................251 HANDLING FORK TOOL.........................................................................252 EXPLANATION OF COMPONENTS..............................................................252 OPERATION..............................................................................253 INDEX..........................................................................................256
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