Komatsu WA250-3 Wheel Loader Operation & Maintenance Manual SN 53001 and up – PDF DOWNLOAD

Description

Komatsu WA250-3 Wheel Loader Operation & Maintenance Manual 

TABLE OF CONTENTS:

Komatsu WA250-3 Wheel Loader Operation & Maintenance Manual 

MAIN MENU........................................................................................  0
INTRODUCTION.....................................................................................  2
	1. FORWARD...................................................................................  3
	2. SAFETY INFORMATION........................................................................  4
	3. INTRODUCTION..............................................................................  5
		3.1 INTENDED USE.........................................................................  5
		3.2 FEATURES.............................................................................  5
		3.3 BREAKING IN A NEW MACHINE............................................................  5
	4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRlBUTOR.............................  6
		4.1 MACHINE SERIAL NO. PLATE POSITION....................................................  6
		4.2 ENGINE SERIAL NO. PLATE POSITION.....................................................  6
		4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR............................................  6
	5. CONTENTS..................................................................................  7
SAFETY........................................................................................... 12
	6. GENERAL PRECAUTIONS....................................................................... 13
	7. PRECAUTIONS DURING OPERATION.............................................................. 19
		7.1 BEFORE STARTING ENGINE............................................................... 19
		7.2 AFTER STARTING ENGINE................................................................ 22
		7.3 TRANSPORTATION....................................................................... 31
		7.4 BATTERY.............................................................................. 32
		7.5 TOWNG................................................................................ 35
	8. PRECAUTIONS FOR MAINTENANCE............................................................... 36
		8.1 BEFORE CARRYING OUT MAINTENANCE...................................................... 36
		8.2 DURING MAINTENANCE................................................................... 41
		8.3 TIRES................................................................................ 46
	9. POSITION FOR ATTACHING SAFETY LABELS...................................................... 48
		9.1 POSITION FOR ATTACHING SAFETY LABELS................................................. 48
OPERATION........................................................................................ 52
	10. GENERAL VIEW............................................................................. 53
		10.1 GENERAL VIEW OF MACHINE............................................................. 53
		10.2 GENERAL VIEW OF CONTROLS AND GAUGES................................................. 54
	11. EXPLANATION OF COMPONENTS................................................................ 55
		11.1 METER, LAMPS........................................................................ 55
			11.1.1 WARNING DISPLAYS.............................................................. 57
			11.1.2 METER DISPLAY PORTION......................................................... 61
		11.2 SWITCHES............................................................................ 65
		11.3 CONTROL LEVERS, PEDAL............................................................... 70
		11.4 STEERING COLUMN TILT LEVER.......................................................... 74
		11.5 CAP WITH LOCK....................................................................... 74
			11.5.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK................................... 74
		11.6 SAFETY BAR.......................................................................... 75
		11.7 TOWING PIN.......................................................................... 75
		11.8 GREASE PUMP CLAMP AND RUBBER RING................................................... 75
		11.9 BACKUP ALARM........................................................................ 76
		11.10 FUSE............................................................................... 77
			11.10.1 FUSE CAPACITY AND NAME OF CIRCUIT............................................ 77
		11.11 SLOW BLOW FUSE..................................................................... 78
		11.12 STORAGE PLACE FOR THIS MANUAL...................................................... 79
		11.13 AUXILIARY POWER SOURCE............................................................. 79
			11.13.1 FOR MACHINES EQUIPPED WITH ROPS CAB.......................................... 79
	12. CHECK BEFORE STARTING ENGINE............................................................. 80
		12.1 WALK AROUND CHECK................................................................... 80
		12.2 CHECK BEFORE STARTING............................................................... 83
			12.2.1 CHECK COOLANT LEVEL, ADD COOLANT.............................................. 83
			12.2.2 CHECK MONITOR PANEL........................................................... 83
			12.2.3 CHECK FUEL LNEL, ADD FUEL..................................................... 84
			12.2.4 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL.................................... 84
			12.2.5 CHECK AND REFILL OF OIL IN BRAKE OIL TANK..................................... 85
			12.2.6 CHECK DUST INDICATOR.......................................................... 85
			12.2.7 CHECK ELECTRICAL WIRING....................................................... 86
			12.2.8 DRAIN THE WATER FROM THE FUEL-WATER SEPARATOR................................. 87
			12.9.9 CHECK EFFECT OF PARKING BRAKE................................................. 87
			12.2.10 CHECK EFFECT OF WHEEL BRAKES................................................. 88
			12.2.11 CHECK SOUND OF HORN AND BACKUP ALARM......................................... 88
			12.2.12 CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE........................... 88
			12.2.13 CHECK ENGINE EXHAUST COLOR AND SOUND......................................... 88
			12.2.14 CHECK OPERATIONS OF GAUGES................................................... 88
			12.2.15 CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING.................... 88
			12.2.16 CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE................ 88
			12.2.17 CHECK LOCK OF CAB DOOR FOR MACHINES EQUIPPED WITH CAB........................ 88
		12.3 ADJUSTMENT BEFORE OPERATION......................................................... 89
			12.3.1 OPERATORS SEAT A.............................................................. 89
			12.3.2 ADJUST SEAT BELT.............................................................. 91
			12.3.3 ADJUST REAR VEIW MIRRORS...................................................... 92
		12.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE........................................ 93
		12.5 STARTING ENGINE..................................................................... 94
			12.5.1 NORMAL STARTING PROCEDURES IN COLD AND WARM CONDITIONS........................ 94
			12.5.2 STARTING PROCEDURES AFTER EXTENDED SHUTDOWN OR OIL CHANGE..................... 95
			12.5.3 STARTING PROCEDURES AFTER CHANGING FUEL FILTERS............................... 95
			12.5.4 STARTING PROCEDURES AFTER RUNNING OUT OF FUEL................................. 95
		12.6 OPERATIONS AND CHECKS AFTER STARTING ENGINE......................................... 96
		12.7 MOVING MACHINE OFF.................................................................. 97
		12.8 CHANGING GEAR SPEED................................................................. 99
		12.9 CHANGING DIRECTION.................................................................. 99
		12.10 TURNING............................................................................100
		12.11 STOPPING MACHINE...................................................................101
		12.12 OPERATION OF WORK EQUIPMENT........................................................102
		12.13 WORK POSSIBLE USING WHEEL LOADER...................................................103
			12.13.1 DIGGING OPERATIONS WITH ROCK PILES...........................................103
			12.13.2 DIGGING OPERATIONS ON LEVEL GROUND...........................................104
			12.13.3 LEVELING OPERATION...........................................................105
			12.13.3 LEVELING OPERATION...........................................................105
			12.13.4 PUSHING OPERATIONS...........................................................105
			12.13.5 LOAD AND CARRY OPERATIONS....................................................105
			12.13.6 LOADING OPERATIONS...........................................................106
		12.14 PRECAUTIONS FOR OPERATION..........................................................107
			12.14.1 PERMISSIBLE WATER DEPTH......................................................107
			12.14.2 IF WHEEL BRAKE DOES NOT WORK.................................................107
			12.14.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...................................107
			12.14.4 PRECAUTIONS WHEN DRIVING MACHINE.............................................108
		12.15 ADJUSTING WORK EQUIPMENT POSTURE...................................................109
			12.151 ADJUSTING BOOM KICKOUT........................................................109
			12.15.2 ADJUSTING BUCKET POSITIONER..................................................110
			12.15.3 BUCKET LEVEL INDICATOR.......................................................110
		12.16 PARKING MACHINE....................................................................111
		12.17 CHECKS AFTER COMPLETION OF ENGINE OPERATION........................................112
		12.18 STOPPING ENGINE....................................................................112
		12.19 CHECKS AFTER STOPPING ENGINE.......................................................113
		12.20 LOCKING............................................................................113
		12.21 HANDLING THE TIRES.................................................................114
			12.21.1 PRECAUTIONS WHEN HANDLING THE TIRES..........................................114
			12.21.2 TIRE PRESSURE................................................................114
	13. TRANSPORTATION...........................................................................116
		13.1 LOADING, UNLOADING WORK.............................................................116
		13.2 PRECAUTION FOR LOADING..............................................................117
		13.3 PRECAUTION FOR LIFTING UP THE VEHICLE...............................................117
			13.3.1 THE LOCATION OF DECALS REFERRING TO LIFTING POSITIONS.........................118
			13.3.2 WEIGHT LIST...................................................................118
			13.3.3 LIFTING PROCEDURE.............................................................119
	14. COLD WEATHER OPERATIONS..................................................................120
		14.1 PRECAUTIONS FOR LOW TEMPERATURE.....................................................120
			14.1.1 FUEL AND LUBRICANTS...........................................................120
			14.1.2 COOLANT.......................................................................120
			14.1.3 BATTERY.......................................................................121
		14.2 PRECAUTIONS AFTER COMPLETION OF WORK................................................122
		14.3 AFTER COLD WEATHER..................................................................122
	15. LONG TERM STORAGE........................................................................123
		15.1 BEFORE STORAGE......................................................................123
		15.2 DURING STORAGE......................................................................123
		15.3 AFTER STORAGE.......................................................................123
	16. TROUBLESHOOTING..........................................................................124
		16.1 WHEN MACHINE RUNS OUT OF FUEL.......................................................124
		16.2 TOWING THE MACHINE..................................................................125
			16.2.1 WHEN ENGINE CAN BE USED.......................................................127
			16.2.2 WHEN ENGINE CANNOT BE USED....................................................127
		16.3 IF BATTERY IS DISCHARGED............................................................128
			16.3.1 REMOVAL AND INSTALLATION OF BATTERY...........................................128
			16.3.2 PRECAUTIONS FOR CHARGING BATTERY..............................................129
			16.3.3 STARTING ENGINE WITH BOOSTER CABLE............................................130
		16.4 OTHER TROUBLE.......................................................................132
			16.4.1 ELECTRICAL SYSTEM.............................................................132
			16.4.2 CHASSIS.......................................................................133
			16.4.3 ENGINE........................................................................136
MAINTENANCE......................................................................................138
	17. GUIDES TO MAINTENANCE....................................................................139
	18. OUTLINES OF SERVICE......................................................................142
		18.1 OUTLINE OF OIL, FUEL, COOLANT.......................................................142
			18.1.1 OIL...........................................................................142
			18.1.2 FUEL..........................................................................143
			18.1.3 COOLANT.......................................................................143
			18.1.4 GREASE........................................................................144
			18.1.5 STORING OIL AND FUEL..........................................................144
			18.2.6 FILTERS.......................................................................144
		18.2 OUTLINE OF ELECTRIC SYSTEM..........................................................145
	19. WEAR PARTS LIST..........................................................................146
	20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.....................147
		20.1 ENGINE OIL SPECIFICATIONS...........................................................148
		20.2 DIESEL FUEL SPECIFICATIONS..........................................................149
		20.3 COOLANT SPECIFICATIONS..............................................................150
	21. STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS............................................156
		21.1 INTRODUCTION OF NECESSARY TOOLS.....................................................156
		21.2 TORQUE LIST.........................................................................157
	22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................................158
	23. MAINTENANCE SCHEDULE CHART...............................................................162
		23.1 MAINTENANCE SCHEDULE CHART..........................................................162
	24. SERVICE PROCEDURES.......................................................................166
		24.1 INITIAL 250 HOURS SERVICE...........................................................166
			24.1.1 REPLACE FUEL FILTERS..........................................................166
			24.1.2 REPLACE TRANSMISSION OIL FILTER ELEMENT.......................................166
			24.1.3 REPLACE HYDRAULIC TANK FILTER ELEMENT.........................................166
		24.2 WHEN REQUIRED.......................................................................167
			24.2.1 CHECK, CLEAN OR REPLACE AIR CLEANER ELEMENT...................................167
			24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL.........................................169
			24.2.3 CHECK AXLE OIL LEVEL, ADD OIL.................................................170
			24.2.4 CLEAN THE AXLE CASE BREATHER..................................................171
			24.2.5 CLEAN RADIATOR FINS...........................................................171
			24.2.6 REPLACE THE BOLT-ON CUTTING EDGES.............................................172
			24.2.7 REPLACE BUCKET TEETH (IF EQUIPPED)............................................173
			24.2.8 CHECK AIR CONDITIONER (IF EQUIPPED)...........................................174
			24.2.9 CHECK THE AIR CONDITIONER CONDENSER (IF EQUIPPED).............................175
			24.2.10 CHECK WINDOW WASHING FLUID...................................................175
			24.2.11 ADJUST PARKING BRAKE.........................................................176
			24.2.12 REPLACE SLOW BLOW FUSE.......................................................177
			24.2.13 CHECK AIR INTAKE HEATER......................................................177
		24.3 CHECK BEFORE STARTING...............................................................178
		24.4 EVERY 50 HOURS SERVICE..............................................................179
			24.4.1 CHECK THE TIRE INFLATION PRESSURE.............................................179
			24.4.2 DRAIN WATER, SEDIMENT FROM FUEL TANK..........................................179
		24.5 EVERY 100 HOURS SERVICE.............................................................180
			24.5.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL....................................180
			24.5.2 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER.............................181
			24.5.3 LUBRICATING...................................................................182
		24.6 EVERY 250 HOURS SERVICE.............................................................183
			24.6.1 CHANGE OIL IN ENGINE OIL PAN AND REPLACE ENGINE OIL FILTER....................183
			24.6.2 CHECK FOR LOOSE WHEEL HUB NUTS. TIGHTEN.......................................184
			24.6.3 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER.........................184
			24.6.4 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.........................185
			24.6.5 CHECK BATTERY ELECTROLYTE LEVEL...............................................186
			24.6.6 CHECK AIR INTAKE SYSTEM.......................................................186
			24.6.7 LUBRICATING...................................................................187
		24.7 EVERY 500 HOURS SERVICE.............................................................188
			24.7.1 REPLACE FUEL FILTERS..........................................................188
			24.7.2 REPLACE TRANSMISSION OIL FILTER ELEMENT.......................................190
			24.7.3 LUBRICATE.....................................................................191
		24.8 EVERY 1000 HOURS SERVICE............................................................192
			24.8.1 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER...............................192
			24.8.2 CLEAN TRANSMISSION CASE BREATHER..............................................193
			24.8.3 LUBRICATE.....................................................................194
			24.8.4 ADJUST ENGINE VALVE LASH CLEARANCE............................................195
			24.8.5 CHECK FAN BELT TENSION........................................................196
			24.8.6 CHECK FAN BELT TENSIONER BEARING 8 FAN HUB BEARING 8 INSPECT FAN BELT.........196
		24.9 EVERY 2000 HOURS SERVICE............................................................197
			24.9.1 CHANGE OIL IN HYDRAULIC OIL TANK, REPLACE HYDRAULIC FILTER ELEMENT............197
			24.9.2 REPLACE HYDRAULIC TANK BREATHER ELEMENT.......................................199
			24.9.3 COOLING SYSTEM, REPLACE COOLANT AND FLUSH THE SYSTEM..........................200
			24.9.4 CHANGE AXLE OIL...............................................................203
			24.9.5 CHECK BRAKE DISC WEAR.........................................................204
			24.9.6 CHECK ALTERNATOR..............................................................204
			24.9.7 CHECK STARTER MOTOR...........................................................204
			24.9.8 CHECK VIBRATION DAMPER........................................................204
			24.9.9 REPLACE ELEMENT IN AIR COND. RECIRCULATION AIR FILTER AND FRESH AIR FILTER....204
			24.9.10 ADJUST ENGINE VALVE LASH CLEARANCE...........................................205
SPECIFICATIONS...................................................................................207
	25. SPECIFICATIONS...........................................................................208
OPTIONS, ATTACHMENTS.............................................................................210
	26. AVAILABLE ATTACHMENTS....................................................................211
	27. SELECTING BUCKETS AND TIRES..............................................................212
	28. HEATER AND AIR CONDITIONING (IF EQUIPPED)................................................213
		28.1 GENERAL LOCATION AND FUNCTION OF CONTROL PANEL......................................213
		28.2 COOL BOX COMPARTMENT................................................................214
	29. HANDLING E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM) (IF EQUIPPED)................215
		29.1 STRUCTURE AND FUNCTION OF E.C.S.S...................................................215
		29.2 METHOD OF OPERATING E.C.S.S.........................................................216
		29.3 PRECAUTIONS WHEN OPERATING E.C.S.S..................................................216
		29.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR...............................................217

KOMATSU WA250-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL SN 53001 AND UP – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu WA250-3 Wheel Loader Operation & Maintenance Manual 

FOREWORD:

• This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel realize peak performance through effective, economical and safe machine operation and maintenance.
• Keep this manual handy and have all personnel read it periodically_ If this manual is lost or becomes dirty and can not be read, request a replacement manual from your local distributor. If you sell the machine, be sure to give this manual to the new owner.
• Continuing improvements in the design of this machine can lead to changes in detail, which may not be reflected in this manual. Consult your local distributor or Komatsu America International Company for the latest availabie information on your machine or for questions regarding information in this manual.

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