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Komatsu Wheel Loader WA150PZ-6, WA200PZ-6, WA250PZ-6, WA320PZ-6 Operation and Maintenance Manual – PDF DOWNLOAD
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Komatsu Wheel Loader WA150PZ-6, WA200PZ-6, WA250PZ-6, WA320PZ-6 Operation and Maintenance Manual
Book Code : VEAM610200
SERIAL NUMBERS:
WA150PZ-6 80042 AND UP
WA200PZ-6 70136 AND UP
H00051 AND UP
WA250PZ-6 75160 AND UP
H00051 AND UP
WA320PZ-6 70092 AND UP
H00051 AND UP
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Description
Komatsu Wheel Loader WA150PZ-6, WA200PZ-6, WA250PZ-6, WA320PZ-6 Operation and Maintenance Manual
FILE DETAILS:
Komatsu Wheel Loader WA150PZ-6, WA200PZ-6, WA250PZ-6, WA320PZ-6 Operation and Maintenance Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Operation and Maintenance Manual
Machine Model: WA150PZ-6, WA200PZ-6, WA250PZ-6, WA320PZ-6
Book Code: VEAM610200
Language: English
Pages: 412
File Format: Portable Document Format (PDF)
KOMATSU WHEEL LOADER WA150PZ-6, WA200PZ-6, WA250PZ-6, WA320PZ-6 OPERATION AND MAINTENANCE MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Wheel Loader WA150PZ-6, WA200PZ-6, WA250PZ-6, WA320PZ-6 Operation and Maintenance Manual
FOREWORD:
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 forthe operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause hazard when performing operation and maintenance.
TABLE OF CONTENTS:
Komatsu Wheel Loader WA150PZ-6, WA200PZ-6, WA250PZ-6, WA320PZ-6 Operation and Maintenance Manual
1. Foreword............................................................................................... 3 1.1 Foreword.......................................................................................... 4 EU Directives..................................................................................... 5 1.2 Safety information................................................................................ 6 1.2.1 Signal words................................................................................ 6 1.2.2 Safety labels............................................................................... 7 1.3 Introduction...................................................................................... 8 1.3.1 Intended use................................................................................ 8 1.3.2 Directions of machine....................................................................... 9 1.3.3 Visibility from operator's seat............................................................. 10 1.4 Necessary information............................................................................. 11 1.4.1 Machine serial no. plate and position....................................................... 11 1.4.2 Engine serial no. plate and position........................................................ 12 1.4.3 ROPS/FOPS-Cab serial no. plate.............................................................. 12 1.4.4 Axle serial no. plate....................................................................... 13 1.4.5 Transmission serial no. plate............................................................... 13 1.4.6 Seat operator serial no. plate.............................................................. 14 1.4.7 Position of service meter................................................................... 14 1.4.8 Table to enter serial no. and distributor................................................... 15 1.4.9 Declaration of conformity (for machines placed on the market as from 29th December 2009).... 16 1.5 Contents.......................................................................................... 17 1.6 Dimensions, weights and operating data............................................................ 25 1.6.1 Dimensions, weights and operating data...................................................... 25 1.7 CE-Conforming equipment........................................................................... 26 1.7.1 CE-Conforming equipment..................................................................... 26 CE-conforming equipment (pin on version)...................................................... 26 CE-conforming equipment (quick coupler version)............................................... 27 1.7.2 Manufacturer-supplied CE-Conforming equipment............................................... 29 2. Safety................................................................................................. 39 2.1 Safety labels..................................................................................... 40 2.1.1 Location of safety labels................................................................... 40 2.1.2 Presentation of safety labels............................................................... 41 2.2 General precautions............................................................................... 46 2.3 Precautions for operation......................................................................... 59 2.3.1 Starting engine............................................................................. 59 2.3.2 Operation................................................................................... 61 2.3.3 Transportation.............................................................................. 70 2.3.4 Battery..................................................................................... 72 2.3.5 Towing...................................................................................... 75 2.4 Precautions for maintenance....................................................................... 76 2.5 Precautions with tyres............................................................................ 86 3. Operation.............................................................................................. 89 3.1 General view...................................................................................... 90 3.1.1 General view of machine..................................................................... 90 3.1.2 General view of controls and gauges......................................................... 92 3.2 Explanation of components......................................................................... 96 3.2.1 Machine monitor............................................................................. 96 Monitor system................................................................................ 97 Types of warning.............................................................................. 98 Central warning lamp.......................................................................... 99 Character display portion.....................................................................100 Emergency stop items..........................................................................108 Caution items.................................................................................111 Warning/limit functions for travel speed......................................................114 Inspection and maintenance item...............................................................115 Pilot display portion.........................................................................118 Meter display portion.........................................................................122 Other functions of machine monitor............................................................124 3.2.2 Switches....................................................................................134 3.2.3 Control levers, pedals......................................................................152 3.2.4 Steering tilt lock lever....................................................................157 3.2.5 Cap and cover with lock.....................................................................157 3.2.6 Safety bar..................................................................................158 3.2.7 Towing pin..................................................................................159 3.2.8 Grease pump.................................................................................160 3.2.9 Opening cab, window door....................................................................161 Cab left door open knob.......................................................................161 Cab door open lock............................................................................162 Cab window open lock cancel knob..............................................................162 Open lock cancel knob for emergency escape right window.......................................163 3.2.10 Fuse.......................................................................................165 Fuse capacity and name of circuit.............................................................166 3.2.11 Slow blow fuse.............................................................................167 3.2.12 Location and presentation of relays........................................................169 3.2.13 Power outlet...............................................................................170 3.2.14 Storage box................................................................................170 3.2.15 Air conditioner............................................................................171 General locations and function of control panel...............................................171 Method of operation...........................................................................175 Precautions when using........................................................................176 Precautions for inspection and maintenance....................................................176 3.2.16 Handling cab wiper.........................................................................177 Preventing damage to wiper arm bracket........................................................177 3.3 Operation.........................................................................................178 3.3.1 Check before starting engine, adjust........................................................178 Walk-around check.............................................................................178 Check before starting.........................................................................182 Adjustment....................................................................................191 Operations and checks before starting engine..................................................199 3.3.2 Starting engine.............................................................................201 Normal starting...............................................................................201 Ambient temperature range for operation and storage...........................................202 Starting in cold weather......................................................................203 Automatic warming-up operation................................................................205 Checks after starting engine..................................................................206 3.3.3 Operations and checks after starting engine.................................................208 Breaking-in the machine.......................................................................208 Normal operation..............................................................................209 3.3.4 Stopping engine.............................................................................211 3.3.5 Moving the machine (directional, speed), stopping the machine...............................212 Moving the machine............................................................................212 Changing direction............................................................................214 Using switch to change between forward and reverse............................................215 Stopping the machine..........................................................................217 3.3.6 Turning.....................................................................................218 Emergency steering............................................................................219 3.3.7 Operation of work equipment.................................................................220 3.3.8 Work possible using wheel loader............................................................222 Digging operations............................................................................222 Levelling operation...........................................................................224 Pushing operation.............................................................................224 Load and carry operations.....................................................................225 Loading operations............................................................................225 3.3.9 Precautions for operation...................................................................227 Permissible water depth.......................................................................227 If wheel brake does not work..................................................................227 Precautions when driving up or down slopes....................................................227 3.3.10 Adjusting work equipment posture...........................................................229 Adjusting boom kickout........................................................................229 Adjusting bucket positioner...................................................................230 Adjusting fork positioner.....................................................................231 Bucket level indicator........................................................................232 3.3.11 Parking machine............................................................................233 3.3.12 Checks after completion of operation.......................................................235 Before stopping engine........................................................................235 After stopping engine.........................................................................235 3.3.13 Locking....................................................................................236 3.3.14 Handling the tyres.........................................................................237 Precautions when handling tyres...............................................................237 Tyre pressure.................................................................................237 Precautions for using load and carry method...................................................239 3.4 Transportation....................................................................................240 3.4.1 Transportation procedure....................................................................240 Ensure machine stability......................................................................240 3.4.2 Loading, unloading work with trailers.......................................................240 Loading.......................................................................................241 Securing machine..............................................................................241 Unloading.....................................................................................243 3.4.3 Lifting machine.............................................................................244 Location of lifting position mark.............................................................245 Lifting procedure.............................................................................245 3.5 Cold weather operation............................................................................247 3.5.1 Precautions for low temperature.............................................................247 Fuel and lubricants...........................................................................247 Coolant.......................................................................................247 Battery.......................................................................................248 3.5.2 Precautions after completion of work........................................................249 3.5.3 After cold weather..........................................................................249 3.5.4 Warming-up operation for steering hydraulic circuit in cold weather.........................250 3.6 Long-term storage.................................................................................251 3.6.1 Before storage..............................................................................251 3.6.2 During storage..............................................................................251 3.6.3 After storage...............................................................................252 3.7 Troubleshooting...................................................................................253 3.7.1 When machine runs out of fuel...............................................................253 3.7.2 Towing the machine..........................................................................253 When engine can be used.......................................................................255 When engine cannot be used....................................................................255 Emergency travel operation....................................................................255 3.7.3 If battery is discharged....................................................................256 Removal and installation of battery...........................................................257 Precautions for charging battery..............................................................257 Starting engine with booster cable............................................................258 3.7.4 Other trouble...............................................................................261 Electrical system.............................................................................261 Chassis.......................................................................................262 Engine........................................................................................264 4. Maintenance............................................................................................267 4.1 Guides to maintenance.............................................................................268 4.2 Outlines of service...............................................................................273 4.2.1 Handling oil, fuel, coolant, grease and carrying out KOWA (KOMATSU Oil Wear Analysis).......274 Oil...........................................................................................274 Fuel..........................................................................................275 Coolant and water for dilution................................................................276 Grease........................................................................................277 Carrying out KOWA (KOMATSU Oil Wear Analysis).................................................277 Storing oil and fuel..........................................................................279 Filters.......................................................................................279 Biodegradable hydraulic oil and lubricants....................................................279 4.2.2 Outline of electric system..................................................................280 4.3 Wear parts........................................................................................281 4.3.1 Wear parts list.............................................................................281 4.4 Fuel, coolant and lubricants......................................................................282 4.4.1 Lubrication chart...........................................................................283 For machine WA150PZ-6.........................................................................283 For machine WA200PZ-6, WA250PZ-6 and WA320PZ-6................................................284 4.4.2 Use of fuel, coolant and lubricants according to ambient temperature........................285 4.4.3 .Recommended brands, recommended quality for products other than KOMATSU genuine oil........288 4.5 Standard tightening torques for bolts and nuts....................................................289 4.5.1 Torque list.................................................................................289 4.6 Periodic replacement of safety critical parts.....................................................291 4.7 Maintenance schedule chart........................................................................293 4.7.1 Maintenance schedule chart..................................................................293 4.8 Service procedure.................................................................................296 4.8.1 Initial 10 hours service (for first 50 hours on new machine)................................296 Lubricating...................................................................................296 4.8.2 Initial 50 hours service (only after the first 50 hours)....................................296 Check for loose wheel hub bolts, tighten......................................................296 4.8.3 Initial 250 hours service (only after the first 250 hours)..................................297 Replace HST filter element....................................................................297 Replace hydraulic tank filter element.........................................................297 4.8.4 Initial 1000 hours service (only after the first 1000 hours)................................297 Check engine valve clearance, adjust..........................................................297 4.8.5 When required...............................................................................298 Check, clean, or replace air cleaner element..................................................298 Clean inside of cooling system................................................................301 Check oil level in transfer case, add oil.....................................................305 Check axle oil level, add oil.................................................................306 Clean axle case breather......................................................................307 Clean slack adjuster..........................................................................308 Clean air conditioner condenser...............................................................309 Check window washing fluid level, add fluid...................................................310 Clean radiator fins and cooler fins...........................................................311 Clean fins with compressed air................................................................313 Replace bolt on cutting edge..................................................................315 Replace bucket teeth..........................................................................316 Check air conditioner.........................................................................317 Replace slow blow fuse........................................................................319 Check function of accumulator.................................................................320 Selection and inspection of tyres.............................................................321 Clean, replace fuel breather filter...........................................................323 4.8.6 Check before starting.......................................................................325 Check before starting.........................................................................325 4.8.7 Every 50 hours service......................................................................326 Drain water, sediment from fuel tank..........................................................326 4.8.8 Every 100 hours service.....................................................................326 Lubricate rear axle pivot pin.................................................................326 Clean element in air conditioner fresh air filter.............................................327 Check oil level in hydraulic tank, add oil....................................................328 Lubricating (WA150PZ-6).......................................................................329 4.8.9 Every 250 hours service.....................................................................330 Check battery electrolyte level...............................................................330 Check parking brake...........................................................................333 Check air conditioner compressor belt tension, adjust.........................................334 Check for loose wheel hub bolts, tighten......................................................335 Clean element in air conditioner recirculation filter.........................................335 Check function of accumulator.................................................................336 Lubricating (WA200PZ-6, WA250PZ-6 and WA320PZ-6)..............................................337 4.8.10 Every 500 hours service....................................................................338 Change oil in engine oil pan, replace engine oil filter cartridge.............................338 Replace fuel pre-filter cartridge.............................................................340 Lubricating (only without Central lubrication system).........................................342 4.8.11 Every 1000 hours service...................................................................343 Change oil in transfer case...................................................................343 Clean transfer case breather..................................................................344 Replace fuel main filter cartridge............................................................345 Replace HST oil filter element................................................................347 Lubricating...................................................................................348 Check of engine air intake piping clamps for looseness........................................348 Check alternator driving belt tension and replacement.........................................348 4.8.12 Every 2000 hours service...................................................................349 Change oil in hydraulic tank, replace hydraulic filter element................................349 Replace hydraulic tank breather element.......................................................350 Replace HST drain filter......................................................................351 Change axle oil...............................................................................352 Replace element in air conditioner recirculation air filter, fresh air filter.................353 Clean the brake circuit strainer..............................................................353 Check brake disc wear.........................................................................354 Check function of accumulator.................................................................355 Check alternator and starting motor...........................................................356 Check engine valve clearance, adjust..........................................................356 Check vibration damper........................................................................356 4.8.13 Every 4000 hours service...................................................................357 Lubricating...................................................................................357 Check water pump..............................................................................358 Check starting motor..........................................................................358 Checking for looseness of high-pressure clamp, hardening of rubber............................358 Checking for missing fuel spray prevention cap, hardening of rubber...........................359 4.8.14 Every 8000 hours service...................................................................360 Replace high-pressure piping clamp............................................................360 Replace fuel spray prevention cap.............................................................360 5. Technical data.........................................................................................361 5.1 Technical data....................................................................................362 WA150PZ-6.........................................................................................362 WA200PZ-6.........................................................................................364 WA250PZ-6.........................................................................................366 WA320PZ-6.........................................................................................368 5.2 Noise emission levels.............................................................................370 5.3 Vibration level...................................................................................371 5.4 Limit values for slopes...........................................................................373 6. Attachments, options...................................................................................375 6.1 Hydraulic quick coupler...........................................................................376 Removing the attachment...........................................................................376 Installing the attachment.........................................................................378 Removal and installation of the attachment........................................................381 Precautions for use...............................................................................381 Precautions when removing the attachment..........................................................381 6.2 Handling fork tool................................................................................382 6.2.1 Explanation of components...................................................................382 6.2.2 Operation...................................................................................383 6.2.3 Loading operation...........................................................................383 Loading.......................................................................................383 Transporting..................................................................................385 Unloading.....................................................................................386 6.3 Method of using 3 levers..........................................................................387 6.3.1 Explanation of components...................................................................387 6.3.2 Operation...................................................................................391 Using switch to change between forward and reverse............................................391 6.4 Reversible fan....................................................................................393 6.5 Central lubrication system........................................................................394 6.5.1 Operating the central lubrication system....................................................394 6.5.2 Display and control unit....................................................................394 LED-display...................................................................................395 Pushbuttons...................................................................................395 6.5.3 Changing the lubrication interval times.....................................................396 6.6 Handling machines equipped with KOMTRAX...........................................................398 6.6.1 Basic precautions...........................................................................399 7. Index..................................................................................................401 7.1 Index.............................................................................................402 8. Notes..................................................................................................407
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