Komatsu WA200-5L Manual

November 2008 Copyright 2008 Komatsu
Published in USA
Komatsu America Corp.
CEAM013101
Operation & Maintenance
Manual
WA200-5L
WHEEL LOADER
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance
with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recom-
mended that customers contact their distributor for information on the latest revision.
SERIAL NUMBERS WA200-5L A82001 and UP

Find manuals at https://best-manuals.com

0-1
INTRODUCTION 0
WA200-5L
Find manuals at https://best-manuals.com

INTRODUCTION
0-2 WA200-5L
FOREWORD
This manual provides the rules and guidelines that 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 fail-
ure to follow the fundamental safety rules for the operation and maintenance of the machines. Knowing hazardous conditions
before the operation or maintenance begins can prevent accidents.
Storage location for the Operation and Maintenance Manual:
Pocket (1) on the backside of the operator's seat.
Operators and maintenance personnel must always do as follows before beginning operation or mainte-
nance.
• Always be sure to read and understand this manual thoroughly before performing operation and main-
tenance
• Read the safety messages given in this manual and the safety labels affixed to the machine thor-
oughly and be sure that you understand them fully.
Keep this manual at the storage location for the Operation and Maintenance Manual given below, and have
all personnel read it periodically.
If this manual has been lost or has become dirty and cannot be read, request a replacement manual imme-
diately from Komatsu or your Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners at the time the machine is trans-
ferred.
Komatsu delivers machines that comply with all applicable regulations and standards of the country to
which the machine has been shipped. If this machine has been purchased in another country or purchased
from someone in another country, it may lack certain safety devices and specifications that are necessary
for use in your country. If there is any question about whether your product complies with the applicable
standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating
the machine.
Find manuals at https://best-manuals.com

INTRODUCTION
WA200-5L 0-3
SAFETY INFORMATION
To enable you to use this machine safely, safety precautions are provided in this manual and labels affixed to the machine to
give an explanation of situations involving potential hazards and of the methods of avoiding such situations.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to personal injury
or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury. This signal word is to be limited to most extreme situations.
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury. It may also be used to alert against unsafe practices.
Example of safety message using signal word
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to protect the
machine or to give information that is useful to know.
NOTICE
This word is used for precautions that must be taken to avoid actions which could shorten the life of
the machine.
Remark
This word is used for information that is useful to know.
Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker at the location of actions that, during
performing operation or maintenance of the machine, may involve hazard.
When standing up from the operator’s seat, always place the safety lock lever in the LOCK position.
If you accidentally touch the levers when they are not locked, this may cause serious injury or damage.
Find manuals at https://best-manuals.com

INTRODUCTION
0-4 WA200-5L
INTRODUCTION
This Komatsu machine is designed to be used mainly for the following work:
•Digging work
•Smoothing
•Pushing work
•Loading work
For details of the operating procedure, see “WORK POSSIBLE USING WHEEL LOADER” on page 2-87.
DIRECTIONS OF MACHINE
In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from the operator's
seat in the direction of travel (front) of the machine.
Find manuals at https://best-manuals.com

INTRODUCTION
WA200-5L 0-5
NECESSARY INFORMATION
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items.
MACHINE SERIAL NO. PLATE
The machine serial number plate is located on the center right of the front frame.
ENGINE SERIAL NO. PLATE AND POSITION
The engine serial number plate is located on the side face of the engine cover, on the right side of the machine.
EPA: Environmental Protection Agency, U.S.A.
Find manuals at https://best-manuals.com

INTRODUCTION
0-6 WA200-5L
SERVICE METER POSITION
The service meter is located in the center at the bottom of the machine
monitor.
For details of the service meter display, see “SERVICE METER” on
page 2-8.
ENTER SERIAL NO. AND DISTRIBUTOR
Machine serial No.
Engine serial No.
Distributor name
Address
Service Personal
Phone/Fax
Find manuals at https://best-manuals.com

INTRODUCTION
WA200-5L 0-7
TABLE OF CONTENTS
INTRODUCTION
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
DIRECTIONS OF MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
NECESSARY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
MACHINE SERIAL NO. PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
ENGINE SERIAL NO. PLATE AND POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
SERVICE METER POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6
ENTER SERIAL NO. AND DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-7
SAFETY
SAFETY AND WARNING DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
LOCATION OF THE SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
DESCRIPTION OF SAFETY LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
SAFETY LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
GENERAL SAFETY RULES AND PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
GENERAL SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
UNAUTHORIZED MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
GENERAL SAFETY AT JOB SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
WORKING ON LOOSE GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
PERSONAL PROTECTIVE EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
FIRE AND EXPLOSION PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
FIRE CAUSED BY FUEL OR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL . . . . . . . . . . . . . 1-14
FIRE COMING FROM ELECTRIC WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
FIRE COMING FROM HYDRAULIC LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
WINDSHIELD WASHER FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
ACTION IF FIRE OCCURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
FIRE EXTINGUISHER AND FIRST AID KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
MOUNTING AND DISMOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
INSIDE OPERATOR’S COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT . . . . . . . . . . . . . . . . . . 1-17
PRECAUTIONS WHEN USING ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
EMERGENCY ESCAPE FROM OPERATOR'S CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
LEAVING OPERATOR’S COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
KEEP OPERATOR'S COMPARTMENT CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
DUST HAZARD PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
ASBESTOS HAZARD ALERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
CRUSH OR PINCH POINT DANGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
PRECAUTIONS BEFORE STARTING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
PRE-OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
STARTING YOUR WORK OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Find manuals at https://best-manuals.com

INTRODUCTION
0-8 WA200-5L
WORK SITE HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
AVOIDING DANGEROUS SITUATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
WORKING CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
RULES FOR ROAD TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
TRAVELING IN REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
TRAVELING ON ICY OR SNOW-COVERED SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
WORKING ON LOOSE OR UNSTABLE GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
TRAVEL ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
PRECAUTIONS DURING MAINTENANCE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
WARNING TAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
EQUIPMENT STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
WORKING UNDER THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
USING DROP LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
KEEPING THE MACHINE CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
RUNNING THE MACHINE DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
RULES FOR REFUELING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
COOLING SYSTEM PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
BATTERY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
STARTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
HIGH-PRESSURE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
SAFETY HANDLING HIGH-PRESSURE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
PRECAUTION FOR HIGH FUEL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
HIGH TEMPERATURES AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
DISPOSAL OF WASTE MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
INFLATING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
DISPOSAL OF WASTE MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
CRITICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
HIGH VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
OPERATION
GENERAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
GENERAL VIEW OF MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
CONTROLS AND GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
MACHINE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
EXPLANATION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
TESTING ACTUATION OF MACHINE MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . 2-6
TYPES OF WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
MISTAKEN OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
CENTRAL WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
CHARACTER DISPLAY PORTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
SERVICE METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
ACTION CODE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Find manuals at https://best-manuals.com