Komatsu WA250-5 Manual

SEAM050500T
Operation&Maintenance
Operation&MaintenanceOperation&Maintenance
Operation&Maintenance
Manual
ManualManual
Manual
WA250 -5
WHEEL LOADER
SERIAL NUMBERS WA250-5 70001 and up
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.
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 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, revisions may be made to this publication. It
is recommended that customers contact their distributor for information on the latest revision.
Copyright 2003 Komatsu
DataKom Publications and Training Division
January 2003

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FOREWORD
FOREWORD
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 for the operation and maintenance of
machines. Accidents can be prevented by knowing beforehand conditions that may cause ahazard when
performing operation and maintenance.
Operators
and
maintenance
personnel
must
always
do
as
follows
before
beginning
operation
or
maintenance.
Always
be
sure
to
read
and
understand
this
manual
thoroughly
before
performing
operation
and
maintenance.
Read
the
safety
messages
given
in
this
manual
and
the
safety
labels
affixed
to
the
machine
thoroughly
and
be
sure
that
you
understand
them
fully.
Keep
this
manual
at
the
storage
location
for
the
Operation
and
aintenance
anual
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
immediately
from
Komatsu
or
your
Komatsu
distributor.
If
you
sell
the
machine,
be
sure
to
give
this
manual
to
the
new
owners
together
with
the
machine.
Komatsu
delivers
machines
that
comply
with
all
applicable
regulations
and
standards
of
the
country
to
which
it
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.
Storage location for the Operation and Maintenance Manual:
ocket (1) at rear of operator's seat
1 - 2

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FOREWORD
FOREWORD
1 - 3

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FOREWORD
FOREWORD
1 - 4

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FOREWORD
SAFETY INFOR ATION
SAFETY INFORMATION
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations 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 apotential 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.
Indicates apotentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates apotentially hazardous situation which, if not avoided, may result in minor or
moderate injury. This word is used also to alert against unsafe practices that may cause
property damage.
Example
of
safety
message
using
signal
word
When
standing
up
from
the
operator's
seat,
always
place
the
safety
lock
lever
in
the
LOCK
position.
If
you
accidentally
touch
the
control
levers
when
they
are
not
locked,
this
may
cause
a
serious
injury
or
death.
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.
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
This word is used for information that is useful to know.
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FOREWORD
SAFETY INFOR ATION
Safety
labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying out
operation or maintenance of the machine that may involve hazard.
This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures.
Example
of
safety
label
using
words
Safety
labels
using
pictogram
Safety pictograms use apicture to express alevel of hazardous
condition equivalent to the signal word. These safety pictograms
use pictures in order to let the operator or maintenance worker
understand the level and type of hazardous condition at all times.
Safety pictograms show the type of hazardous condition at the top
or left side, and the method of avoiding the hazardous condition at
the bottom or right side. In addition, the type of hazardous condition
is displayed inside atriangle and the method of avoiding the
hazardous condition is shown inside acircle.
Komatsu cannot predict every circumstance that might involve apotential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsibility
to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your
machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( )in the text. (For example: j -> (1))
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FOREWORD
INTRODUCTION
INTRODUCTION
This Komatsu machine is designed to be used mainly for the following work:
Digging work
Smoothing
ushing work
Loading work
For details of the operating procedure, see "WORK OSSIBLE USING WHEEL LOADER ( AGE 3-84)".
FRONT/REAR, LEFT/RIGHT 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.
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FOREWORD
NECESSARY INFOR ATION
NECESSARY INFORMATION
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
MACHINE SERIAL NO. PLATE AND POSITION
On the center right of the front frame.
ENGINE SERIAL NO. PLATE AND POSITION
This is on the side face of the engine cover on the right side of the machine.
E A: Environmental rotection Agency, U.S.A.
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FOREWORD
NECESSARY INFOR ATION
POSITION OF SERVICE METER
It is at the center bottom of the machine monitor.
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
Machine serial No.
Engine serial No.
Distributor name
Address
Service Personnel
Phone/Fax
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FOREWORD
CONTENTS
CONTENTS
FOREWORD 1- 1
FOREWORD 1- 2
SAFETY INFORMATION 1- 5
INTRODUCTION 1- 7
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 1- 7
NECESSARY INFORMATION 1- 8
MACHINE SERIAL NO. LATE AND OSITION 1- 8
ENGINE SERIAL NO. LATE AND OSITION 1- 8
OSITION OF SERVICE METER 1- 9
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 9
SAFETY 2- 1
SAFETY 2- 2
SAFETY LABELS 2- 5
LOCATION OF SAFETY LABELS 2- 5
SAFETY LABELS 2- 6
GENERAL RECAUTIONS 2- 11
RECAUTIONS FOR O ERATION 2- 20
STARTING ENGINE 2- 20
O ERATION 2- 22
TRANS ORTATION 2- 28
BATTERY 2- 29
TOWING 2- 31
RECAUTIONS FOR MAINTENANCE 2- 32
RECAUTIONS WITH TIRES 2- 39
O ERATION 3- 1
GENERAL VIEW 3- 2
GENERAL VIEW OF MACHINE 3- 2
GENERAL VIEW OF CONTROLS AND GAUGES 3- 3
EX LANATION OF COM ONENTS 3- 5
MACHINE MONITOR 3- 5
SWITCHES 3- 31
CONTROL LEVERS, EDALS 3- 39
STEERING TILT LOCK LEVER 3- 43
CA AND COVER WITH LOCK 3- 43
SAFETY BAR 3- 44
TOWING IN 3- 45
GREASE UM 3- 45
CAB DOOR INNER LOCK 3- 45
CAB DOOR O EN LOCK 3- 46
CAB WINDOW O EN LOCK CANCEL KNOB 3- 46
FUSE 3- 46
SLOW BLOW FUSE 3- 48
OWER OUTLET 3- 48
AIR CONDITIONER 3- 49
HANDLING CAB WI ER 3- 54
O ERATION 3- 55
CHECK BEFORE STARTING ENGINE, ADJUST 3- 55
STARTING ENGINE 3- 70
O ERATIONS AND CHECKS AFTER STARTING ENGINE 3- 72
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FOREWORD
CONTENTS
STO ING ENGINE 3- 74
MOVING THE MACHINE (DIRECTIONAL, S EED), STO ING THE MACHINE 3- 75
TURNING 3- 80
O ERATION OF WORK EQUI MENT 3- 82
WORK OSSIBLE USING WHEEL LOADER 3- 84
RECAUTIONS FOR O ERATION 3- 89
ADJUSTING WORK EQUI MENT OSTURE 3- 91
ARKING MACHINE 3- 93
CHECK AFTER STO ING ENGINE 3- 95
CHECKS AFTER COM LETION OF O ERATION 3- 95
LOCKING 3- 95
HANDLING THE TIRES 3- 96
TRANS ORTATION 3- 98
TRANS ORTATION ROCEDURE 3- 98
LOADING, UNLOADING WORK WITH TRAILERS 3- 98
LIFTING MACHINE 3-100
COLD WEATHER O ERATION 3-103
RECAUTIONS FOR LOW TEM ERATURE 3-103
RECAUTIONS AFTER COM LETION OF WORK 3-104
AFTER COLD WEATHER 3-105
WARMING-U O ERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER 3-105
LONG-TERM STORAGE 3-106
BEFORE STORAGE 3-106
DURING STORAGE 3-106
AFTER STORAGE 3-106
TROUBLESHOOTING 3-107
WHEN MACHINE RUNS OUT OF FUEL 3-107
TOWING THE MACHINE 3-107
IF BATTERY IS DISCHARGED 3-109
OTHER TROUBLE 3-112
MAINTENANCE 4- 1
GUIDES TO MAINTENANCE 4- 2
OUTLINES OF SERVICE 4- 4
HANDLING OIL, FUEL, COOLANT, AND ERFORMING OIL CLINIC 4- 4
OUTLINE OF ELECTRIC SYSTEM 4- 6
WEAR ARTS 4- 7
WEAR ARTS LIST 4- 7
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEM ERATURE 4- 8
RO ER SELECTION OF FUEL, COOLANT AND LUBRICANTS 4- 8
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 12
TORQUE LIST 4- 12
ERIODIC RE LACEMENT OF SAFETY CRITICAL ARTS 4- 13
MAINTENANCE SCHEDULE CHART 4- 14
MAINTENANCE SCHEDULE CHART 4- 14
SERVICE ROCEDURE 4- 16
INITIAL 250 HOURS SERVICE 4- 16
WHEN REQUIRED 4- 17
CHECK BEFORE STARTING 4- 33
EVERY 50 HOURS SERVICE 4- 34
EVERY 100 HOURS SERVICE 4- 35
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FOREWORD
CONTENTS
EVERY 250 HOURS SERVICE 4- 37
EVERY 500 HOURS SERVICE 4- 43
EVERY 1000 HOURS SERVICE 4- 45
EVERY 2000 HOURS SERVICE 4- 49
EVERY 4000 HOURS SERVICE 4- 54
S ECIFICATIONS 5- 1
S ECIFICATIONS 5- 2
ATTACHMENTS, O TIONS 6- 1
SELECTING BUCKET AND TIRES 6- 2
AM/FM RADIO-CASSETTE STEREO 6- 3
EX LANATION OF COM ONENTS 6- 3
METHOD OF O ERATION 6- 8
RECAUTIONS FOR USE 6- 10
INDEX 7- 1
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SAFETY
SAFETY
SAFETY
SAFETY LABELS 2- 5
LOCATION OF SAFETY LABELS 2- 5
SAFETY LABELS 2- 6
GENERAL RECAUTION
SAFETY RULES 2- 11
IF ABNORMALITIES ARE FOUND 2- 11
CLOTHING AND ERSONAL ROTECTIVE ITEMS 2- 11
FIRE EXTINGUISHER AND FIRST AID KIT 2- 11
SAFETY FEATURES 2- 11
KEE MACHINE CLEAN 2- 12
INSIDE O ERATOR'S COM ARTMENT 2- 12
ALWAYS A LY LOCK WHEN LEAVING O ERATOR'S SEAT 2- 12
HANDRAILS AND STE S 2- 13
MOUNTING AND DISMOUNTING 2- 14
NO EO LE ON ATTACHMENTS 2- 14
DO NOT GET CAUGHT IN ARTICULATED ORTION 2- 14
REVENTION OF BURNS 2- 14
FIRE REVENTION 2- 15
ACTION IF FIRE OCCURS 2- 16
WINDOW WASHER LIQUID 2- 16
RECAUTIONS WHEN USING RO S (Roll Over rotective Structure) 2- 16
RECAUTIONS FOR ATTACHMENTS, O TIONS 2- 16
UNAUTHORIZED MODIFICATION 2- 16
SAFETY AT WORKSITE 2- 17
WORKING ON LOOSE GROUND 2- 17
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 2- 17
ENSURE GOOD VISIBILITY 2- 18
RECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS 2- 18
CHECKING SIGNALMAN'S SIGNALS AND SIGNS 2- 18
EMERGENCY ESCA E FROM O ERATOR'S CAB 2- 18
ASBESTOS DUST HAZARD REVENTION 2- 19
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SAFETY
SAFETY
RECAUTIONS FOR O ERATION 2- 20
BEFORE STARTING ENGINE 2- 20
CHECKS BEFORE STARTING ENGINE 2- 20
RECAUTIONS WHEN STARTING 2- 21
RECAUTIONS IN COLD AREAS 2- 21
O ERATION 2- 22
CHECKS BEFORE STARTING ENGINE 2- 22
CHECK WHEN TRAVELING FORWARD OR REVERSE 2- 22
RECAUTIONS WHEN TRAVELING 2- 23
TRAVELING ON SLO ES 2- 24
ROHIBITED O ERATIONS 2- 25
RECAUTIONS WHEN O ERATING 2- 25
METHODS OF USING BRAKE 2- 26
O ERATE CAREFULLY ON SNOW 2- 26
ARKING MACHINE 2- 27
TRANS ORTATION 2- 28
LOADING AND UNLOADING 2- 28
SHI ING 2- 28
BATTERY 2- 29
BATTERY HAZARD REVENTION 2- 29
STARTING WITH BOOSTER CABLES 2- 30
TOWING 2- 31
WHEN TOWING 2- 31
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SAFETY
SAFETY
RECAUTIONS FOR MAINTENANCE 2- 32
WARNING TAG 2- 32
KEE WORK LACE CLEAN AND TIDY 2- 32
A OINT LEADER WHEN WORKING WITH OTHERS 2- 32
MAINTENANCE WITH ENGINE RUNNING 2- 33
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING 2- 34
INS ECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF 2- 34
RO ER TOOLS 2- 35
ACCUMULATOR 2- 35
ERSONNEL 2- 35
ATTACHMENTS 2- 35
WORK UNDER THE MACHINE 2- 36
NOISE 2- 36
RECAUTIONS WHEN USING HAMMER 2- 36
RE AIR WELDING 2- 36
REMOVING BATTERY TERMINAL 2- 36
RECAUTIONS WITH HIGH- RESSURE OIL 2- 37
HANDLING HIGH- RESSURE HOSES 2- 37
WASTE MATERIALS 2- 37
MAINTENANCE OF AIR CONDITIONER 2- 37
COM RESSED AIR 2- 38
ERIODIC RE LACEMENT OF SAFETY CRITICAL ARTS 2- 38
RECAUTIONS WITH TIRES 2- 39
HANDLING TIRES 2- 39
RECAUTIONS WHEN STORING TIRE 2- 39
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SAFETY
SAFETY LABELS
SAFETY LABELS
The following safety labels are used on this machine. Be sure that you fully understand the correct position and
content of these safety labels.
To ensure that the content of these safety labels can be read properly, be sure that they are in the correct place and
always keep them clean. When cleaning them, use soap and water. Do not use organic solvents or gasoline.
These may cause the safety labels to peel off.
If the safety labels are damaged or lost, or cannot be read, replace them with new parts. For details of the part
numbers, see this manual or check on the actual part, and order the new part from your Komatsu distributor.
There are also other labels in addition to the safety labels. Handle these labels in the same way.
LOCATION OF SAFETY LABELS
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SAFETY
SAFETY LABELS
SAFETY LABELS
(1) recautions before starting (09651-03001) (2) recautions for safety lock lever (09654-03001)
(3) recautions when traveling in reverse (4) recautions for going close to electric cables
(09801-13001)
lease request part number 418-93-22271 for safety label (3).
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SAFETY
SAFETY LABELS
(5) Do not enter (09162-23000) (6) recautions for safety bar (09161-23000)
(7) recautions when coolant is at high temperature
(09668-03001)
(8) recautions when oil is at high temperature
(09653-03001)
2 - 7