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KOMATSU WA250PT-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:70570 & UP) KOMATSU WA250PT-5 – PDF DOWNLOAD


  • KOMATSU WA250PT-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL
  • SERIAL NUMBER:70570 & UP
  • PUBLICATION NUMBER:TEN00157-00

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KOMATSU WA250PT-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:70570 & UP) KOMATSU WA250PT-5

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KOMATSU WA250PT-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:70570 & UP) KOMATSU WA250PT-5

  • 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. In this manual, measurements are expressed in international standard units (SI). For the reference purpose, weight units used in the past are also displayed in ( ).

Table of Contents:

KOMATSU WA250PT-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:70570 & UP) KOMATSU WA250PT-5

COVER..........................................................................................  1
FOREWORD.......................................................................................  3
	FOREWORD...................................................................................  4
	SAFETY INFORMATION.........................................................................  7
	INTRODUCTION...............................................................................  9
		FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...........................................  9
	NECESSARY INFORMATION...................................................................... 10
		PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE........................... 10
		ENGINE SERIAL NO. PLATE................................................................ 10
		POSITION OF SERVICE METER.............................................................. 11
		TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.............................................. 11
CONTENTS....................................................................................... 12
SAFETY......................................................................................... 15
	SAFETY..................................................................................... 16
	SAFETY LABELS.............................................................................. 19
		LOCATION OF SAFETY LABELS.............................................................. 19
		SAFETY LABELS.......................................................................... 20
	GENERAL PRECAUTIONS........................................................................ 25
		SAFETY RULES........................................................................... 25
		IF ABNORMALITIES ARE FOUND............................................................. 25
		CLOTHING AND PERSONAL PROTECTIVE ITEMS................................................. 25
		FIRE EXTINGUISHER AND FIRST AID KIT.................................................... 25
		SAFETY FEATURES........................................................................ 25
		KEEP MACHINE CLEAN..................................................................... 26
		INSIDE OPERATOR'S COMPARTMENT.......................................................... 26
		ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT......................................... 26
		HANDRAILS AND STEPS.................................................................... 27
		MOUNTING AND DISMOUNTING............................................................... 28
		NO PEOPLE ON ATTACHMENTS............................................................... 28
		DO NOT GET CAUGHT IN ARTICULATED PORTION............................................... 28
		PREVENTION OF BURNS.................................................................... 28
		FIRE PREVENTION........................................................................ 29
		ACTION IF FIRE OCCURS.................................................................. 30
		WINDOW WASHER LIQUID................................................................... 30
		PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)........................... 30
		PRECAUTIONS FOR ATTACHMENTS, OPTIONS................................................... 30
		UNAUTHORIZED MODIFICATION.............................................................. 30
		SAFETY AT WORKSITE..................................................................... 31
		WORKING ON LOOSE GROUND................................................................ 31
		DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES................................................. 31
		ENSURE GOOD VISIBILITY................................................................. 32
		VENTILATION FOR ENCLOSED AREAS......................................................... 32
		CHECKING SIGNALMAN'S SIGNALS AND SIGNS................................................. 32
		EMERGENCY EXIT FROM OPERATOR'S CAB..................................................... 32
		BE CAREFUL ABOUT ASBESTOS DUST......................................................... 33
	PRECAUTIONS FOR OPERATION.................................................................. 34
		STARTING ENGINE........................................................................ 34
			CHECKS BEFORE STARTING ENGINE...................................................... 34
			PRECAUTIONS WHEN STARTING.......................................................... 34
			PRECAUTIONS IN COLD AREAS.......................................................... 35
		OPERATION.............................................................................. 36
			CHECKS BEFORE OPERATION............................................................ 36
			PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE................................... 36
			PRECAUTIONS WHEN TRAVELING......................................................... 37
			TRAVELING ON SLOPES................................................................ 38
			PROHIBITED OPERATIONS.............................................................. 39
			PRECAUTIONS WHEN OPERATING......................................................... 39
			METHODS OF USING BRAKE............................................................. 40
			OPERATE CAREFULLY ON SNOW.......................................................... 40
			PARKING MACHINE.................................................................... 41
		TRANSPORTATION......................................................................... 42
			LOADING AND UNLOADING.............................................................. 42
			SHIPPING........................................................................... 42
		BATTERY................................................................................ 43
			BATTERY HAZARD PREVENTION.......................................................... 43
			STARTING WITH BOOSTER CABLES....................................................... 44
		TOWING................................................................................. 45
			WHEN TOWING........................................................................ 45
	PRECAUTIONS FOR MAINTENANCE................................................................ 46
		WARNING TAG............................................................................ 46
		KEEP WORK PLACE CLEAN AND TIDY......................................................... 46
		APPOINT LEADER WHEN WORKING WITH OTHERS................................................ 46
		STOP ENGINE BEFORE CARRYING OUT MAINTENANCE............................................ 47
		TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING..................................... 48
		INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF........................... 48
		PROPER TOOLS........................................................................... 49
		ACCUMULATOR............................................................................ 49
		PERSONNEL.............................................................................. 49
		ATTACHMENTS............................................................................ 49
		WORK UNDER THE MACHINE................................................................. 50
		NOISE.................................................................................. 50
		PRECAUTIONS WHEN USING HAMMER.......................................................... 50
		REPAIR WELDING......................................................................... 50
		REMOVING BATTERY TERMINAL.............................................................. 50
		PRECAUTIONS WITH HIGH-PRESSURE OIL..................................................... 51
		HANDLING HIGH-PRESSURE HOSES........................................................... 51
		WASTE MATERIALS........................................................................ 51
		MAINTENANCE OF AIR CONDITIONER......................................................... 51
		COMPRESSED AIR......................................................................... 52
		PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.......................................... 52
	PRECAUTIONS WITH TIRES..................................................................... 53
		HANDLING TIRES......................................................................... 53
		PRECAUTIONS WHEN STORING TIRES......................................................... 53
OPERATION...................................................................................... 55
	GENERAL VIEW............................................................................... 56
		GENERAL VIEW OF MACHINE................................................................ 56
		GENERAL VIEW OF CONTROLS AND GAUGES.................................................... 57
	EXPLANATION OF COMPONENTS.................................................................. 59
		MACHINE MONITOR........................................................................ 59
		SWITCHES............................................................................... 85
		CONTROL LEVERS, PEDALS................................................................. 93
		STEERING TILT LOCK LEVER............................................................... 97
		CAP AND COVER WITH LOCK................................................................ 97
		FRAME LOCK BAR......................................................................... 98
		TOWING PIN............................................................................. 99
		GREASE PUMP............................................................................ 99
		CAB DOOR INNER LOCK.................................................................... 99
		CAB DOOR OPEN LOCK.....................................................................100
		CAB WINDOW OPEN LOCK CANCEL KNOB.......................................................100
		FUSE...................................................................................100
		SLOW BLOW FUSE.........................................................................102
		POWER OUTLET...........................................................................102
		STORAGE BOX............................................................................102
		AM/FM RADIO............................................................................103
		AM/FM RADIO-CASSETTE STEREO............................................................109
		AIR CONDITIONER........................................................................117
		HANDLING CAB WIPER.....................................................................122
	OPERATION..................................................................................123
		CHECK BEFORE STARTING ENGINE, ADJUST...................................................123
		STARTING ENGINE........................................................................138
		OPERATIONS AND CHECKS AFTER STARTING ENGINE............................................140
		STOPPING ENGINE........................................................................142
		MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE..........................143
		TURNING................................................................................147
		OPERATION OF WORK EQUIPMENT............................................................149
		HANDLING HYDRAULIC QUICK COUPLER.......................................................151
		WORK POSSIBLE USING WHEEL LOADER.......................................................154
		PRECAUTIONS FOR OPERATION..............................................................159
		ADJUSTING WORK EQUIPMENT POSTURE.......................................................161
		PARKING MACHINE........................................................................165
		CHECKS AFTER COMPLETION OF OPERATION...................................................167
		LOCKING................................................................................167
		HANDLING THE TIRES.....................................................................168
	TRANSPORTATION.............................................................................170
		TRANSPORTATION PROCEDURE...............................................................170
		LOADING, UNLOADING WORK WITH TRAILERS..................................................170
		LIFTING MACHINE........................................................................174
	COLD WEATHER OPERATION.....................................................................176
		PRECAUTIONS FOR LOW TEMPERATURE........................................................176
		PRECAUTIONS AFTER COMPLETION OF WORK...................................................177
		AFTER COLD WEATHER.....................................................................177
		WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER....................178
	LONG-TERM STORAGE..........................................................................179
		BEFORE STORAGE.........................................................................179
		DURING STORAGE.........................................................................179
		AFTER STORAGE..........................................................................179
	TROUBLESHOOTING............................................................................180
		WHEN MACHINE RUNS OUT OF FUEL..........................................................180
		METHOD OF TOWING MACHINE...............................................................180
		IF BATTERY IS DISCHARGED...............................................................182
		OTHER TROUBLE..........................................................................185
MAINTENANCE....................................................................................191
	GUIDES TO MAINTENANCE......................................................................192
	OUTLINES OF SERVICE........................................................................194
		HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................194
		OUTLINE OF ELECTRIC SYSTEM.............................................................197
	WEAR PARTS.................................................................................198
		WEAR PARTS LIST........................................................................198
	RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................199
		USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...................200
		RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....201
	STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.............................................202
		TORQUE LIST............................................................................202
	PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..............................................203
	MAINTENANCE SCHEDULE CHART.................................................................204
		MAINTENANCE SCHEDULE CHART.............................................................204
	SERVICE PROCEDURE..........................................................................206
		INITIAL 250 HOURS SERVICE..............................................................206
		WHEN REQUIRED..........................................................................207
			CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT.......................................207
			CLEAN INSIDE OF COOLING SYSTEM.....................................................210
			CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL..........................................213
			CHECK AXLE OIL LEVEL, ADD OIL......................................................214
			CLEAN AXLE CASE BREATHER...........................................................215
			CLEAN AIR CONDITIONER CONDENSER....................................................216
			CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID........................................216
			CLEAN RADIATOR FINS AND COOLER FINS................................................217
			CHECK ELECTRICAL INTAKE AIR HEATER.................................................217
			TURN, REPLACE BOLT-ON CUTTING EDGE.................................................218
			REPLACE BUCKET TEETH...............................................................219
			CHECK AIR CONDITIONER..............................................................221
			REPLACE SLOW BLOW FUSE.............................................................222
			CHECKING FUNCTION OF ACCUMULATOR...................................................223
			SELECTION AND INSPECTION OF TIRES..................................................224
		CHECK BEFORE STARTING..................................................................226
		EVERY 50 HOURS SERVICE.................................................................227
			DRAIN WATER, SEDIMENT FROM FUEL TANK...............................................227
		EVERY 100 HOURS SERVICE................................................................228
			LUBRICATE REAR AXLE PIVOT PIN......................................................228
			CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER..................................228
			CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL.........................................229
		EVERY 250 HOURS SERVICE................................................................230
			CHECK BATTERY ELECTROLYTE LEVEL....................................................230
			CHECK PARKING BRAKE................................................................232
			CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST..............................232
			CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN...........................................233
			CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER..............................234
			CHECKING FUNCTION OF ACCUMULATOR...................................................234
			LUBRICATING........................................................................235
		EVERY 500 HOURS SERVICE................................................................236
			CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..................236
			REPLACE FUEL FILTER CARTRIDGE......................................................237
			REPLACEMENT OF FILTER CARTRIDGE FOR POOR-QUALITY FUEL..............................238
			CLEAN WATER SEPARATOR STRAINER.....................................................239
		EVERY 1000 HOURS SERVICE...............................................................240
			CHANGE OIL IN TRANSFER CASE........................................................240
			CLEAN TRANSFER CASE BREATHER.......................................................241
			REPLACE HST OIL FILTER ELEMENT.....................................................242
			REPLACE CORROSION RESISTOR CARTRIDGE...............................................243
			LUBRICATING........................................................................243
			CHECK TIGHTENING PARTS OF TURBOCHARGER.............................................243
			CHECK PLAY OF TURBOCHARGER ROTOR...................................................243
			CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT..............................244
		EVERY 2000 HOURS SERVICE...............................................................245
			CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT.....................245
			REPLACE HYDRAULIC TANK BREATHER ELEMENT............................................246
			CHANGE AXLE OIL....................................................................247
			REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER......247
			CLEAN BRAKE CIRCUIT STRAINER.......................................................248
			CHECK BRAKE DISC WEAR..............................................................249
			CHECKING FUNCTION OF ACCUMULATOR...................................................250
			CHECK ALTERNATOR, STARTING MOTOR...................................................250
			CHECK ENGINE VALVE CLEARANCE, ADJUST...............................................250
			CLEAN AND CHECK TURBOCHARGER.......................................................250
			CHECK VIBRATION DAMPER.............................................................250
		EVERY 4000 HOURS SERVICE...............................................................251
			LUBRICATING........................................................................251
			CHECK WATER PUMP...................................................................251
SPECIFICATIONS.................................................................................253
	SPECIFICATIONS.............................................................................254
ATTACHMENTS, OPTIONS...........................................................................255
	SELECTING BUCKET AND TIRES.................................................................256
	HANDLING FORK TOOL.........................................................................257
		EXPLANATION OF COMPONENTS..............................................................257
		OPERATION..............................................................................258
INDEX..........................................................................................261

Please Note:

⦁ This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
⦁ You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
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