Komatsu WA250PT-5H Operation & Maintenance Manual Download

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Periodic replacement of safety critical parts

MAINTENANCE

Safety critical parts

4-16

Safety critical parts for periodic replacement

Q'ty

Replacement

interval

Fuel hose (fuel tank - water separator)

Every 2 years or

every 4000

hours,

whichever

comes first

Fuel hose (water separator - pump)

Fuel return hose (pump - fuel tank)

Fuel spill hose (tube - fuel tank)

Turbocharger lubricating hose

Steering hose (pump - priority valve)

Steering hose (priority valve - orbitrol valve)

Steering hose (orbitrol valve - steering cylinder)

Steering hose (steering cylinder line - cushion valve)

Packings, seals, O-rings of steering cylinder

Brake hose (gear pump - master cylinder)

Brake hose (master cylinder - front brake)

Brake hose (master cylinder - rear brake)

Brake hose (master cylinder - accumulator)

Brake hose (accumulator - charge valve)

Brake hose (master cylinder - hydraulic tank)

Brake hose (charge valve - hydraulic tank)

O-rings and oil seals of brake valve

Summary of Contents for WA250PT-5H

Page 1: ...t operation and maintenance of this machine may be hazardous and cause injuries The operator and maintenance personnel must read this manual before commencing operation or maintenance Keep this manual...

Page 2: ......

Page 3: ...FOREWORD 11...

Page 4: ...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...

Page 5: ...ons are observed If you are installing electrical or electronic equipment and or components in the machine and connect them to the vehicle electrical system you must check at own responsibility that t...

Page 6: ...n 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 mod erate injury This word is used also to alert...

Page 7: ...thod of avoiding the hazardous condition is shown inside a circle Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance Therefore the safety mess...

Page 8: ...othing Pushing work Loading work For details of the operating procedure see Work possible using wheel loader on page 3 84 Directions of machine 0 In this manual the directions of the machine front rea...

Page 9: ...rdering replacement parts please inform your Komatsu distributor of the following items Machine serial No plate and position 0 On the center right of the front frame Engine serial No plate and positio...

Page 10: ...tion of service meter 1 8 Position of service meter 0 It is at the center bottom of the machine monitor Table to enter serial No and distributor 0 Machine serial No Engine serial No Distributor name A...

Page 11: ...anufacturer supplied CE conforming equipment according to document 421 93 H1900 1 17 SAFETY Safety labels 2 3 Location of safety labels 2 3 Presentation of safety labels 2 4 General precautions 2 7 Sa...

Page 12: ...age to wiper arm bracket 3 53 Operation 3 54 Check before starting engine adjust 3 54 Walk around check 3 54 Check before starting 3 57 Adjustment 3 62 Operations and checks before starting engine 3 6...

Page 13: ...k 3 101 Weight table 3 101 Lifting procedure 3 102 Cold weather operation 3 103 Precautions for low temperature 3 103 Fuel and lubricants 3 103 Coolant 3 103 Battery 3 104 Precautions after completion...

Page 14: ...enser 4 29 Check window washing fluid level add fluid 4 30 Clean radiator fins and cooler fins 4 30 Clean transfer oil cooler fins 4 31 Check electrical intake air heater 4 31 Replace bolt on cutting...

Page 15: ...57 Check vibration damper 4 57 Every 4000 hours service 4 58 Lubricating 4 58 Check water pump 4 58 TECHNICAL DATA Technical data 5 2 Noise emission levels 5 4 Vibration level 5 4 ATTACHMENTS OPTIONS...

Page 16: ...Contents FOREWORD 1 14...

Page 17: ...force hydraulic kN 109 Lifting capacity hydraulic on ground kN 61 Operating weight kg 12 880 a Reach at 45 discharge mm 1 023 b Dumping height at 45 discharge mm 2 887 c Lift height hinge pin mm 3 95...

Page 18: ...orming equipment 0 CE conforming equipment 0 CE conforming equipment 1 2 3 4 5 Type Part No Volume m Load Capacity kg Hydraulic pressure bar Weight kg Bucket WA250PT 5H 418 70 H2710 2 0 884 418 70 H27...

Page 19: ...CE conformity and road traffic registration are deemed to have been fulfilled when the manufacturer of the equipment confirms fulfilment of the form 421 93 H1900 along side The certification must be...

Page 20: ...CE conforming equipment FOREWORD Manufacturer supplied CE conforming equipment according to document 421 93 H1900 1 18...

Page 21: ...ront axle horizontal D1 Distance headlight centre front axle horizontal D2 Distance headlight centre front axle vertical G Weight of equipment and working load H1 Distance bucket pivoting point bucket...

Page 22: ...CE conforming equipment FOREWORD Manufacturer supplied CE conforming equipment according to document 421 93 H1900 1 20...

Page 23: ...TY 22 WARNING Please be sure that you fully understand this manual and the precautions related to safety for the machine When operat ing or servicing the machine always follow these precau tions stric...

Page 24: ...SAFETY 2 2...

Page 25: ...e 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...

Page 26: ...ng operation inspec tion maintenance or transportation Sign indicates a hazard of unexpected moving of stopped machine Lower working device to ground move safety lever to lock position and take engine...

Page 27: ...coolant is at high tempera ture 421 93 H1280 8 Precautions when oil is at high temperature 421 93 H1280 Sign indicates a burn hazard from spurting hot water if radiator is uncapped while hot Allow rad...

Page 28: ...gine before inspection and mainte nance 13 Do not come under machine sign 421 93 H1370 14 Do not go under work equipment sign 421 93 H1380 Sign indicates a hazard of being run over by moving vehicle K...

Page 29: ...sonal protective items 0 Do not wear loose clothing and accessories There is a haz ard that they may catch on control levers or other protruding parts If you have long hair and it hangs out from your...

Page 30: ...hen the machine is still dirty with mud or oil there is a hazard that you will slip and fall or that dirt or mud will get into your eyes Always keep the machine clean Inside operator s compartiment 0...

Page 31: ...then stop the engine If you accidentally touch the levers when they are not locked there is a hazard that the machine may suddenly move and cause serious injury or property damage When leaving the ma...

Page 32: ...or securely into catcher 1 to hold in position then use the handrail on the inside to get on the machine For details of the method of releasing the door lock see Cab door open lock on page 3 44 Do not...

Page 33: ...ontrol levers by mistake the gap between the work equipment and machine and between the cylinder and work equipment will change and you your hand or arm will be caught and you may suffer serious injur...

Page 34: ...lammable materials accumulated or affixed around the engine exhaust manifold muffler or battery or inside the undercovers Fire coming from electric wiring Short circuits in the electrical system can c...

Page 35: ...matsu When installing and using optional attachments read the instruction manual for the attachment and the gen eral information related to attachments in this manual Unauthorized modification 0 Any m...

Page 36: ...ght between the machine and the electric cable Check with the local power company about safe operating procedure before starting operations To prepare for any possible emergencies wear rubber shoes an...

Page 37: ...y water to keep down the dust when cleaning Do not use compressed air for cleaning If there is danger that there may be asbestos dust in the air always operate the machine from an upwind position All...

Page 38: ...s are all at the neutral position Before starting the engine make sure that the safety lock lever is in the LOCK position Adjust the mirrors so that the rear of the machine can be seen clearly from th...

Page 39: ...reverse 0 Before travelling check again that there is no one in the surrounding area and that there are no obstacles Before travelling sound the horn to warn people in the area Always operate the mach...

Page 40: ...safe distance from people structures or other machines to avoid coming into contact with them When passing over bridges or structures check first that the structure is strong enough to support the wei...

Page 41: ...grass fallen leaves or wet steel plates with low speed Even with slight slopes there is a hazard that the machine may slip If the engine stops depress the brake pedal immediately lower the bucket to...

Page 42: ...ump trucks or other hauling equipment The load may spill or the bucket may hit the dump truck and cause serious injury or property damage Emergency lowering system 0 When the engine is not running you...

Page 43: ...unstable loads such as round or cylindrical objects or piled sheets if the work equipment is raised high there is danger that the load may fall on top of the operator compartment and cause serious inj...

Page 44: ...d that it may tip over or become buried in the snow Be careful not to leave the road shoulder or to get trapped in a snow drift When clearing snow the road shoulder and objects placed beside the road...

Page 45: ...t safety lock lever 1 to the LOCK position pull parking brake lever 2 to the LOCK position then stop the engine Always close the operator s cab door and use the key to lock all the equipment in order...

Page 46: ...ry Run the engine at low speed and travel slowly Never correct your steering on the ramps If necessary drive off the ramps correct the direction then enter the ramps again When loading or unloading to...

Page 47: ...lush the area with large amount of water If acid gets into your eyes flush them immediately with large amount of water and seek medical attention Before working with batteries turn the starting switch...

Page 48: ...m machine There is a hazard that the machine will move when the power is connected Be sure to connect the positive cable first when installing the booster cables Disconnect the negative cable ground s...

Page 49: ...spection of the wire rope For towing see Towing the machine on page 3 107 Always wear leather gloves when handling wire rope During the towing operation never stand between the tow ing machine and the...

Page 50: ...control lever while you are performing service or maintenance you could suffer serious injury or property damage Keep work place clean and tidy 0 Do not leave hammers or other tools lying around in th...

Page 51: ...y to the ground and stop the engine After stopping the engine operate work equipment control lever 1 2 to 3 times fully to the RAISE and LOWER posi tions to release the pressure inside the hydraulic c...

Page 52: ...fan belt Parts may break or be sent flying Set safety lock lever 1 to the LOCK position to prevent the work equipment from moving Then pull parking brake lever 2 to the position to prevent the machin...

Page 53: ...ame or dispose of it in fire Do not make holes in it weld it or use a cutting torch Do not hit or roll the accumulator or subject it to any impact When disposing of the accumulator the gas must be rel...

Page 54: ...position For this purpose you should use a supporting prop 1 which is to be positioned below the boom Park the machine on level solid ground Apply the parking brake Place wheel chocks in front of the...

Page 55: ...pressure oil 0 The hydraulic system is always under internal pressure When inspecting or replacing piping or hoses always check that the pressure in the hydraulic circuit has been released If the cir...

Page 56: ...bjects such as oil fuel coolant solvent filters and batteries Maintenance of air conditioner 0 If air conditioner refrigerant gets into your eyes it may cause blindness if it touches your skin it may...

Page 57: ...the rim parts do not fit the tire there is a problem with the tire or rim parts Always contact your Komatsu distributor for repairs If the rim parts are not fitted properly when the tire is being pump...

Page 58: ...Precautions with tires SAFETY Precautions when storing tires 2 36...

Page 59: ...OPERATION 23 WARNING Please read and make sure that you understand the safety volume before reading this section...

Page 60: ...OPERATION 3 2...

Page 61: ...3 General view 0 General view of machine 0 1 Bucket 8 Turn signal lamp 2 Tilt lever 9 Head lamp 3 Front wheel 10 Lift cylinder 4 Bucket cylinder 11 Lift arm 5 Front working lamp 12 Rear working lamp...

Page 62: ...itch 6 Hazard lamp switch 21 Attachment selection switch 7 Directional lever 22 Dump speed switch 8 Horn switch 23 E C S S switch 9 Steering wheel 24 Directional selector actuation switch 10 Lamp swit...

Page 63: ...ion lamp 4 Preheating pilot lamp 16 Radiator coolant level caution lamp 5 Directional lever position pilot lamp 17 Maintenance caution lamp 6 HST oil temperature gauge 18 HST oil filter clogging cauti...

Page 64: ...ating the machine To carry out suitable operations correctly and safely it is important to understand fully the methods of operating the equipment and the meanings of the displays Machine monitor 0 A...

Page 65: ...n When the starting switch is turned ON if the directional lever is not at the neutral position the central warning lamp lights up and the alarm buzzer sounds intermittently If this happens return the...

Page 66: ...is warning is given if the cooling water or lubricating oil overheat The central warning lamp on the monitor and the individual caution lamps light up and at the same time the alarm buzzer sounds and...

Page 67: ...warning lamp 0 This display portion 1 lights up if any emergency stop item caution item or mistaken operation of any switch or lever occurs At the same time the alarm buzzer sounds Check the content...

Page 68: ...ay when the starting switch is at the ON position check the display to confirm that there is no abnormality before starting to travel Service meter 0 This meter 1 shows the total time that the machine...

Page 69: ...tributor for repairs REMARK E03 CALL is displayed on the character display and then CHECK RIGHT NOW and E03 CALL are displayed in turn for 3 seconds each E02 If overrun related information is display...

Page 70: ...layed after the space on the right side of the failure code indicates the controller that detected the failure code The failure code and the component causing the failure are displayed on the characte...

Page 71: ...hours have passed the display is no longer given The maintenance caution lamp flashes as the replacement time approaches and after the replacement time has passed it lights up Items for display of fil...

Page 72: ...starting switch at the ON posi tion engine stopped the lamps are lighted up and when the engine is started the lamps go out During operation engine running If the brake oil pressure goes down during o...

Page 73: ...N posi tion engine stopped the lamps are lighted up and when the engine is started the lamps go out During operation engine running If an abnormality occurrs in the charging circuit during opera tion...

Page 74: ...igh so the axle oil temperature caution lamp and central warning lamp light up and the alarm buzzer sounds intermittently At the same time E02 and BRAKE OVERHEAT are displayed on the character display...

Page 75: ...m buzzer sounds intermittently At the same time E02 and HST OVERHEAT are displayed on the character display in turn so stop the machine and run the engine at a midrange speed under no load until the l...

Page 76: ...n the character display Warning limit functions for travel speed 0 When the travel speed goes above 40 0 km h 24 9 MPH the central warning lamp lights up and the alarm buzzer sounds At the same time E...

Page 77: ...ator is low At the same time E01 and COOLANT LOW are displayed on the character display in turn so check the coolant level in the radiator sub tank and add coolant Use a suitable climbing aid for exam...

Page 78: ...lacement see Filter oil replacement time display on page 3 12 After replacing the filter or changing the oil reset time for the replacement For details see Reset method for fil ter oil replacement tim...

Page 79: ...up when the engine preheating electric heater is actuated In cold weather when the starting switch is turned to the ON position this lamp lights up and when the preheating is com pleted it goes out T...

Page 80: ...pilot lamp 0 This lamp 4 indicates the position of the directional lever F lights up FORWARD N lights up NEUTRAL R lights up REVERSE REMARK In the following conditions it indicates the position of the...

Page 81: ...OPERATION Explanation of components Machine monitor 3 23 Head lamp high beam pilot lamp 0 This lamp 7 lights up when the head lamp is at high beam...

Page 82: ...der no load and wait for the indicator to return to the white range A Engine coolant temperature gauge 0 This meter 1 indicates the engine coolant temperature During normal operations the indicator sh...

Page 83: ...s full If the indicator is at the E position it indicates that there is little fuel remaining When the amount of remaining fuel goes below 26 liters 6 87 US gal caution lamp A inside the fuel gauge li...

Page 84: ...cking the total distance that the machine has traveled 1 Check that the character display is showing the service meter or the action code If it is giving any other dis play turn the starting switch OF...

Page 85: ...f replace ment is displayed on the right in turn for 3 seconds each 4 Press the or of monitor panel mode selector switch 2 to display the item filter or oil which has reached the replacement time 5 Pr...

Page 86: ...selector switch 2 and display LGUAGE 3 Press the of machine mode panel selector switch 1 The presently selected language is displayed 4 Press or of monitor panel mode selector switch 2 and select the...

Page 87: ...lector switch 2 and display SELECT HST 3 Press the of monitor mode selector switch 1 The present HST selection is displayed 4 Press the or of monitor mode selector switch 2 and align the cursor with A...

Page 88: ...key at this position while cranking Release the key immediately after the engine has been started The key will return to the ON position when released 1 Starting switch 11 Front working lamp switch 2...

Page 89: ...ERSE Before operating this switch check that the condition is as fol lows Directional lever is at N Directional selector switch actuation switch is at ON If the condition is not as above the switch wi...

Page 90: ...top the machine and lower the work equipment to the ground before operating the E C S S switch When carrying out inspection and maintenance first lower the work equipment to the ground then turn the E...

Page 91: ...gnal lever 0 This switch 8 is used to operate the turn signal lamp a position LEFT TURN Push lever FORWARD b position OFF c position RIGHT TURN Pull lever BACK REMARK When the lever is operated the pi...

Page 92: ...ys turn the working lamp off before traveling on public roads This switch 11 is used to light up the front working lamp Position a Working lamp and pilot lamp A light up Position b Working lamp goes o...

Page 93: ...the next screen or to move the cursor forward or to increase the number when enter ing numerals Position Press here to go back to the previous screen or to move the cursor back or to reduce the number...

Page 94: ...Position a OFF Position b Lights up when the cab door opens Position c Lights up REMARK The room lamp lights up even when the main switch is OFF so when leaving the operator s compartment turn the sw...

Page 95: ...t positioner and fork posi tioner Position a When using the bucket set to this position Position b When using the fork set to this position Dump speed switch 0 Use this switch 21 to select the bucket...

Page 96: ...ORWARD Position N NEUTRAL Position b REVERSE REMARK When the starting switch is turned to the ON position if the directional lever is not at the N position the central warning lamp lights up and the a...

Page 97: ...ver is at the LOCK position the work equipment will not move even when the work equipment control lever is operated Work equipment lever 0 Use this lever 3 to operate the lift arm and bucket NOTICE Do...

Page 98: ...f the brake is used too frequently the brake will overheat If this happens the brakes will not work and may lead to a serious accident Do not put your foot on the brake pedal unless necessary These pe...

Page 99: ...ip of the lever and return the lever to the FREE position At the same time the parking brake pilot lamp will go out REMARK If the directional lever is placed at the FORWARD or REVERSE position with th...

Page 100: ...1 Insert the key into the key slot 2 Turn the key clockwise align the key slot with the match mark on the cap then open the cap To lock the cap 0 1 Turn the cap until tight then insert the key into th...

Page 101: ...rames from articulating Towing pin 0 1 Align protrusion 1 in the towing pin with groove 2 in the counterweight then insert the pin and turn it 180 2 To prevent the towing pin from turning fold the han...

Page 102: ...attaching the door in position lock it firmly to the catch 3 When getting on or off the machine hold the handrail on the inside 4 When closing the door from the operator s seat push knob 2 to release...

Page 103: ...e with another of the same capacity Remove cover 1 The fuse boxes are A and B Fuse capacity and name of circuit 0 Fuse box A 0 AE42081B A Front of machine No Name of circuit 1 20A Starting switch 2 10...

Page 104: ...blow fuse see Section Replace slow blow fuse on page 4 34 Slow blow fuse AE42081B A Front of machine No Name of circuit 1 20A Air conditioner A 2 20A Air conditioner B 3 10A Beacon lamp if equipped 4...

Page 105: ...OPERATION Explanation of components Power outlet 3 47 Power outlet 0 Removing the cigarette lighter 1 allows use of its power The maximum electric current is 7 A 168 W...

Page 106: ...dusty jobsites General locations and function of control panel 0 Fan switch 0 This switch 1 can be used to adjust the air flow to four stages It also acts as the main switch for the air conditioner Wh...

Page 107: ...five vent modes are available FACE FACE FOOT FOOT FOOT DEF DEF When the switch is pressed the indicator lamp above the switch lights up to display the vent mode FRESH RECIRC selector switch 0 This sw...

Page 108: ...e the switch to set the temperature The settings for each mode are retained in memory even when the starting switch is turned OFF However in the following cases the settings must be made again When th...

Page 109: ...al minutes from time to time to prevent the loss of the oil film at various parts of the compressor REMARK If the temperature inside the cab is low the air conditioner may not work In such cases use t...

Page 110: ...as a holder for tools or other small objects Precautions when using 0 Precautions when using the cooling 0 If you smoke when using the air conditioner your eyes may start to itch or burn therefore ve...

Page 111: ...wiper arm 1 to the front check that the wiper blade is hanging free When angling the wiper arm 1 to the front such as when wip ing the glass clean if the wiper arm 1 is angled with the wiper blade 2 l...

Page 112: ...lated around the battery or high temperature engine parts such as the engine muffler or turbocharger Remove all such dirt or flammable material 3 Check for coolant or oil leakage around engine Check t...

Page 113: ...agram on the right Check that there are no loose bolts on the equipment mounting the seat belt to the machine and tighten if necessary Tightening torque 24 5 4 9 N m 2 5 0 5 kgf m 18 1 3 6 lbft If the...

Page 114: ...wear or with stepped type wear Damage Tires with damage which has reached the cords or with cracks in the rubber Tires with cut or pulled cords Tires with peeled separated surface Tires with damaged b...

Page 115: ...through oil filler F 5 If the oil is above the H line open drain valve P at the bot tom of the engine oil pan drain the excess engine oil then check the oil level again 6 If the oil level is correct t...

Page 116: ...r ent portion of dust indicator 1 2 If the red piston has appeared clean or replace the element immediately For details of the method of cleaning the element see Check clean or replace air cleaner ele...

Page 117: ...een the FULL and LOW marks on radiator sub tank 2 If the coolant level is low add coolant through the coolant filler of sub tank 2 to the FULL level 3 After adding coolant tighten the cap securely 4 I...

Page 118: ...lectric wir ing Check also for loose terminals and tighten any loose parts Particularly check the wiring of the battery starting motor and alternator carefully When carrying out checks around the batt...

Page 119: ...starting switch to the ON position and check the fuel level with fuel level gauge G After checking turn the switch back to the OFF position 2 If the level is low open rear grill 1 and add through fill...

Page 120: ...tment 180 mm 7 1 in 10 mm 0 4 in x 18 stages B Adjusting seat angle Move lever 2 up and apply your weight to the rear of the seat The seat will tilt to the rear Move lever 3 up and apply your weight t...

Page 121: ...he upper lumbar region When is pressed Tension becomes stronger When is pressed Tension becomes weaker K Side support Operate switch 10 to give a suitable tension to the left and right lumbar region W...

Page 122: ...is worn or damaged replace it Fasten the seat belt before starting operations Always wear the seat belt during operations Fastening and removing belt 0 1 Sit on the seat hold buckle 2 and tongue 3 wi...

Page 123: ...er 2 and adjust the height of wrist rest 1 Amount of adjustment 60 mm 2 4 in REMARK Keep button 3 pressed and operate lock lever 2 to the FREE position The lever can be turned in the desired direction...

Page 124: ...Check that directional lever 2 is at the N position REMARK If directional lever 2 is not set to the N position the engine will not start When directional selector switch actuation switch 3 is ON the e...

Page 125: ...check that the machine monitor system works When the starting switch is turned to the ON position before starting the engine monitors gauges and central warning lamp light up for approx 3 seconds and...

Page 126: ...NOTICE Do not start the engine with the accelerator pedal fully depressed There is danger that the engine parts may be damaged Do not keep the starting motor rotating continuously for more than 20 sec...

Page 127: ...preheating time sec in cold weather X Water temperature when starting the engine C Y Preheating time sec 2 Depress accelerator pedal 3 lightly 3 After the preheating pilot lamp 2 goes out turn the ke...

Page 128: ...fect the performance and shorten the machine life Be sure to break in the machine for the initial 100 hours as indicated by the service meter During breaking in operations follow the precautions descr...

Page 129: ...t position e should be a maximum of 10 seconds With this operation the oil will reach the relief pressure and this will warm up the hydraulic oil more quickly 4 After carrying out the warming up opera...

Page 130: ...not abruptly stop the engine except for an emergency In particular if the engine has overheated do not abruptly stop it but run it at medium speed to allow it to cool gradu ally then stop it 1 Run the...

Page 131: ...that the area around the machine is safe then sound the horn before starting Do not allow people to get near the machine Clear the machine s travel path of any obstacle Pay particular attention to th...

Page 132: ...to the desired position Position a 1st Position b 2nd Position c 3rd Position d 4th 6 Set directional lever 7 to the desired position Position a FORWARD Position N NEUTRAL Position b REVERSE Check th...

Page 133: ...traveling at high speed When switching between FORWARD and REVERSE depress the brake to reduce the travel speed suffi ciently then change the direction of travel Max speed for changing direction 13 km...

Page 134: ...vel in for ward or reverse according to the operation of the direc tional lever regardless of the position of the directional selector switch 2 Priority is given to the operation of the directional le...

Page 135: ...lever 1 is operated to FORWARD or REVERSE the machine will travel in forward or reverse according to the opera tion of the directional lever regardless of the position of the directional selector swit...

Page 136: ...mov ing until the parking brake pilot lamp lights up so keep the brake pedal depressed NOTICE Never use the parking brake lever to brake the machine when traveling except in an emergency Apply the par...

Page 137: ...inspection Emergency steering 0 CAUTION Never actuate the emergency steering except during emergencies or when checking the function Emergency steering pilot lamp green 2 lights up to inform the oper...

Page 138: ...ion the lever is stopped in this position until the lift arm reaches the preset position of the kickout and the lever is returned to the HOLD position Position b HOLD The lift arm is kept in the same...

Page 139: ...h the control lever 2 forward 3 Check that the lock pins has been removed The lock pin indicators 3 may not be visible 4 Check that the selector control levers 1 are in horizontal position 5 Adjust so...

Page 140: ...of the hook of the attachment 7 Tilt the coupler fuily while driving the machine forward 8 Operate the control lever for the coupler 2 backwards to insent lock pins and lock the attachment in position...

Page 141: ...spurt out and lead to serious injury 1 Lower the work equipment to the ground stop the engine then operate the extra control lever fully 4 or 5 times This will release the pressure inside the hose 2...

Page 142: ...p the tire life will be reduced so do not allow the tires to slip during operation Loading piled soil 0 Scoop up the piled soil by moving the machine forward as shown below If the tires begin slipping...

Page 143: ...should be carried out in 1st gear CAUTION Do not set the bucket facing down more than 20 degrees 1 Set the edge of the bucket facing slightly down 2 Drive the machine forward and operate the work equ...

Page 144: ...oth the ground by moving backward Pushing operation 0 CAUTION Never set the bucket to the DUMP position when carrying out pushing operation When carrying out pushing operations set the bottom of the b...

Page 145: ...r the work equipment is raised the moment that the E C S S switch is turned ON the work equipment will move If operations are carried out with the E C S S switch left at the ON position the moment tha...

Page 146: ...forward to load the dump truck The smaller the turning angle of the wheel loader is the more efficient the operation becomes When loading a full bucket and raising it to the maximum height first shak...

Page 147: ...action to take see AXLE OIL TEMPERATURE CAUTION LAMP on page 3 16 in Explanation of components If engine stops 0 If the engine stops on a slope apply the parking brake immediately and lower the work...

Page 148: ...the bucket so that it automatically stops at the desired dig ging angle The setting can be adjusted to match the working conditions Adjusting boom kickout 0 1 Raise the bucket to the desired height s...

Page 149: ...mity switch 3 4 Adjust nut 1 so that the clearance between bar 2 and the sensing surface of proximity switch 3 is 3 to 5 mm then tighten the nut to hold in position Tightening torque 17 2 2 5 N m 1 75...

Page 150: ...ghtening torque 17 2 2 5 N m 1 75 0 25 kgf m 12 7 1 8 lbft 5 Loosen bolt 4 and adjust so that the tip of protector 5 extends 0 5 to 1 0 mm from the sensing surface of proximity switch 3 then tighten t...

Page 151: ...e suddenly and this may lead to a serious accident Before leaving the operator s compartment always set the safety lock lever securely to the LOCK position Even if the parking brake lever is pulled an...

Page 152: ...e 3 94 3 Pull parking brake lever 4 and set it to the LOCK position 4 Operate work equipment control lever 5 to lower the bucket to the ground 5 Set the safety lock lever 6 to the LOCK position 9EA044...

Page 153: ...ping it Checks after completion of operation 0 1 Walk around the machine and check the work equipment body work and undercarriage and check also for oil and water leakage 2 Fill the fuel tank 3 Check...

Page 154: ...s too low there will be overload if it is too high it will cause tire cuts and shock burst To prevent these problems adjust the tire inflation pressure according to the table on the next page Deflecti...

Page 155: ...f this is not done the tires will be damaged so con tact your Komatsu distributor or tire dealer when selecting tires Tire size Pattern Inflation pressure MPa kgf cm2 PSI Soft ground sandy ground Norm...

Page 156: ...In addition remove any water snow ice grease or oil from the ramps Never change direction on the ramps There is danger that the machine may tip over If it is necessary to change direction return to th...

Page 157: ...oad on firm level ground only Maintain a safe distance from the edge of a road 2 Apply the brakes on the trailer securely and insert blocks under the tires to ensure that the trailer does not move The...

Page 158: ...ver raise the machine with any worker on it Always make sure that the wire rope used for lifting the machine is of ample strength for the weight of the machine Never try to lift the machine at any pos...

Page 159: ...Lifting machine 3 101 Location of lifting position mark 0 Weight table 0 Machine weight Front wheel load Rear wheel load Center of gravity WA250PT 5H 12 450 kg 27 452 lb 5 270 kg 11 620 lb 7 180 kg 15...

Page 160: ...ture For details see Moving the machine on page 3 73 2 Operate the safety lock lever to the LOCK position 3 Stop the engine check that the area around the operator s compartment is safe then lock with...

Page 161: ...e Do not smoke when handling antifreeze NOTICE Never use methanol ethanol or propanol based antifreeze Avoid using any leak preventing agent regardless if it is sold separately or in antifreeze Do not...

Page 162: ...nt temperature drops the capacity of the battery will also drop If the battery charge ratio is low the battery electrolyte may freeze Maintain the battery charge as close as possible to 100 and insula...

Page 163: ...cants on page 4 8 If for any reason permanent antifreeze cannot be used and an ethyl glycol base antifreeze winter one season type is used instead or if no antifreeze is used drain the cooling system...

Page 164: ...and prevent gas poisoning During storage always operate the machine once a month so that a new film of oil will be coated over movable parts and component surfaces At the same time also charge the ba...

Page 165: ...towed only in emergencies If the machine must be moved long distances use a transporter To protect the operator if the towing rope or bar should break install a protector plate to the machine being to...

Page 166: ...does not lubricate the system so remove the front and rear drive shafts If necessary block the tires to prevent the machine from moving 2 The steering cannot be operated so remove the steering cylinde...

Page 167: ...careful If the terminals are loose there is danger that the defective contact may generate sparks that will cause an explosion When removing or installing the terminals check which is the positive ter...

Page 168: ...not charge the battery or start the engine with a different power source There is a hazard that this will ignite the battery electrolyte and cause the battery to explode Starting engine with booster c...

Page 169: ...n 1 Make sure the clips are firmly connected to the battery terminals 2 Start the engine of the normal machine and keep it to run at high idling speed 3 Turn the starting switch of the problem machine...

Page 170: ...nerated from alternator Defective alternator Replace Starting motor does not turn when starting switch is turned to ON Defective wiring Insufficient battery charge Defective starting motor Check repai...

Page 171: ...vice on page 4 39 Carry out warming up operation Oil overheats Too much oil or too little oil Clogged oil cooler core Add or drain oil to specified level See When required on page 4 20 Clean oil coole...

Page 172: ...lacks lifting power Bucket takes time to go up Lack of oil Clogged hydraulic filter Add oil to specified level See Every 100 hours service on page 4 39 Replace cartridge see Every 2000 hours service...

Page 173: ...n Defective monitor Check add cooling water repair see When required on page 4 20 Check repair Change cooling water clean inside of cooling system see When required on page 4 20 Clean or repair see Wh...

Page 174: ...ozzle See defective compression above Combustion noise occasionally makes breathing sound Defective nozzle Replace nozzle Abnormal noise generated com bustion or mechanical Low grade fuel being used O...

Page 175: ...MAINTENANCE 34 WARNING Please read and make sure that you understand the safety volume before reading this section...

Page 176: ...Connect grounding cable within 1m 3 3 ft from the area to be welded If grounding cable is connected near instruments connectors etc the instruments may malfunction If a seal or bearing happen to come...

Page 177: ...t twist them or bend them into loops with a small radius This will cause damage to the hose and markedly reduce its service life Checks after inspection and maintenance 0 If you forget carrying out th...

Page 178: ...w 15 C 5 F It is necessary to use the fuel that is suitable for the temperature To prevent the moisture in the air from condensing and forming water inside the fuel tank always fill the fuel tank afte...

Page 179: ...asurer to measure the quantity of large iron particles in the oil Others Measurements are made of items such as the ratio of water or fuel in the oil and the dynamic viscosity Oil sampling 0 Sampling...

Page 180: ...ic esters for Komatsu machines is permitted For information on the products cleared for use and best suited for your application contact our autho rized service workshops Outline of electric system 0...

Page 181: ...check the latest part number when ordering parts Wear parts list 0 The parts in parentheses are to be replaced at the same time See Part No in Parts Book Item Part No Part Name Q ty Replacement freque...

Page 182: ...based on the service meter read ing Abbreviations EO Engine Oil G Lithium Grease No 2 F Diesel Fuel AXO Axle Oil HO Hydraulic Oil Numbers at the left side of the chart indicate the number of lubricat...

Page 183: ...to 45 C 80W SAE 20W 40 each 18 each 18 or Engine oil EO 30 CCMC D4 or if not available API CD or API CE or API CF 4 0 up to 40 C SAE 30 Axle with limited slip differential 4 Axle oil AXO Shell DONAX T...

Page 184: ...c temperature of lower than 0 C 32 F be sure to use engine oil of SAE10W SAE10W 30 and SAE15W 40 even though the atmospheric temperature goes up to 10 C 50 F more or less during the day Use API classi...

Page 185: ...ar EP Energrease LS EP2 Antifreeze 6 CALTEX RPM delo 400 RPM delo 450 Universal thuban Universal thuban EP Marfak all purpose 2 Ultra duty grease 2 AF engine cool ant 7 CASTROL Turbomax RX super CRD E...

Page 186: ...ing grease Antifreeze and summer coolant 15 PETRO FINE FINA kappa TD FINA potonic N FINA potonic NE FINA marson EPL2 FINA tamidor 16 SHELL Rimura X Spirax EP Spirax heavy duty Albania EP grease 17 SUN...

Page 187: ...flats b mm Tightening torque Target value Service limit N m kgf m lbft N m kgf m lbft 6 8 10 12 14 10 13 17 19 22 13 2 31 66 113 172 1 35 3 2 6 7 11 5 17 5 9 8 23 1 48 5 83 2 126 6 11 8 14 7 27 34 59...

Page 188: ...s b mm Tightening torque Target value Permissible range N m kgf m lbft N m kgf m lbft 9 16 18UNF 19 4 4 4 5 32 5 35 63 3 5 6 5 25 3 47 0 11 16 16UN 22 7 4 7 5 54 2 54 93 5 5 9 5 39 8 68 7 13 16 16UN 2...

Page 189: ...ce them with new ones regardless of their condition after a certain period of usage This is impor tant to ensure that these parts maintain their full performance at all times Furthermore should anythi...

Page 190: ...se 1 6 Steering hose pump priority valve 1 7 Steering hose priority valve orbitrol valve 1 8 Steering hose orbitrol valve steering cylinder 6 9 Steering hose steering cylinder line cushion valve 2 10...

Page 191: ...e air heater 4 31 Replace bolt on cutting edge 4 31 Replace bucket teeth 4 32 Check air conditioner 4 33 Replace slow blow fuse 4 34 Selection and inspection of tires 4 35 Check before starting 0 Chec...

Page 192: ...lic filter element 4 54 Replace hydraulic tank breather element 4 55 Change axle oil 4 56 Replace element in air conditioner recirculation air filter fresh air filter 4 56 Check alternator starting mo...

Page 193: ...s service only after the first 250 hours 0 Carry out the following maintenance only after the first 250 hours Replace HST filter element Replace hydraulic tank filter element For details of the method...

Page 194: ...henever the red piston in dust indicator 1 appears clean the air cleaner element NOTICE Do not clean the air cleaner element before the dust indi cator becomes red If the element is cleaned frequently...

Page 195: ...he inner element at the same time Replace both inner and outer elements when the dust indicator red piston appears soon after installing the cleaned outer element even though it has not been cleaned 6...

Page 196: ...uter element 4 Do not remove inner element 5 at this time however 4 Clean the interior of the air cleaner body cover 3 and evacuator valve 6 5 Remove inner element 5 then install a new inner element i...

Page 197: ...ractor is an optional extra The intake screen and the dust extractor gap at the bottom cir cumference of the pre extractor must always be kept clean The pre extractor should be unscrewed and its condi...

Page 198: ...of antifreeze If for some reason it is impossible to use permanent type antifreeze use an antifreeze containing ethylene glycol Super Coolant AF ACL has an anti corrosion effect as well as an antifree...

Page 199: ...urface by hand then turn radiator cap 1 slowly until it contacts the stopper to release the pressure 4 Following this push radiator cap 1 turn it until it contacts the stopper then remove it 5 Set a c...

Page 200: ...and for another 5 minutes at high adling When doing this leave the radiator cap off 12 After draining off the cooling water of reserve tank 3 clean the inside of the reserve tank and refill the water...

Page 201: ...ine and run it at low idling for at least 5 minutes 2 Open the cap of oil filler port F remove dipstick G and wipe the oil off with a cloth 3 Insert dipstick G fully in the oil filler pipe then take i...

Page 202: ...Front B Rear 1 Stop the engine and remove oil level plug 1 REMARK Remove the mud and dirt from around plug 1 then remove the plug 2 Wipe off any oil adhering to the oil level gauge attached to plug 1...

Page 203: ...e condenser with a steam cleaner There is danger that the condenser could overheat If high pressure water hits your body directly or dirt is sent flying there is danger of personal injury Always wear...

Page 204: ...wear safety glasses dust mask or other protective equipment Clean the radiator or cleaner if mud or dirt is stuck to it 1 Open rear grill 1 2 Move lever 3 of fan guard 2 down to release the lock then...

Page 205: ...NG It is extremely dangerous if the work equipment moves when carrying out the turning or replacement operation Set the work equipment in a stable position stop the engine then set the safety lock lev...

Page 206: ...before they wear down as far as the adapter 1 Raise the bucket to a suitable height then put blocks under the bucket to prevent the bucket from coming down Raise the bucket so that the bottom surface...

Page 207: ...ion window to check the condition of the refrigerant gas Freon R134a flowing in the refrigerant circuit No bubbles in refrigerant flow Suitable Some bubbles in flow bubbles pass continuously Lack of r...

Page 208: ...3 Open covers 1 2 and 3 of the slow blow fuse box Covers 2 and 3 can be removed easily by using protru sion A on the body as a fulcrum and levering the catch of the cover with a flat headed screwdrive...

Page 209: ...hop to carry out the work Do not heat or weld the rim to which the tire is installed Do not make a fire near the tire Selection of tires 0 WARNING Select the tires according to the conditions of use a...

Page 210: ...case be sure to ask a tire repair shop to carry out repairs Be sure to observe the specified inflation pressure Do not adjust the inflation pressure of the tires just after high speed travel or heavy...

Page 211: ...see Check before starting on page 3 57 Check oil level in engine oil pan add oil Check water separator Check dust indicator Check coolant level add water Check inflation pressure of tires Check elect...

Page 212: ...e MAINTENANCE Every 50 hours service 4 38 Every 50 hours service 0 Drain water sediment from fuel tank 0 Loosen valve 1 on the left side of the tank so that the sedi ment and water will be drained tog...

Page 213: ...ir filter 0 WARNING If compressed air is used there is danger that dirt may fly and cause personal injury Always wear safety glasses dust mask and other protec tive equipment If the air conditioner ha...

Page 214: ...then check sight gauge G The oil level should be between the H and L marks NOTICE Do not add oil above the H line This will damage the hydraulic circuit or cause the oil to spurt out If oil has been...

Page 215: ...from freezing Inspect the battery electrolyte level at least once a month and follow the basic safety procedures given below WHEN CHECKING ELECTROLYTE LEVEL FROM SIDE OF BATTERY 0 If it is possible t...

Page 216: ...r also to the other cells Use the diagram below for reference and check if the electrolyte reaches the bottom of the sleeve 4 After adding distilled water tighten cap 1 securely REMARK If distilled wa...

Page 217: ...itioner compressor belt tension adjust 0 Checking 0 1 Open the engine side cover on the left side of the chassis 2 Standard deflection a between air conditioner compressor pulley 1 and fan pulley 2 wh...

Page 218: ...rs ask the Komatsu distributor in your territory to replace the belts with new ones The fan belt has elongated leaving little allowance for adjustment A cut or crack is found on the belt Slipping or c...

Page 219: ...nob 1 remove filter inspection cover 2 then open filter inspection cover 3 2 Pull out filters 4 and 5 in the direction of the arrow 3 Clean with compressed air in the same way as for the fresh air fil...

Page 220: ...out NOTICE On jobsites where there is a lot of heavy duty work or on jobsites where operations are carried out contin uously for more than eight hours reduce the greasing interval and carry out greas...

Page 221: ...yourself 5 Check the drained oil and if there are excessive metal parti cles or foreign material please contact your Komatsu dis tributor 6 Tighten drain plug P 7 Open the engine side cover on the le...

Page 222: ...fuel will leak If the filter cartridge is too loose fuel will also leak from the packing so always tighten to the correct amount 5 When installing screw in cartridge until seal comes in con tact with...

Page 223: ...base and wash strainer 4 then install the strainer to the separator base 9 Coat the threaded portion of ring nut 2 thinly with grease 10 Fill cup 3 with clean fuel install it to the separator base th...

Page 224: ...the oil under drain plug P then remove drain plug P and drain the oil To prevent the oil from pouring out suddenly loosen drain plug P and remove it gradually 2 After draining the oil install drain p...

Page 225: ...lean transfer case breather 0 1 Remove cover 1 2 Remove the mud and dirt from around the breather 2 then remove breather 2 After removing the breather take steps to prevent dirt or dust from entering...

Page 226: ...nk add oil on page 4 40 6 Run the engine at low idling and extend and retract the steering bucket and lift arm cylinders 4 to 5 times Be careful not to operate the cylinder to the end of its stroke st...

Page 227: ...lace Check tightening parts of turbocharger 0 Please contact your Komatsu distributor to have the tightening portions checked Check play of turbocharger rotor 0 Please contact your Komatsu distributor...

Page 228: ...l or coat thinly with grease and install When installing the seal tighten it until its surface comes to contact with the filter holder then tighten it 1 3 turn more 8 Add hydraulic oil through the fil...

Page 229: ...r the temperature to go down before starting the work When removing the oil filler cap turn it slowly to release the internal pressure then remove it 1 Remove cover 1 2 Loosen bolt 2 at the top of the...

Page 230: ...lubricating oil is different so always use the specified lubricating oil 5 After adding oil check that the oil is at the specified level For details see Check axle oil level add oil on page 4 28 REMAR...

Page 231: ...If the inspection gauge can be inserted into the tooth por tion the disc has reached the wear limit Please ask your Komatsu distributor to carry out the replacement 4 After checking install check plug...

Page 232: ...grease through the grease fittings marked by the arrows 2 After greasing wipe off any old grease that was pushed out 1 Front drive shaft 2 places 2 Rear drive shaft 2 places 3 Drive shaft spline 1 pl...

Page 233: ...TECHNICAL DATA 45...

Page 234: ...when shaking bucket mm ft in 5 400 17 9 D Overall width mm ft in 2 470 8 1 E Min ground clearance mm ft in 465 1 6 F Bucket width mm ft in 2 560 8 5 G Clearance Cutting edge mm ft in 2 730 8 11 H Rea...

Page 235: ...TECHNICAL DATA Technical data 5 3...

Page 236: ...have an influence on the noise emission levels Vibration level 0 When used for its intended purpose levels of vibration for the earthworking machine transmitted from the operator s seat are lower or...

Page 237: ...ATTACHMENTS OPTIONS 56 WARNING Please read and make sure that you understand the safety volume before reading this section...

Page 238: ...on type cutting edge The displayed travel speed changes according to the tire size so when installing optional tires please contact your Komatsu distributor Type of work Bucket Ground conditions Tire...

Page 239: ...lever is stopped in this position until the lift arm reaches the preset position of the kickout and the lever is returned to the HOLD position Position b HOLD The lift arm and fork stop and remain in...

Page 240: ...ll off or the machine will tilt The fork tilt angle differs according to the load If loads are stacked on top of each other and the tilt angle is excessive there is danger that the top load will exten...

Page 241: ...l extend over the backrest of the carriage and slip to the rear Normally keep the load near the ground surface when transporting If the load must be transported when raised be extremely careful when o...

Page 242: ...ading 0 1 Set several inches above the position of the stacked load 2 Drive slowly forward to the stacking point with the forks hor izontal 3 Lower the load 4 Drive the machine slowly in reverse and r...

Page 243: ...When the lift arm control lever is pulled further from the RAISE position the lever is stopped in this position until the lift arm reaches the preset position of the kickout and the lever is returned...

Page 244: ...lever 0 When multi purpose bucket is installed This lever 3 operates the clam on the multi purpose bucket Position a Clam closes Position b HOLD The clam stops and remains in the same position Positi...

Page 245: ...ector switch is actuated Position b OFF The directional selector switch is turned off REMARK Turn this switch ON when the directional lever and directional selector switch are at the neutral position...

Page 246: ...ress the brake to reduce the travel speed suffi ciently then change the direction of travel Max speed for changing direction 13 km h 8 1 MPH When the directional selector switch actuation switch 3 is...

Page 247: ...tch actuation switch 3 is at the ON position if the directional lever 1 is operated to FORWARD or REVERSE the machine will travel in forward or reverse according to the opera tion of the directional l...

Page 248: ...lubrication is taking place To eliminate the malfunction contact your Komatsu dealer Display and control unit 0 The display and control unit is protected by a transparent plastic cover against splashi...

Page 249: ...r Greasing time 8 minutes Changes are written to the memory and the LED indicators extinguish 9 Press for more than 2s 000 in display flashes Automatically indicates first parameter Example Pause in t...

Page 250: ...Central lubrication system ATTACHMENTS OPTIONS 6 14...

Page 251: ...INDEX 67...

Page 252: ...INDEX 7 2...

Page 253: ...95 Long term storage 3 106 After storage 3 106 Before storage 3 106 During storage 3 106 Lubricants Selection 4 9 Use 4 8 M Machine serial No plate and position 1 7 Maintenance Guide 4 2 Schedule char...

Page 254: ...Noise emission levels 5 4 Vibration level 5 4 Tires 3 96 Selecting 6 2 Torques List 4 13 Standard tightening 4 13 Towing pin 3 43 Traction control 3 32 Transportation 3 98 Procedure 3 98 Troubleshooti...

Page 255: ...Index 7 5...

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Komatsu WA250PT-5H, Operation & Maintenance Manual

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