Page 1 NOTE Komatsu has had the operating and maintenance instructions translated into all the languages of the European Union. Should you require a copy in another language please inquire...
Page 3 FOREWORD...
Page 4 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.
Page 5 FOREWORD Foreword EU Directives Machines supplied by us fulfil the Directive for Machinery 89/392/EEC and its supplements. If the machine is being used in another country, it is possible that certain safety regulations and specifications may not be fulfilled for use in that country.
Page 6: Safety Information
FOREWORD Safety information 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 situa- tions.
Page 7 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.
Page 8: Introduction
FOREWORD Introduction Directions of machine Introduction This Komatsu machine is designed to be used mainly for the following work: Digging work Smoothing Pushing work Loading work For details of the operating procedure, see “Work possible using wheel loader on page 3-84“.
Page 9: Necessary Information
Necessary information Machine serial No. plate and position 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.
Page 10: Position Of Service Meter
FOREWORD Necessary information Position of service meter 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...
Page 11: Table Of Contents
Table to enter serial No. and distributor......................1-8 Contents................................1-9 ..................................1-9 Dimensions, weights and operating data ....................... 1-15 WA250PT-5H: Dimensions, weights and operating data................1-15 CE-conforming equipment ..........................1-16 CE-conforming equipment ..........................1-16 Manufacturer-supplied CE-conforming equipment, according to document 421-93-H1900 ......1-17 SAFETY Safety labels ................................
Page 12: Contents
FOREWORD Contents Character display portion .......................... 3-10 Emergency stop item ..........................3-14 Caution items ............................3-16 Warning/limit functions for travel speed ....................3-18 Inspection and maintenance item ......................3-19 Pilot display portion........................... 3-21 Meter display portion..........................3-24 Other functions of machine monitor ......................3-26 Switches.................................
Page 13 FOREWORD Contents If wheel brake does not work ........................3-89 Precautions when driving up or down slopes.................... 3-89 Adjusting work equipment posture......................... 3-90 Adjusting boom kickout ..........................3-90 Adjusting bucket positioner ........................3-91 Adjusting fork positioner..........................3-92 Bucket level indicator ..........................3-92 Parking machine ............................
Page 14 Contents Fuel ................................4-4 Coolant................................ 4-4 Grease ................................ 4-4 Carrying out KOWA (Komatsu Oil Wear Analysis) ..................4-5 Storing oil and fuel ............................4-5 Filters ................................4-6 Biodegradable hydraulic oil and lubricants ....................4-6 Outline of electric system ..........................4-6 Wear parts................................
Page 15 FOREWORD Contents Replace HST oil filter element ........................4-52 Lubricating ..............................4-53 Check tightening parts of turbocharger..................... 4-53 Check play of turbocharger rotor ......................4-53 Check alternator driving belt tension and replacement................4-53 Every 2000 hours service ..........................4-54 Change oil in hydraulic tank, replace hydraulic filter element ..............4-54 Replace hydraulic tank breather element ....................
Page 16 FOREWORD Contents 1-14...
Page 17: Dimensions, Weights And Operating Data
FOREWORD Dimensions, weights and operating data WA250PT-5H: Dimensions, weights and operating data Dimensions, weights and operating data WA250PT-5H: Dimensions, weights and operating data WA250PT-Abm Measurements, operating data Bucket capacity to ISO 7546 m³ Material density t/m³ Bucket weight without teeth Static tipping load, straight 8.672...
Page 18: Ce-Conforming Equipment
FOREWORD CE-conforming equipment CE-conforming equipment CE-conforming equipment CE-conforming equipment CE-conforming equipment – Load Hydraulic Volume Weight Type Part No. Capacity pressure m³ 418-70-H2710 418-70-H2700 Bucket WA250PT-5H 418-70-H2720 1004 418-70-H2850 GK100392 1-16...
Page 19: Manufacturer-Supplied Ce-Conforming Equipment, According To Document 421-93-H1900
FOREWORD CE-conforming equipment Manufacturer-supplied CE-conforming equipment, according to document 421-93-H1900 Manufacturer-supplied CE-conforming equipment, according to document 421-93-H1900 The responsibility for observing valid regulations in the case of wheel loaders with "interchangeable equipment" (e.g. bucket or fork-lift) which was not supplied from works lies with the cus- tomer which was subsequently fitted to the machine.
Page 20 FOREWORD CE-conforming equipment Manufacturer-supplied CE-conforming equipment, according to document 421-93-H1900 1-18...
Page 21 FOREWORD CE-conforming equipment Manufacturer-supplied CE-conforming equipment, according to document 421-93-H1900 Manufacturer-supplied CE-conforming equipment, according to document 421-93-H1900 WA250PT-5H 421-93-H1900 A1 Distance: bucket pivoting point - front axle, horizontal 2.184 A2 Distance: bucket pivoting point - front axle, vertical 1.960 Sh Distance: road level - front axle...
Page 22 FOREWORD CE-conforming equipment Manufacturer-supplied CE-conforming equipment, according to document 421-93-H1900 1-20...
Page 23: Safety
SAFETY 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 strictly.
Page 24 SAFETY...
Page 25: Safety Labels
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.
Page 26: Presentation Of Safety Labels
Precautions when traveling in reverse Use Komatsu oil only (421-93-H1360) (421-93-H1390) Sign indicates to pre- vere severe injury or death Honk to alert people nearby.
Page 27 SAFETY Safety labels Presentation of safety labels Do not enter (421-93-H1320) Precautions for safety bar (421-93-H1330) Sign indicates a crush Sign indicates a crush hazard between the hazard between the articulating parts of the articulating parts of vehicle. vehicle. Keep away from the Lock vehicle with lock vehicle when it is bar to avoid movement...
Page 28 SAFETY Safety labels Presentation of safety labels Do not climb on fender (421-93-H1400) Do not open when engine is running (09667-A0880) Sign indicates a hazard Sign indicates a hazard of falling. of rotating parts, such as belt. Do not stand on this Turn off engine before place here.
Page 29: General Precautions
SAFETY General precautions Safety rules General precautions Safety rules Only trained and authorized personnel can operate and maintain the machine. Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine. If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may be severly impaired putting yourself and everyone else on your jobsite in danger.
Page 30 SAFETY General precautions Safety rules Safety features Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if they are damaged. Understand the method of use of safety features and use them properly. Never remove any safety features.
Page 31 SAFETY General precautions Safety rules Always apply lock when leaving operator’s seat Before standing up from the operator's seat (such as when adjusting the operator's seat), always lower the work equip- ment completely to the ground, set safety lock lever (1) to Free the LOCK position, pull parking brake lever (2) to the LOCK position, then stop the engine.
Page 32 SAFETY General precautions Safety rules Handrails and steps To prevent personal injury caused by slipping or falling off the machine, always do as follows. Use the handrails and steps marked by arrows in the dia- gram on the right when getting on or off the machine. To ensure safety, always face the machine and maintain three-point contact (both feet and one hand, or both hands and one foot) with the handrails and steps to ensure that...
Page 33 SAFETY General precautions Safety rules Mounting and dismounting Never jump on or off the machine. Never get on or off a moving machine. If the machine starts to move when there is no operator on the machine, do not jump on to the machine and try to stop it.
Page 34 SAFETY General precautions Safety rules Fire prevention Fire caused by fuel or oil Fuel, oil, antifreeze, and window washer liquid are particu- larly flammable and can be hazardous. To prevent fire, always observe the following: Do not smoke or use any flame near fuel or oil. Stop the engine before refueling.
Page 35 Any modification made without authorization from Komatsu can create hazards. Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting from modifications made without authorization from Komatsu.
Page 36 SAFETY General precautions Safety rules Working on loose ground Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine, there is a hazard that the machine may fall or tip over.
Page 37 This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts. Gas, dust, and inflammable vapours Do not operate combustion engines in an environment that may contain inflammable gases or vapours. These gases, dusts, or vapours may ignite or be sucked in by the suction system, thus causing a rise in engine speed or an exceeding of the engine's maximum rpm.
Page 38: Precautions For Operation
SAFETY Precautions for operation Starting engine Precautions for operation Starting engine If there is a warning tag hanging from the work equipment con- trol lever, do not start the engine or touch the levers. 9JA04836-1 Checks before starting engine Carry out the following checks before starting the engine at the beginning of the day's work. Remove all dirt from the surface of the window glass to ensure a good view.
Page 39: Operation
SAFETY Precautions for operation Operation Operation Checks before operation When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate slowly. Do not allow anyone near the machine. Always fasten your seat belt. Check the operation of travel, steering and brake systems, and work equipment control system.
Page 40 If you are going to travel continuously, please consult your Komatsu distributor. Height limitation When working in areas with height limitations, e.g. in tunnels, beneath bridges or power transmission lines, or in garages, pay attention that the work unit does not touch or damage these facilities.
Page 41 SAFETY Precautions for operation Operation Traveling on slopes To prevent the machine from tipping over or slipping to the side, always do as follows: When traveling on slopes, keep the bucket at height “A“ of approximately 20 to 30 cm (8 to 12 in) above the ground. In case of emergency, quickly lower the bucket to the ground to help the machine to stop.
Page 42 SAFETY Precautions for operation Operation Prohibited operations It is dangerous to excavate the bottom of a rock face. Never do this. It is dangerous to use the bucket or lift arm for crane opera- tions, so do not carry out such operations. Do not pass the bucket over the head of other workers or over the operator's seat of dump trucks or other hauling equipment.
Page 43 SAFETY Precautions for operation Operation Precautions when operating When using the machine, to prevent the machine from overturning due to overloading and to avoid damage to the work equipment, do not exceed the maximum permitted load or performance of the machine. If the engine cannot be started again after it has stopped, immediately operate the work equipment control levers to lower the work equipment to the ground.
Page 44 SAFETY Precautions for operation Operation Operate carefully on snow Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the machine, and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be particularly careful when working on slopes.
Page 45 SAFETY Precautions for operation Operation Parking machine Park the machine on firm, level ground. Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low. Lower the work equipment completely to the ground. When leaving the machine, set safety lock lever (1) to the LOCK position, pull parking brake lever (2) to the LOCK position, then stop the engine.
Page 46: Transportation
Transportation Transportation The machine can be divided into parts for transportation, so when transportating the machine, please contact your Komatsu distributor to have the work carried out. Loading and unloading When loading or unloading the machine, mistaken operation may bring the hazard of the machine tipping over or falling, so particular care is necessary.
Page 47: Battery
SAFETY Precautions for operation Battery Battery Battery hazard prevention Battery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode. Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions: Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line.
Page 48 SAFETY Precautions for operation Battery Starting with booster cables If any mistake is made in the method of connecting the booster cables, it may cause the battery to explode, so always do as follows: When starting with a booster cable, carry out the starting operation with two workers (one worker sitting in the opera- tor's seat and the other working with the battery).
Page 49: Towing
SAFETY Precautions for operation Towing Towing When towing Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selec- tion or inspection of the wire rope. For towing, see “Towing the machine on page 3-107“. Always wear leather gloves when handling wire rope.
Page 50: Precautions For Maintenance
SAFETY Precautions for maintenance Safety instructions Precautions for maintenance Safety instructions Warning tag Always attach the “DO NOT OPERATE“ warning tag to the work equipment control lever in the operator's cab to alert others that you are performing service or maintenance on the machine.
Page 51 SAFETY Precautions for maintenance Safety instructions Maintenance with engine running Stop the machine on firm, level ground. Select a place where there is no hazard of falling rocks or landslides, or of flooding if the land is low. Lower the work equipment completely to the ground and stop the engine.
Page 52 SAFETY Precautions for maintenance Safety instructions Two workers for maintenance when engine is running To prevent injury, do not carry out maintenance with the engine running. If maintenance must be carried out with the engine running, carry out the operation with at least two workers and do as follows: One worker must always sit in the operator's seat and be ready to stop the engine at any time.
Page 53 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 released. Please contact your Komatsu distributor to have this work performed. Personnel Only authorized personnel can service and repair the machine.
Page 54 SAFETY Precautions for maintenance Safety instructions Working under the raised boom WARNING Danger of injury! The raised boom may suddenly fall! For safety reasons, a raised boom must be secured against dropping before you pass or stand under it. The boom must be secured against moving if any work is to be carried out under it when it is in a raised position.
Page 55 SAFETY Precautions for maintenance Safety instructions Precautions when using hammer When using a hammer, pins may fly out or metal particles may be scattered. This may lead to serious injury. Always do as follows. If hard metal parts such as pins, bucket teeth, cutting edges, or bearings are hit with a hammer, there is a hazard that pieces might be scattered and cause injury.
Page 56 If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are found, stop operations immediately and contact your Komatsu distributor. Replace all hoses every six years at the latest. The shelf life of the hose should not exceed 2 years.
Page 57: Precautions With Tires
To maintain safety, always do as follows: Maintenance, disassembly, repair, and assembly of the tires and rims requires special equipment and special technol- ogy, so always ask your Komatsu distributor to carry out these operations. Always use the tires specified by Komatsu and maintain the specified inflation pressure.
Page 58 SAFETY Precautions with tires Precautions when storing tires 2-36...
Page 59: Operation
OPERATION WARNING Please read and make sure that you understand the safety volume before reading this section.
Page 60 OPERATION...
Page 61: General View
OPERATION General view General view of machine General view General view of machine (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 (6) ROPS cab (13) Rear combination lamp...
Page 62: General View Of Controls And Gauges
OPERATION General view General view of controls and gauges General view of controls and gauges (1) Parking brake lever (16) Auxiliary control lever (2) Rear wiper switch (17) Variable shift control switch (3) Front wiper switch (18) Speed range selector switch (4) Front working lamp switch (19) Start switch (5) Rear working lamp switch...
Page 63 OPERATION General view General view of controls and gauges Machine monitor (1) Pilot lamp for speed range selector switch position (13) Brake oil pressure caution lamp (2) Steering oil pressure caution lamp (14) Parking brake reminder caution lamp (3) Emergency steering pilot lamp (15) Axle oil temperature caution lamp (4) Preheating pilot lamp (16) Radiator coolant level caution lamp...
Page 64: Explanation Of Components
OPERATION Explanation of components Machine monitor Explanation of components The following is an explanation of the devices needed for operating 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.
Page 65: Monitor System
Lamps (2) go out after the engine starts. If any lamps do not light up there is probably a failure or a disconnection, so please ask your Komatsu distributor to carry out inspection. 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.
Page 66: Types Of Warning
OPERATION Explanation of components Machine monitor Types of warning If an abnormality occurs on the machine, or if any switch or lever is operated accidently, the monitor display and buzzer give a warning to inform the operator. Following are the types of warning depending on the level of danger.
Page 67: Central Warning Lamp
OPERATION Explanation of components Machine monitor Central warning lamp 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 of the display and carry out the specified action for the item.
Page 68: Character Display Portion
When the starting switch is at the OFF position, if the service meter is displayed even though the top ( ) of monitor panel mode selector switch 1 is not being pressed, there is probably a failure in the machine, so please contact your Komatsu distributor for inspection. 3-10...
Page 69 “Failure code display on page 3-12“. Inform your Komatsu distributor of the failure code and ask for repairs. If there is a failure on the machine, or it is necessary to change the method of operation, or if inspection or mainte- nance must be carried out, action code E00, E01, E02, or E03 is displayed on the character display in display por- tion (3).
Page 70 If an action code is displayed on the character display, check the failure code according to the failure code display method given below. When contacting your Komatsu distributor to request repairs, please inform your distributor of the failure code. Method of displaying failure code 1.
Page 71 OPERATION Explanation of components Machine monitor REMARK The ID number and item name of the item needing replacement are displayed on the character display, and then the remaining time to replacement and the number of times of replacement are displayed in turn for 3 seconds each.
Page 72: Emergency Stop Item
OPERATION Explanation of components Machine monitor Emergency stop item CAUTION If these lamps light up and the buzzer sounds, stop operations immediately and carry out inspection and maintenance of the applicable location. If any abnormality is found in the emergency stop items, the alarm buzzer will sound intermittently, and the lamp for the location of the abnormality and the central warning lamp will light up.
Page 73 OPERATION Explanation of components Machine monitor Engine oil pressure caution lamp This lamp (2) lights up to warn the operator that the engine lubricating oil pressure has dropped. During checks before starting (starting switch at the ON posi- tion, engine stopped) the lamps are lighted up, and when the engine is started, the lamps go out.
Page 74: Caution Items
OPERATION Explanation of components Machine monitor Caution items CAUTION If these lamps light up, stop operations quickly and carry out the following action. (1) Axle oil temperature caution lamp (4) Hydraulic oil temperature caution lamp (2) Torque converter oil temperature caution lamp (5) Fuel level caution lamp (3) Engine cooling water temperature caution lamp AXLE OIL TEMPERATURE CAUTION LAMP...
Page 75 OPERATION Explanation of components Machine monitor Parking brake reminder caution lamp This lamp (2) lights up when engine is stopped but the parking brake is not applied. At the same time, the central warning lamp lights up and the alarm buzzer sounds intermittently. When the parking brake is applied, the lamp goes out and the buzzer stops.
Page 76: Warning/Limit Functions For Travel Speed
OPERATION Explanation of components Machine monitor Fuel level caution lamp This monitor (5) lights up if the amount of fuel remaining in the fuel tank goes below 26 liters (6.87 US gal). If it lights up, check and add fuel as soon as possible. REMARK Even if the caution lamp lights up, action code “E02“...
Page 77: Inspection And Maintenance Item
OPERATION Explanation of components Machine monitor Inspection and maintenance item CAUTION If these lamps light up, stop operations quickly and carry out the following action. (1) Radiator water level caution lamp (3) HST oil filter clogging caution lamp (2) Maintenance caution lamp Radiator coolant level caution lamp This lamp (1) lights up to warn the operator that the coolant level in the radiator has gone down.
Page 78 OPERATION Explanation of components Machine monitor Maintenance caution lamp CAUTION If the caution lamp lights up, repair the problem as soon as possible. If this is left as it is, it will lead to fail- ure. When the time for filter and oil change is reached, this monitor (2) flashes or lights up for approx.
Page 79: Pilot Display Portion
OPERATION Explanation of components Machine monitor Pilot display portion When the starting switch is ON, the pilot display lights up when the display items are functioning. (1) Parking brake pilot lamp (5) Pilot lamp for speed range selector switch position (2) Preheating pilot lamp (6) Turn signal pilot lamp (3) Emergency steering pilot lamp...
Page 80 OPERATION Explanation of components Machine monitor Emergency steering pilot lamp (Green) If this lamp (3) lights up when the engine is running or when the machine is operating, it indicates that the condition is normal. If it does not light up, an abnormality has occurred in the emer- gency steering circuit.
Page 81 OPERATION Explanation of components Machine monitor Head lamp high beam pilot lamp This lamp (7) lights up when the head lamp is at high beam. 3-23...
Page 82: Meter Display Portion
OPERATION Explanation of components Machine monitor Meter display portion (1) HST oil temperature gauge (4) Speedometer (2) Engine coolant temperature gauge (5) Meter display pilot lamp (3) Fuel gauge HST oil temperature gauge This meter (1) indicates the HST oil temperature. During normal operations, the indicator should be in the white range (A).
Page 83 OPERATION Explanation of components Machine monitor Fuel gauge This meter (3) indicates the amount of fuel remaining in the fuel tank. If the indicator is at the F position, it indicates that the tank is full. If the indicator is at the E position, it indicates that there is little fuel remaining.
Page 84: Other Functions Of Machine Monitor
OPERATION Explanation of components Machine monitor Other functions of machine monitor The machine monitor also has the following functions: Odometer, filter/oil replacement time reset, language selec- tion, HST selector function. Method of displaying odometer Use this when checking the total distance that the machine has traveled. 1.
Page 85 OPERATION Explanation of components Machine monitor Reset method for filter, oil replacement time The filter and oil replacement time is displayed on the character display, so if the filter and oil have been replaced, reset the filter and oil change time. 1.
Page 86 OPERATION Explanation of components Machine monitor Method for selecting language Use this when switching the language displayed on the character display. The following explanation is for when English is set as the language for the character display. 1. Press the ( ) of monitor panel mode selector switch 1, and display the odometer. 2.
Page 87 OPERATION Explanation of components Machine monitor Method of selecting HST changing function When the speed range selector switch is in 3rd or 4th position, there are two selections available for the HST. Use this when changing the selection. Speed range selector switch position Function 3rd position 4th position...
Page 88: Switches
OPERATION Explanation of components Switches Switches (1) Starting switch (11) Front working lamp switch (2) Speed range selector switch (12) Rear working lamp switch (3) Variable shift control switch (13) Monitor panel mode selector swiitch 1 (4) Directional selector switch (14) Monitor panel mode selector swiitch 2 (5) Directional selector actuation switch (15) Front wiper switch...
Page 89 OPERATION Explanation of components Switches Speed range selector switch Use this switch (2) to switch the speed range. Use 1st and 2nd for operations, and 3rd and 4th for travel. Position (a): 1st Position (b): 2nd Position (c): 3rd Position (d): 4th Variable shift control switch When the speed range is in 1st, it is possible to use this dial (3) to set the maximum speed as desired.
Page 90 OPERATION Explanation of components Switches Switch for traction control The traction control is switched on by means of this switch (6). When the traction control is on, the drive force that is trans- ferred to the wheels is reduced in the 2nd to 4th gears. Position (ON): ON Position (OFF): OFF Reduction...
Page 91 OPERATION Explanation of components Switches Lamp switch This switch (8) is used to light up the front lamps, side clear- ance lamps, tail lamps, and instrument panel. Position (a): OFF Lamps go out. Position (b): Side clearance lamps, tail lamps, and instrument panel light up.
Page 92 OPERATION Explanation of components Switches Hazard lamp switch WARNING Use the hazard lamp only in emergencies. Using the hazard lamp when traveling may cause confusion for other machine operators. This switch (10) is used in emergencies, such as when the machine breaks down and has to be parked on the road.
Page 93 OPERATION Explanation of components Switches Monitor panel mode selector switch 1 This switch (13) is used to switch the function of the character display. When the switch is released, it automatically returns to its origi- nal position. The basic operation is as follows. Position ( ): Press here to select (confirm) each mode or operation.
Page 94 OPERATION Explanation of components Switches Cigarette lighter This is used to light cigarettes. After cigarette lighter (17) is pushed in, it will return to its origi- nal position after a few seconds, then you may pull it out and light a cigarette. Room lamp switch The switch (18) is used to turn the room lamp ON and OFF.
Page 95 OPERATION Explanation of components Switches Attachment selection switch This switch (20) switches the bucket 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 Use this switch (21) to select the bucket dump speed.
Page 96: Control Levers, Pedals
OPERATION Explanation of components Control levers, pedals Control levers, pedals (1) Directional lever (5) Brake pedal (2) Safety lock lever (for work equipment lever) (6) Accelerator pedal (3) Work equipment lever (7) Parking brake lever (4) Auxiliary control lever DIRECTIONAL LEVER This lever (1) is used to switch the direction of travel of the machine between forward and reverse.
Page 97 OPERATION Explanation of components Control levers, pedals Safety lock lever (for work equipment lever) WARNING Before leaving the operator's seat, set the safety lock lever securely to the LOCK position. If the safety lock lever is not at the LOCK position, and work equipment control lever is touched by mistake, it may lead to a serious accident.
Page 98 OPERATION Explanation of components Control levers, pedals Auxiliary control lever (When multi-purpose bucket is installed) This lever (4) operates the clam on the multi-purpose bucket. Position (a): Clam closes Position (b): HOLD The clam stops and remains in the same position. Position (c): Clam opens Brake pedal WARNING...
Page 99: Steering Tilt Lock Lever
If the parking brake has been used as an emergency brake when traveling at high speed (near the max- imum speed), contact your Komatsu distributor to have the parking brake checked for any abnormality. This lever (7) operates the parking brake.
Page 100: Cap And Cover With Lock
OPERATION Explanation of components Cap and cover with lock Cap and cover with lock Use the starting key to open and close the locks on the caps and covers. For details of the locations of the caps and covers with locks, see “Locking on page 3-95“.
Page 101: Safety Bar
OPERATION Explanation of components Safety bar Safety bar WARNING When carrying out maintenance or transporting the machine, always set the safety bar to the LOCK position. Always remove the safety bar for travel operations. If it is not removed, the steering wheel cannot be used for steering, and this may lead to serious damage or injury.
Page 102: Cab Door Inner Lock
OPERATION Explanation of components Cab door inner lock Cab door inner lock (Right door) Press cab door inner lock to lock the door. Position (a): Lock Position (b): Release Cab door open lock When getting in or out of the operator's compartment, or when operating with the door open, use this lock to hold the door in position.
Page 103: Fuse
OPERATION Explanation of components Fuse Fuse NOTICE Before replacing a fuse, be sure to turn off the starting switch. The fuses protect the electrical equipment and wiring from burning out. If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse.
Page 104: Slow Blow Fuse
OPERATION Explanation of components Slow blow fuse Fuse box B Name of circuit Air conditioner A Air conditioner B Beacon lamp (if equipped) KOMTRAX Load meter (if equipped) D/C converter Auxiliary pwr (Key on +24V) Parking brake B Horn (10) Side marker lamp L.H.
Page 105: Power Outlet
OPERATION Explanation of components Power outlet Power outlet Removing the cigarette lighter (1) allows use of its power. The maximum electric current is 7 A (168 W). 3-47...
Page 106: Air Conditioner
OPERATION Explanation of components Air conditioner Air conditioner By taking fresh air into the cab through a filter, it is possible to raise the pressure inside the cab. This makes it pos- sible to provide a pleasant working environment even on dusty jobsites. General locations and function of control panel (1) Fan switch (4) FRESH/RECIRC switch...
Page 107 OPERATION Explanation of components Air conditioner Air conditioner switch This switch (2) is used to start or stop the cooling or dehumidi- fying function. When the fan switch is turned ON and the air conditioner switch is pressed, the indicator lamp above the switch lights up. When the switch is pressed again, the switch is turned OFF and the indicator lamp goes out.
Page 108 OPERATION Explanation of components Air conditioner Temperature control switch The temperature can be adjusted with this switch (5) by press- ing and holding the up or down button. The temperature level indicator lamps (A) light up to display the temperature of the air coming from the vents. The more blue lamps on, the lower the temperature is.
Page 109: Method Of Operation
OPERATION Explanation of components Air conditioner Method of operation Switchs Air conditioner Temperature FRESH/RECIRC Mode selector Fan switch switch control switch selector switch switch Condition of use Rapid All blue RECIRC FACE Cooling More than half Normal HI - LO FRESH FACE are blue...
Page 110: Precautions When Using
OPERATION Explanation of components Air conditioner Cool box When the cooling is being used, this can be used for keeping drinks and other things cool. When the heating is being used, it can be used to keep things warm. When using the box, open the vent grill (1). When not using the box, close the grill (1).
Page 111: Handling Cab Wiper
OPERATION Explanation of components Handling cab wiper Handling cab wiper Preventing damage to wiper arm bracket NOTICE When angling the 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) locked to the arm (the bottom of the blade is caught on the arm), abnormal force is brought to bear on the mounting...
Page 112: Operation
Leakage of fuel or oil will cause the machine to catch fire. Check carefully, and be sure to repair any abnormalities, or please contact your Komatsu distributor. Always carry out the items in this section before starting the engine each day.
Page 113 OPERATION Operation Check before starting engine, adjust 11.Check for damage to seat belt and mounting clamps. REMARK The date of manufacture of the seat belt is marked on the belt at the place indicated by the arrow in the diagram on the right.
Page 114 OPERATION Operation Check before starting engine, adjust 13.Inspect tires. WARNING If worn or damaged tires are used, they may burst and cause serious injury or death. To ensure safety, do not use the following tires. Wear: Cord Tires with a tread groove of less than 15% of that of a new tire.
Page 115: Check Before Starting
OPERATION Operation Check before starting engine, adjust Check before starting Always carry out the items in this section before starting the engine each day. Check oil level in engine oil pan, add oil WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause serious burns.
Page 116 OPERATION Operation Check before starting engine, adjust Check dust indicator 1. Check that the red piston has not appeared in the transpar- ent portion of dust indicator (1). 2. If the red piston has appeared, clean or replace the element immediately.
Page 117 OPERATION Operation Check before starting engine, adjust Check coolant level, add coolant WARNING Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to cool down and check the sub tank. Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure.
Page 118 If fuses are frequently blown or if there are traces of short-circuiting on the electrical wiring, promptly ask your Komatsu distributor to locate the cause and make the repair. Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap to clear the breather hole.
Page 119 Komatsu distributor for adjustment. Check brake pedal Drive the machine forward and check the effect of the brakes. If there is any abnormality in the actuation of the brakes, please contact your Komatsu distributor to have the brakes adjusted. 3-61...
Page 120: Adjustment
OPERATION Operation Check before starting engine, adjust Adjustment Seat adjustment WARNING When adjusting the position of the operator's seat, always set the safety lock lever to the LOCK position to prevent any accidental contact to the control levers. Always adjust the operator's seat before starting each operation or when the operators change shift. When adjusting the seat, put your back against the backrest and adjust to a position where the brake pedal can be fully depressed.
Page 121 OPERATION Operation Check before starting engine, adjust Rear tilt: 40 degrees (2 degrees x 20 stages) (G) Adjusting headrest angle (option) Rotate the headrest to the front or rear. Amount of adjustment: Front tilt: 13 degrees Rear tilt: 13 degrees (H) Adjusting headrest height (option) Move the head rest up or down.
Page 122 OPERATION Operation Check before starting engine, adjust Adjust seat belt Always wear the seat belt. WARNING Before fastening the seat belt, check that there is no abnormality in the belt mounting bracket or mounting belt. If the belt is worn or damaged, replace it. Fasten the seat belt before starting operations.
Page 123 OPERATION Operation Check before starting engine, adjust Adjust lever stand Adjust height of wrist rest Loosen lock lever (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.
Page 124: Operations And Checks Before Starting Engine
OPERATION Operation Check before starting engine, adjust Operations and checks before starting engine WARNING Before starting the engine, check that the safety lock lever is securely at the LOCK position. If the work equipment control lever is touched by accident when starting the engine, the work equipment may move unexpectedly and cause serious damage or personal injury.
Page 125 3 seconds, and the alarm buzzer sounds for approx. 1 sec. If any monitor does not light up, there is probably a failure or disconnection, so contact your Komatsu distributor for inspection. 3-67...
Page 126: Starting Engine
OPERATION Operation Starting engine Starting engine WARNING Start the engine only after sitting down in the opera- tor's seat. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause serious bodily injury or fire. Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.
Page 127 OPERATION Operation Starting engine The preheating time varies according to the engine water tem- perature when the engine is started. The table on the right gives a guide to the preheating time (sec) in cold weather. X: Water temperature when starting the engine (°C) Y: Preheating time (sec) 2.
Page 128: Operations And Checks After Starting Engine
Breaking-in the machine CAUTION Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating the machine under severe conditions at the beginning can adversely affect the performance and shorten the machine life.
Page 129 Run the engine under a light load until engine cooling water temperature gauge (4) and HST oil temperature gauge (5) are in the white range. 5. Check that there is no abnormal exhaust gas color, noise or vibration. If any abnormality is found, contact your Komatsu distributor. 3-71...
Page 130: Stopping Engine
OPERATION Operation Stopping engine Stopping engine NOTICE If the engine is abruptly stopped before it has cooled down, engine life may be greatly shortened. Conse- quently, do 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.
Page 131: Moving The Machine (Directional, Speed), Stopping The Machine
OPERATION Operation Moving the machine (Directional, speed), stopping the machine Moving the machine (Directional, speed), stopping the machine WARNING Always remove the safety bar for travel operations. If it is not removed, the steering wheel cannot be used for steering, and this may lead to serious damage or injury. When moving the machine, check that the area around the machine is safe, then sound the horn before starting.
Page 132 Position (b): REVERSE Check that the backup alarm sounds when the direc- tional lever is set to REVERSE. If the backup alarm does not sound, please contact your Komatsu distributor for repairs. 7. Release brake pedal (4), then depress accelerator pedal (8) to move the machine.
Page 133: Changing Direction
Place directional lever (1) in the desired position. Position (a): FORWARD Position N: NEUTRAL Position (b): REVERSE Check that the backup alarm sounds when the direc- tional lever is set to REVERSE. If the backup alarm does not sound, please contact your Komatsu distributor for repairs. 3-75...
Page 134 OPERATION Operation Moving the machine (Directional, speed), stopping the machine Using switch to change between forward and reverse WARNING When the directional selector switch actuation switch (3) is at the ON position, if the directional lever (1) is operated to FORWARD or REVERSE, the machine will travel in for- ward or reverse according to the operation of the direc- tional lever, regardless of the position of the directional selector switch (2).
Page 135 OPERATION Operation Moving the machine (Directional, speed), stopping the machine REMARK When the directional selector switch 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 lever, regardless of the position of the directional selector switch (2).
Page 136: Stopping The Machine
OPERATION Operation Moving the machine (Directional, speed), stopping the machine Stopping the machine WARNING Avoid stopping suddenly. Give yourself ample room when stopping. Even if the parking brake lever is pulled and set to the LOCK position, there is a danger of the machine mov- ing until the parking brake pilot lamp lights up, so keep the brake pedal depressed.
Page 137: Turning
Check that there is a play of 50 to 100 mm (2.0 to 3.9 in) in the steering wheel. Check also that the steering works properly. If any abnormality is found, please contact your Komatsu distributor for inspection. Emergency steering CAUTION Never actuate the emergency steering except during emergencies or when checking the function.
Page 138: Operation Of Work Equipment
OPERATION Operation Operation of work equipment Operation of work equipment Work equipment control lever (1) can be used to operate the lift arm and bucket as follows. Lift arm operation NOTICE Do not use the FLOAT position when lowering the bucket. Use the FLOAT position when leveling, see “Leveling oper- ations on page 3-86“.
Page 139: Handling Hydraulic Quick Coupler
OPERATION Operation Handling hydraulic quick coupler Handling hydraulic quick coupler Installing the attachment 1. Set the selector levers (1) into position “A“. Start the engine. 2. To remove the pins, push the control lever (2) forward. 3. Check that the lock pins has been removed. The lock pin indicators (3) may not be visible.
Page 140 OPERATION Operation Handling hydraulic quick coupler 6. Drive the machine slowly forward until the guide plate enters the inside 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: Removal And Installation Of The Attachment
OPERATION Operation Handling hydraulic quick coupler 11.After completing the connection of the front attachment set the two control levers up to position “B“. Removal and installation of the attachment WARNING The hydraulic system is always under internal pressure. When replacing and installing the coupling, release the pressure inside the circuit.
Page 142: Work Possible Using Wheel Loader
OPERATION Operation Work possible using wheel loader Work possible using wheel loader In addition to the following, it is possible to further increase the range of applications by using various attachments. Digging operations WARNING Never carry out digging or scooping operations with the machine articulated. There is danger that the machine may tip over.
Page 143 OPERATION Operation Work possible using wheel loader Digging and loading on level ground When digging and loading on level ground, set the bucket edge facing down slightly as follows and drive the machine forward. Always be careful not to load the bucket on one side and cause an unbalanced load. This operation should be carried out in 1st gear.
Page 144: Leveling Operations
OPERATION Operation Work possible using wheel loader Leveling operations NOTICE Always operate the machine in reverse when carrying out leveling operations. If it is necessary to carry out leveling operations when traveling forward, do not set the bucket dumping angle to more than 20 degrees.
Page 145: Loading Operations
OPERATION Operation Work possible using wheel loader Loading operations Select the method of operation which will give the minimum amount of turning and travel in order to provide the most efficient method for the jobsite. WARNING Always keep the jobsite flat, and do not operate the steering wheel suddenly or apply the brakes sud- denly when the lift arm is raised with a loaded bucket.
Page 146 OPERATION Operation Work possible using wheel loader V-SHAPE LOADING Position the dump truck so that the direction of approach of the wheel loader is approx. 60 degrees from the direction of approach to the stockpile. After loading the bucket, drive the wheel loader in reverse, then turn it to face the dump truck and travel forward to load the dump truck.
Page 147: Precautions For Operation
If the machine is not stopped by depressing the brake pedal, use the parking brake to stop the machine. NOTICE If the parking brake has been used as an emergency brake, contact your Komatsu distributor to have the parking brake checked for any abnormality.
Page 148: Adjusting Work Equipment Posture
OPERATION Operation Adjusting work equipment posture Adjusting work equipment posture WARNING Lock Stop the machine on flat ground and put blocks in front and behind the wheels. Set parking brake lever to the LOCK position. Secure the front and rear frames with the safety bar. Free Always attach the warning tag to the work equipment control lever.
Page 149: Adjusting Bucket Positioner
OPERATION Operation Adjusting work equipment posture Adjusting bucket positioner 1. Lower the bucket to the ground, set to the desired digging angle, return the bucket control lever at HOLD, then set the safety lever to the LOCK position and stop the engine. 2.
Page 150: Adjusting Fork Positioner
OPERATION Operation Adjusting work equipment posture Adjusting fork positioner 1. Lower the forks to the ground, set to the horizontal position, return the bucket control lever to the HOLD position, then set the safety lock lever to the LOCK position and stop the engine.
Page 151: Parking Machine
OPERATION Operation Parking machine Parking machine WARNING Avoid stopping suddenly. Give yourself ample room when stopping. Do not park the machine on slopes. If the machine has to be parked on a slope, set it fac- ing directly down the slope, then dig the bucket into the ground and put blocks under the tires to prevent the machine from moving.
Page 152 OPERATION Operation Parking machine 3. Pull parking brake lever (4) and set it to the LOCK position. Lock Free 9EA04476-A 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. Free Lock 9EA04443A...
Page 153: Check After Stopping Engine
OPERATION Operation Check after stopping engine Check after stopping engine Check the engine water temperature, engine oil pressure, HST oil temperature, and fuel level with the meters and lamps. If the engine has overheated, do not stop it suddenly. Run the engine at a midrange speed to allow the engine to cool down before stopping it.
Page 154: Handling The Tires
AE40786B-A For tubeless tires, when there is air leakage or improper repair Please contact your Komatsu distributor when replacing the tires. It is dangerous to jack up the machine without taking due care. Tire pressure Measure the tire pressure before starting operations, when the tires are cool.
Page 155: Precautions For Using Load And Car Method
When traveling continuously with load and carry operations, choose the correct tires to match the operating condi- tions, or choose the operating conditions to match the tires. If this is not done, the tires will be damaged, so con- tact your Komatsu distributor or tire dealer when selecting tires. 3-97...
Page 156: Transportation
OPERATION Transportation Transportation procedure Transportation When transporting the machine, observe all related laws and regulations, and be careful to assure safety. Transportation procedure As a basic rule, always transport the machine on a trailer. When selecting the trailer, see the weights and dimensions given in section “Technical data on page 5-2“. Note that the specifications for the weights and dimensions for transportation differ according to the type of tires and type of bucket.
Page 157: Securing Machine
OPERATION Transportation Loading, unloading work with trailers Securing machine Load the machine on to a trailer as follows. 1. Lower the work equipment slowly. 2. Set the safety lock lever to the LOCK position securely. Free 3. Turn the starting switch to the OFF position to stop the engine, and pull out the starting switch key.
Page 158: Lifting Machine
Never go under the machine when it is raised. CAUTION When the machine is raised, check that there is no oil leakage from the hydraulic circuits. When carrying out the lifting operation, please contact your Komatsu distributor. NOTICE The lifting procedure applies to machines with standard specifications.
Page 159: Location Of Lifting Position Mark
Transportation Lifting machine Location of lifting position mark Weight table Machine weight Front wheel load Rear wheel load Center of gravity 12,450 kg 5,270 kg 7,180 kg 1,670mm WA250PT-5H (27,452 lb) (11,620 lb) (15,832 lb) (5 ft 6 in) 3-101...
Page 160: Lifting Procedure
When the machine is raised, check that there is no oil leakage from the hydraulic circuits. When carrying out the lifting operation, please contact your Komatsu distributor. Lifting work can be carried out only for machines with lifting marks. Before starting the lifting operation, stop the machine in a horizontal place and do as follows.
Page 161: Cold Weather Operation
When changing the coolant or when handling coolant containing antifreeze that has been drained when repairing the radiator, please contact your Komatsu distributor. Antifreeze is toxic, so do not let it flow into drainage ditches or spray it on to the ground surface.
Page 162: Battery
OPERATION Cold weather operation Precautions for low temperature Battery WARNING The battery generates flammable gas, so do not bring fire or sparks near the battery. Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor.
Page 163: Precautions After Completion Of Work
OPERATION Cold weather operation Precautions after completion of work Precautions after completion of work To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, always observe the following precautions. Remove all the mud and water from the machine body.
Page 164: Long-Term Storage
NOTICE If the machine is to be used when the monthly rust prevention operation has not been carried out, please contact your Komatsu distributor. When using the machine after long-term storage, do as follows before using it. Wipe off the grease from the hydraulic cylinder rods.
Page 165: Troubleshooting
The machine must not be towed for long distances. For details of the procedure for towing a machine when it has broken down, please contact your Komatsu distributor. This machine must not be towed except in emergencies. When towing the machine, take the following precau- tions.
Page 166: When Engine Can Be Used
OPERATION Troubleshooting Towing the machine When engine can be used If the transmission and steering wheel can be operated, and the engine is running, it is possible to tow the machine out of mud or to move it for a short distance to the edge of the road. The operator should sit on the machine being towed and operate the steering in the direction that the machine is towed.
Page 167: If Battery Is Discharged
OPERATION Troubleshooting If battery is discharged If battery is discharged WARNING When removing, disconnect the cable from the ground terminal first When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position. The battery generates hydrogen gas, so there is a haz- ard of explosion.
Page 168: Precautions For Charging Battery
OPERATION Troubleshooting If battery is discharged Precautions for charging battery When charging the battery, if the battery is not handled cor- rectly, there is danger that the battery may explode. Always follow the instructions in “Battery on page 3-104“ and the instruction manual accompanying the charger, and do as fol- lows.
Page 169 OPERATION Troubleshooting If battery is discharged Connecting the booster cable Keep the starting switch of the normal machine and problem machine at the OFF position. Connect the booster cable as follows, in the order of the numbers marked in the diagram. 1.
Page 170: Other Trouble
Troubleshooting Other trouble Other trouble Electrical system ): Always contact your Komatsu distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Lamp does not glow brightly even •Defective wiring...
Page 171: Chassis
OPERATION Troubleshooting Other trouble Chassis ): Always contact your Komatsu distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy •Release parking brake Engine is running but machine •Parking brake is applied...
Page 172 OPERATION Troubleshooting Other trouble Problem Main causes Remedy Parking brake Poor braking effect •Linkage is loose •Adjust •Disc is worn (•Replace disc) Steering •Add oil to specified level. See •Defective hydraulic system Steering wheel is heavy "Every 100 hours service on •Lack of oil page 4-39".
Page 173: Engine
OPERATION Troubleshooting Other trouble Engine ): Always contact your Komatsu distributor when dealing with these items. In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy •Add oil to specified level, see Engine oil pressure caution pilot •Low engine oil pan oil level (suck-...
Page 174 OPERATION Troubleshooting Other trouble Problem Main causes Remedy Exhaust gas occasionally turns •Clogged air cleaner element •Clean or replace, see "When black required on page 4-20". •Defective nozzle (•Replace nozzle) •Defective compression (•See defective compression above) Combustion noise occasionally •Defective nozzle (•Replace nozzle) makes breathing sound Abnormal noise generated (com-...
Page 175: Maintenance
MAINTENANCE WARNING Please read and make sure that you understand the safety volume before reading this section.
Page 176: Guides To Maintenance
KOMATSU genuine replacement parts Use Komatsu genuine parts specified in the Parts Book as replacement parts. KOMATSU genuine oils Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient tem- perature. Always clean washer fluid Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 177 MAINTENANCE Guides to maintenance Locking inspection covers Lock inspection cover in position securely with the lock bar. If inspection or maintenance is carried out with the inspection cover not locked in position, there is a hazard that it may be suddenly blown shut by the wind and cause injury to the worker.
Page 178: Outlines Of Service
When changing the oil, always replace the related filters at the same time. We recommend you have an analysis made of the oil periodically to check the condition of the machine. For those who wish to use this service, please contact your Komatsu distributor. Fuel The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly.
Page 179: Carrying Out Kowa (Komatsu Oil Wear Analysis)
Carry out sampling regularly at fixed intervals. Do not carry out sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, please contact your Komatsu distributor. Storing oil and fuel Keep indoors to prevent any water, dirt, or other impurities from getting in.
Page 180: Filters
Biodegradable hydraulic oil and lubricants The use of biodegradable hydraulic oils and lubricants - on the basis of synthetic 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.
Page 181: Wear Parts
When replacing parts, always use Komatsu genuine parts. As a result of our continuous efforts to improve product quality, the part number may change, so inform your Komatsu distributor of the machine serial number and check the latest part number when ordering parts. Wear parts list The parts in parentheses are to be replaced at the same time.
Page 182: Fuel, Coolant And Lubricants
MAINTENANCE Fuel, coolant and lubricants Lubrication chart Fuel, coolant and lubricants Lubrication chart Lubrication intervals are 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.
Page 183: Proper Selection Of Fuel, Coolant And Lubricants
*** North American manufacted DONAX TD 20W-40 must not be used. **** North American manufacted TORQUE FLUID 56 must not be used. (1): Please use SAE10W30 for the oil in the hydraulic system. If Komatsu genuine oil is not available, select the oil from the table below.
Page 184 There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add single grade oil that matches the temperature range in the table. We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications.
Page 185 MAINTENANCE Fuel, coolant and lubricants Proper selection of fuel, coolant and lubricants Engine Oil Antifreeze [CD or CE] Gear Oil Grease Coolant SAE10W, 30, 40 Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol 10W30, 15W40 SAE80, 90, 140 NLGI No.2 Base] (The 15W40 oil Permanent Type marked * is CE.)
Page 186 MAINTENANCE Fuel, coolant and lubricants Proper selection of fuel, coolant and lubricants Engine Oil Antifreeze [CD or CE] Gear Oil Grease Coolant SAE10W, 30, 40 Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol 10W30, 15W40 SAE80, 90, 140 NLGI No.2 Base] (The 15W40 oil Permanent Type marked * is CE.)
Page 187: Standard Tightening Torques For Bolts And Nuts
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below. If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced.
Page 188 MAINTENANCE Standard tightening torques for bolts and nuts Torque list Apply the following table for hydraulic hose. Tightening torque Width Target value Permissible range Nominal - acros No. of s flats threads (a) · · · lbft lbft (mm) · 9/16 - 35 - 3.5 - 6.5...
Page 189: Periodic Replacement Of Safety Critical Parts
Also carry out the following checks with hydraulic hoses which need not be replaced periodically. Tighten a loos- ened clamp or replace a defective hose, as required. When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time. Ask your Komatsu distributor to replace the critical parts. 4-15...
Page 190 MAINTENANCE Periodic replacement of safety critical parts Safety critical parts Replacement Safety critical parts for periodic replacement Q'ty interval Fuel hose (fuel tank - water separator) 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)
Page 191: Maintenance Schedule Chart
MAINTENANCE Maintenance schedule chart Service schedule Maintenance schedule chart Service schedule Initial 250 hours service (only after the first 250 hours) Replace HST oil filter element..........................4-52 Replace hydraulic tank filter element ........................4-54 When required Check, clean, or replace air cleaner element...................... 4-20 Dust pre-extractor "Turbo II": check, clean ......................
Page 192 MAINTENANCE Maintenance schedule chart Service schedule Every 1000 hours service Change oil in transfer case ..........................4-50 Clean transfer case breather..........................4-51 Replace HST oil filter element..........................4-52 Lubricating................................4-53 Check tightening parts of turbocharger ....................... 4-53 Check play of turbocharger rotor......................... 4-53 Check alternator driving belt tension and replacement ..................
Page 193: Service Procedure
MAINTENANCE Service procedure Initial 250 hours service (only after the first 250 hours) Service procedure Initial 250 hours service (only after the first 250 hours) 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 of replacing or maintaining, see the section on "Every 1000 hours service on page 4-50"...
Page 194: When Required
MAINTENANCE Service procedure When required When required Check, clean, or replace air cleaner element WARNING If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and damage it. Always stop the engine before carrying out these operations. When using compressed air, there is danger that dirt may be blown around and cause serious injury.
Page 195 MAINTENANCE Service procedure When required 4. Clean the interior of the air cleaner body, cover (3) and evacuator valve (6). NOTICE The inner element must not be used again even after its cleaning. When replacing the outer element, replace the outer element at the same time.
Page 196 MAINTENANCE Service procedure When required Replacing element 1. Open the engine side cover on the right side of the machine. 2. Remove three clips (2), then remove cover (3). 3. Remove outer element (4). Do not remove inner element (5) at this time, however. 4.
Page 197: Dust Pre-Extractor "Turbo Ii": Check, Clean
MAINTENANCE Service procedure When required Dust pre-extractor "Turbo II": check, clean (This pre-extractor 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 condition checked from time to time depending on use.
Page 198: Clean Inside Of Cooling System
30% by volume is necessary. In areas where the water is hard, always add Komatsu genuine corrosion resistor agent KI. One packet of corro- sion resistor agent (No. 600-411-1120) contains 100g (0.22 lb). The standard density of the mixture should be 7g/ liter (0.065 oz/US gal).
Page 199 If it gets in your eyes, flush your eyes with large amount of fresh water and see a doctor at once. Use city water for the cooling water. If river water, well water or other such water supply must be used, contact your Komatsu distributor. We recommend use of an antifreeze density gauge to control the mixing proportions.
Page 200 MAINTENANCE Service procedure When required 11. To remove the air in the cooling system, run the engine for 5 minutes at low idling, 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 between FULL and LOW level.
Page 201: Check Oil Level In Transfer Case, Add Oil
MAINTENANCE Service procedure When required Check oil level in transfer case, add oil WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. Carry out this procedure if there is any sign of oil on the transfer case.
Page 202: Check Axle Oil Level, Add Oil
MAINTENANCE Service procedure When required Check axle oil level, add oil WARNING When checking the oil level, apply the parking brake and secure the front and rear frames with the safety bar. After stopping the engine, the parts and oil are at a high temperature. Wait for the temperature to go down before starting the operation.
Page 203: Clean Axle Case Breather
MAINTENANCE Service procedure When required Clean axle case breather WARNING When cleaning the axle breather, apply the parking brake and secure the front and rear frames with the safety bar. A: Front B: Rear Remove all mud and dirt from around the breather with a brush.
Page 204: Check Window Washing Fluid Level, Add Fluid
MAINTENANCE Service procedure When required Check window washing fluid level, add fluid Check the washing fluid levels in washer tank (1). When the fluid has run low, add automotive window washing fluid. Be careful not to let dust get into the fluid. Clean radiator fins and cooler fins WARNING Never open the engine side cover when the engine is running.
Page 205: Clean Transfer Oil Cooler Fins
Check electrical intake air heater Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air heater checked for dirt or disconnections. Replace bolt on cutting edge...
Page 206: Replace Bucket Teeth
MAINTENANCE Service procedure When required Replace bucket teeth WARNING If the pin is hit out with strong force, there is danger that the pin may fly out. Check that there is no one in the surrounding area. There is danger of pieces flying during the replacement operation, so always wear protective cloth- ing, such as safety glasses and gloves.
Page 207: Check Air Conditioner
MAINTENANCE Service procedure When required Check air conditioner Check level of refrigerant (gas) WARNING If the refrigerant used in the cooler gets into your eyes or on your hands, it may cause loss of sight or frostbite. Do not touch the refrigerant. Never loosen any part of the refrigerant circuit.
Page 208: Replace Slow Blow Fuse
MAINTENANCE Service procedure When required Replace slow blow fuse NOTICE Always turn the power OFF when replacing the slow blow fuse (turn the starting switch to the OFF position). Always replace the slow blow fuse with a fuse of the same capacity.
Page 209: Selection And Inspection Of Tires
Select the tires according to the conditions of use and the weight of the attachments of the machine. Use the fol- lowing table. Consult your Komatsu distributor when using optional tires. Tire size Maximum load [kg (lb)]...
Page 210 MAINTENANCE Service procedure When required Check inflaion pressure of tires WARNING When inflating a tire, check that no one will enter the working area. Use an air chuck which has a clip and which can be fixed to the air valve. While inflating the tire, check the inflation pressure occasionally so that it will not rise too high.
Page 211: Check Before Starting
MAINTENANCE Service procedure Check before starting Check before starting For the following items, 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 electric wiring Checking with machine monitor...
Page 212: Every 50 Hours Service
MAINTENANCE Service procedure Every 50 hours service Every 50 hours service Drain water, sediment from fuel tank Loosen valve (1) on the left side of the tank so that the sedi- ment and water will be drained together with fuel. 4-38...
Page 213: Every 100 Hours Service
MAINTENANCE Service procedure Every 100 hours service Every 100 hours service Maintenance for every 50 hours service should be carried out at the same time. Lubricate rear axle pivot pin (2 places) 1. Using a grease pump, pump in grease through the grease fittings marked by the arrows.
Page 214: Check Oil Level In Hydraulic Tank, Add Oil
MAINTENANCE Service procedure Every 100 hours service Check oil level in hydraulic tank, add oil WARNING The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for 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.
Page 215: Every 250 Hours Service
If distilled water is added to above the U.L. line, use a syringe to lower the level to the U.L. line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. 4-41...
Page 216 Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. When it is possible to use indicator to check electrolyte level If it is possible to use and indicator to check the electrolyte level, follow the instructions given.
Page 217: Check Parking Brake
MAINTENANCE Service procedure Every 250 hours service Check parking brake Test conditions Tire inflation pressure: as specified Road surface: Dry paved surface with 25% grade Machine: Operating condition Lock Test method 1. Start the engine and set the work equipment to the travel posture.
Page 218: Check For Loose Wheel Hub Bolts, Tighten
Check each pulley for damage, wear of the V-groove, and wear of the V-belt. In particular, be sure to check that the V-belt is not touching the bottom of the V-groove. In case any of the following occurs, ask the Komatsu distributor in your territory to replace the belts with new ones.
Page 219: Clean Element In Air Conditioner Recirculation Filter
MAINTENANCE Service procedure Every 250 hours service Clean element in air conditioner recirculation filter 1. Loosen knob (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.
Page 220: Lubricating
MAINTENANCE Service procedure Every 250 hours service Lubricating 1. Using a grease pump, pump in grease through the grease fittings marked by the arrows. 2. After greasing, wipe off any old grease that was pushed 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 greasing more frequently.
Page 221: Every 500 Hours Service
4. Loosen drain plug (P) and drain the oil. Be careful not to get oil on 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).
Page 222: Replace Fuel Filter Cartridge
MAINTENANCE Service procedure Every 500 hours service Replace fuel filter cartridge WARNING Engine is at high temperature immediately after the machine has been operated. Wait for engine to cool down before replacing the filter. Do not bring fire or sparks near the fuel. REMARK If the machine has run out of fuel, use Steps 3 to 10 to bleed the air.
Page 223: Clean Water Separator Strainer
MAINTENANCE Service procedure Every 500 hours service Clean water separator strainer WARNING Engine is at high temperature immediately after the machine has been operated. Wait for engine to cool down before replacing the filter. Do not bring fire or sparks near the fuel. 1.
Page 224: Every 1000 Hours Service
MAINTENANCE Service procedure Every 1000 hours service Every 1000 hours service Maintenance for every 50, 100, 250 and 500 hours service should be carried out at the same time. Change oil in transfer case WARNING The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
Page 225: Clean Transfer Case Breather
MAINTENANCE Service procedure Every 1000 hours service Clean transfer case breather 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 the mount.
Page 226: Replace Hst Oil Filter Element
MAINTENANCE Service procedure Every 1000 hours service Replace HST oil filter element WARNING The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for 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.
Page 227: Lubricating
Please contact your Komatsu distributor to have the rotor play checked. Check alternator driving belt tension and replacement Since inspection and replacement of the belt require special tools, contact your Komatsu distributor. REMARK The machine is equipped with an auto tensioner, so there is no need to adjust the tension.
Page 228: Every 2000 Hours Service
MAINTENANCE Service procedure Every 2000 hours service Every 2000 hours service Maintenance for every 50, 100, 250, 500 and 1000 hours service should be carried out at the same time. Change oil in hydraulic tank, replace hydraulic filter element WARNING The parts and oil are at high temperature after the engine is stopped, and may cause burns.
Page 229: Replace Hydraulic Tank Breather Element
MAINTENANCE Service procedure Every 2000 hours service Replace hydraulic tank breather element WARNING The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for 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.
Page 230: Change Axle Oil
For details of cleaning the fresh air filter, see “Clean element in air conditioner fresh air filter on page 4-39“. Check alternator, starting motor The brush may be worn or have no grease on the bearing, so contact your Komatsu distributor for inspection or repair.
Page 231: Check Brake Disc Wear
Check accumulator gas pressure When carrying out the EVERY 2000 HOURS SERVICE or EVERY YEAR SERVICE or when making periodic replacement of the critical safety parts, please ask your Komatsu distributor to check the accumulator gas pres- sure. Check vibration damper Check that there are no cracks or peeling in the outside surface of the rubber.
Page 232: Every 4000 Hours Service
Check water pump Check that there is no play in the pulley or any grease leakage, water leakage, or clogging of the drain hole. If any abnormality is found, contact your Komatsu distributor for disassembly and repair or replacement. 4-58...
Page 233 TECHNICAL DATA...
Page 234 (including 1 operator: 75 kg (165 lb).) Normal load kg (lb) 3,540 (7,806) Bucket capacity Heaped (cu.yd) 2.0 (2.6) ³ Engine model Komatsu SAA6D102E diesel engine Flywheel horsepower kW (HP)/rpm 101kw (135)/2000 Overall length mm (ft in) 7,575 (24'10“) Overall height mm (ft in) 3,200 (10'6“) Max.
Page 235 TECHNICAL DATA Technical data...
Page 236 TECHNICAL DATA Noise emission levels Noise emission levels Two signs are attached to the machine that state the noise level produced. In accordance with guideline ISO 6396, the value for the sound pressure level measures is LpA = 72 dB/A. In accordance with EC Directive 2000/14/EC, the guaranteed value for the sound power level measures is LWA = 106 dB/A.
Page 237 ATTACHMENTS, OPTIONS WARNING Please read and make sure that you understand the safety volume before reading this section.
Page 238 20.5-25-12PR (L2 Traction) (2.0 m (2.6 cu.yd) ing products Soft ground 20.5-25-12PR (L2 Traction) BOC indicates a bolt-on type cutting edge. The displayed travel speed changes according to the tire size, so when installing optional tires, please contact your Komatsu distributor.
Page 239 ATTACHMENTS, OPTIONS Handling fork tool Handling fork tool Explanation of components (1) Work equipment control lever Work equipment lever Use this lever (1) to operate the lift arm and fork. NOTICE Do not use the FLOAT position when lowering the fork. Position (a): RAISE When the work equipment control lever is pulled further from the RAISE position, the lever is stopped in this position...
Page 240 ATTACHMENTS, OPTIONS Handling fork tool Operation The operating speed of the forklift is determined according to the configuration of the ground, condition under foot, and size of the operating area. When operating the forklift, maintain the engine speed at near full speed, and carry out the operation with the speed range in 1st or 2nd.
Page 241 ATTACHMENTS, OPTIONS Handling fork tool 6. Lower the load until it is close to the ground surface (30 inches from the ground surface). Transporting WARNING When traveling with a load, do not turn suddenly or accelerate or decelerate suddenly. There is dan- ger that the load will fall off or the machine will tilt.
Page 242 ATTACHMENTS, OPTIONS Handling fork tool Unloading 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 remove the forks from the load.
Page 243 ATTACHMENTS, OPTIONS Method of using 3 levers Method of using 3 levers Explanation of components (1) Lift arm control lever (4) Directional selector switch (2) Bucket control lever (5) Directional selector actuation switch (3) Auxiliary control lever Lift arm control lever This lever (1) is used to operate the lift arm.
Page 244 ATTACHMENTS, OPTIONS Method of using 3 levers Bucket control lever This lever (2) operates the bucket. Position (a): TILT When the bucket control lever is pulled further from the TILT position, the lever is stopped in this position until the bucket reaches the preset position of the positioner, and the lever is returned to the HOLD position.
Page 245 ATTACHMENTS, OPTIONS Method of using 3 levers Directional selector actuation switch When this switch (5) is turned on, the directional selector switch is actuated. Position (a): ON The directional selector 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 ATTACHMENTS, OPTIONS Method of using 3 levers Operation Using switch to change between forward and reverse WARNING When changing direction between FORWARD and REVERSE, check that the new direction of travel is safe. There is a blind spot behind the machine, so be particularly careful when changing direction to travel in reverse.
Page 247 ATTACHMENTS, OPTIONS Method of using 3 levers 3. Place the directional selector switch actuation switch (3) at the ON position (a). 4. Place the directional selector switch (2) at the F (forward) or R (reverse) position. REMARK When the directional selector switch 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 lever, regardless of the position of the directional selector switch (2).
Page 248 OK. If the mixer blades are not turning, no automatic lubrication is taking place. To eliminate the malfunction, contact your Komatsu dealer. Display and control unit The display and control unit is protected by a transparent plastic cover against splashing water and mechanical damage.
Page 249 ATTACHMENTS, OPTIONS Central lubrication system Pushbuttons 1. Turn on display Display values and parameters Set values and parameters 2. Change between programming and display mode Confirm values (SET) 3. Activatev intermediate lubrication Clear fault message (DK) Changing the lubrication interval times The settings when shipping from factory are as follows: Greasing interval: after 1 hour Greasing time: 8 minutes.
Page 250 ATTACHMENTS, OPTIONS Central lubrication system 6-14...
Page 251 INDEX...
Page 252 INDEX...
Page 253 Index Index Locking .................3-95 Long-term storage ............3-106 Adjust ................3-54 After storage ............3-106 After starting engine Before storage .............3-106 Checks ..............3-70 During storage .............3-106 Operations .............3-70 Lubricants Air conditioner ...............3-48 Selection ..............4-9 Attachments ..............6-1 Use ................4-8 Auxiliary control lever .............6-8 Machine serial No. plate and position ......1-7 Bucket Maintenance Selecting ..............6-2...
Page 254 Index Every 4000 hours service ........4-58 Every 50 hours service ..........4-38 Every 500 hours service ........4-47 Initial 250 hours service .........4-19 When required ............4-20 Slow blow fuse ..............3-46 Starting engine .............3-68 Steering tilt lock lever ...........3-41 Stopping engine ............3-72 Checks after ............3-95 Stopping machine ............3-73 Switches ...............3-30 Table to enter serial No.
Page 255 Index...

Komatsu WA250PT-5H Operation & Maintenance Manual

Table of Contents

Safety Information

Introduction

Necessary Information

Contents

Dimensions, Weights and Operating Data

CE-Conforming Equipment

Safety

Safety Labels

General Precautions

Precautions for Operation

Precautions for Maintenance

Precautions with Tires

Operation

General View

Explanation of Components

Operation

Transportation

Cold Weather Operation

Long-Term Storage

Troubleshooting

Maintenance

Guides to Maintenance

Outlines of Service

Wear Parts

Fuel, Coolant and Lubricants

Standard Tightening Torques for Bolts and Nuts

Periodic Replacement of Safety Critical Parts

Maintenance Schedule Chart

Maintenance

Service Procedure

Service Schedule

Maintenance Schedule Chart

Every 1000 Hours Service

Every 2000 Hours Service

Every 4000 Hours Service

Quick Links

Chapters

Need help?

Questions and answers

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Summary of Contents for Komatsu WA250PT-5H