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KOMATSU GALEO WA600-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:52001 & UP) KOMATSU WA600-3 – PDF DOWNLOAD
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- KOMATSU GALEO WA600-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:52001 & UP
- PUBLICATION NUMBER:TEN00002-02
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Description
KOMATSU GALEO WA600-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:52001 & UP) KOMATSU WA600-3
KOMATSU GALEO WA600-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:52001 & UP) KOMATSU WA600-3 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU GALEO WA600-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:52001 & UP) KOMATSU WA600-3
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance.
TABLE OF CONTENTS:
KOMATSU GALEO WA600-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:52001 & UP) KOMATSU WA600-3
MAIN MENU...................................................................................... 0 COVER.......................................................................................... 1 FOREWORD....................................................................................... 2 FOREWORD................................................................................... 3 SAFETY INFORMATION......................................................................... 6 INTRODUCTION............................................................................... 8 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE........................................... 8 NECESSARY INFORMATION...................................................................... 9 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE........................... 9 ENGINE SERIAL NO. PLATE AND POSITION................................................... 9 POSITION OF SERVICE METER.............................................................. 10 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.............................................. 10 CONTENTS....................................................................................... 11 SAFETY......................................................................................... 14 SAFETY..................................................................................... 15 SAFETY LABELS.............................................................................. 17 LOCATION OF SAFETY LABELS.............................................................. 18 GENERAL PRECAUTIONS........................................................................ 24 SAFETY RULES........................................................................... 24 IF ABNORMALITIES ARE FOUND............................................................. 24 CLOTHING AND PERSONAL PROTECTIVE ITEMS................................................. 24 FIRE EXTINGUISHER AND FIRST AID KIT.................................................... 24 SAFETY FEATURES........................................................................ 24 KEEP MACHINE CLEAN..................................................................... 25 INSIDE OPERATOR'S COMPARTMENT.......................................................... 25 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT......................................... 25 HANDRAILS AND STEPS.................................................................... 26 MOUNTING AND DISMOUNTING............................................................... 26 NO PEOPLE ON ATTACHMENTS............................................................... 26 DO NOT GET CAUGHT IN ARTICULATED PORTION............................................... 27 PREVENTION OF BURNS.................................................................... 27 FIRE PREVENTION........................................................................ 28 ACTION IF FIRE OCCURS.................................................................. 29 WINDOW WASHER LIQUID................................................................... 29 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)........................... 29 PRECAUTIONS FOR ATTACHMENTS, OPTIONS................................................... 29 UNAUTHORIZED MODIFICATION.............................................................. 29 SAFETY AT WORKSITE..................................................................... 30 WORKING ON LOOSE GROUND................................................................ 30 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES................................................. 31 ENSURE GOOD VISIBILITY................................................................. 31 PRECAUTIONS RELATED TO VENTILATION EXHAUST GAS......................................... 31 CHECKING SIGNALMAN'S SIGNALS AND SIGNS................................................. 32 EMERGENCY EXIT FROM OPERATOR'S CAB..................................................... 32 BE CAREFUL ABOUT ASBESTOS DUST......................................................... 32 PRECAUTIONS FOR OPERATION.................................................................. 33 STARTING ENGINE........................................................................ 33 CHECKS BEFORE STARTING ENGINE...................................................... 33 PRECAUTIONS WHEN STARTING.......................................................... 33 PRECAUTIONS IN COLD AREAS.......................................................... 34 OPERATION.............................................................................. 35 CHECKS BEFORE OPERATION............................................................ 35 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE................................... 35 PRECAUTIONS WHEN TRAVELING......................................................... 36 TRAVELING ON SLOPES................................................................ 37 PROHIBITED OPERATIONS.............................................................. 38 PRECAUTIONS WHEN OPERATING......................................................... 38 METHODS OF USING BRAKE............................................................. 39 OPERATE CAREFULLY ON SNOW.......................................................... 39 PARKING MACHINE ................................................................... 40 TRANSPORTATION......................................................................... 41 LOADING AND UNLOADING.............................................................. 41 SHIPPING........................................................................... 41 BATTERY................................................................................ 42 BATTERY HAZARD PREVENTION.......................................................... 42 STARTING WITH BOOSTER CABLES....................................................... 43 TOWING................................................................................. 44 PRECAUTIONS FOR MAINTENANCE................................................................ 45 WARNING TAG ........................................................................... 45 KEEP WORK PLACE CLEAN AND TIDY......................................................... 45 APPOINT LEADER WHEN WORKING WITH OTHERS................................................ 45 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE............................................ 46 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING..................................... 47 INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF........................... 47 PROPER TOOLS........................................................................... 48 WORK EQUIPMENT SUPPORT................................................................. 48 ACCUMULATOR............................................................................ 48 PERSONNEL.............................................................................. 48 ATTACHMENTS .......................................................................... 49 NOISE.................................................................................. 49 PRECAUTIONS WHEN USING HAMMER ......................................................... 49 REPAIR WELDING ........................................................................ 49 REMOVING BATTERY TERMINAL ............................................................. 49 PRECAUTIONS WITH HIGH-PRESSURE OIL..................................................... 50 HANDLING HIGH-PRESSURE HOSES........................................................... 50 WASTE MATERIALS ....................................................................... 50 MAINTENANCE OF AIR CONDITIONER......................................................... 50 COMPRESSED AIR......................................................................... 51 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ......................................... 51 PRECAUTIONS WITH TIRES..................................................................... 52 HANDLING TIRES......................................................................... 52 PRECAUTIONS WHEN STORING TIRES......................................................... 52 OPERATION...................................................................................... 53 GENERAL VIEW............................................................................... 54 GENERAL VIEW OF MACHINE................................................................ 54 GENERAL VIEW OF CONTROLS AND GAUGES.................................................... 55 EXPLANATION OF COMPONENTS.................................................................. 57 MACHINE MONITOR........................................................................ 57 SWITCHES............................................................................... 71 CONTROL LEVERS, PEDALS................................................................. 79 STEERING COLUMN TILT LEVER............................................................. 83 CAP WITH LOCK.......................................................................... 84 SAFETY BAR............................................................................. 85 TOWING PIN............................................................................. 85 GREASE PUMP............................................................................ 86 BACKUP ALARM........................................................................... 86 DUST INDICATOR......................................................................... 86 CAB DOOR OPEN LOCK..................................................................... 87 TOOL BOX............................................................................... 87 OIL FILLER LOCATION.................................................................... 87 FUSE................................................................................... 87 SLOW BLOW FUSE......................................................................... 89 LUNCH BOX TRAY......................................................................... 89 POWER OUTLET........................................................................... 89 OPERATION.................................................................................. 90 CHECK BEFORE STARTING ENGINE, ADJUST................................................... 90 STARTING ENGINE........................................................................105 OPERATIONS AND CHECKS AFTER STARTING ENGINE............................................107 STOPPING ENGINE........................................................................109 CHECK AFTER STOPPING ENGINE............................................................109 MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE..........................110 TURNING................................................................................115 OPERATION OF WORK EQUIPMENT............................................................116 WORK POSSIBLE USING WHEEL LOADER.......................................................118 PRECAUTIONS FOR OPERATION..............................................................124 ADJUSTING WORK EQUIPMENT POSTURE.......................................................126 REMOVAL AND INSTALLATION OF THE BUCKET.................................................128 PARKING MACHINE........................................................................132 CHECKS AFTER COMPLETION OF OPERATION...................................................134 LOCKING................................................................................134 HANDLING THE TIRES.....................................................................135 TRANSPORTATION.............................................................................137 TRANSPORTATION PROCEDURE...............................................................137 LOADING, UNLOADING WORK................................................................137 METHOD OF SECURING MACHINE.............................................................137 METHOD OF LIFTING MACHINE..............................................................139 COLD WEATHER OPERATION.....................................................................142 PRECAUTIONS FOR LOW TEMPERATURE........................................................142 PRECAUTIONS AFTER COMPLETION OF WORK...................................................143 AFTER COLD WEATHER.....................................................................144 WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER....................144 LONG-TERM STORAGE..........................................................................145 BEFORE STORAGE.........................................................................145 DURING STORAGE.........................................................................145 AFTER STORAGE..........................................................................145 TROUBLESHOOTING............................................................................146 WHEN MACHINE RUNS OUT OF FUEL..........................................................146 METHOD OF TOWING MACHINE...............................................................148 IF BATTERY IS DISCHARGED...............................................................151 OTHER TROUBLE..........................................................................154 MAINTENANCE....................................................................................158 GUIDES TO MAINTENANCE......................................................................159 OUTLINES OF SERVICE........................................................................161 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.................................161 OUTLINE OF ELECTRIC SYSTEM.............................................................164 WEAR PARTS.................................................................................165 WEAR PARTS LIST........................................................................165 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...................................................166 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...................167 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....168 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.............................................169 TORQUE LIST............................................................................169 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..............................................170 SAFETY CRITICAL PARTS..................................................................170 MAINTENANCE SCHEDULE CHART.................................................................171 MAINTENANCE SCHEDULE CHART.............................................................171 SERVICE PROCEDURE..........................................................................173 INITIAL 250 HOURS SERVICE..............................................................173 INITIAL 2000 HOURS SERVICE.............................................................173 CHECK INJECTOR SETTING LOAD, ADJUST................................................173 WHEN REQUIRED..........................................................................174 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT.......................................174 CLEAN INSIDE OF COOLING SYSTEM.....................................................176 CHECK TRANSMISSION OIL LEVEL, ADD OIL..............................................179 CHECK AXLE OIL LEVEL, ADD OIL......................................................180 CLEAN AXLE CASE BREATHER...........................................................181 CLEAN AIR CONDITIONER CONDENSER....................................................181 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID........................................182 CLEAN RADIATOR FINS................................................................182 CHECK ELECTRICAL INTAKE AIR HEATER.................................................182 REPLACE BUCKET TEETH...............................................................183 LUBRICATING........................................................................184 CHECK AIR CONDITIONER..............................................................184 REPLACE SLOW BLOW FUSE.............................................................185 BLEEDING AIR FROM HYDRAULIC TANK...................................................186 REPLACE FAN BELT, ADJUST AUTO-TENSIONER............................................186 SELECTION AND INSPECTION OF TIRES..................................................188 CHECK BEFORE STARTING..................................................................190 EVERY 50 HOURS SERVICE.................................................................191 DRAIN WATER, SEDIMENT FROM FUEL TANK...............................................191 EVERY 100 HOURS SERVICE................................................................192 LUBRICATE REAR AXLE PIVOT PIN......................................................192 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL.........................................192 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER..................................193 EVERY 250 HOURS SERVICE................................................................194 CHECK BATTERY ELECTROLYTE LEVEL....................................................194 CHECK PARKING BRAKE................................................................195 CHECK ALTERNATOR BELT TENSION, ADJUST..............................................196 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST..............................197 CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN............................................197 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER..............................198 LUBRICATING........................................................................199 EVERY 500 HOURS SERVICE................................................................202 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..................202 REPLACE FUEL FILTER CARTRIDGE......................................................204 REPLACE TRANSMISSION OIL FILTER ELEMENT............................................205 LUBRICATE CENTER DRIVE SHAFT SPLINE................................................206 CHECK FAN BELT FOR WEAR ...........................................................206 EVERY 1000 HOURS SERVICE...............................................................207 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER....................................207 CLEAN TRANSMISSION CASE BREATHER...................................................208 CLEAN RADIATOR SUB-TANK BREATHER...................................................208 LUBRICATING........................................................................209 CHECK TIGHTENING PARTS OF TURBOCHARGER.............................................211 CLEAN FUEL STRAINER................................................................211 REPLACE CORROSION RESISTOR CARTRIDGE...............................................211 EVERY 2000 HOURS SERVICE...............................................................212 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT.....................212 REPLACE HYDRAULIC TANK BREATHER ELEMENT............................................214 CHANGE AXLE OIL....................................................................215 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER......216 CLEAN PPC CIRCUIT STRAINER.........................................................216 CLEAN ENGINE BREATHER ELEMENT......................................................217 CHECK ALTERNATOR, STARTING MOTOR...................................................217 CHECK ENGINE VALVE CLEARANCE, ADJUST...............................................217 CHECK BRAKE DISC WEAR..............................................................217 CLEAN AND CHECK TURBOCHARGER.......................................................217 CHECK ACCUMULATOR FUNCTION.........................................................218 CHECK ACCUMULATOR GAS PRESSURE.....................................................218 EVERY 4000 HOURS SERVICE...............................................................219 CHECK WATER PUMP...................................................................219 CHECK VIBRATION DAMPER.............................................................219 CHECK FAN PULLEY AND TENSION PULLEY................................................219 CHECK AIR CONDITIONER COMPRESSOR, ADJUST...........................................219 SPECIFICATIONS.................................................................................220 SPECIFICATIONS.............................................................................221 ATTACHMENTS, OPTIONS...........................................................................222 SELECTING BUCKET AND TIRES.................................................................223 HANDLING AUTO-GREASING SYSTEM..............................................................224 METHOD OF OPERATING AUTO-GREASING SYSTEM...............................................224 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM.........................................229 HANDLING AUTOMATIC SHIFT SYSTEM............................................................230 METHOD OF OPERATION....................................................................230 PRECAUTION WHEN CHANGING DIRECTION.....................................................231 HANDLING E.C.S.S.(ELECTRONIC CONTROLLED SUSPENSION SYSTEM).................................232 STRUCTURE AND FUNCTION OF E.C.S.S......................................................232 METHOD OF OPERATING E.C.S.S............................................................232 PRECAUTIONS WHEN OPERATING E.C.S.S. SWITCH.............................................232 PRECAUTIONS WHEN HANDLING ACCUMULATOR..................................................233 REMOVAL OF E.C.S.S. PIPING.............................................................233 HANDLING JOYSTICK STEERING SYSTEM..........................................................234 STRUCTURE AND FUNCTION OF JOYSTICK STEERING............................................234 OPERATION METHOD OF JOYSTICK STEERING SYSTEM...........................................238 PRECAUTIONS FOR STEERING WITH JOYSTICK.................................................240 ADJUSTMENT OF JOYSTICK CONSOLE.........................................................241 HANDLING AIR-SUSPENSION SEAT...............................................................242 SEAT ADJUSTMENT........................................................................242 FAILURE DISPLAY ON MAIN MONITOR............................................................244 FAILURE CODE ON MAIN MONITOR...........................................................244 FAILURE CODE ON AUTOMATIC SHIFT, E.C.S.S. AND JOYSTICK STEERING SYSTEM.................244 CAR RADIO..................................................................................245 EXPLANATION OF COMPONENTS..............................................................245 METHOD OF USE..........................................................................248 PRECAUTIONS WHEN USING.................................................................250 AM/FM RADIO-CASSETTE STEREO................................................................251 EXPLANATION OF COMPONENTS..............................................................251 METHOD OF OPERATION....................................................................256 PRECAUTIONS FOR USE....................................................................258 AIR CONDITIONER............................................................................259 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL........................................259 METHOD OF OPERATION....................................................................262 INDEX..........................................................................................264
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