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Komatsu GALEO WA600-6 Wheel Loader Operation & Maintenance Manual 60001 and up – PDF DOWNLOAD
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Komatsu GALEO WA600-6 Wheel Loader Operation & Maintenance Manual
Book Code : TEN00111-06
SERIAL NUMBERS 60001 and up
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Description
Komatsu GALEO WA600-6 Wheel Loader Operation & Maintenance Manual
TABLE OF CONTENTS:
Komatsu GALEO WA600-6 Wheel Loader Operation & Maintenance Manual
COVER...................................................................................................... 1 FOREWORD................................................................................................... 2 FOREWORD............................................................................................... 3 SAFETY INFORMATION..................................................................................... 6 INTRODUCTION........................................................................................... 8 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE....................................................... 8 VISIBILITY FROM OPERATOR'S SEAT.................................................................... 9 NECESSARY INFORMATION.................................................................................. 10 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....................................... 10 EPA REGULATIONS, ENGINE NUMBER PLATE............................................................... 10 POSITION OF SERVICE METER.......................................................................... 11 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.......................................................... 11 CONTENTS................................................................................................... 12 SAFETY..................................................................................................... 16 SAFETY................................................................................................. 17 SAFETY LABELS.......................................................................................... 19 LOCATION OF SAFETY LABELS.......................................................................... 20 SAFETY LABELS...................................................................................... 21 GENERAL PRECAUTIONS.................................................................................... 28 SAFETY RULES....................................................................................... 28 IF ABNORMALITIES ARE FOUND......................................................................... 28 CLOTHING AND PERSONAL PROTECTIVE ITEMS............................................................. 28 FIRE EXTINGUISHER AND FIRST AID KIT................................................................ 28 SAFETY FEATURES.................................................................................... 28 KEEP MACHINE CLEAN................................................................................. 29 INSIDE OPERATOR'S COMPARTMENT...................................................................... 29 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT..................................................... 30 HANDRAILS AND STEPS................................................................................ 31 PRECAUTIONS WHEN CLEANING CAB GLASS................................................................ 32 MOUNTING AND DISMOUNTING........................................................................... 32 NO PEOPLE ON ATTACHMENTS........................................................................... 32 DO NOT GET CAUGHT IN ARTICULATED PORTION........................................................... 32 PREVENTION OF BURNS................................................................................ 33 FIRE PREVENTION.................................................................................... 34 ACTION IF FIRE OCCURS.............................................................................. 34 WINDOW WASHER LIQUID............................................................................... 35 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)....................................... 35 PRECAUTIONS FOR ATTACHMENTS, OPTIONS............................................................... 35 UNAUTHORIZED MODIFICATION.......................................................................... 35 SAFETY AT WORKSITE................................................................................. 36 WORKING ON LOOSE GROUND............................................................................ 36 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES............................................................. 37 ENSURE GOOD VISIBILITY............................................................................. 37 PRECAUTIONS RELATED TO VENTILATION EXHAUST GAS..................................................... 38 CHECKING SIGNALMAN'S SIGNALS AND SIGNS............................................................. 38 EMERGENCY EXIT FROM OPERATOR'S CAB................................................................. 38 BE CAREFUL ABOUT ASBESTOS DUST..................................................................... 38 PRECAUTIONS FOR OPERATION.............................................................................. 39 STARTING ENGINE.................................................................................... 39 CHECKS BEFORE STARTING ENGINE.................................................................. 39 PRECAUTIONS WHEN STARTING...................................................................... 39 PRECAUTIONS IN COLD AREAS...................................................................... 40 OPERATION.......................................................................................... 41 CHECKS BEFORE OPERATION........................................................................ 41 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE............................................... 41 PRECAUTIONS WHEN TRAVELING..................................................................... 42 TRAVELING ON SLOPES............................................................................ 43 PROHIBITED OPERATIONS.......................................................................... 44 PRECAUTIONS WHEN OPERATING..................................................................... 45 METHODS OF USING BRAKE......................................................................... 45 OPERATE CAREFULLY ON SNOW...................................................................... 46 PARKING MACHINE................................................................................ 47 TRANSPORTATION..................................................................................... 49 LOADING AND UNLOADING.......................................................................... 49 SHIPPING....................................................................................... 49 BATTERY............................................................................................ 50 BATTERY HAZARD PREVENTION...................................................................... 50 STARTING WITH BOOSTER CABLES................................................................... 51 TOWING............................................................................................. 52 PRECAUTIONS FOR MAINTENANCE............................................................................ 53 WARNING TAG........................................................................................ 53 KEEP WORK PLACE CLEAN AND TIDY..................................................................... 53 APPOINT LEADER WHEN WORKING WITH OTHERS............................................................ 53 STOP ENGINE BEFORE CARRYING OUT MAINTENANCE........................................................ 54 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING................................................. 56 INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF....................................... 56 PROPER TOOLS....................................................................................... 57 ACCUMULATOR........................................................................................ 57 PERSONNEL.......................................................................................... 57 ATTACHMENTS........................................................................................ 57 WORK UNDER THE MACHINE............................................................................. 58 NOISE.............................................................................................. 58 PRECAUTIONS WHEN USING HAMMER...................................................................... 58 REPAIR WELDING..................................................................................... 58 REMOVING BATTERY TERMINAL.......................................................................... 58 PRECAUTIONS WITH HIGH-PRESSURE OIL................................................................. 59 PRECAUTIONS FOR HIGH-PRESSURE FUEL................................................................. 59 HANDLING HIGH-PRESSURE HOSES....................................................................... 59 WASTE MATERIALS.................................................................................... 60 MAINTENANCE OF AIR CONDITIONER..................................................................... 60 COMPRESSED AIR..................................................................................... 60 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...................................................... 60 PRECAUTIONS WITH TIRES................................................................................. 61 HANDLING TIRES..................................................................................... 61 PRECAUTIONS WHEN STORING TIRES..................................................................... 61 OPERATION.................................................................................................. 62 GENERAL VIEW........................................................................................... 63 GENERAL VIEW OF MACHINE............................................................................ 63 GENERAL VIEW OF CONTROLS AND GAUGES................................................................ 64 EXPLANATION OF COMPONENTS.............................................................................. 70 MACHINE MONITOR.................................................................................... 70 SWITCHES...........................................................................................111 CONTROL LEVERS, PEDALS.............................................................................136 CAP WITH LOCK......................................................................................143 FRAME LOCK BAR.....................................................................................145 TOWING PIN.........................................................................................146 BACKUP ALARM.......................................................................................146 OPENING CAB, WINDOW DOOR...........................................................................147 HANDLING CAB WIPER.................................................................................149 DUST INDICATOR.....................................................................................149 FUSE...............................................................................................150 CIRCUIT BREAKER....................................................................................152 SLOW BLOW FUSE.....................................................................................153 LUNCH BOX TRAY.....................................................................................153 TOOL BOX...........................................................................................153 GREASE PUMP........................................................................................153 LOCATION OF FIRE EXTINGUISHER......................................................................154 POWER OUTLET.......................................................................................154 AM/FM RADIO-CASSETTE STEREO........................................................................155 AIR CONDITIONER....................................................................................164 OPERATION..............................................................................................179 CHECK BEFORE STARTING ENGINE, ADJUST...............................................................179 STARTING ENGINE....................................................................................196 OPERATIONS AND CHECKS AFTER STARTING ENGINE........................................................198 STOPPING ENGINE....................................................................................201 CHECK AFTER STOPPING ENGINE........................................................................201 MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE......................................202 TURNING............................................................................................210 OPERATION OF WORK EQUIPMENT........................................................................212 SEMI AUTO DIGGING OPERATIONS.......................................................................214 REMOTE POSITIONER..................................................................................215 WORK POSSIBLE USING WHEEL LOADER...................................................................217 PRECAUTIONS FOR OPERATION..........................................................................237 REMOVAL AND INSTALLATION OF THE BUCKET.............................................................240 PARKING MACHINE....................................................................................244 CHECKS AFTER COMPLETION OF OPERATION...............................................................246 LOCKING............................................................................................246 HANDLING THE TIRES.................................................................................247 TRANSPORTATION.........................................................................................250 TRANSPORTATION PROCEDURE...........................................................................250 LOADING, UNLOADING WORK............................................................................250 METHOD OF SECURING MACHINE.........................................................................250 METHOD OF LIFTING MACHINE..........................................................................252 PRECAUTIONS WHEN DISASSEMBLY OR REASSEMBLING WORK EQUIPMENT........................................255 COLD WEATHER OPERATION.................................................................................256 PRECAUTIONS FOR LOW TEMPERATURE....................................................................256 PRECAUTIONS AFTER COMPLETION OF WORK...............................................................257 AFTER COLD WEATHER.................................................................................257 WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER................................258 LONG-TERM STORAGE......................................................................................259 BEFORE STORAGE.....................................................................................259 DURING STORAGE.....................................................................................259 AFTER STORAGE......................................................................................259 TROUBLESHOOTING........................................................................................260 WHEN MACHINE RUNS OUT OF FUEL......................................................................260 METHOD OF TOWING MACHINE...........................................................................261 IF BATTERY IS DISCHARGED...........................................................................265 METHOD FOR LOWERING WORK EQUIPMENT WHEN ENGINE HAS STOPPED.........................................269 OTHER TROUBLE......................................................................................270 MAINTENANCE................................................................................................274 GUIDES TO MAINTENANCE..................................................................................275 OUTLINES OF SERVICE....................................................................................277 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.............................................277 OUTLINE OF ELECTRIC SYSTEM.........................................................................281 WEAR PARTS.............................................................................................282 WEAR PARTS LIST....................................................................................283 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...............................................................284 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...............................285 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL................287 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.........................................................288 TORQUE LIST........................................................................................288 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..........................................................290 SAFETY CRITICAL PARTS..............................................................................291 MAINTENANCE SCHEDULE CHART.............................................................................293 MAINTENANCE SCHEDULE CHART.........................................................................293 SERVICE PROCEDURE......................................................................................295 INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE)...............................295 INITIAL 250 HOURS SERVICE..........................................................................295 WHEN REQUIRED......................................................................................296 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT...................................................296 CLEAN INSIDE OF COOLING SYSTEM.................................................................299 CHECK TRANSMISSION OIL LEVEL, ADD OIL..........................................................303 CHECK AXLE OIL LEVEL, ADD OIL..................................................................305 CLEAN AXLE CASE BREATHER.......................................................................306 CLEAN AIR CONDITIONER CONDENSER................................................................307 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID....................................................307 CLEAN RADIATOR FINS............................................................................308 REPLACE BUCKET TEETH...........................................................................313 LUBRICATING....................................................................................315 CHECK AIR CONDITIONER..........................................................................316 REPLACE SLOW BLOW FUSE.........................................................................317 BLEEDING AIR FROM HYDRAULIC TANK...............................................................318 BLEEDING AIR FROM FUEL CIRCUIT.................................................................320 CHECKING FUNCTION OF ACCUMULATOR...............................................................323 SELECTION AND INSPECTION OF TIRES..............................................................324 CHECK BEFORE STARTING..............................................................................326 EVERY 50 HOURS SERVICE.............................................................................327 DRAIN WATER, SEDIMENT FROM FUEL TANK...........................................................327 EVERY 100 HOURS SERVICE............................................................................328 LUBRICATING....................................................................................328 LUBRICATE REAR AXLE PIVOT PIN..................................................................330 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL.....................................................331 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER..............................................332 EVERY 250 HOURS SERVICE............................................................................333 CHECK BATTERY ELECTROLYTE LEVEL................................................................333 CHECK PARKING BRAKE............................................................................335 CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN.......................................................335 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER..........................................335 CHECKING FUNCTION OF ACCUMULATOR...............................................................335 EVERY 500 HOURS SERVICE............................................................................336 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..............................336 REPLACE FUEL PRE-FILTER CARTRIDGE..............................................................338 REPLACE FUEL MAIN FILTER CARTRIDGE.............................................................340 REPLACE TRANSMISSION OIL FILTER ELEMENT........................................................341 REPLACE BRAKE OIL FILTER CARTRIDGE (IF EQUIPPED)...............................................342 CHECK, REPLACE COMPRESSOR DRIVE BELT FOR ALTERNATOR, AIR CONDITIONER...........................343 EVERY 1000 HOURS SERVICE...........................................................................344 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER................................................344 CLEAN TRANSMISSION CASE BREATHER...............................................................345 LUBRICATING....................................................................................346 REPLACE CORROSION RESISTOR CARTRIDGE (ONLY WHEN CORROSION RESISTOR CARTRIDGE IS USED)..........346 CHECK, GREASE COMPRESSOR DRIVE BELT TENSION PULLEY ASSEMBLY FOR ALTERNATOR, AIR CONDITIONER....347 EVERY 2000 HOURS SERVICE...........................................................................348 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT.................................348 CLEAN HYDRAULIC TANK STRAINER..................................................................350 REPLACE HYDRAULIC TANK BREATHER ELEMENT........................................................351 CHANGE AXLE OIL................................................................................352 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER..................353 CLEAN PPC CIRCUIT STRAINER.....................................................................353 CHECK ALTERNATOR...............................................................................354 CHECK ENGINE VALVE CLEARANCE, ADJUST...........................................................354 CHECK BRAKE DISC WEAR..........................................................................354 CHECKING FUNCTION OF ACCUMULATOR...............................................................354 CHECK BOOST PIPING CLAMPS......................................................................354 CHANGE OIL FOR WORK EQUIPMENT PINS.............................................................355 EVERY 4000 HOURS SERVICE...........................................................................356 CHECK WATER PUMP...............................................................................356 CHECK STARTING MOTOR...........................................................................356 CHECK AIR CONDITIONER COMPRESSOR, ADJUST.......................................................356 LUBRICATING....................................................................................357 CHECK FOR LOOSE ENGINE HIGH-PRESSURE PIPING CLAMPS, HARDENING OF RUBBER........................359 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER............................360 EVERY 8000 HOURS SERVICE...........................................................................361 REPLACE ENGINE HIGH-PRESSURE PIPING CLAMPS.....................................................361 REPLACE FUEL SPRAY PREVENTION CAP..............................................................361 OVERHAUL STARTING MOTOR AND ALTERNATOR.........................................................361 SPECIFICATIONS.............................................................................................362 SPECIFICATIONS.........................................................................................363 ATTACHMENTS, OPTIONS.......................................................................................368 HANDLING STEERING WHEEL SPECIFICATION MACHINE..........................................................369 EXPLANATION OF COMPONENTS..........................................................................369 FUNCTIONS OF STEERING WHEEL SPECIFICATION MACHINE..................................................379 SELECTING BUCKET AND TIRES.............................................................................389 STARTING IN COLD AREAS.................................................................................390 ELECTRIC HEATER....................................................................................390 HANDLING LOAD METER....................................................................................393 OUTLINE OF LOAD METER..............................................................................393 PRINCIPLE OF LOAD METER MEASUREMENT................................................................395 POINTS TO REMEMBER TO ENSURE HIGH ACCURACY.........................................................396 USING LOAD METER...................................................................................398 HANDLING AUTO-GREASING SYSTEM..........................................................................426 METHOD OF OPERATING AUTO-GREASING SYSTEM...........................................................426 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM.....................................................433 TROUBLESHOOTING....................................................................................433 HANDLING QUICK COUPLER CONTROL SYSTEM..................................................................434 EXPLANATION OF COMPONENTS..........................................................................434 FUNCTION AND METHOD OF OPERATION OF QUICK COUPLER SWITCH...........................................437 METHOD OF REMOVING AND INSTALLING ATTACHMENT.......................................................439 INSPECTION AND MAINTENANCE.........................................................................444 METHOD OF TURNING BOTTOM FRONT WORKING LAMP ON/OFF.................................................445 HANDLING BATTERY DISCONNECTOR SWITCH...................................................................446 EXPLANATION OF COMPONENTS..........................................................................446 HANDLING...........................................................................................446 HANDLING STARTING AID CONNECTOR........................................................................448 HANDLING REAR FENDER...................................................................................450 HANDLING...........................................................................................450 HANDLING MACHINES EQUIPPED WITH VHMS...................................................................451 VHMS INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED..............................................451 VHMS AND COMMUNICATIONS TERMINAL INSTALLED.........................................................451 INDEX......................................................................................................454
KOMATSU GALEO WA600-6 WHEEL LOADER OPERATION & MAINTENANCE MANUAL 60001 AND UP – PDF DOWNLOAD:
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Komatsu GALEO WA600-6 Wheel Loader Operation & Maintenance Manual
FOREWORD:
- This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance.
- Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance.
PLEASE NOTE:
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