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KOMATSU WA600-1 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A51001 & UP) KOMATSU WA600-1 – PDF DOWNLOAD
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- KOMATSU WA600-1 WHEEL LOADER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:A51001 & UP
- PUBLICATION NUMBER:CEAM000800
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Description
KOMATSU WA600-1 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A51001 & UP) KOMATSU WA600-1
KOMATSU WA600-1 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A51001 & UP) KOMATSU WA600-1 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU WA600-1 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A51001 & UP) KOMATSU WA600-1
- This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel realize peak performance through effective, economical and safe machine operation and maintenance. Keep this manual handy and have all personnel read it periodically.
- If this manual is lost or becomes dirty and can not be read, request a replacement manual from your local distributor. If you sell the machine, be sure to give this manual to the new owner.
- Continuing improvements in the design of this machine can lead to changes in detail, which may not be reflected in this manual. Consult your local distributor or Komatsu America International Company for the latest available information on your machine or for questions regarding information in this manual.
- Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines.To avoid accidents, read, understand and follow all precautions and warnings in this manual and on the machine before performing maintenance and machine operations. To identify safety messages in this manual and on machine product graphics, the following signal words are used.
- Komatsu America International Company cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety message in this manual and on the machine may not include all possible safety precautions. If any procedures or actions not specifically recommended or allowed in this manual are used, you must be sure that you and others can do such procedures and actions safely and without damaging the machine. If you are unsure about the safety of some procedures, contact your local distributor or Komatsu America International Company.
TABLE OF CONTENTS:
KOMATSU WA600-1 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A51001 & UP) KOMATSU WA600-1
MAIN MENU................................................................. 0 FORWARD................................................................... 5 SAFETY INFORMATION........................................................ 6 INTRODUCTION.............................................................. 7 BREAKING IN THE NEW MACHINE........................................... 7 MACHINE AND ENGINE SERIAL NUMBERS..................................... 8 QUICK REFERENCE INFORMATION........................................... 9 CONTENTS.................................................................. 10 SAFETY PRECAUTIONS -- SECTION 1........................................... 19 GENERAL PRECAUTIONS................................................... 20 PERSONNEL PRECAUTIONS............................................. 20 MACHINE PRECAUTIONS............................................... 20 OPERATION............................................................. 21 BEFORE STARTING................................................... 21 START-UP.......................................................... 22 GENERAL OPERATING PRECAUTIONS..................................... 22 DRIVING THE MACHINE............................................... 23 OPERATING THE ATTACHMENTS......................................... 24 PULLING/TOWING.................................................... 24 SHUTDOWN.......................................................... 25 MAINTENANCE........................................................... 25 GENERAL MACHINE PRECAUTIONS....................................... 25 GENERAL WORK PRECAUTIONS.......................................... 26 ACCUMULATORS...................................................... 27 ATTACHMENTS....................................................... 28 BRAKES............................................................ 28 CAB/ROPS.......................................................... 28 COOLING........................................................... 28 ELECTRICAL........................................................ 28 ENGINE............................................................ 29 FUEL SYSTEM....................................................... 30 HYDRAULICS........................................................ 30 TIRES AND RIMS.................................................... 30 TURBOCHARGER...................................................... 30 SAFETY PRODUCT GRAPHICS AND LOCATIONS................................. 32 OPERATION -- SECTION 2.................................................... 39 GENERAL VIEW.......................................................... 40 INSTRUMENTS AND CONTROLS.............................................. 41 MONITOR PANEL..................................................... 41 SYSTEM CHECK.................................................. 42 CHECK MONITOR LAMP GROUP...................................... 43 Brake Oil Level Monitor................................... 43 Engine Oil Level Monitor.................................. 44 Engine Coolant Level Monitor.............................. 44 CAUTION MONITOR LAMP GROUP.................................... 44 Charge Monitor............................................ 44 Fuel Level Monitor........................................ 45 Transmission Oil Filter Monitor........................... 45 CAUTION MONITOR LAMP GROUP.................................... 45 Brake Line Failure Monitor................................ 45 Engine Oil Pressure Monitor............................... 46 Engine Coolant Level Monitor.............................. 46 Air Pressure Monitor...................................... 46 Engine Coolant Temperature Monitor........................ 46 Torque Converter Oil Temperature Monitor.................. 47 Ground Driven Steering Operation Monitor - If Equipped.... 47 METER AND PILOT LAMP GROUP.................................... 48 Parking Brake Pilot Lamp.................................. 48 Working Lamp Pilot Lamp................................... 49 Transmission Cut-Off Selector Pilot Lamp.................. 49 Air Pressure Gauge........................................ 49 Engine Coolant Temperature Gauge.......................... 49 Torque Converter Oil Temperature Gauge.................... 50 Fuel Level Gauge.......................................... 50 Turn Signal Pilot Lamp.................................... 50 High Beam Pilot Lamp...................................... 50 Speedometer............................................... 51 Service Meter............................................. 51 ENGINE COOLANT TEMPERATURE MONITOR LAMP........................... 51 ENGINE MALFUNCTION & DIAGNOSTIC WARNING LIGHTS.................... 52 SWITCHES.......................................................... 53 TRANSMISSION CUT-OFF SELECTOR SWITCH.......................... 53 ETHER START SWITCH............................................ 53 ENGINE CONTROL MODULE (ECM) ON/OFF SWITCH..................... 54 ECM SELECT SWITCH............................................. 54 HORN BUTTON................................................... 54 HAZARD LAMP SWITCH............................................ 55 PARKING BRAKE SWITCH.......................................... 55 WORKING LAMP SWITCH........................................... 56 STARTING SWITCH............................................... 56 LAMP SWITCHES................................................. 56 Lamp switch............................................... 56 Turn signal lever......................................... 57 Dimmer switch............................................. 57 CIGARETTE LIGHTER............................................. 58 TRANSMISSION KICKDOWN SWITCH.................................. 58 FRONT WIPER SWITCH - IF EQUIPPED.............................. 59 REAR WIPER SWITCH - IF EQUIPPED............................... 59 CAB DOME LAMP SWITCH - IF EQUIPPED............................ 60 LEVERS AND PEDALS................................................. 61 DIRECTIONAL LEVER............................................. 61 SPEED CONTROL LEVER........................................... 62 SPEED CONTROL LEVER STOPPER................................... 62 STEERING COLUMN TILT LEVER.................................... 62 ACCELERATOR PEDAL............................................. 63 BRAKE PEDALS.................................................. 63 Right brake pedal......................................... 63 Left brake pedal.......................................... 63 LIFT ARM CONTROL LEVER........................................ 64 BUCKET CONTROL LEVER.......................................... 64 FRONT ATTACHMENT CONTROL LEVER - IF EQUIPPED.................. 65 WORK EQUIPMENT CONTROL LEVER LOCK............................. 65 CAB DOOR HOLD OPEN LOCK - IF EQUIPPED............................. 65 AIR CLEANER SERVICE INDICATOR..................................... 65 FRAME LOCKING BAR................................................. 66 MAIN CIRCUIT BREAKER.............................................. 66 FUSE BOXES........................................................ 66 OPERATOR'S SEAT................................................... 69 FORWARD-BACKWARD ADJUSTMENT................................... 69 SEAT ANGLE ADJUSTMENT......................................... 69 WEIGHT ADJUSTMENT............................................. 69 BACKREST TILT ADJUSTMENT...................................... 69 HEIGHT ADJUSTMENT............................................. 69 RIGHT SIDE ARMREST................................................ 69 HEIGHT ADJUSTMENT............................................. 69 ANGLE ADJUSTMENT.............................................. 69 SEAT BELT......................................................... 70 CAB HEATER AND DEFROSTER - IF EQUIPPED................................ 71 CONTROL PANEL..................................................... 71 FAN SPEED SWITCH.............................................. 71 TEMPERATURE CONTROL KNOB...................................... 71 AIR INTAKE SELECTOR KNOB...................................... 71 METHOD OF OPERATION............................................... 72 CAB HEATER, DEFROSTER AND AIR CONDITIONER - IF EQUIPPED............... 73 CONTROL PANEL..................................................... 73 FAN SPEED SWITCH.............................................. 73 TEMPERATURE CONTROL KNOB...................................... 73 AIR INTAKE SELECTOR KNOB...................................... 73 AIR CONDITIONER SWITCH........................................ 73 METHOD OF OPERATION............................................... 74 PRECAUTIONS FOR USING AIR CONDITIONER......................... 75 HANDLING AIR CONDITIONER IN SEASON............................ 75 HANDLING AIR CONDITIONER IN OFF-SEASONS....................... 75 FUEL TANK FILLER CAP LOCKING COVER.................................... 76 LOCKING FILLER CAPS - IF EQUIPPED..................................... 77 CHECKS BEFORE STARTING ENGINE......................................... 78 WALK AROUND CHECK................................................. 78 CHECKS BEFORE STARTING............................................ 78 OPERATING MACHINE..................................................... 79 OPERATIONS BEFORE STARTING ENGINE................................. 79 STARTING ENGINE................................................... 81 NORMAL STARTING............................................... 81 SPECIAL STARTING.............................................. 81 COLD WEATHER STARTING......................................... 82 OPERATIONS AFTER STARTING ENGINE.................................. 83 COLD WEATHER WARM-UP PROCEDURE.................................... 83 MOVING MACHINE OFF................................................ 84 SHIFTING GEAR..................................................... 86 SHIFTING BETWEEN FORWARD AND REVERSE.............................. 87 STEERING MACHINE.................................................. 87 STOPPING MACHINE.................................................. 88 OPERATIONAL PRECAUTIONS........................................... 89 PERMISSIBLE WATER DEPTH....................................... 89 IF WHEEL BRAKES DO NOT WORK................................... 89 WHEN TRAVELING UP OR DOWN SLOPES.............................. 89 Lower Center of Gravity When Turning...................... 89 Braking on Downhill Slopes................................ 89 lf Engine Stops........................................... 89 POSSIBLE WORK USING LOADER........................................ 90 EXCAVATION.................................................... 90 LEVELING...................................................... 92 LOAD AND CARRY OPERATIONS..................................... 93 LOADING....................................................... 93 Cross Drive Loading....................................... 93 V-Shape Loading........................................... 93 PARKING MACHINE................................................... 94 STOPPING ENGINE................................................... 95 OPERATIONS AFTER STOPPING ENGINE.................................. 95 ADJUSTMENT OF WORK EQUIPMENT.......................................... 96 ADJUSTING BOOM KICK-OUT........................................... 96 ADJUSTING BUCKET POSITIONER....................................... 97 BUCKET LEVEL INDICATOR............................................ 97 BUCKET REMOVAL AND INSTALLATION....................................... 98 REMOVAL........................................................... 98 INSTALLATION......................................................100 HANDLING TIRES........................................................103 PRECAUTIONS WHEN HANDLING TIRES...................................103 PRECAUTIONS WHEN DRIVING MACHINE..................................103 NORMAL OPERATING INFLATION PRESSURE...............................104 INFLATING TIRES...............................................104 PROPER BUCKET AND TIRE SELECTION TABLE............................106 TOWING................................................................107 TOWING THE MACHINE................................................107 WHEN ENGINE CAN BE USED.......................................107 WHEN ENGINE CANNOT BE USED....................................107 RELEASING PARKING BRAKE...........................................107 TRANSPORTATION........................................................108 COLD WEATHER OPERATION................................................109 PREPARATION FOR LOW TEMPERATURE...................................109 FUEL AND LUBRICANTS...............................................109 COOLANT.......................................................109 BATTERY.......................................................109 CAUTIONS AFTER COMPLETION OF WORK.................................110 AFTER COLD WEATHER................................................110 LONG TERM STORAGE.....................................................111 BEFORE STORAGE....................................................111 DURING STORAGE....................................................111 AFTER STORAGE.....................................................111 HANDLING OF BATTERY...................................................112 PRECAUTIONS FOR CHARGING BATTERY..................................112 REMOVAL AND INSTALLATION OF BATTERY...............................112 STARTING ENGINE WITH BOOSTER CABLES...............................113 BEFORE CONNECTING BOOSTER CABLES..............................113 CONNECTING BOOSTER CABLES.....................................113 STARTING ENGINE...............................................113 DISCONNECTING BOOSTER CABLES..................................114 TROUBLESHOOTING.......................................................115 ELECTRICAL SYSTEM.................................................115 ENGINE............................................................115 CHASSIS...........................................................116 TRANSMISSION..................................................116 DRIVE AXLES...................................................116 WHEEL BRAKES..................................................116 PARKING BRAKE.................................................116 STEERING......................................................116 EQUIPMENT HYDRAULIC SYSTEM....................................116 MAINTENANCE -- SECTION 3..................................................117 PERIODIC MAINTENANCE..................................................118 MAINTENANCE GUIDELINES................................................118 OUTLINES OF SERVICE...................................................120 LUBRICATION WHEN SHIPPED..........................................120 RELATING TO ENGINE................................................120 ENGINE OIL....................................................120 COOLANT.......................................................120 DIESEL FUEL...................................................121 RELATING TO HYDRAULIC SYSTEM......................................121 RELATING TO ELECTRICAL SYSTEM.....................................121 RELATING TO LUBRICATION...........................................122 WEAR PARTS REPLACEMENT................................................123 PERIODICAL PART REPLACEMENT...........................................124 LUBRICANTS, FUEL AND COOLANT..........................................125 PROPER SELECTION TABLE............................................125 ENGINE OIL....................................................126 Normal Operation..........................................126 Arctic Operation..........................................126 AXLE OIL......................................................127 GREASE........................................................127 DIESEL FUEL...................................................127 COOLANT.......................................................127 SCHEDULED MAINTENANCE GUIDE...........................................133 FILLER AND LEVEL GAUGE POSITIONS......................................138 INITIAL 250 HOURS SERVICE ONLY........................................140 TRANSMISSION OIL FILTER...........................................140 WHEN REQUIRED.........................................................140 COOLANT ADDITIVE CONCENTRATION - SCA..............................140 AIR CLEANER ELEMENTS..............................................140 CHECKING......................................................140 CLEANING OR REPLACING OUTER ELEMENT...........................140 REPLACING INNER ELEMENT.......................................141 CLEANING OUTER ELEMENT........................................141 Using Compressed Air......................................141 Using Water...............................................141 Using Water With Cleaning Agent...........................141 TRANSMISSION OIL LEVEL............................................142 RADIATOR CORE.....................................................143 DRIVE AXLE OIL LEVEL..............................................144 DRIVE AXLE HOUSING BREATHERS......................................145 LUBRICATION.......................................................146 HYDRAULIC TANK....................................................146 PPC (PROPORTIONAL PRESSURE CONTROL) CIRCUIT.......................147 WHEEL BRAKE HYDRAULIC CIRCUIT.....................................148 PARKING BRAKE.....................................................149 BUCKET TEETH - IF EQUIPPED........................................150 BUCKET EQUIPPED WITH BOLT-ON TEETH............................150 BUCKET EQUIPPED WlTH REPLACEABLE TOOTH TIP....................150 BUCKET BOLT-ON CUTTING EDGE - IF EQUIPPED.........................151 WINDOW WASHER TANKS - IF EQUIPPED.................................151 AIR CONDITIONER CONDENSER - IF EQUIPPED...........................152 AIR CONDITIONER REFRIGERANT CHARGE - IF EQUIPPED..................152 ALTERNATOR DRIVE BELT.............................................153 FAN DRIVE BELT....................................................153 ALTERNATOR........................................................153 CRANKING MOTOR....................................................153 AIR GOVERNOR......................................................153 TRANSMISSION CONTROL LEVERS.......................................154 CHECKS BEFORE STARTING ENGINE.........................................155 COOLANT LEVEL.....................................................155 ENGINE OIL LEVEL..................................................155 FUEL LEVEL........................................................156 AIR CLEANER SERVICE INDICATOR.....................................157 AIR TANKS.........................................................157 BRAKE OIL LEVEL...................................................158 FUEL FILTER/WATER SEPARATOR.......................................158 ENGINE FAN........................................................159 DRIVE BELTS.......................................................159 BELT INSPECTION...............................................159 BELT TENSION CHECK............................................159 MONITOR PANEL.....................................................160 ADDITIONAL CHECKS.................................................161 EVERY 50 HOURS SERVICE................................................161 FUEL TANK.........................................................161 TIRES.............................................................161 ENGINE AIR INTAKE SYSTEM..........................................162 EVERY 100 HOURS SERVICE...............................................162 HYDRAULIC TANK OIL LEVEL..........................................162 LUBRICATION.......................................................163 CAB AIR FILTER - IF EQUIPPED......................................163 EVERY 250 HOURS SERVICE...............................................165 ENGINE OIL AND FILTERS............................................165 FUEL FILTERS......................................................166 GENERAL.......................................................166 REPLACEMENT.......................................................167 COOLANT FILTER....................................................168 GENERAL.......................................................168 REPLACEMENT...................................................168 ENGINE CRANKCASE BREATHERS AND TUBES/HOSES........................169 BATTERY ELECTROLYTE LEVELS........................................169 LUBRICATION.......................................................170 WHEEL HUB NUTS....................................................173 AIR CONDITIONER COMPRESSOR DRIVE BELT - IF EQUIPPED...............173 EVERY 500 HOURS SERVICE...............................................174 TRANSMISSION OIL FILTER...........................................174 LUBRICATION.......................................................174 AIR DRYER - IF EQUIPPED...........................................175 EVERY 1000 HOURS SERVICE..............................................175 TRANSMISSION OIL AND STRAINERS....................................175 TRANSMISSION CASE BREATHER........................................176 LUBRICATION.......................................................177 EVERY 1500 HOURS SERVICE..............................................179 ENGINE VALVES AND INJECTORS.......................................179 EVERY 2000 HOURS SERVICE..............................................179 ENGINE............................................................179 ENGINE MOUNTED HOSES..............................................180 ENGINE MOUNTING HARDWARE..........................................180 ENGINE CRANKSHAFT END CLEARANCE...................................180 ENGINE FAN IDLER PULLEY PIVOT ARM.................................180 TURBOCHARGER MOUNTING.............................................181 BATTERIES.........................................................181 VISUAL INSPECTION.............................................181 STATE OF CHARGE TEST..........................................181 Specific Gravity Hydrometer Test..........................182 Stabilized Open Circuit Voltage Test......................182 HYDRAULIC TANK OIL AND FILTERS....................................183 HYDRAULIC TANK BREATHERS..........................................184 PPC CIRCUIT STRAINER..............................................185 CAB AIR FILTER - IF EQUIPPED......................................185 DRIVE AXLE OIL....................................................186 PARKING BRAKE DISC................................................187 AIR DRYER - IF EQUIPPED...........................................187 ACCUMULATOR.......................................................188 COOLING SYSTEM....................................................188 COOLANT RECOMMENDATlONS/SPEClFlCATiONS........................188 CHANGING COOLANT AND FLUSHING SYSTEM..........................188 EVERY 6000 HOURS SERVICE..............................................191 FUEL PUMP.........................................................191 FUEL INJECTORS....................................................191 ENGINE FAN HUB....................................................191 ENGINE FAN IDLER PULLEY...........................................191 WATER PUMP........................................................191 TURBOCHARGER......................................................191 AIR COMPRESSOR....................................................191 ENGINE VIBRATION DAMPER...........................................191 SPECIFICATION -- SECTION 4................................................193 GENERAL SPECIFICATIONS - MACHINES WITH STANDARD BOOM..................194 OPERATING WEIGHT..................................................194 PERFORMANCE.......................................................194 ENGINE............................................................194 GENERAL SPECIFICATIONS - MACHINES WITH HIGH LIFT BOOM.................195 OPERATING WEIGHT..................................................195 PERFORMANCE.......................................................195 ENGINE............................................................195 DIMENSIONS............................................................196 STANDARD TIGHTENING TORQUES...........................................198 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS......................198 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS...........................198 TIGHTENING TORQUE FOR NUTS OF FLARED FITTINGS.....................199
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