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KOMATSU WA600-1L WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:WA600-1 L Al 0391 and up) KOMATSU WA600-1L – PDF DOWNLOAD
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- KOMATSU WA600-1L WHEEL LOADER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:WA600-1 L Al 0391 and up
- PUBLICATION NUMBER:CEAMW26010
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KOMATSU WA600-1L WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:WA600-1 L Al 0391 and up) KOMATSU WA600-1L
KOMATSU WA600-1L WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:WA600-1 L AL 0391 AND UP) KOMATSU WA600-1L – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU WA600-1L WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:WA600-1 L Al 0391 and up) KOMATSU WA600-1L
- This manual provides rules and guidelines, which will help you use this machine safely and effectively. 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 are the owner or end user or from Komatsu Dresser Co. if you are a 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 if you are the owner or end user or consult Komatsu Dresser Co. if you are a distributor for the latest available information on your machine or for questions regarding information in this manual.
TABLE OF CONTENTS:
KOMATSU WA600-1L WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:WA600-1 L Al 0391 and up) KOMATSU WA600-1L
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........................................... 17 GENERAL PRECAUTIONS................................................... 18 PERSONNEL PRECAUTIONS............................................. 18 MACHINE PRECAUTIONS............................................... 18 OPERATION............................................................. 19 BEFORE STARTING................................................... 19 START-UP.......................................................... 20 GENERAL OPERATING PRECAUTIONS..................................... 20 DRIVING THE MACHINE............................................... 21 OPERATING THE ATTACHMENTS......................................... 22 PULLING/TOWING.................................................... 22 SHUTDOWN.......................................................... 23 MAINTENANCE........................................................... 23 GENERAL MACHINE PRECAUTIONS....................................... 23 GENERAL WORK PRECAUTIONS.......................................... 24 ACCUMULATORS...................................................... 25 ATTACHMENTS....................................................... 26 BRAKES............................................................ 26 CAB/ROPS.......................................................... 26 COOLING........................................................... 26 ELECTRICAL........................................................ 26 ENGINE............................................................ 27 FUEL SYSTEM....................................................... 28 HYDRAULICS........................................................ 28 TIRES AND RIMS.................................................... 28 TURBOCHARGER...................................................... 28 SAFETY PRODUCT GRAPHICS AND LOCATIONS................................. 30 OPERATION -- SECTION 2.................................................... 37 GENERAL VIEW.......................................................... 38 INSTRUMENTS AND CONTROLS.............................................. 39 MONITOR PANEL..................................................... 39 SYSTEM CHECK.................................................. 40 CHECK MONITOR LAMP GROUP...................................... 41 Brake Oil Level Monitor................................... 41 Engine Oil Level Monitor.................................. 42 Engine Coolant Level Monitor.............................. 42 CAUTION MONITOR LAMP GROUP.................................... 42 Charge Monitor............................................ 42 Fuel Level Monitor........................................ 43 Transmission Oil Filter Monitor........................... 43 CAUTION MONITOR LAMP GROUP.................................... 43 Brake Line Failure Monitor................................ 43 Engine Oil Pressure Monitor............................... 44 Engine Coolant Level Monitor.............................. 44 Air Pressure Monitor...................................... 44 Engine Coolant Temperature Monitor........................ 44 Torque Converter Oil Temperature Monitor.................. 45 Ground Driven Steering Operation Monitor - If Equipped.... 45 METER AND PILOT LAMP GROUP.................................... 46 Parking Brake Pilot Lamp.................................. 46 Working Lamp Pilot Lamp................................... 47 Engine Pre-Heating Monitor Lamp........................... 47 Engine After-Heating Monitor Lamp......................... 47 Transmission Cut-Off Selector Pilot Lamp.................. 47 Air Pressure Gauge........................................ 48 Engine Coolant Temperature Gauge.......................... 48 Torque Converter Oil Temperature Gauge.................... 48 Fuel Level Gauge.......................................... 48 Turn Signal Pilot Lamp.................................... 49 High Beam Pilot Lamp...................................... 49 Speedometer............................................... 49 Service Meter............................................. 49 SWITCHES.......................................................... 50 TRANSMISSION CUT-OFF SELECTOR SWITCH.......................... 50 ENGINE FUEL CUT-OFF SWITCH.................................... 51 HORN BUTTON................................................... 51 HAZARD LAMP SWITCH............................................ 51 PARKING BRAKE SWITCH.......................................... 52 WORKING LAMP SWITCH........................................... 53 ENGINE PRE-HEATER SWITCH...................................... 53 STARTING SWITCH............................................... 53 LAMP SWITCHES................................................. 54 Lamp switch............................................... 54 Turn signal lever......................................... 54 Dimmer switch............................................. 54 CIGARETTE LIGHTER............................................. 55 TRANSMISSION KICKDOWN SWITCH.................................. 55 FRONT WIPER SWITCH - IF EQUIPPED.............................. 56 REAR WIPER SWITCH - IF EQUIPPED............................... 56 CAB DOME LAMP SWITCH - IF EQUIPPED............................ 57 LEVERS AND PEDALS................................................. 58 DIRECTIONAL LEVER............................................. 58 SPEED CONTROL LEVER........................................... 59 SPEED CONTROL LEVER STOPPER................................... 59 STEERING COLUMN TILT LEVER.................................... 59 ACCELERATOR PEDAL............................................. 60 BRAKE PEDALS.................................................. 60 Right brake pedal......................................... 60 Left brake pedal.......................................... 60 LIFT ARM CONTROL LEVER........................................ 61 BUCKET CONTROL LEVER.......................................... 61 FRONT ATTACHMENT CONTROL LEVER - IF EQUIPPED.................. 62 WORK EQUIPMENT CONTROL LEVER LOCK............................. 62 CAB DOOR HOLD OPEN LOCK - IF EQUIPPED............................. 62 AIR CLEANER SERVICE INDICATOR..................................... 62 FRAME LOCKING BAR................................................. 63 MAIN CIRCUIT BREAKER.............................................. 63 FUSE BOXES........................................................ 63 OPERATOR'S SEAT................................................... 66 FORWARD-BACKWARD ADJUSTMENT................................... 66 SEAT ANGLE ADJUSTMENT......................................... 66 WEIGHT ADJUSTMENT............................................. 66 BACKREST TILT ADJUSTMENT...................................... 66 HEIGHT ADJUSTMENT............................................. 66 RIGHT SIDE ARMREST................................................ 66 HEIGHT ADJUSTMENT............................................. 66 ANGLE ADJUSTMENT.............................................. 66 SEAT BELT......................................................... 67 CAB HEATER AND DEFROSTER - IF EQUIPPED................................ 68 CONTROL PANEL..................................................... 68 FAN SPEED SWITCH.............................................. 68 TEMPERATURE CONTROL LEVER..................................... 68 AIR INTAKE SELECTOR LEVER..................................... 68 METHOD OF OPERATION............................................... 69 CAB HEATER, DEFROSTER AND AIR CONDITIONER - IF EQUIPPED............... 70 CONTROL PANNEL.................................................... 70 FAN SPEED SWITCH.............................................. 70 AIR CONDITIONER SWITCH........................................ 70 TEMPERATURE CONTROL LEVER..................................... 70 AIR INTAKE SELECTOR LEVER..................................... 70 METHOD OF OPERATION............................................... 71 PRECAUTIONS FOR USING AIR CONDITIONER......................... 72 HANDLING AIR CONDITIONER IN SEASON............................ 72 HANDLING AIR CONDITIONER IN OFF-SEASONS....................... 72 FUEL TANK FILLER CAP LOCKING COVER.................................... 73 LOCKING FILLER CAPS - IF EQUIPPED..................................... 74 CHECKS BEFORE STARTING ENGINE......................................... 75 WALK AROUND CHECK................................................. 75 CHECKS BEFORE STARTING............................................ 75 OPERATING MACHINE..................................................... 76 OPERATIONS BEFORE STARTING ENGINE................................. 76 STARTING ENGINE................................................... 78 NORMAL STARTING............................................... 78 SPECIAL STARTING.............................................. 78 COLD WEATHER STARTING......................................... 79 Using Automatic Priming System (APS)...................... 79 Using Manual Preheating................................... 81 OPERATIONS AFTER STARTING ENGINE.................................. 82 COLD WEATHER WARM-UP PROCEDURE.................................... 82 MOVING MACHINE OFF................................................ 83 SHIFTING GEAR..................................................... 85 SHIFTING BETWEEN FORWARD AND REVERSE.............................. 86 STEERING MACHINE.................................................. 86 STOPPING MACHINE.................................................. 87 OPERATIONAL PRECAUTIONS........................................... 88 PERMISSIBLE WATER DEPTH....................................... 88 IF WHEEL BRAKES DO NOT WORK................................... 88 WHEN TRAVELING UP OR DOWN SLOPES.............................. 88 Lower Center of Gravity When Turning...................... 88 Braking on Downhill Slopes................................ 88 If Engine Stops........................................... 88 POSSIBLE WORK USING LOADER........................................ 89 EXCAVATION.................................................... 89 LEVELING...................................................... 91 LOAD AND CARRY OPERATIONS..................................... 92 LOADING....................................................... 92 Cross Drive Loading....................................... 92 V-Shape Loading........................................... 92 PARKING MACHINE................................................... 93 STOPPING ENGINE................................................... 94 OPERATIONS AFTER STOPPING ENGINE.................................. 94 ADJUSTMENT OF WORK EQUIPMENT.......................................... 95 ADJUSTING BOOM KICKOUT............................................ 95 ADJUSTING BUCKET POSITIONER....................................... 96 BUCKET LEVEL INDICATOR............................................ 96 BUCKET REMOVAL AND INSTALLATION....................................... 97 REMOVAL........................................................... 97 INSTALLATION...................................................... 99 HANDLING TIRES........................................................102 PRECAUTIONS WHEN HANDLING TIRES...................................102 PRECAUTIONS WHEN DRIVING MACHINE..................................102 NORMAL OPERATING INFLATION PRESSURE...............................103 INFLATING TIRES...............................................103 PROPER BUCKET AND TIRE SELECTION TABLE............................105 TOWING................................................................106 TOWING THE MACHINE................................................106 WHEN ENGINE CAN BE USED.......................................106 WHEN ENGINE CANNOT BE USED....................................106 RELEASING PARKING BRAKE...........................................106 TRANSPORTATION........................................................107 COLD WEATHER OPERATION................................................108 PREPARATION FOR LOW TEMPERATURE...................................108 FUEL AND LUBRICANTS...........................................108 COOLANT.......................................................108 BATTERY.......................................................108 CAUTIONS AFTER COMPLETION OF WORK.................................109 AFTER COLD WEATHER................................................109 LONG TERM STORAGE.....................................................110 BEFORE STORAGE....................................................110 DURING STORAGE....................................................110 AFTER STORAGE.....................................................110 HANDLING OF BATTERY...................................................111 PRECAUTIONS FOR CHARGING BATTERY..................................111 REMOVAL AND INSTALLATION OF BATTERY...............................111 STARTING ENGINE WITH BOOSTER CABLES...............................112 BEFORE CONNECTING BOOSTER CABLES..............................112 CONNECTING BOOSTER CABLES.....................................112 STARTING ENGINE...............................................112 DISCONNECTING BOOSTER CABLES..................................113 TROUBLESHOOTING.......................................................114 ELECTRICAL SYSTEM.................................................114 ENGINE............................................................114 CHASSIS...........................................................115 TRANSMISSION..................................................115 DRIVE AXLES...................................................115 WHEEL BRAKES..................................................115 PARKING BRAKE.................................................115 STEERING......................................................115 EQUIPMENT HYDRAULIC SYSTEM....................................115 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..........................................127 AXLE OIL......................................................127 GREASE........................................................127 DIESEL FUEL...................................................127 COOLANT.......................................................128 SCHEDULED MAINTENANCE GUIDE...........................................132 FILLER AND LEVEL GAUGE POSITIONS......................................138 INITIAL 250 HOURS SERVICE ONLY........................................140 TRANSMISSION OIL FILTER...........................................140 FUEL FILTER.......................................................140 ENGINE VALVE CLEARANCE............................................140 WHEN REQUIRED.........................................................141 COOLANT ADDITIVE CONCENTRATION - DCA4.............................141 AIR CLEANER ELEMENTS..............................................141 CHECKING......................................................141 CLEANING OR REPLACING OUTER ELEMENT...........................141 REPLACING INNER ELEMENT.......................................142 CLEANING OUTER ELEMENT........................................142 Using Compressed Air......................................142 Using Water...............................................142 Using Water With Cleaning Agent...........................142 TRANSMISSION OIL LEVEL............................................143 RADIATOR CORE.....................................................144 DRIVE AXLE OIL LEVEL..............................................145 DRIVE AXLE HOUSING BREATHERS......................................146 LUBRICATION.......................................................147 HYDRAULIC TANK....................................................148 PPC (PROPORTIONAL PRESSURE CONTROL) CIRCUIT.......................150 WHEEL BRAKE HYDRAULIC CIRCUIT.....................................151 PARKING BRAKE.....................................................152 BUCKET TEETH - IF EQUIPPED........................................153 BUCKET EQUIPPED WITH BOLT-ON TEETH............................153 BUCKET EQUIPPED WITH REPLACEABLE TOOTH........................153 BUCKET BOLT-ON CUTTING EDGE - IF EQUIPPED.........................154 WINDOW WASHER TANKS - IF EQUIPPED.................................154 AIR CONDITIONER CONDENSER - IF EQUIPPED...........................155 AIR CONDITIONER REFRIGERANT CHARGE - IF EQUIPPED..................155 ALTERNATOR DRIVE BELT.............................................156 FAN DRIVE BELT....................................................157 ALTERNATOR........................................................158 CRANKING MOTOR....................................................158 AIR GOVERNOR......................................................158 TRANSMISSION CONTROL LEVERS.......................................159 CHECKS BEFORE STARTING ENGINE.........................................161 COOLANT LEVEL.....................................................161 ENGINE OIL LEVEL..................................................161 FUEL LEVEL........................................................162 AIR CLEANER SERVICE INDICATOR.....................................163 AIR TANKS.........................................................163 BRAKE OIL LEVEL...................................................164 FUEL FILTER/WATER SEPARATOR.......................................164 ENGINE FAN........................................................165 DRIVE BELTS.......................................................165 BELT INSPECTION...............................................165 BELT TENSION CHECK............................................165 MONITOR PANEL.....................................................166 ADDITIONAL CHECKS.................................................167 EVERY 50 HOURS SERVICE................................................168 FUEL TANK.........................................................168 TIRES.............................................................168 ENGINE AIR INTAKE SYSTEM..........................................168 EVERY 100 HOURS SERVICE...............................................169 HYDRAULIC TANK OIL LEVEL..........................................169 LUBRICATION.......................................................170 CAB AIR FILTER - IF EQUIPPED......................................170 EVERY 250 HOURS SERVICE...............................................172 ENGINE OIL AND FILTERS............................................172 FUEL FILTERS......................................................174 GENERAL.......................................................174 REPLACEMENT...................................................174 COOLANT FILTER....................................................177 GENERAL.......................................................177 REPLACEMENT...................................................177 ENGINE CRANKCASE -BREATHERS AND TUBES/HOSES.......................178 BATTERY ELECTROLYTE LEVELS........................................179 LUBRICATION.......................................................179 WHEEL HUB NUTS....................................................183 AIR CONDITIONER COMPRESSOR DRIVE BELT - IF EQUIPPED...............183 EVERY 500 HOURS SERVICE...............................................185 TRANSMISSION OIL FILTER...........................................185 LUBRICATION.......................................................185 AIR DRYER - IF EQUIPPED...........................................186 FAN BELT..........................................................186 EVERY 1000 HOURS SERVICE..............................................187 TRANSMISSION OIL AND STRAINERS....................................187 TRANSMISSION CASE BREATHER........................................188 LUBRICATION.......................................................189 EVERY 2000 HOURS SERVICE..............................................193 ENGINE............................................................193 ENGINE MOUNTED HOSES..............................................193 ENGINE MOUNTING HARDWARE..........................................193 ENGINE CRANKSHAFT END CLEARANCE...................................194 ENGINE FAN IDLER PULLEY PIVOT ARM.................................194 TURBOCHARGER MOUNTING.............................................194 BATTERIES.........................................................195 VISUAL INSPECTION.............................................195 STATE OF CHARGE TEST..........................................195 Specific Gravity Hydrometer Test..........................196 Stabilized Open Circuit Voltage Test......................196 HYDRAULIC TANK OIL AND FILTERS....................................197 HYDRAULIC TANK BREATHERS..........................................198 PPC CIRCUIT STRAINER..............................................199 CAB AIR FILTER - IF EQUIPPED......................................199 DRIVE AXLE OIL....................................................200 PARKING BRAKE DISC................................................201 AIR DRYER - IF EQUIPPED...........................................201 ACCUMULATOR.......................................................202 COOLING SYSTEM....................................................202 COOLANT RECOMMENDATIONS/SPECIFICATIONS........................202 CHANGING COOLANT AND FLUSHING SYSTEM..........................202 EVERY 4000 HOURS SERVICE..............................................205 FUEL PUMP.........................................................205 FUEL INJECTORS....................................................205 ENGINE FAN HUB....................................................205 ENGINE FAN IDLER PULLEY...........................................205 WATER PUMP........................................................205 TURBOCHARGER......................................................205 AIR COMPRESSOR....................................................206 ENGINE VIBRATION DAMPER...........................................206 SPECIFICATIONS -- SECTION 4...............................................207 GENERAL SPECIFICATIONS - MACHINES WITH STANDARD BOOM..................208 OPERATING WEIGHT .................................................208 PERFORMANCE.......................................................208 ENGINE............................................................208 GENERAL SPECIFICATIONS - MACHINES WITH HIGH LIFT BOOM.................209 OPERATING WEIGHT..................................................209 PERFORMANCE.......................................................209 DIMENSIONS............................................................210 STANDARD TIGHTENING TORQUES...........................................212 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS......................212 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS...........................212 TIGHTENING TORQUE FOR NUTS OF FLARED FITTlNGS.....................213
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⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
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