Komatsu WA600-3 Wheel Loader Operation & Maintenance Manual SN A52001 and up – PDF DOWNLOAD

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Komatsu WA600-3 Wheel Loader Operation & Maintenance Manual

FILE DETAILS:

Komatsu WA600-3 Wheel Loader Operation & Maintenance Manual 

Model Specification: KOMATSU WA600-3 WHEEL LOADER
Language: English
File Format: PDF
Total Pages: 257
Requirements: Adobe PDF Reader
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KOMATSU WA600-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL SN A52001 AND UP – PDF DOWNLOAD:

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DESCRIPTION:

Komatsu WA600-3 Wheel Loader Operation & Maintenance Manual 

FOREWORD:

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.

TABLE OF CONTENTS:

Komatsu WA600-3 Wheel Loader Operation & Maintenance Manual 

MAIN MENU.............................................................................................  0
INTRODUCTION..........................................................................................  4
	1. FORWARD........................................................................................  5
	2. SAFETY INFORMATION.............................................................................  6
	3. INTRODUCTION...................................................................................  7
		3.1 INTENDED USE..............................................................................  7
		3.2 FEATURES..................................................................................  7
		3.3 BREAKING IN A NEW MACHINE.................................................................  7
	4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR..................................  8
		4.1 MACHINE SERIAL NO. PLATE POSITION.........................................................  8
		4.2 ENGINE SERIAL NO. PLATE POSITION..........................................................  8
		4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.................................................  9
	5. TABLE OF CONTENTS.............................................................................. 10
SAFETY ............................................................................................... 16
	6. GENERAL PRECAUTIONS  .......................................................................... 17
	7. PRECAUTIONS DURING OPERATION .................................................................. 23
		7.1 BEFORE STARTING ENGINE ................................................................... 23
		7.2 AFTER STARTING ENGINE .................................................................... 26
		7.3 TRANSPORTATION ........................................................................... 34
		7.4 BATTERY .................................................................................. 35
		7.5 TOWING ................................................................................... 38
	8. PRECAUTIONS FOR MAINTENANCE ................................................................... 39
		8.1 BEFORE CARRYING OUT MAINTENANCE .......................................................... 39
		8.2 DURING MAINTENANCE ....................................................................... 44
		8.3 TIRES .................................................................................... 50
	9. SAFETY LABELS ................................................................................. 52
		9.1 POSITION FOR ATTACHING SAFETY LABELS ..................................................... 52
OPERATION ............................................................................................ 57
	10. GENERAL VIEW ................................................................................. 58
		10.1 GENERAL VIEW OF MACHINE ................................................................. 58
		10.2 GENERAL VIEW OF CONTROLS AND GAUGES ..................................................... 59
			10.2.1 CONTROLS........................................................................... 59
			10.2.2 MAIN MONITOR....................................................................... 59
			10.2.3 MAINTENANCE MONITOR................................................................ 60
	11. EXPLANATION OF COMPONENTS .................................................................... 61
		11.1 MACHINE MONITORS ........................................................................ 61
			11.1.1 WARNING DISPLAYS................................................................... 63
			11.1.2 METER DISPLAY PORTION.............................................................. 68
		11.2 SWITCHES ................................................................................ 72
		11.3 LEVERS AND PEDALS ....................................................................... 80
		11.4 CAB DOOR HOLD-OPEN LOCK ................................................................. 84
		11.5 AIR CLEANER SERVICE INDICATOR ........................................................... 84
		11.6 FRAME LOCKING BAR ....................................................................... 84
		11.7 FUSE BOXES .............................................................................. 85
		11.8 FUSE ARRANGEMENT AND CIRCUIT ............................................................ 85
		11.9 SLOW-BLOW FUSE .......................................................................... 87
		11.10 AIR CONDITIONER MAINTENANCE IN OFF-  SEASON ............................................ 87
		11.11 COOL BOX ............................................................................... 87
		11.12 TANK FILLER CAPS AND LOCKS ............................................................. 88
			11.12.1 FUEL TANK......................................................................... 88
			11.12.2 HYDRAULIC FLUID TANK.............................................................. 88
	12. OPERATING MACHINE ............................................................................ 89
		12.1 CHECKS BEFORE STARTING .................................................................. 89
			12.1.1 WALK-AROUND CHECK.................................................................. 89
			12.1.2 CHECK BEFORE STARTING.............................................................. 91
			12.1.3 ADJUSTMENT BEFORE OPERATION........................................................ 91
			12.1.4 OPERATIONS BEFORE STARTING THE ENGINE.............................................. 94
		12.2 STARTING THE ENGINE ..................................................................... 95
			12.2.1 NORMAL STARTING.................................................................... 95
			12.2.2 SPECIAL STARTING................................................................... 95
			12.2.3 COLD WEATHER STARTING.............................................................. 96
		12.3 OPERATIONS AFTER STARTING THE ENGINE .................................................... 97
			12.3.1 COLD WEATHER WARM-UP PROCEDURE..................................................... 97
		12.4 MOVING THE MACHINE ...................................................................... 99
		12.5 CHANGING GEAR SPEED .....................................................................101
		12.6 SHIFTING BETWEEN FORWARD AND  REVERSE ...................................................102
		12.7 STEERING ................................................................................102
		12.8 STOPPING THE MACHINE ....................................................................103
		12.9 OPERATION OF WORK EQUIPMENT  ............................................................104
		12.10 WORK POSSIBLE USING WHEEL LOADER .......................................................105
			12.10.1 DIGGING PILED GROUND..............................................................105
			12.10.2 DIGGING LEVEL GROUND..............................................................107
			12.10.3 LEVELING OPERATION................................................................108
			12.10.4 PUSHING OPERATION.................................................................108
			12.10.5 LOAD AND CARRY OPERATIONS.........................................................108
			12.10.6 LOADING OPERATIONS................................................................109
		12.11 PRECAUTIONS FOR OPERATION ..............................................................110
			12.11.1 PERMISSIBLE WATER DEPTH...........................................................110
			12.11.2 IF THE WHEEL BRAKE DOES NOT WORK..................................................110
			12.11.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES........................................110
			12.11.4 PRECAUTIONS WHEN DRIVING THE MACHINE..............................................111
		12.12 ADJUSTING THE WORK EQUIPMENT  POSITIONERS ..............................................112
			12.12.1 ADJUSTING BOOM KICK-OUT...........................................................112
			12.12.2 ADJUSTING BUCKET POSITIONER.......................................................113
			12.12.3 BUCKET LEVEL INDICATOR............................................................113
		12.13 PARKING THE MACHINE ....................................................................114
		12.14 CHECKS AFTER COMPLETION OF  OPERATION ..................................................116
		12.15 STOPPING ENGINE ........................................................................116
		12.16 CHECK AFTER STOPPING THE ENGINE ........................................................116
		12.17 LOCKING ................................................................................116
		12.18 HANDLING THE TIRES .....................................................................117
			12.18.1 PRECAUTIONS WHEN HANDLING TIRES...................................................117
			12.18.2 TIRE PRESSURE.....................................................................117
		12.19 REMOVAL AND INSTALLATION OF THE  BUCKET ................................................119
			12.19.1 REMOVING THE BUCKET...............................................................119
			12.19.2 INSTALLING THE BUCKET.............................................................121
	13. TRANSPORTATION ...............................................................................123
		13.1 LOADING AND UNLOADING ...................................................................123
		13.2 PRECAUTIONS FOR LOADING .................................................................124
		13.3 LIFTING THE MACHINE .....................................................................124
			13.3.1 LIFT POINT MARKINGS................................................................125
			13.3.2 WEIGHT TABLE.......................................................................125
			13.3.3 LIFTING PROCEDURE..................................................................125
		13.4 PRECAUTIONS FOR TRANSPORTATION ..........................................................126
	14. COLD WEATHER OPERATION .......................................................................127
		14.1 FUEL AND LUBRICANTS .....................................................................127
		14.2 COOLANT .................................................................................127
		14.3 BATTERY .................................................................................127
		14.4 PRECAUTIONS AFTER COMPLETION OF  WORK ...................................................128
		14.5 AFTER COLD WEATHER ......................................................................128
		14.6 WARMING-UP OPERATION FOR STEERING  HYDRAULIC CIRCUIT IN COLD WEATHER ....................128
	15. LONG TERM STORAGE ............................................................................129
		15.1 BEFORE STORAGE ..........................................................................129
		15.2 DURING STORAGE ..........................................................................129
		15.3 AFTER STORAGE ...........................................................................129
	16. TROUBLESHOOTING ..............................................................................130
		16.1 WHEN MACHINE RUNS OUT OF FUEL ...........................................................130
		16.2 TOWING THE MACHINE ......................................................................130
			16.2.1 WHEN ENGINE CAN BE USED............................................................131
			16.2.2 WHEN ENGINE CANNOT BE USED.........................................................131
			16.2.3 RELEASING PARKING BRAKE............................................................132
			16.2.4 EMERGENCY TRAVEL OPERATION.........................................................133
		16.3 IF THE BATTERY IS DISCHARGED ............................................................134
			16.3.1 REMOVAL AND INSTALLATION OF BATTERY................................................134
			16.3.2 PRECAUTIONS FOR CHARGING THE BATTERY...............................................135
			16.3.3 STARTING THE ENGINE WITH BOOSTER CABLES............................................136
		16.4 OTHER TROUBLE ...........................................................................138
			16.4.1 ELECTRICAL SYSTEM..................................................................138
			16.4.2 CHASSIS............................................................................139
			16.4.3 ENGINE.............................................................................142
			16.4.4 RELATIONSHIP OF ELECTRONIC CONTROL SYSTEM..........................................144
MAINTENANCE ..........................................................................................147
	17. GUIDES TO MAINTENANCE ........................................................................148
	18. OUTLINES OF SERVICE ..........................................................................150
		18.1 OUTLINE OF OIL, FUEL, AND COOLANT .......................................................150
			18.1.1 OIL................................................................................150
			18.1.2 FUEL...............................................................................151
			18.1.3 COOLANT............................................................................151
			18.1.4 STORING OIL AND FUEL...............................................................152
			18.1.5 FILTERS............................................................................152
		18.2 FUEL INJECTION PUMP .....................................................................152
		18.3 OUTLINE OF ELECTRIC SYSTEM ..............................................................152
	19. WEAR PARTS LIST ..............................................................................153
	20. LUBRICANTS, FUEL, AND COOLANT ................................................................154
		20.1 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS ........................................154
		20.2 ENGINE OIL ..............................................................................155
			20.2.1 NORMAL OPERATION...................................................................155
			20.2.2 ARCTIC OPERATION...................................................................155
		20.3 TRANSMISSION, HYDRAULIC SYSTEM, BRAKE SYSTEM OIL ........................................156
		20.4 AXLE OIL ................................................................................156
		20.5 GREASE ..................................................................................156
		20.6 DIESEL FUEL .............................................................................156
		20.7 COOLANT SPECIFICATIONS ..................................................................157
			20.7.1 GENERAL............................................................................157
			20.7.2 WATER..............................................................................157
			20.7.3 ANTIFREEZE.........................................................................157
			20.7.4 SUPPLEMENTAL COOLANT ADDITIVES.....................................................158
			20.7.5 TOOLS..............................................................................161
	21. STANDARD TIGHTENING TORQUE FOR NUTS AND BOLTS ................................................162
		21.1 INTRODUCTION OF NECESSARY TOOLS .........................................................162
		21.2 TORQUE LIST..............................................................................163
	22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ................................................164
	23. MAINTENANCE SCHEDULE CHART ...................................................................166
	24. SERVICE PROCEDURE ............................................................................170
		24.1 INITIAL 250 HOURS SERVICE ...............................................................170
		24.2 WHEN REQUIRED ...........................................................................171
			24.2.1 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT.......................................171
			24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL..............................................173
			24.2.3 CHECK AXLE OIL LEVEL, ADD OIL......................................................175
			24.2.4 CHECK AXLE CASE BREATHER...........................................................176
			24.2.5 CLEAN RADIATOR CORE................................................................176
			24.2.6 REPLACE BOLT-ON CUTTING EDGE.......................................................177
			24.2.7 REPLACE BUCKET TEETH...............................................................178
			24.2.8 CHECK AIR CONDITIONER..............................................................179
			24.2.9 CLEAN CONDENSER OF AIR CONDITIONER.................................................180
			24.2.10 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID.......................................180
			24.2.11 LUBRICATE WORK EQUIPMENT CONTROL VALVE LINKAGE (2 POINTS).........................180
			24.2.12 REPLACE SLOW BLOW FUSE............................................................181
		24.3 CHECKS BEFORE STARTING ..................................................................182
			24.3.1 CHECK MONITOR PANEL................................................................182
			24.3.2 CHECK COOLANT LEVEL, ADD COOLANT...................................................182
			24.3.3 CHECK FUEL LEVEL, ADD FUEL.........................................................183
			24.3.4 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL.........................................183
			24.3.5 CHECK ELECTRICAL WIRING............................................................184
			24.3.6 CHECK EFFECT OF PARKING BRAKE......................................................185
			24.3.7 CHECK EFFECT OF WHEEL BRAKES.......................................................185
			24.3.8 CHECK SOUND OF HORN AND BACKUP ALARM...............................................185
			24.3.9 CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE.................................185
			24.3.10 CHECK ENGINE EXHAUST COLOR AND SOUND..............................................185
			24.3.11 CHECK OPERATIONS OF GAUGES........................................................185
			24.3.12 CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING.........................185
			24.3.13 DRAIN WATER FROM FUEL FILTER......................................................185
			24.3.14 CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE.....................185
		24.4 EVERY 50 HOURS SERVICE ..................................................................186
			24.4.1 CHECK THE TIRE INFLATION PRESSURE..................................................186
			24.4.2 DRAIN WATER, SEDIMENT FROM FUEL TANK...............................................186
			24.4.3 CHECK ENGINE AIR INTAKE SYSTEM.....................................................186
		24.5 EVERY 100 HOURS SERVICE .................................................................187
			24.5.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL.........................................187
			24.5.2 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER..................................188
			24.5.3 LUBRICATE REAR AXLE PIVOT PIN (3 PLACES)...........................................188
		24.6 EVERY 250 HOURS SERVICE .................................................................189
			24.6.1 CHANGE OIL AND REPLACE ENGINE OIL FILTER CARTRIDGE.................................189
			24.6.2 REPLACE FUEL FILTERS...............................................................191
			24.6.3 CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN............................................192
			24.6.4 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER..............................192
			24.6.5 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST..............................193
			24.6.6 CHECK BATTERY ELECTROLYTE LEVEL....................................................194
			24.6.7 LUBRICATING........................................................................195
			24.6.8 CHECK FRAME AND BOOM...............................................................198
			24.6.9 REPLACE COOLANT FILTER.............................................................198
		24.7 EVERY 500 HOURS SERVICE .................................................................200
			24.7.1 REPLACE TRANSMISSION OIL FILTER....................................................200
			24.7.2 LUBRICATE CENTER DRIVE SHAFT SPLINE................................................200
		24.8 EVERY 1000 HOURS SERVICE ................................................................201
			24.8.1 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER....................................201
			24.8.2 CLEAN TRANSMISSION CASE BREATHER...................................................202
			24.8.3 LUBRICATING (DRIVE TRAIN)..........................................................203
		24.9 EVERY 1500 HOURS SERVICE ................................................................205
			24.9.1 CHECK AND ADJUST ENGINE VALVES AND INJECTORS.......................................205
			24.9.2 CHECK AND REPLACE (AS REQUIRED) ENGINE MOUNTED HOSES...............................205
			24.9.3 CHECK AND RETIGHTEN ENGINE MOUNTING HARDWARE.......................................206
			24.9.4 CHECK TURBOCHARGER MOUNTING........................................................206
			24.9.5 CHECK WATER PUMP...................................................................206
			24.9.6 CHECK TENSION OF DRIVE BELT........................................................207
			24.9.7 CHECK DRIVE BELT TENSIONER BEARING AND FAN HUB BEARING.............................207
		24.10 EVERY 2000 HOURS SERVICE ...............................................................209
			24.10.1 CHANGE OIL IN HYDRAULIC TANK, REPLACE FILTER ELEMENT..............................209
			24.10.2 REPLACE HYDRAULIC TANK BREATHER ELEMENT...........................................211
			24.10.3 CHANGE, CLEAN, AND FLUSH COOLING SYSTEM...........................................212
			24.10.4 CLEAN RADIATOR FINS...............................................................215
			24.10.5 CHANGE AXLE OIL...................................................................216
			24.10.6 REPLACE ELEMENT IN AIR CONDITIONER RECIRCUCLATION AIR FILTER, FRESH AIR FILTER....217
			24.10.7 CLEAN P.P.C. (PROPORTIONAL PRESSURE CONTROL) CIRCUIT STRAINER.....................217
			24.10.8 CHECK BRAKE DISC WEAR.............................................................218
			24.10.9 CHECK ACCUMULATOR.................................................................218
			24.10.10 STEAM CLEAN THE ENGINE...........................................................218
		24.11 EVERY 6000 HOURS SERVICE................................................................219
			24.11.1 CLEAN AND CALIBRATE FUEL PUMP.....................................................219
			24.11.2 CLEAN AND CALIBRATE FUEL INJECTORS................................................219
			24.11.3 CHECK ENGINE FAN HUB..............................................................219
			24.11.4 CHECK ENGINE IDLER PULLEY.........................................................219
			24.11.5 CHECK TURBOCHARGER................................................................219
			24.11.6 CHECK AIR COMPRESSOR..............................................................219
			24.11.7 CHECK ENGINE VIBRATION DAMPER.....................................................219
SPECIFICATIONS .......................................................................................220
	25. SPECIFICATIONS ...............................................................................221
OPTIONS, ATTACHMENTS .................................................................................223
	26. OPTIONAL PARTS AND ATI=ACHMENTS ..............................................................224
	27. SELECTING BUCKETS AND TIRES ..................................................................225
	28. RADIO ........................................................................................226
		28.1 EXPLANATION OF PARTS ....................................................................226
		28.2 METHOD OF USE ...........................................................................228
			28.2.1 METHOD OF AUTOMATIC TUNING.........................................................229
			28.2.2 METHOD OF MANUAL TUNING............................................................229
			28.2.3 METHOD OF SETTING PRESET BUTTONS...................................................229
			28.2.4 METHOD OF AUTOMATIC MEMORY.........................................................229
			28.2.5 AUTOMATIC MONAURAUSTEREO SWITCHING.................................................229
			28.2.6 ADJUSTING TIME.....................................................................230
		28.3 PRECAUTIONS WHEN USING ..................................................................230
	29. AIR CONDITIONER ..............................................................................231
		29.1 GENERAL LOCATION AND FUNCTION OF CONTROL PANEL ..........................................231
		29.2 METHOD OF OPERATION .....................................................................233
	30. AUTO-GREASING SYSTEM .........................................................................234
		30.1 METHOD OF OPERATING AUTO-GREASING SYSTEM ................................................234
			30.1.1LUBRICATION CONTROLLER DISPLAY TABLE................................................234
			30.1.2 ACTUATION OF AUTO-GREASING.........................................................236
			30.1.3 SETTING GREASING TIME..............................................................237
			30.1.4 METHOD OF SETTING..................................................................237
			30.1.5 REPLACEMENT OF GREASE CARTRIDGE....................................................239
			30.1.6 METHOD OF FILLING AUTO-GREASING SYSTEM WITH GREASE.................................240
		30.2 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM ..........................................243
		30.3 TROUBLESHOOTING (AUTO-GREASING SYSTEM) ..................................................243
		30.4 SPECIFICATIONS...........................................................................244
	31. AUTO SHIFT SYSTEM ............................................................................245
		31.1 METHOD OF OPERATING .....................................................................245
		31.2 PRECAUTIONS WHEN CHANGING DIRECTION .....................................................246
	32. E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM) ...........................................247
		32.1 STRUCTURE AND FUNCTION OF E.C.S.S. ......................................................247
		32.2 OPERATING E.C.S.S. ......................................................................247
		32.3 PRECAUTIONS WHEN OPERATING E.C.S.S. SWITCH ..............................................248
		32.4 PRECAUTIONS WHEN HANDLING  ACCUMULATOR ..................................................248
		32.5 REMOVAL OF TRAVEL DAMPER PIPING .........................................................249
	33. JOYSTICK STEERING SYSTEM .....................................................................250
		33.1 STRUCTURE AND FUNCTION OF JOYSTICK STEERING .............................................250
		33.2 OPERATION METHOD OF JOYSTICK STEERING SYSTEM.............................................253
		33.3 PRECAUTIONS FOR STEERING WITH JOYSTICK...................................................254
		33.4 ADJUSTMENT OF JOYSTICK CONSOLE...........................................................255
	34. GROUND DRIVEN STEERING .......................................................................256

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