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Komatsu WA600-6 Wheel Loader Operation & Maintenance Manual (60001 and up) – PDF DOWNLOAD
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Komatsu WA600-6 Wheel Loader Operation & Maintenance Manual (60001 and up)
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Description
Komatsu WA600-6 Wheel Loader Operation & Maintenance Manual (60001 and up)
FILE DETAILS:
Komatsu WA600-6 Wheel Loader Operation & Maintenance Manual (60001 and up)
File Format : PDF
Language : English
Bookmarked : Yes
Searchable : Yes
Printable : Yes
Product Code : EEAM024501
Total Pages : 420
DESCRIPTION:
Komatsu WA600-6 Wheel Loader Operation & Maintenance Manual (60001 and up)
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.
TABLE OF CONTENTS:
Komatsu WA600-6 Wheel Loader Operation & Maintenance Manual (60001 and up)
FOREWORD..................................................................................................... 3 FOREWORD................................................................................................. 4 SAFETY INFORMATION....................................................................................... 5 Noise emission levels................................................................................ 7 Vibration levels..................................................................................... 7 Guide to Reduce Vibration Levels on Machine...................................................... 8 INTRODUCTION............................................................................................. 9 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE......................................................... 9 VISIBILITY FROM OPERATOR'S SEAT...................................................................... 10 VISIBILITY IN IMMEDIATE AREA..................................................................... 10 12-M RADIUS VISIBILITY........................................................................... 10 NECESSARY INFORMATION.................................................................................... 11 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE......................................... 11 EPA REGULATIONS, ENGINE NUMBER PLATE................................................................. 11 POSITION OF SERVICE METER............................................................................ 12 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR............................................................ 12 MACHINE SERIAL NUMBER PLATE.......................................................................... 13 FOREWORD............................................................................................. 14 SAFETY............................................................................................... 14 OPERATION............................................................................................ 15 MAINTENANCE.......................................................................................... 18 SPECIFICATIONS....................................................................................... 20 ATTACHMENTS, OPTIONS................................................................................. 20 INDEX................................................................................................ 21 COLOPHON............................................................................................. 21 SAFETY....................................................................................................... 23 SAFETY................................................................................................... 24 SAFETY LABELS............................................................................................ 26 LOCATION OF SAFETY LABELS............................................................................ 27 SAFETY LABELS........................................................................................ 28 GENERAL PRECAUTIONS...................................................................................... 36 PRECAUTIONS FOR OPERATION................................................................................ 46 STARTING ENGINE...................................................................................... 46 OPERATION............................................................................................ 48 TRANSPORTATION....................................................................................... 54 BATTERY.............................................................................................. 55 TOWING............................................................................................... 57 PRECAUTIONS FOR MAINTENANCE.............................................................................. 58 PRECAUTIONS WITH TIRES................................................................................... 66 OPERATION.................................................................................................... 67 GENERAL VIEW............................................................................................. 68 GENERAL VIEW OF MACHINE.............................................................................. 68 GENERAL VIEW OF CONTROLS AND GAUGES.................................................................. 69 EXPLANATION OF COMPONENTS................................................................................ 74 MACHINE MONITOR...................................................................................... 74 TYPES OF WARNING................................................................................. 75 CENTRAL WARNING LAMP............................................................................. 76 CHARACTER DISPLAY PORTION........................................................................ 76 EMERGENCY STOP ITEMS............................................................................. 82 CAUTION ITEMS.................................................................................... 85 INSPECTION AND MAINTENANCE ITEMS................................................................. 88 PILOT DISPLAY PORTION............................................................................ 91 METER DISPLAY PORTION............................................................................ 97 OTHER FUNCTIONS OF MACHINE MONITOR............................................................... 99 SWITCHES.............................................................................................110 FRONT PANEL, AJSS LEVER SWITCH, REAR BOX.........................................................110 RIGHT SWITCH PANEL, CONTROL LEVER SWITCH.........................................................118 OVERHEAD PORTION.................................................................................127 CONTROL LEVERS, PEDALS...............................................................................131 CAP WITH LOCK........................................................................................138 METHOD OF OPENING AND CLOSING CAP WITH LOCK (FOR THE FUEL TANK FILLER PORT)......................138 METHOD OF OPENING AND CLOSING CAP WITH LOCK (FOR THE HYDRAULIC TANK FILLER PORT).................139 FRAME LOCK BAR.......................................................................................140 TOWING PIN...........................................................................................141 BACKUP ALARM.........................................................................................141 OPENING CAB, WINDOW DOOR.............................................................................142 OPEN LOCK CANCEL KNOB FOR RIGHT CAB DOOR.........................................................142 CAB LEFT DOOR OPEN KNOB..........................................................................143 OPEN LOCK CANCEL KNOB FOR LEFT CAB WINDOW........................................................143 HANDLING CAB WIPER...................................................................................144 PREVENTING DAMAGE TO WIPER ARM BRACKET...........................................................144 DUST INDICATOR.......................................................................................144 FUSE.................................................................................................145 FUSE CAPACITY AND NAME OF CIRCUIT................................................................145 CIRCUIT BREAKER......................................................................................146 SLOW BLOW FUSE.......................................................................................147 LUNCH BOX TRAY.......................................................................................147 TOOL BOX.............................................................................................147 GREASE PUMP..........................................................................................148 LOCATION OF FIRE EXTINGUISHER........................................................................148 POWER OUTLET.........................................................................................148 AM/FM RADIO-CASSETTE STEREO..........................................................................149 EXPLANATION OF COMPONENTS........................................................................149 METHOD OF OPERATION..............................................................................154 PRECAUTIONS WHEN USING...........................................................................156 AIR CONDITIONER......................................................................................157 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL..................................................157 METHOD OF OPERATION..............................................................................161 USE AIR CONDITIONER WITH CARE....................................................................167 AIR CONDITIONER MAINTENANCE......................................................................168 COOL BOX.........................................................................................168 OTHER FUNCTIONS..................................................................................168 OPERATION................................................................................................170 CHECK BEFORE STARTING ENGINE, ADJUST.................................................................170 WALK-AROUND CHECK................................................................................170 CHECK BEFORE STARTING............................................................................173 ADJUSTMENT.......................................................................................180 OPERATIONS AND CHECKS BEFORE STARTING ENGINE.....................................................185 STARTING ENGINE......................................................................................186 AUTOMATIC WARMING-UP OPERATION...................................................................188 OPERATIONS AND CHECKS AFTER STARTING ENGINE..........................................................188 BREAKING-IN THE MACHINE..........................................................................188 NORMAL OPERATION.................................................................................189 STOPPING ENGINE......................................................................................190 CHECK AFTER STOPPING ENGINE..........................................................................190 MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE........................................191 PREPARATIONS FOR MOVING MACHINE..................................................................191 CHANGING GEAR SPEED..............................................................................194 CHANGING DIRECTION...............................................................................195 STOPPING THE MACHINE.............................................................................196 TURNING..............................................................................................198 EMERGENCY STEERING...............................................................................199 OPERATION OF WORK EQUIPMENT..........................................................................200 SEMI AUTO DIGGING OPERATIONS.........................................................................201 REMOTE POSITIONER....................................................................................202 WORK POSSIBLE USING WHEEL LOADER.....................................................................204 RECOMMENDED COMBINATION OF SWITCHES FOR OPERATION................................................204 DIGGING OPERATIONS...............................................................................205 LEVELING OPERATIONS..............................................................................208 PUSHING OPERATION................................................................................208 LOAD AND CARRY OPERATIONS........................................................................208 LOADING OPERATIONS...............................................................................209 PRECAUTIONS WHEN HANDLING BLASTED ROCK...........................................................211 PRECAUTIONS FOR OPERATION............................................................................223 PERMISSIBLE WATER DEPTH..........................................................................223 IF WHEEL BRAKE DOES NOT WORK.....................................................................223 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES.......................................................223 REMOVAL AND INSTALLATION OF THE BUCKET...............................................................225 REMOVING THE BUCKET..............................................................................225 INSTALLING THE BUCKET............................................................................227 PARKING MACHINE......................................................................................229 CHECKS AFTER COMPLETION OF OPERATION.................................................................231 LOCKING..............................................................................................231 HANDLING THE TIRES...................................................................................232 PRECAUTIONS WHEN HANDLING TIRES..................................................................232 TIRE PRESSURE....................................................................................232 PRECAUTIONS FOR USING LOAD AND CARRY METHOD......................................................234 PRECAUTIONS FOR USING STONE HANDLING METHOD......................................................234 PRECAUTIONS RELATED TO FITTING TIRE CHAINS AND ADDING BALLAST....................................234 TRANSPORTATION...........................................................................................235 TRANSPORTATION PROCEDURE.............................................................................235 LOADING, UNLOADING WORK..............................................................................235 METHOD OF SECURING MACHINE...........................................................................235 METHOD OF LIFTING MACHINE............................................................................237 LOCATION OF LIFTING POSITION MARK................................................................238 WEIGHT TABLE.....................................................................................238 LIFTING PROCEDURE................................................................................239 PRECAUTIONS WHEN DISASSEMBLY OR REASSEMBLING WORK EQUIPMENT..........................................240 COLD WEATHER OPERATION...................................................................................241 PRECAUTIONS FOR LOW TEMPERATURE......................................................................241 FUEL AND LUBRICANTS..............................................................................241 COOLANT..........................................................................................241 BATTERY..........................................................................................242 PRECAUTIONS AFTER COMPLETION OF WORK.................................................................242 AFTER COLD WEATHER...................................................................................243 WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER..................................243 LONG-TERM STORAGE........................................................................................244 BEFORE STORAGE.......................................................................................244 DURING STORAGE.......................................................................................244 AFTER STORAGE........................................................................................244 TROUBLESHOOTING..........................................................................................245 WHEN MACHINE RUNS OUT OF FUEL........................................................................245 METHOD OF TOWING MACHINE.............................................................................245 WHEN ENGINE RUNS.................................................................................246 WHEN ENGINE DOES NOT RUN.........................................................................246 RELEASING PARKING BRAKE..........................................................................247 EMERGENCY TRAVEL OPERATION.......................................................................248 IF BATTERY IS DISCHARGED.............................................................................249 REMOVAL AND INSTALLATION OF BATTERY..............................................................249 PRECAUTIONS FOR CHARGING BATTERY.................................................................250 STARTING ENGINE WITH BOOSTER CABLE...............................................................250 STARTING ENGINE WHEN USING STARTING AID CONNECTOR (if equipped)..................................252 METHOD FOR LOWERING WORK EQUIPMENT WHEN ENGINE HAS STOPPED...........................................253 OTHER TROUBLE........................................................................................254 ELECTRICAL SYSTEM................................................................................254 CHASSIS..........................................................................................255 ENGINE...........................................................................................257 MAINTENANCE..................................................................................................259 GUIDES TO MAINTENANCE....................................................................................260 OUTLINES OF SERVICE......................................................................................262 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...............................................262 OIL..............................................................................................262 FUEL.............................................................................................263 COOLANT AND WATER FOR DILUTION...................................................................263 GREASE...........................................................................................264 CARRYING OUT KOWA (Komatsu Oil Wear Analysis)....................................................264 STORING OIL AND FUEL.............................................................................265 FILTERS..........................................................................................265 OUTLINE OF ELECTRIC SYSTEM...........................................................................266 WEAR PARTS...............................................................................................267 WEAR PARTS LIST......................................................................................267 RECOMMENDED FUEL, COOLANT, AND LUBRICANT.................................................................268 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.................................269 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL..................271 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...........................................................272 TORQUE LIST..........................................................................................272 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................................................274 SAFETY CRITICAL PARTS................................................................................275 MAINTENANCE SCHEDULE CHART...............................................................................277 MAINTENANCE SCHEDULE CHART...........................................................................277 SERVICE PROCEDURE........................................................................................279 INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE).................................279 INITIAL 250 HOURS SERVICE............................................................................279 WHEN REQUIRED........................................................................................280 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT.....................................................280 CLEAN INSIDE OF COOLING SYSTEM...................................................................282 CHECK TRANSMISSION OIL LEVEL, ADD OIL............................................................286 CHECK AXLE OIL LEVEL, ADD OIL....................................................................288 CLEAN AXLE CASE BREATHER.........................................................................289 CLEAN AIR CONDITIONER CONDENSER..................................................................290 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID......................................................290 CLEAN RADIATOR FINS..............................................................................291 REPLACE BUCKET TEETH.............................................................................295 LUBRICATING......................................................................................296 CHECK AIR CONDITIONER............................................................................297 REPLACE SLOW BLOW FUSE...........................................................................298 BLEEDING AIR FROM HYDRAULIC TANK.................................................................299 BLEEDING AIR FROM FUEL CIRCUIT...................................................................301 CHECKING FUNCTION OF ACCUMULATOR.................................................................304 SELECTION AND INSPECTION OF TIRES................................................................304 CHECK BEFORE STARTING................................................................................306 EVERY 50 HOURS SERVICE...............................................................................307 DRAIN WATER, SEDIMENT FROM FUEL TANK.............................................................307 EVERY 100 HOURS SERVICE..............................................................................308 LUBRICATING......................................................................................308 LUBRICATE REAR AXLE PIVOT PIN....................................................................310 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL.......................................................311 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER................................................312 EVERY 250 HOURS SERVICE..............................................................................313 CHECK BATTERY ELECTROLYTE LEVEL..................................................................313 CHECK PARKING BRAKE..............................................................................314 CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN.........................................................315 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER............................................315 CHECKING FUNCTION OF ACCUMULATOR.................................................................315 EVERY 500 HOURS SERVICE..............................................................................316 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE................................316 REPLACE FUEL PRE-FILTER CARTRIDGE................................................................317 REPLACE FUEL FILTER CARTRIDGE....................................................................319 REPLACE TRANSMISSION OIL FILTER ELEMENT..........................................................320 REPLACE BRAKE OIL FILTER CARTRIDGE...............................................................321 CHECK, REPLACE COMPRESSOR DRIVE BELT FOR ALTERNATOR, AIR CONDITIONER.............................322 EVERY 1000 HOURS SERVICE.............................................................................323 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER..................................................323 CLEAN TRANSMISSION CASE BREATHER.................................................................324 LUBRICATING......................................................................................324 REPLACE CORROSION RESISTOR CARTRIDGE.............................................................325 CHECK, GREASE COMPRESSOR DRIVE BELT TENSION PULLEY ASSEMBLY FOR ALTERNATOR, AIR CONDITIONER......326 EVERY 2000 HOURS SERVICE.............................................................................327 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...................................327 CLEAN HYDRAULIC TANK STRAINER....................................................................329 REPLACE HYDRAULIC TANK BREATHER ELEMENT..........................................................330 CHANGE AXLE OIL..................................................................................330 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER....................331 CLEAN PPC CIRCUIT STRAINER.......................................................................332 CHECK ALTERNATOR.................................................................................332 CHECK ENGINE VALVE CLEARANCE, ADJUST.............................................................332 CHECK BRAKE DISC WEAR............................................................................332 CHECKING FUNCTION OF ACCUMULATOR.................................................................333 CHECK BOOST PIPING CLAMPS........................................................................333 CHANGE OIL FOR WORK EQUIPMENT PINS...............................................................334 EVERY 4000 HOURS SERVICE.............................................................................335 CHECK WATER PUMP.................................................................................335 CHECK STARTING MOTOR.............................................................................335 CHECK AIR CONDITIONER COMPRESSOR, ADJUST.........................................................335 LUBRICATING......................................................................................335 CHECK FOR LOOSE ENGINE HIGH-PRESSURE PIPING CLAMPS, HARDENING OF RUBBER..........................337 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER..............................338 EVERY 8000 HOURS SERVICE.............................................................................339 REPLACE ENGINE HIGH-PRESSURE PIPING CLAMPS.......................................................339 REPLACE FUEL SPRAY PREVENTION CAP................................................................339 OVERHAUL STARTING MOTOR AND ALTERNATOR...........................................................339 SPECIFICATIONS...............................................................................................341 SPECIFICATIONS...........................................................................................342 ATTACHMENTS, OPTIONS.........................................................................................347 HANDLING STEERING WHEEL SPECIFICATION MACHINE............................................................348 EXPLANATION OF COMPONENTS............................................................................348 SWITCHES, FRONT PANEL, STEERING WHEEL SWITCH, REAR BOX...........................................348 CONTROL LEVERS, PEDALS...........................................................................354 STEERING TILT LEVER..............................................................................357 FUNCTIONS OF STEERING WHEEL SPECIFICATION MACHINE....................................................358 CHANGING GEAR SPEED..............................................................................358 CHANGING DIRECTION...............................................................................359 TURNING..........................................................................................361 MOVING MACHINE OFF (MACHINES EQUIPPED WITH STEERING WHEEL).......................................362 METHOD OF STOPPING, PARKING MACHINE (MACHINES EQUIPPED WITH STEERING WHEEL)......................365 SELECTING BUCKET AND TIRES...............................................................................367 STARTING IN COLD AREAS...................................................................................368 ELECTRIC HEATER......................................................................................368 PROCEDURE FOR SETTING UP EXTERNAL POWER SOURCE FOR EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER....368 MANUFACTURING EXTERNAL POWER SOURCE INPUT CABLE..................................................370 ESTABLISHING POWER SUPPLY........................................................................371 CHECK ACTUATION AFTER COMPLETION OF ASSEMBLY.....................................................371 HANDLING LOAD METER......................................................................................372 OUTLINE OF LOAD METER................................................................................372 PRINCIPLE OF LOAD METER MEASUREMENT..................................................................373 POINTS TO REMEMBER TO ENSURE HIGH ACCURACY...........................................................374 USING LOAD METER.....................................................................................376 SETTING ADDITION MODE............................................................................376 SETTING SUBTRACTION MODE.........................................................................376 TOTAL LOAD DATA DISPLAY..........................................................................380 CLEARING TOTAL LOAD..............................................................................381 STOPPING LOAD METER CALCULATION..................................................................381 SELECTING LOAD MATERIAL CATEGORY DISPLAY.........................................................383 CALIBRATING WITH EMPTY BUCKET....................................................................383 CALIBRATION WITH LOADED BUCKET...................................................................386 RESETTING CALIBRATION............................................................................389 METHOD OF USING ADDITION MODE....................................................................390 METHOD OF USING SUBTRACTION MODE.................................................................392 PRINTOUT FROM LOAD METER.........................................................................396 SELECTION OF PRINTOUT MODE.......................................................................397 HANDLING AUTO-GREASING SYSTEM............................................................................400 METHOD OF OPERATING AUTO-GREASING SYSTEM.............................................................400 SETTING GREASING TIME............................................................................402 METHOD OF SETTING................................................................................403 CHECK AMOUNT OF GREASE...........................................................................404 GREASING.........................................................................................405 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM.......................................................406 TROUBLESHOOTING......................................................................................406 HANDLING BATTERY DISCONNECTOR SWITCH.....................................................................407 EXPLANATION OF COMPONENTS............................................................................407 BATTERY DISCONNECTOR SWITCH......................................................................407 HANDLING.............................................................................................407 HANDLING STARTING AID CONNECTOR..........................................................................409 STARTING ENGINE WHEN USING STARTING AID CONNECTOR....................................................409 HANDLING REAR FENDER.....................................................................................411 HANDLING.............................................................................................411 HANDLING MACHINES EQUIPPED WITH VHMS.....................................................................412 VHMS INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED................................................412 BASIC PRECAUTIONS................................................................................412 VHMS AND COMMUNICATIONS TERMINAL INSTALLED...........................................................412 BASIC PRECAUTIONS................................................................................412 INDEX........................................................................................................415 <A>......................................................................................................417 <B>......................................................................................................417 <C>......................................................................................................417 <D>......................................................................................................417 <E>......................................................................................................417 <F>......................................................................................................417 <G>......................................................................................................417 <H>......................................................................................................417 <I>......................................................................................................417 <L>......................................................................................................417 <M>......................................................................................................417 <N>......................................................................................................417 <O>......................................................................................................417 <P>......................................................................................................417 <R>......................................................................................................418 <S>......................................................................................................418 <T>......................................................................................................418 <U>......................................................................................................418 <W>......................................................................................................418 COLOPHON.....................................................................................................419
KOMATSU WA600-6 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (60001 AND UP) – PDF DOWNLOAD:
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