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Komatsu WA600-6 Wheel Loader Operation & Maintenance Manual SN 60361 and up – PDF DOWNLOAD
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Komatsu WA600-6 Wheel Loader Operation & Maintenance Manual
Book Code: TEN00240-02
SERIAL NUMBERS 60361 and up
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Description
Komatsu WA600-6 Wheel Loader Operation & Maintenance Manual
TABLE OF CONTENTS:
Komatsu WA600-6 Wheel Loader Operation & Maintenance Manual
COVER...................................................................................................... 1 FOREWORD................................................................................................... 3 BEFORE READING THIS MANUAL............................................................................. 4 SAFETY INFORMATION..................................................................................... 7 INTRODUCTION........................................................................................... 8 USE OF MACHINE..................................................................................... 8 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE....................................................... 8 VISIBILITY FROM OPERATOR'S SEAT.................................................................... 9 NECESSARY INFORMATION.................................................................................. 10 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....................................... 10 EPA REGULATIONS, ENGINE NUMBER PLATE............................................................... 10 POSITION OF SERVICE METER.......................................................................... 11 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.......................................................... 11 CONTENTS................................................................................................... 12 SAFETY..................................................................................................... 17 SAFETY................................................................................................. 18 SAFETY LABELS.......................................................................................... 21 LOCATION OF SAFETY LABELS.......................................................................... 22 SAFETY LABELS...................................................................................... 23 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE................................................ 30 PRECAUTIONS BEFORE STARTING OPERATION.............................................................. 30 ENSURING SAFE OPERATION........................................................................ 30 UNDERSTANDING THE MACHINE...................................................................... 30 PREPARATIONS FOR SAFE OPERATION.................................................................... 30 PRECAUTIONS REGARDING SAFETY-RELATED EQUIPMENT................................................. 30 INSPECTING MACHINE............................................................................. 30 WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT............................................. 30 KEEP MACHINE CLEAN............................................................................. 31 PRECAUTIONS INSIDE OPERATOR'S COMPARTMENT...................................................... 31 PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT.................................................... 31 IF ANY PROBLEM IS FOUND........................................................................ 31 FIRE PREVENTION.................................................................................... 32 ACTION IF FIRE OCCURS.......................................................................... 32 PRECAUTIONS TO PREVENT FIRE.................................................................... 32 PRECAUTIONS WHEN GETTING ON OR OFF MACHINE......................................................... 33 USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE......................................... 33 NO JUMPING ON OR OFF MACHINE................................................................... 33 NO PEOPLE ON ATTACHMENTS....................................................................... 34 PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT.............................................. 34 PRECAUTIONS WHEN LEAVING MACHINE............................................................... 35 EMERGENCY EXIT FROM OPERATOR'S CAB............................................................. 35 PRECAUTIONS WHEN CLEANING CAB GLASS............................................................ 36 DO NOT GET CAUGHT IN ARTICULATING PORTION.......................................................... 36 PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES....................................................... 36 UNAUTHORIZED MODIFICATION.......................................................................... 36 PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS..................................................... 37 PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING.................................................... 37 PRECAUTIONS FOR OPERATION.............................................................................. 38 PRECAUTIONS FOR JOBSITE............................................................................ 38 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS..................................................... 38 WORKING ON LOOSE GROUND........................................................................ 38 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES......................................................... 39 ENSURE GOOD VISIBILITY......................................................................... 39 CHECKING SIGNS AND SIGNALMAN'S SIGNALS......................................................... 39 BEWARE OF ASBESTOS DUST........................................................................ 40 STARTING ENGINE.................................................................................... 40 WARNING TAG.................................................................................... 40 INSPECTION AND MAINTENANCE BEFORE STARTING ENGINE ............................................. 41 PRECAUTIONS WHEN STARTING ENGINE............................................................... 41 PRECAUTIONS IN COLD AREAS...................................................................... 41 STARTING WITH BOOSTER CABLES................................................................... 42 STARTING WITH STARTING AID CONNECTOR (IF EQUIPPED)............................................. 42 OPERATION.......................................................................................... 43 CHECKS BEFORE OPERATION........................................................................ 43 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE............................................... 43 PRECAUTIONS WHEN TRAVELING..................................................................... 44 TRAVELING ON SLOPES............................................................................ 45 METHOD OF USING BRAKES......................................................................... 45 PRECAUTIONS WHEN OPERATING..................................................................... 46 PROHIBITED OPERATIONS.......................................................................... 47 TRAVELING ON SNOW-COVERED OR FROZEN SURFACES................................................... 47 PARKING MACHINE................................................................................ 48 TRANSPORTATION..................................................................................... 50 LOADING AND UNLOADING.......................................................................... 50 TOWING............................................................................................. 51 PRECAUTIONS WHEN TOWING ....................................................................... 51 PRECAUTIONS FOR MAINTENANCE............................................................................ 52 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ............................................ 52 DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE ......................................... 52 KEEP WORKPLACE CLEAN AND TIDY.................................................................. 52 SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE........................................... 52 ONLY AUTHORIZED PERSONNEL...................................................................... 52 APPOINT LEADER WHEN WORKING WITH OTHERS........................................................ 52 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE .................................... 53 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING............................................. 55 TURNING E.C.S.S. SWITCH OFF BEFORE CARRYING OUT INSPECTION AND MAINTENANCE..................... 55 INSTALLING, REMOVING, OR STORING ATTACHMENTS................................................... 56 PRECAUTIONS WHEN WORKING AT HIGH PLACES........................................................ 56 PRECAUTIONS WHEN WORKING UNDER MACHINE OR WORK EQUIPMENT ...................................... 56 PROPER TOOLS................................................................................... 56 PRECAUTIONS FOR INSPECTION AND MAINTENANCE......................................................... 57 PRECAUTIONS WHEN WELDING....................................................................... 57 HANDLING BATTERY............................................................................... 57 PRECAUTIONS WHEN USING HAMMER.................................................................. 58 PRECAUTIONS WITH HIGH-TEMPERATURE COOLANT...................................................... 58 PRECAUTIONS WITH HIGH-TEMPERATURE OIL.......................................................... 59 PRECAUTIONS WITH HIGH-PRESSURE OIL............................................................. 60 PRECAUTIONS WITH HIGH-PRESSURE FUEL............................................................ 60 HANDLING HIGH-PRESSURE HOSES AND PIPING........................................................ 60 NOISE.......................................................................................... 60 HANDLING ACCUMULATOR AND GAS SPRING ........................................................... 61 PRECAUTIONS WITH COMPRESSED AIR ............................................................... 61 MAINTENANCE OF AIR CONDITIONER................................................................. 61 DISPOSING OF WASTE MATERIALS................................................................... 61 METHOD OF SELECTING WINDOW WASHER FLUID........................................................ 61 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.................................................. 62 TIRES.............................................................................................. 63 HANDLING TIRES................................................................................. 63 PRECAUTIONS WHEN STORING TIRES................................................................. 64 OPERATION.................................................................................................. 65 GENERAL VIEW........................................................................................... 66 GENERAL VIEW OF MACHINE............................................................................ 66 GENERAL VIEW OF CONTROLS AND GAUGES................................................................ 67 EXPLANATION OF COMPONENTS.............................................................................. 73 MACHINE MONITOR.................................................................................... 73 SWITCHES...........................................................................................114 CONTROL LEVERS, PEDALS.............................................................................139 CAP WITH LOCK......................................................................................146 FRAME LOCK BAR.....................................................................................148 TOWING PIN.........................................................................................149 BACKUP ALARM.......................................................................................149 OPENING CAB, WINDOW DOOR...........................................................................150 HANDLING CAB WIPER.................................................................................152 DUST INDICATOR.....................................................................................152 FUSE...............................................................................................153 CIRCUIT BREAKER....................................................................................155 SLOW BLOW FUSE.....................................................................................156 LUNCH BOX TRAY.....................................................................................156 TOOL BOX...........................................................................................156 GREASE PUMP........................................................................................156 LOCATION OF FIRE EXTINGUISHER......................................................................157 POWER OUTLET.......................................................................................157 AM/FM RADIO-CASSETTE STEREO........................................................................158 AIR CONDITIONER....................................................................................167 OPERATION..............................................................................................182 CHECK BEFORE STARTING ENGINE, ADJUST...............................................................182 STARTING ENGINE....................................................................................200 OPERATIONS AND CHECKS AFTER STARTING ENGINE........................................................202 STOPPING ENGINE....................................................................................205 CHECK AFTER STOPPING ENGINE........................................................................205 MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE......................................206 TURNING............................................................................................214 OPERATION OF WORK EQUIPMENT........................................................................216 SEMI AUTO DIGGING OPERATIONS.......................................................................218 REMOTE POSITIONER..................................................................................219 WORK POSSIBLE USING WHEEL LOADER...................................................................221 PRECAUTIONS FOR OPERATION..........................................................................241 REMOVAL AND INSTALLATION OF THE BUCKET.............................................................244 PARKING MACHINE....................................................................................248 CHECKS AFTER COMPLETION OF OPERATION...............................................................250 LOCKING............................................................................................250 HANDLING THE TIRES.................................................................................251 TRANSPORTATION.........................................................................................254 TRANSPORTATION PROCEDURE...........................................................................254 LOADING, UNLOADING WORK............................................................................254 METHOD OF SECURING MACHINE.........................................................................254 METHOD OF LIFTING MACHINE..........................................................................256 PRECAUTIONS WHEN DISASSEMBLY OR REASSEMBLING WORK EQUIPMENT........................................259 COLD WEATHER OPERATION.................................................................................260 PRECAUTIONS FOR LOW TEMPERATURE....................................................................260 PRECAUTIONS AFTER COMPLETION OF WORK...............................................................261 AFTER COLD WEATHER.................................................................................261 WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER................................262 LONG-TERM STORAGE......................................................................................263 BEFORE STORAGE.....................................................................................263 DURING STORAGE.....................................................................................263 AFTER STORAGE......................................................................................263 TROUBLESHOOTING........................................................................................264 WHEN MACHINE RUNS OUT OF FUEL......................................................................264 METHOD OF TOWING MACHINE...........................................................................265 IF BATTERY IS DISCHARGED...........................................................................269 METHOD FOR LOWERING WORK EQUIPMENT WHEN ENGINE HAS STOPPED.........................................273 OTHER TROUBLE......................................................................................274 MAINTENANCE................................................................................................279 GUIDES TO MAINTENANCE..................................................................................280 OUTLINES OF SERVICE....................................................................................282 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.............................................282 OUTLINE OF ELECTRIC SYSTEM.........................................................................286 WEAR PARTS.............................................................................................287 WEAR PARTS LIST....................................................................................288 RECOMMENDED FUEL, COOLANT, AND LUBRICANT...............................................................289 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...............................290 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL................292 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.........................................................293 TORQUE LIST........................................................................................293 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS..........................................................295 SAFETY CRITICAL PARTS..............................................................................296 MAINTENANCE SCHEDULE CHART.............................................................................298 MAINTENANCE SCHEDULE CHART.........................................................................298 SERVICE PROCEDURE......................................................................................300 INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE)...............................300 INITIAL 250 HOURS SERVICE..........................................................................300 WHEN REQUIRED......................................................................................301 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT...................................................301 CLEAN INSIDE OF COOLING SYSTEM.................................................................304 CHECK TRANSMISSION OIL LEVEL, ADD OIL..........................................................308 CHECK AXLE OIL LEVEL, ADD OIL..................................................................310 CLEAN AXLE CASE BREATHER.......................................................................311 CLEAN AIR CONDITIONER CONDENSER................................................................312 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID....................................................312 CLEAN RADIATOR FINS............................................................................313 REPLACE BUCKET TEETH...........................................................................318 LUBRICATING....................................................................................320 CHECK AIR CONDITIONER..........................................................................321 REPLACE SLOW BLOW FUSE.........................................................................322 BLEEDING AIR FROM HYDRAULIC TANK...............................................................323 BLEEDING AIR FROM FUEL CIRCUIT.................................................................325 CHECKING FUNCTION OF ACCUMULATOR...............................................................328 SELECTION AND INSPECTION OF TIRES..............................................................329 CHECK BEFORE STARTING..............................................................................331 EVERY 50 HOURS SERVICE.............................................................................332 DRAIN WATER, SEDIMENT FROM FUEL TANK...........................................................332 EVERY 100 HOURS SERVICE............................................................................333 LUBRICATING....................................................................................333 LUBRICATE REAR AXLE PIVOT PIN..................................................................335 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL.....................................................336 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER..............................................337 EVERY 250 HOURS SERVICE............................................................................338 CHECK BATTERY ELECTROLYTE LEVEL................................................................338 CHECK PARKING BRAKE............................................................................340 CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN.......................................................340 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER..........................................340 CHECKING FUNCTION OF ACCUMULATOR...............................................................341 EVERY 500 HOURS SERVICE............................................................................342 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE..............................342 REPLACE FUEL PRE-FILTER CARTRIDGE..............................................................344 REPLACE FUEL MAIN FILTER CARTRIDGE.............................................................346 REPLACE TRANSMISSION OIL FILTER ELEMENT........................................................347 REPLACE BRAKE OIL FILTER CARTRIDGE (IF EQUIPPED)...............................................348 CHECK, REPLACE COMPRESSOR DRIVE BELT FOR ALTERNATOR, AIR CONDITIONER...........................349 EVERY 1000 HOURS SERVICE...........................................................................350 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER................................................350 CLEAN TRANSMISSION CASE BREATHER...............................................................351 REPLACE FUEL TANK BREATHER ELEMENT.............................................................352 LUBRICATING....................................................................................353 REPLACE CORROSION RESISTOR CARTRIDGE (ONLY WHEN CORROSION RESISTOR CARTRIDGE IS USED)..........353 CHECK, GREASE COMPRESSOR DRIVE BELT TENSION PULLEY ASSEMBLY FOR ALTERNATOR, AIR CONDITIONER....354 EVERY 2000 HOURS SERVICE...........................................................................355 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT.................................355 CLEAN HYDRAULIC TANK STRAINER..................................................................357 REPLACE HYDRAULIC TANK BREATHER ELEMENT........................................................358 CHANGE AXLE OIL................................................................................359 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER..................360 CLEAN PPC CIRCUIT STRAINER.....................................................................360 CHECK ALTERNATOR...............................................................................361 CHECK ENGINE VALVE CLEARANCE, ADJUST...........................................................361 CHECK BRAKE DISC WEAR..........................................................................361 CHECKING FUNCTION OF ACCUMULATOR...............................................................361 CHECK BOOST PIPING CLAMPS......................................................................361 CHANGE OIL FOR WORK EQUIPMENT PINS.............................................................362 EVERY 4000 HOURS SERVICE...........................................................................363 CHECK WATER PUMP...............................................................................363 CHECK STARTING MOTOR...........................................................................363 CHECK AIR CONDITIONER COMPRESSOR, ADJUST.......................................................363 LUBRICATING....................................................................................364 CHECK FOR LOOSE ENGINE HIGH-PRESSURE PIPING CLAMPS, HARDENING OF RUBBER........................366 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER............................367 EVERY 8000 HOURS SERVICE...........................................................................368 REPLACE ENGINE HIGH-PRESSURE PIPING CLAMPS.....................................................368 REPLACE FUEL SPRAY PREVENTION CAP..............................................................368 OVERHAUL STARTING MOTOR AND ALTERNATOR.........................................................368 SPECIFICATIONS.............................................................................................369 SPECIFICATIONS.........................................................................................370 ATTACHMENTS, OPTIONS.......................................................................................375 HANDLING STEERING WHEEL SPECIFICATION MACHINE..........................................................376 EXPLANATION OF COMPONENTS..........................................................................376 FUNCTIONS OF STEERING WHEEL SPECIFICATION MACHINE..................................................386 SELECTING BUCKET AND TIRES.............................................................................396 STARTING IN COLD AREAS.................................................................................397 ELECTRIC HEATER....................................................................................397 HANDLING LOAD METER....................................................................................401 OUTLINE OF LOAD METER..............................................................................401 PRINCIPLE OF LOAD METER MEASUREMENT................................................................403 POINTS TO REMEMBER TO ENSURE HIGH ACCURACY.........................................................404 USING LOAD METER...................................................................................406 HANDLING AUTO-GREASING SYSTEM..........................................................................434 METHOD OF OPERATING AUTO-GREASING SYSTEM...........................................................434 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM.....................................................441 TROUBLESHOOTING....................................................................................441 HANDLING QUICK COUPLER CONTROL SYSTEM..................................................................442 EXPLANATION OF COMPONENTS..........................................................................442 FUNCTION AND METHOD OF OPERATION OF QUICK COUPLER SWITCH...........................................445 METHOD OF REMOVING AND INSTALLING ATTACHMENT.......................................................447 INSPECTION AND MAINTENANCE.........................................................................452 METHOD OF TURNING BOTTOM FRONT WORKING LAMP ON/OFF.................................................453 HANDLING BATTERY DISCONNECTOR SWITCH...................................................................454 EXPLANATION OF COMPONENTS..........................................................................454 HANDLING...........................................................................................454 HANDLING STARTING AID CONNECTOR........................................................................456 HANDLING REAR FENDER...................................................................................458 HANDLING...........................................................................................458 METHOD OF USING 3 LEVERS...............................................................................459 EXPLANATION OF COMPONENTS..........................................................................459 HANDLING MACHINES EQUIPPED WITH VHMS...................................................................461 VHMS INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED..............................................461 VHMS AND COMMUNICATIONS TERMINAL INSTALLED.........................................................461 INDEX......................................................................................................463
KOMATSU WA600-6 WHEEL LOADER OPERATION & MAINTENANCE MANUAL SN 60361 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WA600-6 Wheel Loader Operation & Maintenance Manual
BEFORE READING THIS MANUAL:
This manual gives details of the operation and methods of inspection and maintenance for this machine that must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Read, understand and follow all precautions and warnings in this manual and on the machine before performing operation and maintenance. Failure to do so may result in serious injury or death.
- Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used. Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions. If you carry out any operation, inspection, or maintenance under conditions that are not described in this manual, understand that it is your responsibility to take the necessary precautions to ensure safety.
- In no event should you or others engage in the prohibited uses or actions described in this manual. Improper operation and maintenance of the machine can be hazardous and could result in serious injury or death. If you sell the machine, be sure to give this manual to the new owner together with the machine.
- Always keep this Operation and Maintenance Manual in the location shown on the right so that all relevant personnel can read it at any time. Storage location for the Operation and Maintenance Manual: Main Control Box If this manual is lost or damaged, contact your distributor immediately to arrange for its replacement. For details regarding the machine serial No. you will need to provide your Komatsu distributor, see “TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR (PAGE 1-6)”.
- This manual uses the international units (SI) for units of measurement. For reference, units that have been used in the past are given in ( ). The explanations, values, and illustrations in this manual have been prepared based on the latest information available as of the date of its publication.
- Continuing improvements in the design of this machine may lead to additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information concerning your machine or with questions regarding information contained in this manual.
- The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example:1 → (1)) Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped.
- If this machine has been purchased in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating the machine.
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- 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]
