WA600-3L WHEELLOADER
ThismaterialisproprietarytoKomatsuAmericaInternationalCompanyandisnottobereproduced,used,ordisclosed exceptinaccordancewithwrittenauthorizationfromKomatsuAmericaInternationalCompany.
Itisourpolicytoimproveourproductswheneveritispossibleandpracticaltodoso.Wereservetherighttomake changesoraddimprovementsatanytimewithoutincurringanyobligationtoinstallsuchchangesonproductssold previously.
Duetothiscontinuousprogramofresearchanddevelopment,periodicrevisionsmaybemadetothispublication.Itis recommendedthatcustomerscontacttheirdistributorforinformationonthelatestrevision.
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MEMORANDA
PRODUCTPUBLICATIONSINFORMATION
VARIOUSPRODUCTPARTS&SERVICEPUBLICATIONSAREAVAILABLETOALLKOMATSUCONSTRUCTION EQUIPMENTOWNERS,INCLUDINGOPERATIONANDMAINTENANCEMANUALS,PARTSBOOKSANDSHOP MANUALS.
SPECIALPUBLICATIONSSUCHASSERVICETOOL,AIRCONDITIONING,ANDTURBOCHARGERSERVICE MANUALSAREALSOAVAILABLEASWELLASSELECTEDOPERATION&SERVICEMANUALSINFOREIGN LANGUAGES.
THEPUBLICATIONSLISTEDBELOWAREAVAILABLEFORTHISPARTICULARMACHINE(S).
COMPLETEFORM ANDRETURNTO
•DataKomPublishingCorporation
440NorthFairwayDrive
VernonHills,IL60061-8112U.S.A.
Attn:ServicePublications
FaxNo.(847)970-4186
TelNo.(847)970-5887
IMPORTANT-TOASSURESHIPMENTOFTHECORRECTPUBLICATION(S),THEMODELNUMBERANDMACHINE SERIALNUMBERMUSTBESHOWN. QTY.PUBLICATIONFORM
SAFETY
SAFETYNOTICE
IMPORTANTSAFETYNOTICE
Properserviceandrepairisextremelyimportantforthesafeoperationofyourmachine.Theserviceandrepair techniquesrecommendedanddescribedinthismanualarebotheffectiveandsafemethodsofoperation. Someoftheseoperationsrequiretheuseoftoolsspeciallydesignedforthepurpose.
Topreventinjurytoworkers,thesymbolsandareusedtomarksafetyprecautionsinthismanual.The cautionsaccompanyingthesesymbolsshouldalwaysbefollowedcarefully.Ifanydangeroussituationarises ormaypossiblyarise,firstconsidersafety,andtakethenecessaryactionstodealwiththesituation.
GENERALPRECAUTIONSPREPARATIONSFORWORK
Mistakesinoperationareextremelydangerous.Readthe7.Beforeaddingoilormakingrepairs,parkthemaOPERATION&MAINTENANCEMANUALcarefullychineonhard,levelground,andblockthewheelsor beforeoperatingthemachine.trackstopreventthemachinefrommoving.
1.Beforecarryingoutanygreasingorrepairs,readall8.Beforestartingwork,lowerblade,ripper,bucketor theprecautionsgivenonthedecalswhicharefixedtoanyotherworkequipmenttotheground.Ifthisisnot themachine.possible,insertthesafetypinoruseblockstoprevent
theworkequipmentfromfalling.Inaddition,besure
2.Whencarryingoutanyoperation,alwayswearsafetytolockallthecontrolleversandhangwarningsigns shoesandhelmet.Donotwearlooseworkclothes,onthem. orclotheswithbuttonsmissing.
•Alwayswearsafetyglasseswhenhittingpartswithamachinewithblocks,jacksorstandsbeforestarting hammer.work.
•Alwayswearsafetyglasseswhengrindingpartswith10.Removeallmudandoilfromthestepsorother agrinder,etc.placesusedtogetonandoffthemachine.Always
9.Whendisassemblingorassembling,supportthe usethehandrails,laddersorstepswhengettingonor
3.Ifweldingrepairsareneeded,alwayshaveatrained,offthemachine.Neverjumponoroffthemachine. experiencedweldercarryoutthework.Whencarry-Ifitisimpossibletousethehandrails,laddersor ingoutweldingwork,alwayswearweldinggloves,steps,useastandtoprovidesafefooting. apron,glasses,capandotherclothessuitedfor weldingwork.
PRECAUTIONSDURINGWORK
4.Whencarryingoutanyoperationwithtwoormore11.Whenremovingtheoilfillercap,drainplugorhyworkers,alwaysagreeontheoperatingproceduredraulicpressuremeasuringplugs,loosenthem beforestarting.Alwaysinformyourfellowworkersslowlytopreventtheoilfromspurtingout.Before beforestartinganystepoftheoperation.Beforedisconnectingorremovingcomponentsoftheoil, startingwork,hangUNDERREPAIRsignsonthewateroraircircuits,firstremovethepressurecomcontrolsintheoperator'scompartment.pletelyfromthecircuit.
5.Keepalltoolsingoodconditionandlearnthecorrect12.Thewaterandoilinthecircuitsarehotwhenthe waytousethem.engineisstopped,sobecarefulnottogetburned.
Waitfortheoilandwatertocoolbeforecarryingout
6.Decideaplaceintherepairworkshoptokeeptoolsanyworkontheoilorwatercircuits. andremovedparts.Alwayskeepthetoolsandparts intheircorrectplaces.Alwayskeeptheworkarea13.Beforestartingwork,removetheleadsfromthe cleanandmakesurethatthereisnodirtoroilonthebattery.ALWAYSremovetheleadfromthenegative floor.Smokeonlyintheareasprovidedforsmoking.(G)terminalfirst. Neversmokewhileworking.
14.Whenraisingheavycomponents,useahoistor•Wheninstallinghosesandwires,besurethatthey crane.Checkthatthewirerope,chainsandhookswillnotbedamagedbycontactwithotherpartswhen arefreefromdamage.Alwaysuseliftingequipmentthemachineisbeingoperated. whichhasamplecapacity.Installtheliftingequipment atthecorrectplaces.Useahoistorcraneand20.Wheninstallinghighpressurehoses,makesurethat operateslowlytopreventthecomponentfromhittingtheyarenottwisted.Damagedtubesaredangerous, anyotherpart.Donotworkwithanypartstillraisedsobeextremelycarefulwheninstallingtubesforhigh bythehoistorcrane.pressurecircuits.Alsocheckthatconnectingparts
15.Whenremovingcoverswhichareunderpressureor underpressurefromaspring,alwaysleavetwobolts21.Whenassemblingorinstallingparts,alwaysusethe inpositiononoppositesides.Slowlyreleasethespecifiedtighteningtorques.Wheninstallingprotecpressure,thenslowlyloosentheboltstoremove.tivepartssuchasguards,orpartswhichvibrate
16.Whenremovingcomponents,becarefulnottobreakthattheyareinstalledcorrectly. ordamagethewiring,Damagedwiringmaycause electricalfires.22.Whenaligningtwoholes,neverinsertyourfingersor
17.Whenremovingpiping,stopthefueloroilfromhole. spillingout.Ifanyfueloroildripsontothefloor,wipe itupimmediately.Fueloroilonthefloorcancause23.Whenmeasuringhydraulicpressure,checkthatthe youtoslip,orcanevenstartfires.measuringtooliscorrectlyassembledbeforetaking
arecorrectlyinstalled. violentlyorrotateathighspeed,becarefultocheck hand.Becarefulnottogetyourfingerscaughtina anymeasurements.
18.Asageneralrule,donotusegasolinetowashparts. Inparticular,useonlytheminimumofgasolinewhen24.Takecarewhenremovingorinstallingthetracksof washingelectricalparts.track-typemachines.Whenremovingthetrack,the
trackseparatessuddenly,soneverletanyonestand
19.Besuretoassembleallpartsagainintheiroriginalateitherendofthetrack. places.Replaceanydamagedpartwithnewparts.
GENERAL
Thisshopmanualhasbeenpreparedasanaidtoimprovethequalityofrepairsbygivingtheservicemananaccurate understandingoftheproductandbyshowinghimthecorrectwaytoperformrepairsandmakejudgements.Makesure youunderstandthecontentsofthismanualanduseittofulleffectateveryopportunity.
Thisshopmanualmainlycontainsthenecessarytechnicalinformationforoperationsperformedinaserviceworkshop. Foreaseofunderstanding,themanualisdividedintothefollowingsections.Thesesectionsarefurtherdividedintoeach maingroupofcomponents.
GENERAL
Thissectionliststhegeneralmachinedimensions,performancespecifications,componentweights,andfuel,coolant andlubricantspecificationcharts.
STRUCTUREANDFUNCTION
Thissectionexplainsthestructureandfunctionofeachcomponent.Itservesnotonlytogiveanunderstandingofthe structure,butalsoservesasreferencematerialfortroubleshooting.
TESTING,ADJUSTINGANDTROUBLESHOOTING
Thissectionexplainscheckstobemadebeforeandafterperformingrepairs,aswellasadjustmentstobemadeat completionofthechecksandrepairs.Troubleshootingchartscorrelating"Problems"to"Causes"arealsoincluded inthissection.
DISASSEMBLYANDASSEMBLY
Thissectionexplainstheordertobefollowedwhenremoving,installing,disassemblingorassemblingeach component,aswellasprecautionstobetakenfortheseoperations.
MAINTENANCESTANDARD
Thissectiongivesthejudgementstandardswheninspectingdisassembledparts.
NOTICE
Thespecificationscontainedinthisshopmanualaresubjecttochangeatanytimeandwithoutanyadvance notice.Contactyourdistributorforthelatestinformation.
HOWTOREADTHESHOPMANUAL
VOLUMES
Shopmanualsareissuedasaguidetocarryingout repairs.Theyaredividedasfollows:
Chassisvolume:Issuedforeverymachinemodel
Enginevolume:Issuedforeachengineseries
Electricalvolume:Eachissuedasonetocoverall models
Attachmentvolume:Eachissuedasonetocoverall models
Thesevariousvolumesaredesignedtoavoidduplication ofinformation.Thereforetodealwithallrepairsforany model,itisnecessarythatchassis,engine,electricaland attachmentbeavailable.
DISTRIBUTIONANDUPDATING
Anyadditions,amendmentsorotherchangeswillbesent toyourdistributor.Getthemostup-to-dateinformation beforeyoustartanywork.
FILINGMETHOD
1.Seethepagenumberonthebottomofthepage.File thepagesincorrectorder.
2.Followingexamplesshowhowtoreadthepage number:
Example1(Chassisvolume): 10-3
Sectionnumber(10.StructureandFunction)
Consecutivepagenumber foreachitem
Example2(Enginevolume):
Refertothepertinentenginemanual.
3.Additionalpages:Additionalpagesareindicatedbya hyphen(-)andnumberedafterthepagenumber.File asintheexample.
Example(Chassisvolume): 10-4
10-4-1
•Addedpages10-4-2 10-5
REVISEDEDITIONMARK
Whenamanualisrevised,aneditionmark(....)is••• recordedonthebottomoutsidecornerofthepagethatis revisedornew.
REVISIONS
RevisedpagesarerecordedintheLISTOFORIGINAL, NEWANDREVISEDPAGESfollowingthetitlepage.
SYMBOLS
Sothattheshopmanualcanbeofamplepracticaluse, importantplacesforsafetyandqualityaremarkedwith thefollowingsymbols.
SymbolItemRemarks
SafetySpecialsafetyprecautionsarenecessarywhenperformingthework.
•Caution
Weight
Specialtechnicalprecautionsorother precautionsforpreservingstandards arenecessarywhenperformingthe work.
Weightofpartsorsystems.Caution necessarywhenselectinghoistingwire orwhenworkingpostureisimportant, etc.
TighteningPlacesthatrequirespecialattentionfor torquetighteningtorqueduringassembly.
Coat
Oil,water
Drain
Placestobecoatedwithadhesives andlubricantsetc.
Placeswhereoil,waterorfuelmustbe added,andthecapacity.
Placeswhereoilorwatermustbe drained,andquantitytobedrained.
HOISTINGINSTRUCTIONS
HOISTING
WARNING:Heavyparts(25kgormore)must beliftedwithahoistetc.IntheDISASSEMBLY ANDASSEMBLYsection,everypartweighing 25kgormoreisindicatedclearlywiththissymbol
•Ifapartcannotbesmoothlyremovedfromthe machinebyhoisting,thefollowingchecksshouldbe made:
1)Checkforremovalofallboltsfasteningthepartto therelativeparts.
2)Checkforexistenceofanotherpartcausinginterfacewiththeparttoberemoved.
WIREROPES
1)Useadequatewireropesdependingontheweightof partstobehoisted,referringtothetablebelow:
Wireropes
StandardZorStwistwireropeswithoutgalvanizing
Wireropediameter(mm)Allowableload(tons)
3)Donotslingaheavyloadwithonewireropealone, butslingwithtwoormorewireropessymmetrically woundontotheload.
WARNING:Slingingwithonewireropemay causeturningoftheloadduringhoisting, untwistingofthewirerope,orslippingofthe wireropefromitsoriginalwindingpositionon theload,whichcanresultinadangerous accident.
4)Donotslingaheavyloadwithwireropesforminga widehanginganglefromthehook.Whenhoistinga loadwithtwoormorewireropes,theforcesubjected toeachwireropewillincreasewiththehanging angles.Thetablebelowshowsthevariationofallowableload(kg)whenhoistingismadewithtwowire ropes,eachofwhichisallowedtoslingupto1000kg vertically,atvarioushangingangles.
Whentwowireropesslingaloadvertically,upto 2000kgoftotalweightcanbesuspended.This weightbecomes1000kgwhentwowireropesmake a120•hangingangle.Ontheotherhand,twowire ropesaresubjecttoanexcessiveforceaslargeas 4000kgiftheyslinga2000kgloadataliftingangle of150•.
•Theallowableloadvalueisestimatedtobe1/6or 1/7ofthebreakingstrengthofthewireropeused.
2)Slingwirewireropesfromthemiddleportionofthe hook.Slingingneartheedgeofthehookmaycause thewireropetoslipoffthehookduringhoisting,and aseriousaccidentcanresult.Hookshavemaximum strengthatthemiddleportion.
