KOMATSU WA600-6-M Maintenance Manual
EEAM024501
Operation &
Maintenance Manual
WA600
WHEEL LOADER
SERIAL NUMBER
WA600-6 - 60001
and up
-6
WARNING
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this
machine. This manual should be kept inside the cab for
reference and periodically reviewed by all personnel who
will come into contact with the machine.
FOREWORD
11
FOREWORD FOREWORD
FOREWORD 1
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 acciden ts
are caused by the failure to follow fundamental safety rules for the operation and maintenance of machi nes. Accidents can be prevented by knowing beforehand conditio ns that may cause a haz ard when performing op eration
and maintenance.
WARNING
Operators and maintenance personnel must always do as follows before beginning opera tion or maintenance.
Always be sure to read and understand this manual thoroughly before performing operation and maintenance.
Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly
and be sure that you understand them fully.
Keep this manual in the storage location f or the opera tion and ma intenance ma nual given below, and have
all personnel read it periodically.
If this manual has been lost or has become dirty and cannot be read, request a replacement manua l immediately from Komatsu or your Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners together with the machine.
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 or purchased from
someone 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 count ry, consult Komatsu or your Komatsu distributor before operating
the machine.
Storage location fo r the Operation and Maintenance Manual:
Pocket (1) at rear of operator's seat
1-2
FOREWORD SAFETY INFORMATION
SAFETY INFORMATION 1
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
DANGER
WARNING
CAUTION
Example of safety message using signal word
Indicates an imminently hazardous situation which, if not avoided, will result in death
or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death
or serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. This word is used also to alert against unsafe practices that may
cause property damage.
WARNING
When standing up from the operat or' s se at , always plac e th e wo rk equipment lock le ver in the LOCK position.
If you accidentally touch the work equipment control levers when they are not locked, this may cause a
serious injury or death.
Other signal words
In addition to the above, the following signal words are used to indicate precaution s that shou ld be followed to protect the machine or to give information that is useful to know.
NOTICE
REMARKS
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
This word is used for information that is useful to know.
1-3
SAFETY INFORMATION FOREWORD
q Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying
out operation or maintenance of the machine that may involve hazard.
This machine uses “Safety labels using words“ and “Safety labels using pictograms“ to indicate safety pr ocedur es.
Example of safety label using words
Safety labels using pictogram
Safety pictograms use a picture to expre ss a level of hazardous condition equivalent to the signal word. These safety pictograms use pictures in order to let the operator or maintenance
worker understand the level and type of h azardous condition at
all times. Safety pictograms show the type of hazardous condition at the top or left side, and the me thod of avoiding the hazardous condition at the bottom or right side. In addition, the
type of hazardous condition is displayed inside a triangle and
the method of avoiding the hazardous condition is shown
inside a circle.
Part No.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintena nce.
Therefore, the safety messages in this manual and on the machine may not include all po ssible safety precautions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsibility to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvem ents in the design of this machine can lead to changes in detail which may not
be reflected in this manual.
In addition, the illustrations in this manual may show the machine with optional equipment installed.
If there are any unclear points or you have any questions, please contact your Komatsu distributor.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1 -> (1))
1-4
FOREWORD SAFETY INFORMATION
Noise emission levels 1
Two labels ind icating the machine noise level a re affixed on the
machine.
q Sound pressure level at the operator’s station, measured
according to ISO6396 (Dynamic test method, simulated
working cycle).
q Sound power level emitted by the machine, measured
according to ISO 6395 (Dynamic test method, simulated
working cycle). This is the guaranteed value as specified
in European directive 2000/14/EC.
Vibration levels 1
When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the operator’s seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO
7096.
The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s². The actual acceleratio n
value for the body is less than or equal to 0.5 m/s².
These values were determined using a representat ive machine and measured during the typical operating condi-
tion indicated below according to the measurement procedures that are defined in the standards ISO 2631/1 and
ISO 5349.
1-5
SAFETY INFORMATION FOREWORD
Operating condition:
(WHEEL LOADER:) V-shape loading
Guide to Reduce Vibration Levels on Machine 1
The following guides can help an operator of this machine to
reduce the whole body vibration levels:
1. Use the correct equipment and attachments.
2. Maintain the machine according to this manual
q Tire pressures (for wheeled machines), tension of crawler (fo r crawler machines)
q Brake and steering systems
q Controls, hydraulic system and linkages
3. Keep the terrain where the machine is working and traveling in good condition
q Remove any large rocks or obstacles
q Fill any ditches and holes
q Site manager should provide machine operators with machine and schedule time to maintain terrain con-
ditions
4. Use a seat that meets ISO 7096 and keep the seat maintained and adjusted
q Adjust the seat and suspension for the weight and size of the operator
q Wear seat belt
q Inspect and maintain the seat suspension and adjustment mechanisms
5. Steer, brake, accelerate, shift gears (for wheeled machines), and move the attachment levers and pedals
slowly so that the machine moves smoothly
6. Adjust the machine speed and travel path to minimize the vibration level
q When pushing with bucket or blade, avoid sudden loading; load gradually
q Drive around obstacles and rough terrain conditions
q Slow down when it is necessary to go over rough terrain
q Make the curve radius of traveling path as large as possible
q Travel at low speed when traveling around sharp curves
7. Minimize vibrations for long work cycle or long distance traveling
q Reduce speed to prevent bounce
q Transport machines long distances between worksites
8. The following guidelines can be effective to minimize risks of low back pain
q Operate the machine only when you are in good health.
q Provide breaks to reduce long periods of sitting in the same posture
q Do not jump down from the cab or machine
q Do not repeatedly handle and lift loads.
1-6
FOREWORD INTRODUCTION
INTRODUCTION 1
This Komatsu machine is designed to be used mainly for the following work:
q Digging work
q Smoothing
q Pushing work
q Loading work
For details of the operating procedure, see “WORK POSSIBLE USING WHEEL LOADER (3-138)“.
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 1
A
1
CD
B
(1) Bucket
(A) Front (C) Left
(B) Rear (D) Right
In this manual, the directions of the machine (front, rear, left, right) are determined accord ing to the v iew from th e
operator's seat in the direction of travel (front) of the machine.
1-7
INTRODUCTION FOREWORD
VISIBILITY FROM OPERATOR'S SEAT 1
The visibility standards (ISO 5006) for this machine require a view shown in the diagram below.
VISIBILITY IN IMMEDIATE AREA 1
The visibility of this machine in the area 1 m from the outside surface of the machine at a height of 1.5 m is shown
in the diagram below . The hatched ar ea (A) shows the area where the view is blocked by part of the ma chine when
mirrors or other aids to visibility are installed as standard. Please be fully aware that there are places that cannot
be seen when operating the machine.
12-M RADIUS VISIBILITY 1
The visibility at a radius of 12 m from the machine is as shown in the diagram below. The hatched areas (B) show
the areas where the view is blocked when mirrors or other aids to visibility are installed as standard. Please be
fully aware that there are places that cannot be seen when operating the machine.
1-8
FOREWORD NECESSARY INFORMATION
NECESSARY INFORMATION 1
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1
On the center right of the front frame.
The design of the nameplate differs according to the territory.
EPA REGULATIONS, ENGINE NUMBER PLATE 1
This name plate is affixed on the oil cooler at the side of engine cylinder block on the left side of machine.
EPA: Environmental Protection Agency, U.S.A.
1-9
NECESSARY INFORMATION FOREWORD
POSITION OF SERVICE METER 1
The service meter is displayed on the character display at the
bottom center of the machine monitor.
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1
Machine serial No.
Engine serial No.
Product Identification Number
Manufacturers name:
Address:
Distributor
Address
Phone
Service personnel for your
machine:
KOMATSU LTD.
3-6 Akasaka
Minato-ku, 101 Tokyo
Japan
1-10
FOREWORD NECESSARY INFORMATION
MACHINE SERIAL NUMBER PLATE 1
Model
Serial Number
Manufacturing year
Weight
Engine power
Product Identification Number
Manufacturer
1-11
CONTENTS
CONTENTS
FOREWORD
FOREWORD.........................................................................................................................................................1-2
SAFETY INFORMATION...................................................................................................................................... 1-3
Noise emission levels ...................................... ... ... ... ... .... ... ... ... .... ..............................................................1-5
Vibration levels............................................................................................................................................1-5
Guide to Reduce Vibration Levels on Machine..................................................................................1-6
INTRODUCTION................................................................................................................................................... 1-7
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE....................................................................... 1-7
VISIBILITY FROM OPERATOR'S SEAT....................................................................................................1-8
VISIBILITY IN IMMEDIATE AREA.....................................................................................................1-8
12-M RADIUS VISIBILITY .................................................................................................................1-8
NECESSARY INFORMATION ............................................................................................................................. 1-9
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE........................................ 1-9
EPA REGULATIONS, ENGINE NUMBER PLATE ............. ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... ... .... ... . 1-9
POSITION OF SERVICE METER ............................................................................................................1-10
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ............................................................................ 1-10
MACHINE SERIAL NUMBER PLATE . ... ... ... .... ... ... ... ... ............................................................................. 1-11
SAFETY
SAFETY................................................................................................................................................................2-2
SAFETY LABELS.................................................................................................................................................2-4
LOCATION OF SAFETY LABELS..............................................................................................................2-5
SAFETY LABELS ........................ ... .... ... ... ... .... ...................................... .... ... .............................................. 2-6
GENERAL PRECAUTIONS ...............................................................................................................................2-14
PRECAUTIONS FOR OPERATION................................................................................................................... 2-24
STARTING ENGINE.................................................................................................................................2-24
OPERATION.............................................................................................................................................2-26
TRANSPORTATION................................................................................................................................. 2-32
BATTERY ................................................................................................................................................. 2-33
TOWING ................................................................................................................................................... 2-35
PRECAUTIONS FOR MAINTENANCE.............................................................................................................. 2-36
PRECAUTIONS WITH TIRES ............................................................................................................................ 2-44
1-12
CONTENTS
OPERATION
GENERAL VIEW .................................................................................................................................................. 3-2
GENERAL VIEW OF MACHINE..................................................................... .... ... ... .................................. 3-2
GENERAL VIEW OF CONTROLS AND GAUGES..................................................................................... 3-3
EXPLANATION OF COMPONENTS.................................................................................................................... 3-8
MACHINE MONITOR ........ ... ... .... ... ... ....................................... ... ... .... ... ... ... ... .... ........................................ 3-8
TYPES OF WARNING....................................................................................................................... 3-9
CENTRAL WARNING LAMP...........................................................................................................3-10
CHARACTER DISPLAY PORTION................................................................................................. 3-10
EMERGENCY STOP ITEMS...........................................................................................................3-16
CAUTION ITEMS............................................................................................................................. 3-19
INSPECTION AND MAINTENANCE ITEMS................................ ................................................... 3-22
PILOT DISPLAY PORTION............................................................................................................. 3-25
METER DISPLAY PORTION....................... .... ... ... ... .... ... ... ....................................... ... ... ... .... ... ... ...3-31
OTHER FUNCTIONS OF MACHINE MONITOR.......... ... ... ... .... ... ... ... ... .......................................... 3-33
SWITCHES............................................................................................................................................... 3-44
FRONT PANEL, AJSS LEVER SWITCH, REAR BOX....................................................................3-44
RIGHT SWITCH PANEL, CONTROL LEVER SWITCH.................................................................. 3-52
OVERHEAD PORTION................................... ... ... ... .... ... ... ... .... ... ... ....................................... ... ...... 3-61
CONTROL LEVERS, PEDALS................................................................................................................. 3-65
CAP WITH LOCK...................................................................................................................................... 3-72
METHOD OF OPENING AND CLOSING CAP WITH LOCK
(FOR THE FUEL TANK FILLER PORT).......................................................................................... 3-72
METHOD OF OPENING AND CLOSING CAP WITH LOCK (FOR THE HYDRAULIC TANK FILLER
PORT).............................................................................................................................................. 3-73
FRAME LOCK BAR.................................................................................................................................. 3-74
TOWING PIN............................................................................................................................................ 3-75
BACKUP ALARM...................................................................................................................................... 3-75
OPENING CAB, WINDOW DOOR ........................................................................................................... 3-76
OPEN LOCK CANCEL KNOB FOR RIGHT CAB DOOR............................................................. ... 3-76
CAB LEFT DOOR OPEN KNOB ..... ... ... ... ... .... ... ... ... .... ... ... ... ....................................... ... ... .... ... ... ... 3-77
OPEN LOCK CANCEL KNOB FOR LEFT CAB WINDOW .......................................... ... ... .... ... ... ... 3-77
HANDLING CAB WIPER.......................................................................................................................... 3-78
PREVENTING DAMAGE TO WIPER ARM BRACKET...................................................................3-78
DUST INDICATOR ................................................................................................................................... 3-78
FUSE ........................................................................................................................................................ 3-79
FUSE CAPACITY AND NAME OF CIRCUIT................................................................................... 3-79
CIRCUIT BREAKER................................................................................................................................. 3-80
SLOW BLOW FUSE................................................................................................................................. 3-81
LUNCH BOX TRAY .................................................................................................................................. 3-81
TOOL BOX................................................................................................................................................ 3-81
GREASE PUMP........................................................................................................................................ 3-82
LOCATION OF FIRE EXTINGUISHER .................................................................................................... 3-82
POWER OUTLET........................................... ... ... .... ... ....................................... ... ... ... .... ... ... .
AM/FM RADIO-CASSETTE STEREO......................................................................................................3-83
EXPLANATION OF COMPONENTS............................................................................................... 3-83
.................. 3-82
1-13
CONTENTS
METHOD OF OPERATION.......................................... ... .... ... ... ... .... ... ... ....................................... ..3-88
PRECAUTIONS WHEN USING ......................................................................................................3-90
AIR CONDITIONER..................................................................................................................................3-91
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL ................................................ 3-91
METHOD OF OPERATION.......................................... ... .... ... ... ... .... ... ... ....................................... ..3-95
USE AIR CONDITIONER WITH CARE.........................................................................................3-101
AIR CONDITIONER MAINTENANCE .......................... ... .... ... ... ... .... ... .......................................... 3-102
COOL BOX.................................................................................................................................... 3-102
OTHER FUNCTIONS .................................................................................................................... 3-102
OPERATION.....................................................................................................................................................3-104
CHECK BEFORE STARTING ENGINE, ADJUST . ... ... .... ....................................................................... 3-104
WALK-AROUND CHECK ..............................................................................................................3-104
CHECK BEFORE STARTING .......................................................................................................3-107
ADJUSTMENT...............................................................................................................................3-114
OPERATIONS AND CHECKS BEFORE STARTING ENGINE..................................................... 3-119
STARTING ENGINE............................................................................................................................... 3-120
AUTOMATIC WARMING-UP OPERATION................................................................................... 3-122
OPERATIONS AND CHECKS AFTER STARTING ENGINE.................................................................3-122
BREAKING-IN THE MACHINE......................................................................................................3-122
NORMAL OPERATION ............. ... ... ... ....................................... ... .... ... ... ....................................... 3-123
STOPPING ENGINE . ... ... ... ....................................... ... .... ... ... ....................................... ... ... .... ................3-124
CHECK AFTER STOPPING ENGINE ....................................................................................................3-124
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE................................ 3-125
PREPARATIONS FOR MOVING MACHINE.................................................................................3-125
CHANGING GEAR SPEED...........................................................................................................3-128
CHANGING DIRECTION.............................. ... ... .... ... ... ....................................... ... ... .... ... .............3-129
STOPPING THE MACHINE .......................................................................................................... 3-130
TURNING................................................................................................................................................3-132
EMERGENCY STEERING .... .... ... ... ... .... ... ... ... ....................................... ... ... .... ... .......................... 3-133
OPERATION OF WORK EQUIPMENT .................................................................................................. 3-134
SEMI AUTO DIGGING OPERATIONS ................................................................................................... 3-135
REMOTE POSITIONER .........................................................................................................................3-136
WORK POSSIBLE USING WHEEL LOADER........................................................................................3-138
RECOMMENDED COMBINATION OF SWITCHES FOR OPERATION.......................................3-138
DIGGING OPERATIONS...............................................................................................................3-139
LEVELING OPERATIONS............................... ... .... ...................................... .... ... ... ... ....................3-142
PUSHING OPERATION ................................................................................................................3-142
LOAD AND CARRY OPERATIONS ..............................................................................................3-142
LOADING OPERATIONS....................................... ... ... ... .... ... ... ... .... ...................................... ... ....3-143
PRECAUTIONS WHEN HANDLING BLASTED ROCK.................................................................3-145
PRECAUTIONS FOR OPERATION .......................................................................................................3-157
PERMISSIBLE WATER DEPTH.................................................................................................... 3-157
IF WHEEL BRAKE DOES NOT WORK.........................................................................................3-157
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES.........................................................3-157
REMOVAL AND INSTALLATION OF THE BUCKET ............................................................................. 3-159
REMOVING THE BUCKET ...........................................................................................................3-159
INSTALLING THE BUCKET..........................................................................................................3-161
1-14
CONTENTS
PARKING MACHINE.............................................................................................................................. 3-163
CHECKS AFTER COMPLETION OF OPERATION................................. ... ... ........................................ 3-165
LOCKING................................................................................................................................................ 3-165
HANDLING THE TIRES.......................................................................................................................... 3-166
PRECAUTIONS WHEN HANDLING TIRES.................................................................................. 3-166
TIRE PRESSURE.......................................................................................................................... 3-166
PRECAUTIONS FOR USING LOAD AND CARRY METHOD ........................... .... ... ... ... ... .... ... ... . 3-168
PRECAUTIONS FOR USING STONE HANDLING METHOD ...................................................... 3-168
PRECAUTIONS RELATED TO FITTING TIRE CHAINS AND ADDING BALLAST...................... 3-168
TRANSPORTATION......................................................................................................................................... 3-169
TRANSPORTATION PROCEDURE....................................................................................................... 3-169
LOADING, UNLOADING WORK................................. ... ... .... ... ... ... .... ... ... ... ... .... .................................... 3-169
METHOD OF SECURING MACHINE..................................................................................................... 3-169
METHOD OF LIFTING MACHINE.......................................................................................................... 3-171
LOCATION OF LIFTING POSITION MARK.................................................................................. 3-172
WEIGHT TABLE............................................................................................................................ 3-172
LIFTING PROCEDURE.................................................................................................................3-173
PRECAUTIONS WHEN DISASSEMBLY OR REASSEMBLING WORK EQUIPMENT ......................... 3-174
COLD WEATHER OPERATION...................................................................................................................... 3-175
PRECAUTIONS FOR LOW TEMPERATURE............................................................. .... ... ... ... ... .... ... ... . 3-175
FUEL AND LUBRICANTS .............................................................................................................3-175
COOLANT ..................................................................................................................................... 3-175
BATTERY...................................................................................................................................... 3-176
PRECAUTIONS AFTER COMPLETION OF WORK .......................... ... ... ... ... ........................................ 3-176
AFTER COLD WEATHER...................................................................................................................... 3-177
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER.............. 3-177
LONG-TERM STORAGE..................................................................................................................................3-178
BEFORE STORAGE............................................................................................................................... 3-178
DURING STORAGE............................................................................................................................... 3-178
AFTER STORAGE.................................................................................................................................. 3-178
TROUBLESHOOTING...................................................................................................................................... 3-179
WHEN MACHINE RUNS OUT OF FUEL ............................................................................................... 3-179
METHOD OF TOWING MACHINE.........................................................................................................3-179
WHEN ENGINE RUNS.......................... ... ... .... ... ....................................... ... ... ... .... ... .................... 3-180
WHEN ENGINE DOES NOT RUN .. ... ... ... ... .... ... ... ... .... ... ... .......................................... ... ... .... ....... 3-180
RELEASING PARKING BRAKE.................................................................................................... 3-181
EMERGENCY TRAVEL OPERATION .......................................................................................... 3-182
IF BATTERY IS DISCHARGED.............................................................................................................. 3-183
REMOVAL AND INSTALLATION OF BATTERY .......................................................................... 3-183
PRECAUTIONS FOR CHARGING BATTERY .............................................................................. 3-184
STARTING ENGINE WITH BOOSTER CABLE ............................................................................ 3-184
STARTING ENGINE WHEN USING STARTING AID CONNECTOR (if equipped)...................... 3-186
METHOD FOR LOWERING WORK EQUIPMENT WHEN ENGINE HAS STOPPED........................... 3-187
OTHER TROUBLE ................................................................................................................................. 3-188
ELECTRICAL SYSTEM................................................................................................................. 3-188
1-15
CONTENTS
CHASSIS.......................................................................................................................................3-189
ENGINE......................................................................................................................................... 3-191
MAINTENANCE
GUIDES TO MAINTENANCE...............................................................................................................................4-2
OUTLINES OF SERVICE ..................................................................................................................................... 4-4
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC......................................................4-4
OIL.....................................................................................................................................................4-4
FUEL..................................................................................................................................................4-5
COOLANT AND WATER FOR DILUTION.........................................................................................4-5
GREASE............................................................................................................................................ 4-6
CARRYING OUT KOWA (Komatsu Oil Wear Analysis) .................................................................... 4-6
STORING OIL AND FUEL..... .... ... ....................................... ... ... ... .... ...................................... ... ........ 4-7
FILTERS............................................................................................................................................4-7
OUTLINE OF ELECTRIC SYSTEM............................................................................................................ 4-8
WEAR PARTS......................................................................................................................................................4-9
WEAR PARTS LIST....................................................................................................................................4-9
RECOMMENDED FUEL, COOLANT, AND LUBRICANT .................................................................................4-10
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.............4-11
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU
GENUINE OIL........... ....................................... ... ... ... ... .... ...................................... .... ... ... .........................4-13
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.....................................................................4-14
TORQUE LIST.......................................................................................................................................... 4-14
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS .......................................................................... 4-16
SAFETY CRITICAL PARTS................................... ... ... .... ... ....................................... ... ... ... .... ... ...............4-17
MAINTENANCE SCHEDULE CHART ............................................................................................................... 4-19
MAINTENANCE SCHEDULE CHART......................................................................................................4-19
SERVICE PROCEDURE ....................................................................................................................................4-21
INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE)....................... 4-21
INITIAL 250 HOURS SERVICE................................................................................................................ 4-21
WHEN REQUIRED............................................. ... ... ... .... ... ....................................... ... ... ... .... ..................4-22
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT .......................................................... 4-22
CLEAN INSIDE OF COOLING SYSTEM ........................................................................................ 4-24
CHECK TRANSMISSION OIL LEVEL, ADD OIL ............................................................................4-28
CHECK AXLE OIL LEVEL, ADD OIL...............................................................................................4-30
CLEAN AXLE CASE BREATHER ................................................................................................... 4-31
CLEAN AIR CONDITIONER CONDENSER.................................................................................... 4-32
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID............................................................. 4-32
CLEAN RADIATOR FINS................................................................................................................ 4-33
REPLACE BUCKET TEETH......................................... ... .... ... ... ... .... ... ... ... ... .... ... ... .........................4-37
LUBRICATING.................................................................................................................................4-38
1-16
CONTENTS
CHECK AIR CONDITIONER................................................................. .... ... ... ... .... .........................4-39
REPLACE SLOW BLOW FUSE ...................................................................................................... 4-40
BLEEDING AIR FROM HYDRAULIC TANK.................................................................................... 4-41
BLEEDING AIR FROM FUEL CIRCUIT .......................................................................................... 4-43
CHECKING FUNCTION OF ACCUMULATOR ............................................................................... 4-46
SELECTION AND INSPECTION OF TIRES ................................................................................... 4-46
CHECK BEFORE STARTING .................................................................................................................. 4-48
EVERY 50 HOURS SERVICE.................................................................................................................. 4-49
DRAIN WATER, SEDIMENT FROM FUEL TANK........................................................................... 4-49
EVERY 100 HOURS SERVICE................................................................................................................4-50
LUBRICATING................................................................................................................................. 4-50
LUBRICATE REAR AXLE PIVOT PIN.......................... ... ... ... .... ......................................... .... ... ... ... 4-52
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL.................................................................... 4-53
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER ................................................... 4-54
EVERY 250 HOURS SERVICE................................................................................................................4-55
CHECK BATTERY ELECTROLYTE LEVEL ................................................................................... 4-55
CHECK PARKING BRAKE.............................. ... ... ... ....................................... ... .... ... ... ... ... .... ... ... ... 4-56
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN .............................. ... ... .... ... ... ... ... .... ... ... ... 4-57
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER ......................................... 4-57
CHECKING FUNCTION OF ACCUMULATOR ............................................................................... 4-57
EVERY 500 HOURS SERVICE................................................................................................................4-58
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.................... 4-58
REPLACE FUEL PRE-FILTER CARTRIDGE.................................................................................. 4-59
REPLACE FUEL FILTER CARTRIDGE .......................................................................................... 4-61
REPLACE TRANSMISSION OIL FILTER ELEMENT ..................................................................... 4-62
REPLACE BRAKE OIL FILTER CARTRIDGE ................................................................................ 4-63
CHECK, REPLACE COMPRESSOR DRIVE BELT FOR ALTERNATOR, AIR CONDITIONER ....4-64
EVERY 1000 HOURS SERVICE.............................................................................................................. 4-65
CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER...................................................... 4-65
CLEAN TRANSMISSION CASE BREATHER.................................................................................4-66
LUBRICATING................................................................................................................................. 4-66
REPLACE CORROSION RESISTOR CARTRIDGE ....................................................................... 4-67
CHECK, GREASE COMPRESSOR DRIVE BELT TENSION PULLEY ASSEMBLY FOR
ALTERNATOR, AIR CONDITIONER .............................................................................................. 4-68
EVERY 2000 HOURS SERVICE.......................................................................................................
....... 4-69
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...................... 4-69
CLEAN HYDRAULIC TANK STRAINER ......................................................................................... 4-71
REPLACE HYDRAULIC TANK BREATHER ELEMENT................................................................. 4-72
CHANGE AXLE OIL ........................................................................................................................ 4-72
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER,
FRESH AIR FILTER........................................................................................................................ 4-73
CLEAN PPC CIRCUIT STRAINER.................................................................................................. 4-74
CHECK ALTERNATOR................................................................... ... ... .... ... ... ................................ 4-74
CHECK ENGINE VALVE CLEARANCE, ADJUST.......................... ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... 4-74
CHECK BRAKE DISC WEAR.......................................................................................................... 4-74
CHECKING FUNCTION OF ACCUMULATOR ............................................................................... 4-75
CHECK BOOST PIPING CLAMPS.................................................................................................. 4-75
CHANGE OIL FOR WORK EQUIPMENT PINS.............................................................................. 4-76
1-17
CONTENTS
EVERY 4000 HOURS SERVICE..............................................................................................................4-77
CHECK WATER PUMP...................................................................................................................4-77
CHECK STARTING MOTOR...........................................................................................................4-77
CHECK AIR CONDITIONER COMPRESSOR, ADJUST................................................................4-77
LUBRICATING.................................................................................................................................4-77
CHECK FOR LOOSE ENGINE HIGH-PRESSURE PIPING CLAMPS,
HARDENING OF RUBBER .............................................................................................................4-79
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER ....... 4-80
EVERY 8000 HOURS SERVICE..............................................................................................................4-81
REPLACE ENGINE HIGH-PRESSURE PIPING CLAMPS ............................................................. 4-81
REPLACE FUEL SPRAY PREVENTION CAP................................................................................4-81
OVERHAUL STARTING MOTOR AND ALTERNATOR.................................................................. 4-81
SPECIFICATIONS
SPECIFICATIONS................................................................................................................................................5-2
ATTACHMENTS, OPTIONS
HANDLING STEERING WHEEL SPECIFICATION MACHINE ........................................................................... 6-2
EXPLANATION OF COMPONENTS .......................................................................................................... 6-2
SWITCHES, FRONT PANEL, STEERING WHEEL SWITCH, REAR BOX....................................... 6-2
CONTROL LEVERS, PEDALS..........................................................................................................6-8
STEERING TILT LEVER ................................................................................................................. 6-11
FUNCTIONS OF STEERING WHEEL SPECIFICATION MACHINE........................................................6-12
CHANGING GEAR SPEED.............................................................................................................6-12
CHANGING DIRECTION.............................. ... ... .... ... ... ....................................... ... ... .... ... ...............6-13
TURNING ........................................................................................................................................6-15
MOVING MACHINE OFF (MACHINES EQUIPPED WITH STEERING WHEEL)...........................6-16
METHOD OF STOPPING, PARKING MACHINE
(MACHINES EQUIPPED WITH STEERING WHEEL).....................................................................6-19
SELECTING BUCKET AND TIRES ................................................................................................................... 6-21
STARTING IN COLD AREAS ............................................................................................................................6-22
ELECTRIC HEATER.................................................................................................................................6-22
PROCEDURE FOR SETTING UP EXTERNAL POWER SOURCE FOR EXTERNAL POWER
SOURCE TYPE ELECTRIC HEATER............................................................................................. 6-22
MANUFACTURING EXTERNAL POWER SOURCE INPUT CABLE..............................................6-24
ESTABLISHING POWER SUPPLY. ... .... ... ... ... ... .... ... ... ... .... ... ... ... .... ... .......................................... .. 6-25
CHECK ACTUATION AFTER COMPLETION OF ASSEMBLY....................................................... 6-25
HANDLING LOAD METER ................................................................................................................................6-26
OUTLINE OF LOAD METER....................................................................................................................6-26
PRINCIPLE OF LOAD METER MEASUREMENT....................................................................................6-27
POINTS TO REMEMBER TO ENSURE HIGH ACCURACY.................................................................... 6-28
USING LOAD METER .............................................................................................................................. 6-30
1-18
CONTENTS
SETTING ADDITION MODE........................... ... ... ... .... ... ... ... ....................................... ... ... .... ... ......6-30
SETTING SUBTRACTION MODE............ ... .... ... ... ... .... ... ... ... .... ... ... .......................................... ... ... 6-30
TOTAL LOAD DATA DISPLAY........................................................................................................ 6-34
CLEARING TOTAL LOAD...............................................................................................................6-35
STOPPING LOAD METER CALCULATION.................................................................................... 6-35
SELECTING LOAD MATERIAL CATEGORY DISPLAY................................................................. 6-37
CALIBRATING WITH EMPTY BUCKET.......................................................................................... 6-37
CALIBRATION WITH LOADED BUCKET ....................................................................................... 6-40
RESETTING CALIBRATION...........................................................................................................6-43
METHOD OF USING ADDITION MODE......................................................................................... 6-44
METHOD OF USING SUBTRACTION MODE ................................................................................ 6-46
PRINTOUT FROM LOAD METER ............................................ ... ... ... ... .... ... ... ................................ 6-50
SELECTION OF PRINTOUT MODE ............................................................................................... 6-51
HANDLING AUTO-GREASING SYSTEM.......................................................................................................... 6-54
METHOD OF OPERATING AUTO-GREASING SYSTEM....................................................................... 6-54
SETTING GREASING TIME...................................................... ... ... ... ... .... ... ... ... ............................. 6-56
METHOD OF SETTING................................................................................................................... 6-57
CHECK AMOUNT OF GREASE.................. .... ... ... ... ....................................... ... .... ... ... ... ... .... ... ... ... 6-58
GREASING...................................................................................................................................... 6-59
PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM ......................................................... 6-60
TROUBLESHOOTING.............................................................................................................................. 6-60
HANDLING BATTERY DISCONNECTOR SWITCH.......................................................................................... 6-61
EXPLANATION OF COMPONENTS........................................................................................................6-61
BATTERY DISCONNECTOR SWITCH........................................................................................... 6-61
HANDLING ............................................................................................................................................... 6-61
HANDLING STARTING AID CONNECTOR ...................................................................................................... 6-63
STARTING ENGINE WHEN USING STARTING AID CONNECTOR............................................. 6-63
HANDLING REAR FENDER.............................................................................................................................. 6-65
HANDLING ............................................................................................................................................... 6-65
HANDLING MACHINES EQUIPPED WITH VHMS............................................................................................ 6-66
VHMS INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED............................................... 6-66
BASIC PRECAUTIONS................................................................ ... ... ... .... ...................................... 6-66
VHMS AND COMMUNICATIONS TERMINAL INSTALLED..................................................................... 6-66
BASIC PRECAUTIONS................................................................ ... ... ... .... ...................................... 6-66
INDEX
COLOPHON
1-19
CONTENTS
1-20
SAFETY
12
WARNING
Please be sure that you fully underst an d this manual an d the
precautions discribed in this manual and the safety labels
on the machine. When operating or servicing the machine,
always follow these precaustions strictly.
SAFETY SAFETY
SAFETY 2
SAFETY LABELS................................................................................................................................................ 2-42
LOCATION OF SAFETY LABELS............................... ... .... ... ... ... ....................................... ... .... ... ... ............ 2-52
SAFETY LABELS.........................................................................................................................................2-62
GENERAL PRECAUTIONS
SAFETY RULES........................................................................................................................................2-142
IF ABNORMALITIES ARE FOUND............................................................................................................2-142
CLOTHING AND PERSONAL PROTECTIVE ITEMS ...............................................................................2-142
FIRE EXTINGUISHER AND FIRST AID KIT .............................................................................................2-142
SAFETY FEATURES.................................................................................................................................2-152
KEEP MACHINE CLEAN........................................................................................................................... 2-152
INSIDE OPERATOR'S COMPARTMENT.................................................................................................. 2-152
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT ............................................................. 2-162
HANDRAILS AND STEPS .........................................................................................................................2-162
PRECAUTIONS WHEN CLEANING CAB GLASS .................................................................................... 2-172
MOUNTING AND DISMOUNTING ............................................................................................................2-182
NO PEOPLE ON ATTACHMENTS............................................................................................................2-182
DO NOT GET CAUGHT IN ARTICULATED PORTION.............................................................................2-182
PREVENTION OF BURNS ........................................................................................................................2-182
FIRE PREVENTION...................................................................................................................................2-192
ACTION IF FIRE OCCURS........................................................................................................................ 2-202
WINDOW WASHER LIQUID...................................................................................................................... 2-202
PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure)................................................... 2-202
PRECAUTIONS FOR ATTACHMENTS, OPTIONS ..................................................................................2-202
UNAUTHORIZED MODIFICATION ........................................................................................................... 2-212
SAFETY AT WORKSITE ........................................................................................................................... 2-21
WORKING ON LOOSE GROUND.................. .... ...................................... .... ... ... ... ... .... ... ... .......................2-212
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES................................................................................2-222
ENSURE GOOD VISIBILITY ..................................................................................................................... 2-222
PRECAUTIONS RELATED TO VENTILATION EXHAUST GAS .............................................................. 2-232
CHECKING SIGNALMAN'S SIGNALS AND SIGNS ................................................................................. 2-232
EMERGENCY EXIT FROM OPERATOR'S CAB....................................................................................... 2-232
BE CAREFUL ABOUT ASBESTOS DUST................................................................................................2-232
2
PRECAUTIONS FOR OPERATION .................................................................................................................2-242
STARTING ENGINE..................................................................................................................................2-242
CHECKS BEFORE STARTING ENGINE ...........................................................................................2-242
PRECAUTIONS WHEN STARTING...................................................................................................2-252
PRECAUTIONS IN COLD AREAS .....................................................................................................2-252
OPERATION.............................................................................................................................................. 2-262
CHECKS BEFORE OPERATION.......................................................................................................2-262
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE................................................2-262
PRECAUTIONS WHEN TRAVELING................................................................................................. 2-272
TRAVELING ON SLOPES........................................................................................................ ..........2-282
PROHIBITED OPERATIONS .............................................................................................................2-292
PRECAUTIONS WHEN OPERATING................................................................................................ 2-292
METHODS OF USING BRAKE ..........................................................................................................2-302
OPERATE CAREFULLY ON SNOW........................................................... ... ....................................2-302
PARKING MACHINE ............................ ... .... ... ... ... ... ....................................... ... .... ... ... ... .... ................2-312
TRANSPORTATION..................................................................................................................................2-322
LOADING AND UNLOADING............ ....................................... ... ... ... .... ... ... ... .................................... 2-322
SHIPPING...........................................................................................................................................2-322
BATTERY...................................................................................................................................................2-332
BATTERY HAZARD PREVENTION ...................................................................................................2-332
2-2
SAFETY SAFETY
STARTING WITH BOOSTER CABLES..............................................................................................2-342
TOWING ....................................................................................................................................................2-352
PRECAUTIONS FOR MAINTENANCE ............................................................................................................ 2-362
WARNING TAG ......................................................................................................................................... 2-362
KEEP WORK PLACE CLEAN AND TIDY.................................................................................................. 2-362
APPOINT LEADER WHEN WORKING WITH OTHERS...........................................................................2-362
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE................................................................... 2-372
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING .................................................. 2-382
INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF.....................................2-392
PROPER TOOLS.......................................................................................................................................2-392
ACCUMULATOR....................................................................................................................................... 2-392
PERSONNEL.............................................................................................................................................2-402
ATTACHMENTS........................................................................................................................................ 2-402
WORK UNDER THE MACHINE ................................................................................................................ 2-402
NOISE........................................................................................................................................................ 2-402
PRECAUTIONS WHEN USING HAMMER................................................................................................ 2-412
REPAIR WELDING.................................................................................................................................... 2-412
REMOVING BATTERY TERMINAL........................................................................................................... 2-412
PRECAUTIONS WITH HIGH-PRESSURE OIL ......................................................................................... 2-412
PRECAUTIONS FOR HIGH-PRESSURE FUEL ....................................................................................... 2-422
HANDLING HIGH-PRESSURE HOSES.................................................................................................... 2-422
WASTE MATERIALS................................................................................................................................. 2-422
MAINTENANCE OF AIR CONDITIONER.................................................................................................. 2-422
COMPRESSED AIR .................................................................................................................................. 2-422
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS .................................................................. 2-43
2
PRECAUTIONS WITH TIRES .......................................................................................................................... 2-442
HANDLING TIRES................... ... .... ... ... ... .... ... ... ....................................... ... ... ... .... ... ................................. 2-442
PRECAUTIONS WHEN STORING TIRES ................................................................................................2-442
2-3
SAFETY LABELS SAFETY
SAFETY LABELS 2
The following safety labels are used on this machine. Be sure that you fully understand the correct position and
content of these safety labels.
To ensure that the content of these safety labels can be read properly, be sure that they are in the correct place
and always keep them clean. When cleaning them, use soa p a nd water. Do not use organic solvents or gasoline.
These may cause the safety labels to peel off.
If the safety labels are damaged or lost, or cannot be read, replace them with new parts. For details of the part
numbers, see this manual or check on the actual part, and order the new part from your Komatsu distributor.
There are also other labels in addition to the safety labels. Handle these labels in the same way.
2-4
SAFETY SAFETY LABELS
LOCATION OF SAFETY LABELS 2
2-5
SAFETY LABELS SAFETY
SAFETY LABELS 2
(1) Caution before starting (09651-A0481)
q Warning!
q Read manual before operation, maintenance, disassembly,
assembly and transportation.
(2) Caution for lock lever (09654-C0481)
q Sign indicates a hazard of unexpected moving of stopped
machine.
q Lower working device to the ground, move safety lever to
lock position and take engine key with you before leaving
machine.
(3) Caution when traveling in reverse
WARNING
To prevent SEVERE INJURY or DEATH, do the following
before moving machine or its attachments:
q Honk horn to alert people nearby.
q Be sure no one is on or near the machine.
q Use spotter if view is obstructed.
Follow above even if the machine is equipped with backup alarm and mirrors.
2-6
SAFETY SAFETY LABELS
(4) Caution for going close to electric cables (09801-C0481
q Sign indicates an electrocution hazard if machine is
brought too near electric power lines.
q Keep a safe distance from electric power lines.
(5) Do not enter (09162-C0641)
q Sign indicates a crush hazard between the articulating
parts of the vehicle.
q Keep away from the vehicle when it is moving.
(6) Caution for frame lock bar (09161-C0641)
q Sign indicates a crush hazard between the articulating
parts of vehicle.
q Lock vehicle with lock bar to avoid movement during main-
tenance and transportation.
2-7
SAFETY LABELS SAFETY
(7) Precautions when releasing parking brake (09809-03000)
WARNING
If the switch is set to RELEASE, a serious accident could
result, as this operation releases the p arking brake and the
machine may move off suddenly.
Never set the switch to RELEASE except when towing a
disabled machine.
Before towing such machine, read its manual carefully and
be sure to follow the instructions given therein.
(8) Caution when coolant is at high temperature
(09653-A0641)
q Sign indicates a burn hazard from spurting hot water or oil
if radiator or hydraulic tank is uncapped while hot.
q Allow radiator of hydraulic tank to cool before removing
cap.
(9) Caution when oil is at high temperature (09653-A0641)
q Sign indicates a burn hazard from spurting hot water or oil
if radiator or hydraulic tank is uncapped while hot.
q Allow radiator of hydraulic tank to cool before removing
cap.
2-8
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