Komatsu WH609-WH716-1 Telescopic Handlers Operation & Maintenance Manual - WEAM005900

This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the WH609-1, WH613-1, WH713-1, WH714-1, WH714H-1, WH716-1 Komatsu Telescopic Handler. It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.


APPLICABLE MODELS :

Komatsu WH609-1 Telescopic Handler
Serial Numbers : 395F60001 and up

Komatsu WH613-1 Telescopic Handler
Serial Numbers : 395F60003 and up

Komatsu WH713-1 Telescopic Handler
Serial Numbers : 395F70001 and up

Komatsu WH714-1 Telescopic Handler
Serial Numbers : 395F70002 and up

Komatsu WH714H-1 Telescopic Handler
Serial Numbers : 395F70003 and up

Komatsu WH716-1 Telescopic Handler
Serial Numbers : 395F70004 and up


TABLE OF CONTENTS :

1.1 FOREWORD
1.2 INFORMATION ON SAFETY
1.3 INTRODUCTION
1.4 PRODUCT IDENTIFICATION
2.1 SAFETY, NOISE AND VIBRATION PLATES
2.2 GENERAL PRECAUTIONS
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING WORK
2.4 PRECAUTIONS TO BE TAKEN DURING WORK
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES
2.6 BATTERY
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE
3.1 GENERAL VIEWS
3.2 INSTRUMENTS AND CONTROLS
3.3 LIFTING LOADS
3.4 FUSES AND RELAYS
3.5 GUARDS, CAB AND DRIVER’S SEAT
3.6 USE OF THE MACHINE
3.7 PARKING THE MACHINE
3.8 STOPPING THE ENGINE
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES
3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON AND IN COLD PLACES
3.11 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON
3.12 EQUIPMENT
3.13 LONG PERIODS OF INACTIVITY
3.14 OPERATIONS IN CASE OF FAILURE
4.1 GUIDE TO MAINTENANCE
4.2 MAINTENANCE NOTES
4.3 FUEL, COOLANT AND LUBRICANTS
4.4 DRIVING TORQUES FOR SCREWS AND NUTS
4.5 LUBRICATION
4.6 PERIODICAL CHANGE OF THE SAFETY-RELATED COMPONENTS
4.7 MAINTENANCE PLAN
5.1 TECHNICAL DATA


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : WEAM005900
Total Pages : 254


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.

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1.1 FOREWORD
1.2 INFORMATION ON SAFETY
1.3 INTRODUCTION
1.3.1 INTENDED USES
1.3.2 IMPROPER OR UNAUTHORIZED USE
1.3.3 MAIN CHARACTERISTICS
1.3.4 RUNNING-IN
1.4 PRODUCT IDENTIFICATION
1.4.1 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)
1.4.2 MACHINE IDENTIFICATION PLATE
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE
1.4.4 FRONT AXLE SERIAL NUMBER
1.4.5 REAR AXLE SERIAL NUMBER
1.4.6 TRANSMISSION SERIAL NUMBER
1.4.7 CAB SERIAL NUMBER
1.4.8 SERIAL NUMBERS AND DEALER’S ADDRESS

TABLE OF CONTENTS

2.1 SAFETY, NOISE AND VIBRATION PLATES
2.1.1 POSITION OF THE SAFETY PLATES
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS
2.1.3 POSITION OF THE NOISE PLATES
2.2 GENERAL PRECAUTIONS
2.2.1 GENERAL SAFETY RULES
2.2.2 SAFETY DEVICES AND GUARDS
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS
2.2.4 UNAUTHORIZED MODIFICATIONS
2.2.5 LEAVING THE OPERATOR’S SEAT
2.2.6 GETTING ON AND OFF THE MACHINE
2.2.7 CHECKING THE REAR-VIEW MIRRORS
2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL
2.2.9 PREVENTING BURNS
2.2.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER
2.2.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT
2.2.12 FIRE EXTINGUISHERS AND FIRST AID KIT
2.2.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE
2.2.14 PRECAUTIONS CONCERNING THE EQUIPMENT
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING WORK
2.3.1 SAFETY ON THE WORKSITE
2.3.2 FIRE PREVENTION
2.3.3 PRECAUTIONS CONCERNING THE DRIVING POSITION
2.3.4 ROOM VENTILATION
2.3.5 PRECAUTIONS CONCERNING THE LIGHTS
2.3.6 CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS- CHECKING THE WINDSHIELD WIPER BLADES
2.4 PRECAUTIONS TO BE TAKEN DURING WORK
2.4.1 WHEN STARTING THE ENGINE
2.4.2 RULES FOR TRAVELLING ON ROADS
2.4.3 CHECKS FOR TRAVELLING IN REVERSE.
2.4.4 MOVING THE MACHINE
2.4.5 MOVING ON SLOPES
2.4.6 WORKING ON SLOPES
2.4.7 UNAUTHORIZED OPERATIONS
2.4.8 WORKING IN WINDY WEATHER CONDITIONS
2.4.9 MAIN OPERATING MODES
2.4.9.1 LOADING THE MATERIAL
2.4.9.2 UNLOADING THE MATERIAL
2.4.10 PREVENTING ELECTROCUTION
2.4.11 VISIBILITY
2.4.12 WORKING ON ICY OR SNOW-COVERED SURFACES
2.4.13 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT
2.4.14 WORKING ON LOOSE GROUND
2.4.15 PARKING THE MACHINE
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES
2.5.1 LOADING AND UNLOADING THE MACHINE
2.5.2 THE ROUTE
2.6 BATTERY
2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES
2.6.2 STARTING WITH BOOSTER CABLES
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE
2.8.1 WARNING PLATES
2.8.2 TOOLS
2.8.3 PERSONNEL
2.8.4 EQUIPMENT
2.8.5 WORKING UNDER THE MACHINE
2.8.6 KEEPING THE MACHINE CLEAN
2.8.7 USE OF THE ENGINE DURING MAINTENANCE
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY
2.8.9 RULES TO BE FOLLOWED WHEN REFUELLING OR ADDING OIL
2.8.10 CHECKING THE COOLANT LEVEL IN THE RADIATOR
2.8.11 USING LAMPS
2.8.12 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR
2.8.13 PRECAUTIONS CONCERNING THE STARTER
2.8.14 PRECAUTIONS CONCERNING THE GEAR LEVER
2.8.15 PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES AND FUEL PIPES
2.8.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH- PRESSURE SYSTEMS
2.8.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES
2.8.18 COOLING FAN AND FAN BELT
2.8.19 WASTE MATERIALS
2.8.20 PRECAUTIONS CONCERNING TECHNOPOLYMERS AND ELASTOMERS
2.8.21 PRECAUTIONS TO BE TAKEN WHEN INFLATING TYRES
2.8.22 PRECAUTIONS TO BE TAKEN WHEN USING SYNTHETIC BIODEGRADABLE OIL TYPE «HEES»

3.1 GENERAL VIEWS
3.1.1 RIGHT SIDE VIEW
3.1.2 LEFT SIDE VIEW
3.1.3 CAB INSIDE GENERAL VIEW
3.2 INSTRUMENTS AND CONTROLS
3.2.1 INSTRUMENTS
3.2.2 WARNING LIGHTS
3.2.3 SWITCHES AND PUSH BUTTONS
3.2.4 ELECTRIC ACCESSORIES
3.2.5 MACHINE CONTROLS
3.3 LIFTING LOADS
3.3.1 READING THE LOAD CHARTS
3.3.1.1 DESCRIPTION OF THE LOAD CHARTS
3.3.1.2 USING THE CHARTS
3.4 FUSES AND RELAYS
3.4.1 CENTRAL UNIT FUSES AND RELAYS
3.4.1.1 CENTRAL UNIT FUSES
3.4.1.2 CENTRAL UNIT RELAYS
3.4.2 ENGINE LINE FUSES AND RELAYS
3.4.2.1 ENGINE LINE FUSES
3.4.2.2 ENGINE LINE RELAYS
3.5 GUARDS, CAB AND DRIVER’S SEAT
3.5.1 ENGINE HOOD
3.5.2 CAB
3.5.3 EMERGENCY EXIT
3.5.4 VENTILATION AND HEATING
3.5.5 AIR CONDITIONER (optional)
3.5.6 SEAT
3.5.6.1 STANDARD SEAT
3.5.6.2 OPTIONAL SEAT
3.5.7 STEERING WHEEL
3.5.8 SAFETY BELT
3.5.9 WINDOW SHADE
3.5.10 TECHNICAL DOCUMENTATION
3.5.11 FIRE EXTINGUISHER
3.6 USE OF THE MACHINE
3.6.1 CHECKS TO BE CARRIED OUT BEFORE STARTING THE ENGINE
3.6.1.1 VISUAL CHECKS
3.6.1.2 DAILY CHECKS
3.6.1.3 OPERATIONAL CHECKS
3.6.2 STARTING THE ENGINE
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES
3.6.3 WARMING THE ENGINE
3.6.4 HEATING THE HYDRAULIC OIL
3.6.5 HOW TO MOVE THE MACHINE
3.6.5.1 MOVING ON SLOPES
3.6.5.2 MAXIMUM IMMERSION DEPTH
3.7 PARKING THE MACHINE
3.7.1 PARKING ON LEVEL GROUND
3.7.2 PARKING ON SLOPES
3.8 STOPPING THE ENGINE
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES
3.9.1 LOADING AND UNLOADING THE MACHINE
3.9.2 TRANSPORT
3.9.3 LIFTING THE MACHINE
3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON AND IN COLD PLACES
3.10.1 FUEL AND LUBRICANTS
3.10.2 ENGINE COOLANT
3.10.3 BATTERY
3.10.4 OTHER PRECAUTIONS
3.10.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK
3.11 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON
3.12 EQUIPMENT
3.12.1 INSTALLING EQUIPMENT WITH HYDRAULIC QUICK COUPLING
3.12.2 INSTALLING EQUIPMENT WITH MANUAL COUPLING
3.12.3 INSTALLING EQUIPMENT REQUIRING HYDRAULIC POWER (4X1 BUCKET - FORKS - ROUND BALE GRIPPERS, ETC.)
3.12.4 ORGANIZING THE WORK AREA
3.12.5 OPERATING THE EQUIPMENT
3.12.6 OPERATING THE MACHINE FITTED WITH FORKS
3.12.6.1 FORKING A LOAD
3.12.6.2 TRANSPORTING THE LOAD
3.12.6.3 STACKING THE LOAD
3.12.7 PREPARING THE MACHINE FOR TRAVELLING ON ROADS
3.12.8 USING THE MACHINE AS A LOADER
3.12.8.1 ORGANIZING THE WORK AREA
3.12.8.2 LOADING HEAPED AND LEVEL MATERIAL
3.13 LONG PERIODS OF INACTIVITY
3.13.1 PREPARING THE MACHINE FOR A LONG PERIOD OF INACTIVITY
3.13.2 PREPARING THE ENGINE FOR A LONG PERIOD OF INACTIVITY
3.13.3 MAINTENANCE DURING A PERIOD OF INACTIVITY
3.13.4 RESTARTING THE ENGINE
3.13.5 AFTER A LONG PERIOD OF INACTIVITY
3.14 OPERATIONS IN CASE OF FAILURE
3.14.1 IF THE ENGINE BREAKS DOWN WITH BOOM LOADED, LIFTED AND EXTENDED
3.14.2 REMOVING THE MACHINE IN CASE OF FAILURE
3.14.3 IF THE FUEL HAS RUN OUT
3.14.4 IF THE ENGINE FAILS TO START BECAUSE THE BATTERY HAS RUN DOWN
3.14.4.1 STARTING WITH BOOSTER CABLES
3.14.5 OTHER TROUBLES
3.14.5.1 ELECTRIC CIRCUIT
3.14.5.2 HYDRAULIC SYSTEM
3.14.5.3 BRAKING SYSTEM
3.14.5.4 CONVERTER
3.14.5.5 ENGINE

4.1 GUIDE TO MAINTENANCE
4.2 MAINTENANCE NOTES
4.2.1 NOTES REGARDING THE ENGINE
4.2.1.1 ENGINE OIL
4.2.1.2 COOLANT
4.2.1.3 FUEL
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM
4.2.3 NOTES REGARDING THE ELECTRIC SYSTEM
4.2.4 NOTES REGARDING LUBRICATION
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING
4.3 FUEL, COOLANT AND LUBRICANTS
LUBRICATION WITH GREASE
4.3.1 HOMOLOGATED SYNTHETIC BIODEGRADABLE LUBRICANTS “HEES”
4.4 DRIVING TORQUES FOR SCREWS AND NUTS
4.4.1 STANDARD DRIVING TORQUES
4.4.2 SPECIFIC DRIVING TORQUES
4.5 LUBRICATION
4.5.1 LUBRICATION DIAGRAM (2-SECTION BOOM)
4.5.2 LUBRICATION DIAGRAM (3-SECTION BOOM)
4.6 PERIODICAL CHANGE OF THE SAFETY-RELATED COMPONENTS
4.6.1 CRITICAL PARTS FOR SAFETY
4.6.1.1 FUEL SUPPLY SYSTEM
4.6.1.2 DELIVERY HYDRAULIC SYSTEM
4.6.1.3 CONTROL VALVE HYDRAULIC SYSTEM
4.6.1.4 BOOM HYDRAULIC SYSTEM
4.7 MAINTENANCE PLAN
4.7.1 WHEN REQUIRED
4.7.1.a CHECKING THE BATTERY ELECTROLYTE LEVEL - INSPECTING TERMINALS AND CABLES
4.7.1.b CHECKING, CLEANING OR CHANGING THE ENGINE AIR CLEANERS
4.7.1.c CHECKING AND CLEANING THE CAB AIR FILTER
4.7.1.d FUSES AND RELAYS - CHECK AND CHANGE
4.7.1.e CHECKING THE WINDSHIELD WASHER FLUID LEVEL
4.7.1.f CHECKING THE WINDSHIELD WIPER BLADES
4.7.1.g LUBRICATING THE CAB DOOR AND ENGINE HOOD HINGES
4.7.1.h LUBRICATING THE FORK SUPPORT ROD
4.7.1.i CHECKING THE FUEL LEVEL
4.7.1.j TOPPING UP THE BRAKING SYSTEM OIL RESERVOIR
4.7.2 MAINTENANCE EVERY 10 HOURS OF OPERATION OR EVERY DAY
4.7.2.a VARIOUS CHECKS
4.7.2.b CHECKING THE ACOUSTIC ALARMS, WARNING LIGHTS AND INSTRUMENTS
4.7.2.c CHECKING THE ENGINE COOLANT LEVEL
4.7.2.d CHECKING THE RADIATOR FLUID LEVEL
4.7.2.e CHECKING THE ENGINE OIL LEVEL
4.7.2.f CHECKING THE TYRE PRESSURE
4.7.2.g CHECKING THE SERVICE BRAKES
4.7.2.h CHECKING AND ADJUSTING THE PARKING BRAKE
4.7.3 MAINTENANCE EVERY 50 HOURS OF OPERATION OR EVERY 2 WEEKS
4.7.3.a LUBRICATING THE ARTICULATED JOINTS AND THE PADS
4.7.3.b LUBRICATING THE CHAIN GEAR SHAFTS (Only for 3-section boom version)
4.7.3.c DRAINING THE WATER SEPARATOR
4.7.3.d LUBRICATING BOOM
4.7.4 MAINTENANCE EVERY 100 HOURS OF OPERATION
4.7.4.a LUBRICATING THE DRIVE SHAFTS
4.7.4.b LUBRICATING THE FRONT AND REAR AXLE SWING JOINT
4.7.4.c LUBRICATING THE WHEEL HUB JOINTS
4.7.5 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION
4.7.6 MAINTENANCE EVERY 250 HOURS OF OPERATION OR EVERY 3 MONTHS
4.7.6.a LUBRICATING THE ARTICULATED JOINTS
4.7.6.b LUBRICATING THE BOOM INNER HOSES, ROLLERS AND GUARD
4.7.6.c CHECKING THE AXLE OIL LEVEL (FRONT AND REAR AXLE)
4.7.6.d CHECKING THE TRANSMISSION OIL LEVEL
4.7.6.e CLEANING THE OUTSIDE OF THE RADIATOR AND OF THE HEAT EXCHANGER
4.7.6.f CHECKING THE ALTERNATOR-FAN BELT
4.7.6.g CHECKING AND ADJUSTING THE A/C COMPRESSOR BELT TENSION (Optional)
4.7.6.h CHECKING THE ADJUSTMENT OF THE PARKING BRAKE
4.7.6.i CHECKING THE ELECTROLYTE LEVEL
4.7.7 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which synthetic biodegradable oil HEES is used)
4.7.8 MAINTENANCE EVERY 500 HOURS OF OPERATION OR EVERY 6 MONTHS
4.7.8.a CHANGING THE FUEL FILTER
4.7.8.b DRAINING THE FUEL TANK
4.7.8.c CHECKING THE HYDRAULIC OIL LEVEL
4.7.8.d CHANGING THE HYDRAULIC OIL DRAIN FILTER
4.7.8.e DRAINING CONDENSATE FROM THE OIL TANK (Only for machines in which synthetic biodegradable oil HEES is used)
4.7.8.f CHANGING THE ENGINE OIL
4.7.8.g CHANGING THE ENGINE OIL FILTER
4.7.8.h CHECKING THE CHAINS FOR OXIDATION (Only for the 3-section boom version)
4.7.8.i CHECKING AND TIGHTENING THE BOOM CHAINS (Only for the 3-section boom version)
4.7.8.j CHECKING THE LENGTH OF THE CHAINS (Only for the 3-section boom version)
4.7.8.k LUBRICATING THE EXTENSION CHAINS (Only for the 3-section boom version)
4.7.8.l CHECKING THE CLEARANCE OF THE CHAIN DRIVING GEAR BUSHINGS (Only for the 3-section boom version)
4.7.8.m CHECKING THE SLIDING BLOCK CLEARANCE
4.7.8.n CHECKING THE WHEEL NUT DRIVING TORQUE
4.7.9 MAINTENANCE EVERY 1000 HOURS OF OPERATION OR EVERY YEAR
4.7.9.a CHANGING THE FRONT AND REAR AXLE OIL
4.7.9.b CHANGING THE HYDRAULIC TRANSMISSION OIL
4.7.9.c CHANGING THE HYDRAULIC TRANSMISSION FILTER
4.7.9.d CHECKING THE ENGINE COOLANT LEVEL AND TOPPING UP
4.7.10 MAINTENANCE EVERY 2000 HOURS OF OPERATION OR EVERY 2 YEARS
4.7.10.a CHECKING THE ALTERNATOR AND THE STARTER
4.7.10.b CHANGING THE ALTERNATOR BELT
4.7.10.c CHANGING THE COOLANT
4.7.10.d CHANGING THE BRAKING SYSTEM OIL
4.7.10.e CHANGING THE HYDRAULIC OIL AND CLEANING THE INTAKE FILTER
4.7.11 MAINTENANCE EVERY 3 YEARS
4.7.11.a CHANGING THE SAFETY BELT
4.7.12 MAINTENANCE EVERY 3000 HOURS OF OPERATION OR EVERY 3 YEARS
4.7.12.a CHANGING THE ENGINE THERMOSTATIC VALVE
4.7.12.b CHECKING THE ENGINE ANTIVIBRATION AND RETAINING SCREWS
4.7.12.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE AND THE INJECTION TIMING ADVANCE

5.1 TECHNICAL DATA
5.1.1 DIMENSIONS WITH FORKS
5.1.2 TECHNICAL CHARACTERISTICS
5.1.2.1 TECHNICAL CHARACTERISTICS WH609 (Aspirated engine)
5.1.2.2 TECHNICAL CHARACTERISTICS WH609 (Turbo engine)
5.1.2.3 TECHNICAL CHARACTERISTICS WH613 (Aspirated engine)
5.1.2.4 TECHNICAL CHARACTERISTICS WH613 (Turbo engine)
5.1.2.5 TECHNICAL CHARACTERISTICS WH713
5.1.2.6 TECHNICAL CHARACTERISTICS WH714
5.1.2.7 TECHNICAL CHARACTERISTICS WH714H
5.1.2.8 TECHNICAL CHARACTERISTICS WH716
5.1.3 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED
5.1.4 LOAD DISTRIBUTION ON THE AXLES
5.1.5 OPERATING PERFORMANCE
5.1.5.1 OPERATING PERFORMANCE WITH FORKS (ON WHEELS)
5.1.5.2 OPERATING PERFORMANCE WITH FORKS (ON STABILIZERS)

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