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KOMATSU GALEO WA320PT-5L PARALLEL TOOL CARRIER OPERATION & MAINTENANCE MANUAL (SN:A39001 & UP) – PDF DOWNLOAD
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- KOMATSU GALEO WA320PT-5L PARALLEL TOOL CARRIER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:A39001 & UP
- PUBLICATION NUMBER:CEAM013800
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Description
KOMATSU GALEO WA320PT-5L PARALLEL TOOL CARRIER OPERATION & MAINTENANCE MANUAL (SN:A39001 & UP)
KOMATSU GALEO WA320PT-5L PARALLEL TOOL CARRIER OPERATION & MAINTENANCE MANUAL (SN:A39001 & UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU GALEO WA320PT-5L PARALLEL TOOL CARRIER OPERATION & MAINTENANCE MANUAL (SN:A39001 & UP)
- This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel achieve peak performance through effective, economical and safe machine operation and maintenance. Keep this manual handy and have all personnel read it periodically.
- If this manual is lost, damaged or becomes dirty and can not be read, request a replacement manual from your local distributor. If you sell the machine, be sure to give this manual to the new owner. Continuing improvements in the design of this machine can lead to changes, which may not be reflected in this manual.
- Consult your local KOMATSU distributor or for the latest available information on your machine or for questions regarding information in this manual. This manual may contain attachments and optional equipment that are not available in your area. Consult your local KOMATSU Distributor or for those items that you may require
TABLE OF CONTENTS:
KOMATSU GALEO WA320PT-5L PARALLEL TOOL CARRIER OPERATION & MAINTENANCE MANUAL (SN:A39001 & UP)
MAIN MENU..................................................................... 0 COVER......................................................................... 1 INTRODUCTION.................................................................. 7 FOREWORD.................................................................. 8 SAFETY INFORMATION........................................................ 10 APPROVED AND NON-APPROVED USES............................................ 11 NON-APPROVED.......................................................... 11 PRODUCT IDENTIFICATION.................................................... 12 MACHINE SERIAL NUMBER................................................. 12 ENGINE SERIAL NUMBER AND EMISSION LABEL............................... 13 SERVICE METER LOCATION................................................ 13 SERIAL NUMBERS AND DEALER INFORMATION..................................... 14 CONTENTS...................................................................... 15 SAFETY........................................................................ 25 GENERAL SAFETY RULES AND PRECAUTIONS...................................... 26 GENERAL SAFETY RULES.................................................. 26 SAFETY FEATURES....................................................... 27 PERSONAL PROTECTIVE EQUIPMENT......................................... 27 UNAUTHORIZED MODIFICATIONS............................................ 28 LEAVING OPERATOR’S COMPARTMENT........................................ 28 MOUNTING AND DISMOUNTING.............................................. 29 FIRE PREVENTION FOR FUEL AND OIL...................................... 30 DUST HAZARD PRECAUTIONS............................................... 30 CRUSH OR PINCH POINT DANGERS.......................................... 30 FIRE EXTINGUISHER AND FIRST AID KIT................................... 31 INSIDE OPERATOR’S COMPARTMENT......................................... 31 PRECAUTIONS WHEN USING ROPS........................................... 31 PRECAUTIONS FOR ATTACHMENTS........................................... 31 STARTING YOUR WORK OPERATIONS............................................. 32 WORK SITE HAZARDS..................................................... 32 AVOIDING DANGEROUS SITUATIONS......................................... 32 WORKING CLEARANCES.................................................... 34 RULES FOR ROAD TRAVEL..................................................... 35 TRAVELING IN REVERSE.................................................. 35 TRAVELING ON ICY OR SNOW-COVERED SURFACES............................. 35 WORKING ON LOOSE OR UNSTABLE GROUND................................... 35 TRAVEL ON SLOPES...................................................... 36 PARKING THE MACHINE................................................... 37 PRECAUTIONS DURING MAINTEMANCE OPERATIONS................................. 38 WARNING TAGS.......................................................... 38 EQUIPMENT STORAGE..................................................... 38 WORKING UNDER THE MACHINE............................................. 39 USING DROP LAMPS...................................................... 39 KEEPING THE MACHINE CLEAN............................................. 40 RUNNING THE MACHINE DURING MAINTENANCE................................ 40 RULES FOR REFUELING THE MACHINE....................................... 41 COOLING SYSTEM PRECAUTIONS............................................ 41 BATTERY PRECAUTIONS................................................... 42 STARTING THE MACHINE.................................................. 42 HIGH PRESSURE HOSES................................................... 43 HIGH TEMPERATURES AREAS............................................... 43 DISPOSAL OF WASTE MATERIALS........................................... 43 INFLATING TIRES....................................................... 44 ACCUMULATOR........................................................... 44 CRITICAL PARTS........................................................ 44 VIBRATIONS TO WHICH THE OPERATOR IS EXPOSED........................... 44 SAFETY AND WARNING DECALS................................................. 45 LOCATION OF THE SAFETY DECALS......................................... 45 OPERATION..................................................................... 53 GENERAL VIEW OF MACHINE................................................... 54 OUTSIDE VIEW OF THE MACHINE........................................... 54 INSIDE VIEW OF THE CAB................................................ 55 DESCRIPTION OF ALERTS, GAUGES AND MONITOR SYSTEM.......................... 56 INSTRUMENT BEZEL...................................................... 56 CENTRAL WARNING LAMP.................................................. 57 CENTRAL WARNING LAMP.............................................. 57 EMERGENCY STOP WARNING SYSTEM......................................... 58 BRAKE PRESSURE WARNING LAMP....................................... 58 ENGINE OIL PRESSURE WARNING LAMP.................................. 58 BATTERY CHARGE WARNING LAMP....................................... 59 STEERING OIL PRESSURE WARNING LAMP................................ 59 CAUTION LAMPS......................................................... 60 AXLE OIL TEMPERATURE CAUTION LAMP................................. 60 PARKING BRAKE REMINDER LAMP....................................... 61 HST OIL TEMPERATURE CAUTION LAMP.................................. 61 COOLANT TEMPERATURE CAUTION LAMP.................................. 61 FUEL LEVEL CAUTION LAMP........................................... 61 INSPECTION AND MAINTENANCE ALLERTS.................................... 62 RADIATOR COOLANT LEVEL ALERT LAMP................................. 62 ENGINE OIL LEVEL ALERT LAMP....................................... 63 MAINTENANCE ALERT LAMP............................................ 63 HST OIL FILTER CLOG ALERT LAMP.................................... 63 AIR CLEANER CLOGGING ALERT LAMP................................... 63 MODE ALERT LAMPS...................................................... 64 PARKING BRAKE INDICATOR LAMP...................................... 64 ENGINE PREHEAT LAMP............................................... 64 STEERING OIL PRESSURE LAMP (GREEN)................................ 65 DIRECTION INDICATOR LAMP.......................................... 65 DIRECTION INDICATOR LAMP.......................................... 65 TURN SIGNAL INDICATOR LAMP........................................ 65 HEAD LAMP BEAM INDICATOR.......................................... 65 GAUGE DISPLAY......................................................... 66 HST OIL TEMPERATURE GAUGE......................................... 66 ENGINE COOLANT TEMPERATURE GAUGE.................................. 67 FUEL LEVEL GAUGE.................................................. 67 SPEEDOMETER....................................................... 67 METER MODE DISPLAY................................................ 67 MACHINE ELECTRONIC MONITORING DISPLAY..................................... 68 MONITOR MODE SELECTOR SWITCHES........................................ 68 MODE SELECTOR SWITCH 1............................................ 68 MODE SELECTOR SWITCH 2............................................ 69 MONITOR DISPLAY INFORMATION........................................... 69 HOUR METER AND ODOMETER DISPLAY................................... 69 ADJUSTING MONITOR BRIGHTNESS...................................... 69 PROGRAMING TELEPHONE NUMBER....................................... 69 ACTION CODE DISPLAY............................................... 70 FAILURE CODE DISPLAY.............................................. 71 SERVICE DISPLAY................................................... 71 SELECTING LANGUAGE................................................ 73 SETTING HST FUNCTION.............................................. 73 MACHINE SWITCHES AND CONTROLS............................................. 74 SWITCHES.............................................................. 75 IGNITION SWITCH................................................... 75 SPEED RANGE SELECTOR SWITCH....................................... 75 VARIABLE SHIFT CONTROL SWITCH..................................... 75 TRACTION CONTROL SWITCH........................................... 76 ECSS SWITCH....................................................... 76 HEAD LAMPS-TURN SIGNALS-DIMMER SWITCH............................. 77 HORN BUTTON....................................................... 77 HAZARD LAMP SWITCH................................................ 78 FRONT WORK LAMPS SWITCH........................................... 78 REAR WORK LAMPS SWITCH............................................ 78 MODE SELECTOR SWITCH 1............................................ 78 MODE SELECTOR SWITCH 2............................................ 79 ATTACHMENT SELECT SWITCH.......................................... 79 DUMP SPEED SWITCH................................................. 79 QUICK COUPLER SWITCH.............................................. 79 FRONT WIPER SWITCH................................................ 79 REAR WIPER SWITCH................................................. 80 CIGARETTE LIGHTER................................................. 80 CAB LAMP SWITCH................................................... 80 REAR WINDOW HEATER SWITCH......................................... 80 CONTROLS.............................................................. 81 DIRECTIONAL CONTROL LEVER......................................... 81 WORK EQUIPMENT LOCK LEVER......................................... 81 LIFT ARM CONTROL LEVER............................................ 81 BUCKET CONTROL LEVER.............................................. 82 AUXILIARY CONTROL LEVER........................................... 82 BRAKE PEDALS...................................................... 83 ACCELERATOR PEDAL................................................. 83 PARKING BRAKE LEVER............................................... 83 STEERING TILT LOCK LEVER.......................................... 84 SECURITY, LOCKS AND SAFETY FEATURES....................................... 85 IGNITION KEY LOCKED AREAS............................................. 85 CAB DOOR LOCKS.................................................... 85 ENGINE ACCESS DOORS............................................... 85 REAR GRIL AND FUEL CAP............................................ 86 PADLOCKED AREAS....................................................... 87 BATTERY AND TOOL BOX.............................................. 87 TRANSFER CASE..................................................... 87 UPPER HOOD ACCESS PANEL........................................... 87 CAB DOORS AND WINDOWS................................................. 88 CAB DOOR LOCK BUTTON.............................................. 88 CAB DOOR OPEN LOCK................................................ 88 CAB WINDOW LOCK CANCEL KNOB....................................... 88 SAFETY LOCK BAR....................................................... 89 FUSES AND ELECTRICAL OUTLETS.............................................. 90 FUSE PANEL............................................................ 90 FUSE BOX (A)...................................................... 90 FUSE BOX (B)...................................................... 91 SLOW BLOW FUSE.................................................... 91 ADDITIONAL FEATURES....................................................... 92 POWER OUTLET.......................................................... 92 COOL BOX.............................................................. 92 STORAGE BOX........................................................... 92 AIR CONDITIONING SYSTEM................................................... 93 BLOWER MOTOR SWITCH................................................... 93 AIR CONDITIONER SWITCH................................................ 93 MODE SELECTOR SWITCH.................................................. 94 (FRESH/RECIRC) SELECTOR SWITCH........................................ 94 TEMPERATURE CONTROL SWITCH............................................ 94 CLIMATE CONTROL OPERATION............................................. 95 WHEN NOT USING THE AIR CONDITIONER................................ 95 AM/FM RADIO-CASSETTE STEREO............................................... 96 RADIO OPERATION....................................................... 97 POWER SWITCH/VOLUME............................................... 97 AUTO-STORE/PRESET SCAN BUTTON..................................... 97 BASS CONTROL KNOB................................................. 97 TREBLE CONTROL KNOB............................................... 97 LOUDNESS BUTTON................................................... 98 TIME/RADIO DISPLAY SELECTOR BUTTON................................ 98 TAPE EJECT BUTTON................................................. 98 CASSETTE DOOR..................................................... 98 FAST FORWARD, REWIND BUTTONS...................................... 99 PRESET BUTTONS.................................................... 99 METAL TAPE BUTTON................................................. 99 SEEK TUNING BUTTONS............................................... 99 BAND SELECTOR BUTTON..............................................100 USING RADIO FEATURE...................................................100 USING AUTO PRESET.................................................100 USING MANUAL PRESET...............................................100 LISTENING TO RADIO................................................101 LISTENING TO CASSETTE TAPE........................................101 REVERSING TAPE....................................................101 START-UP PREPERATIONS AND CHECKS..........................................102 PRE-OPERATIONAL CHECKS................................................102 PERFORM A WALK AROUND CHECK OF YOUR MACHINE.......................102 TIRE PRESSURES AND CHECKS.........................................103 CHECKS UNDER THE HOOD.............................................104 IN THE OPERATOR’S CAB.............................................106 START-UP AND CHECKS...............................................109 STARTING YOUR WORK OPERATIONS.............................................111 WARMING THE HYDRAULIC OIL.............................................111 PARALLEL TOOL KIT.........................................................112 WORK EQUIPMENT CONTROL LEVERS.........................................112 USING THE FORKS.......................................................113 FORK LIFT LIMITATIONS.............................................113 LOAD HANDLING SAFETY TIPS.........................................114 TRAVELING SAFETY TIPS.............................................114 LOADING OPERATIONS................................................114 TRANSPORTING A LOAD...............................................116 UNLOADING.........................................................116 ADJUSTING THE WORK EQUIPMENT..............................................118 ADJUSTING THE BOOM KICKOUT............................................118 ADJUSTING THE BUCKET POSITIONER.......................................118 BUCKET LEVEL INDICATOR................................................119 ADJUSTING FORK POSITIONER.............................................119 USING THE HYDRAULIC QUICK COUPLER.........................................121 REMOVING THE ATTACHMENT...............................................121 INSTALLING THE ATTACHMENT.............................................122 TRAVELING, STOPPING AND PARKING THE MACHINE...............................125 TRAVELING.............................................................125 CHANGING DIRECTION....................................................127 TURNING THE MACHINE...................................................127 TURNING ON SLOPES.................................................127 EMERGENCY STEERING (IF EQUIPPED)......................................128 STOPPING THE MACHINE..................................................129 PARKING THE MACHINE...................................................130 TRANSPORTING THE MACHINE..................................................132 LOADING AND SECURING THE MACHINE......................................132 LIFTING THE MACHINE.......................................................133 LIFTING LOCATIONS AND PROCEDURES......................................133 USING WIRE ROPE.......................................................134 PRE LIFTING PROCEDURES............................................134 TOWING THE MACHINE........................................................136 COLD WEATHER OPERATION....................................................137 FUEL AND LUBRICANTS...................................................137 COOLANT...............................................................137 PRECAUTIONS AFTER COMPLETION OF WORK..................................137 AFTER COLD WEATHER....................................................137 WARMING UP THE STEERING...............................................137 LONG-TERM STORAGE.........................................................138 BEFORE STORAGE........................................................138 DURING STORAGE........................................................138 AFTER STORAGE.........................................................138 MAINTENANCE...................................................................139 BASIC TROUBLESHOOTING.....................................................140 ENGINE................................................................140 CHASSIS...............................................................141 ELECTRICAL............................................................142 GUIDE TO MAINTENANCE......................................................143 CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS).........................144 KOWA ANALYSIS ITEMS...............................................144 OIL SAMPLING......................................................144 WEAR PARTS................................................................145 FUEL SPECIFICATIONS.......................................................146 FUELS.................................................................146 NOTES REGARDING THE ELECTRICAL SYSTEM.................................147 NOTES REGARDING LUBRICATION...........................................147 PROPER SELECTION ACCORDING TO THE AMBIENT TEMPERATURE.................148 STANDARD TIGHTNING TORQUES................................................149 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.............................150 MAINTENANCE SCHEDULE CHART................................................151 SERVICING WHEN REQUIRED...............................................151 EVERY 50 HOURS SERVICE................................................151 EVERY 100 HOURS SERVICE...............................................151 EVERY 250 HOURS SERVICE...............................................151 EVERY 500 HOURS SERVICE...............................................151 EVERY 1000 HOURS SERVICE..............................................152 EVERY 2000 HOURS SERVICE..............................................152 EVERY 4000 HOURS SERVICE..............................................152 FIRST 250 HOURS SERVICE...............................................152 SERVICING WHEN REQUIRED...................................................153 CHECK, CLEAN OR REPLACE AIR CLEANER ELEMENT...........................153 CHECK.............................................................153 CLEAN.............................................................153 REPLACE AIR CLEANER ELEMENT.......................................154 FLUSHING THE COOLING SYSTEM...........................................156 CHECKING OIL LEVEL IN TRANSFER CASE, ADD OIL..........................158 CHECKING AXLE OIL LEVEL, ADD OIL......................................159 CLEANING AXLE CASE BREATHER...........................................160 CLEANING AIR CONDITIONER CONDENSER....................................160 WASHING METHOD....................................................160 CHECKING WINDOW WASHER FLUID LEVEL....................................161 CLEANING RADIATOR COOLING FINS........................................161 CLEANING TRANSFER OIL COOLER FINS.....................................162 CHECKING ELECTRICAL INTAKE AIR HEATER.................................162 REPLACING BOLT ON CUTTING EDGE........................................162 REPLACING BUCKET TEETH................................................163 CHECKING AIR CONDITIONER..............................................163 REPLACING SLOW BLOW FUSE..............................................164 SELECTION AND INSPECTION OF TIRES.....................................165 SELECTION OF TIRES................................................165 INFLATION OF TIRES................................................165 EVERY 50 HOURS SERVICE....................................................166 DRAIN WATER, SEDIMENT FROM FUEL TANK..................................166 EVERY 100 HOURS SERVICE...................................................167 LUBRICATING REAR AXLE PIVOT PIN.......................................167 CLEANING FRESH AIR FILTER.............................................167 CHECKING OIL LEVEL IN HYDRAULIC TANK, ADD OIL.........................168 EVERY 250 HOURS SERVICE...................................................169 CHECK BATTERY ELECTROLYTE LEVEL.......................................169 CHECKING ELECTROLYTE LEVEL FROM SIDE OF BATTERY...................169 WHEN ELECTROLYTE LEVEL CANNOT BE CHECKED FROM THE BATTERY SIDE....170 CHECKING PARKING BRAKE................................................171 CHECKING V-BELT TENSION/ADJUST........................................171 INSPECTION........................................................171 CHECK WHEN CHANGING THE V-BELT....................................171 ADJUSTING.........................................................171 CHECKING FOR LOOSE WHEEL HUB BOLTS, TIGHTENING........................172 CLEANING A/C RECIRCULATION FILTER.....................................172 LUBRICATING WORK EQUIPMENT............................................173 EVERY 500 HOURS SERVICE...................................................175 CHANGING ENGINE OIL AND OIL FILTER CARTRIDGE..........................175 REPLACING ENGINE OIL FILTER CARTRIDGE.............................176 CLEANING WATER SEPARATOR STRAINER.....................................177 EVERY 1000 HOURS SERVICE..................................................178 CHANGING OIL IN TRANSFER CASE.........................................178 CLEANING TRANSFER CASE BREATHER.......................................179 REPLACING HST OIL FILTER ELEMENT......................................180 LUBRICATING CHASSIS...................................................180 CHECKING PARTS OF TURBOCHARGER........................................181 CHECKING PLAY IN TURBOCHARGER ROTOR...................................181 CHECKING ALTERNATOR BELT TENSION, REPLACE.............................181 EVERY 2000 HOURS SERVICE..................................................182 CHANGING HYDRAULIC OIL AND FILTER ELEMENT.............................182 REPLACING HYDRAULIC TANK BREATHER ELEMENT.............................183 CHANGING AXLE OIl.....................................................183 REPLACING AIR CONDITIONER RECIRCULATION AIR FILTER....................184 CHECKING ALTERNATOR, STARTING MOTOR...................................184 CHECKING ENGINE VALVE CLEARANCE, ADJUST...............................184 CHECKING BRAKE DISC WEAR..............................................184 CLEANING AND CHECK TURBOCHARGER.......................................185 CHECKING ACCUMULATOR GAS PRESSURE.....................................185 CHECKING VIBRATION DAMPER.............................................185 CHECKING FUNCTION OF ACCUMULATOR......................................185 PPC ACCUMULATOR...................................................185 EVERY 4000 HOURS SERVICE..................................................186 LUBRICATING DRIVE LINE................................................186 CHECK WATER PUMP......................................................186 ADDITIONAL SERVICE TIPS...................................................187 HANDLING CAB WIPER....................................................187 PREVENTING DAMAGE TO WIPER ARM BRACKET............................187 ENGINE STARTING PROBLEMS..............................................187 WHEN ENGINE CAN BE USED...........................................187 WHEN ENGINE CANNOT BE USED........................................187 BATTERY SERVICING.........................................................188 IF BATTERY IS DISCHARGED..............................................188 PRECAUTIONS.......................................................188 REMOVAL AND INSTALLATION OF BATTERY...................................188 PRECAUTIONS WHEN CHARGING THE BATTERY.................................189 STARTING ENGINE WITH BOOSTER CABLES...................................189 PRECAUTIONS WHEN USING BOOSTER CABLES.............................189 CONNECTING THE BOOSTER CABLES AND STARTING THE ENGINE.................190 STARTING THE ENGINE...............................................190 DISCONNECTING THE BOOSTER CABLES..................................190 SPECIFICATIONS................................................................191 TECHNICAL DATA............................................................192 OVERALL DIMENSIONS WITH WORK EQUIPMENT ATTACHED.......................192 FORK LIFT KIT.....................................................192 MATERIAL HANDLING ARM.............................................193 LOADER BUCKET.....................................................194 BASIC MACHINE SPECIFICATIONS..............................................195 WEIGHT CHANGES........................................................195 ENGINE................................................................195 TRANSMISSION..........................................................195 AXLES AND FINAL DRIVES................................................196 BRAKES................................................................196 STEERING SYSTEM.......................................................196 SERVICE REFILL CAPACITIES.............................................196 RECOMMENDED LUBRICANTS....................................................197 OPTIONAL ATTACHMENTS..........................................................199 AUTHORIZED OPTIONAL EQUIPMENT.............................................200 BASIC PRECAUTIONS.....................................................200 SELECTING BUCKET AND TIRES............................................200 USING LOADER WORK EQUIPMENT...............................................201 LOADING PILED SOIL OR BLASTED ROCK....................................201 LOAD AND CARRY OPERATIONS.........................................203 LOADING TRUCKS OR HOPPERS.........................................203 V-SHAPED LOADING TECHNIQUE........................................203 CUTTING OR DIGGING....................................................204 GRADING OR LEVELING A SURFACE.........................................205 USING MULTI-FUNCTION LEVER................................................206 EXPLANATION OF OPERATION..............................................206 WORK EQUIPMENT LEVER..............................................206 DIRECTIONAL SELECTOR SWITCH.......................................207 DIRECTIONAL SELECTOR ACTUATION SWITCH.............................207 DIRECTIONAL SELECTOR LAMP.........................................208 USING SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE................208 OPTIONAL WORK EQUIPMENT...................................................210 COUPLER SYSTEM........................................................210 ATTACHMENTS.......................................................210
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