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Komatsu WA320-5H Wheel Loader Operation & Maintenance Manual – PDF Download
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- Komatsu WA320-5H Wheel Loader Operation & Maintenance Manual
- SERIAL NUMBERS WA320H50051 AND UP
- PUBLICATION NUMBER:VEAM240100
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Description
Komatsu WA320-5H Wheel Loader Operation & Maintenance Manual
Description:
Komatsu WA320-5H Wheel Loader Operation & Maintenance Manual
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 accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance
Table of Contents:
Komatsu WA320-5H Wheel Loader Operation & Maintenance Manual
FOREWORD......................................................................................... 2 FOREWORD..................................................................................... 3 SAFETY INFORMATION........................................................................... 5 INTRODUCTION................................................................................. 7 INTENDED USE............................................................................. 7 DIRECTIONS OF MACHINE.................................................................... 7 NECESSARY INFORMATION........................................................................ 8 MACHINE SERIAL NO. PLATE AND POSITION.................................................... 8 ENGINE SERIAL NO. PLATE AND POSITION..................................................... 8 ROPS/FOPS-CAB SERIAL NO. PLATE........................................................... 9 AXLE SERIAL NO. PLATE.................................................................... 9 TRANSMISSION SERIAL NO. PLATE............................................................ 9 SEAT OPERATOR SERIAL NO. PLATE........................................................... 9 POSITION OF SERVICE METER................................................................ 10 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................................................ 10 CONTENTS..................................................................................... 11 DIMENSIONS, WEIGHTS AND OPERATING DATA....................................................... 18 WA320-5H: DIMENSIONS, WEIGHTS AND OPERATING DATA......................................... 18 CE-CONFORMING EQUIPMENT...................................................................... 19 CE-CONFORMING EQUIPMENT.................................................................. 19 MANUFACTURER-SUPPLIED CE-CONFORMING EQUIPMENT, ACCORDING TO DOCUMENT 421-93-H1900........ 20 SAFETY........................................................................................... 24 SAFETY LABELS................................................................................ 26 LOCATION OF SAFETY LABELS................................................................ 26 PRESENTATION OF SAFETY LABELS............................................................ 27 GENERAL PRECAUTIONS.......................................................................... 30 PRECAUTIONS FOR OPERATION.................................................................... 40 STARTING ENGINE.......................................................................... 40 OPERATION................................................................................ 42 TRANSPORTATION........................................................................... 48 BATTERY.................................................................................. 49 TOWING................................................................................... 51 PRECAUTIONS FOR MAINTENANCE.................................................................. 52 PRECAUTIONS WITH TIRES....................................................................... 59 OPERATION........................................................................................ 60 GENERAL VIEW................................................................................. 61 GENERAL VIEW OF MACHINE.................................................................. 61 GENERAL VIEW OF CONTROLS AND GAUGES...................................................... 62 EXPLANATION OF COMPONENTS.................................................................... 64 MACHINE MONITOR.......................................................................... 64 MONITOR SYSTEM....................................................................... 65 TYPES OF WARNING..................................................................... 66 CENTRAL WARNING LAMP................................................................. 66 CHARACTER DISPLAY PORTION............................................................ 67 EMERGENCY STOP ITEM.................................................................. 73 CAUTION ITEMS........................................................................ 75 WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED............................................. 77 INSPECTION AND MAINTENANCE ITEM...................................................... 78 PILOT DISPLAY PORTION................................................................ 81 METER DISPLAY PORTION................................................................ 84 OTHER FUNCTIONS OF MACHINE MONITOR................................................... 86 SWITCHES................................................................................. 89 CONTROL LEVERS, PEDALS................................................................... 98 STEERING TILT LOCK LEVER.................................................................102 CAP AND COVER WITH LOCK..................................................................102 SAFETY BAR...............................................................................103 TOWING PIN...............................................................................104 GREASE PUMP..............................................................................104 CAB DOOR INNER LOCK......................................................................104 CAB DOOR OPEN LOCK.......................................................................105 CAB WINDOW OPEN LOCK CANCEL KNOB.........................................................105 FUSE.....................................................................................105 FUSE CAPACITY AND NAME OF CIRCUIT....................................................106 SLOW BLOW FUSE...........................................................................107 POWER OUTLET.............................................................................107 STORAGE BOX..............................................................................107 AIR CONDITIONER..........................................................................108 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL......................................108 METHOD OF OPERATION..................................................................111 PRECAUTIONS WHEN USING...............................................................112 HANDLING CAB WIPER.......................................................................112 PREVENTING DAMAGE TO WIPER ARM BRACKET...............................................112 OPERATION....................................................................................113 CHECK BEFORE STARTING ENGINE, ADJUST.....................................................113 WALK-AROUND CHECK....................................................................113 CHECK BEFORE STARTING................................................................116 ADJUSTMENT...........................................................................122 OPERATIONS AND CHECKS BEFORE STARTING ENGINE.........................................127 STARTING ENGINE..........................................................................129 NORMAL STARTING......................................................................129 STARTING IN COLD WEATHER.............................................................131 OPERATIONS AND CHECKS AFTER STARTING ENGINE..............................................133 BREAKING-IN THE MACHINE..............................................................133 NORMAL OPERATION.....................................................................134 STOPPING ENGINE..........................................................................135 MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE............................136 MOVING THE MACHINE...................................................................136 CHANGING DIRECTION...................................................................138 STOPPING THE MACHINE.................................................................140 TURNING..................................................................................141 EMERGENCY STEERING...................................................................142 OPERATION OF WORK EQUIPMENT..............................................................143 WORK POSSIBLE USING WHEEL LOADER.........................................................145 DIGGING OPERATIONS...................................................................145 LEVELING OPERATIONS..................................................................148 PUSHING OPERATION....................................................................148 LOAD AND CARRY OPERATIONS............................................................148 LOADING OPERATIONS...................................................................149 PRECAUTIONS FOR OPERATION................................................................151 PERMISSIBLE WATER DEPTH..............................................................151 IF WHEEL BRAKE DOES NOT WORK.........................................................151 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...........................................151 ADJUSTING WORK EQUIPMENT POSTURE.........................................................153 ADJUSTING BOOM KICKOUT...............................................................153 ADJUSTING BUCKET POSITIONER..........................................................154 BUCKET LEVEL INDICATOR...............................................................154 PARKING MACHINE..........................................................................155 CHECK AFTER STOPPING ENGINE..............................................................156 CHECKS AFTER COMPLETION OF OPERATION.....................................................156 LOCKING..................................................................................157 HANDLING THE TIRES.......................................................................158 PRECAUTIONS WHEN HANDLING TIRES......................................................158 TIRE PRESSURE........................................................................158 PRECAUTIONS FOR USING LOAD AND CARRY METHOD..........................................159 TRANSPORTATION...............................................................................160 TRANSPORTATION PROCEDURE.................................................................160 LOADING, UNLOADING WORK WITH TRAILERS....................................................160 LOADING..............................................................................160 SECURING MACHINE.....................................................................161 UNLOADING............................................................................162 LIFTING MACHINE..........................................................................163 LOCATION OF LIFTING POSITION MARK....................................................164 WEIGHT TABLE.........................................................................164 LIFTING PROCEDURE....................................................................165 COLD WEATHER OPERATION.......................................................................166 PRECAUTIONS FOR LOW TEMPERATURE..........................................................166 FUEL AND LUBRICANTS..................................................................166 COOLANT..............................................................................166 BATTERY..............................................................................167 PRECAUTIONS AFTER COMPLETION OF WORK.....................................................167 AFTER COLD WEATHER.......................................................................168 WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER......................168 LONG-TERM STORAGE............................................................................169 BEFORE STORAGE...........................................................................169 DURING STORAGE...........................................................................169 AFTER STORAGE............................................................................169 TROUBLESHOOTING..............................................................................170 WHEN MACHINE RUNS OUT OF FUEL............................................................170 TOWING THE MACHINE.......................................................................170 WHEN ENGINE CAN BE USED..............................................................171 WHEN ENGINE CANNOT BE USED...........................................................171 IF BATTERY IS DISCHARGED.................................................................172 REMOVAL AND INSTALLATION OF BATTERY..................................................172 PRECAUTIONS FOR CHARGING BATTERY.....................................................173 STARTING ENGINE WITH BOOSTER CABLE...................................................174 OTHER TROUBLE............................................................................176 ELECTRICAL SYSTEM....................................................................176 CHASSIS..............................................................................177 ENGINE...............................................................................179 MAINTENANCE......................................................................................182 GUIDES TO MAINTENANCE........................................................................183 OUTLINES OF SERVICE..........................................................................185 HANDLING OIL, FUEL, COOLANT, GREASE AND CARRYING OUT KOWA (Komatsu Oil Wear Analysis)....185 OIL..................................................................................185 FUEL.................................................................................185 COOLANT..............................................................................186 GREASE...............................................................................186 CARRYING OUT KOWA (Komatsu Oil Wear Analysis)........................................186 STORING OIL AND FUEL.................................................................187 FILTERS..............................................................................187 BIODEGRADABLE HYDRAULIC OIL AND LUBRICANTS...........................................188 OUTLINE OF ELECTRIC SYSTEM...............................................................188 WEAR PARTS...................................................................................189 WEAR PARTS LIST..........................................................................189 FUEL, COOLANT AND LUBRICANTS.................................................................190 LUBRICATION CHART........................................................................190 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS.........................................191 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...............................................196 TORQUE LIST..............................................................................196 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................197 MAINTENANCE SCHEDULE CHART...................................................................198 MAINTENANCE SCHEDULE CHART...............................................................198 SERVICE PROCEDURE............................................................................200 INITIAL 250 HOURS SERVICE................................................................200 WHEN REQUIRED............................................................................201 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT.........................................201 DUST PRE-EXTRACTOR "TURBO II": CHECK, CLEAN..........................................203 CLEAN INSIDE OF COOLING SYSTEM.......................................................204 CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL............................................207 CHECK AXLE OIL LEVEL, ADD OIL........................................................208 CLEAN AXLE CASE BREATHER.............................................................209 CLEAN AIR CONDITIONER CONDENSER......................................................210 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID..........................................210 CLEAN RADIATOR FINS AND COOLER FINS..................................................211 CLEAN TRANSFER OIL COOLER FINS.......................................................212 CHECK ELECTRICAL INTAKE AIR HEATER...................................................212 REPLACE BOLT ON CUTTING EDGE.........................................................213 REPLACE BUCKET TEETH.................................................................214 CHECK AIR CONDITIONER................................................................215 REPLACE SLOW BLOW FUSE...............................................................216 SELECTION AND INSPECTION OF TIRES....................................................217 CHECK BEFORE STARTING....................................................................219 EVERY 50 HOURS SERVICE...................................................................220 DRAIN WATER, SEDIMENT FROM FUEL TANK.................................................220 EVERY 100 HOURS SERVICE..................................................................221 LUBRICATE REAR AXLE PIVOT PIN........................................................221 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER....................................221 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...........................................222 EVERY 250 HOURS SERVICE..................................................................223 CHECK BATTERY ELECTROLYTE LEVEL......................................................223 CHECK PARKING BRAKE..................................................................225 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST................................225 CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN.............................................226 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER................................227 LUBRICATING..........................................................................227 EVERY 500 HOURS SERVICE..................................................................229 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....................229 REPLACE FUEL FILTER CARTRIDGE........................................................230 CLEAN WATER SEPARATOR STRAINER.......................................................231 EVERY 1000 HOURS SERVICE.................................................................232 CHANGE OIL IN TRANSFER CASE..........................................................232 CLEAN TRANSFER CASE BREATHER.........................................................233 REPLACE HST OIL FILTER ELEMENT.......................................................234 LUBRICATING..........................................................................235 CHECK TIGHTENING PARTS OF TURBOCHARGER...............................................235 CHECK PLAY OF TURBOCHARGER ROTOR.....................................................235 CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT................................235 EVERY 2000 HOURS SERVICE.................................................................236 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT.......................236 REPLACE HYDRAULIC TANK BREATHER ELEMENT..............................................237 CLEANING THE STRAINER OF THE BRAKE FILTER............................................238 CHANGE AXLE OIL......................................................................239 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER........240 CHECK ALTERNATOR, STARTING MOTOR.....................................................240 CHECK ENGINE VALVE CLEARANCE, ADJUST.................................................240 CHECK BRAKE DISC WEAR................................................................240 CLEAN AND CHECK TURBOCHARGER.........................................................241 CHECK ACCUMULATOR GAS PRESSURE.......................................................241 CHECK VIBRATION DAMPER...............................................................241 EVERY 4000 HOURS SERVICE.................................................................242 LUBRICATING..........................................................................242 CHECK WATER PUMP.....................................................................242 TECHNICAL DATA...................................................................................244 TECHNICAL DATA...............................................................................245 NOISE EMISSION LEVELS........................................................................247 VIBRATION LEVEL..............................................................................247 ATTACHMENTS, OPTIONS.............................................................................248 SELECTING BUCKET AND TIRES...................................................................249 MACHINE MONITOR WITH LOAD METER..............................................................250 EXPLANATION OF COMPONENTS................................................................250 MACHINE MONITOR......................................................................250 MONITOR PANEL MODE SELECTOR SWITCH 1.................................................251 MONITOR PANEL MODE SELECTOR SWITCH 2.................................................251 LOAD METER CANCEL SWITCH.............................................................251 LOAD METER SUB TOTAL SWITCH..........................................................252 MACHINE MONITOR..........................................................................253 MONITOR SYSTEM.......................................................................253 TYPES OF WARNING.....................................................................254 CENTRAL WARNING LAMP.................................................................254 CHARACTER DISPLAY PORTION............................................................255 EMERGENCY STOP ITEM..................................................................261 CAUTION ITEMS........................................................................264 WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED.............................................266 INSPECTION AND MAINTENANCE ITEM......................................................267 PILOT DISPLAY PORTION................................................................270 METER DISPLAY PORTION................................................................273 LOAD METER...........................................................................275 OTHER FUNCTIONS OF MACHINE MONITOR...................................................298 HANDLING MULTI-FUNCTION LEVER................................................................305 EXPLANATION OF COMPONENTS................................................................305 WORK EQUIPMENT LEVER.................................................................305 DIRECTIONAL SELECTOR SWITCH..........................................................306 DIRECTIONAL SELECTOR SWITCH ACTUATION SWITCH.........................................306 DIRECTIONAL SELECTOR PILOT LAMP......................................................307 OPERATION................................................................................308 USING SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE...................................308 CENTRAL LUBRICATION SYSTEM...................................................................310 OPERATING THE CENTRAL LUBRICATION SYSTEM.................................................310 DISPLAY AND CONTROL UNIT.................................................................310 LED-DISPLAY..........................................................................311 PUSHBUTTONS..........................................................................311 CHANGING THE LUBRICATION INTERVAL TIMES..................................................312 INDEX............................................................................................314 INDEX........................................................................................316 A........................................................................................316 C........................................................................................316 D........................................................................................316 E........................................................................................316 F........................................................................................316 G........................................................................................316 H........................................................................................316 I........................................................................................316 L........................................................................................316 M........................................................................................316 N........................................................................................316 O........................................................................................316 P........................................................................................316 R........................................................................................317 S........................................................................................317 T........................................................................................317 U........................................................................................317 V........................................................................................317 W........................................................................................317 NOTES............................................................................................318 NOTES........................................................................................319
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KOMATSU WA320-5H WHEEL LOADER OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:
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