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WA380-5
Komatsu WA380-5 Service Manual
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MAINTENANCE
SERVICE PROCEDURE
EVERY 8000 HOURS SERVICE
Maintenance
for
every
50,
250,
500,
1000,
2000
and
4000
hours
service
should
be
carried
out
at
the
same
time.
REPLACE HIGH-PRESSURE PIPING CLAMP
Ask
your
Komatsu
distributor
to
carry
out
this
work.
REPLACE FUEL SPRAY PREVENTION CAP
Ask
your
Komatsu
distributor
to
carry
out
this
work.
4 - 66
282
284
Table of Contents
Table of Contents
9
Foreword
3
Safety Information
4
Introduction
6
Front/Rear, Left/Right Directions of Machine
6
Necessary Information
7
Product Identification Number (Pin)/Machine Serial No. Plate
7
Engine Serial No. Plate
7
Position of Service Meter
8
Table of Contents
9
Safety
13
Location of Safety Labels
16
Safety Labels
16
Safety Labels
17
Clothing and Personal Protective Items
22
Fire Extinguisher and First Aid Kit
22
General Precautions
22
If Abnormalities Are Found
22
Safety Features
22
Safety Rules
22
Always Apply Lock When Leaving Operator's Seat
23
Inside Operator's Compartment
23
Keep Machine Clean
23
Handrails and Steps
24
Do Not Get Caught in Articulated Portion
25
Mounting and Dismounting
25
No People on Attachments
25
Prevention of Burns
25
Fire Prevention
26
Action if Fire Occurs
27
Precautions for Attachments, Options
27
PRECAUTIONS WHEN USING ROPS (Roll over Protective Structure)
27
Unauthorized Modification
27
Window Washer Liquid
27
Safety at Worksite
28
Working on Loose Ground
28
Do Not Go Close to High-Voltage Cables
29
Ensure Good Visibility
29
Ventilation for Enclosed Areas
29
Be Careful about Asbestos Dust
30
Checking Signalman's Signals and Signs
30
Emergency Exit from Operator's Cab
30
Checks before Starting Engine
31
Precautions for Operation Starting Engine
31
Precautions When Starting
31
Starting Engine
31
Precautions in Cold Areas
32
Checks before Operation
33
Operation
33
Precautions When Traveling in Forward or Reverse
33
Precautions When Traveling
34
Traveling on Slopes
35
Precautions When Operating
36
Prohibited Operations
36
Methods of Using Brake
37
Operate Carefully on Snow
37
Parking Machine
38
Loading and Unloading
39
Shipping
39
Transportation
39
Battery
40
Battery Hazard Prevention
40
Starting with Booster Cables
41
Towing
42
When Towing
42
Appoint Leader When Working with Others
43
Keep Work Place Clean and Tidy
43
Precautions for Maintenance
43
Warning Tag
43
Stop Engine before Carrying out Maintenance
44
Inspection and Maintenance after Turning E.C.s.s. Switch off
45
Two Workers for Maintenance When Engine Is Running
45
Accumulator
46
Attachments
46
Personnel
46
Proper Tools
46
Noise
47
Precautions When Using Hammer
47
Removing Battery Terminal
47
Repair Welding
47
Work under the Machine
47
Handling High-Pressure Hoses
48
Maintenance of Air Conditioner
48
Precautions with High-Pressure Oil
48
Waste Materials
48
Compressed Air
49
Periodic Replacement of Safety Critical Parts
49
Handling Tires
50
Operation
50
Precautions When Storing Tires
50
Precautions with Tires
50
General View
53
General View of Machine
53
General View of Controls and Gauges
54
Explanation of Components
57
Machine Monitor
57
Switches
87
Control Levers, Pedals
101
Steering Tilt Lock Lever
106
Cap with Lock
107
Frame Lock Bar
109
Towing Pin
109
Cab Door Open Lock
110
Cab Window Open Lock Cancel Knob
110
Grease Pump
110
Fuse
111
Slow Blow Fuse
112
Power Outlet
113
Am/Fm Radio
114
Am/Fm Radio-Cassette Stereo
120
Air Conditioner
128
Handling Auto Air Conditioner
133
Handling Cab Wiper
140
Check before Starting Engine, Adjust
141
Operation
141
Starting Engine
157
Operations and Checks after Starting Engine
161
Stopping Engine
163
Moving the Machine (Directional, Speed), Stopping the Machine
164
Turning
174
Operation of Work Equipment
176
Work Possible Using Wheel Loader
178
Precautions for Operation
184
Adjusting Work Equipment Posture
186
Parking Machine
188
Checks after Completion of Operation
190
Locking
190
Handling the Tires
191
Loading, Unloading Work with Trailers
193
Transportation
193
Transportation Procedure
193
Lifting Machine
197
Cold Weather Operation
199
Precautions for Low Temperature
199
After Cold Weather
200
Precautions after Completion of Work
200
Warming-Up Operation for Steering Hydraulic Circuit in Cold Weather
201
After Storage
202
Before Storage
202
During Storage
202
Long-Term Storage
202
Troubleshooting
203
When Machine Runs out of Fuel
203
Method of Towing Machine
204
If Battery Is Discharged
209
Other Trouble
212
Guides to Maintenance
219
Maintenance
219
Handling Oil, Fuel, Coolant, and Performing Oil Clinic
221
Outlines of Service
221
Outline of Electric System
224
Wear Parts
225
Wear Parts List
225
Recommended Fuel, Coolant, and Lubricant
226
Use of Fuel, Coolant and Lubricants According to Ambient Temperature
227
Recommended Brands, Recommended Quality for Products Other than Komatsu Genuine Oil
228
Standard Tightening Torques for Bolts and Nuts
229
Torque List
229
Periodic Replacement of Safety Critical Parts
230
Maintenance Schedule Chart
231
Change Transmission Oil Filter Cartridge
233
Check Engine Valve Clearance, Adjust
233
Initial 1000 Hours Service
233
Initial 1000 Hours Service (Only after the First 1000 Hours)
233
Initial 250 Hours Service
233
Initial 250 Hours Service (Only after the First 250 Hours)
233
Replace Hydraulic Tank Filter Element
233
Service Procedure
233
Check, Clean, or Replace Air Cleaner Element
234
When Required
234
Clean Inside of Cooling System
238
Check Water Separator
241
Check Transmission Oil Level, Add Oil
242
Check Axle Oil Level, Add Oil
243
Check Window Washing Fluid Level, Add Fluid
245
Clean Radiator Fins and Cooler Fins
246
Check Electrical Intake Air Heater
249
Turn, Replace Bolt on Cutting Edge
250
Replace Bucket Teeth
251
Check Air Conditioner
253
Replace Slow-Blow Fuse
254
Checking Function of Accumulator
255
Selection and Inspection of Tires
256
Check before Starting
258
Drain Water, Sediment from Fuel Tank
259
Every 50 Hours Service
259
Check Oil Level in Hydraulic Tank, Add Oil
260
Every 100 Hours Service
260
Lubricate Rear Axle Pivot Pin
260
Clean Element in Air Conditioner Fresh Air Filter
261
Check Battery Electrolyte Level
262
Every 250 Hours Service
262
Check Air Conditioner Compressor Belt Tension, Adjust
264
Check Parking Brake
264
Check for Loose Wheel Hub Bolts, Tighten
265
Clean Element in Air Conditioner Recirculation Filter
265
Checking Function of Accumulator
266
Lubricating
267
Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge
268
Every 500 Hours Service
268
Replace Fuel Filter Cartridge
269
Change Oil in Transmission Case and Transmission Oil Filter Cartridge, Clean Strainer
270
Every 1000 Hours Service
270
Clean Transmission Case Breather
271
Lubricating
271
Check Alternator Driving Belt Tension and Replacement
272
Check Play of Turbocharger Rotor
272
Check Tightening Parts of Turbocharger
272
Replace Corrosion Resistor Cartridge
272
Change Oil in Hydraulic Tank, Replace Hydraulic Filter Element
273
Every 2000 Hours Service
273
Replace Hydraulic Tank Breather Element
275
Change Axle Oil
276
Replace Element in Air Conditioner Recirculation Air Filter, Fresh Air Filter
276
Clean Engine Breather Element
277
Clean Ppc Circuit Strainer
277
Check Brake Disc Wear
278
Check Engine Valve Clearance, Adjust
279
Check Injector
279
Checking Function of Accumulator
279
Chek Alternator, Starting Motor
279
Clean and Check Turbocharger
279
Check Vibration Damper
280
Every 4000 Hours Service
281
Lubricating
281
Check Air Conditioner Compressor, Adjust
282
Check Water Pump
282
Checking for Looseness of High-Pressure Clamp, Hardening of Rubber
282
Checking for Missing Fuel Spray Prevention Cap, Hardening of Rubber
282
Replace Injector Assembly
282
Every 8000 Hours Service
283
Replace Fuel Spray Prevention Cap
283
Replace High-Pressure Piping Clamp
283
4
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Komatsu WA380-5 Specifications
General
Brand
Komatsu
Model
WA380-5
Category
Front End Loaders
Language
English
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