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Komatsu
Compact Loader
WA380-8
Komatsu WA380-8 Service Manual
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SEA
T PLA
TE LOCA
TION
This plate is located in front of seat, covered by the bellows.
SER
VICE METER LOCA
TION
It is at the center bottom of the machine monitor
.
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUT
OR
Machine serial No.
Engine serial No.
Product identification
number (PIN)
Manufacturer name
Address
Komatsu
Germany
GmbH
Hanomag Strasse 9
30449 Hannover
Germany
Distributor name
Address
Phone/Fax
Service personnel
PRODUCT INFORMA
TION
FOREWORD
1-10
11
13
Table of Contents
Table of Contents
16
Eu Directives
4
Safety Information
6
Safety Labels
7
Introduction
8
Main Use of Machine
8
Directions of Machine
8
Visibility from Operator's Seat
8
Engine Technology to Conform Exhaust Gas Emission
9
Product Information
10
Location of Product Identification Number (Pin)/Machine Serial No. Plate
10
Location of Engine Number Plate
10
Rops/Fops Serial Plate Location
11
Transmission Serial Plate Location
11
Seat Plate Location
12
Your Machine Serial Numbers and Distributor
12
Declaration of Conformity
13
Retrofitting by Third-Party Suppliers
14
Explanation of Acronyms
15
Table of Contents
16
Safety
22
Safety Labels
24
Location of Safety Labels
25
Contents of Safety Labels
27
General Precautions Common to Operation and Maintenance
35
Precautions before Starting Operation
35
Preparations for Safe Operation
35
Ensure Safe Operation
35
Understand the Machine
35
Precautions for Safety-Related Equipment
35
Inspect Machine
35
Wear Well-Fitting Clothes and Protective Equipment
35
Keep Machine Clean
35
Precautions for Inside Operator's Compartment
36
Provide Fire Extinguisher and First Aid Kit
36
If any Problem Is Found
36
Precautions to Prevent Fire
37
Actions if Fire Occurs
37
Prevent Fire
37
Precautions When Getting on or off Machine
38
Use Handrails and Steps When Getting on or off Machine
38
No Jumping on or off Machine
39
No People on Attachments
39
Lifting of Personnel Prohibited
39
Precautions When Standing up from Operator's Seat
39
Precautions When Leaving Machine
39
Do Not Get Caught in Work Equipment
40
Emergency Exit from Operator's Cab
40
Precautions for Cleaning Cab Glass
40
Precautions Related to Protective Structures
41
Unauthorized Modification
41
Precautions Related to Attachments and Options
41
Precautions When Running Engine Inside Building
41
Precautions for Operation
42
Precautions for Jobsite
42
Investigate and Confirm Jobsite Conditions
42
Precautions When Working on Loose Ground
42
Do Not Go Close to High-Voltage Cables
42
Ensure Good Visibility
43
Check Signs and Signalman's Signals
43
Start Engine
44
Beware of Asbestos Dust
44
Use Warning Tags
44
Checks and Adjustment before Starting Engine
44
Precautions When Starting Engine
45
In Cold Weather
45
Start Engine with Jumper Cables
45
Precautions for Operation
46
Checks before Operation
46
Precautions When Traveling in Forward or Reverse
46
Precautions When Traveling
47
Precautions When Traveling on Slopes
48
Method of Using Brakes
49
Precautions When Operating Machine
49
Prohibited Operations
50
Precautions When Operating on Snow or Frozen Surfaces
50
Precautions When Parking Machine
50
Precautions for Transportation
51
Precautions When Loading and Unloading
51
Towing and Being Towed
52
Precautions for Towing and Being Towed
52
Precautions for Maintenance
53
Precautions before Starting Inspection and Maintenance
53
Display Warning Tag During Inspection and Maintenance
53
Keep Work Place Clean and Tidy
53
Select Suitable Place for Inspection and Maintenance
53
Only Authorized Personnel
53
Appoint Leader When Working with Others
53
Stability
53
Guards
54
End of Service Life
54
Stop Engine before Carrying out Inspection and Maintenance
54
Two Workers for Maintenance When Engine Is Running
55
Turn off Ecss Switch before Performing Inspection and Maintenance
56
Precautions When Installing, Removing, or Storing Attachments
56
Precautions for Working at High Places
56
Precautions When Working under Machine or Work Equipment
56
Precautions for Check and Maintenance
57
Use Proper Tools
57
Turn Battery Disconnect Switch to off Position
57
Precautions for Welding
57
Handle Battery
57
Precautions When Using Hammer
58
Precautions for High-Temperature Coolant
59
Precautions for High-Temperature Oil
59
Precautions for High-Temperature Parts
59
Precautions for High-Pressure Oil
59
Precautions for High-Pressure Fuel
59
Handle High-Pressure Hoses and Piping
60
Precautions for Noise
60
Handle Accumulator and Gas Spring
60
Precautions for Compressed Air
60
Maintenance of Air Conditioner
60
Chemical Hazard
60
Precautions for Disposing of Waste Materials
61
Method for Selecting Window Washer Fluid
61
Periodic Replacement of Defined Life Parts
61
Tires
62
Handle Tires
62
Precautions for Storing Tires
62
Precautions for Def
63
General Character and Precautions for Handling
63
Precautions for Adding
63
Precautions for Storing
63
Precautions for Fire Hazard and Leakage
63
Other Precautions
63
Operation
65
General View
66
Machine Equipment Name
66
Controls and Gauges Names
67
Other Equipment Name
71
Explanation of Components
74
Explanation of Machine Monitor Equipment
74
Switches
158
Control Levers and Pedals
175
Other Components
178
Machine Operations and Controls
223
Checks and Adjustment before Starting Engine
223
Method for Starting Engine
247
Method for Operations and Checks after Starting Engine
251
Method for Stopping Engine
254
Method for Starting Machine (Travel Forward and Reverse, and Shifting Gear) and Stopping Machine
255
Method for Steering Machine
264
Method for Operating Work Equipment
267
Precautions for Operation
271
Method for Checking Bucket Angle
272
Recommended Applications
272
Remote Positioner
278
Method for Parking Machine
282
Method for Checking after Finishing Work
283
Lock
284
Handle Tire
286
Handle Air Conditioner
288
Explanation of Air Conditioner Equipment
289
Method for Operating Air Conditioner
294
Transportation
298
Transportation Procedure
298
Loading and Unloading with Trailer
298
Method for Lifting Machine
302
Cold Weather Operation
304
Cold Weather Operation Information
304
Precautions after Daily Work Completion
305
Precautions in Cold Weather
305
After Cold Weather Season
305
Precautions for Long-Term Storage
306
Preparation for Long-Term Storage
306
Maintenance During Long-Term Storage
306
Starting Machine after Long-Term Storage
306
Troubles and Actions
308
Actions When Running out of Fuel
308
Precautions for Towing Machine
308
Precautions for Discharged Battery
312
Other Trouble
315
Maintenance
321
Precautions for Maintenance
322
Check Service Meter Reading
322
Komatsu Genuine Replacement Parts
322
Komatsu Genuine Lubricants
322
Always Use Clean Washer Fluid
322
Fresh and Clean Lubricants
322
Check Drained Oil and Used Filter
322
Precautions for Refilling Oil or Fuel
322
Precautions for Adding Def
322
Welding Instructions
322
Precautions for Scr Assembly
323
Dusty Jobsites
323
Avoid Mixing Oil
323
Lock Inspection Covers
323
Bleed Air from Hydraulic Circuit
323
Precautions When Installing Hydraulic Hoses
323
Checks after Inspection and Maintenance
323
Fuel and Lubricants to Match the Ambient Temperature
324
Close Engine Side Cover Securely
324
Outline of Maintenance
325
Handle Oil, Fuel, Coolant, and Performing Oil Clinic
325
Handle Electrical Components
329
Standard Tightening Torque for Bolts and Nuts
330
Maintenance Schedule
332
Maintenance Schedule Table
332
Maintenance Procedure
334
Initial 250 Hours Maintenance (Only after the First 250 Hours)
334
Initial 1000 Hours Maintenance (Only after the First 1000 Hours)
334
When Required
334
Method for Checking, Cleaning and Replacing Air Cleaner
334
Method for Cleaning Inside of Cooling System
340
Method for Checking Oil Level in Transmission Case, Adding Oil
343
Method for Checking Oil Level in Axle Case and Adding Oil
345
Method for Cleaning Axle Breather
346
Method for Cleaning Air Conditioner Condenser
347
Method for Cleaning Radiator Fin and Cooler Fin
347
Method for Cleaning Fin with Compressed Air
348
Method for Cleaning Fins by Rotating Cooling Fan in Reverse
348
Method for Reversing Automatic Operation Fan
348
Method for Reversing Manual Operation Fan
348
Method for Inverting and Replacing Bolt on Cutting Edge
350
Method for Replacing Bucket Teeth
351
Method for Checking and Maintenance Air Conditioner
353
Method for Checking Window Washer Fluid Level, Adding Fluid
353
Method for Replacing Slow-Blow Fuse
354
Method for Checking Function of Ecss Accumulator
355
Select and Check Tires
356
Method for Cleaning and Replacing Fuel Tank Breather Element
357
Method for Lubricating Rear Full-Length Fender Hinge
358
Checking Auto-Greasing and Operation Method for Filling Grease
359
Checks before Starting
360
Every 50 Hours Maintenance
361
Every 100 Hours Maintenance
361
Method for Draining Water and Sediment from Fuel Tank
361
Method for Checking Oil Level in Hydraulic Tank, Adding Oil
362
Method for Cleaning Air Conditioner Fresh Air Filter
362
Every 250 Hours Maintenance
363
Method for Checking Battery Electrolyte Level
363
Method for Checking and Adjusting Air Conditioner Compressor Belt Tension
365
Method for Testing Parking Brake
365
Method for Checking Looseness of Wheel Hub Bolts, Retightening Bolts
367
Method for Cleaning Air Conditioner Recirc Air Filter
367
Every 500 Hours Maintenance
368
Method for Checking Function of Brake Accumulator
368
Method for Replacing Fuel Prefilter Cartridge
370
Every 1000 Hours Maintenance
372
Method for Replacing Fuel Main Filter Cartridge
372
Method for Changing Oil in Transmission Case and Cleaning Transmission Case Strainer
373
Method for Replacing Transmission Oil Filter Cartridge
374
Method for Checking All Tightening Points of Engine Intake Pipe Clamps
375
Every 2000 Hours Maintenance
376
Method for Checking and Replacing Alternator Belt
376
Method for Changing Oil in Hydraulic Tank, Cleaning Hydraulic Tank Strainer
376
Method for Cleaning Transmission Breather
375
Method for Replacing Hydraulic Oil Filter Element
377
Method for Changing Oil in Axle Case
379
Method for Replacing Hydraulic Tank Breather Element
379
Method for Replacing Air Conditioner Fresh/Recirc Air Filters
380
Method for Checking Brake Disc Wear Amount
381
Method for Checking Function of Ppc Accumulator
381
Method for Checking Alternator
382
Method for Checking and Adjusting Engine Valve Clearance
382
Method for Checking Vibration Damper
382
Method for Replacing Kccv Filter Element
382
Method for Replacing Def Filter
385
Method for Replacing Def Tank Breather Element
388
Every 4000 Hours Maintenance
389
Replace Defined Life Parts
389
Method for Lubricating Drive Shaft
390
Method for Checking and Adjusting Air Conditioner Compressor
392
Method for Checking Starting Motor
392
Method for Checking Water Pump
392
Method for Checking for Looseness of Engine High-Pressure Piping Clamp, Hard- Ening of Rubber
393
Every 4500 Hours Maintenance
394
Every 8000 Hours Maintenance
394
Every 9000 Hours Maintenance
394
Method for Cleaning Kdpf
394
Method for Cleaning Def Tank
394
Method for Replacing Fuel Spray Prevention Cap
394
Method for Replacing Starting Motor
394
Method for Replacing Def Hose
394
End of Service Life
394
Specifications
395
Specifications: Wa380-8
396
Noise Emission Levels
398
Vibration Level
399
Attachments and Options
401
Bucket and Tire Selection
402
Handle Multifunction Mono-Lever
403
Explanation of Equipment on Multifunction Mono-Lever
403
Multifunction Mono-Lever
403
Kickdown Switch
404
Hold Switch
405
Directional Selecter Switch on Multifunction Mono-Lever
405
Pcs(Proportional Control Switch)
406
Lcd Unit
407
Oil Flow Control Mode Pilot Lamp (Fixed Oil Flow Mode)
407
Oil Flow Control Mode Pilot Lamp (Proportional Oil Flow Mode)
408
Detent Operation Pilot Lamp
408
Attachment Oil Flow Level
408
Method for Setting Pcs
409
Handle Quick Coupler
411
To Remove Attachment
411
To Install Attachment
412
Replacement Parts
417
Periodic Replacement of Defined Life Parts
418
Defined Life Parts List
418
Consumable Parts
419
Consumable Parts List
419
Recommended Fuel, Coolant, and Lubricant
420
Lubrication Chart
420
Method for Using Fuel, Coolant and Lubricants According to Ambient Temperature
422
Recommended Brands and Qualities Other than Komatsu Genuine Oils
423
Index
425
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Komatsu WA380-8 Specifications
General
Brand
Komatsu
Model
WA380-8
Category
Compact Loader
Language
English
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