KOMATSU WA380-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A51001 & UP) KOMATSU WA380-3 – PDF DOWNLOAD

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KOMATSU WA380-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A51001 & UP) KOMATSU WA380-3

KOMATSU WA380-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A51001 & UP) KOMATSU WA380-3 – PDF DOWNLOAD:

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KOMATSU WA380-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A51001 & UP) KOMATSU WA380-3

• This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel realize 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 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 in detail, which may not be reflected in this manual. Consult your local distributor or Komatsu America International Company for the latest available information on your machine or for questions regarding information in this manual.

Table of Contents:

KOMATSU WA380-3 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A51001 & UP) KOMATSU WA380-3

MAIN MENU............................................................................................................................  0
COVER................................................................................................................................  1
INTRODUCTION.........................................................................................................................  4
	1. FORWARD.......................................................................................................................  5
	2. SAFETY INFORMATION............................................................................................................  6
	3. INTRODUCTION..................................................................................................................  7
		3.1 INTENDED USE.............................................................................................................  7
		3.2 FEATURES.................................................................................................................  7
		3.3 BREAKING IN A NEW MACHINE................................................................................................  7
	4. PLATE LOCATIONS AND TABLE TO ENTER P.I.N. AND DISTRIBUTOR.....................................................................  8
		4.1 P.I.N. PLATE LOCATION....................................................................................................  8
			4.1.1 POSITION OF PLATE (A)..............................................................................................  8
			4.1.2 POSITION OF STAMP (B)..............................................................................................  8
		4.2 ENGINE SERIAL NUMBER PLATE...............................................................................................  8
		4.3 TABLE TO ENTER NUMBERS AND DISTRIBUTOR...................................................................................  8
	5. TABLE OF CONTENTS.............................................................................................................  9
SAFETY............................................................................................................................... 15
	6. GENERAL PRECAUTIONS........................................................................................................... 16
	7. PRECAUTIONS DURING OPERATION.................................................................................................. 22
		7.1 BEFORE STARTING ENGINE................................................................................................... 22
		7.2 AFTER STARTING ENGINE.................................................................................................... 24
		7.3 TRANSPORTATION........................................................................................................... 30
		7.4 BATTERY.................................................................................................................. 31
		7.5 TOWING................................................................................................................... 32
	8. PRECAUTIONS FOR MAINTENANCE................................................................................................... 33
		8.1 BEFORE PERFORMING MAINTENANCE............................................................................................ 33
		8.2 DURING MAINTENANCE....................................................................................................... 37
		8.3 TIRES.................................................................................................................... 42
	9. POSITION FOR ATTACHING SAFETY LABELS.......................................................................................... 44
OPERATION............................................................................................................................ 49
	10. GENERAL VIEW................................................................................................................. 50
		10.1 GENERAL VIEW OF MACHINE................................................................................................. 50
		10.2 GENERAL OF CONTROLS AND GAUGES.......................................................................................... 51
	11. COMPONENT EXPLANATION........................................................................................................ 52
		11.1 MACHINE MONITOR......................................................................................................... 52
			11.1.1 WARNING DISPLAYS.................................................................................................. 54
			11.1.2 METER DISPLAY PORTION............................................................................................. 58
		11.2 SWITCHES................................................................................................................ 62
		11.3 CONTROL LEVERS, PEDALS.................................................................................................. 70
		11.4 STEERING COLUMN TILT LEVER.............................................................................................. 75
		11.5 CAP WITH LOCK........................................................................................................... 76
			11.5.1 METHOD OF OPENING AND CLOSING THE CAP WITH LOCK................................................................... 76
		11.6 SAFETY BAR.............................................................................................................. 77
		11.7 TOWING PIN.............................................................................................................. 77
		11.8 GREASE PUMP............................................................................................................. 78
		11.9 BACKUP ALARM............................................................................................................ 78
		11.10 FUSE................................................................................................................... 79
			11.10.1 FUSE CAPACITY AND CIRCUIT NAME................................................................................... 79
		11.11 SLOW-BLOW FUSE......................................................................................................... 80
		11.12 STORING THIS MANUAL.................................................................................................... 81
		11.13 ELECTRIC POWER (WITH ROPS CAB)......................................................................................... 81
	12. OPERATION.................................................................................................................... 82
		12.1 CHECK BEFORE STARTING................................................................................................... 82
			12.1.1 WALK- AROUND CHECK................................................................................................ 82
			12.1.2 CHECK BEFORE STARTING............................................................................................. 85
			12.1.3 ADJUSTMENT BEFORE OPERATION....................................................................................... 91
			12.1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE...................................................................... 94
		12.2 STARTING THE ENGINE..................................................................................................... 96
			12.2.1 COLD WEATHER STARTING............................................................................................. 97
		12.3 OPERATIONS AND CHECKS AFTER STARTING THE ENGINE......................................................................... 98
		12.4 MOVING THE MACHINE......................................................................................................100
		12.5 CHANGING GEAR SPEED.....................................................................................................102
		12.6 CHANGING DIRECTION......................................................................................................102
		12.7 TURNING.................................................................................................................103
		12.8 STOPPING THE MACHINE....................................................................................................104
		12.9 WORK EQUIPMENT OPERATION................................................................................................105
			12.9.1 STANDARD WORK EQUIPMENT CONTROLS..................................................................................105
			12.9.2 MONO-LEVER WORK EQUIPMENT CONTROLS................................................................................106
		12.10 WORK POSSIBLE USING A WHEEL LOADER.....................................................................................108
			12.10.1 DIGGING OPERATIONS...............................................................................................108
			12.10.2 LEVELING OPERATIONS..............................................................................................111
			12.10.3 PUSHING OPERATION................................................................................................111
			12.10.4 LOAD AND CARRY OPERATIONS........................................................................................111
			12.10.5 LOADING OPERATIONS...............................................................................................112
		12.11 PRECAUTION FOR OPERATION...............................................................................................113
			12.11.1 PERMISSIBLE WATER DEPTH..........................................................................................113
			12.11.2 IF WHEEL BRAKES DO NOT  WORK.....................................................................................113
			12.11.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES.......................................................................113
			12.11.4 PRECAUTIONS WHEN DRIVING THE MACHINE.............................................................................114
		12.12 ADJUSTING THE WORK EQUIPMENT POSTURE...................................................................................115
			12.12.1 ADJUSTING THE BOOM KICKOUT.......................................................................................115
			12.12.2 ADJUSTING THE BUCKET POSITIONER..................................................................................116
			12.12.3 BUCKET LEVEL INDICATOR...........................................................................................116
		12.13 PARKING MACHINE........................................................................................................117
		12.14 CHECK AFTER COMPLETION OF OPERATION....................................................................................118
		12.15 STOPPING THE ENGINE....................................................................................................118
		12.16 CHECK AFTER STOPPING THE ENGINE........................................................................................119
		12.17 LOCKING................................................................................................................119
		12.18 HANDLING THE TIRES.....................................................................................................120
			12.18.1 PRECAUTIONS WHEN HANDLING TIRES..................................................................................120
			12.18.2 TIRE PRESSURE....................................................................................................120
	13. TRANSPORTATION...............................................................................................................122
		13.1 LOADING, UNLOADING WORK.................................................................................................122
		13.2 LOADING PRECAUTIONS.....................................................................................................123
		13.3 LIFTING THE MACHINE.....................................................................................................123
			13.3.1 POSITION FOR STICKING THE LIFITING POSITOIN MARK..................................................................124
			13.3.2 WEIGHT TABLE......................................................................................................124
			13.3.3 LIFTING PROCEDURE.................................................................................................125
		13.4 TRANSPORTAION PRECAUTIONS...............................................................................................126
	14. COLD WEATHER OPERATION.......................................................................................................126
		14.1 LOW TEMPERATURE PRECAUTIONS.............................................................................................126
			14.1.1 FUEL AND LUBRICANTS...............................................................................................126
			14.1.2 COOLANT...........................................................................................................126
			14.1.3 BATTERY...........................................................................................................126
		14.2 PRECAUTIONS AFTER WORK COMPLETION.......................................................................................127
		14.3 AFTER COLD WEATHER......................................................................................................127
	15. LONG-TERM STORAGE............................................................................................................127
		15.1 BEFORE STORAGE..........................................................................................................127
		15.2 DURING STORAGE..........................................................................................................127
		15.3 AFTER STORAGE...........................................................................................................127
	16. TROUBLESHOOTING..............................................................................................................128
		16.1 WHEN THE MACHINE RUNS OUT OF FUEL.......................................................................................128
		16.2 TOWING THE MACHINE......................................................................................................128
			16.2.1 WHEN ENGINE CAN BE USED...........................................................................................129
			16.2.2 WHEN ENGINE CANNOT BE USED........................................................................................129
			16.2.3 RELEASING THE PARKING BRAKE.......................................................................................130
			16.2.4 EMERGENCY TRAVEL OPERATION........................................................................................132
		16.3 IF THE BATTERY IS DISCHARGED............................................................................................133
			16.3.1 BATTERY INSTALLATION AND REMOVAL..................................................................................133
			16.3.2 PRECAUTION FOR CHARGING THE BATTERY...............................................................................134
			16.3.3 STARTING THE ENGINE WITH BOOSTER CABLE............................................................................135
		16.4 OTHER TROUBLE...........................................................................................................137
			16.4.1 ELECTRICAL SYSEM..................................................................................................137
			16.4.2 CHASSIS...........................................................................................................138
			16.4.3 ENGINE............................................................................................................141
MAINTENANCE..........................................................................................................................143
	17. GUIDES TO MAINTENANCE........................................................................................................144
	18. OUTLINES OF SERVICE..........................................................................................................146
		18.1 OUTLINE OF OIL, FUEL, COOLANT...........................................................................................146
			18.1.1 OIL...............................................................................................................146
			18.1.2 FUEL..............................................................................................................147
			18.1.3 COOLANT...........................................................................................................147
			18.1.4 GREASE............................................................................................................147
			18.1.5 STORING OIL AND FUEL..............................................................................................148
			18.1.6 FILTERS...........................................................................................................148
		18.2 FUEL INJECTION PUMP.....................................................................................................148
		18.3 OUTLINE OF ELECTRIC SYSTEM..............................................................................................148
		18.4 OUTLINE OF HYDRAULIC SYSTEM.............................................................................................149
	19. WEAR PARTS LIST..............................................................................................................150
	20. FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE................................................................151
		20.1 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS........................................................................151
		20.2 ENGINE OIL SPECIFICATIONS...............................................................................................152
			20.2.1 NORMAL OPERATION..................................................................................................152
			20.2.2 ARCTIC OPERATION..................................................................................................152
		20.3 TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS....153
		20.4 DRIVE AXLE OIL SPECIFICATIONS...........................................................................................153
		20.5 DIESEL FUEL SPECIFICATIONS..............................................................................................153
		20.6 COOLANT SPECIFICATIONS..................................................................................................154
			20.6.1 GENERAL...........................................................................................................154
			20.6.2 WATER.............................................................................................................154
			20.6.3 ANTIFREEZE........................................................................................................154
			20.6.4 SUPPLEMENTAL COOLANT ADDITIVES....................................................................................155
	21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...............................................................................159
		21.1 INTRODUCTIONS OF NECESSARY TOOLS........................................................................................159
		21.2 TORQUE LIST.............................................................................................................160
	22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................................................161
	23. MAINTENANCE SCHEDULE CHART...................................................................................................164
		23.1 SCHEDULED MAINTENANCE CHART.............................................................................................164
	24. SERVICE PROCEDURE............................................................................................................167
		24.1 INITAL 250 HOURS SERVICE................................................................................................167
			24.1.1 FUEL FILTER CARTRIDGE.............................................................................................167
			24.1.2 TRANSMISSION OIL FILTER ELEMENT...................................................................................167
			24.1.3 HYDRAULIC FILTER ELEMENT..........................................................................................167
		24.2 WHEN REQUIRED...........................................................................................................168
			24.2.1 CLEAN OR REPLACE AIR CLEANER ELEMENT..............................................................................168
			24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL.............................................................................170
			24.2.3 CHECK AXLE OIL LEVEL, ADD OIL.....................................................................................171
			24.2.4 CLEAN THE AXLE CASE BREATHER......................................................................................172
			24.2.5 CLEAN THE RADIATOR FINS...........................................................................................172
			24.2.6 REPLACE THE BOLT-ON CUTTING EDGES.................................................................................173
			24.2.7 REPLACE BUCKET TEETH..............................................................................................174
			24.2.8 CHECK AIR CONDITIONER.............................................................................................174
			24.2.9 CLEAN THE AIR CONDITIONER CONDENSER...............................................................................176
			24.2.10 CHECK WINDOW WASHING FLUID, ADD FLUID............................................................................176
			24.2.11 LUBRICATE WORK EQUIPMENT CONTROL VALVE LINKAGE (2 PLACES)........................................................176
			24.2.12 REPLACE SLOW BLOW FUSE...........................................................................................177
			24.2.13 SELECTION AND INSPECTION OF TIRES................................................................................178
		24.3 CHECK BEFORE STARTING ..................................................................................................179
			24.3.1 CHECK MONITOR PANEL...............................................................................................179
			24.3.2 CHECK COOLANT LEVEL, ADD WATER....................................................................................179
			24.3.3 CHECK FUEL LEVEL, ADD FUEL........................................................................................179
			24.3.4 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL........................................................................180
			24.3.5 CHECK ELECTRIC WIRING.............................................................................................181
			24.3.6 DRAIN WATER FROM FUEL WATER SEPARATOR.............................................................................181
			24.3.7 CHECK EFFECT OF PARKING BRAKE.....................................................................................182
			24.3.8 CHECK EFFECT OF BRAKE.............................................................................................182
			24.3.9 CHECK SOUND OF HORN AND BACKUP ALARM..............................................................................182
			24.3.10 CHECK FLASHING OF LAMPS, CHECK FOR DIRT OR DAMAGE................................................................182
			24.3.11 CHECK ENGINE EXHAUST COLOR AND SOUND.............................................................................182
			24.3.12 CHECK OPERATION OF GAUGES........................................................................................182
			24.3.13 CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING........................................................182
			24.3.14 CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE....................................................182
		24.4 EVERY 50 HOURS SERVICE .................................................................................................183
			24.4.1 DRAIN WATER, SEDIMENT FROM FUEL TANK..............................................................................183
		24.5 EVERY 100 HOURS OF SERVICE..............................................................................................183
			24.5.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL........................................................................183
			24.5.2 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER.................................................................184
			24.5.3 LUBRICATE REAR AXLE PIVOT PIN (3 PLACES)..........................................................................184
		24.6 EVERY 250 HOURS SERVICE.................................................................................................185
			24.6.1 CHANGE OIL IN ENGINE OIL PAN, REPLACE OIL FILTER CARTRIDGE........................................................185
			24.6.2 CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN..........................................................................186
			24.6.3 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER.............................................................187
			24.6.4 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.............................................................187
			24.6.5 CHECK BATTERY ELECTROLYTE LEVEL...................................................................................188
			24.6.6 LUBRICATING.......................................................................................................189
		24.7 EVERY 500 HOURS SERVICE.................................................................................................190
			24.7.1 CORROSION RESISTOR................................................................................................190
			24.7.2 REPLACE FUEL FILTER CARTRIDGE AND IN-LINE FUEL STAINER............................................................191
			24.7.3 REPLACE TRANSMISSION OIL FILTER ELEMENT...........................................................................193
		24.8 EVERY 1,000 HOURS SERVICE...............................................................................................194
			24.8.1 CHANGE OIL IN TRANSMISSION, CLEAN STRAINER........................................................................194
			24.8.2 CLEAN TRANSMISSION CASE BREATHER..................................................................................195
			24.8.3 LUBRICATE.........................................................................................................195
			24.8.4 CHECK ENGINE VALVE CLEARANCE, ADJUST..............................................................................197
			24.8.5 CHECK TENSION OF DRIVE BELT.......................................................................................200
			24.8.6 CHECK DRIVE BELT TENSIONER BEARING AND FAN HUB BEARING............................................................200
		24.9 EVERY 2,000 HOURS SERVICE...............................................................................................202
			24.9.1 COOLING SYSTEM, REPLACE COOLANT AND FLUSH THE SYSTEM..............................................................202
			24.9.2 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT....................................................205
			24.9.3 REPLACE HYDRAULIC TANK BREATHER ELEMENT...........................................................................207
			24.9.4 CHANGE AXLE OIL...................................................................................................207
			24.9.5 CHECK BRAKE DISC WEAR.............................................................................................208
			24.9.6 CHECK VIBRATION  DAMPER...........................................................................................208
			24.9.7 REPLACE ELEMENT IN AIR CONDITIONER RECIRCUTLAION FILTER AND FRESH FILTER..........................................208
			24.9.8 CLEAN PPC CIRCUIT STRAINER........................................................................................208
			24.9.9 CHECK ACCUMULATOR GAS PRESSURE....................................................................................208
SPECIFICATIONS.......................................................................................................................209
	25. SPECIFICATIONS...............................................................................................................210
		25.1 GENERAL.................................................................................................................210
		25.2 MACHINE SPECIFICATIONS..................................................................................................211
OPTIONS, ATTACHMENTS.................................................................................................................212
	26. OPTIONAL PARTS AND ATTACHMENTS...............................................................................................213
	27. SELECTING BUCKETS AND TIRES..................................................................................................214
	28. AIR CONDITIONING.............................................................................................................215
		28.1 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL.........................................................................215
			28.1.1 FAN SWITCH........................................................................................................215
			28.1.2 AIR CONDITIONER SWITCH............................................................................................215
			28.1.3 MODE SELECTOR SWITCH..............................................................................................216
			28.1.4 FRESH/RECIRC SELECTOR SWITCH......................................................................................216
			28.1.5 TEMPERATURE CONTROL SWITCH........................................................................................216
		28.2 METHOD OF OPERATION.....................................................................................................217
			28.2.1 WHEN NOT USING THE AIR CONDITIONER REGULARLY......................................................................217
		28.3 COOL BOX................................................................................................................217
	29. HANDLING ECSS................................................................................................................218
		29.1 STRUCTURE AND FUNCTION OF ECSS..........................................................................................218
		29.2 METHOD OF OPERATING ECSS................................................................................................219
		29.3 PRECAUTIONS WHEN OPERATING ECSS SWITCH..................................................................................219
		29.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR...................................................................................220
	30. OPTION DISPLAY...............................................................................................................221
		30.1 EMERGENGY STEERING PILOT LAMP...........................................................................................221
		30.2 RADIO...................................................................................................................222
			30.2.1 OPERATING CONTROLS................................................................................................222
			30.2.2 OPERATION.........................................................................................................223
			30.2.3 SETTING THE CLOCK.................................................................................................225
			30.2.4 REMOTE CONTROL UNIT...............................................................................................226
			30.2.5 BATTERY REPLACEMENT...............................................................................................226
			30.2.6 PRECAUTIONS WHEN USING............................................................................................226

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