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Komatsu WA380-5H Wheel Loader Operation & Maintenance Manual – PDF Download
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- Komatsu WA380-5H Wheel Loader Operation & Maintenance Manual
- SERIAL NUMBERS WA380H50051 AND UP
- PUBLICATION NUMBER:VEAM920100
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Description
Komatsu WA380-5H Wheel Loader Operation & Maintenance Manual
Description:
Komatsu WA380-5H 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 hazard when performing operation and maintenance.
Table of Contents:
Komatsu WA380-5H Wheel Loader Operation & Maintenance Manual
WA380-5H..................................................................................... 1 FOREWORD..................................................................................... 3 FOREWORD................................................................................. 4 SAFETY INFORMATION....................................................................... 5 INTRODUCTION............................................................................. 7 DIRECTIONS OF MACHINE................................................................ 7 NECESSARY INFORMATION.................................................................... 8 MACHINE SERIAL NO. PLATE AND POSITION................................................ 8 ENGINE SERIAL NO. PLATE AND POSITION................................................. 8 POSITION OF SERVICE METER............................................................ 9 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR............................................ 9 CONTENTS................................................................................. 10 SAFETY....................................................................................... 18 SAFETY................................................................................... 19 SAFETY LABELS............................................................................ 21 LOCATION OF SAFETY LABELS............................................................ 21 SAFETY LABELS........................................................................ 22 GENERAL PRECAUTIONS...................................................................... 23 PRECAUTIONS FOR OPERATION................................................................ 31 STARTING ENGINE...................................................................... 31 OPERATION............................................................................ 32 TRANSPORTATION....................................................................... 38 BATTERY.............................................................................. 39 TOWING............................................................................... 41 PRECAUTIONS FOR MAINTENANCE.............................................................. 42 PRECAUTIONS WITH TIRES................................................................... 49 OPERATION.................................................................................... 50 GENERAL VIEW............................................................................. 51 GENERAL VIEW OF MACHINE.............................................................. 51 GENERAL VIEW OF CONTROLS AND GAUGES.................................................. 52 EXPLANATION OF COMPONENTS................................................................ 55 MACHINE MONITOR...................................................................... 55 TYPES OF WARNING................................................................. 56 CENTRAL WARNING LAMP............................................................. 56 CHARACTER DISPLAY PORTION........................................................ 57 EMERGENCY STOP ITEM.............................................................. 63 CAUTION ITEMS.................................................................... 65 INSPECTION AND MAINTENANCE ITEM.................................................. 67 PILOT DISPLAY PORTION............................................................ 71 METER DISPLAY PORTION............................................................ 75 OTHER FUNCTIONS OF MACHINE MONITOR............................................... 77 SWITCHES............................................................................. 82 CONTROL LEVERS, PEDALS............................................................... 94 STEERING TILT LOCK LEVER............................................................. 99 CAP WITH LOCK........................................................................100 CAP WITH LOCK FOR THE FUEL TANK FILLER PORT......................................100 CAP WITH LOCK FOR THE HYDRAULIC TANK FILLER PORT.................................101 SAFETY BAR...........................................................................101 TOWING PIN...........................................................................102 GREASE PUMP..........................................................................102 CAB DOOR OPEN LOCK...................................................................103 CAB WINDOW OPEN LOCK.................................................................103 BACKUP ALARM.........................................................................103 FUSE.................................................................................104 FUSE CAPACITY AND NAME OF CIRCUIT................................................104 SLOW-BLOW FUSE.......................................................................105 TAKING OFF POWER.....................................................................106 AIR CONDITIONER......................................................................107 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL..................................107 METHOD OF OPERATION..............................................................110 PRECAUTIONS WHEN USING...........................................................111 CAB WIPER............................................................................112 PREVENTING DAMAGE TO WIPER ARM BRACKET...........................................112 DUST INDICATOR.......................................................................112 OPERATION................................................................................113 CHECK BEFORE STARTING................................................................113 WALK-AROUND CHECK................................................................113 CHECK BEFORE STARTING............................................................116 ADJUSTMENT BEFORE STARTING...........................................................121 OPERATIONS BEFORE STARTING...........................................................125 STARTING ENGINE......................................................................127 NORMAL STARTING..................................................................127 STARTING IN COLD WEATHER.........................................................129 CHECKS AFTER STARTING................................................................131 BREAKING IN THE MACHINE..........................................................131 NORMAL OPERATION.................................................................131 STOPPING ENGINE......................................................................133 CHECKS AFTER STOPPING ENGINE.....................................................133 MOVING MACHINE OFF (DIRECTIONAL, SPEED), STOPPING....................................134 PREPARATIONS FOR MOVING MACHINE..................................................134 CHANGING GEAR SPEED..................................................................137 CHANGING DIRECTION...................................................................138 STOPPING MACHINE.....................................................................140 TRANSMISSION CUT-OFF.................................................................141 TURNING..............................................................................143 EMERGENCY STEERING...............................................................143 OPERATION OF WORK EQUIPMENT..........................................................145 WORKING POSSIBILITY..................................................................146 DIGGING OPERATIONS...............................................................146 LEVELING OPERATIONS..............................................................149 PUSHING OPERATION................................................................149 LOAD AND CARRY OPERATIONS........................................................149 LOADING OPERATIONS...............................................................150 PRECAUTIONS FOR OPERATION............................................................152 PERMISSIBLE WATER DEPTH..........................................................152 IF WHEEL BRAKE DOES NOT WORK.....................................................152 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES.......................................152 PRECAUTIONS REGARDING BRAKE FUNCTION.............................................153 ADJUSTING WORK EQUIPMENT.............................................................154 ADJUSTING BOOM KICKOUT...........................................................154 ADJUSTING BUCKET POSITIONER......................................................155 BUCKET LEVEL INDICATOR...........................................................155 PARKING MACHINE......................................................................156 CHECKS AFTER WORK....................................................................158 LOCKING..............................................................................158 HANDLING THE TIRES...................................................................159 PRECAUTIONS WHEN HANDLING TIRES..................................................159 TIRE PRESSURE....................................................................159 PRECAUTIONS FOR USING LOAD AND CARRY METHOD......................................160 TRANSPORTATION...........................................................................161 TRANSPORTATION PROCEDURE.............................................................161 LOADING, UNLOADING WORK WITH TRAILERS............................................161 LOADING..........................................................................161 SECURING MACHINE.................................................................162 UNLOADING........................................................................162 LIFTING MACHINE......................................................................163 LOCATION OF LIFTING POSITION MARK................................................164 WEIGHT TABLE.....................................................................164 LIFTING PROCEDURE................................................................165 COLD WEATHER OPERATION...................................................................166 LOW TEMPERATURE......................................................................166 FUEL AND LUBRICANTS..............................................................166 COOLANT..........................................................................166 BATTERY..........................................................................167 AFTER COMPLETION OF WORK.............................................................167 AFTER COLD WEATHER...................................................................167 WARMING-UP OF STEERING HYDRAULIC.....................................................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...................................................................171 WHEN ENGINE CAN BE USED..........................................................171 WHEN ENGINE CANNOT BE USED.......................................................172 RELEASING PARKING BRAKE..........................................................172 EMERGENCY TRAVEL OPERATION.......................................................174 BATTERY IS DISCHARGED................................................................175 REMOVAL AND INSTALLATION OF BATTERY..............................................175 PRECAUTIONS FOR CHARGING BATTERY.................................................176 STARTING ENGINE WITH BOOSTER CABLE...............................................176 OTHER TROUBLE........................................................................178 ELECTRICAL SYSTEM................................................................178 CHASSIS..........................................................................179 ENGINE...........................................................................181 MAINTENANCE..................................................................................184 GUIDES TO MAINTENANCE....................................................................185 OUTLINES OF SERVICE......................................................................187 OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC........................................187 OIL..............................................................................187 FUEL.............................................................................187 COOLANT..........................................................................187 GREASE...........................................................................187 CARRYING OUT KOWA (Komatsu Oil Wear Analysis)....................................188 STORING OIL AND FUEL.............................................................188 FILTERS..........................................................................189 OUTLINE OF ELECTRIC SYSTEM...........................................................189 WEAR PARTS...............................................................................190 WEAR PARTS LIST......................................................................190 FUEL, COOLANT AND LUBRICANTS.............................................................191 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS.....................................191 STANDARD TIGHTENING TORQUES..............................................................196 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................................197 MAINTENANCE SCHEDULE CHART...............................................................199 MAINTENANCE SCHEDULE CHART...........................................................199 SERVICE PROCEDURE........................................................................201 INITIAL 250 HOURS SERVICE............................................................201 INITIAL 1000 HOURS SERVICE...........................................................201 WHEN REQUIRED........................................................................202 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT.....................................202 CLEAN INSIDE OF COOLING SYSTEM...................................................205 CHECK WATER SEPARATOR............................................................208 CHECK TRANSMISSION OIL LEVEL, ADD OIL............................................209 CHECK AXLE OIL LEVEL, ADD OIL....................................................210 CLEAN AXLE CASE BREATHER.........................................................211 CLEAN CONDENSER OF AIR CONDITIONER...............................................211 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID......................................212 CLEAN RADIATOR FINS AND COOLER FINS..............................................212 CHECK ELECTRICAL INTAKE AIR HEATER...............................................215 REPLACE BOLT ON CUTTING EDGE.....................................................215 REPLACE BUCKET TEETH.............................................................216 CHECK AIR CONDITIONER............................................................217 REPLACE SLOW-BLOW FUSE...........................................................218 SELECTION AND INSPECTION OF TIRES................................................219 CHECK BEFORE STARTING................................................................221 EVERY 50 HOURS SERVICE...............................................................222 DRAIN WATER, SEDIMENT FROM FUEL TANK.............................................222 EVERY 100 HOURS SERVICE..............................................................223 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL.......................................223 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER................................224 EVERY 250 HOURS SERVICE..............................................................225 CHECK BATTERY ELECTROLYTE LEVEL..................................................225 CHECK PARKING BRAKE..............................................................227 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST............................227 CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN..........................................228 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER............................228 EVERY 500 HOURS SERVICE..............................................................229 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE................229 REPLACE FUEL FILTER CARTRIDGE....................................................230 EVERY 1000 HOURS SERVICE.............................................................231 CHANGE TRANSMISSION OIL AND FILTER, CLEAN STRAINER...............................231 CLEAN TRANSMISSION CASE BREATHER.................................................232 CHECK TIGHTENING PARTS OF TURBOCHARGER...........................................232 CHECK PLAY OF TURBOCHARGER ROTOR.................................................232 CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT............................232 REPLACE CORROSION RESISTOR CARTRIDGE.............................................232 EVERY 2000 HOURS SERVICE.............................................................233 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...................233 REPLACE HYDRAULIC TANK BREATHER ELEMENT..........................................235 CHANGE AXLE OIL..................................................................236 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER....236 CLEAN PPC CIRCUIT STRAINER.......................................................237 CLEAN ENGINE BREATHER ELEMENT....................................................237 CHEK ALTERNATOR, STARTING MOTOR..................................................237 CHECK ENGINE VALVE CLEARANCE, ADJUST.............................................237 CLEAN AND CHECK TURBOCHARGER.....................................................237 CHECK INJECTOR...................................................................238 CHECK ACCUMULATOR GAS PRESSURE...................................................238 CHECK VIBRATION DAMPER...........................................................238 CHECK BRAKE DISC WEAR............................................................239 EVERY 4000 HOURS SERVICE.............................................................240 LUBRICATING......................................................................240 CHECK WATER PUMP.................................................................240 CHECK AIR CONDITIONER COMPRESSOR, ADJUST.........................................241 REPLACE INJECTOR NOZZLE TIP......................................................241 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER...............241 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER..............241 EVERY 8000 HOURS SERVICE.............................................................242 REPLACE HIGH-PRESSURE PIPING CLAMP...............................................242 REPLACE FUEL SPRAY PREVENTION CAP................................................242 SPECIFICATIONS...............................................................................244 SPECIFICATIONS...........................................................................245 ATTACHMENTS, OPTIONS.........................................................................246 SELECTING BUCKET AND TIRES...............................................................247 HANDLING LOAD METER......................................................................248 GENERAL LOCATIONS....................................................................248 MACHINE MONITOR WITH LOAD METER..................................................248 SWITCHES.........................................................................249 LOAD METER FUNCTIONS.................................................................250 HANDLING LOAD METER DISPLAY..........................................................253 SETTING ADDITION MODE............................................................253 SETTING REMAIN MODE..............................................................255 TOTAL LOAD DATA DISPLAY..........................................................257 STOPPING CALCULATION.............................................................259 CARRYING OUT CALIBRATION (ADJUSTING 0 POINT) WHEN EMPTY..........................260 CARRYING OUT CALIBRATION (ADJUSTING 0 POINT) WHEN LOADED.........................262 SUBTRACTION FUNCTION.............................................................265 METHOD OF SETTING TIME ON CLOCK......................................................267 PRINTER OUTPUT.......................................................................269 PRINTOUT MODE....................................................................269 METHOD OF SELECTING PRINTOUT MODE................................................270 HANDLING TORQUE CONVERTER LOCK-UP........................................................272 GENERAL LOCATIONS....................................................................272 METHOD OF OPERATION..................................................................273 WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED.............................................274 HANDLING AUTOMATIC AIR-CONDITIONER.......................................................275 GENERAL LOCATIONS AND FUNCTIONS OF CONTROL PANEL.....................................275 METHOD OF OPERATION..................................................................279 PRECAUTIONS WHEN USING...............................................................281 INSPECTION AND MAINTENANCE...........................................................281 CENTRAL LUBRICATION......................................................................282 OPERATION............................................................................282 JOYSTICK STEERING SYSTEM.................................................................283 COMPONENTS...........................................................................283 SHIFT UP, SHIFT DOWN SWITCHES....................................................283 F-N-R SWITCH.....................................................................284 JOYSTICK STEERING LEVER..........................................................284 JOYSTICK ON/OFF SWITCH...........................................................284 HI/LOW SELECTOR SWITCH...........................................................284 HORN SWITCH......................................................................285 CONSOLE LOCK LEVER...............................................................285 HEIGHT ADJUSTMENT LOCK LEVER.....................................................285 ANGLE, FORE/AFT ADJUSTMENT LOCK LEVER............................................285 STRUCTURE AND FUNCTION...............................................................285 GETTING IN OR OUT....................................................................287 ADJUSTMENT OF JOYSTICK CONSOLE.......................................................287 OPERATION METHOD OF JOYSTICK STEERING SYSTEM.........................................288 EPC WORK EQUIPMENT LEVER.................................................................290 OPERATIONAL FEATURES.................................................................290 SWITCHES.............................................................................290 SAFETY LOCK LEVER (FOR WORK EQUIPMENT LEVER).....................................291 SEMI AUTO DIGGING OPERATIONS.........................................................291 SEMI AUTO DIGGING OPERATIONS.....................................................291 METHOD OF OPERATION..............................................................292 SELECTING DIGGING PATTERN........................................................292 MANUAL OPERATION DURING AUTOMATIC CONTROL........................................292 END OF CONTROL...................................................................292 METHOD OF REMOTE POSITIONER..........................................................292 REMOTE POSITIONER RAISE MODE SWITCH..............................................293 REMOTE POSITIONER LOWER MODE SWITCH..............................................293 REMOTE POSITIONER RAISE/LOWER SET SWITCH.........................................293 METHOD OF OPERATION..............................................................294 INDEX........................................................................................296 INDEX....................................................................................298
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KOMATSU WA380-5H WHEEL LOADER OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:
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