Komatsu WA380-6H Wheel Loader Operation & Maintenance Manual – PDF Download

Description

Komatsu WA380-6H Wheel Loader Operation & Maintenance Manual 

Description:

Komatsu WA380-6H 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 WA380-6H Wheel Loader Operation & Maintenance Manual

1. Foreword............................................................................................  3
	1.1 Foreword.......................................................................................  4
		1.1.1 EU Directives............................................................................  5
	1.2 Safety information.............................................................................  6
		1.2.1 Signal words.............................................................................  6
		1.2.2 Safety labels............................................................................  8
	1.3 Introduction...................................................................................  9
		1.3.1 Intended use.............................................................................  9
		1.3.2 Directions of machine.................................................................... 10
		1.3.3 Visibility from operator's seat.......................................................... 11
	1.4 Necessary information.......................................................................... 12
		1.4.1 Product Identification Number (PIN)/Machine serial no. plate and position................ 12
		1.4.2 Engine serial no. plate and position..................................................... 12
		1.4.3 ROPS/FOPS-Cab serial no. plate........................................................... 13
		1.4.4 Axle serial no. plate.................................................................... 13
		1.4.5 Transmission serial no. plate............................................................ 13
		1.4.6 Seat operator serial no. plate........................................................... 14
		1.4.7 Position of service meter................................................................ 14
		1.4.8 Table to enter serial no. and distributor................................................ 14
	1.5 Contents....................................................................................... 15
	1.6 Dimensions, weights and operating data......................................................... 23
		1.6.1 WA380-6: Dimensions, weights and operating data.......................................... 23
	1.7 CE-Conforming equipment........................................................................ 24
		1.7.1 CE-Conforming equipment.................................................................. 24
		1.7.2 Manufacturer-supplied CE-Conforming equipment, according to document 419-93-H1250........ 25
2. Safety.............................................................................................. 29
	2.1 Safety labels.................................................................................. 30
		2.1.1 Location of safety labels................................................................ 30
		2.1.2 Presentation of safety labels............................................................ 31
	2.2 General precautions............................................................................ 34
	2.3 Precautions for operation...................................................................... 46
		2.3.1 Starting engine.......................................................................... 46
		2.3.2 Operation................................................................................ 48
		2.3.3 Transportation........................................................................... 56
		2.3.4 Battery.................................................................................. 58
		2.3.5 Towing................................................................................... 60
	2.4 Precautions for maintenance.................................................................... 61
	2.5 Precautions with tires......................................................................... 71
3. Operation........................................................................................... 73
	3.1 General view................................................................................... 74
		3.1.1 General view of machine.................................................................. 74
		3.1.2 General view of controls and gauges...................................................... 75
	3.2 Explanation of components...................................................................... 79
		3.2.1 Machine monitor.......................................................................... 79
			Types of warning........................................................................... 80
			Central warning lamp....................................................................... 81
			Character display portion.................................................................. 82
			Emergency stop item........................................................................ 88
			Caution items.............................................................................. 91
			Inspection and maintenance item............................................................ 94
			Pilot display portion...................................................................... 98
			Meter display portion......................................................................104
			Other functions of machine monitor.........................................................107
		3.2.2 Switches.................................................................................112
		3.2.3 Control levers, pedals...................................................................129
		3.2.4 Steering tilt lock lever.................................................................136
		3.2.5 Cap with lock............................................................................137
		3.2.6 Safety bar...............................................................................138
		3.2.7 Towing pin...............................................................................139
		3.2.8 Grease pump..............................................................................139
		3.2.9 Cab door.................................................................................140
		3.2.10 Cab door open lock......................................................................140
		3.2.11 Cab window open lock....................................................................141
			Cab left window open lock reset knob.......................................................141
			Cab right window open lock reset knob......................................................141
			Reset right window open lock for escape....................................................142
		3.2.12 Backup alarm............................................................................142
		3.2.13 Fuse....................................................................................143
			Fuse capacity and name of circuit..........................................................143
		3.2.14 Slow blow fuse..........................................................................144
		3.2.15 Power outlet............................................................................145
		3.2.16 Air conditioner.........................................................................146
			General locations and function of control panel............................................146
			Method of operation........................................................................149
			Precautions when using.....................................................................151
			Precautions for inspection and maintenance.................................................151
			Cool box...................................................................................152
		3.2.17 Handling cab wiper......................................................................152
			Preventing damage to wiper arm bracket.....................................................152
	3.3 Operation......................................................................................153
		3.3.1 Check before starting engine, adjust.....................................................153
			Walk-around check..........................................................................153
			Check before starting......................................................................156
			Adjustment.................................................................................164
			Safety belt................................................................................165
			Adjust lever stand.........................................................................166
			Operations and checks before starting engine...............................................168
		3.3.2 Starting engine..........................................................................170
			Normal starting............................................................................170
			Starting in cold weather...................................................................172
			Automatic warming-up operation.............................................................173
		3.3.3 Operations and checks after starting engine..............................................174
			Breaking-in the machine....................................................................174
			Normal operation...........................................................................175
		3.3.4 Stopping engine..........................................................................177
		3.3.5 Check after stopping engine..............................................................177
		3.3.6 Moving the machine (directional, speed), stopping the machine............................178
			Preparations for moving the machine........................................................178
			Changing gear speed........................................................................181
			Changing direction.........................................................................182
			Using switch to change between forward and reverse.........................................184
			Stopping the machine.......................................................................186
			Transmission cut-off function..............................................................187
		3.3.7 Turning..................................................................................189
			Emergency steering.........................................................................190
		3.3.8 Operation of work equipment..............................................................192
			Lift arm operation.........................................................................193
			Bucket operation...........................................................................193
		3.3.9 Work possible using wheel loader.........................................................194
			Digging operations.........................................................................194
			Leveling operation.........................................................................198
			Pushing operation..........................................................................198
			Load and carry operations..................................................................199
			Loading operations.........................................................................199
		3.3.10 Precautions for operation...............................................................201
			Permissible water depth....................................................................201
			If wheel brake does not work...............................................................201
			Precautions when driving up or down slopes.................................................201
		3.3.11 Adjusting work equipment posture........................................................203
			Adjusting boom kickout.....................................................................204
			Adjusting bucket positioner................................................................204
			Bucket level indicator.....................................................................205
		3.3.12 Parking machine.........................................................................205
		3.3.13 Checks after completion of operation....................................................207
			Before stopping engine.....................................................................207
			After stopping engine......................................................................207
		3.3.14 Locking.................................................................................208
		3.3.15 Handling the tires......................................................................209
			Precautions when handling tires............................................................209
			Tire pressure..............................................................................209
			Precautions for using load and carry method................................................211
	3.4 Transportation.................................................................................212
		3.4.1 Transportation procedure.................................................................212
		3.4.2 Loading, unloading work with trailers....................................................212
			Loading....................................................................................213
			Securing machine...........................................................................213
			Unloading..................................................................................215
		3.4.3 Lifting machine..........................................................................216
			Location of lifting position mark..........................................................217
			Weight table...............................................................................217
			Lifting procedure..........................................................................218
	3.5 Cold weather operation.........................................................................219
		3.5.1 Precautions for low temperature..........................................................219
			Fuel and lubricants........................................................................219
			Coolant....................................................................................219
			Battery....................................................................................220
		3.5.2 Precautions after completion of work.....................................................221
		3.5.3 After cold weather.......................................................................221
		3.5.4 Warming-up operation for steering hydraulic circuit in cold weather......................222
	3.6 Long-term storage..............................................................................223
		3.6.1 Before storage...........................................................................223
		3.6.2 During storage...........................................................................223
		3.6.3 After storage............................................................................224
	3.7 Troubleshooting................................................................................225
		3.7.1 When machine runs out of fuel............................................................225
		3.7.2 Towing the machine.......................................................................225
			When engine can be used....................................................................227
			When engine cannot be used.................................................................227
			Releasing parking brake....................................................................228
			Emergency travel operation.................................................................230
		3.7.3 If battery is discharged.................................................................231
			Removal and installation of battery........................................................232
			Precautions for charging battery...........................................................233
			Starting engine with booster cable.........................................................234
		3.7.4 Other trouble............................................................................236
			Electrical system..........................................................................236
			Chassis....................................................................................237
			Engine.....................................................................................239
4. Maintenance.........................................................................................241
	4.1 Guides to maintenance..........................................................................242
	4.2 Outlines of service............................................................................246
		4.2.1 Handling oil, fuel, coolant, grease and carrying out KOWA (KOMATSU Oil Wear Analysis)....247
			Oil........................................................................................247
			Fuel.......................................................................................248
			Coolant and water for dilution.............................................................249
			Grease.....................................................................................250
			Carrying out KOWA (KOMATSU Oil Wear Analysis)..............................................250
			Storing oil and fuel.......................................................................252
			Filters....................................................................................252
		4.2.2 Outline of electric system...............................................................253
	4.3 Wear parts.....................................................................................254
		4.3.1 Wear parts list..........................................................................254
	4.4 Fuel, coolant and lubricants...................................................................256
		4.4.1 Lubrication chart........................................................................258
		4.4.2 Use of fuel, coolant and lubricants according to ambient temperature.....................259
		4.4.3 Recommended brands, recommended quality for products other than KOMATSU genuine oil......262
	4.5 Standard tightening torques for bolts and nuts.................................................263
		4.5.1 Torque list..............................................................................263
	4.6 Periodic replacement of safety critical parts..................................................265
	4.7 Maintenance schedule chart.....................................................................267
		4.7.1 Maintenance schedule chart...............................................................267
	4.8 Replace injector assembly......................................................................270
	4.9 Service procedure..............................................................................271
		4.9.1 Initial 50 hours service (only after the first 50 hours).................................271
			Check for loose wheel hub bolts, tighten...................................................271
		4.9.2 Initial 250 hours service (only after the first 250 hours)...............................271
			Replace transmission oil filter cartridge..................................................271
			Replace hydraulic tank filter element......................................................271
		4.9.3 Initial 1000 hours service (only after the first 1000 hours).............................271
			Check engine valve clearance, adjust.......................................................271
		4.9.4 When required............................................................................272
			Clean, replace air cleaner element.........................................................272
			Clean inside of cooling system.............................................................275
			Check transmission oil level, add oil......................................................279
			Check axle oil level, add oil..............................................................280
			Clean axle case breather...................................................................281
			Clean air conditioner condenser............................................................282
			Check window washing fluid level, add fluid................................................282
			Clean radiator fins and cooler fins........................................................283
			Check electrical intake air heater.........................................................286
			Turn, replace bolt on cutting edge.........................................................287
			Replace bucket teeth.......................................................................288
			Check air conditioner......................................................................290
			Replace slow blow fuse.....................................................................291
			Checking function of accumulator...........................................................292
			Selection and inspection of tires..........................................................293
		4.9.5 Check before starting....................................................................295
			Check before starting......................................................................295
		4.9.6 Every 50 hours service...................................................................295
			Drain water, sediment from fuel tank.......................................................295
		4.9.7 Every 100 hours service..................................................................296
			Lubricate rear axle pivot pin..............................................................296
			Check oil level in hydraulic tank, add oil.................................................296
			Clean element in air conditioner fresh air filter..........................................297
		4.9.8 Every 250 hours service..................................................................298
			Check battery electrolyte level............................................................298
			Check parking brake........................................................................301
			Check air conditioner compressor belt tension, adjust......................................301
			Check for loose wheel hub bolts, tighten...................................................302
			Clean element in air conditioner recirculation filter......................................303
			Checking function of accumulator...........................................................304
			Lubricating................................................................................305
		4.9.9 Every 500 hours service..................................................................306
			Change oil in engine oil pan, replace engine oil filter cartridge..........................306
			Replace fuel pre-filter cartridge..........................................................308
		4.9.10 Every 1000 hours service................................................................311
			Replace fuel filter cartridge..............................................................311
			Change oil in transmission case and transmission oil filter cartridge, clean strainer......313
			Clean transmission case breather...........................................................314
			Lubricating................................................................................314
			Check tightening parts of turbocharger.....................................................315
			Check alternator driving belt tension and replacement......................................315
			Replace corrosion resistor cartridge.......................................................315
		4.9.11 Every 2000 hours service................................................................316
			Change oil in hydraulic tank, replace hydraulic filter element.............................316
			Replace hydraulic tank breather element....................................................319
			Change axle oil............................................................................320
			Replace element in air conditioner recirculation air filter, fresh air filter..............321
			Check brake disc wear......................................................................321
			Checking function of accumulator...........................................................323
			Check alternator, starting motor...........................................................324
			Check engine valve clearance, adjust.......................................................324
			Check vibration damper.....................................................................324
		4.9.12 Every 4000 hours service................................................................325
			Lubricating................................................................................325
			Check water pump...........................................................................326
			Check air conditioner compressor, adjust...................................................326
			Checking for looseness of high-pressure clamp, hardening of rubber.........................327
			Checking for missing fuel spray prevention cap, hardening of rubber........................328
		4.9.13 Every 8000 hours service................................................................329
			Replace high-pressure piping clamp.........................................................329
			Replace injector nozzle tip................................................................329
5. Technical Data......................................................................................331
	5.1 Technical data.................................................................................332
	5.2 Noise emission levels..........................................................................334
	5.3 Vibration level................................................................................335
		Guide to reduce vibration levels on machine....................................................335
	5.4 Limit values for slopes........................................................................337
6. Attachments, Options................................................................................339
	6.1 Selecting bucket and tires.....................................................................340
	6.2 Handling torque converter lock-up..............................................................341
		6.2.1 General locations........................................................................342
		6.2.2 Method of operation......................................................................344
		6.2.3 Warning/limit functions for travel speed.................................................345
			Travel speed warning function..............................................................345
			Travel speed limit function................................................................345
	6.3 Handling machines equipped with KOMTRAX........................................................346
		6.3.1 Basic precautions........................................................................347
	6.4 Joystick steering system.......................................................................348
		6.4.1 Components...............................................................................348
		6.4.2 Structure and function...................................................................351
			Operation using joystick lever and operation using steering wheel..........................352
			Getting in or out..........................................................................353
			Adjustment of joystick console.............................................................354
		6.4.3 Operation method of joystick steering system.............................................355
	6.5 Multi-function lever (with/without auxiliary control lever)....................................358
		6.5.1 Explanation of components................................................................358
		6.5.2 Operation................................................................................363
			Using switch to change between forward and reverse.........................................363
	6.6 3-lever control................................................................................365
		6.6.1 Explanation of components................................................................365
	6.7 Hydraulic quick coupler........................................................................368
		6.7.1 Installing the attachment................................................................368
		6.7.2 Removal and installation of the attachment...............................................371
		6.7.3 Precautions for use......................................................................371
		6.7.4 Precautions when removing the attachment.................................................371
	6.8 Central lubrication system.....................................................................372
		6.8.1 Operating the central lubrication system.................................................372
		6.8.2 Display and control unit.................................................................372
			LED-display................................................................................373
			Pushbuttons................................................................................373
		6.8.3 Changing the lubrication interval times..................................................374
7. Index...............................................................................................375
	7.1 Index..........................................................................................376
8. Notes...............................................................................................381

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KOMATSU WA380-6H WHEEL LOADER OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:

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