Komatsu WA380-5 Manual

WHEEL LOADER
TEN00089-03
WA380
-5
SERIAL NUMBERS
60001
and up
Komatsu has Operation & Maintenance Manuals
written in some other languages. If a foreign language
manual is necessary, contact your local distributor for
availability.
NOTICE
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this machine.
This manual should be kept near the machine for
reference and periodically reviewed by all personnel who
will come into contact with it.
WARNING

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FOREWORD
FOREWORD
FOREWORD
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.
WARNING
Before beginning operation or maintenance, operators and maintenance personnel must always observe the following points.
Read this manual thoroughly and understand its contents fully.
Read the safety messages and safety labels given in this manual carefully so that they should be understood fully.
Keep this manual at the storage location for the Operation and Maintenance Manual given below so that all personnel involved
in working on the machine can consult it periodically.
In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu distributor to obtain a new copy.
When you sell the machine, make sure that this manual should be provided to the new owner together with the machine.
In this manual, measurements are expressed in international standard units (SI). For the reference purpose, weight units used in
the past are also displayed in ( ).
Storage location for the Operation and Maintenance Manual:
Pocket (1) at rear of operator's seat
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FOREWORD
SAFETY INFORMATION
SAFETY INFORMATION
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such
situations.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to
personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. This word is used also to alert against unsafe practices that may cause
property damage.
Example of safety message using signal word
WARNING
When standing up from the operator's seat, always place the work equipment lock lever in the LOCK position.
If you accidentally touch the control levers when they are not locked, this may cause a serious injury or death.
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to
protect the machine or to give information that is useful to know.
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
This word is used for information that is useful to know.
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FOREWORD
SAFETY INFORMATION
Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying out
operation or maintenance of the machine that may involve hazard.
This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures.
Example of safety label using words
Safety labels using pictogram
Safety pictograms use a picture to express a level of hazardous
condition equivalent to the signal word. These safety pictograms
use pictures in order to let the operator or maintenance worker
understand the level and type of hazardous condition at all times.
Safety pictograms show the type of hazardous condition at the top
or left side, and the method of avoiding the hazardous condition at
the bottom or right side. In addition, the type of hazardous condition
is displayed inside a triangle and the method of avoiding the
hazardous condition is shown inside a circle.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsibility
to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your
machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1J(1))
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FOREWORD
INTRODUCTION
INTRODUCTION
This Komatsu machine is designed to be used mainly for the following work:
Digging work
Smoothing
Pushing work
Loading work
For details of the operating procedure, see "WORK POSSIBLE USING WHEEL LOADER (PAGE 3-127)".
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE
In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from the
operator's seat in the direction of travel (front) of the machine.
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FOREWORD
NECESSARY INFORMATION
NECESSARY INFORMATION
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE
On the center right of the front frame.
The design of the nameplate differs according to the territory.
ENGINE SERIAL NO. PLATE
This name plate is affixed on the oil cooler at the side of engine cylinder block on the left side of machine.
EPA: Environmental Protection Agency, U.S.A.
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FOREWORD
NECESSARY INFORMATION
POSITION OF SERVICE METER
It is at the center bottom of the machine monitor.
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
Machine serial No.
Engine serial No.
Product identification number (PIN)
Distributor name
Address
Service Personnel
Phone/Fax
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FOREWORD
CONTENTS
CONTENTS
FOREWORD 1- 1
FOREWORD 1- 2
SAFETY INFORMATION 1- 3
INTRODUCTION 1- 5
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 1- 5
NECESSARY INFORMATION 1- 6
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1- 6
ENGINE SERIAL NO. PLATE 1- 6
POSITION OF SERVICE METER 1- 7
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 7
SAFETY 2- 1
SAFETY 2- 2
SAFETY LABELS 2- 5
LOCATION OF SAFETY LABELS 2- 5
SAFETY LABELS 2- 6
GENERAL PRECAUTIONS 2- 11
PRECAUTIONS FOR OPERATION 2- 20
STARTING ENGINE 2- 20
OPERATION 2- 22
TRANSPORTATION 2- 28
BATTERY 2- 29
TOWING 2- 31
PRECAUTIONS FOR MAINTENANCE 2- 32
PRECAUTIONS WITH TIRES 2- 39
OPERATION 3- 1
GENERAL VIEW 3- 2
GENERAL VIEW OF MACHINE 3- 2
GENERAL VIEW OF CONTROLS AND GAUGES 3- 3
EXPLANATION OF COMPONENTS 3- 6
MACHINE MONITOR 3- 6
SWITCHES 3- 36
CONTROL LEVERS, PEDALS 3- 50
STEERING TILT LOCK LEVER 3- 55
CAP WITH LOCK 3- 56
FRAME LOCK BAR 3- 58
TOWING PIN 3- 58
GREASE PUMP 3- 59
CAB DOOR OPEN LOCK 3- 59
CAB WINDOW OPEN LOCK CANCEL KNOB 3- 59
FUSE 3- 60
SLOW BLOW FUSE 3- 61
POWER OUTLET 3- 62
AM/FM RADIO 3- 63
AM/FM RADIO-CASSETTE STEREO 3- 69
AIR CONDITIONER 3- 77
HANDLING AUTO AIR CONDITIONER 3- 82
HANDLING CAB WIPER 3- 89
OPERATION 3- 90
CHECK BEFORE STARTING ENGINE, ADJUST 3- 90
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FOREWORD
CONTENTS
STARTING ENGINE 3-106
OPERATIONS AND CHECKS AFTER STARTING ENGINE 3-110
STOPPING ENGINE 3-112
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE 3-113
TURNING 3-123
OPERATION OF WORK EQUIPMENT 3-125
WORK POSSIBLE USING WHEEL LOADER 3-127
PRECAUTIONS FOR OPERATION 3-133
ADJUSTING WORK EQUIPMENT POSTURE 3-135
PARKING MACHINE 3-137
CHECKS AFTER COMPLETION OF OPERATION 3-139
LOCKING 3-139
HANDLING THE TIRES 3-140
TRANSPORTATION 3-142
TRANSPORTATION PROCEDURE 3-142
LOADING, UNLOADING WORK WITH TRAILERS 3-142
LIFTING MACHINE 3-146
COLD WEATHER OPERATION 3-148
PRECAUTIONS FOR LOW TEMPERATURE 3-148
PRECAUTIONS AFTER COMPLETION OF WORK 3-149
AFTER COLD WEATHER 3-149
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER 3-150
LONG-TERM STORAGE 3-151
BEFORE STORAGE 3-151
DURING STORAGE 3-151
AFTER STORAGE 3-151
TROUBLESHOOTING 3-152
WHEN MACHINE RUNS OUT OF FUEL 3-152
METHOD OF TOWING MACHINE 3-153
IF BATTERY IS DISCHARGED 3-158
OTHER TROUBLE 3-161
MAINTENANCE 4- 1
GUIDES TO MAINTENANCE 4- 2
OUTLINES OF SERVICE 4- 4
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 4
OUTLINE OF ELECTRIC SYSTEM 4- 7
WEAR PARTS 4- 8
WEAR PARTS LIST 4- 8
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 9
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 10
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN
KOMATSU GENUINE OIL 4- 11
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 12
TORQUE LIST 4- 12
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4- 13
MAINTENANCE SCHEDULE CHART 4- 14
MAINTENANCE SCHEDULE CHART 4- 14
SERVICE PROCEDURE 4- 16
INITIAL 250 HOURS SERVICE 4- 16
INITIAL 1000 HOURS SERVICE 4- 16
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FOREWORD
CONTENTS
WHEN REQUIRED 4- 17
CHECK BEFORE STARTING 4- 41
EVERY 50 HOURS SERVICE 4- 42
EVERY 100 HOURS SERVICE 4- 43
EVERY 250 HOURS SERVICE 4- 45
EVERY 500 HOURS SERVICE 4- 51
EVERY 1000 HOURS SERVICE 4- 53
EVERY 2000 HOURS SERVICE 4- 56
EVERY 4000 HOURS SERVICE 4- 64
EVERY 8000 HOURS SERVICE 4- 66
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS, OPTIONS 6- 1
SELECTING BUCKET AND TIRES 6- 2
HANDLING LOAD METER 6- 3
GENERAL LOCATIONS 6- 3
LOAD METER FUNCTIONS 6- 5
HANDLING LOAD METER DISPLAY 6- 8
METHOD OF SETTING TIME ON CLOCK 6- 23
PRINTER OUTPUT 6- 25
HANDLING TORQUE CONVERTER LOCK-UP 6- 28
GENERAL LOCATIONS 6- 28
METHOD OF OPERATION 6- 29
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED 6- 30
HANDLING AUTO-GREASING SYSTEM 6- 31
METHOD OF OPERATING AUTO-GREASING SYSTEM 6- 31
PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM 6- 37
TROUBLESHOOTING 6- 37
HANDLING JOYSTICK STEERING SYSTEM 6- 38
EXPLANATION OF COMPONENTS 6- 38
STRUCTURE AND FUNCTION OF JOYSTICK STEERING 6- 40
GETTING IN OR OUT OF OPERATOR'S CAB 6- 42
ADJUSTMENT OF JOYSTICK CONSOLE 6- 42
OPERATION METHOD OF JOYSTICK STEERING SYSTEM 6- 43
HANDLING EPC WORK EQUIPMENT LEVER 6- 46
OPERATIONAL FEATURES 6- 46
SWITCHES 6- 46
SEMI AUTO DIGGING OPERATIONS 6- 47
METHOD OF REMOTE POSITIONER 6- 49
HANDLING MULTI-FUNCTION LEVER 6- 51
EXPLANATION OF COMPONENTS 6- 51
USING FNR SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE 6- 55
INDEX 7- 1
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SAFETY
SAFETY
SAFETY
SAFETY LABELS 2- 5
LOCATION OF SAFETY LABELS 2- 5
SAFETY LABELS 2- 6
GENERAL PRECAUTION
SAFETY RULES 2- 11
IF ABNORMALITIES ARE FOUND 2- 11
CLOTHING AND PERSONAL PROTECTIVE ITEMS 2- 11
FIRE EXTINGUISHER AND FIRST AID KIT 2- 11
SAFETY FEATURES 2- 11
KEEP MACHINE CLEAN 2- 12
INSIDE OPERATOR'S COMPARTMENT 2- 12
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT 2- 12
HANDRAILS AND STEPS 2- 13
MOUNTING AND DISMOUNTING 2- 14
NO PEOPLE ON ATTACHMENTS 2- 14
DO NOT GET CAUGHT IN ARTICULATED PORTION 2- 14
PREVENTION OF BURNS 2- 14
FIRE PREVENTION 2- 15
ACTION IF FIRE OCCURS 2- 16
WINDOW WASHER LIQUID 2- 16
PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure) 2- 16
PRECAUTIONS FOR ATTACHMENTS, OPTIONS 2- 16
UNAUTHORIZED MODIFICATION 2- 16
SAFETY AT WORKSITE 2- 17
WORKING ON LOOSE GROUND 2- 17
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 2- 18
ENSURE GOOD VISIBILITY 2- 18
VENTILATION FOR ENCLOSED AREAS 2- 18
CHECKING SIGNALMAN'S SIGNALS AND SIGNS 2- 19
EMERGENCY EXIT FROM OPERATOR'S CAB 2- 19
BE CAREFUL ABOUT ASBESTOS DUST 2- 19
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SAFETY
SAFETY
PRECAUTIONS FOR OPERATION 2- 20
STARTING ENGINE 2- 20
CHECKS BEFORE STARTING ENGINE 2- 20
PRECAUTIONS WHEN STARTING 2- 20
PRECAUTIONS IN COLD AREAS 2- 21
OPERATION 2- 22
CHECKS BEFORE OPERATION 2- 22
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE 2- 22
PRECAUTIONS WHEN TRAVELING 2- 23
TRAVELING ON SLOPES 2- 24
PROHIBITED OPERATIONS 2- 25
PRECAUTIONS WHEN OPERATING 2- 25
METHODS OF USING BRAKE 2- 26
OPERATE CAREFULLY ON SNOW 2- 26
PARKING MACHINE 2- 27
TRANSPORTATION 2- 28
LOADING AND UNLOADING 2- 28
SHIPPING 2- 28
BATTERY 2- 29
BATTERY HAZARD PREVENTION 2- 29
STARTING WITH BOOSTER CABLES 2- 30
TOWING 2- 31
WHEN TOWING 2- 31
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SAFETY
SAFETY
PRECAUTIONS FOR MAINTENANCE 2- 32
WARNING TAG 2- 32
KEEP WORK PLACE CLEAN AND TIDY 2- 32
APPOINT LEADER WHEN WORKING WITH OTHERS 2- 32
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE 2- 33
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING 2- 34
INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF 2- 34
PROPER TOOLS 2- 35
ACCUMULATOR 2- 35
PERSONNEL 2- 35
ATTACHMENTS 2- 35
WORK UNDER THE MACHINE 2- 36
NOISE 2- 36
PRECAUTIONS WHEN USING HAMMER 2- 36
REPAIR WELDING 2- 36
REMOVING BATTERY TERMINAL 2- 36
PRECAUTIONS WITH HIGH-PRESSURE OIL 2- 37
HANDLING HIGH-PRESSURE HOSES 2- 37
WASTE MATERIALS 2- 37
MAINTENANCE OF AIR CONDITIONER 2- 37
COMPRESSED AIR 2- 38
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 2- 38
PRECAUTIONS WITH TIRES 2- 39
HANDLING TIRES 2- 39
PRECAUTIONS WHEN STORING TIRES 2- 39
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SAFETY
SAFETY LABELS
SAFETY LABELS
The following safety labels are used on this machine. Be sure that you fully understand the correct position and
content of these safety labels.
To ensure that the content of these safety labels can be read properly, be sure that they are in the correct place and
always keep them clean. When cleaning them, use soap and water. Do not use organic solvents or gasoline.
These may cause the safety labels to peel off.
If the safety labels are damaged or lost, or cannot be read, replace them with new parts. For details of the part
numbers, see this manual or check on the actual part, and order the new part from your Komatsu distributor.
There are also other labels in addition to the safety labels. Handle these labels in the same way.
LOCATION OF SAFETY LABELS
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SAFETY
SAFETY LABELS
SAFETY LABELS
(1) Caution before starting (09651-03001)
(2) Caution for leaving the operator's seat (09654-03001)
(3) Caution when traveling in reverse
Please request part No. 421-93-23251 for this safety label.
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SAFETY
SAFETY LABELS
SAFETY
SAFETY LABELS
(4) Caution for going close to electric cables (09801-13001)
(5) Caution to keep away from movable parts (09162-23000)
(6) Caution for frame lock bar (09161-23000)
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SAFETY
SAFETY LABELS
SAFETY
SAFETY LABELS
(7) Caution for parking brake (421-93-23351)
(8) Warning for hot cooling water (09668-03001)
(9) Caution when oil is at high temperature (09653-03001)
(10) Caution when handling battery cable (09808-03000)
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SAFETY
SAFETY LABELS
SAFETY
SAFETY LABELS
(11) High pressure warning (09659-53000)
(12) Do not climb on fender (09805-03000)
(Machines with equipped with rear full fender)
(13) "Do not open when engine is running" sign
(09667-03001)
(14) "Do not come near machine" sign (09812-13000)
(15) "Do not go under work equipment" sign (09807-C0883)
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