KOMATSU WA380-5L Wheel Loader Operation & Maintenance Manual

June 2005 Copyright 2005 Komatsu Published in USA Komatsu America Corp. CEAM009301 Operation and Maintenance Manual WA380-5L WHEEL LOADER This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision. SERIAL NUMBERS WA380-5L A52001 and UP

PUB INFO PAGE.fm 6/23/05 PRODUCT PUBLICATIONS INFORMATION Various product Parts and Service Publications are available to all KOMATSU construction equipment owners, including operation and maintenance manuals, parts books and service manuals. Special publications, such as service tool, air conditioning and turbocharger service manuals are also available as well as selected Operation and Service manuals in foreign languages. The Publications listed below are available for this particular machine(s). DESCRIPTION FORM NUMBER PARTS BOOK - PAPER: Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB020701 OPERATION AND MAINTENANCE MANUAL: Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEAM009301 SHOP MANUAL Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM009702 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SEBM024208 SAFETY MANUAL Machine Specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WLT03-04 Parts and Service Publications can only be acquired by authorized KOMATSU distributors using the Komatsu America Corp. Extranet Literature Ordering System. If the Extranet Literature Ordering System is not available at the distributor location, then the following Requisition for Technical Service Publications and Service Forms can be used. Form KDC91E is shown on the reverse side of this page. Komatsu America Corp. reserves the right to add a surcharge to all fax orders.

REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE SERIAL NUMBER MUST BE SHOWN. KDC91E 071403 CURRENT PRICES WILL BE CHARGED COMPLETE FORM AND RETURN TO DataKom Publications and Training Division 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. Attn: Service Publications Fax No. (847) 970-4186 Tel No. (847) 970-5887 SHIP TO COMPANY NAME PURCHASE ORDER NO. TYPE or PRINT ONLY ATTN. STREET ADDRESS ORDER DATE CITY, STATE, ZIP CODE COUNTRY PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE QTY. PUBLICATION FORM NO. PARTS BOOK PUBLICATION DESCRIPTION MODEL NUMBER SERIAL NUMBER ➥ P-Paper M-Microfiche

CEKQ000600 - Komatsu America International Company 12/99 EMISSION CONTROL WARRANTY EMISSION CONTROL WARRANTY STATEMENT (APPLIES TO CANADA ONLY) 1. Products Warranted Komatsu America International Company, Komatsu Mining Systems Inc. and Komatsu Utility Corporation (collectively “Komatsu”) produce and/or market products under brand names of Komatsu, Dresser, Dressta, Haulpak and Galion. This emissions warranty applies to new engines bearing the Komatsu name installed in these products and used in Canada in machines designed for industrial off-highway use. This warranty applies only to these engines produced on or after January 1, 2000. This warranty will be administered by Komatsu distribution in Canada. 2. Coverage Komatsu warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built and equipped so as to conform, at the time of sale by Komatsu, with all U.S. Federal emission regulations applicable at the time of manufacture and that it is free from defects in workmanship or material which would cause it not to meet these regulations within five years or 3,000 hours of operation, whichever occurs first, as measured from the date of delivery of the engine to the ultimate purchaser. 3. Limitations Failures, other than those resulting from defects in materials or workmanship, are not covered by this warranty. Komatsu is not responsible for failures or damage resulting from what Komatsu determines to be abuse or neglect, including, but not limited to: operation without adequate coolant or lubricants; over fueling; over speeding; lack of maintenance of lubricating, cooling or intake systems; improper storage, starting, warm-up, run-in or shutdown practices; unauthorized modifications of the engine. Komatsu is also not responsible for failures caused by incorrect fuel or by water, dirt or other contaminants in the fuel. Komatsu is not responsible for non-engine repairs, “downtime” expense, related damage, fines, all business costs or other losses resulting from a warrantable failure. KOMATSU IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. This warranty, together with the express commercial warranties, are the sole warranties of Komatsu. THERE ARE NO OTHER WARRANTIES, EXPRESS OR IMPLIED, OR OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS ÉNONCÉ DE GARANTIE SUR LE CONTRÔLE DES ÉMISSIONS (APPLICABLE AU CANADA SEULEMENT) : 1. Produits garantis: Komatsu America International Company, Komatsu Mining Systems Inc. et Komatsu Utility Corporation (collectivement Komatsu) produisent et/ou font la mise en marché de produits portant les noms de marque Komatsu, Dresser, Dressta, Haulpak et Galion. Cette garantie sur les émissions s’applique à tous les nouveaux moteurs portant le nom Komatsu, installés dans ces produits et utilisés au Canada dans des machines conçues pour utilisation industrielle non- routière. Cette garantie s’applique seulement sur les moteurs produits à partir du 1er Janvier 2000. Cette garantie sera administrée par la distribution de Komatsu au Canada . 2. Couverture: Komatsu garantit à l’acheteur ultime et chaque acheteur subséquent que le moteur est conçu, construit et équipé en toute conformité, au moment de la vente par Komatsu, avec toutes les Réglementations fédérales américaines sur les émissions applicables au moment de la fabrication et qu’il est exempt de défauts de construction ou de matériaux qui auraient pour effet de contrevenir à ces réglementations en dedans de 5 ans ou 3000 heures d’opération, mesuré à partir de la date de livraison du moteur au client ultime. 3. Limitations: Les bris, autres que ceux résultant de défauts de matériaux ou de construction, ne sont pas couverts par cette Garantie. Komatsu n’est pas responsable pour bris ou dommages résultant de ce que Komatsu détermine comme étant de l’abus ou négligence, incluant mais ne se limitant pas à: l’opération sans lubrifiants ou agent refroidissants adéquats; la suralimentation d’essence; la survitesse; le manque d’entretien des systèmes de lubrification, de refroidissement ou d’entrée; de pratiques non-propices d’entreposage, de mise en marche, de réchauffement, de conditionnement ou d’arrêt; les modifications non-autorisées du moteur. De plus, Komatsu n’est pas responsable de bris causés par de l’essence inadéquate ou de l’eau, des saletés ou autres contaminants dans l’essence. Komatsu n’est pas responsable des réparations non-reliées au moteur, des dépenses encourues suite aux temps d’arrêts, des dommages relatifs, amendes, et de tout autre coût d’affaires ou autres pertes résultant d’un bris couvert par la garantie. KOMATSU N’EST PAS RESPONSABLE DES INCIDENTS OU DOMMAGES CONSÉQUENTS. Cette garantie, ainsi que les garanties expresses commerciales, sont les seules garanties de Komatsu. IL N’Y A AUCUNE AUTRE GARANTIE, EXPRESSE OU SOUS -ENTENDUE, MARCHANDABLE OU PROPICE A UNE UTILISATION PARTICULIÈRE.

INFORMATION IMPORTANTE SUR LE MOTEUR CE MOTEUR EST CONFORME AUX NORMES AMÉRICAINES DE L’EPA (ANNÉE DU MODÈLE) ET DE LA CALIFORNIE POUR LES MOTEURS LARGES NON-ROUTIERS A IGNI- TION PAR COMPRESSION. CE MOTEUR EST CERTIFIÉ POUR OPERATION À ESSENCE DIÉSEL. AVERTISSEMENT DES BLESSURES PEUVENT RÉSULTER ET LA GARANTIE S’ANNULER SI LES RPM DU TAUX D’ESSENCE OU L’ALTITUDE EXCÈDENT LES VALEURS MAXIMALES PUBLIÉES POUR CE MODÈLE ET SON APPLICATION. IMPORTANT ENGINE INFORMATION THIS ENGINE CONFORMS TO YYYY MODEL YEAR U.S. EPA REGULATION AND THE CALIFORNIA REGULATIONS LARGE NON ROAD COMPRESSION IGNITION ENGINES. THIS ENGINE IS CERTI- FIED TO OPERATE ON DIESEL FUEL. MODÈLE DU MOTEUR WARNING INJURY MAY RESULT AND WARRANTY IS VOIDED IF FUEL RATE RPM OR ALTITUDES EXCEED PUBLISHED MAXIMUM VALUES FOR THIS MODEL AND APPLICATION. NO. SÉRIE FAMILLE DU MOTEUR ENGINE MODEL SERIAL NO. DÉPLACEMENT SYSTÈME DE CONTROLE DES ÉMISSIONS D’ÉCHAPPEMENT ENGINE FAMILY DISPLACEMENT LITERS EXHAUST EMISSION CONTROL SYSTEM FIRING ORDER 1 - 5 - 3 - 6 - 2 - 4 LITRES CHARGE DE SORTIE ADV. ADV. LOAD OUTPUT Kw ( HP) RPM SÉQUENCE DE MISE À FEU PORTÉE DE VALVE À FROID (mm) VALVE LASH COLD (mm) IN. EX. FUEL RATE AT ADV. mm 3 /STROKE mm 3 /BATTEMENT TAUX D’ESSENCE À ADV. VITESSE STATIQUE IDLE SPEED RPM FAMILY EMISSION LIMIT INITIAL INJECTION TIMING DEG. BTDC DATE OF MANUFACTURE LIMITE D’ÉMISSION DE LA FAMILLE RÉGLAGE DE L’ALLUMAGE - INJECTION INITIALE _____________________________________________ KOMATSU LTD. MADE IN JAPAN DATE DE FABRICATION DEG. BTDC KOMATSU LTÉE FABRIQUÉ AU JAPON ENGINE DATAPLATE - ENGLISH / FRENCH

0-1 0INTRODUCTION WA380-5L

INTRODUCTION 0-2 WA380-5L FOREWORD This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel achieve 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, damaged 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, which may not be reflected in this manual. Consult your local KOMATSU distributor or for the latest available information on your machine or for questions regarding information in this manual. This manual may contain attachments and optional equipment that are not available in your area. Consult your local KOMATSU Distributor or for those items that you may require. Improper operation and maintenance of this machine can be hazardous and could result in serious injury or death. • Operators and maintenance personnel must read this manual thoroughly before operating or maintaining this machine. • This manual should be kept near or with the machine for reference and periodically reviewed by all personnel who operate it. • Some actions involved in operation and maintenance can cause a serious accident, if they are not performed in the manner described in this manual. • The procedures and precautions given in this manual apply only to the intended uses of this machine. If you use your machine for any unintended uses that are not specifically prohibited, you must be sure that it is safe for you and others. In no event should you or others engage in prohibited uses or actions as described in this manual. • KOMATSU delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety features and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult your local distributor or KOMATSU before operating the machine. • The safety description is given in SAFETY INFORMATION and in the SAFETY section 1 ★

INTRODUCTION WA380-5L 0-3 ❉ Storage location for Operation and Maintenance Manual is in the pocket (1) at rear of operators seat back rest.

INTRODUCTION 0-4 WA380-5L SAFETY INFORMATION Most accidents are caused by failure to follow fundamental safety rules for the operation and maintenance of the machine. To avoid accidents, read, understand and follow all precautions and warnings in this manual and on the machine before performing maintenance and machine operations. To identify safety messages in this manual and on machine product graphics, the following signal words are used: DANGER! - This word is used on safety messages and product graphics where there is a high probability of serious injury or death if the hazard is not avoided. These safety messages and product graphics usually describe precautions that must be taken to avoid the hazard. Failure to avoid this hazard may result in serious damage to the machine, injury or even death. WARNING! - This word is used on safety messages and product graphics where there is a potentially dangerous situation, which could result in serious injury or possibly death if the hazard is not avoided. These safety messages and product graphics usually describe precautions that must be taken to avoid the hazard. Failure to avoid this hazard may result in serious damage to the machine or possible injury. CAUTION! - This word is used on safety messages and product graphics for hazards, which could result in minor or moderate injury if the hazard is not avoided. These safety messages and product graphics might also use this word for hazards where the only result could be damage to the machine. Remark This word is used for precautions that must be taken to avoid actions, which could shorten the life or damage the machine. Safety precautions are described in SAFETY section (1-1) KOMATSU cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety message 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, you must be sure that you and others can do such procedures and actions safely and without damaging the machine or causing injury. If you are unsure about the safety of some procedures, contact your local KOMATSU Distributor.

KOMATSU WA380-5L Wheel Loader Operation & Maintenance Manual

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