WA380-3MC
WHEELLOADER
MACHINEMODELSERIALNUMBERS
WA380-3MCA51001andup
ThismaterialisproprietarytoKomatsuAmericaInternationalCompanyandisnottobereproduced,used,ordisclosed exceptinaccordancewithwrittenauthorizationfromKomatsuAmericaInternationalCompany.
Itisourpolicytoimproveourproductswheneveritispossibleandpracticaltodoso.Wereservetherighttomake changesoraddimprovementsatanytimewithoutincurringanyobligationtoinstallsuchchangesonproductssold previously.
Duetothiscontinuousprogramofresearchanddevelopment,periodicrevisionsmaybemadetothispublication.Itis recommendedthatcustomerscontacttheirdistributorforinformationonthelatestrevision.
Theaffectedpagesareindicatedbyusingthefollowing marks.Itisrequestedthatnecessaryactionsbetakento thesepagesaccordingtothetablebelow.
Pageswithoutmarkswerepreviousadditionsorrevised pages.
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PRODUCTPUBLICATIONSINFORMATION
VARIOUSPRODUCTPARTS&SERVICEPUBLICATIONSAREAVAILABLETOALLKOMATSUCONSTRUCTIONEQUIPMENT OWNERS,INCLUDINGOPERATION&MAINTENANCEMANUALS,PARTSBOOKSANDSHOPMANUALS.
SPECIALPUBLICATIONSSUCHASSERVICETOOL,AIRCONDITIONING,ANDTURBOCHARGERSHOPMANUALSARE ALSOAVAILABLEASWELLASSELECTEDOPERATION&MAINTENANCEANDSHOPMANUALSINFOREIGNLANGUAGES.
THEPUBLICATIONSLISTEDBELOWAREAVAILABLEFORTHISPARTICULARMACHINE(S).
PARTSBOOK-PAPER:
andChassis...........................................................BEPB005500
PARTSBOOK-MICROFICHE:
OPERATION&MAINTENANCEMANUAL:
PARTSANDSERVICEPUBLICATIONSCANONLYBEACQUIREDBYAUTHORIZEDKOMATSUDISTRIBUTORS,USING THEKOMATSUAMERICAINTERNATIONALCOMPANYPARTSINFORMATIONPROCESSINGSYSTEM(PIPS).
IFTHEPIPSSYSTEMISNOTAVAILABLEATTHEDISTRIBUTORLOCATION,THENTHEFOLLOWINGREQUISITIONFOR TECHNICALSERVICEPUBLICATIONSANDSERVICEFORMSCANBEUSED.FORMKDC91DISSHOWNONTHEREVERSE SIDEOFTHISPAGE.
COMPLETEFORM ANDRETURNTO•KomatsuAmericaInternationalCompany
440NorthFairwayDrive
VernonHills,IL60061-8112U.S.A.
Attn:TechnicalPublications
FaxNo.(847)970-4186
TelNo.(847)970-5887
COMPANY
IMPORTANT-TOASSURESHIPMENTOFTHECORRECTPUBLICATION(S),THEMODELNUMBERANDMACHINE SERIALNUMBERMUSTBESHOWN.
SAFETY
SAFETYNOTICE
IMPORTANTSAFETYNOTICE
Properserviceandrepairisextremelyimportantforthesafeoperationofyourmachine.Theserviceandrepair techniquesrecommendedanddescribedinthismanualarebotheffectiveandsafemethodsofoperation. Someoftheseoperationsrequiretheuseoftoolsspeciallydesignedforthepurpose.
Topreventinjurytoworkers,thesymbolsandareusedtomarksafetyprecautionsinthismanual.The cautionsaccompanyingthesesymbolsshouldalwaysbefollowedcarefully.Ifanydangeroussituationarises ormaypossiblyarise,firstconsidersafety,andtakethenecessaryactionstodealwiththesituation.
GENERALPRECAUTIONS
6.Decideaplaceintherepairworkshoptokeeptools
Mistakesinoperationareextremelydangerous.Readthepartsintheircorrectplaces.Alwayskeepthework OPERATION&MAINTENANCEMANUALcarefullyareacleanandmakesurethatthereisnodirtoroil BEFOREoperatingthemachine.onthefloor.Smokeonlyintheareasprovidedfor
1.Beforecarryingoutanygreasingorrepairs,readall theprecautionsgivenonthedecalswhicharefixedto
themachine.
PREPARATIONSFORWORK
7.Beforeaddingoilormakingrepairs,parkthe
2.Whencarryingoutanyoperation,alwayswearsafetymachineonhard,levelground,andblockthe shoesandhelmet.Donotwearlooseworkclothes,wheelsortrackstopreventthemachinefrom orclotheswithbuttonsmissing.moving.
•Alwayswearsafetyglasseswhenhittingparts withahammer.
•Alwayswearsafetyglasseswhengrindingparts withagrinder,etc.
3.Ifweldingrepairsareneeded,alwayshaveatrained, experiencedweldercarryoutthework.When carryingoutweldingwork,alwayswearwelding gloves,apron,glasses,capandotherclothessuited forweldingwork.
4.Whencarryingoutanyoperationwithtwoormore workers,alwaysagreeontheoperatingprocedure beforestarting.Alwaysinformyourfellowworkers beforestartinganystepoftheoperation.Before startingwork,hangUNDERREPAIRsignsonthe controlsintheoperator'scompartment.
8.Beforestartingwork,lowerblade,ripper,bucketor anyotherworkequipmenttotheground.Ifthisis notpossible,insertthesafetypinoruseblocksto preventtheworkequipmentfromfalling.In addition,besuretolockallthecontrolleversand hangwarningsignsonthem.
9.Whendisassemblingorassembling,supportthe machinewithblocks,jacksorstandsbefore startingwork.
10.Removeallmudandoilfromthestepsorother placesusedtogetonandoffthemachine.Always usethehandrails,laddersorstepswhengettingon oroffthemachine.Neverjumponoroffthe machine.Ifitisimpossibletousethehandrails, laddersorsteps,useastandtoprovidesafe footing.
5.Keepalltoolsingoodconditionandlearnthecorrect waytousethem. andremovedparts.Alwayskeepthetoolsand smoking.Neversmokewhileworking.
PRECAUTIONSDURINGWORK
11.Whenremovingtheoilfillercap,drainplugor18.Asageneralrule,donotusegasolinetowash hydraulicpressuremeasuringplugs,loosenthemparts.Inparticular,useonlytheminimumof slowlytopreventtheoilfromspurtingout.Beforegasolinewhenwashingelectricalparts. disconnectingorremovingcomponentsoftheoil, wateroraircircuits,firstremovethepressure19.Besuretoassembleallpartsagainintheiroriginal completelyfromthecircuit.places.Replaceanydamagedpartwithnewparts.
12.Thewaterandoilinthecircuitsarehotwhenthe engineisstopped,sobecarefulnottogetburned. Waitfortheoilandwatertocoolbeforecarryingout anyworkontheoilorwatercircuits.
13.Beforestartingwork,removetheleadsfromthe battery.ALWAYSremovetheleadfromthenegative (-)terminalfirst.
14.Whenraisingheavycomponents,useahoistor crane.Checkthatthewirerope,chainsandhooks arefreefromdamage.Alwaysuseliftingequipment whichhasamplecapacity.Installtheliftingequipment atthecorrectplaces.Useahoistorcraneand operateslowlytopreventthecomponentfromhitting anyotherpart.Donotworkwithanypartstillraised bythehoistorcrane.
15.Whenremovingcoverswhichareunderinternal pressureorunderpressurefromaspring,always leavetwoboltsinpositiononoppositesides.Slowly releasethepressure,thenslowlyloosentheboltsto remove.
16.Whenremovingcomponents,becarefulnottobreak ordamagethewiring.Damagedwiringmaycause electricalfires.
17.Whenremovingpiping,stopthefueloroilfrom spillingout.Ifanyfueloroildripsontothefloor,wipe itupimmediately.Fueloroilonthefloorcancause youtoslip,orcanevenstartfires.
•Wheninstallinghosesandwires,besurethat theywillnotbedamagedbycontactwithother partswhenthemachineisbeingoperated.
20.Wheninstallinghighpressurehoses,makesure thattheyarenottwisted.Damagedtubesare dangerous,sobeextremelycarefulwheninstalling tubesforhighpressurecircuits.Alsocheckthat connectingpartsarecorrectlyinstalled.
21.Whenassemblingorinstallingparts,alwaysuse thespecifiedtighteningtorques.Wheninstalling protectivepartssuchasguards,orpartswhich vibrateviolentlyorrotateathighspeed,be particularlycarefultocheckthattheyareinstalled correctly.
22.Whenaligningtwoholes,neverinsertyourfingers orhand.Becarefulnottogetyourfingerscaughtin ahole.
23.Whenmeasuringhydraulicpressure,checkthat themeasuringtooliscorrectlyassembledbefore takinganymeasurements.
24.Takecarewhenremovingorinstallingthetracksof track-typemachines.Whenremovingthetrack,the trackseparatessuddenly,soneverletanyone standateitherendofthetrack.
FOREWORD
GENERAL
Thisshopmanualhasbeenpreparedasanaidtoimprovethequalityofrepairsbygivingtheservicemananaccurate understandingoftheproductandbyshowinghimthecorrectwaytoperformrepairsandmakejudgements.Makesure youunderstandthecontentsofthismanualanduseittofulleffectateveryopportunity.
Thisshopmanualmainlycontainsthenecessarytechnicalinformationforoperationsperformedinaserviceworkshop. Foreaseofunderstanding,themanualisdividedintothefollowingsections.Thesesectionsarefurtherdividedintoeach maingroupofcomponents.
GENERAL
Thissectionliststhegeneralmachinedimensions,performancespecifications,componentweights,andfuel, coolantandlubricantspecificationcharts.
STRUCTUREANDFUNCTION
Thissectionexplainsthestructureandfunctionofeachcomponent.Itservesnotonlytogiveanunderstanding ofthestructure,butalsoservesasreferencematerialfortroubleshooting.
TESTINGANDADJUSTING
Thissectionexplainscheckstobemadebeforeandafterperformingrepairs,aswellasadjustmentstobe madeatcompletionofthechecksandrepairs.Troubleshootingchartscorrelating"Problems"to"Causes"are alsoincludedinthissection.
DISASSEMBLYANDASSEMBLY
Thissectionexplainstheordertobefollowedwhenremoving,installing,disassemblingorassemblingeach component,aswellasprecautionstobetakenfortheseoperations.
MAINTENANCESTANDARD
Thissectiongivesthejudgementstandardswheninspectingdisassembledparts.
NOTICE
Thespecificationscontainedinthisshopmanualaresubjecttochangeatanytimeandwithoutanyadvance notice.Contactyourdistributorforthelatestinformation.
HOWTOREADTHESHOPMANUAL
VOLUMESREVISEDEDITIONMARK
Shopmanualsareissuedasaguidetocarryingout repairs.Theyaredividedasfollows:
Chassisvolume:Issuedforeverymachinemodel
Enginevolume:Issuedforeachengineseries
Electricalvolume:Eachissuedasonetocoverall models
Attachmentvolume:Eachissuedasonetocoverall models
Thesevariousvolumesaredesignedtoavoidduplication ofinformation.Thereforetodealwithallrepairsforany model,itisnecessarythatchassis,engineelectricaland attachmentbeavailable.
DISTRIBUTIONANDUPDATING
Anyadditions,amendmentsorotherchangeswillbesent toyourdistributors.Getthemostup-to-dateinformation beforeyoustartanywork.
FILINGMETHOD
1.Seethepagenumberonthebottomofthepage.File thepagesincorrectorder.
2.Followingexamplesshowhowtoreadthepage number:
Example1(Chassisvolume): 10-3
Itemnumber(10.Structureand Function)
Consecutivepagenumberfor eachitem
Example2(Enginevolume): Refertothepertinentenginemanual.
3.Additionalpages:Additionalpagesareindicatedbya hyphen(-)andnumberedafterthepagenumber.File asintheexample.
Example: 10-4
10-4-1
•Addedpages10-4-2 10-5
Whenamanualisrevised,aneditionmark(•••....)is recordedonthebottomoutsidecornerofthepages.
REVISIONS
RevisedpagesareshownattheLISTOFREVISED PAGESbetweenthetitlepageandSAFETYpage.
SYMBOLS
Sothattheshopmanualcanbeofamplepracticaluse, importantplacesforsafetyandqualityaremarkedwith thefollowingsymbols.
SymbolItemRemarks
Safety
Caution
Weight
Tightening torque
Coat
Oil,water
Specialsafetyprecautionsare necessarywhenperformingthe work.
Specialtechnicalprecautionsor otherprecautionsforpreserving standardsarenecessarywhen performingthework.
Weightofpartsorsystems. Cautionnecessarywhenselecting hoistingwireorwhenworking postureisimportant,etc.
Placesthatrequirespecialattention fortighteningtorqueduring assembly.
Placestobecoatedwithadhesives andlubricantsetc.
Placeswhereoil,waterorfuelmust beadded,andthecapacity.
DrainPlaceswhereoilorwatermustbe drained,andquantitytobedrained.
HOISTINGINSTRUCTIONS
HOISTING
Heavyparts(25kgormore)mustbeliftedwith ahoistetc.IntheDISASSEMBLYAND ASSEMBLYsection,everypartweighing25kgor moreisindicatedclearlywiththesymbol
•Ifapartcannotbesmoothlyremovedfromthe machinebyhoisting,thefollowingchecksshouldbe made:
1)Checkforremovalofallboltsfasteningthepart totherelativeparts.
2)Checkforexistenceofanotherpartcausing interfacewiththeparttoberemoved.
WIREROPES
1)Useadequateropesdependingontheweightof partstobehoisted,referringtothetablebelow:
Wireropes (Standard"Z"or"S"twistropeswithoutgalvanizing)
Ropediameter(mm)Allowableload(tons)
3)Donotslingaheavyloadwithoneropealone,but slingwithtwoormoreropessymmetricallywound ontotheload.
Slingingwithoneropemaycauseturningof theloadduringhoisting,untwistingoftherope, orslippingoftheropefromitsoriginalwinding positionontheload,whichcanresultinadangerous accident.
4)Donotslingaheavyloadwithropesformingawide hanginganglefromthehook.Whenhoistingaload withtwoormoreropes,theforcesubjectedtoeach ropewillincreasewiththehangingangles.The tablebelowshowsthevariationofallowableload (kg)whenhoistingismadewithtworopes,eachof whichisallowedtoslingupto1000kgvertically,at varioushangingangles.Whentworopesslinga loadvertically,upto2000kgoftotalweightcanbe suspended.Thisweightbecomes1000kgwhen tworopesmakea120•hangingangle.Onthe otherhand,tworopesaresubjecttoanexcessive forceaslargeas4000kgiftheyslinga2000kg loadataliftingangleof150•.
Theallowableloadvalueisestimatedtobe1/6or 1/7ofthebreakingstrengthoftheropeused.
2)Slingwireropesfromthemiddleportionofthehook. Slingingneartheedgeofthehookmaycausethe ropetoslipoffthehookduringhoisting,andaserious accidentcanresult.Hookshavemaximumstrength atthemiddleportion.
COATINGMATERIALS
Therecommendedcoatingmaterialsprescribedintheshopmanualsarelistedbelow.
CategoryCodePartNo.QtyContainerMainapplications,features
LT-1A790-129-9030150gTube
Adhesive
Gasketsealant
•Usedtopreventrubbergaskets,rubbercushionsandcorkplugsfrom comingout
LT-1B790-129-905020g(x2)Usedforplastics(exceptpolyethylene,polypropylene,
LT-209940-0003050g
Plastic container
•Usedinplacesrequiringanimmediatelyeffective,strongadhesive. tetrafluoroethylene,andvinylchloride),rubber,metalandnon-metal.
Plastic•Features:Resistancetoheat,chemicals container•Usedforanti-looseningandsealantpurposesforboltsandplugs.
LT-3ofadhesiveandHardagtCan•Usedasadhesiveorsealantformetal,glassorplastic.
790-129-9060SetAdh1kg hardeningagent500kg
LT-4790-129-9040250g•Usedassealantformachinedholes.
Plastic container
cc---
Loctite•Features:Resistancetoheat,chemicals 648-50•Usedatjointportionssubjecttohigh 79A-129-911050temperature.
LG-1790-129-9010200gTube
•Usedasadhesiveorsealantforgasketsandpackingofpowertrain case,etc.
•Features:Resistancetoheat
•Usedassealantforflangesurfacesandboltsathightemperature
LG-3790-129-90701kgCanlocations;usedtopreventseizure.
•Usedassealantforheatresistantgasketforathightemperature locationssuchasenginepre-combustionchamber,exhaustpipe.
•Features:Resistancetowater,oil
•Usedassealantforflangesurface,thread.
LG-4790-129-9020200gTube•Alsopossibletouseassealantforflangeswithlargeclearance.
•Usedassealantformatingsurfacesoffinaldrivecase,transmission case.
LG-5790-129-90801kgPlastic•Usedassealantforvariousthreads,pipejoints,flanges. container•Usedassealantfortaperedplugs,elbows,nipplesofhydraulicpiping.
•Features:Siliconbased,resistanttoheat,cold.
LG-609940-00011250gTube•Usedassealantforflangesurface,thread.
•Usedassealantforoilpan,finaldrivecase,etc.
LG-709920-00150150gTube•Usedassealantforflywheelhousing,intakemanifold,oilpan,
•Features:Siliconbased,quickhardeningtype. thermostathousing,etc.
Rustprevention lubricant---09940-0005160gCan•Usedaslubricantforslidingparts(topreventsqueaking).
•Usedtopreventseizureorscuffingofthethreadwhenpressfittingor
Molybdenum disulfidelubricant---09940-00040200gTubeshrinkfitting.
•Usedaslubricantforlinkage,bearings,etc.
SYG-350Ll SYG-400Ll
LithiumgreaseG2-L1SYG-400Ll-AVariousVarious•Generalpurposetype
SYG-160Ll SYGA-160CNLl
SSG2-400CA
SYG2-350CA
CalciumgreaseG2-CASYG2-400CA-AVariousVarious
SYG2-160CA SYGA-16CNCA
•Usedfornormaltemperature,lightloadbearingatplacesincontactwith waterorsteam.
Molybdenum400g disulfidegrease(10/case)---SYG2-400MBellowstype•Usedforplaceswithheavyload.
STANDARDTORQUEREQUIREMENTS
STANDARDTORQUEREQUIREMENTSOFBOLTSANDNUTS
Thefollowingchartsgivethestandardtorquesvaluesofboltsandnuts.Exceptionsaregiveninsectionsof DISASSEMBLYANDASSEMBLY.
Thistorquetabledoesnotapplytotheboltswithwhichnylonpackingorothernon-ferrousmetalwashersareto beused,orwhichrequiretorquingtootherwisespecifiedvalues.