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Komatsu WA380-6 Shop Manual
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Komatsu WA380-6 Shop Manual

Komatsu WA380-6 Shop Manual

Wheel loader
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WA380
WHEEL LOADER
SERIAL NUMBERS
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 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, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
January 2007
-6
WA380-6
Copyright 2007 Komatsu
Printed in U.S.A.
Komatsu America Corp.
SEN00769-03
65001
and up

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Summary of Contents for Komatsu WA380-6

  • Page 1 SERIAL NUMBERS and up 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 improvements at any time without incurring any obligation to install such changes on products sold previously.
  • Page 2 Find manuals at https://best-manuals.com...
  • Page 3 SEN00778-03 WHEEL LOADER 1SHOP MANUAL WA380-6 (KA SPEC.) Machine model Serial number WA380-6 65001 and up (KA SPEC.) 00 Index and foreword Index Composition of shop manual........................ 2 Table of contents ..........................4 WA380-6 (KA SPEC.) Find manuals at https://best-manuals.com...
  • Page 4 Troubleshooting by failure code (Display of code), Part 1 SEN01231-00 Troubleshooting by failure code (Display of code), Part 2 SEN01232-00 Troubleshooting by failure code (Display of code), Part 3 SEN01233-00 Troubleshooting by failure code (Display of code), Part 4 SEN01234-00 WA380-6 (KA SPEC.) Find manuals at https://best-manuals.com...
  • Page 5 Undercarriage and frame SEN01151-00 Hydraulic system SEN01152-00 Work equipment SEN01153-00 Cab and its attachments SEN01154-00 Electrical system SEN01155-00 90 Diagrams and drawings SEN00777-02 Hydraulic diagrams and drawings SEN00781-00 SEN00782-01 q Electrical diagrams and drawings WA380-6 (KA SPEC.) Find manuals at https://best-manuals.com...
  • Page 6 Main relief valve and torque converter relief valve ..............42 Axle............................44 Front axle..........................44 Rear axle ..........................45 Differential..........................46 Front differential ........................46 Rear differential ........................47 Limited slip differential ......................51 Final drive ..........................58 WA380-6 (KA SPEC.) Find manuals at https://best-manuals.com...
  • Page 7 Stabilizer valve......................... Accumulator (for PPC circuit) ....................13 Accumulator (for ECSS) ......................14 Work equipment SEN00884-00 Work equipment .......................... Work equipment linkage ......................Bucket............................Bucket positioner and boom kick-out..................Work equipment cylinder ......................WA380-6 (KA SPEC.) Find manuals at https://best-manuals.com...
  • Page 8 Releasing residual pressure in fuel system ................18 Measuring fuel pressure ......................19 Measuring fuel return rate and leakage ................... 21 Bleeding air from fuel circuit ....................24 Testing leakage in fuel system....................26 WA380-6 (KA SPEC.) Find manuals at https://best-manuals.com...
  • Page 9 Points to remember when troubleshooting ................Sequence of events in troubleshooting ................... Testing before troubleshooting ....................Classification and procedures of troubleshooting..............Connection table for connector pin numbers ................T-branch box and T-branch adapter table ................31 WA380-6 (KA SPEC.) Find manuals at https://best-manuals.com...
  • Page 10 Failure code [CA272] (PCV1 Disconnection)................Failure code [CA322] (Injector #1 (L/B #1) open/short error) ..........Failure code [CA323] (Injector #5 (L/B #5) open/short error) ..........10 Failure code [CA324] (Injector #3 (L/B #3) open/short error) ..........12 WA380-6 (KA SPEC.) Find manuals at https://best-manuals.com...
  • Page 11 Failure code [DAF5KP] (Machine monitor: Low output voltage)..........46 Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system))......49 Failure code [DAQ0KK] (Transmission controller: Low source voltage)........51 Failure code [DAQ0KT] (Transmission controller: Abnormality in controller) ......53 WA380-6 (KA SPEC.)
  • Page 12 Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range) . Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range) ..Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection)......Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit) ......... 10 WA380-6 (KA SPEC.)
  • Page 13 E-12 Air conditioner does not operate or stop ................. 50 E-13 The KOMTRAX system does not work properly ............. 53 Troubleshooting of hydraulic and mechanical system (H-mode) SEN01242-00 Troubleshooting of hydraulic and mechanical system (H-mode) ..........Method of using troubleshooting chart ..................WA380-6 (KA SPEC.)
  • Page 14 S-11 Coolant contains oil (blows back or reduces) ..............18 S-12 Oil pressure drops......................19 S-13 Oil level rises (Water, fuel in oil) ..................20 S-14 Coolant temperature rises too high (Overheating) ............21 S-15 Abnormal noise is made....................22 WA380-6 (KA SPEC.)
  • Page 15 Work equipment .......................... Removal and installation of work equipment assembly ............Disassembly and assembly of hydraulic cylinder assembly ............ Cab and its attachments SEN01154-00 Cab and its attachments......................Removal and installation of operator's cab and floor frame assembly ........WA380-6 (KA SPEC.)
  • Page 16 SEN00781-00 Hydraulic diagrams and drawings ....................Power train hydraulic circuit diagram..................Hydraulic circuit diagram ......................Electrical diagrams and drawings SEN00782-01 Electrical diagrams and drawings....................Electrical circuit diagram (1/2) ....................Electrical circuit diagram (2/2) ....................Connector arrangement diagram..................... WA380-6 (KA SPEC.)
  • Page 17 00 Index and foreword SEN00778-03 WA380-6 (KA SPEC.)
  • Page 18 SEN00778-03 WA380-6 (KA SPEC.) Wheel loader Form No. SEN00778-03...
  • Page 19 Handling electric equipment and hydraulic component .................11 How to read electric wire code........................23 Precautions when carrying out operation...................... 26 Method of disassembling and connecting push-pull type coupler..............29 Standard tightening torque table ........................32 Conversion table ............................36 WA380-6 (KA SPEC.)

  • Page 20: Safety Notice

    Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.
  • Page 21 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. When removing components, be careful not to break or damage the electrical wir- ing. Damaged wiring may cause electrical fires. WA380-6 (KA SPEC.)
  • Page 22 If you grasp them, your fingers as large as 39.2 kN {4,000 kg}. may be caught. After the wire ropes are stretched, stop the crane and check the condi- tion of the slung load, wire ropes, and pads. WA380-6 (KA SPEC.)
  • Page 23 11) After operating the hoist, do not swing the control switch. 12) Remember the position of the main switch so that you can turn off the power immedi- ately in an emergency. WA380-6 (KA SPEC.)
  • Page 24 ( R1 34 a ) ( DEN SO: ND -OIL8 , ZEXEL: ZXL100PG (equivalent to PAG46)) to its O-rings. Example of O-ring (Fitted to every joint of hoses and tubes) For tightening torque, see the precautions for installation in each section of "Disassembly and assembly". WA380-6 (KA SPEC.)

  • Page 25: Specification

    This section explains the method of reproducing, repairing, and replacing parts. Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. WA380-6 (KA SPEC.)
  • Page 26 Places where oil, etc. must be drained, and quantity to be drained. Units In this shop manual, the units are indicated with International System of units (SI). For reference, con- ventionally used Gravitational System of units is indicated in parentheses { }. WA380-6 (KA SPEC.)
  • Page 27 The tightness of fit is decided by the toler- ance. Indication of size of rotating shaft and hole and relationship drawing of them Example: Tolerance Standard size Shaft Hole –0.030 +0.046 –0.076 WA380-6 (KA SPEC.)
  • Page 28 If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from vari- ous tests or experiences in most cases, however, it must be judged after consider- ing the operating condition and customer's requirement. WA380-6 (KA SPEC.)
  • Page 29 WA380-6 (KA SPEC.)
  • Page 30 If there is oil or water in the com- pressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air com- pletely before cleaning with com- pressed air. WA380-6 (KA SPEC.)
  • Page 31 If the machine is left disassem- bled for a long time, it is particu- larly easy for improper contact to occur, so always cover the con- nector. WA380-6 (KA SPEC.)
  • Page 32 If the connector cannot be cor- rected easily, remove the clamp and adjust the position. If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps. WA380-6 (KA SPEC.)
  • Page 33 (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a), (b): Locks WA380-6 (KA SPEC.)
  • Page 34 After completely drying the con- n e c t o r, b l o w i t w i t h c o n t a c t restorer and reassemble. WA380-6 (KA SPEC.)
  • Page 35 If there is any change, there is proba- bly defective contact in that circuit. WA380-6 (KA SPEC.)
  • Page 36 If an oil clean- ing device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method. WA380-6 (KA SPEC.)
  • Page 37 The oil cleaning equipment is used to remove the ultra fine (about 3 ) particles that the filter built in the hydraulic equipment can- not remove, so it is an extremely effective device. WA380-6 (KA SPEC.)
  • Page 38 (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screw- driver while press lock (L2), and then pull out connector (1) toward you. WA380-6 (KA SPEC.)
  • Page 39 If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up lock (C) of the connec- tor with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow. WA380-6 (KA SPEC.)
  • Page 40 Insert the connector to the end, while setting its groove. Turn housing (H1) in the direction of the arrow until it “clicks”. Example) Speed sensor of fuel supply pump: G (SUMITOMO-3) Pull the connector straight up. WA380-6 (KA SPEC.)
  • Page 41 Insulator Soft polyvinyl chloride automobile Conduc- Annealed copper for elec- Heat-resis- General wiring in extremely tric appliance tant low-volt- –50 to +110 cold district, wiring at high-tem- age wire for Heat-resistant crosslinked perature place Insulator automobile polyethylene WA380-6 (KA SPEC.)
  • Page 42 (approx.) 10.4 12.0 13.6 Standard – – – – – – – – – Cov- Standard 10.8 11.4 13.0 13.6 16.0 17.6 er D Standard 10.8 11.4 13.0 13.6 16.0 17.6 “f” of nominal No. denotes flexible”. WA380-6 (KA SPEC.)
  • Page 43 – Others – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – WA380-6 (KA SPEC.)
  • Page 44 07379-00500 07378-10500 07371-30500 If the part is not under hydraulic pressure, the following corks can be used. Dimensions Nominal Part Number number 07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 11.5 07049-01620 13.5 07049-01822 07049-02025 07049-02228 18.5 07049-02430 07049-02734 22.5 WA380-6 (KA SPEC.)
  • Page 45 If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it. WA380-6 (KA SPEC.)
  • Page 46 If any bolt or nut is loosened, retighten it. Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler. If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly and assembly”. WA380-6 (KA SPEC.)
  • Page 47 After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (Fig. 5) When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however. WA380-6 (KA SPEC.)
  • Page 48 2), pull out whole body (7) to discon- nect it. (Fig. 8) Connection Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexag- onal portion at the male end. (Fig. 9) WA380-6 (KA SPEC.)
  • Page 49 2), pull out whole body (9) to discon- nect it. (Fig. 12) Connection Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexag- onal portion at the male end. (Fig. 13) WA380-6 (KA SPEC.)
  • Page 50 Thread diameter of bolt Width across flats Tightening torque 5.9 – 9.8 0.6 – 1.0 13.7 – 23.5 1.4 – 2.4 34.3 – 46.1 3.5 – 4.7 74.5 – 90.2 7.6 – 9.2 Fig. A Fig. B WA380-6 (KA SPEC.)
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This manual is also suitable for:

65001