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Komatsu WA380-8 Shop Manual
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Komatsu WA380-8 Shop Manual

Wheel loader
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Manual
WA380
WHEEL LOADER
SERIAL NUMBERS
ENGINE
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.
July 2015
-8
WA380-8 A74001
6D107E-3
and up
Copyright 2015 Komatsu
Printed in U.S.A.
Komatsu America Corp.
CEBM030400

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Summary of Contents for Komatsu WA380-8

  • Page 1 6D107E-3 ENGINE 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 00 INDEX AND FOREWORD WA380-8 00-1 Find manuals at https://best-manuals.com...
  • Page 4 ENGINE CONTROL SYSTEM ....................... 10-43 ENGINE POWER MODE SELECTOR SYSTEM................10-49 AUTOMATIC IDLE STOP SYSTEM ....................10-50 COMPONENT PARTS OF ENGINE SYSTEM ................10-51 COOLING SYSTEM..........................10-69 LAYOUT DRAWING OF COOLING SYSTEM ................10-69 00-2 WA380-8 Find manuals at https://best-manuals.com...
  • Page 5 STANDARD VALUE TABLE FOR ENGINE ..................... 20-3 STANDARD VALUE TABLE FOR ENGINE: WA380-8..............20-3 STANDARD VALUE TABLE FOR MACHINE................... 20-7 STANDARD VALUE TABLE FOR MACHINE: WA380-8 ..............20-7 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE ......20-26 STANDARD VALUE TABLE FOR ELECTRICAL ................... 20-29 STANDARD VALUE TABLE FOR ELECTRICITY................
  • Page 6 TEST WEAR OF WHEEL BRAKE DISC ..................30-156 TEST PARKING BRAKE OIL PRESSURE ..................30-158 TEST PARKING BRAKE PERFORMANCE...................30-160 RELEASE PARKING BRAKE MANUALLY ..................30-161 TEST WEAR AMOUNT OF PARKING BRAKE DISC..............30-163 HYDRAULIC SYSTEM.........................30-165 RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT .......30-165 00-4 WA380-8 Find manuals at https://best-manuals.com...
  • Page 7 FAILURE CODE [15SBLH] ECMV Engage Trouble (Reverse) ............40-191 FAILURE CODE [15SEL1] ECMV Release Trouble (1st Clutch) ...........40-193 FAILURE CODE [15SELH] ECMV Engage Trouble (1st) ..............40-195 FAILURE CODE [15SFL1] ECMV Release Trouble (2nd Clutch) ..........40-197 WA380-8 00-5 Find manuals at https://best-manuals.com...
  • Page 8 FAILURE CODE [CA187] Sensor 2 Supply Voltage Low Error ............40-295 FAILURE CODE [CA221] Ambient Pressure Sensor High Error............40-297 FAILURE CODE [CA222] Ambient Pressure Sensor Low Error ............40-299 FAILURE CODE [CA227] Sensor 2 Supply Voltage High Error .............40-301 FAILURE CODE [CA234] Engine Overspeed................40-302 00-6 WA380-8 Find manuals at https://best-manuals.com...
  • Page 9 FAILURE CODE [CA1691] Defective Regeneration ..............40-405 FAILURE CODE [CA1694] SCR Outlet NOx Sensor In Range Error..........40-408 FAILURE CODE [CA1695] Sensor 5 Supply Voltage High Error ...........40-411 FAILURE CODE [CA1696] Sensor 5 Supply Voltage Low Error ............40-412 WA380-8 00-7 Find manuals at https://best-manuals.com...
  • Page 10 FAILURE CODE [CA3235] SCR Outlet Temperature High Error - Non Regeneration....40-543 FAILURE CODE [CA3239] AdBlue/DEF Line Heater 2 Voltage High Error........40-545 FAILURE CODE [CA3241] AdBlue/DEF Line Heater 2 Voltage Low Error ........40-548 FAILURE CODE [CA3242] AdBlue/DEF Tank Heating Error ............40-551 00-8 WA380-8 Find manuals at https://best-manuals.com...
  • Page 11 FAILURE CODE [CA3912] SCR NH3 Sensor Heater Warming up Error ........40-689 FAILURE CODE [CA3932] SCR NH3 Sensor Heater Voltage High Error ........40-691 FAILURE CODE [CA3933] SCR NH3 Sensor Heater Voltage Low Error........40-693 FAILURE CODE [CA3934] SCR NH3 Sensor Power Interrupt Error ..........40-695 WA380-8 00-9...
  • Page 12 FAILURE CODE [D5ZHKA] Key SW C Terminal Signal Open Circuit or Ground Fault ....40-823 FAILURE CODE [D5ZHKB] Key SW C Terminal Signal Short Circuit ..........40-825 FAILURE CODE [D5ZHKZ] Key SW C Terminal Signal Open Circuit or Short Circuit....40-827 FAILURE CODE [D5ZHL6] Key SW C Terminal Signal Mismatch ..........40-830 00-10 WA380-8...
  • Page 13 FAILURE CODE [DDK6KB] Directional Lever Signal Short Circuit ..........40-934 FAILURE CODE [DDKLKA] Failure of J/S ON/OFF Switch ............40-937 FAILURE CODE [DDKLKB] Hot Short of J/S ON/OFF Switch ............40-940 FAILURE CODE [DDNRKY] W/E Lock SW Hot Short Circuit ............40-942 WA380-8 00-11...
  • Page 14 FAILURE CODE [DK5KL8] 4th Lever Potentiometer Main or Sub Signal Abnormality....40-1085 FAILURE CODE [DK5LKA] 4th Lever Potentiometer Open Circuit or Ground Fault (Sub)...40-1089 FAILURE CODE [DK5LKY] 4th Lever Potentiometer Hot Short Circuit (Sub) ......40-1092 FAILURE CODE [DKA0KA] Boom Angle Sensor Open Circuit or Ground Fault ......40-1095 00-12 WA380-8...
  • Page 15 FAILURE CODE [DXH4KA] ECMV Solenoid Open Circuit (1st Clutch) ........40-1214 FAILURE CODE [DXH4KB] ECMV Solenoid Ground Fault (1st Clutch) ........40-1216 FAILURE CODE [DXH4KY] ECMV Solenoid Hot Short Circuit (1st Clutch).........40-1218 FAILURE CODE [DXH5KA] ECMV Solenoid Open Circuit (2nd Clutch) ........40-1220 WA380-8 00-13...
  • Page 16 E-18 REAR VIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED........40-1338 E-19 NIGHT LIGHTING LAMP OF REAR VIEW MONITOR IS ABNORMAL ......40-1342 E-20 AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP ......40-1344 E-21 RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP ......40-1346 00-14 WA380-8...
  • Page 17 H-5 LARGE SHOCK IS MADE WHEN MACHINE MOVES OFF OR GEAR IS SHIFTED ...40-1464 H-6 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED ..40-1467 H-7 WHEN OPERATING WORK EQUIPMENT ENGINE SPEED DROPS LARGELY OR ENGINE STOPS ............................40-1470 WA380-8 00-15...
  • Page 18 S-12 FUEL CONSUMPTION IS EXCESSIVE ................40-1541 S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) ...............................40-1542 S-14 OIL PRESSURE DROPS ....................40-1543 S-15 FUEL MIXES INTO ENGINE OIL..................40-1545 S-16 WATER MIXES INTO ENGINE OIL (MILKY) ..............40-1546 00-16 WA380-8...
  • Page 19 MAINTENANCE STANDARD OF CONTROL VALVE..............60-63 MAINTENANCE STANDARD OF STABILIZER VALVE ..............60-74 MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE ....... 60-75 WORK EQUIPMENT..........................60-76 MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE..........60-76 MAINTENANCE STANDARD OF BUCKET..................60-79 WA380-8 00-17...
  • Page 20 A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) ............................. 80-77 A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER..........80-81 TROUBLESHOOTING USING GAUGE PRESSURE................80-83 CONNECTION OF SERVICE TOOL ..................... 80-86 METHOD FOR CONNECTING SERVICE TOOL ................80-87 00-18 WA380-8...
  • Page 21 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (3/8)..............90-33 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (4/8)..............90-35 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (5/8)..............90-37 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (6/8)..............90-39 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (7/8)..............90-41 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (8/8)..............90-43 INDEX..................................1 WA380-8 00-19...
  • Page 22 REMARK • Some of the attachments and options described in this shop manual may not be available in some areas. If they are required, consult your Komatsu distributor. • The materials and specifications are subject to change without notice. • Shop Manuals are available for "machine part" and "engine part". For the engine unit, see the shop manual for the machine which has the same engine model.
  • Page 23 REMARK Remarks This signal word contains useful information to know. Unit International System of Units (SI) is used in this manual. For reference, units that have been used in the past are given in { }. WA380-8 00-21...
  • Page 24 Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of the servicing and repair methods require the use of special tools designed by Komatsu for special purpos- •...
  • Page 25 When removing or installing the checking plug or the piping in the fuel circuit, wait 30 seconds or longer after the engine is shut down and start the work after the remaining pressure is released from the fuel cir- cuit. WA380-8 00-23...
  • Page 26 When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In addition, check that high pressure hoses and tubes are correctly installed. 00-24 WA380-8...
  • Page 27 • Hanging angle must be 60 ° or smaller as a rule. • When slinging a heavy load (25 kg or heavier), the hanging angle of the rope must be narrower than that of the hook. WA380-8 00-25...
  • Page 28 Precautions for using mobile crane REMARK Read Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead traveling crane When raising a heavy component (heavier than 25 kg), use a hoist or crane. 00-26 WA380-8...
  • Page 29 Wire rope (JIS G3525 6x37-A type) (Standard Z twist wire ropes without galvanizing) Nominal diameter of rope ( mm) Allowable load ( kN { t} ) 8.8 {0.9} 12.7 {1.3} 17.3 {1.7} 22.6 {2.3} 28.6 {2.9} 35.3 {3.6} 55.3 {5.6} 79.6 {8.1} 141.6 {14.4} 221.6 {22.6} 318.3 {32.4} WA380-8 00-27...
  • Page 30 When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches. Use one wrench to fix and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening). 00-28 WA380-8...
  • Page 31 • The figure shows an example of fitting of O-ring. • An O-ring is fitted to every joint of the air conditioner piping. For tightening torques, see THE OTHER INFORMATION, "Pre- cautions for disconnection and connection of air conditioner piping". WA380-8 00-29...
  • Page 32 Fire around the machine due to highly heated exhaust gas This machine is equipped with KDPF (Komatsu Diesel Particulate Filter). KDPF is a system for purifying exhaust gas by removing soot in exhaust gas. In the process of purification (re- generation), the temperature of discharged exhaust gas may be higher than that of conventional models.
  • Page 33 • When checking fuel, oil, battery electrolyte, or coolant, always use lighting equipment with anti-explosion specifications. • When taking the electrical power for the lighting equipment from the machine, follow the instructions in the Operation and Maintenance Manual. WA380-8 00-31...
  • Page 34 Be sure to wear rubber gloves when handle the materials left after the fire. The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in the lower temperature environment). When wearing cotton-work-gloves, wear rubber gloves under them. 00-32 WA380-8...
  • Page 35 Avoid exposure to burning rubber or plastics which produce a toxic gas that is harmful to people. • When disposing of parts made of rubber or plastics (hoses, cables, and harnesses), always comply with the local regulations for disposing industrial waste products. WA380-8 00-33...
  • Page 36 This machine is equipped with the following two exhaust gas treatment systems: • Komatsu Diesel Particulate Filter (hereafter KDPF): A device which captures soot in the exhaust gas to pu- rify exhaust gas. This process performs the combustion of soot referred to as "regeneration".
  • Page 37 If it gets on your skin, thoroughly wash it off with water. Never relocate or modify the exhaust gas after-treatment device. The harmful gas may be exhausted and it can cause serious damage to the environment as well as violation of laws. WA380-8 00-35...
  • Page 38 If AdBlue/DEF or the machine installed with AdBlue/DEF cannot be stored in the indoors where the temper- ature is at –11 °C or higher (if they are left outdoors in cold weather), AdBlue/DEF in the tank may freeze. Drain AdBlue/DEF to prevent it from freezing. 00-36 WA380-8...
  • Page 39 • Clean the oil filler port and its around, refilling pump, oil jug, or etc. • Refilling by using an oil cleaning device is better method since it can filtrate the contaminants accumulated in the oil during storage. WA380-8 00-37...
  • Page 40 (pump, or control valve) or during operation of the machine. REMARK The oil cleaning equipment can remove the ultra fine (approxi- mately 3 μm) particles that the filter built in the hydraulic equip- ment cannot remove. So, it is very effective device. 00-38 WA380-8...
  • Page 41 Introduction of parts for the disassembly of the face seal type hoses and tubes Hose side Pipe joint side Nominal No. O-ring (3) Plug (1) Nut (2) 07376-70210 02789-00210 02896-11008 07376-70315 02789-00315 02896-11009 07376-70422 02789-00422 02896-11012 07376-70522 02789-00522 02896-11015 07376-70628 02789-00628 02896-11018 WA380-8 00-39...
  • Page 42 Split flange Sleeve head Flange (1) 38.1 17.5 07379-00400 07371-30400 07378-10400 07000-12021 01010-80825 01643-50823 42.9 19.8 07379-00500 07371-30500 07378-10500 07000-13022 01010-80830 01643-50823 47.6 22.2 07379-00640 07371-30640 07378-10600 07000-13025 07372-51035 01643-51032 52.4 26.2 07379-01044 07371-31049 07378-11000 07000-13032 07372-51035 01643-51032 00-40 WA380-8...
  • Page 43 Introduction of parts for the removal of O-ring boss type joint Nominal No. Plug (1) O-ring (2) 07040-10807 07002-10823 07040-11007 07002-11023 07040-11209 07002-11223 07040-11409 07002-11423 07040-11612 07002-11623 07040-11812 07002-11823 07040-12012 07002-12034 07040-12412 07002-12434 07041-13012 07002-13034 07040-13316 07002-13334 07041-13612 07002-13634 07040-14220 07002-14234 07040-15223 07002-15234 WA380-8 00-41...
  • Page 44 When installing split flanges, tighten the bolts uniformly and alternately to prevent uneven tightening. • As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded portion of each taper male screws which receive pressure. 00-42 WA380-8...
  • Page 45 When the coolant is drained, be sure that the drain valve is securely tightened, then refill the coolant reser- voir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping, and add the coolant to the specified level again.
  • Page 46 • Parts which connects the above, or etc. Check that there is no unusual noise by comparing to it of the time when the machine was new. If there is any unusual noise, repair KDPF or muffler, referring to "TROUBLESHOOTING" and "DISASSEMBLY AND ASSEMBLY". 00-44 WA380-8...
  • Page 47 The pins of the male and female connectors are attached to wires by crimping or soldering. If excessive force is applied to the wire, the jointed portion may become loose, and it may re- sult in a defective connection or breakage. WA380-8 00-45...
  • Page 48 • If there is oil or water in the compressed air, it causes the contacts to become dirtier. Use clean air which any oil and water has been removed from. 00-46 WA380-8...
  • Page 49 If a filter oth- er than a Komatsu genuine filter is used, fuel system contamination and damage may occur. Therefore Komatsu recommends using only Komatsu fuel filters and install them following the procedures in the shop manual.
  • Page 50 00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT The machines equipped with Komatsu Variable Geometry Turbocharger (KVGT) consists of more precise parts (variable system)than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause a failure.
  • Page 51 Propose the periodic inspection (Pm clinic, etc.) according to the service meter reading. How to operate KOMTRAX For the operating method of each screen of KOMTRAX, see “Global KOMTRAX Web Reference Manual (For Key Person)”. WA380-8 00-49...
  • Page 52 Provide an oil container to receive a quantity of hydraulic oil which may flow out. Connection Hold hose adapter (1) or hose (5), and insert it in mating adapter (3), aligning the axis. REMARK Do not hold rubber cap portion (4). 00-50 WA380-8...
  • Page 53 While keeping the condition of step 1, turn lever (3) to the right (clockwise). While keeping the conditions of steps 1 and 2, pull out whole body (2) to disconnect it. REMARK Provide an container to receive a quantity of hydraulic oil which may flow out. WA380-8 00-51...
  • Page 54 While keeping the conditions of steps 1 and 2, pull out whole body (2) to disconnect it. REMARK Provide an container to receive a quantity of hydraulic oil which may flow out. 00-52 WA380-8...
  • Page 55 00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER Connection Hold the tightening adapter part, and push body (2) straight un- til sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end. WA380-8 00-53...
  • Page 56 Connecting connectors Check the connector visually. • Check that there is no dust, dirt, oil, or water stuck to the connector pins (joint portion). 00-54 WA380-8...
  • Page 57 If the wiring harness is dirty with oil and dust, wipe it off with a dry cloth. Avoid water washing or steam washing. If water washing is unavoidable, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. WA380-8 00-55...
  • Page 58 After the connector is completely dried, blow the contact restorer, and reassemble them. Handling controller When performing arc welding on the machine body, disconnect all of the wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point. 00-56 WA380-8...
  • Page 59 When performing the troubleshooting for the circuit (measurement of voltage, resistance,continuity, current, etc.), shake the related wiring harnesses and connectors several times and check that the multimeter read- ing does not change. NOTICE If the value changes on the multimeter, there may be a defective contact in the circuit. WA380-8 00-57...
  • Page 60 In order to check whether locks (a) and (b) are completely inserted, insert female connector (2) by rocking it vertically (in the arrow z direction). (Arrow: x, y, z) REMARK Lock (a) in the figure is pulled down (not set completely), and lock (b) is set completely. 00-58 WA380-8...
  • Page 61 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

This manual is also suitable for:

A74001