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Komatsu WA380-6 Shop Manual

Wheel loader
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WHEEL LOADER
WA380
WA380Z
SERIAL NUMBERS
SEN06411-02
-6
-6
WA380- 65001
WA380Z- 66847
and up

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Summary of Contents for Komatsu WA380-6

  • Page 1 SEN06411-02 WHEEL LOADER WA380 WA380Z WA380- 65001 SERIAL NUMBERS and up WA380Z- 66847...
  • Page 2 Find manuals at https://best-manuals.com...
  • Page 3 WHEEL LOADER 1SHOP MANUAL WA380-6 WA380Z-6 Machine model Serial number WA380-6 65001 and up WA380Z-6 66847 and up 00 Index and foreword Index Composition of shop manual .......................... 2 Table of contents ............................. 4 WA380-6, WA380Z-6 Find manuals at https://best-manuals.com...
  • Page 4 General information on troubleshooting SEN06438-00 Troubleshooting by failure code (Display of code), Part 1 SEN06439-00 Troubleshooting by failure code (Display of code), Part 2 SEN06440-00 Troubleshooting by failure code (Display of code), Part 3 SEN06441-00 WA380-6, WA380Z-6 Find manuals at https://best-manuals.com...
  • Page 5 SEN06457-00 Undercarriage and frame SEN06458-00 Hydraulic system SEN06459-00 Work equipment SEN06460-00 Cab and its attachments SEN06461-00 Electrical system SEN06462-00 90 Diagrams and drawings SEN06463-01 Hydraulic diagrams and drawings SEN06464-00 Electrical diagrams and drawings SEN06465-01 WA380-6, WA380Z-6 Find manuals at https://best-manuals.com...
  • Page 6 SEN06420-00 Steering piping diagram ......................Steering column ........................Steering pump.......................... Steering valve .......................... 26 Orbit-roll valve.......................... 41 Stop valve ..........................49 Steering relief valve ......................... 50 Steering cylinder ........................51 Emergency steering motor....................... 53 WA380-6, WA380Z-6 Find manuals at https://best-manuals.com...
  • Page 7 SEN06429-00 Electric transmission control....................Kickdown switch and hold switch .................... Multi-function knob ........................Joystick steering knob ......................KOMTRAX terminal system..................... 10 Engine starting circuit ......................12 Engine stopping circuit ......................16 Preheating circuit........................18 WA380-6, WA380Z-6 Find manuals at https://best-manuals.com...
  • Page 8 Bleeding air from hydraulic drive fan circuit ................Testing brake pedal........................10 Testing and adjusting brake pedal linkage................11 Testing brake performance ...................... 12 Testing and adjusting accumulator charge pressure ............... 13 Testing wheel brake oil pressure ..................... 15 WA380-6, WA380Z-6 Find manuals at https://best-manuals.com...
  • Page 9 Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF) . Failure code [2F00MA] (Parking brake: Malfunction) ..............Failure code [2G43ZG] (Accumulator: Low oil pressure) ............Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree) ........WA380-6, WA380Z-6 Find manuals at https://best-manuals.com...
  • Page 10 Failure code [CA553] (Common rail pressure high error 1)............. 48 Failure code [CA559] (Supply pump pressure very low error)..........49 Failure code [CA689] (Engine Ne speed sensor error)............50 Failure code [CA731] (Engine Bkup speed sensor phase error) ..........53 WA380-6, WA380Z-6 Find manuals at https://best-manuals.com...
  • Page 11 Out of input signal range..................29 Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals) ............32 Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system) ....... 33 WA380-6, WA380Z-6...
  • Page 12 Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree) .. 22 Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection) ....25 Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)..............28 WA380-6, WA380Z-6...
  • Page 13 Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit) ......34 Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source) 36 Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection) ......... 38 Failure code [DX16KA] (Fan motor EPC solenoid: Disconnection) ......... 39 WA380-6, WA380Z-6...
  • Page 14 E-12 Air conditioner does not operate or stop ................. 86 E-13 The KOMTRAX system does not work properly ............. 90 E-14 When kick-down switch is turned ON, kick-down operation does not start ..... 93 E-15 When hold switch is pressed, holding operation does not start ........96 WA380-6, WA380Z-6...
  • Page 15 H-28 The bucket cylinder cannot hold down the bucket............41 H-29 Hydraulic drifts of the bucket is large ................41 H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to "HOLD") ..............41 WA380-6, WA380Z-6...
  • Page 16 Disassembly and assembly of parking brake assembly ............54 Removal and installation of front axle assembly..............63 Removal and installation of rear axle assembly ..............65 Disassembly and assembly of axle housing ................68 Disassembly and assembly of differential assembly ............... 77 WA380-6, WA380Z-6...
  • Page 17 Hydraulic diagrams and drawings SEN06464-00 Power train hydraulic circuit diagram..................Automatic greasing circuit diagram ..................Hydraulic circuit diagram ......................Electrical diagrams and drawings SEN06465-01 Electrical circuit diagram......................Work equipment controller system electrical circuit diagram........... 49 Connector list and stereogram ....................51 WA380-6, WA380Z-6...
  • Page 18 SEN06413-02 WA380-6, WA380Z-6 WHEEL LOADER Form No. SEN06413-02 © 2015 KOMATSU All Rights Reserved Printed in Japan 03-15 (01)

  • Page 19: Table Of Contents

    Handling of connectors newly used for engines ................... 20 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, WA380Z-6...

  • 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 Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. WA380-6, WA380Z-6...
  • 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, WA380Z-6...
  • 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, WA380Z-6...
  • Page 24 When connecting the refrigerant pip- ing, apply compressor oil for refriger- ant (R134a) (DENSO: ND-OIL8, VA L E O T H E R M A L S Y S T E M S : ZXL100PG (equivalent to PAG46)) to its O-rings. WA380-6, WA380Z-6...

  • Page 25: How To Read The Shop Manual

    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, WA380Z-6...
  • 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, WA380Z-6...

  • Page 27: Explanation Of Terms For Maintenance Standard

    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, WA380Z-6...
  • 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, WA380Z-6...

  • Page 29: Handling Of Electric Equipment And Hydraulic Component

    The pins of the male and female connec- tors are in contact at the crimped terminal or soldered portion, but if there is exces- sive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage. WA380-6, WA380Z-6...
  • 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, WA380Z-6...
  • 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, WA380Z-6...
  • 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, WA380Z-6...
  • Page 33 (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) a 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, WA380Z-6...
  • 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 ta c t restorer and reassemble. WA380-6, WA380Z-6...
  • Page 35 If there is any change, there is proba- bly defective contact in that circuit. WA380-6, WA380Z-6...
  • 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, WA380Z-6...
  • 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, WA380Z-6...

  • Page 38: Handling Of Connectors Newly Used For Engines

    Even if lock (L2) is pressed, connec- tor (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, WA380Z-6...
  • 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, WA380Z-6...
  • 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) a Pull the connector straight up. WA380-6, WA380Z-6...

  • Page 41: How To Read Electric Wire Code

    (Nominal No. 3 and below) 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, WA380Z-6...
  • 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, WA380Z-6...
  • Page 43 – – Others – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – WA380-6, WA380Z-6...

  • Page 44: Precautions When Carrying Out Operation

    07371-30400 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, WA380Z-6...
  • 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, WA380Z-6...
  • 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, WA380Z-6...

  • Page 47: Method Of Disassembling And Connecting Push-Pull Type Coupler

    After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (Fig. 5) a 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, WA380Z-6...
  • 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, WA380Z-6...
  • 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, WA380Z-6...

  • Page 50: Standard Tightening Torque Table

    Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are the ones indicated in the table for bolts shown in Fig. B. (Values of tightening torques shown in the table for Fig. A are applied.) WA380-6, WA380Z-6...
  • Page 51 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0} – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0} 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5} – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5} – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0} WA380-6, WA380Z-6...
  • Page 52 Tightening torque Thread size Bolts and nuts 10 ± 2 1.02 ± 0.20 24 ± 4 2.45 ± 0.41 43 ± 6 4.38 ± 0.61 77 ± 12 7.85 ± 1.22 — — WA380-6, WA380Z-6...
  • Page 53 2.04 ± 0.20 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51 WA380-6, WA380Z-6...

  • Page 54: Conversion Table

    2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898 WA380-6, WA380Z-6...
  • Page 55 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153 WA380-6, WA380Z-6...
  • Page 56 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4 WA380-6, WA380Z-6...
  • Page 57 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542 WA380-6, WA380Z-6...
  • Page 58 167.0 65.6 302.0 –14.4 42.8 105.8 24.4 168.8 68.3 311.0 –13.9 44.6 107.6 25.0 170.6 71.1 320.0 –13.3 46.4 109.4 25.6 172.4 73.9 329.0 –12.8 48.2 111.2 26.1 174.2 76.7 338.0 –12.2 50.0 113.0 26.7 176.0 79.4 347.0 WA380-6, WA380Z-6...
  • Page 59 00 Index and foreword SEN06414-00 WA380-6, WA380Z-6...
  • Page 60 SEN06414-00 WA380-6, WA380Z-6 WHEEL LOADER Form No. SEN06414-00 © 2013 KOMATSU All Rights Reserved Printed in Japan 04-13 (01)
  • Page 61 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

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