Komatsu WA380-6 Wheel Loader Service Repair Manual SN A53001 and up

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CEBM017402Shop ManualWA380-6 WHEEL LOADERSERIAL NUMBERSWA380-6A53001and UPThis material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or…
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CEBM017402Shop ManualWA380-6 WHEEL LOADERSERIAL NUMBERSWA380-6A53001and UPThis 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.August 2011 Printed in USACopyright 2011 Komatsu DataKom Publications Division 00-1 cFOREWORDCONTENTS12CONTENTS 01GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-110STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-120STANDARD VALUE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-140TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-190DIAGRAMS AND SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-100-2 c00FOREWORDSAFETY12aSAFETY Safety Notice0000IMPORTANT SAFETY NOTICE00Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose. To prevent injury to workers, the symbol is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.General PrecautionsMistakes in operation are extremely dangerous. Read the Operation & Maintenance Manual carefully BEFORE operating the machine. In addition, read this manual and understand its contents before starting the work. 1.2.Before carrying out any greasing or repairs, read all the precautions given on the labels which are fixed to the machine. For the locations of the safety labels and a detailed explanation of precautions, see the Operation & Maintenance Manual. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • •3.Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap, and other clothes suited for welding work. WARNING! Never modify, weld, cut, or drill on any part of a ROPS structure. Doing so may weaken the structure which could lead to possible failure in a rollover situation4.When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment.WA380-65.Keep all tools in good condition; learn the correct way to use them; and use the proper ones. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.6.Only qualified workers must carry out work and operations which require license or qualification.7.Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.8.Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.00Safety Points 1Good arrangement2Correct work clothes3Following work standard4Making and checking signs5Prohibition of operation and handling by unlicensed workers6Safety check before starting work7Wearing protective goggles (for cleaning or grinding work)8Wearing shielding goggles and protectors (for welding work)9Good physical condition and preparation10Precautions against work which you are not used to or work with which you are too familiar00-3 cFOREWORD Preparations for Work 1.2.SAFETY 006.Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires.7.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.8.Gasoline or other fuels should never be used to clean parts. Clean parts with appropriate solvents.9.Be sure to assemble all parts again in their original places. Replace any damaged parts or parts that must not be reused with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated.Before starting work, lower blade, ripper, bucket, or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.3.When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work.4.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders, or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders, or steps, use a stand to provide safe footing.Precautions During Work 1.00When removing the oil filler cap, drain plug, or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit.10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed. 11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.2.The coolant and oil in the circuits are hot when the engine is stopped; be careful not to get burned. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits.13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements.3.Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly; never let anyone stand at either end of the track.4.When raising heavy components (in excess of 25 kg (55 lb)), use a hoist or crane. Check that the wire rope, chains, and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.5.When removing a cover which is under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Loosen the bolts gradually and alternately to release the pressure, and then remove the cover.00-4 c15. When jump-starting the machine, only use a machine of similar size and voltage. Never use an arc welder or other electrical generating equipment to jump-start the machine. Carefully review the safety procedures for jump starting the machine. 16. Before starting work, stop the engine. When working on or around a rotating part, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), be extremely careful not to get rolled or caught in rotating or moving parts. 17. If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Before starting the engine, open the windows and doors so that the area is well ventilated.FOREWORDGENERAL12GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgments. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components. General00Standard Value Table This section explains the standard values for a new machine and the judgment criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. Testing and Adjusting This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. TroubleshootingThis section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant, and lubricant specification charts.Troubleshooting charts correlating Problems to Causes are included in this section.Structure, Function, and Maintenance StandardDisassembly and AssemblyThis section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section gives the judgment standards when inspecting disassembled parts.This section explains the order to be followed when removing, installing, disassembling, or assembling each component, as well as precautions to be taken for these operations. Other This section has the foldout drawings for the machine.NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your distributor for the latest information.WA380-600-5 cFOREWORDHOW TO READ THE SHOP MANUAL12HOW TO READ THE SHOP MANUAL Volumes0000Revised Edition Mark00Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:When a manual is revised, an edition mark (bcd‌) is recorded on the bottom, outside corner of the pages.Chassis volume: Issued for every machine modelRevisionsEngine volume: Issued for each engine seriesRevised pages are shown at the List of Revised Pages between the title page and SAFETY page.Electrical volume: One issued to cover all modelsSymbolsAttachment volume: One issued to cover all models These various volumes are designed to avoid duplication of information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical, and attachment manuals be available.Distribution and UpdatingSymbolItemRemarksSafetySpecial safety precautions are necessary when performing the work.CautionSpecial technical precautions or other precautions for preserving standards are necessary when performing the work.WeightWeight of parts or systems. Caution necessary when selecting hoisting wire or when working posture is important, etc.00★ 001.See the page number on the bottom of the page. File the pages in correct order.2.Following examples show how to read the page number: Example:Places that require special Tightening attention for tightening torque torque during assembly.10 - 3 Item number (10. Structure and Function) Consecutive page number for each item 3.00So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols.Any additions, amendments, or other changes will be sent to your distributors. Get the most up-to-date information before you start any work.Filing Method00Additional pages: Additional pages are indicated by a hyphen (-) and numbered after the page number. File as in the example.CoatPlaces to be coated with adhesives and lubricants, etc.Oil, waterPlaces where oil, water, or fuel must be added, and the capacity.DrainPlaces where oil or water must be drained, and quantity to be drained.Example: 10-4 10-4-1 10-4-2Added pages10-500-6 cWA380-6FOREWORDHOISTING INSTRUCTIONS12HOISTING INSTRUCTIONS Hoisting00005.★ If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made. 1.Check for removal of all bolts fastening the part to the relative parts.2.Check for existence of another part causing interface with the part to be removed.Making SignsWARNING! Slinging with one rope may cause the load to turn during hoisting, the rope to untwist, or the rope to slip from its original winding position on the load, which can result in a dangerous accident.001.Only one appointed worker must make signs and coworkers must communicate with each other frequently.2.The appointed signaler must make specified signs clearly at a place where he is well seen from the operator’s seat and where he can see the working condition easily.3.6.••Do not stand under the load. Do not step on the load.Precautions Precautions for Sling Work00001.Check the slings before starting sling work.2.Wear gloves during sling work. Use leather gloves, if available.3.Measure the weight of the load visually and check its center of gravity.4.Use a proper sling according to the weight of the load and method of slinging. If the wire ropes you use are too thick when slinging a light load, the load may slip and fall.WA380-6Limit the hanging angle to 60°, as a rule. •The signaler must always stand in front of the load and guide the operator safely. • •Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load.Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The following table shows the variation of allowable load in kg (lbs) when hoisting is made with two ropes, each of which is allowed to sling up to 1,000 kg (2,205 lbs) vertically, at various hanging angles. When two ropes sling a load vertically, up to 2,000 kg (4,409 lbs) of total weight can be suspended. This weight is reduced to 1,000 kg (2,205 lbs) when two ropes make a 120° hanging angle. On the other hand, two ropes are subject to an excessive force as large as 4,000 kg (8,819 lbs) if they sling a 2,000 kg (4,409 lbs) load at a lifting angle of 150°.7.When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping.8.Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc.00-7 cFOREWORD 9.HOISTING INSTRUCTIONSApply wire ropes from the middle portion of the hook. •Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.10. Do not use twisted or kinked wire ropes. 11. When lifting up a load, observe the following. ••• •Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes by hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads. If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. Do not lift the load at a slanted angle.12. When lowering a load, observe the following. • • •When lowering a load, stop it temporarily at 30 cm (12 in) above the floor, and then lower it slowly. Check that the load is stable, and then remove the sling. Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.Precautions for Using Mobile Crane00WARNING! Heavy parts (25 kg (55 lb) or more) must be lifted with a hoist, etc. In the Disassembly and Assembly section, every part weighing 25 kg or more is indicated clearly with the symbol.1.Before starting work, inspect the wire ropes, brake, clutch, controller, rails, overwind stop device, ground fault protection circuit breaker, crane collision prevention device, and power application warning lamp, and check safety.2.Observe the signs for sling work.3.Operate the hoist at a safe place.4.Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail.5.Do not sling a load at an angle. Do not move the crane while the slung load is swinging.6.Do not raise or lower a load while the crane is moving longitudinally or laterally.7.Do not drag a sling.8.When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up.9.Consider the travel route in advance and lift up a load to a safe height.10. Place the control switch at a position where it will not be an obstacle to work and passage. 11. After operating the hoist, do not swing the control switch.00★ Read the Operation & Maintenance Manual provided with the crane in advance and operate the crane safely.00-8 cPrecautions for Using Overhead Hoist Crane12. Remember the position of the main switch so that you can turn off the power immediately in an emergency.FOREWORD 13. If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the ground fault protection circuit breaker, check that the devices related to that switch are not in operational state. 14. If there is an obstacle around the hoist, stop the operation. 15. After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m (6.6 ft) above the floor. Do not leave the sling installed to the hook.HOISTING INSTRUCTIONSSelecting Wire Ropes 1.00Use adequate ropes depending on the weight of parts to be hoisted. Refer to the following table. Wire ropes (Standard “Z” twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Rope Allowable load Diameter mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4★ The allowable load value is 1/6 of the breaking strength of the rope used. Safety coefficient: 6WA380-600-9 cFOREW
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