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Komatsu WA380-7 Shop Manual

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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.
October 2013
-7
WA380-7 A64001
6D107E-2
and up
Copyright 2013 Komatsu
Printed in U.S.A.
Komatsu America Corp.
CEBM25604

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Summary of Contents for Komatsu WA380-7

  • Page 1 6D107E-2 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 DIAGRAMS AND DRAWINGS ..........90-1 00-2 WA380-7 Find manuals at https://best-manuals.com...
  • Page 3 00-2-19 ● 00-31 00-60 10-13 00-2-20 00-32 10-14 00-3 00-33 01-1 10-15 00-4 00-34 01-2 10-16 00-5 00-35 01-3 10-17 00-6 00-36 01-4 10-18 00-7 00-37 01-5 10-19 00-8 00-38 01-6 10-20 00-9 WA380-7 00-2-1 WA380-7 Find manuals at https://best-manuals.com...
  • Page 4 10-111 10-144 10-46 10-79 10-112 10-145 10-47 10-80 10-113 10-146 10-48 10-81 10-114 10-147 10-49 10-82 10-115 10-148 10-50 10-83 10-116 10-149 10-51 10-84 10-117 10-150 10-52 10-85 10-118 10-151 10-53 10-86 10-119 10-152 00-2-2 WA380-7 Find manuals at https://best-manuals.com...
  • Page 5 10-243 10-276 10-178 10-211 10-244 10-277 10-179 10-212 10-245 10-278 10-180 10-213 10-246 10-279 10-181 10-214 10-247 10-280 10-182 10-215 10-248 10-281 10-183 10-216 10-249 10-282 10-184 10-217 10-250 10-283 10-185 10-218 10-251 10-284 WA380-7 00-2-3 Find manuals at https://best-manuals.com...
  • Page 6 10-342 10-375 20-17 10-310 10-343 10-376 20-18 10-311 10-344 10-377 10-312 10-345 10-378 30-1 10-313 10-346 10-379 30-2 10-314 10-347 10-380 30-3 10-315 10-348 10-381 30-4 10-316 10-349 10-382 30-5 10-317 10-350 10-383 30-6 00-2-4 WA380-7 Find manuals at https://best-manuals.com...
  • Page 7 30-97 30-130 30-32 30-65 30-98 30-131 30-33 30-66 30-99 30-132 30-34 30-67 30-100 30-133 30-35 30-68 30-101 30-134 30-36 30-69 30-102 30-135 30-37 30-70 30-103 30-136 30-38 30-71 30-104 30-137 30-39 30-72 30-105 30-138 WA380-7 00-2-5 Find manuals at https://best-manuals.com...
  • Page 8 30-196 30-229 30-262 30-164 30-197 30-230 30-263 30-165 30-198 30-231 30-264 30-166 30-199 30-232 30-265 30-167 30-200 30-233 30-266 30-168 30-201 30-234 30-267 30-169 30-202 30-235 30-268 30-170 30-203 30-236 30-171 30-204 30-237 40-1 00-2-6 WA380-7 Find manuals at https://best-manuals.com...
  • Page 9 40-27 40-60 40-93 40-126 40-28 40-61 40-94 40-127 40-29 40-62 40-95 40-128 40-30 40-63 40-96 40-129 40-31 40-64 40-97 40-130 40-32 40-65 40-98 40-131 ● 40-33 40-66 40-99 40-132 ● 40-34 40-67 40-100 40-133 WA380-7 00-2-7 Find manuals at https://best-manuals.com...
  • Page 10 40-228 40-261 ● ● ● ● 40-163 40-196 40-229 40-262 ● ● ● ● 40-164 40-197 40-230 40-263 ● ● ● ● 40-165 40-198 40-231 40-264 ● ● ● ● 40-166 40-199 40-232 40-265 00-2-8 WA380-7 Find manuals at https://best-manuals.com...
  • Page 11 ● ● 40-294 40-327 40-360 40-393 ● ● ● ● 40-295 40-328 40-361 40-394 ● ● ● ● 40-296 40-329 40-362 40-395 ● ● ● ● 40-297 40-330 40-363 40-396 ● ● ● ● 40-298 40-331 40-364 40-397 WA380-7 00-2-9...
  • Page 12 ● ● 40-426 40-459 40-492 40-525 ● ● ● ● 40-427 40-460 40-493 40-526 ● ● ● ● 40-428 40-461 40-494 40-527 ● ● ● ● 40-429 40-462 40-495 40-528 ● ● ● ● 40-430 40-463 40-496 40-529 00-2-10 WA380-7...
  • Page 13 ● ● 40-558 40-591 40-624 40-657 ● ● ● ● 40-559 40-592 40-625 40-658 ● ● ● ● 40-560 40-593 40-626 40-659 ● ● ● ● 40-561 40-594 40-627 40-660 ● ● ● ● 40-562 40-595 40-628 40-661 WA380-7 00-2-11...
  • Page 14 ● ● 40-690 40-723 40-756 40-789 ● ● ● ● 40-691 40-724 40-757 40-790 ● ● ● ● 40-692 40-725 40-758 40-791 ● ● ● ● 40-693 40-726 40-759 40-792 ● ● ● ● 40-694 40-727 40-760 40-793 00-2-12 WA380-7...
  • Page 15 ● ● 40-822 40-855 40-888 40-921 ● ● ● ● 40-823 40-856 40-889 40-922 ● ● ● ● 40-824 40-857 40-890 40-923 ● ● ● ● 40-825 40-858 40-891 40-924 ● ● ● ● 40-826 40-859 40-892 40-925 WA380-7 00-2-13...
  • Page 16 ● ● 40-954 40-987 40-1020 40-1053 ● ● ● ● 40-955 40-988 40-1021 40-1054 ● ● ● ● 40-956 40-989 40-1022 40-1055 ● ● ● ● 40-957 40-990 40-1023 40-1056 ● ● ● ● 40-958 40-991 40-1024 40-1057 00-2-14 WA380-7...
  • Page 17 ● ● 40-1086 40-1119 40-1152 40-1185 ● ● ● ● 40-1087 40-1120 40-1153 40-1186 ● ● ● ● 40-1088 40-1121 40-1154 40-1187 ● ● ● ● 40-1089 40-1122 40-1155 40-1188 ● ● ● ● 40-1090 40-1123 40-1156 40-1189 WA380-7 00-2-15...
  • Page 18 50-70 50-103 50-5 50-38 50-71 50-104 50-6 50-39 50-72 50-105 50-7 50-40 50-73 50-106 50-8 50-41 50-74 50-107 50-9 50-42 50-75 50-108 50-10 50-43 50-76 50-109 50-11 50-44 50-77 50-110 50-12 50-45 50-78 50-111 50-13 50-46 50-79 50-112 00-2-16 WA380-7...
  • Page 19 50-202 50-235 50-137 50-170 50-203 50-236 50-138 50-171 50-204 50-237 50-139 50-172 50-205 50-238 50-140 50-173 50-206 50-239 50-141 50-174 50-207 50-240 50-142 50-175 50-208 50-241 50-143 50-176 50-209 50-242 50-144 50-177 50-210 50-243 50-145 50-178 50-211 50-244 WA380-7 00-2-17...
  • Page 20 60-3 60-36 50-269 50-302 60-4 60-37 50-270 50-303 60-5 60-38 50-271 50-304 60-6 60-39 50-272 50-305 60-7 60-40 50-273 50-306 60-8 60-41 50-274 50-307 60-9 60-42 50-275 50-308 60-10 60-43 50-276 50-309 60-11 60-44 50-277 50-310 60-12 60-45 00-2-18 WA380-7...
  • Page 21 60-71 80-15 80-48 ● 60-72 80-16 80-49 90-1 ● 60-73 80-17 80-50 90-2 ● 60-74 80-18 80-51 90-3 ● 60-75 80-19 80-52 90-4 ● 60-76 80-20 80-53 90-5 ● 60-77 80-21 80-54 90-6 ● 60-78 80-22 80-55 90-7 WA380-7 00-2-19...
  • Page 22 Mark Page Mark Page 90-8 90-41 90-9 90-10 90-11 90-12 90-13 90-14 90-15 90-16 90-17 90-18 90-19 90-20 90-21 90-22 90-23 90-24 90-25 90-26 90-27 90-28 90-29 90-30 90-31 90-32 90-33 90-34 90-35 90-36 90-37 90-38 90-39 90-40 00-2-20 WA380-7...
  • Page 23 FOREWORD CONTENTS MEMORANDUM WA380-7 00-3...

  • Page 24: Important Safety Notice

    Before starting used to or work with which you are too work, hang UNDER REPAIR signs on the controls in familiar the operator's compartment. Only qualified workers must perform the work and operation which require license or qualification. 00-4 WA380-7...

  • Page 25: Preparations For Work

    12. 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. WA380-7 00-5...
  • Page 26 When tightening nuts of the air conditioner hoses and tubes, be sure to use two wrenches; one to fix the nut and the other to tighten the nut to the specified torque (Use a torque wrench for tightening). 00-6 WA380-7...
  • Page 27 18. 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 and procedures for jump starting the machine. WA380-7 00-7...
  • Page 28 NOTICE Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the "Chassis volume" and "Engine volume". For the engine unit, see the engine volume of the engine model mounted on the machine.

  • Page 29: How To Read The Shop Manual

    International System of units (SI). ● For reference, conventionally used Gravitational System 10-5 of units is indicated in parentheses {}. Revised Edition Mark When a manual is revised, an edition mark (…) is recorded on the bottom outside corner of the pages. WA380-7 00-9...

  • Page 30: Hoisting Instructions

    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. Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 00-10 WA380-7...
  • Page 31 Precautions for Using Mobile Crane 12. Remember the position of the main switch so that you Read the Operation & Maintenance Manual provided with can turn off the power immediately in an emergency. the crane in advance and operate the crane safely. WA380-7 00-11...
  • Page 32 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. 00-12 WA380-7...
  • Page 33 Allowable load tons 11.2 13.7 12.5 15.7 21.6 27.5 35.3 43.1 22.4 54.9 98.1 10.0 176.5 18.0 274.6 28.0 392.2 40.0 The allowable load value is 1/6 of the breaking strength of the rope used. Safety coefficient: 6 WA380-7 00-13...
  • Page 34 The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage. 00-14 WA380-7...
  • Page 35 If any water or mud or dirt is stuck to the outside surface of a connector, it can enter inside the connector when the connector is disconnected. Before disconnecting a connector, wipe off any stuck water or dirt using a piece of dry cloth or blow it with compressed air. WA380-7 00-15...
  • Page 36 ★ If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector. 00-16 WA380-7...
  • Page 37 Since the DT 8-pin and 12-pin heavy duty wire connectors have 2 latches respectively, push them in until they click 2 times. Male connector Female connector ★ Normal locking state (Horizontal):a, b, d ★ Incomplete locking state (Diagonal):c WA380-7 00-17...
  • Page 38 ★ Mainly, following engines are object for following connectors. • 95E-5 • 107E-1, 107E-2 • 114E-3, 114E-5 • 125E-5, 125E-6 • 140E-5, 140E-6 • 170E-5 • 12V140E-3 Slide, lock type (Type 1) (FRAMATOME-3, FRAMATOME-2) • 95/107/114/125/140/170/12V140 Series • Various pressure sensors and Ne speed sensor. Examples: 00-18 WA380-7...
  • Page 39 Insert the connector straight until it “clicks.” Slide, lock type (Type 2) (FRAMATOME-24) • 107/114/125 Series • Intermediate connector between machine wiring harness and engine wiring harness. Examples: Intermediate connector (engine wiring harness): OEM CONNECTION (107/114/125 series) A. Disconnection Slide down lock (red) (L1). WA380-7 00-19...
  • Page 40 Oil temperature sensor: TOIL iv. Coolant temperature sensor: TWTR and other. A. Disconnection Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward. B. Connection Insert the connector straight in until it “clicks.” 00-20 WA380-7...
  • Page 41 [1] since you cannot insert your fingers. While pressing up lock (C) of the connector with the flat- head screwdriver [1], pull out connector (3) in the direction of the arrow. B. Connection Insert the connector straight until it “clicks.” WA380-7 00-21...
  • Page 42 While pressing lock (E) of the connector, pull out connector (5) in the direction of the arrow. • Example: Fuel pressure sensor in common rail PFUEL etc. (AMP-3) • Example: Injection pressure control valve of supply pump: PCV (SUMITOMO-2) 00-22 WA380-7...
  • Page 43 Pull out housing (H1) in the direction of the arrow. ★ Housing (H1) is left on the wiring harness. B. Connection Insert the connector to the end, while aligning its groove to the other. ii. Turn housing (H1) in the direction of the arrow until it “clicks.” WA380-7 00-23...
  • Page 44 • If there is any value change on the tester, there may be a defective contact in that circuit. 00-24 WA380-7...
  • Page 45 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS MEMORANDUM WA380-7 00-25...
  • Page 46 If any old oil is left, contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. 00-26 WA380-7...
  • Page 47 The oil cleaning equipment is used to remove the ultra fine {about 3 (10 ft)} particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device. WA380-7 00-27...
  • Page 48 After inserting the hose in the mating adapter, pull it back to check its connecting condition. When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate an abnormality. 00-28 WA380-7...
  • Page 49 Hold conditions of Steps 1 and 2, pull out the whole body (2) to disconnect it. Connection Hold the connector of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts surface a of the hexagonal portion at the male end to connect it. WA380-7 00-29...
  • Page 50 Connection Hold the connector of the tightening portion and push the body (2) in straight until the slide prevention ring (1) contacts surface a of the hexagonal portion at the male end to connect it. 00-30 WA380-7...
  • Page 51 After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range. Repair Limit And Allowable Value • The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the “repair limit”. WA380-7 00-31...
  • Page 52 Wash the system carefully with clean fuel if dusts enter the system. Precautions for replacing fuel filter cartridge ● Be sure to use the Komatsu genuine fuel filter cartridge. ● Since the common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzles, it employs a high-efficiency special filter to prevent foreign matter from entering it.
  • Page 53 HANDLING OF INTAKE SYSTEM PARTS ● The Komatsu Variable Geometry Turbocharger (KVGT) consists of more precise parts (variable mechanism) than the conventional turbocharger. If foreign matter enters this system, it can cause a problem. Use special care to prevent entry of foreign matter when servicing the air intake system.

  • Page 54: Standard Tightening Torque

    13.7 - 23.5 10.10 - 17.33 34.3 - 46.1 25.29 - 34.00 74.5 - 90.2 54.94 - 66.52 Figure A Figure B ★ Values with ( ) are applied to * marked bolt (flange bolt) as the width across flats. 00-34 WA380-7...
  • Page 55 36.1 ± 14.4 78.5 ± 19.6 57.8 ± 14.4 137.3 ± 29.4 101.2 ± 21.6 176.5 ± 29.4 130.1 ± 21.6 196.1 ± 49 144.6 ± 36.1 245.2 ± 49 180.8 ± 36.1 294.2 ± 49 216.9 ± 36.1 WA380-7 00-35...
  • Page 56 93.1 - 122.5 (68.66 - 90.35) 107.8 (79.50) – 107.8 - 147.0 (79.50 - 108.42) 127.4 (93.96) 127.4 - 176.4 (93.96 - 130.10) 151.9 (112.03) – 181.3 - 240.1 (133.72 - 177.08) 210.7 (155.40) – 274.4 - 367.5 (202.38 - 271.05) 323.4 (238.52) 00-36 WA380-7...
  • Page 57 Tightening Torque Thread Size Bolts and Nuts N•m lbf in 10 ±2 1.02 ±0.20 88.51 ±17.70 24 ±4 2.45 ±0.41 17.70 ±2.95 43 ±6 4.38 ±0.61 31.72 ±4.43 77 ±12 7.85 ±1.22 56.79 ±8.85 — — — WA380-7 00-37...
  • Page 58 14.75 ±1.48 35 ±4 3.57 ±0.41 25.81 ±2.95 25 ±3 2.55 ±0.31 18.44 ±2.21 55 ±6 5.61 ±0.61 40.57 ±4.43 35 ±4 3.57 ±0.41 25.81 ±2.95 75 ±8 7.65 ±0.82 55.32 ±5.90 45 ±5 4.59 ±0.51 33.19 ±3.69 00-38 WA380-7...
  • Page 59 — White & Red & Yellow & Green & Blue & Color — — Green Green Blue Black Black Code — — — — Yellow & Green & Color — — — Red & Blue — White Blue WA380-7 00-39...

  • Page 60: How To Read Electric Wire Code

    (nominal No. 125 and below) Insulator Soft polyvinyl chloride (type 2) Annealed copper for electric Heat-resistant Conductor General wiring in extremely cold appliance low-voltage –50 to +110 district, wiring at high-temperature wire for (-58 to +230) Heat-resistant crosslinked place Insulator automobile polyethylene 00-40 WA380-7...
  • Page 61 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

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A64001