Komatsu WA380-6 Install guide
WHEEL LOADER
SEN06411-02
WA380
-6
WA380Z
-6
SERIAL NUMBERS
WA380- 65001
WA380Z-66847
and up
WA380-6, WA380Z-6 1
SEN06413-02
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 1
Index
Composition of shop manual .......................................................................................................................... 2
Table of contents............................................................................................................................................. 4
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SEN06413-02 00 Index and foreword
2WA380-6, WA380Z-6
Composition of shop manual
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN06411-02
00 Index and foreword SEN06412-02
Index SEN06413-02 q
Foreword and general information SEN06414-00
01 Specification SEN06415-00
Specification and technical data SEN06416-00
10 Structure, function and maintenance standard SEN06417-00
Engine and cooling system SEN06418-00
Power train SEN06419-00
Steering system SEN06420-00
Brake system SEN06421-00
Undercarriage and frame SEN06422-00
Hydraulic system, Part 1 SEN06423-00
Hydraulic system, Part 2 SEN06424-00
Work equipment SEN06425-00
Cab and its attachments SEN06426-00
Electrical system, Part 1 SEN06427-00
Electrical system, Part 2 SEN06428-00
Electrical system, Part 3 SEN06429-00
20 Standard value table SEN06430-00
Standard service value table SEN06431-00
30 Testing and adjusting SEN06432-01
Testing and adjusting, Part 1 SEN06433-01 q
Testing and adjusting, Part 2 SEN06434-00
Testing and adjusting, Part 3 SEN06435-00
40 Troubleshooting SEN06436-00
Failure code table and fuse locations SEN06437-00
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
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00 Index and foreword SEN06413-02
WA380-6, WA380Z-6 3
Troubleshooting by failure code (Display of code), Part 4 SEN06442-00
Troubleshooting by failure code (Display of code), Part 5 SEN06443-00
Troubleshooting by failure code (Display of code), Part 6 SEN06444-00
Troubleshooting by failure code (Display of code), Part 7 SEN06445-00
Troubleshooting by failure code (Display of code), Part 8 SEN06446-00
Troubleshooting by failure code (Display of code), Part 9 SEN06447-00
Troubleshooting by failure code (Display of code), Part 10 SEN06448-00
Troubleshooting of electrical system (E-mode) SEN06449-00
Troubleshooting of hydraulic and mechanical system (H-mode) SEN06450-00
Troubleshooting of engine (S-mode) SEN06451-00
50 Disassembly and assembly SEN06452-01
General information on disassembly and assembly SEN06453-00
Engine and cooling system SEN06454-00
Power train SEN06455-01 q
Steering system SEN06456-00
Brake system 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
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SEN06413-02 00 Index and foreword
4WA380-6, WA380Z-6
Table of contents
00 Index and foreword
Index SEN06413-02
Composition of shop manual................................................................................................... 2
Table of contents...................................................................................................................... 4
Foreword and general information SEN06414-00
Safety notice............................................................................................................................ 2
How to read the shop manual.................................................................................................. 7
Explanation of terms for maintenance standard...................................................................... 9
Handling of electric equipment and hydraulic component....................................................... 11
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
01 Specification
Specification and technical data SEN06416-00
Specification dimension drawing.............................................................................................. 2
Specifications........................................................................................................................... 4
Weight table............................................................................................................................. 12
Table of fuel, coolant and lubricants ........................................................................................ 16
10 Structure, function and maintenance standard
Engine and cooling system SEN06418-00
Engine mount and transmission mount ................................................................................... 2
Cooling system........................................................................................................................ 3
Cooling fan pump..................................................................................................................... 5
Brake and fan pump ................................................................................................................ 12
Cooling fan motor .................................................................................................................... 13
Power train SEN06419-00
Power train............................................................................................................................... 3
Power train system diagram .................................................................................................... 4
Drive shaft................................................................................................................................ 7
Power train piping diagram......................................................................................................8
Torque converter...................................................................................................................... 10
Transmission............................................................................................................................ 18
Flow control valve.................................................................................................................... 52
Valve assembly........................................................................................................................ 54
ECMV ...................................................................................................................................... 55
Main relief valve and torque converter relief valve .................................................................. 63
Axle.......................................................................................................................................... 65
Differential................................................................................................................................ 67
Limited slip differential ............................................................................................................. 71
Final drive................................................................................................................................ 78
Steering system SEN06420-00
Steering piping diagram........................................................................................................... 2
Steering column....................................................................................................................... 4
Steering pump.......................................................................................................................... 6
Steering valve.......................................................................................................................... 26
Orbit-roll valve.......................................................................................................................... 41
Stop valve................................................................................................................................ 49
Steering relief valve ................................................................................................................. 50
Steering cylinder...................................................................................................................... 51
Emergency steering motor....................................................................................................... 53
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00 Index and foreword SEN06413-02
WA380-6, WA380Z-6 5
Emergency steering pump....................................................................................................... 54
Joystick steering lever linkage.................................................................................................55
Steering electric lever.............................................................................................................. 56
Joystick EPC valve.................................................................................................................. 57
Brake system SEN06421-00
Brake piping diagram............................................................................................................... 2
Charge valve ........................................................................................................................... 4
Brake valve.............................................................................................................................. 11
Accumulator (for brake)........................................................................................................... 16
Brake....................................................................................................................................... 18
Parking brake control............................................................................................................... 23
Parking brake .......................................................................................................................... 24
Parking brake solenoid valve................................................................................................... 26
Emergency parking brake release valve ................................................................................. 28
Undercarriage and frame SEN06422-00
Axle mount and center hinge pin............................................................................................. 2
Tires......................................................................................................................................... 7
Hydraulic system, Part 1 SEN06423-00
Hydraulic piping diagram......................................................................................................... 2
Work equipment control lever linkage ..................................................................................... 8
Hydraulic tank.......................................................................................................................... 11
Power train pump .................................................................................................................... 15
Work equipment pump ............................................................................................................ 16
Work equipment control valve ................................................................................................. 38
CLSS....................................................................................................................................... 66
Each function and operation of each valve.............................................................................. 70
Hydraulic system, Part 2 SEN06424-00
PPC valve................................................................................................................................ 2
Stabilizer valve......................................................................................................................... 8
Accumulator (for PPC circuit).................................................................................................. 14
Accumulator (for ECSS)..........................................................................................................15
Work equipment PPC cut-off solenoid valve ........................................................................... 16
Work equipment SEN06425-00
Work equipment linkage..........................................................................................................2
Bucket...................................................................................................................................... 6
Bucket positioner and boom kick-out....................................................................................... 8
Work equipment cylinder.........................................................................................................14
Cab and its attachments SEN06426-00
Cab.......................................................................................................................................... 3
Air conditioner.......................................................................................................................... 4
Electrical system, Part 1 SEN06427-00
Machine monitor system..........................................................................................................2
Machine monitor...................................................................................................................... 10
Electrical system, Part 2 SEN06428-00
Electrical system (Transmission controller system)................................................................. 2
Transmission controller............................................................................................................ 46
Electrical system (Work equipment controller system)............................................................ 50
Work equipment controller.......................................................................................................56
Electrical system, Part 3 SEN06429-00
Electric transmission control.................................................................................................... 2
Kickdown switch and hold switch ............................................................................................ 6
Multi-function knob .................................................................................................................. 8
Joystick steering knob............................................................................................................. 9
KOMTRAX terminal system..................................................................................................... 10
Engine starting circuit .............................................................................................................. 12
Engine stopping circuit ............................................................................................................ 16
Preheating circuit..................................................................................................................... 18
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SEN06413-02 00 Index and foreword
6WA380-6, WA380Z-6
Engine power mode selector circuit......................................................................................... 19
Engine output derating function............................................................................................... 20
Automatic warm-up function.................................................................................................... 20
Parking brake circuit................................................................................................................ 22
Sensor ..................................................................................................................................... 24
20 Standard value table
Standard service value table SEN06431-00
Standard service value table for engine................................................................................... 2
Standard service value table for chassis ................................................................................. 4
30 Testing and adjusting
Testing and adjusting, Part 1 SEN06433-01
Tools for testing, adjusting, and troubleshooting...................................................................... 3
Testing engine speed............................................................................................................... 10
Testing exhaust gas color........................................................................................................ 12
Adjusting valve clearance........................................................................................................ 14
Testing compression pressure................................................................................................. 19
Testing blow-by pressure......................................................................................................... 25
Testing engine oil pressure...................................................................................................... 26
Testing intake air (boost) pressure........................................................................................... 28
Handling fuel system equipment.............................................................................................. 30
Releasing residual pressure in fuel system............................................................................. 30
Testing fuel pressure................................................................................................................ 31
Testing fuel delivery, return and leak amount .......................................................................... 36
Bleeding air from fuel circuit .................................................................................................... 44
Testing leakage in fuel system................................................................................................. 46
Handling reduced cylinder mode operation............................................................................. 47
Handling no-injection cranking operation................................................................................. 47
Handling controller voltage circuit............................................................................................ 48
Testing muffler (main body) and muffler stack for looseness or damage................................. 48
Testing muffler for functions..................................................................................................... 49
Testing cylinder head and manifold parts for tightness............................................................ 49
Testing engine piping for damage and tightness ..................................................................... 50
Testing and adjusting air conditioner compressor belt tension ................................................ 51
Replacing alternator belt.......................................................................................................... 52
Adjusting transmission speed sensor...................................................................................... 53
Adjusting length of directional lever......................................................................................... 54
Adjusting length of gearshift lever............................................................................................ 54
Testing directional lever........................................................................................................... 55
Testing and adjusting power train oil pressure......................................................................... 56
Procedure for flushing torque converter and transmission hydraulic circuit ............................ 85
Method of moving machine when transmission valve is broken.............................................. 86
Testing axle end for oil leakage ............................................................................................... 90
Testing drive shaft for looseness, backlash and damage ........................................................ 90
Testing and adjusting steering stop valve................................................................................ 91
Testing and adjusting steering wheel....................................................................................... 93
Testing and adjusting steering oil pressure.............................................................................. 95
Bleeding air from steering circuit ............................................................................................. 98
Testing and adjusting, Part 2 SEN06434-00
Testing hydraulic drive fan....................................................................................................... 3
Bleeding air from hydraulic drive fan circuit............................................................................. 7
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
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00 Index and foreword SEN06413-02
WA380-6, WA380Z-6 7
Testing wheel brake oil pressure drop..................................................................................... 16
Testing wear of wheel brake disc............................................................................................. 18
Bleeding air from wheel brake circuit....................................................................................... 19
Releasing residual pressure in brake accumulator circuit ....................................................... 20
Testing parking brake performance ......................................................................................... 21
Testing parking brake oil pressure........................................................................................... 22
Testing wear of parking brake disc .......................................................................................... 24
Method of releasing parking brake manually........................................................................... 25
Testing and adjusting work equipment control lever................................................................ 26
Testing and adjusting work equipment PPC oil pressure ........................................................ 27
Testing and adjusting work equipment oil pressure................................................................. 33
Bleeding air from work equipment circuit................................................................................. 37
Releasing residual pressure in work equipment circuit ........................................................... 38
Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of ECSS
(Electronically Controlled Suspension System) accumulator........................................... 40
Testing and adjusting bucket positioner................................................................................... 46
Testing and adjusting boom kick-out ....................................................................................... 48
Checking proximity switch operation pilot lamp....................................................................... 49
Procedure for testing diodes....................................................................................................50
Preparation work for troubleshooting for electric system......................................................... 51
How to start operation of KOMTRAX terminal......................................................................... 60
Lamp display of KOMTRAX terminal....................................................................................... 65
Testing and adjusting, Part 3 SEN06435-00
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ...... 3
Special functions of machine monitor (EMMS)........................................................................ 5
Pm-clinic inspection table........................................................................................................ 74
40 Troubleshooting
Failure code table and fuse locations SEN06437-00
Failure code table.................................................................................................................... 2
Fuse locations ......................................................................................................................... 19
General information on troubleshooting SEN06438-00
Points to remember when troubleshooting.............................................................................. 2
Sequence of events in troubleshooting ................................................................................... 3
Testing before troubleshooting ................................................................................................ 5
Classification and procedures of troubleshooting.................................................................... 6
Information contained in troubleshooting table........................................................................ 9
Connection table for connector pin numbers........................................................................... 11
T- branch box and T- branch adapter table ............................................................................. 47
Troubleshooting by failure code (Display of code), Part 1 SEN06439-00
Failure code [1500L0] (TORQFLOW transmission: Double meshing)...................................... 3
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON) ..... 4
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF) .... 6
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)..... 8
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF).... 10
Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)... 12
Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF).. 14
Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON).. 16
Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF). 18
Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON).. 20
Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF). 22
Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON).. 24
Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF) . 26
Failure code [2F00MA] (Parking brake: Malfunction)................................................................ 28
Failure code [2G43ZG] (Accumulator: Low oil pressure).......................................................... 31
Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree) ..................................... 35
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SEN06413-02 00 Index and foreword
8WA380-6, WA380Z-6
Troubleshooting by failure code (Display of code), Part 2 SEN06440-00
Failure code [AA1ANX] (Air cleaner: Clogging)....................................................................... 4
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine).............. 7
Failure code [AB00MA] (Alternator: Malfunction) .................................................................... 11
Failure code [B@BAZG] (Rotation derating by low engine oil pressure)................................. 15
Failure code [B@BAZK] (Engine oil: Low level) ...................................................................... 16
Failure code [B@BCNS] (Coolant: Overheating)..................................................................... 17
Failure code [B@BCZK] (Coolant: Low level).......................................................................... 19
Failure code [B@BEBF] (Water in fuel error) .......................................................................... 22
Failure code [B@C7NS] (Brake oil: Overheating) ................................................................... 24
Failure code [b@CENS] (Torque converter oil: Overheating).................................................. 26
Failure code [B@CENS] (Torque converter oil: Overheating) ................................................. 29
Failure code [B@HANS] (Hydraulic oil: Overheating) ............................................................. 32
Failure code [CA111] (Abnormality in engine controller).......................................................... 34
Failure code [CA115] (Engine Ne or Bkup speed sensor error) .............................................. 35
Failure code [CA122] (Charge pressure sensor high error)..................................................... 36
Failure code [CA123] (Charge pressure sensor low error)...................................................... 38
Failure code [CA131] (Throttle sensor high error) ................................................................... 40
Failure code [CA132] (Throttle sensor low error)..................................................................... 42
Failure code [CA144] (Coolant sensor high error)................................................................... 44
Failure code [CA145] (Coolant sensor low error) .................................................................... 46
Failure code [CA153] (Charge temperature sensor high error) ............................................... 48
Failure code [CA154] (Charge temperature sensor low error)................................................. 50
Failure code [CA155] (Derating of speed by abnormally high charge temperature)................ 52
Failure code [CA187] (Sensor power supply 2 low error)........................................................ 54
Failure code [CA221] (Atmospheric pressure sensor high error) ............................................ 56
Failure code [CA222] (Atmospheric sensor low error)............................................................. 58
Failure code [CA227] (Sensor power supply 2 high error)....................................................... 60
Failure code [CA234] (Engine overspeed)............................................................................... 61
Failure code [CA238] (Ne speed sensor power supply error).................................................. 62
Troubleshooting by failure code (Display of code), Part 3 SEN06441-00
Failure code [CA271] (IMV/PCV1 Short circuit)....................................................................... 3
Failure code [CA272] (IMV/PCV1 Disconnection) ................................................................... 4
Failure code [CA322] (Injector #1 open/short error)................................................................ 6
Failure code [CA323] (Injector #5 open/short error)................................................................ 8
Failure code [CA324] (Injector #3 open/short error)................................................................ 10
Failure code [CA325] (Injector #6 open/short error)................................................................ 12
Failure code [CA331] (Injector #2 open/short error)................................................................ 14
Failure code [CA332] (Injector #4 open/short error)................................................................ 16
Failure code [CA342] (Calibration code inconsistency)........................................................... 18
Failure code [CA351] (Injectors drive circuit error).................................................................. 20
Failure code [CA352] (Sensor power supply 1 low error)........................................................ 23
Failure code [CA386] (Sensor power supply 1 high error)....................................................... 25
Failure code [CA428] (Abnormally high level in water sensor)................................................ 26
Failure code [CA429] (Abnormally low level in water sensor) ................................................. 27
Failure code [CA431] (Idle validation switch error).................................................................. 28
Failure code [CA432] (Idle validation action error) .................................................................. 31
Failure code [CA435] (Engine oil pressure switch error) ......................................................... 33
Failure code [CA441] (Battery voltage low error)..................................................................... 34
Failure code [CA442] (Battery voltage high error) ................................................................... 38
Failure code [CA449] Common rail pressure high error 2....................................................... 41
Failure code [CA451] (Common rail pressure sensor high error)............................................ 43
Failure code [CA452] (Common rail pressure sensor low error) ............................................. 45
Failure code [CA488] (Derating of torque by abnormally high charge temperature) ............... 47
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
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00 Index and foreword SEN06413-02
WA380-6, WA380Z-6 9
Failure code [CA757] (All continuous data lost error).............................................................. 54
Failure code [CA778] (Engine Bkup speed sensor error)........................................................ 58
Failure code [CA1633] (KOMNET datalink timeout error) ....................................................... 61
Failure code [CA2185] (Throttle sensor power supply voltage high error) .............................. 64
Failure code [CA2186] (Throttle sensor power supply voltage low error)................................ 65
Troubleshooting by failure code (Display of code), Part 4 SEN06442-00
Failure code [CA2249] (Supply pump pressure very low error 2)............................................ 3
Failure code [CA2311] (Abnormality in IMV solenoid)............................................................. 4
Failure code [CA2555] (Intake heater relay disconnection error)............................................ 6
Failure code [CA2556] (Intake heater relay short circuit error)................................................ 9
Failure code [D150KA] (Emergency steering relay: Disconnection)........................................ 12
Failure code [D150KB] (Emergency steering relay: Short circuit) ........................................... 15
Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line)....... 18
Failure code [D160KA] (Backup lamp relay: Disconnection)................................................... 21
Failure code [D160KB] (Backup lamp relay: Short circuit) ...................................................... 24
Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection) ...................... 27
Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit).......................... 29
Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit
with power supply line)....................................................................................... 31
Failure code [D192KA] (ECSS solenoid: Disconnection) ........................................................ 33
Failure code [D192KB] (ECSS solenoid: Short circuit)............................................................ 34
Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)........................ 35
Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection)......................... 36
Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit) ............................ 38
Failure code [D193KY] (Joystick steering solenoid cut relay: Short circuit
with power supply line)....................................................................................... 40
Failure code [D5ZHKA] (Terminal C signal: Disconnection).................................................... 43
Failure code [D5ZHKB] (Terminal C signal: Short circuit)........................................................ 49
Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit)............................. 54
Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running
or stopped state)................................................................................................ 61
Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)............................ 66
Failure code [DAF3KK] (Machine monitor: Low source voltage (input)................................... 68
Failure code [DAF5KP] (Machine monitor: Low output voltage).............................................. 72
Failure code [DAFRKR] (CAN communication with machine monitor: Defective
communication (Abnormality in target component system) .............................. 76
Troubleshooting by failure code (Display of code), Part 5 SEN06443-00
Failure code [DAQ0KK] (Transmission controller: Low source voltage).................................. 4
Failure code [DAQ0KT] (Transmission controller: Abnormality in controller) .......................... 8
Failure code [DAQ2KK] (Transmission controller load power supply line:
Low source voltage (input)................................................................................. 9
Failure code [DAQ9KQ] (Transmission controller model selection:
Disagreement of model selection signals) ......................................................... 12
Failure code [DAQRKR] (CAN communication with transmission controller:
Defective communication (Abnormality in target component system) ............... 13
Failure code [DAQRMA] (Transmission controller option setting: Malfunction)....................... 19
Failure code [DB2RKR] (CAN communication with engine controller: Defective
communication (Abnormality in target component system) ............................... 20
Failure code [DB90KK] Work equipment controller: Low source voltage (input)..................... 24
Failure code [DB90KT] Work equipment controller: Abnormality in controller......................... 26
Failure code [DB92KK] Work equipment controller load power supply line:
Low source voltage (input)................................................................................. 27
Failure code [DB95KX] Work equipment controller power supply output:
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
SEN06413-02 00 Index and foreword
10 WA380-6, WA380Z-6
Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)................... 35
Failure code [DB9RMC] (CAN communication with transmission controller,
engine controller and machine monitor: Defective operation)............................ 36
Failure code [DD15LD] tswitch (Panel switch 1): Switch is kept pressed for long time........ 40
Failure code [DD16LD] Uswitch (Panel switch 2): Switch is kept pressed for long time....... 43
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time......... 46
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time......... 49
Failure code [DD1ALD] Remote positioner raise/lower set switch (raise):
Switch is kept pressed for long time................................................................... 52
Failure code [DD1BLD] Remote positioner raise/lower set switch (lower):
Switch is kept pressed for long time................................................................... 54
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time ..... 56
Failure code [DD1FLD] Load meter mode selector switch (A/B):
Switch is kept pressed for long time................................................................... 58
Failure code [DD1GLD] Load meter mode selector switch (+/–):
Switch is kept pressed for long time................................................................... 60
Failure code [DD1HLD] (Load meter display selector switch:
Switch is kept pressed for long time) ................................................................. 62
Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time) ............... 64
Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time) 66
Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree) ........ 68
Troubleshooting by failure code (Display of code), Part 6 SEN06444-00
Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)................................ 4
Failure code [DDK3KA] (Right FNR switch: Disconnection).................................................... 7
Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection).................................. 10
Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)... 13
Failure code [DDK6KA] (FNR lever switch: Disconnection)..................................................... 15
Failure code [DDK6KB] (FNR lever switch: Short circuit) ........................................................ 22
Failure code [DDS5KA] (Steering pressure switch: Disconnected).......................................... 26
Failure code [DDS5KB] (Steering pressure switch: Grounded) ............................................... 28
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)..................... 30
Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time) 33
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time).................. 36
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)........................... 39
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time) ..... 42
Failure code [DF10KA] (Transmission shift lever switch: Disconnected)................................. 44
Failure code [DF10KB] (Transmission shift lever switch: Short circuit).................................... 48
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected)....................... 51
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit) ......................... 54
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)........... 57
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected).......................... 59
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range) ........ 61
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range) 63
Failure code [DH21KA] (Loader pump pressure sensor: Disconnection) ................................ 66
Failure code [DH21KB] (Loader pump pressure sensor: Power supply line short).................. 68
Troubleshooting by failure code (Display of code), Part 7 SEN06445-00
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range) 4
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range) . 6
Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range).... 8
Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection).............................. 12
Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit) ................................. 14
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)................. 16
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main):
Short circuit with power supply line)................................................................... 19
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
00 Index and foreword SEN06413-02
WA380-6, WA380Z-6 11
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection) ................. 31
Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main):
Short circuit with power supply line)................................................................... 34
Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree) .. 37
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection) .................. 40
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub):
Short circuit with power supply line)................................................................... 43
Troubleshooting by failure code (Display of code), Part 8 SEN06446-00
Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection).. 3
Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main):
Short circuit with power supply line)................................................................... 6
Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)... 8
Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub):
Short circuit with power supply line)................................................................... 12
Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main):
Analog signals disagree).................................................................................... 14
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection).............................................. 18
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line).............. 20
Failure code [DKA0L0] (Lift arm angle sensor: Dislocation of sensor).................................... 22
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)................. 24
Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range). 26
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit) ............................ 28
Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)............... 32
Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit) .............. 34
Failure code [DV00KB] (Alarm buzzer: Short circuit) .............................................................. 36
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)................................... 38
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)....................................... 40
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line)... 42
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection).................................. 44
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)...................................... 45
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line) . 46
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)........................................ 48
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)............................................ 49
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line) ....... 50
Troubleshooting by failure code (Display of code), Part 9 SEN06447-00
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)................................... 3
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit) ...................................... 4
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line) .. 6
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)............................................. 8
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)................................................. 10
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line) ............ 12
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection).................. 14
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)...................... 16
Failure code [DWM1KY] (Work equipment neutral lock solenoid:
Short circuit with power supply line)................................................................... 18
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection) ................... 20
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit)....................... 22
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid:
Short circuit with power supply line)................................................................... 24
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection) .................... 26
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit)........................ 28
Failure code [DWN7KY] (Lift arm float magnet detent solenoid:
Short circuit with power supply line)................................................................... 30
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection) ........................ 32
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
SEN06413-02 00 Index and foreword
12 WA380-6, WA380Z-6
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)............................................. 40
Failure code [DX16KB] (Fan motor EPC solenoid: Short circuit)............................................. 41
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)......... 42
Failure code [DX16KY] (Fan motor EPC solenoid: Short circuit with power supply line) ........ 43
Failure code [DXA1KA] (Loader pump EPC solenoid: Disconnection).................................... 44
Failure code [DXA1KB] (Loader pump EPC solenoid: Short circuit) ....................................... 46
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection).......................................... 48
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit).............................................. 50
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line).......... 52
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)....................................... 54
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit).......................................... 56
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)...... 58
Troubleshooting by failure code (Display of code), Part 10 SEN06448-00
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection) ..................................... 4
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)......................................... 6
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)..... 8
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)...................................... 10
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit).......................................... 12
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)...... 14
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)......................................... 16
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit) ............................................ 18
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)........ 20
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)......................................... 22
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)............................................. 24
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)......... 26
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)...................................... 28
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit) ......................................... 30
Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)..... 32
Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)...................... 34
Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit).......................... 36
Failure code [DXHLKY] (Joystick steering right EPC solenoid:
Short circuit with power supply line)................................................................... 38
Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection) ....................... 40
Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit)........................... 42
Failure code [DXHMKY] (Joystick steering left EPC solenoid:
Short circuit with power supply line)................................................................... 44
Failure code [DY30MA] Motor-driven emergency steering pump failure
(During operation of machine)............................................................................ 46
Failure code [DY30MC] Motor-driven emergency steering pump failure
(Malfunction in manual mode)............................................................................ 51
Troubleshooting of electrical system (E-mode) SEN06449-00
Installing positions of fuses...................................................................................................... 3
Information in troubleshooting table......................................................................................... 8
E-1 Engine does not start ........................................................................................................ 9
E-2 Wiper does not operate..................................................................................................... 22
E-3 Windshield washer does not operate................................................................................ 27
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off ............. 31
E-5 Working lamp does not light up or go off........................................................................... 47
E-6 Turn signal lamp and hazard lamp do not light up or go off.............................................. 57
E-7 Brake lamp does not light or it keeps lighting up............................................................... 69
E-8 Backup lamp does not light or it keeps lighting up............................................................ 73
E-9 Backup buzzer does not sound or it keeps sounding........................................................ 77
E-10 Horn does not sound or it keeps sounding...................................................................... 80
E-11 Alarm buzzer does not sound or it keeps sounding......................................................... 84
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
00 Index and foreword SEN06413-02
WA380-6, WA380Z-6 13
E-16 Transmission is kept in neutral, or brake drags
when directional lever is operated while parking brake is applied ..................... 99
E-17 Transmission cut-off mode cannot be set or reset.......................................................... 102
E-18 Transmission cut-off set cannot be reset ........................................................................ 105
E-19 FNR switch mode cannot be set or reset........................................................................ 108
E-20 Fan reverse function cannot be used or reset ................................................................ 110
E-21 Discharge from loader pump does not rise from minimum level..................................... 112
E-22 ECSS function cannot be used or reset.......................................................................... 114
E-23 When parking brake is turned ON, parking brake indicator lamp does not light up........ 116
E-24 When emergency brake operates, brake oil pressure caution lamp does not operate... 120
E-25 Air cleaner clogging indicator lamp does not light up...................................................... 124
E-26 Radiator coolant level caution lamp does not light up..................................................... 127
E-27 Hydraulic oil temperature gauge does not rise and
hydraulic oil temperature caution lamp does not light up................................... 129
E-28 Torque converter oil temperature gauge does not rise and
torque converter oil temperature caution lamp does not light up....................... 131
E-29 Steering oil pressure caution lamp does not light up ...................................................... 133
E-30 Abnormality in tswitch (panel switch 1) input ............................................................... 136
E-31 Abnormality in Uswitch (panel switch 2) input .............................................................. 139
E-32 Abnormality in < switch (panel switch 3) input................................................................ 142
E-33 Abnormality in > switch (panel switch 4) input................................................................ 145
Troubleshooting of hydraulic and mechanical system (H-mode) SEN06450-00
Method of using troubleshooting chart .................................................................................... 3
Table of failure modes and causes.......................................................................................... 6
H-1 The machine does not start.............................................................................................. 14
H-2 Torque converter lockup is not switched off (engine stalls)
[Machine with lockup clutch]............................................................................................. 16
H-3 Torque converter lockup is not switched on [Machine with lockup clutch]........................ 17
H-4 The travel speed is slow, the thrusting force is weak,
the uphill traveling power is weak, and the gear is not shifted........................... 18
H-5 Shocks are large at the times of starting and shifting gear............................................... 20
H-6 Time lag is large at the times of starting and shifting gear................................................ 22
H-7 The torque converter oil temperature is high.................................................................... 24
H-8 Steering does not turn....................................................................................................... 25
H-9 Steering does not turn [Machine with joystick steering].................................................... 26
H-10 Steering response is low................................................................................................. 27
H-11 Turning, response of steering is poor [machine with joystick steering]........................... 28
H-12 Steering is heavy ............................................................................................................ 29
H-13 When machine turns, it shakes or makes large shocks.................................................. 30
H-14 When machine turns, it shakes or makes large shocks
[machine with joystick steering]........................................................................................ 31
H-15 The wheel brake does not work or does not work well................................................... 32
H-16 The wheel brake is not released or it drags.................................................................... 33
H-17 The parking brake does not work or does not work well................................................. 34
H-18 The parking brake is not released or it drags (including emergency release system).... 35
H-19 Lift arm does not rise ...................................................................................................... 36
H-20 Lift arm speed is low or rising force of lift arm is insufficient........................................... 37
H-21 When rising, the lift arm comes to move slowly at specific height.................................. 38
H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats).................................. 38
H-23 Hydraulic drifts of the lift arm is large.............................................................................. 38
H-24 The lift arm wobbles during operation............................................................................. 38
H-25 Bucket does not tilt back................................................................................................. 39
H-26 Bucket speed is low or tilting back force is insufficient ................................................... 40
H-27 The bucket comes to operate slowly in the midst of tilting-back..................................... 41
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
SEN06413-02 00 Index and foreword
14 WA380-6, WA380Z-6
H-31 Lift arm and bucket control levers do not move smoothly and are heavy....................... 42
H-32 During operation of the machine, engine speed lowers remarkably or engine stalls...... 43
H-33 Large shock is made when work equipment starts and stops......................................... 43
H-34 When work equipment circuit is relieved singly, other work equipment moves .............. 43
H-35 ECSS does not operate, and pitching, bouncing occur .................................................. 44
H-36 Fan revolution is abnormal (Fan sound/ vibration is abnormally large or engine
overheats)......................................................................................................................... 45
Troubleshooting of engine (S-mode) SEN06451-00
Method of using troubleshooting charts................................................................................... 3
S-1 Engine does not start easily. ............................................................................................. 6
S-2 Engine does not start ........................................................................................................ 7
S-3 Engine does not pick up smoothly .................................................................................... 10
S-4 Engine stops during operations......................................................................................... 11
S-5 Engine does not rotate smoothly....................................................................................... 12
S-6 Engine lacks output (or lacks power)................................................................................ 13
S-7 Exhaust smoke is black (Incomplete combustion) ............................................................ 14
S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 15
S-9 Engine oil becomes contaminated quickly ........................................................................ 16
S-10 Fuel consumption is excessive ....................................................................................... 17
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
S-16 Vibration is excessive...................................................................................................... 23
50 Disassembly and assembly
General information on disassembly and assembly SEN06453-00
How to read this manual.......................................................................................................... 2
Coating materials list ............................................................................................................... 4
Special tools list....................................................................................................................... 7
Sketches of special tools......................................................................................................... 10
Engine and cooling system SEN06454-00
Removal and installation of fuel supply pump assembly ......................................................... 2
Removal and installation of fuel injector assembly.................................................................. 6
Removal and installation of cylinder head assembly............................................................... 20
Removal and installation of engine hood assembly................................................................. 42
Removal and installation of radiator assembly........................................................................ 47
Removal and installation of air aftercooler............................................................................... 52
Removal and installation of hydraulic oil cooler assembly....................................................... 54
Removal and installation of engine assembly.......................................................................... 56
Removal and installation of engine front oil seal assembly ..................................................... 61
Removal and installation of engine rear oil seal assembly...................................................... 64
Removal and installation of cooling fan and fan motor assembly............................................ 67
Removal and installation of fuel tank assembly....................................................................... 73
Power train SEN06455-01
Removal and installation of torque converter and transmission assembly.............................. 2
Disassembly and assembly of torque converter assembly (Standard specification) ............... 8
Disassembly and assembly of torque converter assembly (Lockup specification).................. 12
Disassembly and assembly of transmission assembly............................................................ 18
Disassembly and assembly of transmission clutch pack assembly......................................... 35
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
00 Index and foreword SEN06413-02
WA380-6, WA380Z-6 15
Steering system SEN06456-00
Removal and installation of steering valve assembly.............................................................. 2
Brake system SEN06457-00
Removal and installation of parking brake discs and plates.................................................... 2
Undercarriage and frame SEN06458-00
Removal and installation of center hinge pin........................................................................... 2
Removal and installation of counterweight.............................................................................. 10
Hydraulic system SEN06459-00
Removal and installation of work equipment control valve assembly...................................... 2
Removal and installation of power train pump and work equipment pump assembly............. 8
Removal and installation of steering pump and cooling fan pump assembly.......................... 9
Removal and installation of hydraulic tank assembly.............................................................. 11
Work equipment SEN06460-00
Removal and installation of work equipment assembly........................................................... 2
Disassembly and assembly of hydraulic cylinder assembly.................................................... 6
Cab and its attachments SEN06461-00
Removal and installation of operator's cab and floor frame assembly .................................... 2
Removal and installation of operator's cab glass (stuck glass)............................................... 6
Disassembly and assembly of operator's seat assembly (Standard specification).................. 14
Disassembly and assembly of operator's seat assembly (Manufactured by GRAMMER)...... 23
Removal and installation of air conditioner unit assembly....................................................... 56
Electrical system SEN06462-00
Removal and installation of engine controller assembly.......................................................... 2
90 Diagrams and drawings
Hydraulic diagrams and drawings SEN06464-00
Power train hydraulic circuit diagram....................................................................................... 2
Automatic greasing circuit diagram ......................................................................................... 4
Hydraulic circuit diagram......................................................................................................... 7
Electrical diagrams and drawings SEN06465-01
Electrical circuit diagram.......................................................................................................... 3
Work equipment controller system electrical circuit diagram................................................... 49
Connector list and stereogram ................................................................................................ 51
16
SEN06413-02
WA380-6, WA380Z-6 WHEEL LOADER
Form No. SEN06413-02
© 2015 KOMATSU
All Rights Reserved
Printed in Japan 03-15 (01)
WA380-6, WA380Z-6 1
SEN06414-00
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 1
Foreword and general information
Safety notice................................................................................................................................................... 2
How to read the shop manual......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
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
SEN06414-00 00 Index and foreword
2WA380-6, WA380Z-6
Safety notice 1(Rev. 2010/02)
Important 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.
To prevent injury to workers, the symbol kis used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions
kMistakes in operation are extremely
dangerous. Read the Operation and
Maintenance Manual carefully before
operating the machine. In addition,
read this manual and understand its
contents before starting the work.
1) Before carrying out any greasing or
repairs, read all the safety labels stuck to
the machine. For the locations of the
safety labels and detailed explanation of
precautions, see the Operation and Main-
tenance Manual.
2) 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, water,
or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while
working.
3) When carrying out any operation, always
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with
buttons missing.
qAlways wear safety glasses when hit-
ting parts with a hammer.
qAlways wear safety glasses when
grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or
more workers, always agree on the oper-
ating procedure before starting. Always
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, fork-
lift, service car, etc.
7) If welding repairs are needed, always
have a trained and 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.
8) Before starting work, warm up your body
thoroughly to start work under good condi-
tion.
9) 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.
Safety points
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signs
5Prohibition of operation and handling by
unlicensed workers
6 Safety check before starting work
7Wearing protective goggles
(for cleaning or grinding work)
8Wearing shielding goggles and protectors
(for welding work)
9 Good physical condition and preparation
10 Precautions against work which you are
not used to or you are used to too much
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