Issuu

SEBM024708

MACHINE MODEL

SERIAL NUMBER

WA380-5

60001 and up

This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice.

WA380-5 mounts the SAA6D114E-2 engine. For details of the engine, see the 114 Series Engine Shop Manual.

00-1 (8)

CONTENTS No. of page

GENERAL ......................................................................................... 01-1

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ...... 10-1

TESTING AND ADJUSTING ............................................................. 20-1

DISASSEMBLY AND ASSEMBLY ................................................... 30-1

OTHERS ............................................................................................ 90-1

00-2 2

WA380-5

The affected pages are indicated by the use of the following marks. It is requested that necessary actions must be taken to these pages according to the list below.

Mark

Indication

Action required

Page to be newly added

Add

Page to be replaced

Replace

Page to be deleted

Discard

(

)

Pages having no marks are not revised at this time.

LIST OF REVISED PAGES Mark

Pages

00- 1 00- 2 00- 2-1 00- 2-2 00- 2-3 00- 2-4 00- 2-5 00- 3 00- 4 00- 5 00- 6 00- 7 00- 8 00- 9 00-10 00-11 00-12 00-13 00-14 00-15 00-16 00-17 00-18 00-19 00-20 00-21 00-22

q q q q q

q q q q

01- 1 01- 2 01- 3 01- 4 01- 5 01- 6 01- 7 01- 8 01- 9 01-10 10- 1 10- 2 10- 3 10- 4

WA380-5

Revision number

Mark

(8) (2) (8) (8) (8) (8) (8)

(8) (8) (4) (8) (8) (4) (4) (8) (4)

q Q q Q q q q q

Pages

10- 5 10- 6 10- 7 10- 8 10- 9 10-10 10-11 10-12 10-13 10-14 10-15 10-16 10-17 10-18 10-19 10-20 10-21 10-22 10-23 10-24 10-25 10-26 10-27 10-28 10-29 10-30 10-31 10-32 10-34 10-34-1 10-35 10-36 10-36-1 10-37 10-38 10-39 10-40 10-41 10-42 10-43 10-44 10-45 10-46

Revision number

(4)

(4) (4)

(4)

(4) (4) (4) (4) (4) (8) (8) (8) (8) (8) (8) (8) (8) (4) (4)

Mark

Pages

10-48 10-49 10-50 10-51 10-52 10-53 10-54 10-55 10-56 10-57 10-58 10-59 10-60 10-61 10-62 10-63 10-64 10-65 10-66 10-67 10-68 10-69 10-70 10-71 10-72 10-73 10-74 10-75 10-76 10-77 10-78 10-79 10-80 10-81 10-82 10-83 10-84 10-85 10-86 10-87 10-88 10-89 10-90

Revision number

Mark

(4) (1)

q q

Pages

10-91 10-92 10-93 10-94 10-95 10-96 10-97 10-98 10-99 10-100 10-101 10-102 10-103 10-104 10-105 10-106 10-107 10-108 10-109 10- 110 10- 111 10- 112 10- 113 10- 114 10- 115 10- 116 10- 117 10- 118 10- 119 10-120 10-121 10-122 10-123 10-124 10-125 10-126 10-127 10-128 10-129 10-130 10-131 10-132 10-133

Revision number

Mark

(1) (1)

(4) (8) (8) q q

(8)

q q

Pages

Revision number

10-134 10-135 10-136 10-137 10-138 10-139 10-140 10-141 10-142 10-143 10-144 10-145 10-146 10-147 10-148 10-149 10-150 10-151 10-152 10-153 10-154 10-155 10-156 10-157 10-158 10-159 10-159-1 10-159-2 10-159-3 10-159-4 10-159-5 10-159-6 10-160 10-161 10-162 10-163 10-164 10-165 10-166 10-167 10-168 10-169 10-170

(8)

(1) (1) (1) (1) (1) (1) (8) (8)

(8) (8)

00-2-1 (8)

Mark

q q q q q q

q q q

q q q q

q q q

Pages

10-171 10-172 10-173 10-174 10-175 10-176 10-177 10-178 10-179 10-180 10-181 10-182 10-183 10-184 10-185 10-186 10-187 10-188 10-189 10-190 10-191 10-192 10-193 10-194 10-195 10-196 10-197 10-198 10-199 10-200 10-201 10-202 10-203 10-204 10-205 10-206 10-207 10-208 10-209 10-210 10- 211 10-212 10-213 10-214 10-215 10-216 10-217 10-218 10-219 10-220 10-221 10-222 10-224 10-225 10-226 10-227 10-228 10-229 10-230

00-2-2 (8)

Revision number

Mark

q q

q q q

(8) (8) (8) (8) (8) (8) (4) (4) (4) (4) (4) (4) (8) (4) (8) (4) (8) (4) (4) (8) (8)

q q q

q q

(8) (8) (4) (4)

(4) (4) (4) (4)

(8) (8) (8) (4)

Pages

Revision number

10-231 10-232 10-233 10-234 10-235 10-236 10-236-1 10-236-2 10-236-3 10-236-4 10-236-5 10-236-6 10-236-7 10-236-8 10-236-9 10-237 10-238 10-239 10-240 10-241 10-242 10-243 10-244 10-245 10-246 10-247 10-248 10-249 10-250 10-251 10-252 10-253 10-254 10-255 10-256 10-257 10-258 10-259 10-260 10-261 10-262 10-263 10-264 10-265 10-266 10-267 10-268 10-269 10-270 10-271 10-272 10-273 10-274 10-275 10-276 10-277 10-278 10-279 10-279-1

Mark

(8) (8) (4) (4) (8) (4) (8) (4) (8) (4) (4)

q q q q q

(4) (8) (8) (8)

q q q

(1) (8) (8)

(4) (8) (8) (8)

(1)

q q q q q q q q q q q q q q q q q

Revision number

Pages

10-279-2 10-279-3 10-279-4 10-280 10-281 10-282 10-283 10-284 10-285 10-286 10-287 10-288 10-289 10-290 10-291 10-292 10-293 10-294 10-295 10-296 10-297 10-298 10-300 10-301 10-302 10-303 10-304 10-305 10-306 10-307 10-308 10-309 10-310 10- 311 10-312 10-313 10-314 10-315 10-316 10-317 10-318 10-319 10-320 10-321 10-322 10-323 10-324 10-325 10-326 10-327 (10-328) 20202020202020-

1 2 3 4 5 6 7

(1) (1) (4) (8) (8) (8) (8) (1) (8)

(8) (8) (8) (4)

(8) (8) (8) (8) (8) (8) (8) (8) (8) (8) (8) (8) (8) (8) (8) (8) (8) (8)

(7)

Mark

Pages

Revision number

20- 8 20- 9 20-101 20-101-2 20-102 20-103 20-104 20-105 20-106 20-107 20-108 20-109 20- 110 20- 111 20- 112 20- 113 20- 114 20- 115 20- 117 20- 118 20- 119 20-120 20-121 20-122 20-123 20-124 20-125 20-126 20-127 20-128 20-129 20-130 20-131 20-132 20-133 20-134 20-135 20-136 20-137 20-138 20-139 20-140 20-141 20-142 20-143 20-144 20-145 20-146 20-147 20-148 20-149 20-150 20-151 20-152 20-153 20-154 20-155 20-156 20-157

Mark

(7) (5)

(5) (5)

(5) (5) (5)

(6) (7) (7) (7) (5) (5) (7) (7)

Pages

Revision number

20-201 20-202 20-203 20-204 20-205 20-206 20-207 20-208 20-209 20-210 20- 211 20-212 20-214 20-215 20-216 20-217 20-218 20-219 20-220 20-221 20-222 20-223 20-224 20-225 20-226 20-227 20-228 20-229 20-230 20-231 20-232 20-233 20-234 20-235 20-236 20-237 20-238 20-239 20-240 20-241 20-242 20-244 20-245 20-246 20-247 20-248 20-249 20-249-1 20-249-2 20-249-3 20-249-4 20-250 20-251 20-252 20-254 20-255 20-256 20-257 20-258

(7)

(5)

(8)

(5) (5) (5) (5)

(8) (7) (1) (1) (8) (7) (5) (5) (5) (5) (5) (5) (7) (7)

WA380-5

Mark

Pages

Revision number

20-256 20-257 20-258 20-259 20-260 20-261 20-262 20-263 20-264 20-265 20-266 20-267 20-268 20-269 20-270 20-271 20-272 20-273 20-274 20-275 20-276 20-277 20-301 20-302 20-302-1 20-303 20-304 20-305 20-306 20-307 20-308 20-309 20-310 20-312 20-313 20-314 20-315 20-316 20-317 20-318 20-319 20-320 20-321 20-322 20-323 20-324 20-325 20-326 20-327 20-328 20-329 20-330 20-331 20-332 20-333 20-334 20-335 20-336 20-338

WA380-5

(7)

(5) (5) (5) (5) (5) (5) (7) (5) (5) (5) (7) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5)

Mark

Pages

Revision number

20-339 20-340 20-341 20-342 20-344 20-345 20-346 20-347 20-348 20-349 20-349-1 20-349-2 20-350 20-351 20-352 20-354 20-355 20-356 20-356-1 20-357 20-358 20-359 20-360 20-361 20-362 20-363 20-364 20-365 20-366 20-367 20-368 20-369 20-370 20-371 20-371-1 20-372 20-373 20-374 20-375 20-376 20-377 20-378 20-379 20-380 20-381 20-382 20-383 20-384 20-385 20-386 20-387 20-388 20-389 20-390 20-391 20-392 20-393 20-394 20-395

(1) (1) (1)

(5) (5)

(1) (1) (1) (1)

(5) (5)

(1) (1) (1) (5)

(7) (7) (7) (7)

Mark

Pages

Revision number

20-396 20-397 20-398 20-399 20-400 20-401 20-402 20-403 20-404 20-405 20-406 20-407 20-408 20-409 20-410 20-410-1 20-410-2 20- 411 20-412 20-414 20-415 20-416 20-417 20-418 20-419 20-420 20-421 20-422 20-423 20-424 20-426 20-427 20-428 20-429 20-430 20-431 20-432 20-433 20-434 20-435 20-436 20-437 20-438 20-439 20-440 20-441 20-442 20-443 20-444 20-445 20-501 20-502 20-502-1 20-503 20-504 20-505 20-506 20-507 20-508

(7) (7) (7) (7) (7) (7) (7) (7) (7) (7)

(5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (7) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (7) (7) (7) (7) (5) (7) (7) (7) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5)

Mark

Pages

20-509 20-510 20-512 20-513 20-514 20-515 20-516 20-517 20-518 20-519 20-520 20-521 20-522 20-523 20-524 20-526 20-527 20-528 20-529 20-530 20-531 20-532 20-533 20-534 20-535 20-536 20-537 20-538 20-539 20-540 20-541 20-542 20-543 20-544 20-545 20-546 20-547 20-548 20-549 20-550 20-551 20-552 20-553 20-554 20-555 20-556 20-557 20-558 20-559 20-560 20-561 20-562 20-563 20-564 20-565 20-566 20-567 20-568 20-569

Revision number

(5) (5) (5) (5) (5) (5) (5)

(5) (5)

Mark

Revision number

Pages

20-570 20-571 20-572 20-573 20-574 20-575 20-576 20-577 20-578 20-579 20-580 20-581 20-582 20-583 20-584 20-585 20-586 20-587 20-588 20-589 20-590 20-591 20-592 20-593 20-594 20-596 20-597 20-598 20-599 20-600 20-601 20-602 20-603 20-604 20-605 20-606 20-607 20-608 20-609 20-610 20- 611 20-612 20-613 20-614 20-615 20-616 20-617 20-618 20-619 20-701 20-702 20-703 20-704 20-705 20-706 20-707 20-708 20-709 20-710

(5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5)

00-2-3 (8)

Mark

Pages

20-712 20-713 20-714 20-715 20-716 20-717 20-718 20-719 20-720 20-721 20-722 20-723 20-724 20-725 20-726 20-727 20-728 20-729 20-730 20-731 20-732 20-733 20-734 20-735 20-736 20-737 20-738 20-739 20-740 20-741 20-742 20-744 20-745 20-746 20-747 20-748 20-749 20-750 20-751 20-752 20-753 20-754 20-755 20-756 20-757 20-758 20-759 20-760 20-761 20-762 20-763 20-764 20-765 20-766 20-768 20-769 20-770 20-771 20-772

00-2-4 (8)

Revision number

Mark

(5) (5) (5) (5) (5)

(5) (5) (5) (5)

(5) (7)

(5) (5) (5) (5) (5) (5)

(7) (5) (7) (5) (5)

q q q q q q q q q q q q q q q q q q q q q q q q q q q

Pages

Revision number

20-773 20-774 20-775 20-776 20-777 20-778 20-779 20-780 20-781 20-782 20-783 20-784 20-785 20-786 20-787 20-788 20-789 20-790 20-791 20-792 20-793 20-794 20-795 20-796 20-797 20-801 20-802 20-803 20-804 20-805 20-806 20-807 20-808 20-809 20-810 20- 811 20-812 20-813 20-814 20-815 20-816 20-817 20-818 20-819 20-820 20-821 20-822 20-823 20-824 20-825 20-826 20-827 (20-828) (20-829) 20-901 20-903 20-904 20-905 20-906

(7) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (7) (7) (5) (8) (8) (8) (8) (8) (8) (8) (8) (8) (8) (8) (8) (8) (8) (8) (8) (8) (8) (8) (8) (8) (8) (8) (8) (8) (8) (8) (5) (5) (5) (5) (5)

Mark

Pages

Revision number

20-907 20-908 20-909 20-910 20-912 20-913 20-914 20-915 20-916 20-917 20-918 20-920 20-921 20-922 20-923 20-924 20-925 20-926 20-927 20-928 20-929 20-930 20-931 20-932 20-933 20-934 20-935 20-936 20-937 20-938 20-939 20-940 20-941 20-942 20-943 20-944 20-945 20-946 20-947 20-948 20-949 20-950 20-951 20-952 20-1001 20-1002 20-1003 20-1004 20-1005 20-1006 20-1007 20-1008 20-1009 20-1010 20-1011 20-1012 20-1013 20-1014 20-1015

(5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (7) (7) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7)

Mark

Pages

Revision number

20-1016 20-1017 20-1018 20-1019 20-1020 20-1021 20-1022 20-1023 30- 1 30- 2 30- 3 30- 4 30- 5 30- 5-2 30- 5-3 30- 5-4 30- 6 30- 7 30- 8 30- 9 30- 10 30- 11 30- 12 30- 13 30- 14 30- 15 30- 16 30- 17 30- 18 30- 19 30- 20 30- 21 30- 22 30- 23 30- 24 30- 25 30- 26 30- 27 30- 28 30- 29 30- 30 30- 31 30- 32 30- 33 30- 34 30- 35 30- 36 30- 37 30- 38 30- 39 30- 40 30- 41 30- 42 30- 43 30- 44 30- 45 30- 46 30- 47 30- 48

(7) (7) (7) (7) (7) (7) (7) (7) (7) (2) (5) (2) (2) (5) (5) (5) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (5) (2) (2) (2) (5) (2) (5) (2) (2) (2) (2) (2) (2)

Mark

q q q

Pages

Revision number

30- 49 30- 50 30- 51 30- 52 30- 53 30- 54 30- 55 30- 56 30- 57 30- 58 30- 59 30- 60 30- 61 30- 62 30- 63 30- 64 30- 65 30- 66 30- 67 30- 68 30- 69 30- 70 30- 71 30- 72 30- 73 30- 74 30- 75 30- 76 30- 77 30- 78 30- 79 30- 80 30- 81 30- 82 30- 83 30- 84 30- 85 30- 86 30- 87 30- 88 30- 89 30- 90 30- 91 30- 92 30- 93 30- 94 30- 95 30- 96 30- 97 30- 98 30- 99 30-100 30-101 30-102 30-103 30-104 30-105 30-106 30-107

(2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (8) (2) (2) (8) (8) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (8) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2)

WA380-5

This is the sample of the manual Click on the download link for complete manual

Download Link

Mark

Pages

Revision number

30-108 30-109 30- 110 30- 111 30- 112 30- 113 30- 114 30- 115 30- 116 30- 117 30- 118 30- 119 30-120 30-121 30-122 30-123 30-124 30-125 30-126 30-127 30-128 30-129 30-130 30-131 30-132 30-133 30-134 30-135 30-136 30-137 30-138 30-139 30-140 30-141 30-142 30-143 30-144 30-145 30-146 30-147 30-148 30-149 30-150 30-151 30-152 30-153 30-154 30-155 30-156

(2) (2) (2) (8) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (5) (2) (2) (2) (5) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7)

90- 1 90- 3 90- 5 90- 7 90- 9 90- 11 90- 13 90- 15 90- 17

(4) (4) (4)

WA380-5

Mark

Pages

Revision number

90- 19 90- 21 90- 23 90- 25 90- 27 90- 29 90- 31 90- 33 90- 35 90- 37 90- 39

(8) (4) (4) (4) (8) (4) (4) (4) (4) (4) (4)

Mark

Pages

Revision number

Mark

Pages

Revision number

Mark

Pages

Revision number

(4) (4) (4)

00-2-5 (8)

SAFETY

SAFETY NOTICE

SAFETY

SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is 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 ¤ is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.

GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.

Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.

3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.

6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

00-3

SAFETY PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13.Before starting work, remove the leads from the battery. Always remove the lead from the negative ( ) terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15.When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16.When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.

00-4

SAFETY NOTICE 19.Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21.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. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24.Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.

FOREWORD

GENERAL

FOREWORD GENERAL

This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.

STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" with "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. MAINTENANCE STANDARD This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.

NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.

00-5

FOREWORD

HOW TO READ THE SHOP MANUAL

REVISED EDITION MARK

VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:

When a man ual is re vise d, a n edition mark (123....) is recorded on the bottom of the pages.

Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume: Attachments volume: · volume to cover all models

REVISIONS

These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-todate information before you start any work. FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5

00-6

Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page. SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.

Symbol

Item

Remarks

Safety

Special safety precautions are necessary when performing the work.

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing the work.

Weight

Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.

Tightening torque

Places that require special attention for the tightening torque during assembly.

Coat

Places to be coated with adhesives and lubricants, etc.

Oil, water

Places where oil, water or fuel must be added, and the capacity.

Drain

Places where oil or water mu s t b e d r a in ed , a n d quantity to be drained.

¤ s

FOREWORD

HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS HOISTING

¤ Heavy parts (25 kg or more) must be lifted

with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol 4

If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed.

WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter

Allowable load

tons

10 11.5 12.5 14 16 18 20 22.4 30 40 50 60

9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2

1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0

Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.

3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. ¤ Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150°.

The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of the rope used. 2) Sling wire ropes from the middle portion of the hook.

00-7

FOREWORD

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

¤ Before carrying out the following work, release

the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank.

¤ Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.

Disconnection 1) Release the residual pressure from the hydraulic tank. For details, see T ESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) The adapter can be pushed in about 3.5 mm. Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.

00-8

Type 1

FOREWORD

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Type 3

1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.

2) Hold in the condition in Step 1), and turn lever (4) to the right (clockwise).

2) Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.

3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.

Disassembly

Type 2

Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.

Connection

Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.

00-9

This is the sample of the manual Click on the download link for complete manual

Download Link

WA380-5 Komatsu Service Manual PDF Download