Komatsu WA380-5 Wheel Loader Shop Manual 60001 and Up – PDF Repair & Troubleshooting Guide

Description

Komatsu WA380-5 Wheel Loader Shop Manual – Complete Service & Repair Guide

This Komatsu WA380-5 Shop Manual is the comprehensive service and repair guide for the WA380-5 wheel loader, covering serial numbers 60001 and up. The manual is issued by Komatsu as a workshop reference for professional servicemen, technicians, and repair facilities working on this machine. It assumes the WA380-5 mounts the SAA6D114E-2 engine, and for engine-specific details directs the reader to the 114 Series Engine Shop Manual.

The document is arranged into chapters covering the complete machine — from general assembly drawings and specifications through the structure and function of every major system, testing and adjusting procedures, troubleshooting, and full disassembly and assembly of components.

File Details

• Manual Type: Shop Manual
• Brand: Komatsu
• Model: WA380-5 Wheel Loader
• Serial Number: 60001 and up
• Engine: SAA6D114E-2
• Language: English
• Page Count: 1173 pages
• File Format: PDF
• Document Number: SEBM024710

Chapters Covered

The manual is divided into five main sections, further divided by component group:

• 01 GENERAL – General assembly drawing, specifications, general specifications, weight table, fuel/coolant/lubricant table
• 10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD – Cooling system, engine mount, power train, drive shaft, torque converter, transmission, transmission control valve, axle, differential, final drive, axle mounting, steering piping, steering column, steering valve, orbit-roll valve, stop valve, steering pump, emergency steering, brake piping, brake valve, charge valve, accumulator, brake, parking brake, hydraulic piping, work equipment control lever, hydraulic tank, pumps, PPC valves, EPC solenoid valve, cooling fan, work equipment linkage, bucket, cab, air conditioner, machine monitoring system, transmission control system, work equipment control system, electric transmission control, engine starting circuits, sensors
• 20 TESTING AND ADJUSTING – Standard value tables for engine and chassis, testing and adjusting procedures, troubleshooting charts, special tools, PM clinic inspection table
• 30 DISASSEMBLY AND ASSEMBLY – Removal and installation of engine, cylinder head, radiator, aftercooler, fuel injection pump, nozzle holder, fan, fuel tank, parking brake disc, torque converter and transmission, transmission clutch pack, parking brake, torque converter (standard and lock-up), rear axle, front axle, axle housing, differential, center hinge pin, cab, cab glass, pumps, steering demand valve, E.C.S.S. valve, work equipment valve, hydraulic cylinders, hydraulic tank, work equipment, counterweight, air conditioner, operator’s seat
• 90 OTHERS – Hydraulic circuit diagrams, electrical circuit diagrams, transmission ECMV circuits

This shop manual gives a technician the full structure and function of every major assembly on the WA380-5, along with the maintenance standards needed to judge wear and service limits. The testing and adjusting chapter provides the measurement conditions, standard values, and service limits for the engine and chassis, plus troubleshooting charts that correlate problems with causes. The disassembly and assembly chapter walks through removal, installation, and overhaul of each component with special tool references and tightening torques.

What This Manual Enables You to Do

With this Komatsu WA380-5 shop manual you can perform complete repairs and overhauls on the wheel loader. The power train section alone covers the torque converter, transmission (including clutch pack disassembly and assembly), drive shafts, differential, final drive, and axles. The hydraulic section covers the work equipment valve, PPC valve, EPC solenoid valve, hydraulic tank, cooling fan motor and drive pump, and all cylinders including steering, lift, and bucket. The brake section covers the brake valve, charge valve, accumulator, wet-type multiple-disc brakes, and parking brake with its solenoid and emergency release valve.

Electrical troubleshooting is supported by the machine monitoring system chapter, transmission control system, work equipment control system, and the electrical circuit diagrams in the OTHERS section. The manual includes connector types and mounting locations, connector layout drawings, and system diagrams for the transmission control system, work equipment control system, and monitor panel system.

For engine work, the manual gives the SAA6D114E-2 specifications, valve clearance adjustment, compression pressure measurement, blow-by pressure measurement, engine oil pressure measurement, intake air pressure (boost pressure) measurement, fuel injection timing testing and adjusting, engine speed sensor adjustment, and engine stop solenoid adjustment. It also includes the engine starting circuit, engine stop circuit, preheating circuit, and engine power mode selector circuit.

Who This Manual Is For

This WA380-5 shop manual is written for professional service technicians, fleet maintenance shops, and repair facilities that need accurate specifications, correct procedures, and clear judgement criteria for the WA380-5 wheel loader. It is equally useful for an owner-operator who wants to understand the machine’s systems and perform maintenance correctly. Every procedure is written with the serviceman in mind — it explains the structure and function first, then the testing and adjusting, then the disassembly and assembly, so the technician understands why a step is performed, not just how.

Why Correct Procedures and Specifications Matter

The WA380-5 is a heavy machine with high-pressure hydraulics, a torque converter, a power-shift transmission, wet disc brakes, and a network of electronic controllers. Tightening torques, clearances, and adjustment values in this manual are the difference between a repair that lasts and one that fails. The Komatsu WA380-5 shop manual gives the standard values, service limits, and judgement criteria for wear parts, so the technician can decide whether a component is within specification or needs replacement.

The troubleshooting charts in the testing and adjusting chapter are organised by symptom — for example engine problems, transmission problems, hydraulic and mechanical problems, electrical problems, and monitor system problems. Each chart narrows down the cause step by step, which saves time and prevents unnecessary disassembly. The failure code table and machine monitor special functions let the technician read the machine’s own diagnostics and act on the correct fault.

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Instant PDF Delivery

This Komatsu WA380-5 shop manual is delivered as an instant PDF download. There is no shipping and no waiting. The file can be viewed on any device — computer, tablet, or smartphone — and pages can be printed for use in the workshop. The complete 1173-page manual is included, covering all chapters from general information through disassembly and assembly. Whether you are servicing the engine, overhauling the transmission, repairing the axles, troubleshooting the electrical system, or adjusting the hydraulics, this manual provides the procedures, specifications, and diagrams you need.