Technical Presentation Kit

Wheel Loaders

WA380/WA430-5

FUNCTION AND STRUCTURE

Komatsu WA380/430-
WA380/430-5
Wheel Loaders
MN20020601
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COOLING FAN CONTROL FUNCTION Wheel Loaders

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z Fan control
This system reduces loss of
horsepower and noise at low
temperature by employing the
hydraulic drive for the cooling fan
and controlling the swash plate of
the hydraulic pump swash.

z Engine water temperature, operating

oil temperature and oil temperature
of the torque converter detected by
the machine monitor are sent to the
transmission controller via the
network. Upon receiving above
information, the transmission
controller turns on a fan revolution
suitable to the temperature and
engine speed by controlling the
swash plate of the hydraulic pump
by use of electric current.

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OPERATION OF REVOLUTION Wheel Loaders

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DIRECTION CHANGEOVER VALVE

zWhen ON-OFF solenoid for changeover valve is
turned OFF
z If ON-OFF solenoid (1) for changeover valve is
turned "OFF", the hydraulic oil from the pump is
blocked by ON-OFF changeover valve (2) and port
C is connected to the tank circuit.
z Accordingly, changeover spool (3) is pushed by
changeover spool spring (4) to the right to open
motor port MA and then the hydraulic oil flows in
to revolve the motor forward (clockwise).
zWhen ON-OFF solenoid for changeover valve is turned
ON
z If ON-OFF solenoid (1) for changeover valve is turned
"ON", ON-OFF changeover valve (2) changes to let the
hydraulic oil from the pump flow through port C into
spool chamber D.
z The hydraulic oil in chamber D pushes changeover
spool (3) against changeover spool spring (4). As a
result, motor port MB opens and the hydraulic oil flows
in to revolve the motor in reverse (counterclockwise).

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Wheel Loaders

COOLING FAN 10/00

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zCooling fan motor drive pump zCooling fan motor

(1) Output shaft (8) End cover

(2) Case (9) Center spring
(1) Shaft (6) Piston (3) Thrust plate (10) Check valve spring
(2) Oil seal (7) Cylinder block (4) Shoe (11) Check valve
(3) Case (8) Valve plate (5) Piston (12) Pilot valve
(4) Rocker cam (9) Spring (6) Cylinder block (13) Changeover spool
(5) Shoe (10) Servo piston (7) Valve plate (14) Changeover spool spring

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EMERGENCY STEERING Wheel Loaders

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PUMP & MOTOR [NO.1] (OPTION)

zEMERGENCY STEERING PUMP
z The emergency steering pump is installed to the transmission
together with the emergency steering motor. If the engine stops or if
the oil pressure in the steering circuit drops below the set pressure,
it supplies oil to the steering circuit.
z If there is an abnormal drop in the oil pressure in the steering circuit,
the emergency steering motor receives a signal from the transmission
controller and drives the emergency pump.

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EMERGENCY STEERING Wheel Loaders

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PUMP & MOTOR [NO.2] (OPTION)

z Electric Emergency Steering Function (OP)
„ Operation of electric emergency steering function

The transmission controller constantly monitors state of the steering oil

pressure switch of the steering circuit. If oil pressure of the steering
goes low, thereby increasing the travel speed above the emergency
steering activation level, the transmission controller outputs the
emergency steering ON signal to the relay to turn on the emergency
steering.

This function can also be turned on from the emergency steering switch
independent of the travel speed or steering oil pressure.

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EMERGENCY STEERING Wheel Loaders

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PUMP & MOTOR [NO.3] (OPTION)

SBL(1)21
EMERGENCY STEERING PUMP

EMERGENCY STEERING MOTOR

(1) Terminal E
(2) Terminal M

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TORQUE CONVERTER [NO.1] Wheel Loaders

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zLock-up clutch disengaged

z When the lock-up clutch is disengaged, the
connection of drive case (3) and turbine (6)
is disconnected, and the torque converter
functions as normal.
The power generated by the engine is
transmitted from flywheel (1) to clutch
housing (2), and rotates drive case (3) and
pump (4) as one unit. The power from pump
(4) uses oil as a medium to rotate turbine (6)
and transmits the power from turbine (6) to
transmission input shaft (8) through boss (7).
The power from drive case (3) passes through
PTO gear (5) and is used as the power to
drive the gear pump.

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TORQUE CONVERTER [NO.2] Wheel Loaders

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zLock-up clutch engaged

z When the lock-up clutch is engaged, drive
case (3) and turbine (6) are connected and
form one unit. Stator (9) is rotated by the
rotation of pump (4) and turbine (6).
The power generated by the engine is
transmitted from flywheel (1) to clutch
housing (2), and rotates drive case (3) and
pump (4) as one unit. In addition, drive case
(3) and turbine (6) are connected by the lock-
up clutch, so the power is transmitted
directly from turbine (6) to transmission
input shaft (8) without using oil as a medium.
The power from drive case (3) passes through
PTO gear (5) and is used as the power to
drive the gear pump.

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TORQUE CONVERTER [NO.3] Wheel Loaders

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zFlow of oil
z The oil passes through the main relief valve
and its pressure is adjusted by the torque
converter relief valve so that it is less than the
set pressure. It then enters inlet port A,
passes through the passage in stator shaft (1)
and guide (2), and flows to pump (3).
The oil is given centrifugal force by pump (3).
It then enters turbine (4) and transmits the
energy of the oil to turbine (4).
The oil from turbine (4) is sent to stator (5),
and enters pump (3) again. However, part of
the oil is fed to the torque converter oil cooler
from the stator (5) passing through the outlet
port B.

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TORQUE CONVERTER [NO.4] Wheel Loaders

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z Torque Converter Lockup Control Function (Option)

(1)The torque converter lockup switch operation (ON/OFF) enables to implement the lockup automatically.
When the lockup switch is turned on, the torque converter lockup can be automatically turned on or off in the manual
shift mode, too.
Following table shows the lockup specification-based gear speeds

Lockup specification-based gear speeds Lockup:

Travel mode F1 F2 F3 F4 R1 R2 R3 R4

Manual shift
Auto-shift (L, M, H) * *
* In the auto-shift mode, the lockup is not available only at the 3rd gear speed (gearshift
lever position).

(2)Lockup travel speed

For the travel speed that turns ON/OFF the lockup, refer to the [Auto-Shift Point List].
In the manual shift mode, too, the lockup is turned on or off at the same travel as in the auto-shift mode.
The lockup is cancelled as the travel speed reaches 40km/h or above. This arrangement is prepared to ensure the driver
safety. After the cancellation, if the travel speed is increased from below 38km/h to 38km/h or above, the lockup is
applied again.
(3)Lockup protection function
The lockup is turned on only when the machine traveling direction matches the lever position.
Judgment of machine travel direction
1.When the travel speed is 10km/h, the lever position decides the machine travel direction.
2.As long as the travel speed 10km/h is kept, judgment of 1 above is maintained.
3.When the travel speed < 10km/h is detected continuously for one second or more, the protection function judges that
no speed data is available.
4.When data on FR travel direction is not stored in the memory or when the travel direction does not match the lever
position, the lockup function is not turned on.

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TORQUE CONVERTER [NO.5] Wheel Loaders

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z With lock-up clutch

(1) Flywheel
(2) Clutch housing (Number of teeth: 72)
(3) Boss (Number of teeth: 90)
(4) Turbine
(5) Drive case
(6) Stator Disc
(7) Pump
(8) PTO drive gear (Number of teeth: 97)
(9) Stator shaft
(10) Guide
(11) Transmission input shaft
(12) One way clutch
(13) Race
(14) Disc
(15) Piston

„Specifications
Type 3-element, 1-stage, 2-phase

Stall torque ratio 2.98

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AXLE & BRAKE [NO.1] Wheel Loaders

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zAXLE
„ Outline
z The power from the engine passes through the torque
converter, transmission, and drive shafts, and is transmitted
to the front and rear axles.
z Inside the axle, the power is transmitted from bevel pinion (1)
to bevel gear (5) and the direction is changed 90 . It is also
reduced and passes through pinion gear (4) and is
transmitted to sun gear shaft (2).
z The power of the sun gear is further reduced by the planetary
gear type final drive and is transmitted to the axle shaft and
wheels.

„ When traveling in a straight line

z When traveling in a straight line, the rotating speed of the
left and right wheels is the same, so pinion gear (4) inside
the differential assembly does not rotate. The power of
carrier (6) passes through pinion gear (4) and side gear (3),
and is transmitted equally to the left and right sun gear
shafts (2).

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AXLE & BRAKE [NO.2] Wheel Loaders

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„ When turning
z When turning, the rotating speed of the left and right
wheels is different, so pinion gear (4) and side gear
(3) inside the differential transmit the power of
carrier (6) to sun gear shaft (2) while rotating in
accordance with the difference between the left and
right rotating speeds.

„ Outline
z The final drive reduces the speed of the power from
the engine and increases the drive force.
z Ring gear (4) is press fitted to the axle housing and
is fixed in position by a pin.
z The power transmitted from the differential and
passing through sun gear shaft (5) has its speed
reduced by the planetary gear mechanism and the
drive force increased.
The increased drive force passes through planetary
carrier (2) and axle shaft (3) and is transmitted to the
wheels.

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AXLE & BRAKE [NO.3] Wheel Loaders

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zBRAKE
„Outline
y The front brake has a wet-type multiple-disc structure, and consists of
piston (3), inner ring (5), discs (9), outer ring (8), and spring (4).
y The brake cylinder consists of differential housing (1) and bearing carrier
(2), and piston (3) is assembled in it.
Inner ring (5) and outer ring (8) are joined to the spline portion of axle
housing (7).
y Discs (9) have a lining adhered to both sides. They are assembled
between inner ring (5) and outer ring (8), and are joined by the spline of
sun gear shaft (6).
y The rear brake has a wet-type single-disc structure, and consists of
piston (3), inner ring (5), disc (9), outer ring (8), and spring (4).
y The brake cylinder consists of differential housing (1) and bearing carrier
(2), and piston (3) is assembled in it.
Inner ring (5) and outer ring (8) are joined to the spline portion of axle
housing (7).
y Disc (9) has a lining stuck to both sides. It is assembled between inner
ring (5) and outer ring (8), and is joined by the spline of sun gear shaft
(6).

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AXLE & BRAKE [NO.4] Wheel Loaders

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„ When brake is applied

z When the brake pedal is depressed, pressure oil P
goes from the hydraulic tank through the pump and
brake charge valve. It acts on the piston inside the
brake cylinder and the piston slides.
Therefore, piston (2) stops the rotation of discs (4)
fitted between inner ring (3) and outer ring (5), and
applies the brake to the machine.

„ When brake is released

z When the oil pressure is released, piston (2) is
returned to its original position by the force of
spring (8), a gap is formed between inner ring (3)
and outer ring (5), and discs (4) become free.
Lattice shape grooves are cut into the lining stuck
to disc (4), and when disc (4) is rotating, oil flows in
the grooves and carries out cooling of the lining.

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AXLE & BRAKE [NO.5] Wheel Loaders

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z AXLE
„ FRONT AXLE
(1) Differential
(2) Final drive
(3) Axle shaft
(4) Axle housing
(5) Wet-type multiple-disc brake
(6) Coupling
(7) Oil filler port/level plug
(8) Drain plug

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AXLE & BRAKE [NO.6] Wheel Loaders

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„REAR AXLE
(1) Differential
(2) Final drive
(3) Axle shaft
(4) Axle housing
(5) Wet-type multiple-disc brake
(6) Coupling
(7) Oil filler port/level plug
(8) Drain plug

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LSD (LIMITED SLIP DIFFERENTIAL) Wheel Loaders

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[No.1] (OPTION)
zA LSD (Limited-Slip Differential) is offered as an option.

LSD prevents each drive wheel from slipping until the

resistance difference between both drive wheels becomes
2.64 times. With this function, cutting of tires is prevented
and wear of the tires is reduced greatly on soft ground,
sandy ground, ground covered with snow or rainwater,
compared to the conventional axles. On normal ground,
when the operator scoops on a slightly graded surface or
when the load is unbalanced laterally during scooping or
pilling up operation, the tires do not slip and the operation is
stabilized and the fuel consumption is reduced during
acceleration.

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LSD (LIMITED SLIP DIFFERENTIAL) Wheel Loaders

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[No.2] (OPTION)

LSD (Limited Slip Differential)

Model KOMATSU CAT VOLVO

Item WA480/470 WA430-5 WA380 966G L150D
LSD axle Option Option Option Option Option

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LSD (LIMITED SLIP DIFFERENTIAL) Wheel Loaders

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[No.3] (OPTION)

Torque proportioning Conventional

Differential LSD
differential differential
Side gear brake, Differential pinion gear Wheel on slippery side
consisting of plates and has odd number of teeth slips easily in mud.
discs and installed on and are shaped specially
rear of side gear, so that each wheel will
prevents each wheel not slip until the
from slipping until the resistance difference
resistance difference between both wheels
between both wheels becomes 38%.
becomes 2.64 times.
Item
Slipping
tire (A)
１ １ １
* Drive
Locked
Force of
tire (B)
2.64 1.38 １
wheel
Total
3.64［1.53］ 2.38［１］ ２［0.84］
(A + B)
* The drive force for the slipping tire is taken as 1

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INCREASED DRIVE SHAFT Wheel Loaders

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GREASING INTERVAL
z The sealing performance of the greased parts of the spiders
and splines is improved to increase the greasing interval.

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DUAL MODE ENGINE POWER SELECT Wheel Loaders

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SYSTEM [No.1]
z The operator can select the Normal mode or Power mode according to the
work environment to increase the working ability and efficiency and
reduce the fuel consumption.

(1) Normal mode

This mode is used for the general work such as loading
products, gravel, crushed stone into dump trucks or
hoppers or carrying them on level roads and relatively
light load work.
Mode selector switch
(2) Power mode
In this mode, the power of the
loader is used to the maximum
to increase the production to the
maximum.This mode is suitable to
jobsites where the loader must move
faster on uphill grades or blasted
rock digging sites, etc. where larger
power is required and priority is
given to production.

[Use of Power/Normal mode]

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DUAL MODE ENGINE POWER SELECT Wheel Loaders

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SYSTEM [No.2]

z Structure and function of dual mode engine power select

system

z The operator can select engine power with the dual mode select switch on
the right side in the operator's cab.
z In the Power mode, maximum engine power is provided.

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POWER MODE SELECTOR SWITCH

Wheel Loaders
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zPOWER MODE SELECTOR SWITCH

z This switch (2) can be used to switch the engine
output to match the purpose of the operation.

z When the POWER mode is selected, the output

mode pilot lamp (POWER mode) on the machine
monitor lights up.

NORMAL position: Normal mode (low engine output), operations where emphasis
is on fuel consumption, such as operations on flat ground
where high engine output is not needed.
POWER position: Power mode (high engine output), operations where emphasis is
on production.

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ECSS (ELECTRONICALLY CONTROLLED Wheel Loaders

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SUSPENSION SYSTEM) (OPTION)

z Structure and function of ECSS
ECSS of the WA430-5 is equipped with a travel speed sensor and a
controller that restricts vibration depending on the working condition and
travel condition. It is automatically turned on when the travel speed
exceeds 5 km/h (3.1 MPH) and turned off when the travel speed is below 5
km/h (3.1 MPH) for digging or approaching a dump truck. Accordingly, the
operator is free of troublesome switching operations.

W orking condition Operation of accumulator Applicable work

1st gear OFF Digging, approaching dump truck
Below 5 km/h (3.1 MPH) OFF Digging, approaching dump truck
2nd - 4th gear
Above 5 km/h (3.1 MPH) ON Travelling (empty, loaded)

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E.C.S.S. SWITCH (If equipped) Wheel Loaders

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WARNING z If the machine is traveling or the work equipment is raised, the moment the E.C.S.S.
switch is turned ON, the work equipment will move.
z If operations are carried out with the E.C.S.S. switch at the ON position, the moment
the E.C.S.S. switch is operated, the work equipment may move.
z Never turn on the E.C.S.S. switch ON during inspection or maintenance. The work
equipment will move and this will create a dangerous situation.

NOTICE
z Always stop the machine and lower the work equipment to the ground before operating the
E.C.S.S. switch.
z When carrying out inspection and maintenance, first lower the work equipment to the
ground, then turn the E.C.S.S. switch OFF before starting the inspection and maintenance
operation.
z When carrying out leveling work, turn the E.C.S.S. switch OFF.

This switch (21) is used to turn the E.C.S.S. ON and OFF.

Position (a): ON
The pilot lamp lights up and the E.C.S.S. is actuated.
Position (b): OFF
The E.C.S.S. is not actuated.
REMARK
z The E.C.S.S. is a device that uses the hydraulic spring effect of an accumulator to absorb
the vibration of the chassis during travel and allows the machine to travel smoothly and at
high speed.
z When traveling in 1st, the E.C.S.S. is not actuated.
z When the speed range is 2nd to 4th, and the travel speed becomes more than 5 km/h (3.1
MPH), the E.C.S.S. is automatically actuated; when the travel speed goes below 3 km/h
(1.9 MPH), it is automatically disengaged.

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