Komatsu WA380-6 Wheel Loader Shop Manual SEN00114-15 PDF

Description

Komatsu WA380-6 Wheel Loader Shop Manual SEN00114-15 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA380-6 Wheel Loader Shop Manual SEN00114-15 – PDF DOWNLOAD 

Language : English
Pages : 1728
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu WA380-6 Wheel Loader Shop Manual SEN00114-15 – PDF DOWNLOAD 

SERIAL NUMBERS 65001 and up

COVER 1
00 Index and foreword 0
Index 2
Composition of shop manual 3
Table of contents 5
Foreword and general information 18
Safety notice 19
How to read the shop manual 24
Explanation of terms for maintenance standard 26
Handling of electric equipment and hydraulic component 28
Handling of connectors newly used for engines 37
How to read electric wire code 40
Precautions when carrying out operation 43
Method of disassembling and connecting push-pull type coupler 46
Standard tightening torque table 49
Conversion table 53
01 Specification 0
Specification and technical data 60
Specification dimension drawing 62
Specifications 63
Weight table 67
Table of fuel, coolant and lubricants 69
10 Structure, function and maintenance standard 0
Engine and cooling system 72
Engine mount and transmission mount 73
Cooling system 74
Cooling fan pump 75
Cooling fan motor 83
Power train 90
Power train 92
Power train system diagram 93
Drive shaft 95
Power train piping diagram 96
Torque converter 97
Transmission 105
Flow control valve 122
Valve assembly 123
ECMV 124
Main relief valve and torque converter relief valve 131
Axle 133
Differential 135
Limited slip differential 140
Final drive 147
Steering system 152
Steering piping diagram 154
Steering column 155
Steering pump 156
Steering valve 168
Orbit-roll valve 183
Stop valve 191
Steering relief valve 192
Steering cylinder 193
Emergency steering motor 195
Emergency steering pump 196
Joystick steering lever linkage 197
Steering electric lever 198
Joystick EPC valve 199
Brake system 202
Brake piping diagram 203
Charge valve 204
Brake valve 211
Accumulator (for brake) 216
Brake 217
Parking brake control 222
Parking brake 223
Parking brake solenoid valve 225
Emergency parking brake release valve 227
Undercarriage and frame 230
Axle mount and center hinge pin 231
Tires 235
Hydraulic system, Part 1 238
Hydraulic piping diagram 239
Work equipment control lever linkage 242
Hydraulic tank 245
Power train pump 247
Work equipment pump 248
Work equipment control valve 259
CLSS 273
Each function and operation of each valve 277
Hydraulic system, Part 2 300
PPC valve 301
Stabilizer valve 307
Accumulator (for PPC circuit) 313
Accumulator (for ECSS) 314
Work equipment PPC cut-off solenoid valve 315
Work equipment 318
Work equipment linkage 319
Bucket 321
Bucket positioner and boom kick-out 322
Work equipment cylinder 328
Cab and its attachments 330
Cab 332
Air conditioner 333
Electrical system, Part 1 352
Machine monitor system 353
Machine monitor 357
Electrical system, Part 2 390
Electrical system (Transmission controller system) 391
Transmission controller 431
Electrical system (Work equipment controller system) 433
Work equipment controller 439
Electrical system, Part 3 442
Electric transmission control 445
Kickdown switch and hold switch 449
Load meter cancel switch and load meter subtotal switch 449
Multi-function knob 450
Joystick steering knob 451
KOMTRAX terminal system 453
Engine starting circuit 455
Engine stopping circuit 457
Preheating circuit 458
Engine power mode selector circuit 459
Engine output derating function 460
Automatic warm-up function 460
Parking brake circuit 461
Sensor 463
20 Standard value table 0
Standard service value table 474
Standard service value table for engine 475
Standard service value table for chassis 476
30 Testing and adjusting 0
Testing and adjusting, Part 1 484
Tools for testing, adjusting, and troubleshooting 486
Testing engine speed 493
Testing exhaust gas color 495
Adjusting valve clearance 497
Testing compression pressure 499
Testing blow-by pressure 502
Testing engine oil pressure 503
Testing intake air (boost) pressure 504
Handling fuel system equipment 505
Releasing residual pressure in fuel system 505
Testing fuel pressure 506
Testing fuel delivery, return and leak amount 508
Bleeding air from fuel circuit 511
Testing leakage in fuel system 512
Handling reduced cylinder mode operation 513
Handling no-injection cranking operation 513
Handling controller voltage circuit 514
Testing and adjusting air conditioner compressor belt tension 515
Replacing alternator belt 516
Adjusting transmission speed sensor 517
Testing directional lever 518
Testing and adjusting power train oil pressure 519
Procedure for flushing torque converter and transmission hydraulic circuit 534
Method of moving machine when transmission valve is broken 535
Testing and adjusting steering stop valve 537
Testing and adjusting steering wheel 539
Testing and adjusting steering oil pressure 541
Bleeding air from steering circuit 544
Testing and adjusting, Part 2 546
Testing hydraulic drive fan 548
Bleeding air from hydraulic drive fan circuit 550
Testing brake pedal 552
Testing brake performance 553
Testing and adjusting accumulator charge pressure 554
Testing wheel brake oil pressure 555
Testing wear of wheel brake disc 557
Bleeding air from wheel brake circuit 558
Releasing residual pressure in brake accumulator circuit 559
Testing parking brake performance 560
Testing parking brake oil pressure 561
Testing wear of parking brake disc 563
Method of releasing parking brake manually 564
Testing and adjusting work equipment control lever 565
Testing and adjusting work equipment PPC oil pressure 566
Testing and adjusting work equipment oil pressure 569
Bleeding air from work equipment circuit 573
Releasing residual pressure in work equipment circuit 574
Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of ECSS (Electronically Controlled Suspension System) accumulator 575
Testing and adjusting bucket positioner 581
Testing and adjusting boom kick-out 583
Checking proximity switch operation pilot lamp 584
Procedure for testing diodes 585
Preparation work for troubleshooting for electric system 586
How to start operation of KOMTRAX terminal 591
Lamp display of KOMTRAX terminal 596
Testing and adjusting, Part 3 600
Adjusting replaced, reassembled or added sensor, controller, etc with machine monitor 602
Special functions of machine monitor (EMMS) 604
Pm-clinic inspection table 673
40 Troubleshooting 0
Failure code table and fuse locations 678
Failure code table 679
Fuse locations 689
General information on troubleshooting 694
Points to remember when troubleshooting 695
Sequence of events in troubleshooting 696
Testing before troubleshooting 697
Classification and procedures of troubleshooting 698
Information contained in troubleshooting table 701
Connection table for connector pin numbers 703
T- branch box and T- branch adapter table 739
Troubleshooting by failure code (Display of code), Part 1 744
Failure code [1500L0] (TORQFLOW transmission: Double meshing) 746
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON) 747
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF) 749
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON) 751
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF) 753
Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON) 755
Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF) 757
Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON) 759
Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF) 761
Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON) 763
Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF) 765
Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON) 767
Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF) 769
Failure code [2F00MA] (Parking brake: Malfunction) 771
Failure code [2G43ZG] (Accumulator: Low oil pressure) 773
Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree) 775
Troubleshooting by failure code (Display of code), Part 2 780
Failure code [AA1ANX] (Air cleaner: Clogging) 783
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine) 785
Failure code [AB00MA] (Alternator: Malfunction) 787
Failure code [B@BAZG] (Rotation derating by low engine oil pressure) 789
Failure code [B@BAZK] (Engine oil: Low level) 790
Failure code [B@BCNS] (Coolant: Overheating) 791
Failure code [B@BCZK] (Coolant: Low level) 793
Failure code [B@BEBF] (Water in fuel error) 795
Failure code [B@C7NS] (Brake oil: Overheating) 797
Failure code [b@CENS] (Torque converter oil: Overheating) 799
Failure code [B@CENS] (Torque converter oil: Overheating) 801
Failure code [B@HANS] (Hydraulic oil: Overheating) 803
Failure code [CA111] (Abnormality in engine controller) 805
Failure code [CA115] (Engine Ne or Bkup speed sensor error) 806
Failure code [CA122] (Charge pressure sensor high error) 807
Failure code [CA123] (Charge pressure sensor low error) 809
Failure code [CA131] (Throttle sensor high error) 811
Failure code [CA132] (Throttle sensor low error) 813
Failure code [CA144] (Coolant sensor high error) 815
Failure code [CA145] (Coolant sensor low error) 817
Failure code [CA153] (Charge temperature sensor high error) 819
Failure code [CA154] (Charge temperature sensor low error) 821
Failure code [CA155] (Derating of speed by abnormally high charge temperature) 823
Failure code [CA187] (Sensor power supply 2 low error) 825
Failure code [CA221] (Atmospheric pressure sensor high error) 827
Failure code [CA222] (Atmospheric sensor low error) 829
Failure code [CA227] (Sensor power supply 2 high error) 831
Failure code [CA234] (Engine overspeed) 832
Failure code [CA238] (Ne speed sensor power supply error) 833
Troubleshooting by failure code (Display of code), Part 3 836
Failure code [CA271] (IMV/PCV1 Short circuit) 838
Failure code [CA272] (IMV/PCV1 Disconnection) 839
Failure code [CA322] (Injector #1 open/short error) 841
Failure code [CA323] (Injector #5 open/short error) 843
Failure code [CA324] (Injector #3 open/short error) 845
Failure code [CA325] (Injector #6 open/short error) 847
Failure code [CA331] (Injector #2 open/short error) 849
Failure code [CA332] (Injector #4 open/short error) 851
Failure code [CA342] (Calibration code inconsistency) 853
Failure code [CA351] (Injectors drive circuit error) 855
Failure code [CA352] (Sensor power supply 1 low error) 857
Failure code [CA386] (Sensor power supply 1 high error) 859
Failure code [CA428] (Abnormally high level in water sensor) 860
Failure code [CA429] (Abnormally low level in water sensor) 861
Failure code [CA431] (Idle validation switch error) 862
Failure code [CA432] (Idle validation action error) 865
Failure code [CA435] (Engine oil pressure switch error) 867
Failure code [CA441] (Battery voltage low error) 868
Failure code [CA442] (Battery voltage high error) 871
Failure code [CA449] Common rail pressure high error 2 873
Failure code [CA451] (Common rail pressure sensor high error) 875
Failure code [CA452] (Common rail pressure sensor low error) 877
Failure code [CA488] (Derating of torque by abnormally high charge temperature) 879
Failure code [CA553] (Common rail pressure high error 1) 880
Failure code [CA559] (Supply pump pressure very low error) 881
Failure code [CA689] (Engine Ne speed sensor error) 883
Failure code [CA731] (Engine Bkup speed sensor phase error) 885
Failure code [CA757] (All continuous data lost error) 886
Failure code [CA778] (Engine Bkup speed sensor error) 889
Failure code [CA1633] (KOMNET datalink timeout error) 891
Failure code [CA2185] (Throttle sensor power supply voltage high error) 893
Failure code [CA2186] (Throttle sensor power supply voltage low error) 894
Troubleshooting by failure code (Display of code), Part 4 896
Failure code [CA2249] (Supply pump pressure very low error 2) 898
Failure code [CA2311] (Abnormality in IMV solenoid) 899
Failure code [CA2555] (Intake heater relay disconnection error) 901
Failure code [CA2556] (Intake heater relay short circuit error) 903
Failure code [D150KA] (Emergency steering relay: Disconnection) 905
Failure code [D150KB] (Emergency steering relay: Short circuit) 907
Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line) 909
Failure code [D160KA] (Backup lamp relay: Disconnection) 911
Failure code [D160KB] (Backup lamp relay: Short circuit) 913
Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection) 915
Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit) 917
Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line) 919
Failure code [D192KA] (ECSS solenoid: Disconnection) 921
Failure code [D192KB] (ECSS solenoid: Short circuit) 922
Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line) 923
Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection) 925
Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit) 927
Failure code [D193KY] (Joystick steering solenoid cut relay: Short circuit with power supply line) 929
Failure code [D5ZHKA] (Terminal C signal: Disconnection) 932
Failure code [D5ZHKB] (Terminal C signal: Short circuit) 936
Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit) 939
Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state) 944
Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree) 947
Failure code [DAF3KK] (Machine monitor: Low source voltage (input) 949
Failure code [DAF5KP] (Machine monitor: Low output voltage) 951
Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system) 955
Troubleshooting by failure code (Display of code), Part 5 958
Failure code [DAQ0KK] (Transmission controller: Low source voltage) 961
Failure code [DAQ0KT] (Transmission controller: Abnormality in controller) 963
Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input) 964
Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals) 966
Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system)) 967
Failure code [DAQRMA] (Transmission controller option setting: Malfunction) 970
Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system) 971
Failure code [DB90KK] Work equipment controller: Low source voltage (input) 973
Failure code [DB90KT] Work equipment controller: Abnormality in controller 975
Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input) 976
Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range 978
Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals) 981
Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system) 982
Failure code [DB9RMA] (Work equipment controller option setting: Malfunction) 984
Failure code [DB9RMC] (CAN communication with transmission controller, engine controller and machine monitor: Defective operation) 985
Failure code [DD15LD] ■ switch (Panel switch 1): Switch is kept pressed for long time 989
Failure code [DD16LD] ◇ switch (Panel switch 2): Switch is kept pressed for long time 991
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time 993
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time 995
Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time 997
Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time 999
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time 1001
Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time 1003
Failure code [DD1GLD] Load meter mode selector switch (+/-): Switch is kept pressed for long time 1005
Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time) 1007
Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time) 1009
Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time) 1011
Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree) 1013
Troubleshooting by failure code (Display of code), Part 6 1018
Failure code [DDE5MA] (Emergency steering drive switch: Malfunction) 1021
Failure code [DDK3KA] (Right FNR switch: Disconnection) 1023
Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection) 1026
Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree) 1029
Failure code [DDK6KA] (FNR lever switch: Disconnection) 1031
Failure code [DDK6KB] (FNR lever switch: Short circuit) 1035
Failure code [DDS5KA] (Steering pressure switch: Disconnected) 1037
Failure code [DDS5KB] (Steering pressure switch: Grounded) 1039
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree) 1041
Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time) 1043
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time) 1045
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time) 1047
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time) 1049
Failure code [DF10KA] (Transmission shift lever switch: Disconnected) 1051
Failure code [DF10KB] (Transmission shift lever switch: Short circuit) 1055
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected) 1057
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit) 1059
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range) 1061
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected) 1063
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range) 1065
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range) 1067
Failure code [DH21KA] (Loader pump pressure sensor: Disconnection) 1069
Failure code [DH21KB] (Loader pump pressure sensor: Power supply line short) 1071
Troubleshooting by failure code (Display of code), Part 7 1074
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range) 1077
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range) 1079
Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range) 1081
Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection) 1083
Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit) 1085
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection) 1087
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line) 1090
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree) 1093
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection) 1096
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line) 1099
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection) 1102
Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line) 1105
Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree) 1108
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection) 1111
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line) 1114
Troubleshooting by failure code (Display of code), Part 8 1118
Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection) 1120
Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line) 1123
Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection) 1125
Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line) 1129
Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree) 1131
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection) 1135
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line) 1137
Failure code [DKA0L0] (Lift arm angle sensor: Dislocation of sensor) 1139
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection) 1141
Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range) 1143
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit) 1145
Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit) 1147
Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit) 1149
Failure code [DV00KB] (Alarm buzzer: Short circuit) 1151
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection) 1153
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit) 1155
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line) 1157
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection) 1159
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit) 1160
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line) 1161
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection) 1163
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit) 1164
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line) 1165
Troubleshooting by failure code (Display of code), Part 9 1168
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection) 1170
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit) 1171
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line) 1173
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection) 1175
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit) 1176
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line) 1177
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection) 1179
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit) 1181
Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line) 1183
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection) 1185
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit) 1187
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line) 1189
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection) 1191
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit) 1193
Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line) 1195
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection) 1197
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit) 1199
Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source) 1201
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection) 1203
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit) 1204
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line) 1205
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection) 1207
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit) 1209
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line) 1211
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection) 1213
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit) 1215
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line) 1217
Troubleshooting by failure code (Display of code), Part 10 1220
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection) 1223
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit) 1225
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line) 1227
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection) 1229
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit) 1231
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line) 1233
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection) 1235
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit) 1237
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line) 1239
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection) 1241
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit) 1243
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line) 1245
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection) 1247
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit) 1249
Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line) 1251
Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection) 1253
Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit) 1255
Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line) 1257
Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection) 1259
Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit) 1261
Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line) 1263
Failure code [DY30MA] Motor-driven emergency steering pump failure (During operation of machine) 1265
Failure code [DY30MC] Motor-driven emergency steering pump failure (Malfunction in manual mode) 1268
Troubleshooting of electrical system (E-mode) 1272
Installing positions of fuses 1274
Information in troubleshooting table 1277
E-1 Engine does not start 1278
E-2 Wiper does not operate 1285
E-3 Windshield washer does not operate 1289
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off 1292
E-5 Working lamp does not light up or go off 1300
E-6 Turn signal lamp and hazard lamp do not light up or go off 1305
E-7 Brake lamp does not light or it keeps lighting up 1311
E-8 Backup lamp does not light or it keeps lighting up 1313
E-9 Backup buzzer does not sound or it keeps sounding 1315
E-10 Horn does not sound or it keeps sounding 1317
E-11 Alarm buzzer does not sound or it keeps sounding 1319
E-12 Air conditioner does not operate or stop 1321
E-13 The KOMTRAX system does not work properly 1324
E-14 When kick-down switch is turned ON, kick-down operation does not start 1327
E-15 When hold switch is pressed, holding operation does not start 1329
E-16 Transmission is kept in neutral, or brake drags when directional lever is operated while parking brake is applied 1331
E-17 Transmission cut-off mode cannot be set or reset 1333
E-18 Transmission cut-off set cannot be reset 1335
E-19 FNR switch mode cannot be set or reset 1337
E-20 Fan reverse function cannot be used or reset 1339
E-21 Discharge from loader pump does not rise from minimum level 1341
E-22 ECSS function cannot be used or reset 1343
E-23 When parking brake is turned ON, parking brake indicator lamp does not light up 1345
E-24 When emergency brake operates, brake oil pressure caution lamp does not operate 1349
E-25 Air cleaner clogging indicator lamp does not light up 1351
E-26 Radiator coolant level caution lamp does not light up 1353
E-27 Hydraulic oil temperature gauge does not rise and hydraulic oil temperature caution lamp does not light up 1354
E-28 Torque converter oil temperature gauge does not rise and torque converter oil temperature caution lamp does not light up 1355
E-29 Steering oil pressure caution lamp does not light up 1357
E-30 Abnormality in ■ switch (panel switch 1) input 1359
E-31 Abnormality in ◇ switch (panel switch 2) input 1361
E-32 Abnormality in < switch (panel switch 3) input 1363
E-33 Abnormality in > switch (panel switch 4) input 1365
Troubleshooting of hydraulic and mechanical system (H-mode) 1368
Method of using troubleshooting chart 1370
Table of failure modes and causes 1373
H-1 The machine does not start 1377
H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)] 1379
H-3 Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)] 1380
H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted 1381
H-5 Shocks are large at the times of starting and shifting gear 1383
H-6 Time lag is large at the times of starting and shifting gear 1385
H-7 The torque converter oil temperature is high 1387
H-8 Steering does not turn 1388
H-9 Steering does not turn [Machine with joystick steering (if equipped)] 1389
H-10 Steering response is low 1390
H-11 Turning, response of steering is poor [machine with joystick steering (if equipped)] 1391
H-12 Steering is heavy 1392
H-13 When machine turns, it shakes or makes large shocks 1393
H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)] 1394
H-15 The wheel brake does not work or does not work well 1395
H-16 The wheel brake is not released or it drags 1396
H-17 The parking brake does not work or does not work well 1397
H-18 The parking brake is not released or it drags (including emergency release system) 1398
H-19 Lift arm does not rise 1399
H-20 Lift arm speed is low or rising force of lift arm is insufficient 1400
H-21 When rising, the lift arm comes to move slowly at specific height 1401
H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats) 1401
H-23 Hydraulic drifts of the lift arm is large 1401
H-24 The lift arm wobbles during operation 1401
H-25 Bucket does not tilt back 1402
H-26 Bucket speed is low or tilting back force is insufficient 1403
H-27 The bucket comes to operate slowly in the midst of tilting-back 1404
H-28 The bucket cylinder cannot hold down the bucket 1404
H-29 Hydraulic drifts of the bucket is large 1404
H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”) 1404
H-31 Lift arm and bucket control levers do not move smoothly and are heavy 1405
H-32 During operation of the machine, engine speed lowers remarkably or engine stalls 1406
H-33 Large shock is made when work equipment starts and stops 1406
H-34 When work equipment circuit is relieved singly, other work equipment moves 1406
H-35 ECSS does not operate, and pitching, bouncing occur 1407
Troubleshooting of engine (S-mode) 1410
Method of using troubleshooting charts 1412
S-1 Engine does not start easily 1415
S-2 Engine does not start 1416
S-3 Engine does not pick up smoothly 1419
S-4 Engine stops during operations 1420
S-5 Engine does not rotate smoothly 1421
S-6 Engine lacks output (or lacks power) 1422
S-7 Exhaust smoke is black (Incomplete combustion) 1423
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1424
S-9 Engine oil becomes contaminated quickly 1425
S-10 Fuel consumption is excessive 1426
S-11 Coolant contains oil (blows back or reduces) 1427
S-12 Oil pressure drops 1428
S-13 Oil level rises (Water, fuel in oil) 1429
S-14 Coolant temperature rises too high (Overheating) 1430
S-15 Abnormal noise is made 1431
S-16 Vibration is excessive 1432
50 Disassembly and assembly 0
General information on disassembly and assembly 1434
How to read this manual 1435
Coating materials list 1437
Special tools list 1440
Sketches of special tools 1443
Engine and cooling system 1450
Removal and installation of fuel supply pump assembly 1451
Removal and installation of fuel injector assembly 1454
Removal and installation of cylinder head assembly 1461
Removal and installation of engine hood assembly 1472
Removal and installation of radiator assembly 1474
Removal and installation of air aftercooler 1476
Removal and installation of hydraulic oil cooler assembly 1478
Removal and installation of engine assembly 1480
Removal and installation of engine front oil seal assembly 1485
Removal and installation of engine rear oil seal assembly 1488
Removal and installation of cooling fan and fan motor assembly 1491
Removal and installation of fuel tank assembly 1494
Power train 1498
Removal and installation of torque converter and transmission assembly 1499
Disassembly and assembly of torque converter assembly (Standard specification) 1505
Disassembly and assembly of torque converter assembly (Lockup specification) 1509
Disassembly and assembly of transmission assembly 1515
Disassembly and assembly of transmission clutch pack assembly 1531
Disassembly and assembly of parking brake assembly 1549
Removal and installation of front axle assembly 1558
Removal and installation of rear axle assembly 1560
Disassembly and assembly of axle housing 1563
Disassembly and assembly of differential assembly 1572
Steering system 1592
Removal and installation of steering valve assembly 1593
Brake system 1596
Removal and installation of parking brake discs and plates 1597
Undercarriage and frame 1602
Removal and installation of center hinge pin 1603
Removal and installation of counterweight 1611
Hydraulic system 1614
Removal and installation of work equipment control valve assembly 1615
Removal and installation of power train pump and work equipment pump assembly 1618
Removal and installation of steering pump and cooling fan pump assembly 1619
Removal and installation of hydraulic tank assembly 1620
Work equipment 1624
Removal and installation of work equipment assembly 1625
Disassembly and assembly of hydraulic cylinder assembly 1629
Cab and its attachments 1638
Removal and installation of operator’s cab and floor frame assembly 1639
Removal and installation of operator’s cab glass (stuck glass) 1642
Disassembly and assembly of operator’s seat assembly (Standard specification) 1650
Disassembly and assembly of operator’s seat assembly (Manufactured by GRAMMER) 1659
Removal and installation of air conditioner unit assembly 1692
Electrical system 1696
Removal and installation of engine controller assembly 1697
90 Diagrams and drawings 0
Hydraulic diagrams and drawings 1700
Power train hydraulic circuit diagram 1701
Automatic greasing circuit diagram 1703
Hydraulic circuit diagram 1706
Electrical diagrams and drawings 1709
Electrical circuit diagram 1711
Work equipment controller system electrical circuit diagram 1725
Connector list and stereogram 1726

DESCRIPTION:

Komatsu WA380-6 Wheel Loader Shop Manual SEN00114-15 – PDF DOWNLOAD 

SERIAL NUMBERS 65001 and up

How to read the shop manual 1
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

S.V 29/12/24