Komatsu WA380-6 Wheel Loader Shop Manual VEBM440102 PDF

Description

Komatsu WA380-6 Wheel Loader Shop Manual VEBM440102 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA380-6 Wheel Loader Shop Manual VEBM440102 – PDF DOWNLOAD 

Language : English
Pages : 1733
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu WA380-6 Wheel Loader Shop Manual VEBM440102 – PDF DOWNLOAD 

SERIAL NUMBERS H60051 and up

Cover 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword and general information 21
Safety notice 22
How to read the shop manual 27
Explanation of terms for maintenance standard 29
Handling of electric equipment and hydraulic component 31
Handling of connectors newly used for engines 40
How to read electric wire code 43
Precautions when carrying out operation 46
Method of disassembling and connecting push-pull type coupler 49
Standard tightening torque table 52
Conversion table 56
01 Specification 61
Specification and technical data 61
Specification dimension drawing 63
Specifications 64
Weight table 68
Table of fuel, coolant and lubricants 70
10 Structure, function and maintenance standard 73
Engine and cooling system 73
Engine mount and transmission mount 74
Cooling system 75
Cooling fan pump 76
Cooling fan motor 84
Power train 91
Power train 93
Power train system diagram 94
Drive shaft 96
Power train piping diagram 97
Torque converter 98
Transmission 106
Flow control valve 123
Valve assembly 124
ECMV 125
Main relief valve and torque converter relief valve 132
Axle 134
Differential 136
Limited slip differential 141
Final drive 148
Steering system 151
Steering piping diagram 153
Steering column 154
Steering pump 155
Steering valve 167
Orbit-roll valve 182
Stop valve 190
Steering relief valve 191
Steering cylinder 192
Emergency steering motor 194
Emergency steering pump 195
Joystick steering lever linkage 196
Steering electric lever 197
Joystick EPC valve 198
Brake system 199
Brake piping diagram 200
Charge valve 201
Brake valve 208
Accumulator (for brake) 213
Brake 214
Parking brake control 219
Parking brake 220
Parking brake solenoid valve 222
Emergency parking brake release valve 224
Undercarriage and frame 225
Axle mount and center hinge pin 226
Tires 230
Hydraulic system, Part 1 231
Hydraulic piping diagram 232
Work equipment control lever linkage 235
Hydraulic tank 238
Power train pump 240
Work equipment pump 241
Work equipment control valve 252
CLSS 266
Each function and operation of each valve 270
Hydraulic system, Part 2 293
PPC valve 294
Stabilizer valve 300
Accumulator (for PPC circuit) 306
Accumulator (for ECSS) 307
Work equipment PPC cut-off solenoid valve 308
Work equipment 311
Work equipment linkage 312
Bucket 314
Bucket positioner and boom kick-out 315
Work equipment cylinder 321
Cab and its attachments 323
Cab 325
Air conditioner 326
Electrical system, Part 1 343
Machine monitor system 344
Machine monitor 348
Electrical system, Part 2 381
Electrical system (Transmission controller system) 382
Transmission controller 428
Electrical system (Work equipment controller system) 430
Work equipment controller 436
Electrical system, Part 3 439
Electric transmission control 442
Kickdown switch and hold switch 446
Load meter cancel switch and load meter subtotal switch 446
Multi-function knob 447
Joystick steering knob 448
KOMTRAX terminal system 450
Engine starting circuit 452
Engine stopping circuit 454
Preheating circuit 455
Engine power mode selector circuit 456
Engine output derating function 457
Automatic warm-up function 457
Parking brake circuit 458
Sensor 460
Central Lubrication System (CLS) 469
Function of central lubrication system (CLS) 470
Auto-grease pump 470
Changing the lubrication interval times 471
Operating the central lubrication system 472
Display and control unit 473
LED-display 473
Push buttons 473
Three-digit LED display 474
Check central lubrication system, fill up grease 475
20 Standard value table 477
Standard service value table 477
Standard service value table for engine 478
Standard service value table for chassis 479
30 Testing and adjusting 487
Testing and adjusting, Part 1 487
Tools for testing, adjusting, and troubleshooting 489
Testing engine speed 496
Testing exhaust gas color 498
Adjusting valve clearance 500
Testing compression pressure 502
Testing blow-by pressure 505
Testing engine oil pressure 506
Testing intake air (boost) pressure 507
Handling fuel system equipment 508
Releasing residual pressure in fuel system 508
Testing fuel pressure 509
Testing fuel delivery, return and leak amount 511
Bleeding air from fuel circuit 514
Testing leakage in fuel system 515
Handling reduced cylinder mode operation 516
Handling no-injection cranking operation 516
Handling controller voltage circuit 517
Testing and adjusting air conditioner compressor belt tension 518
Replacing alternator belt 519
Adjusting transmission speed sensor 520
Testing directional lever 521
Testing and adjusting power train oil pressure 522
Procedure for flushing torque converter and transmission hydraulic circuit 537
Method of moving machine when transmission valve is broken 538
Testing and adjusting steering stop valve 540
Testing and adjusting steering wheel 542
Testing and adjusting steering oil pressure 544
Bleeding air from steering circuit 547
Testing and adjusting, Part 2 549
Testing hydraulic drive fan 551
Bleeding air from hydraulic drive fan circuit 553
Testing brake pedal 555
Testing brake performance 556
Testing and adjusting accumulator charge pressure 557
Testing wheel brake oil pressure 558
Testing wear of wheel brake disc 560
Bleeding air from wheel brake circuit 561
Releasing residual pressure in brake accumulator circuit 562
Testing parking brake performance 563
Testing parking brake oil pressure 564
Testing wear of parking brake disc 566
Method of releasing parking brake manually 567
Testing and adjusting work equipment control lever 568
Testing and adjusting work equipment PPC oil pressure 569
Testing and adjusting work equipment oil pressure 572
Bleeding air from work equipment circuit 576
Releasing residual pressure in work equipment circuit 577
Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of ECSS (Electronically Controlled Suspension System) accumulator 578
Testing and adjusting bucket positioner 584
Testing and adjusting boom kick-out 586
Checking proximity switch operation pilot lamp 587
Procedure for testing diodes 588
Preparation work for troubleshooting for electric system 589
How to start operation of KOMTRAX terminal 594
Lamp display of KOMTRAX terminal 599
Testing and adjusting, Part 3 603
Adjusting replaced, reassembled or added sensor, controller, etc with machine monitor 605
Special functions of machine monitor (EMMS) 607
Pm-clinic inspection table 676
40 Troubleshooting 679
Failure code table and fuse locations 679
Failure code table 680
Fuse locations 690
General information on troubleshooting 693
Points to remember when troubleshooting 694
Sequence of events in troubleshooting 695
Testing before troubleshooting 696
Classification and procedures of troubleshooting 697
Information contained in troubleshooting table 700
Connection table for connector pin numbers 702
T- branch box and T- branch adapter table 738
“ * ” Shows not T-adapter but socket 740
Troubleshooting by failure code (Display of code), Part 1 741
Failure code [1500L0] (TORQFLOW transmission: Double meshing) 743
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON) 744
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF) 746
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON) 748
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF) 750
Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON) 752
Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF) 754
Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON) 756
Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF) 758
Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON) 760
Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF) 762
Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON) 764
Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF) 766
Failure code [2F00MA] (Parking brake: Malfunction) 768
Failure code [2G43ZG] (Accumulator: Low oil pressure) 770
Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree) 772
Troubleshooting by failure code (Display of code), Part 2 775
Failure code [AA1ANX] (Air cleaner: Clogging) 778
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine) 780
Failure code [AB00MA] (Alternator: Malfunction) 782
Failure code [B@BAZG] (Rotation derating by low engine oil pressure) 784
Failure code [B@BAZK] (Engine oil: Low level) 785
Failure code [B@BCNS] (Coolant: Overheating) 786
Failure code [B@BCZK] (Coolant: Low level) 788
Failure code [B@BEBF] (Water in fuel error) 790
Failure code [B@C7NS] (Brake oil: Overheating) 792
Failure code [b@CENS] (Torque converter oil: Overheating) 794
Failure code [B@CENS] (Torque converter oil: Overheating) 796
Failure code [B@HANS] (Hydraulic oil: Overheating) 798
Failure code [CA111] (Abnormality in engine controller) 800
Failure code [CA115] (Engine Ne or Bkup speed sensor error) 801
Failure code [CA122] (Charge pressure sensor high error) 802
Failure code [CA123] (Charge pressure sensor low error) 804
Failure code [CA131] (Throttle sensor high error) 806
Failure code [CA132] (Throttle sensor low error) 808
Failure code [CA144] (Coolant sensor high error) 810
Failure code [CA145] (Coolant sensor low error) 812
Failure code [CA153] (Charge temperature sensor high error) 814
Failure code [CA154] (Charge temperature sensor low error) 816
Failure code [CA155] (Derating of speed by abnormally high charge temperature) 818
Failure code [CA187] (Sensor power supply 2 low error) 820
Failure code [CA221] (Atmospheric pressure sensor high error) 822
Failure code [CA222] (Atmospheric sensor low error) 824
Failure code [CA227] (Sensor power supply 2 high error) 826
Failure code [CA234] (Engine overspeed) 827
Failure code [CA238] (Ne speed sensor power supply error) 828
Troubleshooting by failure code (Display of code), Part 3 829
Failure code [CA271] (IMV/PCV1 Short circuit) 831
Failure code [CA272] (IMV/PCV1 Disconnection) 832
Failure code [CA322] (Injector #1 open/short error) 834
Failure code [CA323] (Injector #5 open/short error) 836
Failure code [CA324] (Injector #3 open/short error) 838
Failure code [CA325] (Injector #6 open/short error) 840
Failure code [CA331] (Injector #2 open/short error) 842
Failure code [CA332] (Injector #4 open/short error) 844
Failure code [CA342] (Calibration code inconsistency) 846
Failure code [CA351] (Injectors drive circuit error) 848
Failure code [CA352] (Sensor power supply 1 low error) 850
Failure code [CA386] (Sensor power supply 1 high error) 852
Failure code [CA428] (Abnormally high level in water sensor) 853
Failure code [CA429] (Abnormally low level in water sensor) 854
Failure code [CA431] (Idle validation switch error) 855
Failure code [CA432] (Idle validation action error) 858
Failure code [CA435] (Engine oil pressure switch error) 860
Failure code [CA441] (Battery voltage low error) 861
Failure code [CA442] (Battery voltage high error) 864
Failure code [CA449] Common rail pressure high error 2 866
Failure code [CA451] (Common rail pressure sensor high error) 868
Failure code [CA452] (Common rail pressure sensor low error) 870
Failure code [CA488] (Derating of torque by abnormally high charge temperature) 872
Failure code [CA553] (Common rail pressure high error 1) 873
Failure code [CA559] (Supply pump pressure very low error) 874
Failure code [CA689] (Engine Ne speed sensor error) 876
Failure code [CA731] (Engine Bkup speed sensor phase error) 878
Failure code [CA757] (All continuous data lost error) 879
Failure code [CA778] (Engine Bkup speed sensor error) 882
Failure code [CA1633] (KOMNET datalink timeout error) 884
Failure code [CA2185] (Throttle sensor power supply voltage high error) 886
Failure code [CA2186] (Throttle sensor power supply voltage low error) 887
Troubleshooting by failure code (Display of code), Part 4 889
Failure code [CA2249] (Supply pump pressure very low error 2) 891
Failure code [CA2311] (Abnormality in IMV solenoid) 892
Failure code [CA2555] (Intake heater relay disconnection error) 894
Failure code [CA2556] (Intake heater relay short circuit error) 896
Failure code [D150KA] (Emergency steering relay: Disconnection) 898
Failure code [D150KB] (Emergency steering relay: Short circuit) 900
Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line) 902
Failure code [D160KA] (Backup lamp relay: Disconnection) 904
Failure code [D160KB] (Backup lamp relay: Short circuit) 906
Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection) 908
Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit) 910
Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line) 912
Failure code [D192KA] (ECSS solenoid: Disconnection) 914
Failure code [D192KB] (ECSS solenoid: Short circuit) 915
Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line) 916
Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection) 918
Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit) 920
Failure code [D193KY] (Joystick steering solenoid cut relay: Short circuit with power supply line) 922
Failure code [D5ZHKA] (Terminal C signal: Disconnection) 925
Failure code [D5ZHKB] (Terminal C signal: Short circuit) 929
Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit) 932
Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state) 937
Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree) 940
Failure code [DAF3KK] (Machine monitor: Low source voltage (input) 942
Failure code [DAF5KP] (Machine monitor: Low output voltage) 944
Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system) 948
Troubleshooting by failure code (Display of code), Part 5 951
Failure code [DAQ0KK] (Transmission controller: Low source voltage) 954
Failure code [DAQ0KT] (Transmission controller: Abnormality in controller) 956
Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input) 957
Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals) 959
Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system) 960
Failure code [DAQRMA] (Transmission controller option setting: Malfunction) 963
Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system) 964
Failure code [DB90KK] Work equipment controller: Low source voltage (input) 966
Failure code [DB90KT] Work equipment controller: Abnormality in controller 968
Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input) 969
Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range 971
Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals) 974
Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system) 975
Failure code [DB9RMA] (Work equipment controller option setting: Malfunction) 977
Failure code [DB9RMC] (CAN communication with transmission controller, engine controller and machine monitor: Defective operation) 978
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time 982
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time 984
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time 986
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time 988
Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time 990
Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time 992
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time 994
Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time 996
Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is kept pressed for long time 998
Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time) 1000
Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time) 1002
Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time) 1004
Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree) 1006
Troubleshooting by failure code (Display of code), Part 6 1009
Failure code [DDE5MA] (Emergency steering drive switch: Malfunction) 1012
Failure code [DDK3KA] (Right FNR switch: Disconnection) 1014
Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection) 1017
Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree) 1020
Failure code [DDK6KA] (FNR lever switch: Disconnection) 1022
Failure code [DDK6KB] (FNR lever switch: Short circuit) 1026
Failure code [DDS5KA] (Steering pressure switch: Disconnected) 1028
Failure code [DDS5KB] (Steering pressure switch: Grounded) 1030
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree) 1032
Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time) 1034
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time) 1036
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time) 1038
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time) 1040
Failure code [DF10KA] (Transmission shift lever switch: Disconnected) 1042
Failure code [DF10KB] (Transmission shift lever switch: Short circuit) 1046
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected) 1048
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit) 1050
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range) 1052
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected) 1054
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range) 1056
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range) 1058
Failure code [DH21KA] (Loader pump pressure sensor: Disconnection) 1060
Failure code [DH21KB] (Loader pump pressure sensor: Power supply line short) 1062
Troubleshooting by failure code (Display of code), Part 7 1065
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range) 1068
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range) 1070
Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range) 1072
Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection) 1074
Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit) 1076
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection) 1078
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line) 1081
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree) 1084
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection) 1087
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line) 1090
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection) 1093
Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line) 1096
Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree) 1099
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection) 1102
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line) 1105
Troubleshooting by failure code (Display of code), Part 8 1109
Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection) 1111
Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line) 1114
Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection) 1116
Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line) 1120
Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree) 1122
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection) 1126
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line) 1128
Failure code [DKA0L0] (Lift arm angle sensor: Dislocation of sensor) 1130
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection) 1132
Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range) 1134
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit) 1136
Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit) 1138
Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit) 1140
Failure code [DV00KB] (Alarm buzzer: Short circuit) 1142
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection) 1144
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit) 1146
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line) 1148
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection) 1150
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit) 1151
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line) 1152
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection) 1154
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit) 1155
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line) 1156
Troubleshooting by failure code (Display of code), Part 9 1159
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection) 1161
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit) 1162
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line) 1164
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection) 1166
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit) 1167
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line) 1168
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection) 1170
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit) 1172
Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line) 1174
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection) 1176
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit) 1178
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line) 1180
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection) 1182
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit) 1184
Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line) 1186
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection) 1188
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit) 1190
Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source) 1192
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection) 1194
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit) 1195
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line) 1196
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection) 1198
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit) 1200
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line) 1202
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection) 1204
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit) 1206
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line) 1208
Troubleshooting by failure code (Display of code), Part 10 1211
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection) 1214
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit) 1216
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line) 1218
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection) 1220
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit) 1222
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line) 1224
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection) 1226
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit) 1228
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line) 1230
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection) 1232
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit) 1234
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line) 1236
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection) 1238
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit) 1240
Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line) 1242
Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection) 1244
Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit) 1246
Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line) 1248
Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection) 1250
Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit) 1252
Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line) 1254
Failure code [DY30MA] Motor-driven emergency steering pump failure (During operation of machine) 1256
Failure code [DY30MC] Motor-driven emergency steering pump failure (Malfunction in manual mode) 1259
Troubleshooting of electrical system (E-mode) 1263
Installing positions of fuses 1265
Information in troubleshooting table 1268
E-1 Engine does not start 1269
E-2 Wiper does not operate 1276
E-3 Windshield washer does not operate 1280
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off 1283
E-5 Working lamp does not light up or go off 1291
E-6 Turn signal lamp and hazard lamp do not light up or go off 1296
E-7 Brake lamp does not light or it keeps lighting up 1302
E-8 Backup lamp does not light or it keeps lighting up 1304
E-9 Backup buzzer does not sound or it keeps sounding 1306
E-10 Horn does not sound or it keeps sounding 1308
E-11 Alarm buzzer does not sound or it keeps sounding 1310
E-12 Air conditioner does not operate or stop 1312
E-13 The KOMTRAX system does not work properly 1315
E-14 When kick-down switch is turned ON, kick-down operation does not start 1318
E-15 When hold switch is pressed, holding operation does not start 1320
E-16 Transmission is kept in neutral, or brake drags when directional lever is operated while parking brake is applied 1322
E-17 Transmission cut-off mode cannot be set or reset 1324
E-18 Transmission cut-off set cannot be reset 1326
E-19 FNR switch mode cannot be set or reset 1328
E-20 Fan reverse function cannot be used or reset 1330
E-21 Discharge from loader pump does not rise from minimum level 1332
E-22 ECSS function cannot be used or reset 1334
E-23 When parking brake is turned ON, parking brake indicator lamp does not light up 1336
E-24 When emergency brake operates, brake oil pressure caution lamp does not operate 1340
E-25 Air cleaner clogging indicator lamp does not light up 1342
E-26 Radiator coolant level caution lamp does not light up 1344
E-27 Hydraulic oil temperature gauge does not rise and hydraulic oil temperature caution lamp does not light up 1345
E-28 Torque converter oil temperature gauge does not rise and torque converter oil temperature caution lamp does not light up 1346
E-29 Steering oil pressure caution lamp does not light up 1348
E-30 Abnormality in t switch (panel switch 1) input 1350
E-31 Abnormality in U switch (panel switch 2) input 1352
E-32 Abnormality in < switch (panel switch 3) input 1354
E-33 Abnormality in > switch (panel switch 4) input 1356
Troubleshooting of hydraulic and mechanical system (H-mode) 1359
Method of using troubleshooting chart 1361
Table of failure modes and causes 1364
H-1 The machine does not start 1368
H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)] 1370
H-3 Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)] 1371
H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted 1372
H-5 Shocks are large at the times of starting and shifting gear 1374
H-6 Time lag is large at the times of starting and shifting gear 1376
H-7 The torque converter oil temperature is high 1378
H-8 Steering does not turn 1379
H-9 Steering does not turn [Machine with joystick steering (if equipped)] 1380
H-10 Steering response is low 1381
H-11 Turning, response of steering is poor [machine with joystick steering (if equipped)] 1382
H-12 Steering is heavy 1383
H-13 When machine turns, it shakes or makes large shocks 1384
H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)] 1385
H-15 The wheel brake does not work or does not work well 1386
H-16 The wheel brake is not released or it drags 1387
H-17 The parking brake does not work or does not work well 1388
H-18 The parking brake is not released or it drags (including emergency release system) 1389
H-19 Lift arm does not rise 1390
H-20 Lift arm speed is low or rising force of lift arm is insufficient 1391
H-21 When rising, the lift arm comes to move slowly at specific height 1392
H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats) 1392
H-23 Hydraulic drifts of the lift arm is large 1392
H-24 The lift arm wobbles during operation 1392
H-25 Bucket does not tilt back 1393
H-26 Bucket speed is low or tilting back force is insufficient 1394
H-27 The bucket comes to operate slowly in the midst of tilting-back 1395
H-28 The bucket cylinder cannot hold down the bucket 1395
H-29 Hydraulic drifts of the bucket is large 1395
H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”) 1395
H-31 Lift arm and bucket control levers do not move smoothly and are heavy 1396
H-32 During operation of the machine, engine speed lowers remarkably or engine stalls 1397
H-33 Large shock is made when work equipment starts and stops 1397
H-34 When work equipment circuit is relieved singly, other work equipment moves 1397
H-35 ECSS does not operate, and pitching, bouncing occur 1398
Troubleshooting of engine (S-mode) 1399
Method of using troubleshooting charts 1401
S-1 Engine does not start easily 1404
S-2 Engine does not start 1405
S-3 Engine does not pick up smoothly 1408
S-4 Engine stops during operations 1409
S-5 Engine does not rotate smoothly 1410
S-6 Engine lacks output (or lacks power) 1411
S-7 Exhaust smoke is black (Incomplete combustion) 1412
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1413
S-9 Engine oil becomes contaminated quickly 1414
S-10 Fuel consumption is excessive 1415
S-11 Coolant contains oil (blows back or reduces) 1416
S-12 Oil pressure drops 1417
S-13 Oil level rises (Water, fuel in oil) 1418
S-14 Coolant temperature rises too high (Overheating) 1419
S-15 Abnormal noise is made 1420
S-16 Vibration is excessive 1421
Troubleshooting of Central Lubrication System (CLS) 1423
Trouble 1424
Troubleshooting FPS 1425
Troubleshooting 1426
Pump Faults 1426
Replace pump element 1428
Check power supply 1428
Changing the control unit: 1428
Troubleshooting – grease system faults 1429
Venting of the system 1430
General assembly advice 1431
50 Disassembly and assembly 1433
General information on disassembly and assembly 1433
How to read this manual 1434
Coating materials list 1436
Special tools list 1439
Sketches of special tools 1442
Engine and cooling system 1449
Removal and installation of fuel supply pump assembly 1450
Removal and installation of fuel injector assembly 1453
Removal and installation of cylinder head assembly 1460
Removal and installation of engine hood assembly 1471
Removal and installation of radiator assembly 1473
Removal and installation of air aftercooler 1475
Removal and installation of hydraulic oil cooler assembly 1477
Removal and installation of engine assembly 1479
Removal and installation of engine front oil seal assembly 1484
Removal and installation of engine rear oil seal assembly 1487
Removal and installation of cooling fan and fan motor assembly 1490
Removal and installation of fuel tank assembly 1493
Power train 1495
Removal and installation of torque converter and transmission assembly 1496
Disassembly and assembly of torque converter assembly (Standard specification) 1502
Disassembly and assembly of torque converter assembly (Lockup specification) 1506
Disassembly and assembly of transmission assembly 1512
Disassembly and assembly of transmission clutch pack assembly 1528
Disassembly and assembly of parking brake assembly 1546
Removal and installation of front axle assembly 1555
Removal and installation of rear axle assembly 1557
Disassembly and assembly of axle housing 1560
Disassembly and assembly of differential assembly 1569
Steering system 1589
Removal and installation of steering valve assembly 1590
Brake system 1593
Removal and installation of parking brake discs and plates 1594
Undercarriage and frame 1597
Removal and installation of center hinge pin 1598
Removal and installation of counterweight 1606
Hydraulic system 1609
Removal and installation of work equipment control valve assembly 1610
Removal and installation of power train pump and work equipment pump assembly 1613
Removal and installation of steering pump and cooling fan pump assembly 1614
Removal and installation of hydraulic tank assembly 1615
Work equipment 1619
Removal and installation of work equipment assembly 1620
Disassembly and assembly of hydraulic cylinder assembly 1624
Cab and its attachments 1633
Removal and installation of operator’s cab and floor frame assembly 1634
Removal and installation of operator’s cab glass (stuck glass) 1637
Disassembly and assembly of operator’s seat assembly (Standard specification) 1645
Disassembly and assembly of operator’s seat assembly (Manufactured by GRAMMER) 1654
Removal and installation of air conditioner unit assembly 1687
Electrical system 1691
Removal and installation of engine controller assembly 1692
90 Diagrams and drawings 1693
Hydraulic diagrams and drawings 1693
Power train hydraulic circuit diagram 1694
Automatic greasing circuit diagram 1696
Electrical diagrams and drawings 1701
Connector list and tables 1719
Connector list 1720
Connector diagram 1/3 1730
Connector diagram 2/3 1732
Connector diagram 3/3 1732

DESCRIPTION:

Komatsu WA380-6 Wheel Loader Shop Manual VEBM440102 – PDF DOWNLOAD 

SERIAL NUMBERS H60051 and up

How to read the shop manual 
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 28/12/24