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KOMATSU WA380-1LC WHEEL LOADER SERVICE REPAIR MANUAL – PDF Download
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- KOMATSU WA380-1LC WHEEL LOADER SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:CEBMW23030
- SERIAL NUMBERS:WA380-1 Lc A45001 and up
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Description
KOMATSU WA380-1LC WHEEL LOADER SERVICE REPAIR MANUAL
KOMATSU WA380-1LC WHEEL LOADER SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU WA380-1LC WHEEL LOADER SERVICE REPAIR MANUAL
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into chapters for each main group of components; thes chapters are further divided into the following sections.
- STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. - TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. - MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
KOMATSU WA380-1LC WHEEL LOADER SERVICE REPAIR MANUAL
MAIN MENU........................................................................................................................................ 0 COVER............................................................................................................................................ 1 CONTENTS......................................................................................................................................... 6 SAFETY........................................................................................................................................... 7 GENERAL PRECAUTIONS.......................................................................................................................... 7 PREPARATIONS FOR WORK........................................................................................................................ 7 PRECAUTIONS DURING WORK...................................................................................................................... 7 FOREWORD......................................................................................................................................... 9 HOW TO READ THE SERVICE MANUAL............................................................................................................... 10 HOISTING INSTRUCTIONS........................................................................................................................ 11 STANDARD TIGHTENING TORQUE................................................................................................................... 12 COATING MATERIAL............................................................................................................................. 13 ELECTRIC WIRE CODE........................................................................................................................... 14 WEIGHT TABLE................................................................................................................................. 15 LUBRICANTS, FUEL AND COOLANT................................................................................................................. 16 10 ENGINE........................................................................................................................................ 20 12 TESTING AND ADJUSTING..................................................................................................................... 20 STANDARD VALUE TABLE..................................................................................................................... 21 TOOL LIST FOR TESTING AND ADJUSTING...................................................................................................... 24 VALVE CLEARANCE.......................................................................................................................... 26 FUEL INJECTION TIMING.................................................................................................................... 26 ENGINE OIL PRESSURE AND TEMPERATURE...................................................................................................... 27 BLOW-BY PRESSURE ........................................................................................................................ 28 EXHAUST GAS COLOR........................................................................................................................ 29 ACCELERATOR PEDAL, OPERATING FORCE AND OPERATING ANGLE................................................................................... 31 13 DISASSEMBLY AND ASSEMBLY.................................................................................................................. 34 STARTING MOTOR........................................................................................................................... 36 REMOVAL ............................................................................................................................. 36 INSTALLATION......................................................................................................................... 36 ALTERNATOR............................................................................................................................... 37 REMOVAL ............................................................................................................................. 37 INSTALLATION......................................................................................................................... 37 OIL COOLER............................................................................................................................... 38 REMOVAL.............................................................................................................................. 38 INSTALLATION......................................................................................................................... 38 FUEL INJECTION PUMP...................................................................................................................... 39 REMOVAL ............................................................................................................................. 39 INSTALLATION......................................................................................................................... 39 WATER PUMP............................................................................................................................... 40 REMOVAL.............................................................................................................................. 40 INSTALLATION......................................................................................................................... 40 NOZZLE HOLDER............................................................................................................................ 41 REMOVAL.............................................................................................................................. 41 INSTALLATION......................................................................................................................... 41 TURBOCHARGER............................................................................................................................. 42 REMOVAL.............................................................................................................................. 42 INSTALLATION......................................................................................................................... 42 COMPRESSOR............................................................................................................................... 43 REMOVAL.............................................................................................................................. 43 INSTALLATION......................................................................................................................... 43 CYLINDER HEAD............................................................................................................................ 44 REMOVAL.............................................................................................................................. 44 INSTALLATION......................................................................................................................... 45 RADIATOR................................................................................................................................. 46 REMOVAL.............................................................................................................................. 46 INSTALLATION......................................................................................................................... 50 ENGINE................................................................................................................................... 53 REMOVAL.............................................................................................................................. 53 INSTALLATION......................................................................................................................... 57 FUEL TANK................................................................................................................................ 60 REMOVAL.............................................................................................................................. 60 INSTALLATION......................................................................................................................... 62 20 POWER TRAIN................................................................................................................................... 64 21 STRUCTURE AND FUNCTION.................................................................................................................... 64 GENERAL.................................................................................................................................. 65 HYDRAULIC CIRCUIT FOR POWER TRAIN.................................................................................................... 67 HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN............................................................................................ 68 TORQUE CONVERTER AND TRANSMISSION PIPING................................................................................................. 69 TORQUE CONVERTER CHARGING PUMP........................................................................................................... 70 TORQUE CONVERTER......................................................................................................................... 71 TORQUE CONVERTER OIL FILTER.............................................................................................................. 74 TORQUE CONVERTER OIL COOLER.............................................................................................................. 75 TORQUE CONVETER RELIEF VALVE............................................................................................................. 76 TRANSMISSION............................................................................................................................. 77 TRANSMISSION CONTROL VALVE............................................................................................................... 85 UPPER VALVE.......................................................................................................................... 87 LOWER VALVE.......................................................................................................................... 88 TRANSMISSION SOLENOID VALVE.......................................................................................................... 89 EMERGENCY MANUAL SPOOL............................................................................................................... 90 PRIORITY VALVE....................................................................................................................... 93 MODULATING VALVE AND QUICK RETURN VALVE.............................................................................................. 94 ACCUMULATOR VALVE.................................................................................................................... 97 PILOT REDUCING VALVE................................................................................................................. 99 TRANMISSION PILOT FILTER.................................................................................................................100 TRANSFER.................................................................................................................................101 DRIVE SHAFT..............................................................................................................................102 AXLE MOUNT...............................................................................................................................103 AXLE AND DIFFERENTIAL....................................................................................................................105 TORQUE PROPORTIONING DIFFERENTIAL....................................................................................................110 FINAL DRIVE..............................................................................................................................112 TIRE AND WHEEL...........................................................................................................................113 22 TESTING AND ADJUSTING.....................................................................................................................114 STANDARD VALUE TABLE.....................................................................................................................115 TOOL LIST FOR TESTING AND ADJUSTING......................................................................................................116 MEASURING ENGINE SPEED...................................................................................................................117 MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION..............................................................................119 MEASURING SHIFT LEVER....................................................................................................................121 METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL...........................................................................................122 TIRE AND WHEEL...........................................................................................................................124 TROUBLESHOOTING..........................................................................................................................126 PRECAUTIONS WHEN TROUBLESHOOTING.....................................................................................................127 METHOD OF READING TROUBLESHOOTING TABLES.............................................................................................129 PREVENTING RECURRENCE OF TROUBLE.....................................................................................................131 JUDGEMENT OF POWER TRAIN.............................................................................................................132 TROUBLESHOOTING TABLE................................................................................................................134 1. MACHINE DOES NOT MOVE.........................................................................................................134 2. MACHINE LACKS POWER OR SPEED..................................................................................................136 3. EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR.....................................................................137 4. TORQUE CONVERTER OIL TEMPERATURE TOO HIGH.....................................................................................138 23 DISASSEMBLY AND ASSEMBLY..................................................................................................................140 TORQUE CONVERTER CHARGING PUMP...........................................................................................................142 REMOVAL..............................................................................................................................142 INSTALLATION.........................................................................................................................143 TORQUE CONVERTER, TRANSMISSION, TRANSFER.................................................................................................144 REMOVAL..............................................................................................................................144 INSTALLATION.........................................................................................................................151 TORQUE CONVERTER.........................................................................................................................159 DISASSEMBLY..........................................................................................................................159 ASSEMBLY.............................................................................................................................163 TRANSMISSION.............................................................................................................................169 DISASSEMBLY..........................................................................................................................169 INPUT SHAFT, NO. 1 CARRIER ASSEMBLY..............................................................................................176 NO. 2, 3, 4 CARRIER ASSEMBLY.....................................................................................................178 NO. 4, 5 HOUSING ASSEMBLY........................................................................................................179 ASSEMBLY.............................................................................................................................180 NO. 4, 5 HOUSING ASSEMBLY........................................................................................................180 NO. 2, 3 CARRIER ASSEMBLY........................................................................................................181 INPUT SHAFT, NO. 1 CARRIER ASSEMBLY..............................................................................................182 TRANSMISSION.....................................................................................................................184 TRANSFER CONTROL VLAVE...................................................................................................................193 DISASSEMBLY..........................................................................................................................193 ASSEMBLY.............................................................................................................................195 TRANSMISSION CONTROL VALVE...............................................................................................................201 REMOVAL..............................................................................................................................201 INSTALLATION.........................................................................................................................202 DISASSEMBLY OF LOWER VALVE.......................................................................................................203 ASSEMBLY OF LOWER VALVE..........................................................................................................203 DISASSEMBLY OF UPPER VALVE.......................................................................................................205 ASSEMBLY OF UPPER VALVE..........................................................................................................205 FRONT DIFFERENTIAL.......................................................................................................................207 REMOVAL..............................................................................................................................207 INSTALLATION.........................................................................................................................210 REAR DIFFERENTIAL........................................................................................................................213 REMOVAL..............................................................................................................................213 INSTALLATION.........................................................................................................................214 DIFFERENTIAL ............................................................................................................................215 DISASSEMBLY..........................................................................................................................215 ASSEMBLY.............................................................................................................................218 FRONT AXLE...............................................................................................................................226 REMOVAL..............................................................................................................................226 INSTALLATION.........................................................................................................................229 REAR AXLE................................................................................................................................231 REMOVAL..............................................................................................................................231 INSTALLATION.........................................................................................................................235 DRIVE SHAFT..............................................................................................................................239 DISASSEMBLY..........................................................................................................................239 ASSEMBLY.............................................................................................................................241 FINAL DRIVE .............................................................................................................................243 DISASSEMBLY..........................................................................................................................243 ASSEMBLY.............................................................................................................................246 24 MAINTENANCE STANDARD......................................................................................................................250 TRANSMISSION AND ENGINE MOUNT............................................................................................................251 TORQUE CONVERTER CHARGING PUMP...........................................................................................................253 TORQUE CONVERTER.........................................................................................................................254 TORQFLOW TRANSMISSION....................................................................................................................256 1. TRANSMISSION......................................................................................................................256 2. TRANSMISSION CONTROL VALVE........................................................................................................259 UPPER VALVE......................................................................................................................259 LOWER VALVE......................................................................................................................261 3. SOLENOID VALVE....................................................................................................................263 TRANSFER.................................................................................................................................264 DIFFERENTIAL.............................................................................................................................266 FINAL DRIVE..............................................................................................................................268 DRIVE SHAFT..............................................................................................................................269 AXLE MOUNT...............................................................................................................................270 40 STEERING SYSTEM...............................................................................................................................272 41 STRUCTURE AND FUNCTION....................................................................................................................272 HYDRAULIC PIPING.........................................................................................................................273 HYDRAULIC CIRCUIT DIAGRAM................................................................................................................274 STEERING CONTROL SYSTEM..................................................................................................................275 STEERING VALVE.......................................................................................................................275 ORBIT-ROLL VALVE.....................................................................................................................276 RELIEF VALVE.........................................................................................................................277 STOP VALVE...........................................................................................................................278 STEERING CYLINDER........................................................................................................................279 STEERING COLUMN AND ORBIT-ROLL...........................................................................................................280 CENTER HINGE PIN.........................................................................................................................281 42 TESTING AND ADJUSTING.....................................................................................................................282 STANDARD VALUE TABLE.....................................................................................................................283 TOOL LIST FOR TESTING AND ADJUSTING......................................................................................................283 MEASURING STEERING WHEEL PLAY............................................................................................................284 MEASURING OPERATING FORCE OF STEERING WHEEL..............................................................................................285 OPERATING TIME OF STEERING WHEEL LOCK TO LOCK............................................................................................286 TESTING AND ADJUSTING STEERING CONTROL...................................................................................................287 MEASURING STEERING OIL PRESSURE..........................................................................................................288 TROUBLESHOOTING..........................................................................................................................290 TROUBLESHOOTING TABLE................................................................................................................291 1. STEERING WHEEL DOES NOT TURN..................................................................................................291 2. STEERING WHEEL IS HEAVY.......................................................................................................292 3. STEERING WHEEL WOBBLES OR THERE IS EXCESSIVE SHOCK............................................................................293 4. MACHINE STEERS TO ONE SIDE WHEN TRAVELING.....................................................................................293 5. TURNING RADIUS TO LEFT AND RIGHT IS DIFFERENT.................................................................................293 43 DISASSEMBLY AND ASSEMBLY..................................................................................................................294 STEERING VALVE...........................................................................................................................295 DISASSEMBLY..........................................................................................................................295 ASSEMBLY.............................................................................................................................298 STEERING DEMAND VALVE....................................................................................................................303 DISASSEMBLY..........................................................................................................................303 ASSEMBLY.............................................................................................................................307 STEERING CYLINDER .......................................................................................................................311 DISASSEMBLY..........................................................................................................................311 ASSEMBLY.............................................................................................................................313 CENTER HINGE PIN.........................................................................................................................316 REMOVAL..............................................................................................................................316 INSTALLATION.........................................................................................................................325 44 MAINTENANCE STANDARD......................................................................................................................336 STEERING COLUMN AND ORBIT-ROLL...........................................................................................................337 STEERING VALVE...........................................................................................................................338 STEERING CYLINDER MOUNT..................................................................................................................339 STEERING CYLINDER........................................................................................................................341 CENTER HINGE PIN.........................................................................................................................343 50 BRAKE AND AIR SYSTEM..........................................................................................................................346 51 STRUCTURE AND FUNCTION....................................................................................................................346 AIR PIPING...............................................................................................................................347 AIR CIRCUIT DIAGRAM......................................................................................................................348 AIR TANK.................................................................................................................................349 SAFETY VALVE.............................................................................................................................351 BRAKE VALVE..............................................................................................................................352 BRAKE ACTUATED.......................................................................................................................353 OPERATING IN BALANCE.................................................................................................................354 BRAKE RELEASE........................................................................................................................355 AIR GOVERNOR.............................................................................................................................356 TWO-WAY VALVE............................................................................................................................358 BRAKE CHAMBER............................................................................................................................359 SLACK ADJUSTER...........................................................................................................................361 BRAKE....................................................................................................................................364 PARKING BRAKE............................................................................................................................366 PARKING BRAKE SOLENOID VALVE.............................................................................................................368 SPRING CYLINDER..........................................................................................................................369 BRAKE CALIPER............................................................................................................................370 52 TESTING AND ADJUSTING.....................................................................................................................372 STANDARD VALUE TABLE.....................................................................................................................373 TOOL LIST FOR TESTING AND ADJUSTING......................................................................................................374 MEASURING BRAKE PEDAL....................................................................................................................375 MEASURING AIR............................................................................................................................376 BRAKE PERFORMANCE........................................................................................................................379 CHECKING BRAKE OIL PRESSURE..............................................................................................................380 MEASURING WEAR OF BRAKE DISC.............................................................................................................381 AIR BLEEDING FROM BRAKE LINE.............................................................................................................382 PARKING BRAKE PERFORMANCE................................................................................................................383 CHECKING AND ADJUSTING PARKING BRAKE.....................................................................................................384 TROUBLESHOOTING..........................................................................................................................386 TROUBLESHOOTING TALBE................................................................................................................387 1. AIR PRESSURE DOES NOT RISE AT ALL.............................................................................................387 2. AIR PRESSURE DOES NOT RISE TO THE SPECIFIED RANGE.............................................................................388 3. BRAKE IS INEFFECTIVE OR NOT VERY EFFECTIVE....................................................................................389 4. BRAKE DOES NOT RELEASE, OR DRAGS..............................................................................................390 5. PARKING BRAKE DOES NOT RELEASE, OR DRAGS (APPLIES TO MACHINE EQUIPPED WITH AIR PARKING BRAKE.)................................391 53 DISASSEMBLY AND ASSEMBLY..................................................................................................................392 AIR GOVERNOR.............................................................................................................................394 DISASSEMBLY..........................................................................................................................394 ASSEMBLY.............................................................................................................................395 BRAKE VALVE..............................................................................................................................396 REMOVAL..............................................................................................................................396 INSTALLATION.........................................................................................................................397 DISASSEMBLY..........................................................................................................................398 ASSEMBLY.............................................................................................................................400 BRAKE CHAMBER............................................................................................................................402 REMOVAL..............................................................................................................................402 INSTALLATION.........................................................................................................................404 DISASSEMBLY..........................................................................................................................405 ASSEMBLY.............................................................................................................................408 SLACK ADJUSTER...........................................................................................................................412 REMOVAL..............................................................................................................................412 INSTALLATION.........................................................................................................................412 DISASSEMBLY..........................................................................................................................413 ASSEMBLY.............................................................................................................................414 BRAKE....................................................................................................................................415 DISASSEMBLY..........................................................................................................................415 ASSEMBLY.............................................................................................................................421 SPRING CYLINDER..........................................................................................................................429 REMOVAL..............................................................................................................................429 INSTALLATION.........................................................................................................................430 DISASSEMBLY..........................................................................................................................431 ASSEMBLY.............................................................................................................................432 PARKING BRAKE............................................................................................................................433 REMOVAL..............................................................................................................................433 INSTALLATION.........................................................................................................................435 PARKING BRAKE PAD........................................................................................................................437 REMOVAL..............................................................................................................................437 INSTALLATION.........................................................................................................................438 54 MAINTENANCE STANDARD......................................................................................................................440 BRAKE VALVE..............................................................................................................................441 BRAKE CHAMBER............................................................................................................................443 SLACK ADJUSTER...........................................................................................................................444 BRAKE ...................................................................................................................................445 PARKING BRAKE............................................................................................................................447 SPRING CYLINDER..........................................................................................................................448 60 WORK EQUIPMENT SYSTEM.........................................................................................................................450 61 STRUCTURE AND FUNCTION....................................................................................................................450 HYDRAULIC PIPING ........................................................................................................................451 HYDRAULIC PIPING DIAGRAM.............................................................................................................452 HYDRAULIC CIRCUIT DIAGRAM................................................................................................................453 BUCKET LINKAGE...........................................................................................................................456 BUCKET POSITIONER AND BOOM KICK-OUT......................................................................................................458 HYDRAULIC TANK...........................................................................................................................460 OIL FILTER BYPASS VALVE..............................................................................................................462 BREATHER.............................................................................................................................463 HYDRAULIC PUMP...........................................................................................................................464 MAIN CONTROL VALVE.......................................................................................................................465 HYDRAULIC CYLINDER.......................................................................................................................478 62 TESTING AND ADJUSTING.....................................................................................................................480 STANDARD VALUE TABLE.....................................................................................................................482 TOOL LIST FOR TESTING AND ADJUSTING......................................................................................................483 DUMP AND LIFT CONTROL LEVERS.............................................................................................................484 HYDRAULIC PRESSURE.......................................................................................................................486 LIFT ARM AND BUCKET......................................................................................................................488 HYDRAULIC DRIFT OF LIFT ARM AND BUCKET...................................................................................................489 BUCKET POSITIONER........................................................................................................................490 BOOM KICK-OUT............................................................................................................................491 TROUBLESHOOTING..........................................................................................................................492 TROUBLESHOOTING TABLE................................................................................................................493 1. LIFT ARM DOES NOT RISE............................................................................................................493 2. LIFT ARM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER...................................................................494 3. LIFT ARM MOVEMENT BECOMES SLOW AFTER IT REACHES A CERTAIN HEIGHT..................................................................495 4. BUCKET CANNOT BE HELD DOWN WITH LIFT ARM CYLINDER.................................................................................495 5. LIFT ARM HAS LARGE HYDRAULIC DRIFT................................................................................................495 6. LIFT ARM MOVEMENT IS UNSTEADY DURING WORK.........................................................................................495 7. LIFT ARM DESCENDS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM 'HOLD' TO 'RAISE'................................................495 8. BUCKET DOES NOT TILT BACK.........................................................................................................496 9. BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER...........................................................................497 10. BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK....................................................................................498 11. BUCKET CANNOT BE HELD DOWN BY BUCKET CYLINDER....................................................................................498 12. BUCKET HAS LARGE HYDRAULIC DRIFT.................................................................................................498 13. BUCKET MOVES UNSTEADILY WHEN MACHINE TRAVELS UNDER LOAD (MAIN CONTROL VALVE IN 'HOLD')...........................................498 14. BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS SHIFTEDFROM 'HOLD' TO 'TILT BACK'.................................................498 15. CONTROL LEVERS OF LIFT ARM AND DUMP MOVE STIFFLY AND SLUGGISHLY..................................................................499 63 DISASSEMBLY AND ASSEMBLY..................................................................................................................500 HYDRAULIC TANK...........................................................................................................................502 REMOVAL..............................................................................................................................502 INSTALLATION.........................................................................................................................505 HYDRAULIC FILTER.........................................................................................................................508 REMOVAL..............................................................................................................................508 INSTALLATION.........................................................................................................................508 STEERING PUMP............................................................................................................................509 REMOVAL..............................................................................................................................509 INSTALLATION.........................................................................................................................509 MAIN CONTROL VALVE.......................................................................................................................510 REMOVAL..............................................................................................................................510 INSTALLATION.........................................................................................................................513 DISASSEMBLY..........................................................................................................................515 ASSEMBLY.............................................................................................................................517 DUMP CYLINDER............................................................................................................................519 REMOVAL..............................................................................................................................519 INSTALLATION.........................................................................................................................521 LIFT CYLINDER............................................................................................................................522 REMOVAL..............................................................................................................................522 INSTALLATION.........................................................................................................................523 HYDRAULIC CYLINDER.......................................................................................................................524 DISASSEMBLY..........................................................................................................................524 ASSEMBLY.............................................................................................................................526 WORK EQUIPMENT...........................................................................................................................529 REMOVAL..............................................................................................................................529 INSTALLATION.........................................................................................................................532 COUNTERWEIGHT............................................................................................................................535 REMOVAL..............................................................................................................................535 INSTALLATION.........................................................................................................................535 64 MAINTENANCE STANDARD......................................................................................................................536 MAIN CONTROL VALVE.......................................................................................................................537 DUMP CYLINDER............................................................................................................................541 LIFT CYLINDER............................................................................................................................542 BUCKET LINKAGE...........................................................................................................................543 BUCKET POSITIONER AND BOOM KICK-OUT......................................................................................................546 BUCKET...................................................................................................................................547 HYDRAULIC PUMP...........................................................................................................................548 80 ELECTRIC AND ELECTRONIC SYSTEM................................................................................................................550 81 STRUCTURE AND FUNCTION....................................................................................................................550 ELECTRICAL WIRING DIAGRAM................................................................................................................551 ELECTRICAL WIRING DIAGRAM CIRCUIT........................................................................................................551 ENGINE STARTING CIRCUIT..................................................................................................................552 ENGINE STOP CIRCUIT......................................................................................................................554 ELECTRICAL TRANSMISSION CONTROL..........................................................................................................555 COMBINATION SWITCH...................................................................................................................556 TRANSMISSION CUT-OFF SWITCH..........................................................................................................557 TRANSMISSION CUT-OFF SELECTOR SWITCH.................................................................................................558 NEUTRALIZER RELAY....................................................................................................................559 KICK-DOWN SWITCH.........................................................................................................................560 KICK-DOWN ELECTRIC SWITCH................................................................................................................561 ELECTRICAL PARKING BRAKE CONTROL.........................................................................................................567 ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)..............................................................................................576 INDICATION ON MONITOR PANEL..........................................................................................................578 SENSORS..............................................................................................................................581 ENGINE OIL LEVEL SENSOR..........................................................................................................582 COOLANT LEVEL SENSOR.............................................................................................................582 COOLANT TEMPERATURE SENSOR.......................................................................................................583 TORQUE CONVERTER OIL TEMPERTURE SENSOR...........................................................................................583 PARKING BRAKE SENSOR.............................................................................................................584 ENGINE OIL PRESURE SENSOR........................................................................................................585 BRAKE CHAMBER STROKE SENSOR......................................................................................................586 AIR PRESSURE SENSOR..............................................................................................................587 ROTATIONAL SPEED SENSOR.........................................................................................................587 FUEL GAUGE SENSOR................................................................................................................588 WIRING HARNESS.......................................................................................................................589 BUCKET POSITIONER AND BOOM KICK-OUT......................................................................................................590 82 TESTING AND ADJUSTING..................................................................................................................... 0 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM............................................................................................... 0 ADJUSTING SPEEDOMETER MODULE IN THE VEHICLE MONITOR...................................................................................... 0 TROUBLESHOOTING.......................................................................................................................... 0 CHECKS BEFORE TROUBLSHOOTING......................................................................................................... 0 METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART.................................................................................... 0 CONNECTOR TERMINAL NUMBERS .......................................................................................................... 0 PRECAUTION WHEN HANDLING CONNECTOR................................................................................................... 0 ELECTRICAL WIRING DIAGRAM............................................................................................................ 0 ELECTRICAL CIRCUIT SYSTEM............................................................................................................ 0 ENGINE STARTING AND STOP CIRCUIT SYSTEM.......................................................................................... 0 TRANSMISSION CONTROL, PARKING BRAKE CIRCUIT SYSTEM............................................................................... 0 ETHER INJECTION CIRCUIT SYSTEM................................................................................................... 0 KICK-DOWN CIRCUIT SYSTEM......................................................................................................... 0 POSITION OF CONNECTORS FOR TROUBLESHOOTING....................................................................................... 0 TROUBLESHOOTING CHARTS FOR ELECTRIC SYSTEM........................................................................................... 0 E-1 ENGINE DOES NOT START........................................................................................................ 0 E-2 ENGINE DOES NOT STOP......................................................................................................... 0 E-3 ENGINE STOPS WHEN TRAVEL ING ................................................................................................ 0 E-4 PARKING BRAKE DOES NOT WORK.................................................................................................. 0 E-5 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON.................................................................. 0 E-6 PARKING BRAKE IS RELEASED WHEN STARTIN SWITCH IS TURNED ON .................................................................. 0 E-7 WHEN PARKING BRAKE IS APPLIED, SHIFT LEVER DOES NOT ENTER NEUTRAL............................................................ 0 E-8 TRANSMISSION DOES NOT WORK................................................................................................... 0 E-9 KICK-DOWN SWITCH DOES NOT WORK............................................................................................... 0 E-10 KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON............................................................................ 0 E-11 KICK-DOWN OPERATION IS NOT CANCELLED........................................................................................ 0 E-12 KICK-DOWN WORKS BY MISTAKE WHEN TARVELING IN F2............................................................................. 0 E-13 MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED.................................................................... 0 VEHICLE MONITOR SYSTEM FOLDOUT ...................................................................................................... 0 TROUBLESHOOTING CHARTS FOR ELECTRONIC VEHICLE MONITORING SYSTEM...................................................................... 0 POSTION OF CONNECTORS FOR TROUBLESHOOTING........................................................................................ 0 M-1 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MONITOR PANEL DOES NOT LIGHT UP FOR 3 SECONDS................................. 0 A) NONE OF MONITOR PANEL LIGHTS UP........................................................................................... 0 B) EXCEPT FOR SPEEDOMETER MODULE, NONE OF MONITOR PANEL LIGHT UP............................................................. 0 C) NONE OF CAUTION ITEMS LIGHT UP............................................................................................ 0 D) SOME OTHER PARTS DO NOT LIGHT UP.......................................................................................... 0 M-2 WHEN STARTING SWITCH IS TURNED TO ON POSTION, ALL MONITOR PANEL LIGHTS UP AND DOES NOT GO OUT................................ 0 M-3 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), CHECK ITEM FLASHES, (LEVELS OF CHECK ITEMS ARE CORRECT)...... 0 A) (ENGINE OIL LEVEL) FLASHES................................................................................................ 0 B) (RADIATOR WATER LEVEL) FLASHES............................................................................................ 0 M-4 NO OPERATION IS BEING CARRIED OUT, BUT PILOT DISPLAY LIGHTS UP ABNORMALLY.................................................... 0 A) (TRANMISSION CUT-OFF) LIGHT UP............................................................................................ 0 B) (PARKING BRAKE) LIGHTS UP................................................................................................. 0 C) (WORKING LAMP) LIGHT UP................................................................................................... 0 M-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED), CHECK ITEM FLASHES........................................... 0 A) ENGINE OIL PRESSURE SYSTEM................................................................................................ 0 B) ALTERNATOR SYSTEM......................................................................................................... 0 M-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED), CAUTION ITEM FLASHES......................................... 0 A) ENGINE OIL PRESSURE SYSTEM................................................................................................ 0 B) ALTERNATOR SYSTEM......................................................................................................... 0 M-7 WHEN STARTING SWITCH IS TURNED TO ON POSTION (ENGINE STARTED), CAUTION ITEM FLASHES.......................................... 0 A) (CHARGE LEVEL) FLASHES.................................................................................................... 0 B) (FUEL LEVEL) FLASHES...................................................................................................... 0 C) (BRAKE LINE FAILURE) FLASHES.............................................................................................. 0 D) (ENGINE OIL PRESSURE) FLASHES............................................................................................. 0 E) (RADIATIOR WATER LEVEL) FLASHES........................................................................................... 0 F) (AIR PRESSURE) FLASHES.................................................................................................... 0 G) (ENGINGE WATER TEMPERATURE) FLASHES....................................................................................... 0 H) (TORQUE CONVETER OIL TEMPERATURE) FLASHES................................................................................. 0 M-8 SPEED SENSOR DISPLAY STAYS AT "0"............................................................................................ 0 M-9 HIGH BEAM DOES NOT LIGHT UP, OR LIGHTS UP ABNORMALLY......................................................................... 0 A) IF HIGH BEAM DOES NOT LIGHT UP............................................................................................ 0 B) IF HIGH BEAM LIGHTS UP WHEN HEAD LAMP SWITCH IS OFF....................................................................... 0 C) IF HIGH BEAM DISPLAY LIGHTS UP WHEN HEAD LAMP DIMMER SWITCH IS AT LO BEAM POSITION........................................ 0 M-10 TURN SIGNAL LAMP DOES NOT FLASH, TURN SIGNAL LAMP STAYS ON OR DOES NOT STOP FLASHING........................................ 0 A) IF TURN SIGNAL LAMP DOES NOT FLASH........................................................................................ 0 B) IF TUREN SIGNAL LAMP STAYES ON OR DOES NOT STOP FLASHIING................................................................. 0 M-11 WHEN STARTING SWITCH IS TURNED TO ON POSTION (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SEC CAUTION ITEM IS FLASHING .... 0 M-12 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY BUT, ALARM BUZZER SOUNDS........................................................ 0 M-13 WHEN STARTING SWITCHIS TURNED TO ON POSTIION (ENGINE STOPPED), WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC. CAUTION ITEM IS.... 0 M-14 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT WARNING LAMP LIGHTS UP...................................................... 0 M-15 WHEN STARTIN SWITCH IS TURNED TO ON POSITION, LAMPS DO NOT LIGHT UP FOR 4 SEC. WHEN LAMP SWITCH IS ON, LAMPS TO NOT LIG.... 0 A) NONE OF PANEL LIGHTS UP................................................................................................... 0 B) SOME OF PANEL LAMPS DO NOT LIGHT UP....................................................................................... 0 M-16 LAMP SWITCH IS NOT BEING OPERATED, BUT NIGHT LIGHTING LIGHTS UP, NIGHT LIGHTING STAYS ON.................................... 0 M-17 SERVICE METER DOES NOT WORK................................................................................................. 0 M-18 SERVICE METER MOVES WHEN ENGINE IS STOPPED.................................................................................. 0 M-19 ABNORMALITY IN AIR PRESSURE GAUGE........................................................................................... 0 A) IF NOTHING IS DISPLAYED IN DISPLAY AREA................................................................................... 0 B) IF INDICATOR REMAINS AT MAXIMUM LEVLE..................................................................................... 0 M-20 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE............................................................................... 0 A) IF NOTHING IS DISPLAY IN DISPLAY AREA..................................................................................... 0 B) IF INDICATOR REMAINS AT MINIMUM LEVEL..................................................................................... 0 M-21 ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE....................................................................... 0 A) IF NOTHING IS DISPLAYED IN DISPLAY AREA................................................................................... 0 B) IF INDICATOR REMAINS AT MINIMUM LEVEL..................................................................................... 0 M-22 ABNORMALITY IN FUEL GAUGE................................................................................................... 0 A) IF NOTHING IS DISPLAYED IN DISPLAY AREA................................................................................... 0 B) IF INDICATOR REMAINS AT FULL.............................................................................................. 0 83 DISASSEMBLY AND ASSEMBLY..................................................................................................................696 MACHINE MONITOR..........................................................................................................................697 REMOVAL..............................................................................................................................697 INSTALLATION.........................................................................................................................697 90 OTHER.........................................................................................................................................698 93 DISASSEMBLY AND ASSEMBLY..................................................................................................................698 CAB .....................................................................................................................................699 REMOVAL .............................................................................................................................699 INSTALLATION.........................................................................................................................699 97 GEAR PUMP SA SERIES.......................................................................................................................700 GENERAL..................................................................................................................................701 PRINCIPLE OF OPERATION...............................................................................................................702 PRESSURE LOADED TYPE GEAR PUMP.......................................................................................................705 FIXED SIDE PLATE TYPE GEAR PUMP......................................................................................................707 SA SERIES................................................................................................................................708 STRUCTURE............................................................................................................................708 TESTING AND ADJUSTING................................................................................................................712 DISASSEMBLY..........................................................................................................................715 ASSEMBLY.............................................................................................................................719 MAINTENANCE STANDARD.................................................................................................................724 99 METRIC CONVERSIONS........................................................................................................................726 FOLDOUTS.........................................................................................................................................732 1. TRANSMISSION .............................................................................................................................733 2. AIR PIPING................................................................................................................................734 3. AIR CIRCUIT DIAGRAM.......................................................................................................................735 4. HYDRULIC PIPING DIAGRAM...................................................................................................................736 5. ELECTRICAL WIRING DIAGRAM, PG 1...........................................................................................................737 6. ELECTRICAL WIRING DIAGRAM, PG 2...........................................................................................................742 7. ELECTRICAL WIRING DIAGRAM, PG 3...........................................................................................................748 8. ELECTRICAL WIRING DIAGRAM CIRCUIT.........................................................................................................752 9. ELECTRICAL WIRING DIAGRAM CONNECTORS (CN).................................................................................................753 10. ELECTRONIC VEHICLE MONITORING SYSTEM.....................................................................................................754
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2 reviews for KOMATSU WA380-1LC WHEEL LOADER SERVICE REPAIR MANUAL – PDF Download
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Brixton Avi –
Good original factory manual. Print/text quality is good but the illustration photos are of poor quality. Reminds me of copies of a copy. Otherwise the price was very reasonable and worth the money.
Samuel Curtis –
Easy purchase