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Komatsu WA380-3, WA380-3LE Wheel Loader Shop Manual CEBMW23091 – PDF DOWNLOAD
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Komatsu WA380-3, WA380-3LE Wheel Loader Shop Manual
SERIAL NUMBERS WA380-3LE – A50001 mdup
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Description
Komatsu WA380-3, WA380-3LE Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA380-3, WA380-3LE Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA380-3, WA380-3LE
Serial Number: A50001 and up
Book Code: CEBMW23091
Language: English
Pages: 758
File Format: Portable Document Format (PDF)
KOMATSU WA380-3, WA380-3LE WHEEL LOADER SHOP MANUAL CEBMW23091 – PDF DOWNLOAD:
DESCRIPTION:
Komatsu WA380-3, WA380-3LE Wheel Loader Shop Manual
FOREWORD:
GENERAL:
- 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 the following chapters; these chapters are further divided into the each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
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 WA380-3, WA380-3LE Wheel Loader Shop Manual
MAIN MENU.......................................................................................................................................... 0 CONTENTS........................................................................................................................................... 2 01 GENERAL......................................................................................................................................... 24 SPECIFICATION DRAWINGS......................................................................................................................... 25 SPECIFICATIONS................................................................................................................................. 26 WEIGHT TABLE................................................................................................................................... 29 FUEL, COOLANT AND LUBRICANTS................................................................................................................... 30 ENGINE OIL SPECIFICATIONS...................................................................................................................... 31 DIESEL FUEL SPECIFICATIONS..................................................................................................................... 32 COOLANT SPECIFICATIONS......................................................................................................................... 33 10 STRUCTURE AND FUNCTION.......................................................................................................................... 38 POWER TRAIN.................................................................................................................................... 39 POWER TRAIN SYSTEM............................................................................................................................. 40 TORQUE CONVERTER, TRANSMISSION PIPING.......................................................................................................... 42 TRANSMISSION HYDRAULIC SYSTEM DIAGRAM.......................................................................................................... 43 TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM......................................................................................................... 44 TORQUE CONVERTER............................................................................................................................... 45 TORQUE CONVERTER OIL FILTER.................................................................................................................... 47 TRANSMISSION................................................................................................................................... 48 TRANSMISSION CONTROL VALVE..................................................................................................................... 59 DRIVE SHAFT.................................................................................................................................... 83 AXLE........................................................................................................................................... 84 DIFFERENTIAL................................................................................................................................... 86 FINAL DRIVE.................................................................................................................................... 90 AXLE MOUNT, CENTER HINGE PIN................................................................................................................... 91 STEERING PIPING................................................................................................................................ 93 STEERING COLUMN................................................................................................................................ 94 STEERING VALVE................................................................................................................................. 95 ORBIT-ROLL VALVE...............................................................................................................................109 STOP VALVE.....................................................................................................................................113 EMERGENCY STEERING PUMP........................................................................................................................114 DIVERTER VALVE.................................................................................................................................115 BRAKE PIPING...................................................................................................................................118 BRAKE HYDRAULIC CIRCUIT DIAGRAM................................................................................................................119 BRAKE VALVE....................................................................................................................................120 ACCUMULATOR CHARGE VALVE.......................................................................................................................125 ACCUMULATOR (FOR BRAKE)........................................................................................................................129 BRAKE..........................................................................................................................................131 PARKING BRAKE CONTROL..........................................................................................................................133 PARKING BRAKE..................................................................................................................................134 PARKING BRAKE SOLENOID VALVE...................................................................................................................135 PARKING BRAKE VALVE............................................................................................................................136 PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE.................................................................................................137 HYDRAULIC PIPING...............................................................................................................................138 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM........................................................................................................140 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM.......................................................................................................141 STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM................................................................................142 WORK EQUIPMENT LEVER LINKAGE...................................................................................................................143 HYDRAULIC TANK.................................................................................................................................144 PPC VALVE......................................................................................................................................146 PPC RELIEF VALVE...............................................................................................................................151 ACCUMULATOR (FOR PPC VALVE)....................................................................................................................152 MAIN CONTROL VALVE.............................................................................................................................153 WORK EQUIPMENT LINKAGE.........................................................................................................................168 BUCKET.........................................................................................................................................170 BUCKET POSITIONER AND BOOM KICK-OUT............................................................................................................171 CAB............................................................................................................................................177 AIR CONDITIONER................................................................................................................................178 ELECRIC CIRCUIT DIAGRAM........................................................................................................................179 ELECTRIC CIRCUIT DIAGRAM (1/4).................................................................................................................180 ELECTRIC CIRCUIT DIAGRAM (2/4).................................................................................................................181 ELECTRIC CIRCUIT DIAGRAM (3/4).................................................................................................................182 ELECTRIC CIRCUIT DIAGRAM (4/4).................................................................................................................183 ELECTRIC CIRCUIT DIAGRAM.......................................................................................................................184 ELECTRIC CIRCUIT DIAGRAM.......................................................................................................................185 MACHINE MONITOR SYSTEM.........................................................................................................................186 MAIN MONITOR...................................................................................................................................187 MAINTENANCE MONITOR............................................................................................................................191 TRANSMISSION AUTO-SHIFT CONTROL SYSTEM.........................................................................................................194 E.C.S.S. (ELECTRONICALLY CONTROL SUSPENSION SYSTEM)............................................................................................201 SENSORS........................................................................................................................................205 ENGINE STARTING CIRCUIT........................................................................................................................209 ENGINE STOP CIRCUIT............................................................................................................................210 ETHER START CIRCUIT............................................................................................................................211 ELECTRIC TRANSMISSION CONTROL..................................................................................................................212 KICK-DOWN, HOLD SWITCH.........................................................................................................................215 KICK-DOWN ELECTRIC CIRCUIT DIAGRAM.............................................................................................................216 TRANSMISSION CUT-OFF FUNCTION..................................................................................................................221 ELECTRIC PARKING BRAKE CONTROL.................................................................................................................223 20 STRUCTURE AND FUNCTION..........................................................................................................................235 STANDARD VALUE TABLE FOR ENGINE................................................................................................................236 STANDARD VALUE TABLE FOR CHASSIS...............................................................................................................237 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM.....................................................................................................241 SERVICE TOOLS FOR TESTING, ADJUSTING & TROUBLESHOOTING.........................................................................................245 MEASURING ENGINE SPEEDS........................................................................................................................246 MEASURING INTAKE MANIFOLD PRESSURE.............................................................................................................246 MEASURING INTAKE AIR RESTRICTION...............................................................................................................246 MEASURING LUBRICATING OIL PRESSURE.............................................................................................................247 MEASURING FUEL FILTER INLET RESTRICTION........................................................................................................247 MEASURING BLOW-BY PRESSURE.....................................................................................................................247 MEASURING EXHAUST BACK PRESSURE................................................................................................................248 MEASURING EXHAUST GAS COLOR....................................................................................................................249 MEASURING COOLANT TEMPERATURE..................................................................................................................250 MEASURING AND ADJUSTING VALVE CLEARANCE........................................................................................................250 MEASURING WASTEGATE ACTUATOR CALIBRATION.......................................................................................................250 MEASURING STALL SPEEDS.........................................................................................................................251 MEASURING ACCELERATOR PEDAL....................................................................................................................253 MEASURING OPERATING FORCE & TRAVEL OF DIRECTIONAL & SPEED LEVERS...............................................................................255 MEASURING TORQUE CONVERTER, TRANSMISSION, PARKING BRAKE OIL PRESSURE...........................................................................256 METHOD OF OPERATING EMERGENCY MANUAL SPOOL.....................................................................................................258 MEASURING CLEARANCE BETWEEN TIRE AND WHEEL.....................................................................................................260 TESTING AND ADJUSTING STEERING WHEEL...........................................................................................................261 TESTING AND ADJUSTING STEERING CONTROL.........................................................................................................264 MEASURING STEERING OIL PRESSURE................................................................................................................265 MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL...............................................................................................267 MEASURING BRAKE PERFORMANCE....................................................................................................................268 TESTING BRAKE OIL PRESSURE.....................................................................................................................269 TESTING FOR BRAKE DISC WEAR....................................................................................................................270 BLEEDING AIR FROM BRAKE SYSTEM.................................................................................................................271 MEASURING PARKING BRAKE PERFORMANCE............................................................................................................272 MANUAL RELEASE METHOD FOR PARKING BRAKE........................................................................................................273 TESTING WEAR OF PARKING BRAKE DISC.............................................................................................................274 MEASURING WORK EQUIPMENT CONTROL LEVER.........................................................................................................275 MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE....................................................................................................277 MEASURING PPC VALVE PRESSURE...................................................................................................................279 MEASURING WORK EQUIPMENT.......................................................................................................................281 TESTING AND ADJUSTING BUCKET POSITIONER........................................................................................................283 TESTING AND ADJUSTING BOOM KICK-OUT............................................................................................................284 ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)....................................................................................................286 TROUBLESHOOTING................................................................................................................................287 POINTS TO REMEMBER WHEN TROUBLESHOOTING....................................................................................................288 SEQUENCE OF EVENTS IN TROUBLESHOOTING......................................................................................................289 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE..................................................................................................290 HANDLING CONNECTORS........................................................................................................................297 CHECKS BEFORE TROUBLESHOOTING..............................................................................................................298 METHOD OF USING TROUBLESHOOTING CHARTS.....................................................................................................299 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)..................................................................................................307 S-1 Starting performance is poor (Starting always takes time)..........................................................................308 S-2 Engine does not start..............................................................................................................309 (1) Engine does not turn...........................................................................................................309 (2) Engine turns but no exhaust gas comes out (Fuel is not being injected).........................................................310 (3) Exhaust gas comes out but engine does not start (Fuel is being injected).......................................................311 S-3 Engine does not pick up smoothly (Follow-up is poor)...............................................................................312 S-4 Engine stops during operations.....................................................................................................313 S-5 Engine does not rotate smoothly (hunting)..........................................................................................314 S-6 Engine lacks output (no power).....................................................................................................315 S-7 Exhaust gas is black (incomplete combustion).......................................................................................316 S-8 Oil consumption is excessive (or exhaust gas is blue)..............................................................................317 S-9 Oil becomes contaminated quickly...................................................................................................318 S-10 Fuel consumption is excessive.....................................................................................................319 S-11 Oil is in cooling water, or water spurts back, or water level goes down...........................................................320 S-12 Oil pressure lamp lights up (drop in oil pressure)................................................................................321 S-13 Oil level rises...................................................................................................................322 S-14 Water temperature becomes too high (overheating)..................................................................................323 S-15 Abnormal noise is made............................................................................................................324 S-16 Vibration is excessive............................................................................................................325 TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)............................................................................................326 TROUBLE DATA DISPLAY...................................................................................................................328 M-1 Main monitor does not work.........................................................................................................330 M-2 When starting switch is turned ON and engine is started immediately, all lamps stay lighted up.....................................331 M-3 Speedometer display does not work properly.........................................................................................332 M-4 Abnormality in shift indicator.....................................................................................................333 (a) Stays at N even when directional lever is at F.................................................................................333 (b) Stays at N even when directional lever is at R.................................................................................333 (c) Does not display N even when directional lever is at N and displays R when directional lever is at F...........................333 (d) Does not display N even when directional lever is at N and displays F when directional lever Cause Remedy......................334 (e) Does not display lst, 4th......................................................................................................334 (f) Does not display 3rd, 4th......................................................................................................334 (g) Does not display 2nd, 3rd......................................................................................................335 (h) Does not display 1st 2nd.......................................................................................................335 M-5 High beam does not light up........................................................................................................336 M-6 Turn signal display does not light up..............................................................................................337 (a) L.H. turn signal does not light up.............................................................................................337 (b) R.H. turn signal does not light up.............................................................................................337 M-7 Abnormality in parking display.....................................................................................................338 (a) Parking lamp does not light up.................................................................................................338 (b) Parking lamp stays lighted up..................................................................................................338 M-8 NOT USED........................................................................................................................... 0 M-9 Night lighting does not light up...................................................................................................339 M-10 Abnormality in front working lamp.................................................................................................340 (a) Neither monitor display nor front working lamp light up........................................................................340 (b) Working lamp lights up but monitor display does not light up...................................................................340 (c) Monitor lights up but working lamp does not light up...........................................................................340 M-11 Abnormality in rear working lamp..................................................................................................341 (a) Neither monitor display nor rear working lamp light up.........................................................................341 (b) Working lamp lights up but monitor display does not light......................................................................341 (c) Monitor lights up but working lamp does not light up...........................................................................341 M-12 Abnormality in transmission cut-off...............................................................................................343 (a) When monitor switch is pressed, cut-off function is not switched and display is not given Cause Remedy.........................343 (b) Monitor display goes out but cut-off function stays on.........................................................................343 (c) Monitor display lights up but cut-off function is not actuated.................................................................344 M-13 Abnormality in parking brake dragging warning.....................................................................................345 (a) When parking brake is applied, buzzer sounds (intermittently) even when directional lever is at N, and caution lamp flashes....345 (b) When parking brake is applied, buzzer does not sound and caution lamp does not light up even ..................................345 M-14 When parking brake dragging warning is given, buzzer and caution lamp are actuated continuously, or they are not actuated.........346 (a) Actuated continuously..........................................................................................................346 (b) Not actuated...................................................................................................................346 M-15 Abnormality in buzzer.............................................................................................................347 (a) Buzzer does not sound when starting switch is turned ON (during self-check)....................................................347 (b) Buzzer always sounds...........................................................................................................347 M-16 Condition of monitor switches is not stored in memory.............................................................................348 M-17 Abnormality in failure display mode...............................................................................................349 (a) Does not enter failure display mode............................................................................................349 (b) Time for time elapsed since failure on failure display mode does no? advance...................................................349 M-18 Abnormality in emergency steering normal display..................................................................................350 (a) Emergency steering normal display does not light up............................................................................350 (b) Emergency steering normal display stays lighted up.............................................................................350 M-19 Abnormality in emergency steering actuation display...............................................................................351 (a) Emergency steering actuation display does not light up.........................................................................351 (b) Emergency steering actuation display stays lighted.............................................................................351 M-20 Abnormality in auto-greasing system...............................................................................................352 (a) Forced greasing cannot be carried out..........................................................................................352 (b) Monitor display flashes rapidly (2 times/sec)..................................................................................352 (c) When no more grease remains, monitor display flashes rapidly (2 times/se4......................................................352 (d) Monitor display flashes slowly (1 time/sec)....................................................................................353 (e) Monitor display goes out.......................................................................................................353 M-21 Abnormality in ECSS system........................................................................................................354 (a) Display does not change when switch is pressed.................................................................................354 (b) Monitor display lights up but ECSS function does not work......................................................................354 M-22 Buzzer does not sound when auto-leveling switch is actuated.......................................................................354 M-23 Failure code is not sent to main monitor (abnormality in network).................................................................355 TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE).....................................................................................356 K-1 When starting switch is turned ON, all lamps on maintenance monitor do not light up for 3 seconds, maintenance monitor does........357 (a) All lamps on maintenance monitor do not light up for 3 seconds.................................................................357 (b) Some lamps do not light up.....................................................................................................358 K-2 When starting switch is turned ON, all lamps on maintenance monitor light up but do not go out.....................................358 K-3 When engine is started immediately after starting switch is turned.................................................................359 K-4 When starting switch is turned ON (engine stopped), CHECK items flash..............................................................360 (a) Engine oil level display flashes...............................................................................................360 (b) Engine water level display flashes.............................................................................................361 K-5 When starting switch is turned ON (engine started), CAUTION items flash............................................................362 (a) Engine oil pressure display flashes............................................................................................362 (b) Battery charge level display flashes...........................................................................................363 (c) Brake oil pressure display flashes.............................................................................................364 (d) Air cleaner display flashes....................................................................................................365 K-6 CAUTION items are flashing but alarm buzzer does not sound.........................................................................366 K-7 There is no abnormality in monitor display but alarm buzzer sounds.................................................................367 K-8 CAUTION items are flashing but warning lamp (CHECK CAUTION lamp) does not light up lamp,...........................................368 (a) CHECK lamp.....................................................................................................................368 (b) CAUTION lamp...................................................................................................................368 K-9 There is no abnormality in maintenance monitor display but warning lamp (CHECK lamp, CAUTION lamp) lights up.......................369 (a) CHECK lamp.....................................................................................................................369 (b) CAUTION lamp...................................................................................................................369 K-10 Night lighting does not light up when lamp switch is turned ON (only lighting of maintenance monitor does not light up)...........370 K-11 Night lighting lights up even when lamp switch is OFF, night lighting stays lighted up............................................371 K-12 Service meter does not work.......................................................................................................372 K-13 Service meter is running even when engine is stopped..............................................................................372 K-14 Abnormality in gauge items........................................................................................................373 (a) Abnormality in fuel gauge......................................................................................................373 (b) Abnormality in engine water temperature gauge..................................................................................374 (c) Abnormality in torque converter oil temperature gauge..........................................................................375 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)..............................................................................................376 E-1 Engine does not start..............................................................................................................377 (a) Starting motor does not turn...................................................................................................377 (b) Starting motor turns...........................................................................................................381 E-2 Engine does not stop...............................................................................................................383 E-3 Engine stops when machine is traveling.............................................................................................383 E-4 Parking brake does not work........................................................................................................384 (a) Parking brake has no effect when parking brake switch is turned ON (parking)...................................................384 (b) Parking brake has no effect when brake pressure drops (Does not work as emergency brake).......................................384 E-5 Parking brake is applied when machine is traveling.................................................................................385 E-6 Parking brake is released when starting switch is turned ON........................................................................387 E-7 Transmission does not change when parking brake is applied to neutral when parking brake is applied................................387 E-8 Transmission does not work normally................................................................................................388 (a) Problem in common circuit for transmission (always stays in 2nd)...............................................................390 (b) Problem in H-L circuit.........................................................................................................390 (c) Problem in speed circuit.......................................................................................................391 (d) Problem in 4th circuit (does not enter 4th)....................................................................................391 (e) Contact in H-L circuit.........................................................................................................392 (f) Contact in speed circuit.......................................................................................................394 (g) Contact in 4th circuit (always stays in 4th)...................................................................................396 (h) Problem in FORWARD circuit (REVERSE is normal).................................................................................397 (i) Problem in REVERSE circuit (FORWARD is normal).................................................................................399 (j) Problem in common circuit for FORWARD and REVERSE (does not travel forward, parking brake is normal)...........................401 (k) Contact in FORWARD circuit.....................................................................................................403 (I) Contact in REVERSE circuit.....................................................................................................405 (m) Problem in common circuit for FORWARD and REVERSE..............................................................................407 E-9 Kick-down switch does not work (the regular F1 to F4 shifts normally)..............................................................408 E-10 Kick-down works only when kick-down switch is ON (Kick-down switch relay does not hold in position (self-holding function)........410 E-11 Kick-down operation cannot be canceled............................................................................................410 (a) Not canceled even when directional lever is moved from F to N or R.............................................................410 (b) Not canceled even when speed lever is moved from 2nd to other position (becomes 4th)...........................................411 E-12 Kick-down switch is actuated by mistake when traveling in 2nd.....................................................................413 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (T MODE)..............................................................414 POWER TRAIN............................................................................................................................415 T-1 Machine does not start.........................................................................................................415 T-2 Travel speed is slow, thrusting power is weak, lacks power on slopes...........................................................417 T-3 Excessive shock when starting machine or shifting gear.........................................................................419 T-4 Excessive time lag when starting machine or shifting...........................................................................420 T-5 Torque converter oil temperature is high.......................................................................................421 STEERING SYSTEM........................................................................................................................422 T-6 Steering does not turn.........................................................................................................422 T-7 Steering wheel is heavy........................................................................................................423 T-8 Steering wheel wobbles or there is excessive shock.............................................................................424 T-9 Machine steers to one side when traveling......................................................................................424 T-10 Turning radius to left and right is different.................................................................................424 BRAKE SYSTEM...........................................................................................................................425 T-11 Brakes do not work or braking effect is poor..................................................................................425 T-12 Brakes are not released or brakes drag........................................................................................426 T-13 Parking brake is not released or brake drags..................................................................................427 WORK EQUIPMENT.........................................................................................................................428 T-14 Boom does not rise............................................................................................................428 T-15 Boom movement is slow or boom lacks lifting power.............................................................................429 T-16 When boom is raised, it moves slowly at a certain height......................................................................430 T-17 Bucket cannot be pushed with boom cylinder (bucket floats)....................................................................430 T-18 Excessive hydraulic drift of boom.............................................................................................430 T-19 Boom shakes during operation..................................................................................................430 T-20 Boom drops momentarily when control lever is operated from HOLD to RAISE......................................................431 T-21 Bucket does not tilt back.....................................................................................................432 T-22 Bucket movement is slow or tilt-back lacks power..............................................................................433 T-23 Bucket movement becomes slow during tilt-back operation.......................................................................434 T-24 Bucket cannot be pushed with bucket cylinder..................................................................................434 T-25 Excessive hydraulic drift of bucket...........................................................................................434 T-26 Bucket shakes during loading operation (Main control valve at HOLD)...........................................................435 T-27 Bucket dumps momentarily when control lever is operated from HOLD to TILT.....................................................435 T-28 Boom, bucket control levers are heavy or do not move smoothly.................................................................436 TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE).............................................................437 JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM.......................................................................................438 D-1 ECSS does not work.................................................................................................................439 (a) Error code [d0] is displayed...................................................................................................440 (b) Error code [d1] is displayed...................................................................................................440 (c) Error code [d2] is displayed...................................................................................................441 (e) Error code [d4] is displayed...................................................................................................442 (f) No abnormality display is given................................................................................................442 D-2 ECSS cannot be canceled............................................................................................................446 D-3 Output is turned ON (travel speed does not become 5 km/h) (deviates around 5 km/h).................................................447 D-4 Output is turned ON when transmission is in 1st....................................................................................447 D-5 Output is turned ON when transmission is in 4th....................................................................................448 D-6 Controller LED code is not displayed...............................................................................................449 D-7 ECSS is abnormal but main monitor does not give abnormality display................................................................449 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE).................................................................................450 OUTLINE................................................................................................................................451 1. Function............................................................................................................................451 2. When carrying out troubleshooting...................................................................................................451 3. Failure code table..................................................................................................................451 4. Table of troubleshooting modes and causes...........................................................................................452 A-1 Troubleshooting code [10] Modulation valve solenoid system (disconnection, short circuit)..........................................453 A-2 Troubleshooting code [11] Short circuit in power source for modulation valve solenoid system.......................................454 A-3 Troubleshooting code [12] F solenoid signal system.................................................................................455 A-4 Troubleshooting code [13] R solenoid signal system.................................................................................455 A-5 Troubleshooting code [14] Abnormality system in H-L solenoid signal................................................................456 A-6 Troubleshooting code [16] Abnormality in speed solenoid signal system..............................................................457 A-7 Troubleshooting code [17] Brake output signal......................................................................................458 A-8 Troubleshooting code [20] Abnormality in directional lever signal system...........................................................459 A-9 Troubleshooting code [21] Abnormality in speed lever signal system.................................................................460 A-10 Troubleshooting code [22] Abnormality in travel speed signal......................................................................461 A-11 Troubleshooting code [23] Abnormality in engine speed signal......................................................................462 A-12 Hold switch system................................................................................................................463 A-13 Kick-down switch system...........................................................................................................463 A-14 Kick-down output signal system....................................................................................................464 A-15 Transmission cut-off signal system................................................................................................465 A-16 Neutralizer signal system.........................................................................................................466 A-17 Buzzer signal system..............................................................................................................467 A-18 Network signal system.............................................................................................................468 A-19 Controller power source system....................................................................................................469 A-20 Abnormality in model selection wiring harness.....................................................................................470 TROUBLESHOOTING OF EAGLE AIR CONDITIONER...................................................................................................471 30 DISASSEMBLY AND ASSEMBLY........................................................................................................................475 METHOD OF USING MANUAL.........................................................................................................................477 PRECAUTIONS WHEN CARRYING OUT OPERATION........................................................................................................478 SPECIAL TOOL LIST..............................................................................................................................480 STARTING MOTOR.................................................................................................................................482 REMOVAL AND INSTALLATION (SEE ENGINE SHOP MANUAL)..........................................................................................482 ENGINE OIL COOLER..............................................................................................................................484 REMOVAL AND INSTALLATION (SEE ENGINE SHOP MANUAL)..........................................................................................484 FUEL INJECTION PUMP............................................................................................................................485 REMOVAL (SEE ENGINE SHOP MANUAL)...........................................................................................................485 INSTALLATION (SEE ENGINE SHOP MANUAL)......................................................................................................486 WATER PUMP.....................................................................................................................................487 REMOVAL AND INSTALLATION (SEE ENGINE SHOP MANUAL)..........................................................................................487 TURBOCHARGER...................................................................................................................................488 REMOVAL AND INSTALLATION (SEE ENGINE SHOP MANUAL)..........................................................................................488 NOZZLE HOLDER..................................................................................................................................489 REMOVAL AND INSTALLATION (SEE ENGINE SHOP MANUAL)..........................................................................................489 THERMOSTAT.....................................................................................................................................490 REMOVAL AND INSTALLATION (SEE ENGINE SHOP MANUAL)..........................................................................................490 CYLINDER HEAD..................................................................................................................................491 REMOVAL (SEE ENGINE SHOP MANUAL)...........................................................................................................491 INSTALLATION (SEE ENGINE SHOP MANUAL)......................................................................................................492 RADIATOR.......................................................................................................................................493 REMOVAL....................................................................................................................................493 INSTALLATION ..............................................................................................................................496 ENGINE.........................................................................................................................................497 REMOVAL ...................................................................................................................................497 ENGINE.....................................................................................................................................498 TORQUE CONVERTER CHARGING PUMP.................................................................................................................499 REMOVAL....................................................................................................................................499 INSTALLATION...............................................................................................................................500 TORQUE CONVERTER, TRANSMISSION.................................................................................................................501 REMOVAL....................................................................................................................................501 INSTALLATION...............................................................................................................................505 TORQUE CONVERTER...............................................................................................................................506 DISASSEMBLY................................................................................................................................506 ASSEMBLY...................................................................................................................................508 TRANSMISSION...................................................................................................................................511 DISASSEMBLY................................................................................................................................511 ASSEMBLY...................................................................................................................................521 TRANSMISSION CLUTCH PACK.......................................................................................................................534 DISASSEMBLY................................................................................................................................534 ASSEMBLY...................................................................................................................................541 TRANSMISSION CONTROL VALVE.....................................................................................................................553 REMOVAL....................................................................................................................................553 INSTALLATION...............................................................................................................................555 DISASSEMBLY................................................................................................................................556 ASSEMBLY...................................................................................................................................558 TRANSMISSION ACCUMULATOR VALVE.................................................................................................................561 DISASSEMBLY................................................................................................................................561 ASSEMBLY...................................................................................................................................562 DRIVE SHAFT....................................................................................................................................563 DISASSEMBLY................................................................................................................................563 ASSEMBLY...................................................................................................................................566 FRONT AXLE.....................................................................................................................................568 REMOVAL....................................................................................................................................568 INSTALLATION...............................................................................................................................570 REAR AXLE......................................................................................................................................571 REMOVAL....................................................................................................................................571 INSTALLATION...............................................................................................................................575 DIFFERENTIAL...................................................................................................................................577 DISASSEMBLY................................................................................................................................577 ASSEMBLY...................................................................................................................................582 AXLE HOUSING...................................................................................................................................592 DISASSEMBLY................................................................................................................................592 ASSEMBLY...................................................................................................................................599 CENTER HINGE PIN...............................................................................................................................609 REMOVAL....................................................................................................................................609 INSTALLATION...............................................................................................................................613 STEERING VALVE.................................................................................................................................616 REMOVAL....................................................................................................................................616 INSTALLATION...............................................................................................................................618 DISASSEMBLY................................................................................................................................619 ASSEMBLY...................................................................................................................................623 ORBIT-ROLL VALVE...............................................................................................................................626 REMOVAL....................................................................................................................................626 INSTALLATION...............................................................................................................................627 DISASSEMBLY................................................................................................................................628 ASSEMBLY...................................................................................................................................631 STEERING CYLINDER..............................................................................................................................636 REMOVAL....................................................................................................................................636 INSTALLATION...............................................................................................................................637 BRAKE VALUE....................................................................................................................................638 REMOVAL....................................................................................................................................638 INSTALLATION...............................................................................................................................639 RIGHT BRAKE VALVE..............................................................................................................................640 DISASSEMBLY................................................................................................................................640 ASSEMBLY...................................................................................................................................641 LEFT BRAKE VALVE...............................................................................................................................642 DISASSEMBLY................................................................................................................................642 ASSEMBLY...................................................................................................................................643 PARKING BRAKE DISC.............................................................................................................................644 REMOVAL....................................................................................................................................644 INSTALLATION...............................................................................................................................646 HYDRAULIC TANK.................................................................................................................................647 REMOVAL....................................................................................................................................647 INSTALLATION...............................................................................................................................649 HYDRAULIC FILTER...............................................................................................................................650 HYDRAULIC, STEERING, SWITCH, PPC PUMP..........................................................................................................651 REMOVAL....................................................................................................................................651 INSTALLATION...............................................................................................................................654 MAIN CONTROL VALVE.............................................................................................................................655 REMOVAL....................................................................................................................................655 INSTALLATION...............................................................................................................................657 DISASSEMBLY................................................................................................................................658 ASSEMBLY...................................................................................................................................660 3 SPOOL VALVE..................................................................................................................................663 DISASSEMBLY................................................................................................................................663 ASSEMBLY...................................................................................................................................665 PPC VALVE......................................................................................................................................668 REMOVAL....................................................................................................................................668 INSTALLATION...............................................................................................................................670 DISASSEMBLY................................................................................................................................671 ASSEMBLY...................................................................................................................................672 BUCKET CYLINDER................................................................................................................................673 REMOVAL....................................................................................................................................673 INSTALLATION...............................................................................................................................675 BOOM CYLINDER..................................................................................................................................676 REMOVAL....................................................................................................................................676 INSTALLATION...............................................................................................................................677 HYDRAULIC CYLINDER.............................................................................................................................678 DISASSEMBLY................................................................................................................................678 ASSEMBLY...................................................................................................................................681 WORK EQUIPMENT.................................................................................................................................684 REMOVAL....................................................................................................................................684 INSTALLATION...............................................................................................................................687 COUNTERWEIGHT..................................................................................................................................689 REMOVAL AND INSTALLATION...................................................................................................................689 FUEL TANK......................................................................................................................................690 REMOVAL....................................................................................................................................690 INSTALLATION...............................................................................................................................692 CAB, FLOOR FRAME...............................................................................................................................693 REMOVAL....................................................................................................................................693 INSTALLATION...............................................................................................................................696 CAB............................................................................................................................................697 REMOVAL....................................................................................................................................697 INSTALLATION...............................................................................................................................698 MAIN MONITOR...................................................................................................................................699 REMOVAL....................................................................................................................................699 INSTALLATION...............................................................................................................................700 MAINTENANCE MONITOR............................................................................................................................701 REMOVAL AND INSTALLATION...................................................................................................................701 AIR CONDITIONER UNIT...........................................................................................................................702 REMOVAL....................................................................................................................................702 INSTALLATION...............................................................................................................................707 AIR CONDITIONER CONDENSER......................................................................................................................708 REMOVAL....................................................................................................................................708 INSTALLATION...............................................................................................................................709 DRY RECEIVER...................................................................................................................................710 REMOVAL AND INSTALLATION...................................................................................................................710 AIR CONDITIONER CONDENSER COMPRESSOR...........................................................................................................711 REMOVAL AND INSTALLATION...................................................................................................................711 40 MAINTENANCE STANDARD............................................................................................................................712 ENGINE MOUNT, TRANSMISSION MOUNT...............................................................................................................713 TORQUE CONVERTER CHARGING PUMP.................................................................................................................714 TORQUE CONVERTER...............................................................................................................................715 TRANSMISSION...................................................................................................................................716 TRANSMISSION CONTROL VALVE.....................................................................................................................725 FLOW CONTROL VALVE.............................................................................................................................729 ACCUMULATOR VALVE..............................................................................................................................730 DRIVE SHAFT....................................................................................................................................731 DIFFERENTIAL (1/2).............................................................................................................................732 FINAL DRIVE....................................................................................................................................735 AXLE MOUNT.....................................................................................................................................737 CENTER HINGE PIN...............................................................................................................................738 STEERING COLUMN................................................................................................................................740 STEERING VALVE.................................................................................................................................741 STEERING CYLINDER MOUNT........................................................................................................................742 BRAKE..........................................................................................................................................743 BRAKE VALVE....................................................................................................................................744 PARKING BRAKE..................................................................................................................................747 MAIN CONTROL VALVE.............................................................................................................................748 PPC VALVE......................................................................................................................................752 HYDRAULIC CYLINDER.............................................................................................................................753 WORK EQUIPMENT LINKAGE.........................................................................................................................754 BUCKET.........................................................................................................................................756 BUCKET POSITIONER AND BOOM KICK-OUT............................................................................................................757
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- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
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1 review for Komatsu WA380-3, WA380-3LE Wheel Loader Shop Manual CEBMW23091 – PDF DOWNLOAD
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Carmelo Callahan –
Found what I needed at a fair price. Customer service was quick to respond when I needed help and seller was very responsive. I’ll use the service again I’m sure.