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KOMATSU WA380-3 WHEEL LOADER SHOP MANUAL SMEW380000 – PDF DOWNLOAD
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Description
KOMATSU WA380-3 WHEEL LOADER SHOP MANUAL SMEW380000 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WA380-3 WHEEL LOADER SHOP MANUAL SMEW380000 – PDF DOWNLOAD
Language : English
Pages : 592
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU WA380-3 WHEEL LOADER SHOP MANUAL SMEW380000 – PDF DOWNLOAD
COVER..................................................................................................................... 1 CONTENTS.................................................................................................................. 3 SAFETY.................................................................................................................... 4 FOREWORD.................................................................................................................. 6 01 GENERAL................................................................................................................ 19 GENERAL ASSEMBLY DRAWING.............................................................................................. 20 SPCIFICATIONS......................................................................................................... 21 WEIGHT TABLE.......................................................................................................... 24 LIST OF LUBRICANT AND WATER........................................................................................... 25 10 STRUCTURE AND FUNCTION................................................................................................. 27 POWER TRAIN........................................................................................................... 29 POWER TRAIN SYSTEM.................................................................................................... 30 TORQUE CONVERTER，TRANSMISSION PIPING.................................................................................. 32 TRANSMISSION HYDRAULIC SYSTEM DIAGRAM................................................................................. 34 TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM................................................................................ 35 TORQUE CONVERTER...................................................................................................... 36 TORQUE CONVERTER OIL FILTER........................................................................................... 38 TRANSMISSION.......................................................................................................... 40 TRANSMISSION CONTROL VALVE............................................................................................ 50 DRIVE SHAFT........................................................................................................... 72 AXLE.................................................................................................................. 73 DIFFERENTIAL.......................................................................................................... 75 FINAL DRIVE........................................................................................................... 79 AXLE MOUNT,CENTER HINGE PIN........................................................................................... 80 STEERING PIPING....................................................................................................... 82 STEERING COLUMN....................................................................................................... 83 STEERING VALVE........................................................................................................ 84 ORBIT-ROLL VALVE...................................................................................................... 98 STOP VALVE............................................................................................................102 BRAKE PIPING.........................................................................................................104 BRAKE HYDRAULIC CIRCUIT DIAGRAM......................................................................................105 BRAKE VALVE...........................................................................................................106 ACCUMULATOR CHARGE VALVE..............................................................................................111 ACCUMULATOR(FOR BRAKE)................................................................................................115 BRAKE.................................................................................................................117 PARKING BRAKE CONTROL.................................................................................................119 PARKING BRAKE.........................................................................................................120 PARKING BRAKE SOLENOID VALVE..........................................................................................121 PARKING BRAKE VALVE...................................................................................................122 HYDRAULIC PIPING......................................................................................................123 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM...............................................................................124 WORK EQUIPMENT HYDRAULIC CUIRCUIT DIAGRAM.............................................................................125 WORK EQUIPMENT LEVER LINKAGE..........................................................................................127 HYDRAULIC TANK........................................................................................................128 MAIN CONTROL VALVE....................................................................................................130 WORK EQUIPMENT LINKAGE................................................................................................144 BUCKET................................................................................................................146 BUCKET POSITIONER AND BOOM KICK-OUT...................................................................................147 AIR CONDITIONER.......................................................................................................154 ELECTRIC CIRCUIT DIAGRAM..............................................................................................156 ENGINE STARTING CIRCUIT...............................................................................................161 ENGINE STOP CIRCUIT...................................................................................................162 ENGINE STOP FUEL SOLENOID.............................................................................................163 ELECTRIC TRANSMISSION CONTROL.........................................................................................164 KICK-DOWN SWITCH......................................................................................................167 KICK-DOWN ELECTRIC CIRCUIT DIAGRAM....................................................................................168 TRANSMISSION CUT-OFF SWITCH...........................................................................................173 TRANSMISSION CUT-OFF FUNCTION.........................................................................................174 20 TESTING AND ADJUSTING..................................................................................................177 STANDARD VALUE TABLE FOR ENGINE.......................................................................................178 STANDARD VALUE TABLE FOR CHASSIS......................................................................................179 TOOLS FOR TESTING,ADJUSTING AND TROUBLESHOOTING.......................................................................185 MEASURING ENGINE SPEED................................................................................................187 MEASURING EXHAUST COLOR...............................................................................................189 TESTING AND ADJUSTING FUEL INJECTION TIMING...........................................................................190 MEASURING ENGINE OIL PRESSURE.........................................................................................192 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION.........................................................193 MEASURING TORQUE CONVERTER, TRANSMISSION,PARKING BRAKE OIL PRESSURE...................................................194 PROCEDURE FOR MOVING MATHINE WHEN TRANSMISSION VALVE FAILS............................................................196 TESTING WHEEL BRAKE PERFORMANCE.......................................................................................197 TESTING DROP IN WHEEL BRAKE OIL PRESSURE..............................................................................198 MEASURING CLEARANCE BETWEEN TIRE AND WHEEL............................................................................199 TESTING FOR BRAKE DISC WEAR...........................................................................................200 BLEEDING AIR FROM WHEEL BRAKE CIRCUIT.................................................................................201 TESTING AND ADJUSTING ACCUMULATOR CHANRGE CUT-IN AND CUT-OUT PRESSURE.................................................202 MEASURING PARKING BRAKE PERFORMANCE...................................................................................204 TESTING WEAR OF PARKING BRAKE DISC....................................................................................205 MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE...........................................................................206 BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT..............................................................................208 ADJUSTING WORK EQUIPMENT LEVER LINKAGE................................................................................209 TESTING AND ADJUSTING OF BUCKET PROXIMITY SWITCH......................................................................213 TESTING AND ADJUSTING OF BOOM PROXIMITY SWITCH........................................................................213 TESTING AND ADJUSTING STEERING CONTROL................................................................................215 TROUBLESHOOTING.......................................................................................................216 POINTS TO REMEMBER WHEN TROUBLESHOOTING...........................................................................217 SEQUENCE OF EVENTS IN TROUBLESHOOTING.............................................................................218 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE.........................................................................219 HANDLING CONNECTORS...............................................................................................226 CHECK BEFORE TROUBLESHOOTING......................................................................................227 METHOD OF USING TROUBLESHOOTING CHARTS............................................................................228 CONNECTOR TYPES AND MOUNTING LOCATIONS............................................................................252 CONNECTOR PIN ARRANGEMENT DIAGRAM.................................................................................238 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS........................................................................242 TROUBLESHOOTING OF ENGINE SYSTEM(S MODE)..........................................................................250 S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME)..................................................251 S-2 ENGINE DOES NOT START.....................................................................................252 (1) ENGINE DOES NOT TURN..................................................................................252 (2) ENGINE TURNS BUT TO EXHAUST GAS COMES OUT(FUEL IS NOT BEING INJECTED).................................253 (3) ENGINE GAS COMES OUT BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED)................................254 S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR).......................................................255 S-4 ENGINE STOPS DURING OPERATIONS............................................................................256 S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)..................................................................257 S-6 ENGINE LACKS OUTPUT(NO POWER).............................................................................258 S-7 EXHAUST GAS IS BLACK(INCOMPLETE COMBUSTION)...............................................................259 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE).....................................................260 S-9 OIL BECOMES CONTAMINATED QUICKLY..........................................................................261 S-10 FUEL CONSUMPTION IS EXCESSIVE............................................................................262 S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN....................................263 S-12 OIL PRESSURE LAMP LIGHTS UP(DROP IN OIL PRESSURE)........................................................264 S-13 OIL LEVEL RISES..........................................................................................265 S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING)..........................................................266 S-15 ABNORMAL NOISE IS MADE...................................................................................267 S-16 VIBRATION IS EXCESSIVE...................................................................................268 TROUBLESHOOTING OF ELECTRICAL SYSTEM(E MODE)......................................................................269 E-1 ENGINE DOES NOT START.....................................................................................270 E-2 TRANSMISSION DOES NOT WORK NORMALLY.......................................................................273 (a) PROBLEM IN COMMON CIRCUIT FOR TRANSMISSION(ALWAYS STAYS IN 2ND).......................................275 (b) PROBLEM IN H-L CIRCUIT................................................................................276 (c) PROBLEM IN SPEED CIRCUIT).............................................................................277 (d) PROBLEM IN 4TH CIRCUIT(DOES NOT ENTER 4TH)............................................................278 (e) CONTACT IN H-L CIRCUIT................................................................................279 (f) CONTACT IN SPEED CIRCUIT..............................................................................280 (g) CONTACT IN 4TH CIRCUIT(ALWAYS STAYS IN 4TH)...........................................................281 (h) PROBLEM IN FORWARD CIRCUIT(REVERSE IS NORMAL).........................................................282 (i) PROBLEM IN REVERSE CIRCUIT(FORWARD IN NORMAL).........................................................284 (j) PROBLEM IN COMMON CIRCUIT FOR FORWARD AND REVERSE(DOES NOT TRAVEL FORWARD,PARKING BRAKE IS NORMAL)....286 (k) CONTACT IN FORWARD CIRCUIT............................................................................288 (l) CONTRACT IN REVERSE CIRCUIT...........................................................................290 (m) PROBLEM IN COMMON CIRCUIT FOR FORWARD AND REVERSE.....................................................292 E-3 KICK-DOWN SWITCH DOES NOT WORK(THE REGULAR F1 TO F4 SHIFTS NORMALLY)......................................293 E-4 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IN ON(KICK-DOWN SWITCH RELAY DOES NOT HOLD IN POSITION)........295 E-5 KICK-DOWN OPERATION CANNOT BE CANCELED....................................................................295 (a) NOT CANCELED EVEN WHEN DIRECTIONAL LEVER IS MOVED FROM F TO N OR R....................................295 (b) NOT CANCELED EVEN WHEN SPEED LEVER IS MOVED FROM 2ND TO OTHER POSITION................................296 E-6 KICK-DOWN SWITCH IS ACTUATED BY MISTAKE WHEN TRAVELING IN 2ND.............................................298 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEN(CHASSIS RELATED)(T MODE).......................................299 POWER TRAIN...................................................................................................300 T-1 MACHINE DOES NOT START................................................................................300 T-2 TRAVEL SPEED IS SLOW,THRUSTING POWER IS WEAK,LACKS POWER ON SLOPES....................................302 T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR................................................304 T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR.............................................305 T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH..............................................................306 STEERING SYSTEM...............................................................................................307 T-6 STEERING DOES NOT TURN................................................................................307 T-7 STEERING WHEEL IS HEAVY...............................................................................308 T-8 STEERING WHEEL WOBBLES OR THERE IS EXCESSIVE SHOCK....................................................309 T-9 MACHINE STEERS TO ONE SIDE WHEN TRAVELING.............................................................309 T-10 TURNING RADISU TO LEFT AND RIGHT IS DIFFERENT........................................................309 BRAKE SYSTEM..................................................................................................310 T-11 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR........................................................310 T-12 BRAKES ARE NOT RELEASED OR BRAKES DRAG...............................................................311 T-13 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS.........................................................312 WORK QUIPMENT.................................................................................................313 T-14 BOOM DOES NOT RISE...................................................................................313 T-15 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER....................................................314 T-16 WHEN BOOM IS RAISED,IT MOVES SLOWLY AT A CERTAIN HEIGHT..............................................315 T-17 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER(BUCKET FLOATS)............................................315 T-18 EXCESSIVE HYDRAULIC DIRFT OF BOOM....................................................................315 T-19 BOOM SHAKES DURING OPERATION.........................................................................315 T-20 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE.............................316 T-21 BUCKET DOES NOT TILT BACK............................................................................317 T-22 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER.....................................................318 T-23 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION..............................................319 T-24 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER.........................................................319 T-25 EXCESSIVE HYDRAULIC DRIFT OF BUCKET..................................................................319 T-26 BUCKET SHAKES DURING LOADING OPERATION...............................................................320 T-27 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT............................320 T-28 BOOM,BUCKET CONTROL LEVER ARE HEAVY OR DO NOT MOVE SMOOTHLY..........................................321 30 DISASSEMBLY AND ASSEMBLY...............................................................................................322 METHOD OF USING MANUAL................................................................................................324 PRECAUTIONS WHEN CARRYING OUT OPERAION................................................................................325 GENERAL TOOL LIST.....................................................................................................327 RADIATOR..............................................................................................................329 REMOVAL ..........................................................................................................329 INSTALLATION......................................................................................................332 ENGINE................................................................................................................333 REMOVAL...........................................................................................................333 INSTALLATION......................................................................................................338 TORQUE CONVERTER CHARGING PUMP .......................................................................................339 REMOVALE..........................................................................................................339 INSTALLATION......................................................................................................340 TORQUE CONVERTER,TRANSMISSION.........................................................................................341 REMOVAL...........................................................................................................341 INSTALLATION......................................................................................................345 TORQUE CONVERTER......................................................................................................346 DISASSEMBLY.......................................................................................................346 ASSEMBLY..........................................................................................................348 TRANSMISSION..........................................................................................................351 DISASSEMBLY ......................................................................................................351 ASSEMBLY..........................................................................................................360 TRANSMISSION CLUTCH PACK..............................................................................................374 DISASSEMBLY.......................................................................................................374 ASSEMBLY..........................................................................................................380 TRANSMISSION CONTROL VALVE............................................................................................374 REMOVAL...........................................................................................................396 INSTALLATION......................................................................................................394 DISASSEMBLY.......................................................................................................396 ASSEMBLY..........................................................................................................398 TRANSMISSION ACCUMULATOR VALVE........................................................................................401 DISASSEMBLY.......................................................................................................401 ASSEMBLY..........................................................................................................402 MODULATING VALVE......................................................................................................403 DISASSEMBLY.......................................................................................................403 ASSEMBLY..........................................................................................................404 DRIVE SHAFT...........................................................................................................405 DISASSEMBLY.......................................................................................................405 ASSEMBLY..........................................................................................................408 FRONT AXLE............................................................................................................410 REMOVAL...........................................................................................................410 INSTALLATION......................................................................................................412 REAR AXLE.............................................................................................................413 REMOVAL...........................................................................................................413 INSTALLATION......................................................................................................417 DIFFERENTIAL..........................................................................................................419 DISASSEMBLY.......................................................................................................419 ASSEMBLY..........................................................................................................425 AXLE HOUSING..........................................................................................................435 DISASSEMBLY.......................................................................................................435 ASSEMBLY..........................................................................................................442 CENTER HINGE PIN......................................................................................................452 REMOVAL...........................................................................................................452 INSTALLATION......................................................................................................456 STEERING VALVE........................................................................................................459 REMOVAL...........................................................................................................459 INSTALLATION......................................................................................................461 DISASSEMBLY.......................................................................................................462 ASSEMBLY..........................................................................................................466 ORBIT-ROLL VALVE......................................................................................................469 REMOVAL...........................................................................................................469 INSTALLATION......................................................................................................470 DISASSEMBLY.......................................................................................................471 ASSEMBLY..........................................................................................................474 STEERING CYLINDER.....................................................................................................479 REMOVAL...........................................................................................................479 INSTALLATION......................................................................................................480 BRAKE VALVE...........................................................................................................481 REMOVAL...........................................................................................................481 INSTALLATION......................................................................................................482 BRAKE VALVE（TANDEM）...................................................................................................483 DISASSEMBLY.......................................................................................................483 ASSEMBLY..........................................................................................................484 PARKING BRAKE DISC....................................................................................................485 REMOVAL...........................................................................................................485 INSTALLATION......................................................................................................487 HYDRAULIC TANK........................................................................................................488 REMOVAL...........................................................................................................488 INSTALLATION......................................................................................................490 HYDRAULIC FILTER......................................................................................................491 REMOVAL AND INSTALLATION..........................................................................................491 HYDRAULIC，STEERING，SWITCH，PPC PUMP....................................................................................492 REMOVAL...........................................................................................................492 INSTALLATION......................................................................................................495 MAIN CONTROL VALVE....................................................................................................496 REMOVAL...........................................................................................................496 INSTALLATION......................................................................................................498 DISASSEMBLY.......................................................................................................499 ASSEMBLY..........................................................................................................502 BUCKET CYLINDER.......................................................................................................504 REMOVAL...........................................................................................................504 INSTALLATION......................................................................................................506 BOOM CYLNDER..........................................................................................................507 REMOVAL...........................................................................................................507 INSTALLATION......................................................................................................508 HYDRAULCI CYLINDER....................................................................................................509 DISASSEMBLY.......................................................................................................509 ASSEMBLY..........................................................................................................512 WORK EQUIPMENT........................................................................................................515 REMOVAL...........................................................................................................515 INSTALLATION......................................................................................................518 COUNTER WEIGHT........................................................................................................520 REMOVAL AND INSTALLATION..........................................................................................520 FUEL TANK.............................................................................................................521 REMOVAL...........................................................................................................521 INSTALLATION......................................................................................................523 CAB FLOOR FRAME.......................................................................................................524 REMOVAL...........................................................................................................524 INSTALLATION......................................................................................................527 CAB...................................................................................................................528 REMOVAL...........................................................................................................528 INSTALLATION......................................................................................................529 MAIN MONITOR..........................................................................................................530 REMOVAL...........................................................................................................530 INSTALLATION......................................................................................................531 AIR CONDITION UNIT....................................................................................................532 REMOVAL...........................................................................................................532 INSTALLATION......................................................................................................537 AIR CONDITIONER CONDENSER.............................................................................................538 REMOVAL...........................................................................................................538 INSTALLATION......................................................................................................539 DRY RECEIVER..........................................................................................................540 REMOVAL AND INSTALLATION..........................................................................................540 AIR CONDITIONER CONDENSER COMPRESSOR..................................................................................541 REMOVAL AND STALLATION............................................................................................541 TIRE AND WHEEL........................................................................................................542 REMOVAL OF TIRE...................................................................................................542 REMOVAL OF WHEEL..................................................................................................544 40MAINTENANCE STANDARD....................................................................................................545 ENGINE MOUNT，TRANSMISSION MOUNT.......................................................................................546 TORQUE CONVERTER CHARGING PUMP........................................................................................547 TORQUE CONVERTER......................................................................................................548 TRANSMISSION..........................................................................................................549 TRANSMISSION CONTROL VALVE............................................................................................558 MODULATION VALVE......................................................................................................562 ACCUMULATOR VALVE.....................................................................................................563 DRIVE SHAFT...........................................................................................................564 DIFFERENTIAL..........................................................................................................565 FINAL DRIVE...........................................................................................................568 AXLE MOUNT............................................................................................................570 CENTER HINGE PIN......................................................................................................572 STEERING COLUMN.......................................................................................................574 STEERING VALVE........................................................................................................575 STEERING CYLINDER MOUNT...............................................................................................576 BRAKE.................................................................................................................577 BRAKE VALVE...........................................................................................................578 PARKING BRAKE.........................................................................................................580 HYDRAULIC PUMP........................................................................................................581 MAIN CONTROL VALVE....................................................................................................582 HYDRAULIC CYLINDER....................................................................................................587 WORK EQUIPMENT LINKAGE................................................................................................588 BUCKET................................................................................................................590 BUCKET POSITIONER AND BOOM KICK-OUT...................................................................................591 PROPOSAL..............................................................................................................592
DESCRIPTION:
KOMATSU WA380-3 WHEEL LOADER SHOP MANUAL SMEW380000 – PDF DOWNLOAD
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.
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 consisting ‘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.
S.S 21/12/24
