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KOMATSU WA380-3 WHEEL LOADER SHOP MANUAL VEBM460104 – PDF DOWNLOAD
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KOMATSU WA380-3 WHEEL LOADER SHOP MANUAL VEBM460104 – PDF DOWNLOAD
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Description
KOMATSU WA380-3 WHEEL LOADER SHOP MANUAL VEBM460104 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WA380-3 WHEEL LOADER SHOP MANUAL VEBM460104 – PDF DOWNLOAD
Language : English
Pages : 970
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU WA380-3 WHEEL LOADER SHOP MANUAL VEBM460104 – PDF DOWNLOAD
Contents........................................................................ 2 01 General.................................................................. 9 Up to SN WA380H20500.................................................... 11 Dimensions and weights.................................................. 11 Dimensions and weights high-lift........................................ 12 Specifications.......................................................... 13 Weight table............................................................ 16 List of lubricant and water............................................. 17 SN WA380H20501 and up................................................... 18 Dimensions and weights.................................................. 18 Specifications.......................................................... 19 Weight table............................................................ 22 List of lubricant and water............................................. 23 Outlines of service..................................................... 25 General view of controls and gauges..................................... 28 Torque list............................................................. 30 10 Structure and function................................................... 31 Power train............................................................. 33 Power train system...................................................... 34 Torque converter, transmission piping................................... 36 Transmission hydraulic circuit diagram.................................. 37 Torque converter........................................................ 39 Torque converter oil filter............................................. 41 Transmission............................................................ 43 Transmission control valve.............................................. 53 Upper valve............................................................. 54 Transmission solenoid valve............................................. 56 Pilot reducing valve.................................................... 57 Main relief valve....................................................... 58 Torque converter outlet port valve...................................... 59 Priority valve.......................................................... 60 Directional selector valve.............................................. 61 H-L selector valve and range selector valve............................. 62 Emergency manuel spool.................................................. 64 Electronic control modulation valve (ECMV).............................. 65 Pilot oil filter........................................................ 68 Accumulator valve....................................................... 69 Flow control valve...................................................... 71 Check valve............................................................. 72 Drife shaft............................................................. 73 Axle.................................................................... 74 Differential............................................................ 76 Final drive............................................................. 81 Axle mount, center hinge pin............................................ 82 Steering piping......................................................... 85 Steering control, orbit roll............................................ 86 Orbit roll valve........................................................ 87 Steering valve.......................................................... 88 Overload relief valve................................................... 89 Steering relief valve................................................... 91 Operation of demand valve............................................... 92 Emergency steering...................................................... 99 Brake piping............................................................109 Park brake and foot brake circuits......................................110 Brake valve.............................................................111 Accumulator charge valve................................................116 Accumulator for brake system............................................120 Brake circuit diagram...................................................122 Brake...................................................................134 Parking brake control...................................................136 Parking brake...........................................................137 Parking brake valve.....................................................138 Hydraulic piping........................................................139 Work equipment hydraulic system diagram.................................140 Work equipment lever linkage............................................150 Hydraulic tank..........................................................151 Oil filter bypass valve.................................................152 PPC valve...............................................................153 Operation of PPC valve..................................................158 PPC relief valve........................................................161 Accumulator (for PPC valve).............................................162 Main control valve (up to H20383).......................................163 Relief valve (up to H20383).............................................167 Safety valve with suction (up to H20383)................................168 Suction valve (up to H20383)............................................169 Main control valve (from H20384 up to H20836)..........................170 Safety valve with suction (H20384 and up)...............................172 Antcavitation valve (H20384 and up).....................................173 Safety valve (H20384 and up)............................................173 Main control valve (H20837 and up)......................................174 Operation of cut-off valve (up to H20383)...............................176 Work equipment valve operation..........................................178 Hydraulic safety system (up to H20836)..................................184 Hydraulic safety system location (up to H20836).........................185 Hydraulic safety valve (up to H20836)...................................186 Work equipment linkage..................................................187 Bucket..................................................................189 Bucket positioner and boom kick-out.....................................190 Wiring diagrams.........................................................197 Machine monitor system..................................................241 Transmission auot-shift control system..................................248 Transmission controller.................................................253 ECSS (ALS electronic)...................................................255 Sensors.................................................................265 Engine starting circuit.................................................270 Engine stop circuit.....................................................271 Preheating circuit......................................................272 Electric transmission...................................................277 Combination switch......................................................278 Kick-down, hold switch..................................................280 Kick-down electric circuit diagram......................................281 Transmission cut-off function...........................................286 Parking brake: transmission neutralizer.................................287 Air conditioner.........................................................289 20 Testing and adjusting....................................................343 Standard value table for engine.........................................344 Standard value table for chassis........................................346 Tesz certificate........................................................350 Standard value table for electrical system..............................354 Tools for testing, adjusting and troubleshooting........................367 Adjusting valve clearance...............................................369 Measuring compression pressure..........................................373 Measuring blow-by pressure..............................................375 Testing and adjusting fuel injection timing.............................377 Measuring intake air pressure ..........................................379 Measuring engine oil pressure...........................................380 Measuring engine speed..................................................381 Measuring stall speed...................................................382 Testing the fan belt tension............................................384 Measuring turbocharger clearance........................................385 Turbocharger wastegate actuator - visual inspection.....................386 Turbocharger wastegate actuator - functional checking...................388 Adjusting valve clearance...............................................389 Measuring compression pressure..........................................390 Measuring blow-by pressure..............................................391 Testing and adjusting fuel injection timing.............................392 Measuring exhaust color.................................................395 Measuring inkake air pressure (boost pressure)..........................396 Measuring exhaust gas pressure..........................................397 Measuring engine oil pressure...........................................398 Measuring engine speed..................................................399 Testing and adjusting fan belt tension..................................400 Method for adjusting engine stop cable..................................401 Measuring accelerator pedal.............................................403 Basic adjustment of accelerator pedal...................................405 Measuring operating force, travel of speed lever........................407 Measuring stall speed...................................................408 Measuring torque converter, transmission, parking brake oil pressure....410 Method of operating emergency manual spool..............................412 Measuring clearance between tire and wheel..............................414 Measuring steering oil pressure.........................................417 Measuring operating force, travel of brake pedal........................419 Measuring brake performance.............................................420 Testing brake oil pressure..............................................421 Testing for brake disk wear.............................................422 Bleeding air from brake system..........................................423 Measuring parking brake performance.....................................424 Manual release method for parking brake.................................425 Testing wear of parking brake disk......................................426 Measuring work equipment control lever..................................427 Measuring work equipment hydraulic pressure.............................429 Measuring PPC-valve pressure............................................431 Measuring work equipment................................................435 Testing and adjusting bucket positioner.................................437 Testing and adjusting boom kick-out.....................................438 Adjusting main monitor..................................................440 Gas side test and topping up gas pressure...............................441 Hydraulic accumulator...................................................443 Troubleshooting.........................................................445 POINTS TO REMEMBER WHEN TROUBLESHOOTING.............................446 SEQUENCE OF EVENTS IN TROUBLESHOOTING...............................447 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...........................448 HANDLING CONNECTORS.................................................455 CHECKS BEFORE TROUBLESHOOTING.......................................456 METHOD OF USING TROUBLESHOOTING CHARTS..............................457 CONNECTOR TYPES AND MOUNTING LOCATION...............................466 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..........................475 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)...........................483 TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE).....................503 TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)..............541 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE).......................561 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE)..........599 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (T MODE).........619 TROUBLESHOOTING OF ECSS (D MODE)....................................643 30 Disassembly and assembly.................................................657 Precautions when carrying out operations................................659 Special tool list.......................................................662 Starting motor..........................................................665 Alternator..............................................................666 Engine oil cooler.......................................................667 Fuel injection pump.....................................................668 Water pump..............................................................672 Turbocharger............................................................673 Nozzle holder...........................................................674 Thermostat..............................................................675 Cylinder head...........................................................676 Radiator................................................................683 Engine..................................................................687 Torque converter charging pump..........................................693 Torque converter, transmission..........................................695 Torque converter........................................................700 Transmission............................................................705 Transmission clutch pack................................................729 Transmission control valve..............................................749 Transmission accumulator valve..........................................757 Drive shaft.............................................................759 Front axle..............................................................764 Rear axle...............................................................765 Differential............................................................771 Axle housing............................................................786 Center hinge pin........................................................803 Steering gear...........................................................810 Steering valve..........................................................813 Steering cylinder.......................................................830 Brake valve.............................................................832 Right brake valve (tandem)..............................................834 Left brake valve (single)...............................................836 Parking brake disc......................................................838 Hydraulic tank..........................................................841 Hydraulic filter........................................................844 Hydraulic, steering, switch, PPC pump...................................845 Main control valve......................................................849 PPC valve...............................................................857 Bucket cylinder.........................................................862 Boom cylinder...........................................................865 Hydraulic cylinder......................................................867 Work equipment..........................................................873 Counterweight...........................................................878 Fuel tank...............................................................879 Cab, floor frame........................................................882 Cab.....................................................................885 Main monitor............................................................887 Maintenance monitor.....................................................889 Air conditioner unit....................................................890 Air conditioner condenser...............................................896 Dry receiver............................................................898 Air conditioner condenser compressor....................................899 40 Maintenance standard.....................................................901 Engine mount, transmission mount........................................902 Torque converter charging pump..........................................903 Torque converter........................................................904 Transmission............................................................905 Transmission control valve..............................................913 Flow control valve......................................................917 Accumulator valve.......................................................918 Drive shaft.............................................................919 Differential............................................................920 Final drive.............................................................923 Axle mount..............................................................925 Center hinge pin........................................................926 Steering column.........................................................928 Steering valve..........................................................929 Steering cylinder mount.................................................930 Brake...................................................................931 Brake valve.............................................................932 Parking brake...........................................................935 Hydraulic pump..........................................................936 Main control valve......................................................937 PPC valve...............................................................941 Hydraulic cylinder......................................................942 Work equipment linkage..................................................943 Bucket..................................................................945 Bucket positioner and boom kick-out.....................................946 Diagrams........................................................................947 A3..........................................................................947 A0..........................................................................967
DESCRIPTION:
KOMATSU WA380-3 WHEEL LOADER SHOP MANUAL VEBM460104 – PDF DOWNLOAD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the service personnel an accurate understanding of the product and by showing them 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 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
S.S 21/12/24
