Komatsu WA380-3MC Wheel Loader Shop Manual CEBM003402 – PDF DOWNLOAD

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Komatsu WA380-3MC Wheel Loader Shop Manual CEBM003402 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA380-3MC Wheel Loader Shop Manual CEBM003402 – PDF DOWNLOAD

Language : English
Pages : 797
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu WA380-3MC Wheel Loader Shop Manual CEBM003402 – PDF DOWNLOAD

• MACHINE MODEL                SERIAL NUMBERS
• WA380-3MC                           A51001 and up

MAIN MENU 0
COVER 1
CONTENTS 2
01 GENERAL 25
SPECIFICATION DRAWINGS 26
SPECIFICATIONS 27
WEIGHT TABLE 30
LIST OF LUBRICANTS AND COOLANT 31
ENGINE OIL SPECIFICATIONS 32
TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE BRAKES AND YDRAULIC SYSTEM OIL SPECIFICATONS 33
FINAL DRIVE OIL SPECIFICATIONS 33
DRIVE AXLE OIL SPECIFICATIONS 33
DIESEL FUEL SPECIFICATIONS 33
COOLANT SPECIFICATIONS 34
10 STRUCTURE AND FUNCTION 41
POWER TRAIN 43
POWER TRAIN SYSTEM 44
TORQUE CONVERTER, TRANSMISSION PIPING 46
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM 48
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 49
TORQUE CONVERTER 50
TORQUE CONVERTER OIL FILTER 52
TRANSMISSION 53
CLUTCH 56
FORWARD, REVERSE CLUTCH 56
1ST, 3RD CLUTCH 57
2ND, 4TH CLUTCH 57
FORWARD 1ST 59
FORWARD 2ND 60
FORWARD 3RD 61
FORWARD 4TH 62
REVERSE 1ST 63
TRANSMISSION CONTROL VALVE 64
UPPER VALVE 65
LOWER VALVE 66
TRANSMISSION SOLENOID VALVE 67
PILOT REDUCING VALVE 68
MAIN RELIEF VALVE 69
TORQUE CONVERTER OUTLET PORT VALVE 70
PRIORITY VALVE 71
DIRECTIONAL SELECTOR VALVE 72
H-L SELECTOR VALVE AND RANGE SELECTOR VALVE 73
EMERGENCY MANUAL SPOOL 75
FLOW CONTROL VALVE 76
CHECK VALVE 77
ELECTRONIC CONTROL MODULATION VALVE (ECMV) 78
PILOT OIL FILTER 81
ACCUMULTOR 82
DRIVE SHAFT 84
FRONT AXLE 85
REAR AXLE 86
DIFFERENTIAL 87
FRONT DIFFERENTIAL 87
REAR DIFFERENTIAL 88
TORQUE PROPORTIONAL DIFFERENTIAL 90
LIMITED SLIP DEFERENTIAL (OPTIONAL) 91
FINAL DRIVE 94
AXLE MOUNT, CENTER HINGE PIN 95
STEERING PIPING 97
STEERING COLUMN 98
STEERING VALVE 100
OPERATION OF DEMAND VALVE 101
STEERING SPOOL OPERATED 102
FLOW OPERATION 104
OPERATION OF STEERING VALVE 107
TURNING RIGHT 108
TURNING LEFT 109
STEERING RELIEF VALVE 110
OPERATION OF RELIEF VALVE 111
SAFETY VALVE (WITH SUCTION) 112
ORBIT-ROLL VALVE 114
CONNECTION BETWEEN HAND PUMP AND SLEEVE 116
STOP VALVE 118
GROUND DRIVEN STEERING PUMP (OPTION) 119
DIVERTER VALVE (OPTION) 120
BRAKE PIPING 124
BRAKE HYDRAULIC CIRCUIT DIAGRAM 125
BRAKE VALVE (RIGHT) 126
BRAKE VALVE (LEFT) 127
ACCUMULATOR CHARGE VALVE 131
ACCUMULATOR (FOR BRAKE) 135
BRAKE 137
PARKING BRAKE CONTROL 139
PARKING BRAKE 140
PARKING BRAKE SOLENOID VALVE 141
PARKING BRAKE VALVE 142
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE 143
HYDRAULIC PIPING 144
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM (FOLDOUT) 147
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 149
FOR 2-SPOOL VALVE (FOLDOUT) 149
FOR 3-SPOOL VALVE (FOLDOUT) 151
WORK EQUIPMENT LEVER LINKAGE 153
HYDRAULIC TANK 154
OIL FILTER BYPASS VALVE 155
BREATHER 155
PPC VALVE 156
OPERATION OF PPC VALVE 158
FUNCTION OF PPC VALVE 159
PPC RELIEF VALVE 161
ACCUMULATOR (FOR PPC VALVE) 162
MAIN CONTROL VALVE 164
2-SPOOL 164
3-SPOOL (OPTION) 166
RELIEF VALVE 168
SAFETY VALVE (WITH SUCTION) 169
SUCTION VALVE 170
OPERATION OF CUT-OFF VALVE 171
BOOM AND BUCKET SPOOL HOLD POSITION 173
BOOM SPOOL AT RAISED POSITION 174
BOOM SPOOL AT LOWER POSITION 175
BOOM SPOOL AT FLOAT POSITION 176
BUCKET SPOOL AT TILT POSITION 177
BUCKET SPOOL AT DUMP POSITION 178
WORK EQUIPMENT LINKAGE 180
BUCKET 182
BUCKET POSITIONER AND BOOM KICK-OUT 183
ROPS CAB 189
AIR CONDITIONER 190
ELECTRIC CIRCUIT DIAGRAM (FOLDOUT) 192
ELECTRIC CIRCUIT DIAGRAM ECSS (FOLDOUT) 193
MACHINE MONITOR SYSTEM 195
MAIN MONITOR 196
MAINTENANCE MONITOR 200
TRANSMISSION AUTO-SHIFT CONTROL SYSTEM 202
SYSTEM STRUCTURE DIAGRAM 202
SHIFT CONTROL SYSTEM FUNCTION 203
TABLE 2: GEAR SHIFT CHARACTERISTICS 206
SAFETY FUNCTION 207
TRANSMISSION CONTROLLER 208
ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) 209
SENSORS 213
ENGINE OIL LEVEL SENSOR 213
RADIATOR WATER LEVEL SENSORS 214
ENGINE WATER TEMPERATURE SENSOR 214
TORQUE CONVERTER OIL TEMPERATURE SENSOR 214
FUEL LEVEL SENSOR 215
ENGINE SPEED SENSOR 216
ENGINE OIL PRESSURE SENSOR 216
ENGINE STARTING CIRCUIT 217
ENGINE STOP CIRCUIT 218
ETHER START CIRCUIT 219
ELECTRIC TRANSMISSION CONTROL 220
COMBINATION SWITCH 221
KICK-DOWN, HOLD SWITCH 223
KICK-DOWN ELECTRIC CIRCUIT DIAGRAM 224
NORMAL OPERATION 224
KICK-DOWN SWITCH OPERATED 225
CANCELING ACTUATION OF KICK-DOWN SWITCH (CASE I) 226
CANCELING ACTUATION OF KICK-DOWN SWITCH (CASE II) 227
TRANSMISSION CUT-OFF SWITCH 228
TRANSMISSION CUT-OFF FUNCTION 229
ELECTRIC PARKING BRAKE CONTROL 231
PARKING BRAKE EMERGENCY RELEASE SWITCH 233
EMERGENCY BRAKE SWITCH 233
PARKING BRAKE SAFETY RELAY 234
NEUTRALIZER RELAY 234
FUNCTION OF PARKING BRAKE NEUTRALIZER RELAY 242
20 TESTING, ADJUSTING AND TROUBLE SHOOTING 243
STANDARD VALUE TABLE FOR ENGINE 246
STANDARD VALUE TABLE FOR CHASSIS 247
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM 251
SERVICE TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING 254
MEASURING ENGINE SPEEDS 255
MEASURING INTAKE MANIFOLD PRESSURE 255
MEASURING INTAKE AIR RESTRICTION 255
MEASURING ENGINE LUBRICATING OIL PRESSURE 256
MEASURING FUEL FILTER INLET RESTRICTION 256
MEASURING BLOW-BY PRESSURE 256
MEASURING EXHAUST BACK PRESSURE 257
MEASURING EXHAUST GAS COLOR 258
MEASURING COOLANT TEMPERATURE 259
MEASURING AND ADJUSTING VALVE CLEARANCE 259
MEASURING WASTEGATE ACTUATOR CALIBRATION 259
MEASURING STALL SPEEDS 260
MEASURING ACCELERATOR PEDAL 262
MEASURING OPERATING ANGLE OF ACCELERATOR PEDAL 263
MEASURING OPERATING FORCE AND TRAVEL OF DIRECTIONAL & SPEED LEVERS 264
MEASURING TORQUE CONVERTER, TRANSMISSION, AND PARKING BRAKE OIL PRESSURE 265
METHOD OF OPERATING EMERGENCY MANUAL SPOOL 267
MEASURING CLEARANCE BETWEEN TIRE AND WHEEL 269
TESTING AND ADJUSTING STEERING WHEEL 270
MEASURING OPERATING FORCE OF STEERING WHEEL 271
MEASURING OPERATING TIME FOR STEERING WHEEL 272
TESTING AND ADJUSTING STEERING CONTROL 273
MEASURING STEERING OIL PRESSURE 274
MEASURING OPERATING FORCE AND TRAVEL OF BRAKE PEDAL 276
MEASURING BRAKE PERFORMANCE 277
TESTING BRAKE OIL PRESSURE 278
MEASURING BRAKE DISC WEAR 279
BLEEDING AIR FROM BRAKE SYSTEM 280
MEASURING PARKING BRAKE PERFORMANCE 281
MANUAL RELEASE METHOD FOR PARKING BRAKE 282
MEASURING WEAR OF PARKING BRAKE DISC 283
MEASURING WORK EQUIPMENT CONTROL LEVER 284
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE 286
MEASURING PPC VALVE PRESSURE 288
MEASURING WORK EQUIPMENT 290
MEASURING WORK EQUIPMENT HYDRAULIC DRIFT 291
TESTING AND ADJUSTING BUCKET POSITIONER 292
TESTING AND ADJUSTING BOOM KICK-OUT 293
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE) 295
TROUBLESHOOTING (TABLE OF CONTENTS) 297
POINTS TO REMEMBER WHEN TROUBLESHOOTING 298
SEQUENCE OF EVENTS IN TROUBLESHOOTING 299
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 300
1 PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT 300
2 HANDLING CONTROL BOX 305
3 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT 306
CHECKS BEFORE TROUBLESHOOTING 308
METHOD OF USING TROUBLESHOOTING CHARTS 310
1 CATEGORY OF TROUBLESHOOTING CODE NUMBER 310
2 METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE 310
3 USING TROUBLESHOOTING CHART FOR ENGINE-RELATED FAILURE 312
CONNECTOR TYPES AND MOUNTING LOCATIONS 318
CONNECTOR PIN ARRANGEMENT DIAGRAM 319
TABLE FOR CONNECTOR PIN NUMBERS 324
X TYPE CONNECTOR 324
AMP040 TYPE CONNECTOR 325
SWP TYPE CONNECTOR 326
M TYPE CONNECTOR 327
S TYPE CONNECTOR 328
L TYPE CONNECTOR 329
MIC TYPE CONNECTOR 329
DIODE TYPE CONNECTOR 329
SIMPLE CONNECTOR (RING CONNECTOR) 330
TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE) (TABLE OF CONTENTS) 331
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 332
S-2 ENGINE DOES NOT START 333
1 ENGINE DOES NOT TURN 333
2 ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED) 334
3 EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 335
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 336
S-4 ENGINE STOPS DURING OPERATION 337
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 338
S-6 ENGINE LACKS OUTPUT (NO POWER) 339
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION) 340
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE) 341
S-9 OIL BECOMES CONTAMINATED QUICKLY 342
S-10 FUEL CONSUMPTION IS EXCESSIVE 343
S-11 OIL IS IN COOLANT WATER, OR COOLANT WATER SPURTS BACK, OR COOLANT WATER LEVEL GOES DOWN 344
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE) 345
S-13 OIL LEVEL RISES 346
S-14 COOLANT WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 347
S-15 ABNORMAL NOISE IS MADE 348
S-16 VIBRATION IS EXCESSIVE 349
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M-MODE) 351
TROUBLE DATA DISPLAY 353
M-1 MAIN MONITOR DOES NOT WORK 355
M-2 WHEN STARTING SWITCH IS TURN ON AN DENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIT 356
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY 357
M-4 ABNORMALITY IN SHIFT INDICATOR 358
A) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT F 358
B) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT R 358
C) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS R WHEN DIRECTIONAL LEVER IS AT F 358
D) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS F WHEN DIRECTIONAL LEVER IS AT R 359
E) DOES NOT DISPLAY 1ST, 4TH 359
F) DOES NOT DISPLAY 3RD, 4TH 359
G) DOES NOT DISPLAY 2ND, 3RD 360
H) DOES NOT DISPLAY 1ST, 2ND 360
M-5 HIGH BEAM DOES NOT LIGHT UP 361
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP 362
A) L H TURN SIGNAL DOES NOT LIGHT UP 362
B) R H TURN SIGNAL DOES NOT LIGHT UP 362
M-7 ABNORMALITY IN PARKING DISPLAY 363
A) PARKING LAMP DOES NOT LIGHT 363
B) PARKING LAMP STAYS LIT 363
M-8 IS NOT APPLICABLE TO THIS MODEL 364
M-9 NIGHT LIGHTING DOES NOT LIGHT UP 365
M-10 ABNORMALITY IN FRONT WORKING LAMP 366
A) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMPS LIGHT UP 366
B) WORKING LAMP LIGHTS UP, BUT MONITOR DISPLAY DOES NOT LIGHT UP 366
C) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP 366
M-11 ABNORMALITY IN REAR WORKING LAMP 367
A) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP 367
B) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP 367
C) MONITOR LIGHTS UP, BUT WORKING LAMP DOES NOT LIGHT UP 367
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF 369
A) WHEN MONITOR SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY IS NOT SHOWN 369
B) MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION STAYS ON 369
C) MONITOR DISPLAY LIGHTS UP BUT CUT-OFF FUNCTION IS NOT ACTUATED 370
M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING 371
A) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) EVEN WHEN DIRECTIONAL LEVER IS AT N AND CAUTION LAMP FLASHES 371
B) WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT 371
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATE 372
A) ACTUATED CONTINUOUSLY 372
B) NOT ACTUATED 372
M-15 ABNORMALITY IN BUZZER 373
A) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS TURNED ON (DURING SELF-CHECK) 373
B) BUZZER ALWAYS SOUNDS 373
M-16 CONDITION OF MONITOR SWITCHES ARE NOT STORED IN MEMORY 374
M-17 ABNORMALITY IN FAILURE DISPLAY MODE 375
A) DOES NOT ENTER FAILURE DISPLAY MODE 375
B) TIME FOR TIME ELAPSED SINCE FAILURE ON FAILURE DISPLAY MODE DOES NOT ADVANCE 375
M-18 ABNORMALITY IN GROUND DRIVEN STEERING NORMAL DISPLAY 376
A) GROUND DRIVEN STEERING NORMAL DISPLAY DOES NOT LIGHT UP 376
B) GROUND DRIVEN STEERING NORMAL DISPLAY STAYS LIT 376
M-19 ABNORMALITY IN GROUND DRIVEN STEERING ACTUATION DISPLAY 377
A) GROUND DRIVEN STEERING ACTUATION DISPLAY DOES NOT LIGHT UP 377
B) GROUND DRIVEN STEERING ACTUATION DISPLAY STAYS LIT 377
M-20 IS NOT APPLICABLE TO THIS MODEL 378
M-21 ABNORMALITY IN ECSS SYSTEM 379
A) DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED 379
B) MONITOR DISPLAY LIGHTS UP, BUT ECSS FUNCTION DOES NOT WORK 379
M-22 BUZZER DOES NOT SOUND WHEN AUTO-LEVELING SWITCH IS ACTUATED 379
M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK) 380
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K-MODE) 381
K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DO 382
A) ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS 382
B) SOME LAMPS DO NOT LIGHT UP 383
K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT, BUT DO NOT GO OUT 383
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), ALL LAMPS ON MAINTENANCE MONITO 384
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH 385
A) ENGINE OIL LEVEL DISPLAY FLASHES 385
B) ENGINE COOLANT WATER LEVEL DISPLAY FLASHES 386
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH 387
A) ENGINE OIL PRESSURE DISPLAY FLASHES 387
B) BATTERY CHARGE LEVEL DISPLAY FLASHES 388
C) BRAKE OIL PRESSURE DISPLAY FLASHES 389
D) AIR CLEANER DISPLAY FLASHES 390
K-6 CAUTION ITEMS ARE FLASHING, BUT ALARM BUZZER DOES NOT SOUND 391
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY, BUT ALARM BUZZER SOUNDS 392
K-8 CAUTION ITEMS ARE FLASHING, BUT WARNING LAMP ( CHECK LAMP, CAUTION LAMP) DOES NOT LIGHT UP 393
A) CHECK LAMP 393
B) CAUTION LAMP 393
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY, BUT WARNING LAMP 394
A) CHECK LAMP 394
B) CAUTION LAMP 394
K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURN ON (ONLY LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP) 395
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF 396
K-12 SERVICE METER DOES NOT WORK 397
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED 397
K-14 ABNORMALITY IN GUAGE ITEMS 398
A) ABNORMALITY IN FUEL GAUGE 398
B) ABNORMALITY IN ENGINE COOLANT WATER TEMPERATURE GAUGE 399
C) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE 400
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 401
E-1 ENGINE DOES NOT START (STARTER MOTOR DOES NOT TURN) 402
E-2 ENGINE DOES NOT STOP 406
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING 406
E-4 PARKING BRAKE DOES NOT WORK 407
E-5 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING 408
E-6 PARKING BRAKE IS RELEASED WHEN STARTER SWITCH IS TURNED ON 410
E-7 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING IS APPLIED (BUT PARKING BRAKE WORKS NORMALLY) 410
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (T-MODE) 411
POWER TRAIN 412
T-1 MACHINE DOES NOT START 412
T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES 413
T-3 EXCESSIVE SHOCKS WHEN STARTING MACHINE IS SHIFTING GEARS 414
T-4 EXCESSIVE TIME LAG WHEN STARTING TO MOVE MACHINE OR AFTER SHIFTING GEARS 415
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 416
STEERING SYSTEM 417
T-6 STEERING DOES NOT TURN 417
T-7 STEERING WHEEL IS HEAVY 418
T-8 STEERING WHEEL WOBBLES OR THERE IS EXCESSIVE SHOCK 419
T-9 MACHINE STEERS TO ONE SIDE WHEN TRAVELING 419
T-10 TURNING RADIUS TO LEFT AND RIGHT IS DIFFERENT 419
BRAKE SYSTEM 420
T-11 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR 420
T-12 BRAKES ARE NOT RELEASED OR BRAKES DRAG 421
T-13 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS 422
WORK EQUIPMENT 423
T-14 BOOM DOES NOT RISE 423
T-15 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER 424
T-16 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT 425
T-17 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS) 425
T-18 EXCESSIVE HYDRAULIC DRIFT OF BOOM 425
T-19 BOOM SHAKES DURING OPERATION 425
T-20 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE 425
T-21 BUCKET DOES NOT TILT BACK 426
T-22 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER 427
T-23 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION 428
T-24 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER 428
T-25 EXCESSIVE HYDRAULIC DRIFT OF BUCKET 428
T-26 BUCKET SHAKES DURING LOADING OPERATION (MAIN CONTROL VALVE AT HOLD) 429
T-27 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT 429
T-28 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY 430
TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM (D-MODE) 431
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM 432
D-1 ECSS DOES NOT WORK 433
A) ERROR CODE (d0) IS DISPLAYED 434
B) ERROR CODE (d1) IS DISPLAYED 434
C) ERROR CODE (d2) IS DISPLAYED 435
D) ERROR CODE (d3) IS DISPLAYED 435
E) ERROR CODE (d4) IS DISPLAYED 436
F) NO ABNORMALITY DISPLAY IS GIVEN (1) DOES NOT WORK AT ALL 436
D-2 ECSS CANNOT BE CANCELED 440
D-3 OUTPUT IS TURNED ON (TRAVEL SPEED DOES NOT BECOME 5 KM/H) (DEVIATES AROUND 5 KM/H) 441
D-4 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 1ST 441
D-5 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 4TH 442
D-6 CONTROLLER LED CODE IS NOT DISPLAYED 443
D-7 ECSS IS ABNORMAL, BUT MAIN MONITOR DOES NOT GIVE ABNORMALITY DISPLAY 443
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A-MODE) 445
OUTLINE 446
1 FUNCTION 446
2 WHEN CARRYING OUT TROUBLESHOOTING 446
3 FAILURE CODE TABLE 446
4 TABLE OF TROUBLESHOOTING MODES AND CAUSES 447
A-1 TROUBLESHOOTING CODE [10] MODULATION VALVE SOLENOID SYSTEM (DISCONNECTION, SHORT CIRCUIT) 448
A-2 TROUBLESHOOTING CODE [11] SHORT CIRCUIT IN POWER SOURCE FOR MODULATION VALVE SOLENOID SYSTEM 449
A-3 TROUBLESHOOTING CODE [12] F SOLENOID SIGNAL SYSTEM 450
A-4 TROUBLESHOOTING CODE [13] R SOLENOID SIGNAL SYSTEM 450
A-5 TROUBLESHOOTING CODE [14] ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM 451
A-6 TROUBLESHOOTING CODE [16] ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM 452
A-7 TROUBLESHOOTING CODE [17] BRAKE OUTPUT SIGNAL 453
A-8 TROUBLESHOOTING CODE [20] ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM 454
A-9 TROUBLESHOOTING CODE [21] ABNORMALITY IN SPEED LEVER SIGNAL SYSTEM 455
A-10 TROUBLESHOOTING CODE [22] ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM 456
A-11 TROUBLESHOOTING CODE [23] ABNORMALITY IN ENGINE SPEED SIGNAL 457
A-12 HOLD SWITCH SYSTEM 458
A-13 KICK-DOWN SWITCH SYSTEM 458
A-14 KICK-DOWN OUTPUT SIGNAL SYSTEM 459
A-15 TRANSMISSION CUT-OFF SIGNAL SYSTEM 460
A-16 NEUTRALIZER SIGNAL SYSTEM 461
A-17 BUZZER SIGNAL SYSTEM 462
A-18 NETWORK SIGNAL SYSTEM 463
A-19 CONTROLLER POWER SOURCE SYSTEM 464
A-20 ABNORMALITY IN MODEL SELECTION WIRE HARNESS 465
30 DISASSEMBLY AND ASSEMBLY 467
METHOD OF USING MANUAL 471
PRECAUTIONS WHEN CARRYING OUT OPERATION 472
1 PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK 472
2 PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK 473
3 PRECAUTIONS WHEN COMPLETING THE OPERATIONS 474
SPECIAL TOOL LIST 475
STARTING MOTOR 477
REMOVAL 477
INSTALLATION 477
ALTERNATOR 478
REMOVAL 478
INSTALLATION 478
ENGINE OIL COOLER 479
FUEL INJECTION PUMP 480
WATER PUMP 481
TURBOCHARGER 482
NOZZLE HOLDER ASSEMBLY 483
THERMOSTAT 484
CYLINDER HEAD 485
RADIATOR 486
REMOVAL 486
INSTALLATION 490
ENGINE 492
REMOVAL 492
INSTALLATION 498
TORQUE CONVERTER CHARGING PUMP 500
REMOVAL 500
INSTALLATION 501
TORQUE CONVERTER, TRANSMISSION 502
REMOVAL 502
INSTALLATION 506
DISASSEMBLY 507
ASSEMBLY 509
TRANSMISSION 512
DISASSEMBLY 512
ASSEMBLY 522
TRANSMISSION CLUTCH PACK 536
DISASSEMBLY OF FORWARD, REVERSE CLUTCH PACK 536
DISASSEMBLY OF 1ST, 3RD CLUTCH 539
ASSEMBLY (FORWARD, REVERSE CLUTCH PACK) 543
ASSEMBLY (1ST, 3RD CLUTCH PACK) 548
TRANSMISSION CONTROL VALVE 556
REMOVAL 556
INSTALLATION 558
DISASSEMBLY 561
ASSEMBLY 563
TRANSMISSION ACCUMULATOR VALVE 565
DISASSEMBLY 565
ASSEMBLY 566
DRIVE SHAFT 567
DISASSEMBLY 567
ASSEMBLY 570
FRONT AXLE 572
REMOVAL 572
INSTALLATION 574
REAR AXLE 575
REMOVAL 575
INSTALLATION 579
DIFFERENTIAL 580
DISASSEMBLY 580
ASSEMBLY 585
AXLE HOUSING ASSEMBLY 595
DISASSEMBLY 595
ASSEMBLY 602
CENTER HINGE PIN 612
REMOVAL 612
INSTALLATION 617
STEERING VALVE 622
REMOVAL 622
INSTALLATION 623
DISASSEMBLY 624
ASSEMBLY 629
ORBITROL VALVE (STEERING PILOT VALVE) 633
REMOVAL 633
INSTALLATION 635
DISASSEMBLY 636
ROTOR 636
CONTROL SIDE 637
ASSEMBLY 639
CONTROL SIDE 639
ROTOR 641
STEERING CYLINDER 644
REMOVAL 644
INSTALLATION 645
BRAKE VALVE 646
REMOVAL 646
INSTALLATION 647
RIGHT BRAKE VALVE (TANDEM) 648
DISASSEMBLY 648
ASSEMBLY 649
LEFT BRAKE VALVE (SINGLE) 650
DISASSEMBLY 650
ASSEMBLY 651
PARKING BRAKE DISC 652
REMOVAL 652
INSTALLATION 655
HYDRAULIC TANK 656
REMOVAL 656
INSTALLATION 658
HYDRAULIC FILTER 659
REMOVAL 659
INSTALLATION 659
HYDRAULIC, STEERING, SWITCH, PPC PUMP ASSEMBLY 660
REMOVAL 660
INSTALLATION 663
MAIN CONTROL VALVE 664
REMOVAL 664
INSTALLATION 667
DISASSEMBLY (2-SPOOL MAIN CONTROL VALVE) 669
ASSEMBLY 671
DISASSEMBLY (3-SPOOL MAIN CONTROL VALVE) 675
ASSEMBLY 677
PPC VALVE 681
REMOVAL 681
INSTALLATION 683
DISASSEMBLY 684
ASSEMBLY 685
BUCKET CYLINDER 686
REMOVAL 686
INSTALLATION 688
BOOM CYLINDER 689
REMOVAL 689
INSTALLATION 691
HYDRAULIC CYLINDERS STEERING, BOOM, AND BUCKET CYLINDERS) 692
DISASSEMBLY 692
ASSEMBLY 695
WORK EQUIPMENT 699
REMOVAL 699
INSTALLATION 703
COUNTERWEIGHT 706
REMOVAL 706
INSTALLATION 707
FUEL TANK 708
REMOVAL 708
INSTALLATION 711
CAB AND FLOOR FRAME ASSEMBLY 712
REMOVAL 712
INSTALLATION 715
CAB 716
REMOVAL 716
INSTALLATION 718
MAIN MOTOR 719
REMOVAL 719
INSTALLATION 720
MAINTENANCE MONITOR 721
REMOVAL 721
INSTALLATION 722
AIR CONDITIONER UNIT ASSEMBLY 723
REMOVAL 723
INSTALLATION 729
AIR CONDITIONER CONDENSER 730
REMOVAL 730
INSTALLATION 733
AIR CONDITIONER RECEIVER DRIER 734
REMOVAL 734
INSTALLATION 735
AIR CONDITIONER COMPRESSOR 736
REMOVAL 736
INSTALLATION 737
40 MAINTENANCE STANDARD 739
ENGINE MOUNT, TRANSMISSION MOUNT 741
TORQUE CONVERTER CHARGING PUMP 742
TORQUE CONVERTER 743
TRANSMISSION 744
FORWARD/REVERSE CLUTCH 749
1ST AND 3RD CLUTCH 751
2ND AND 4TH CLUTCH 752
TRANSMISSION CONTROL VALVE 753
UPPER VALVE 753
LOWER VALVE 755
FLOW CONTROL VALVE 757
ACCUMULATOR VALVE 758
DRIVE SHAFTS 759
DIFFERENTIAL (1/2) 760
DIFFERENTIAL (2/2) 761
LIMITED SLIP DIFFERENTIAL (OPTIONAL) 763
FINAL DRIVE 764
AXLE MOUNT 766
CENTER HINGE PIN 768
STEERING COLUMN 770
STEERING VALVE 771
STEERING CYLINDER MOUNT 772
DIVERTER VALVE 773
GROUND DRIVEN STEERING PUMP 775
BRAKE 776
BRAKE VALVE 777
BRAKE VALVE (LEFT) 777
BRAKE VALVE (RIGHT) 778
PARKING BRAKE 780
HYDRAULIC PUMP (HYDRAULIC, STEERING, SWITCH, PPC PUMP) 781
MAIN CONTROL VALVE 782
2-SPOOL VALVE 782
3-SPOOL VALVE (OPTIONAL) 784
PPC VALVE 786
HYDRAULIC CYLINDER 787
WORK EQUIPMENT LINKAGE 788
BUCKET 790
BUCKET POSITIONER AND BOOM KICK-OUT 791
90 OTHERS 793
ELECTRICAL CIRCUIT DIAGRAM (1 OF 4) 794
ELECTRICAL CIRCUIT DIAGRAM (2 OF 4) 795
ELECTRICAL CIRCUIT DIAGRAM (3 OF 4) 796
ELECTRICAL CIRCUIT DIAGRAM (4 OF 4) 797

DESCRIPTION:

Komatsu WA380-3MC Wheel Loader Shop Manual CEBM003402 – PDF DOWNLOAD

• MACHINE MODEL                SERIAL NUMBERS
• WA380-3MC                           A51001 and up

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 sections. These sections are further divided into 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.

G.B  16/12/24