Komatsu WA380-5 Wheel Loader Shop Manual SEBM024708 PDF DOWNLOAD

Description

Komatsu WA380-5 Wheel Loader Shop Manual SEBM024708  – PDF DOWNLOAD

FILE DETAILS:
Komatsu WA380-5 Wheel Loader Shop Manual SEBM024708  – PDF DOWNLOAD

Language : English
Pages : 1207
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu WA380-5 Wheel Loader Shop Manual SEBM024708  – PDF DOWNLOAD

 MACHINE MODEL            SERIAL NUMBER

• WA380-5                            60001 and up

MAIN MENU 0
COVER 1
CONTENTS . 2
SAFETY . 9
FOREWORD . 11
GENERAL 11
HOW TO READ THE SHOP MANUAL 12
HOISTING INSTRUCTIONS 13
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER . 14
COATING MATERIALS 16
STANDARD TIGHTENING TORQUE . 18
ELECTRIC WIRE CODE . 21
CONVERSION TABLES 22
UNITS 28
01 GENERAL . 29
GENERAL ASSEMBLY DRAWING . 30
SPECIFICATIONS . 31
WEIGHT TABLE . 35
LIST OF LUBRICANTS AND COOLANT . 37
10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD 39
COOLING SYSTEM . 40
ENGINE MOUNT, TRANSMISSION MOUNT . 41
POWER TRAIN 42
POWER TRAIN SYSTEM DIAGRAM . 43
DRIVE SHAFT (PROPELLER SHAFT) 46
TORQUE CONVERTER, TRANSMISSION PIPING 47
TORQUE CONVERER 48
TRANSMISSION . 56
TRANSMISSION CONTROL VALVE . 72
AXLE . 88
DIFFERENTIAL . 90
FINAL DRIVE 99
AXLE MOUNTING, CENTER HINGE PIN 102
STEERING PIPING 106
STEERING COLUMN, ORBIT-ROLL 107
STEERING VALVE . 108
ORBIT-ROLL VALVE . 123
STOP VALVE . 127
STEERING PUMP, SWITCH PUMP . 128
EMERGENCY STEERING PUMP (OP) . 130
EMERGENCY STEERING MOTOR (OP) 131
STEERING CYLINDER 132
JOYSTICK STEERING LEVER (OP) . 134
STEERING LEVER (OP) 135
STEERING SWITCH VALVE (OP) . 137
BRAKE PIPING . 138
BRAKE VALVE 140
CHARGE VALVE . 147
ACCUMULATOR (FOR BRAKE) 151
BRAKE 153
PARKING BRAKE CONTROL 158
PARKING BRAKE 159
PARKING BRAKE SOLENOID VALVE . 161
PARKING BRAKE EMERGENCY RELEASE VALVE 163
HYDRAULIC PIPING . 164
WORK EQUIPMENT CONTROL LEVER . 167
HYDRAULIC TANK . 169
TORQUE CONVERTER CHARGING, WORK EQUIPMENT, AND PILOT CONTROL PUMPS . 171
PPC RELIEF VALVE . 173
ECSS VALVE (OP) 175
WORK EQUIPMENT CONTROL VALVE . 177
WORK EQUIPMENT PPC VALVE . 194
PPC VALVE (FOR MULTI FUNCTION MONO LEVER) 200
EPC SOLENOID VALVE (OP) 206
SHUT OFF VALVE (OP) 209
ATTACHMENT PPC VALVE (OP) 210
COOLING FAN MOTOR 214
COOLING FAN MOTOR DRIVE PUMP . 219
WORK EQUIPMENT LINKAGE . 227
BUCKET . 229
BUCKET POSITIONER, LIFT ARM KICK-OUT . 230
WORK EQUIPMENT CYLINDER . 236
CAB . 237
AIR CONDITIONER (OP) . 238
MACHINE MONITORING SYSTEM 239
MACHINE MONITOR 246
TRANSMISSION CONTROL SYSTEM 314
TRANSMISSION CONTROLLER 342
WORK EQUIPMENT CONTROL SYSTEM (OP) . 344
WORK EQUIPMENT CONTROLLER 360
ELECTRIC TRANSMISSION CONTROL 362
KICK DOWN, HOLD SWITCH . 366
ENGINE STARTING CIRCUIT 367
ENGINE STOP CIRCUIT 369
PREHEATING CIRCUIT . 370
ENGINE POWER MODE SELECTOR CIRCUIT . 371
PARKING BRAKE CIRCUIT 372
SENSORS 376
20 TESTING AND ADJUSTING . 386
STANDARD VALUE TABLES 387
STANDARD VALUE TABLE FOR ENGINE . 387
STANDARD VALUE TABLE FOR CHASSIS . 388
TESTING AND ADJUSTING 396
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 397
MEASURING ENGINE SPEED . 398
MEASURING EXHAUST COLOR 400
MEASURING EXHAUST TEMPERATURE 401
ADJUSTING VALVE CLEARANCE 402
MEASURING COMPRESSION PRESSURE . 404
MEASURING BLOW-BY PRESSURE . 405
MEASURING ENGINE OIL PRESSURE 406
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) . 407
TESTING AND ADJUSTING FUEL INJECTION TIMING 408
ADJUSTING ENGINE SPEED SENSOR 409
BLEEDING AIR FROM FUEL CIRCUIT . 410
ADJUSTING ENGINE STOP SOLENOID . 411
ADJUSTING ACCELERATOR PEDAL 413
ADJUSTING TRANSMISSION SPEED SENSOR 415
TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE . 416
DRAWING OF SPECIAL TOOL 420
PROCEDURE FOR FLUSHING TORQUE CONVERTER, TRANSMISSION HYDRAULIC CIRCUIT 421
PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS . 422
TESTING AND ADJUSTING STEERING CONTROL . 424
TESTING AND ADJUSING STEERING OIL PRESSURE . 425
TESTING HYDRAULIC FAN 427
MEASURING BRAKE OIL PRESSURE . 428
TESTING WEAR OF WHEEL BRAKE DISC . 430
BLEEDING AIR FROM BRAKE CIRCUIT 431
TESTING WEAR OF PARKING BRAKE DISC . 432
MANUAL RELEASE METHOD FOR PARKING BRAKE 433
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE 434
TESTING AND ADJUSTING WORKING EQUIPMENT PPC OIL PRESSURE . 436
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE 438
TESTING AND ADJUSTING BUCKET POSITIONER 440
TESTING AND ADJUSTING LIFT ARM KICK-OUT 441
CHECKING PROXIMITY SWITCH ACTUATION PILOT LAMP . 442
ADJUSTING MACHINE MONITOR 443
TESTING AND ADJUSTING LOAD METER . 446
BLEEDING AIR . 450
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 451
RELEASING REMAINING PRESSURE IN TRAVEL DAMPER CIRCUIT 451
PM CLINIC INSPECTION TABLE . 452
TROUBLESHOOTING 454
POINTS TO REMEMBER WHEN TROUBLESHOOTING 455
SEQUENCE OF EVENTS IN TROUBLESHOOTING 456
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 457
CHECKS BEFORE TROUBLESHOOTING 465
EQUIPMENT FOR TROUBLESHOOTING ELECTRICAL SYSTEM 466
SPECIAL FUNCTIONS OF MACHINE MONITOR . 467
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS 502
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS . 511
T-ADAPTER TABLE 532
TROUBLESHOOTING TRANSMISSION CONTROL SYSTEM (TM MODE) 535
CONNECTOR TYPES AND MOUNTING LOCATIONS . 538
CONNECTOR LAYOUT DRAWING . 547
TRANSMISSION CONTROL SYSTEM DIAGRAM 553
ERROR CODE [1500L1] (DOUBLE ENGAGEMENT DETECTED) IS DISPLAYED 556
ERROR CODE [15SAL1] (F_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED . 557
ERROR CODE [15SALH] (F_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 558
ERROR CODE [15SBL1] (R_ECMV FILL SWITCH SSYTEM SHORT CIRCUITED) IS DISPLAYED . 559
ERROR CODE [15SBLH] (R_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 560
ERROR CODE [15SEL1] (1ST_ECMV FILL SWITCH SYSTEM SHORT -CIRCUITED) IS DISPLAYED 561
ERROR CODE [15SELH] (1ST_ECMV FILL SWTICH SYSTEM DISCONNECTED) IS DISPLAYED 562
ERROR CODE [15SFL1] (2ND_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED . 563
ERROR CODE [15SFLH] (2ND_ECMV FILL SWTICH SYSTEM DISCONNECTED) IS DISPLAYED 564
ERROR CODE [15SGL1] (3RD_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED . 565
ERROR CODE [15SGLH] (3RD_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 566
ERROR CODE [15SHL1] (4TH_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED . 567
ERROR CODE [15SHLH] (4TH_ECMV FILL SWTICH SYSTEM DISCONNECTED) IS DISPLAYED 568
ERROR CODE [15SJL1] (LOCKUP_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED 569
ERROR CODE [15SJLH] (LOCKUP_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED . 570
ERROR CODE [989F00] (TRANSMISSION PROTECTION CAUTION) IS DISPLAYED . 571
ERROR CODE [B@C7NS] (REAR BRAKE COOLING OIL OVERHEAT) IS DISPLAYED . 572
ERROR CODE [D150KA] (EMERGENCY STEERING RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED . 573
ERROR CODE [D150KB] (EMERGENCY STEERING RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED . 574
ERROR CODE [D160KA] (BACKUP LAMP RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED 575
ERROR CODE [D160KB] (BACKUP LAMP RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED 576
ERROR CODE [D191KA] (NEUTRAL SAFETY RELAY OUPUT SYSTEM DISCONNECTED) IS DISPLAYED 578
ERROR CODE [D191KB] (NEUTRAL SAFETY RELAY OUTPUT SYSTEM GROUNDED ) IS DISPLAYED 580
ERROR CODE [D192KA] (TRAVEL DAMPER RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED 582
ERROR CODE [D192KB] (TRAVEL DAMPER RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED 583
ERROR CODE [D198KB] (GROUND FAULT IN THE LOW TEMPERATURE BYPASS RELAY SYSTEM) IS DISPLAYED . 584
ERROR CODE [D198KY] (HOT-SHORT IN THE LOW TEMPERATURE BYPASS RELAY SYSTEM) IS DISPLAYED 585
ERROR CODE [DAQ0KK] (CONTROLLER POWER SUPPLY VOLTAGE LOWERED) IS DISPLAYED . 586
ERROR CODE [DAQ2KK] (DEFECTIVE SOLENOID POWER SUPPLY SYSTEM) IS DISPLAYED . 587
ERROR CODE [DAQ9KQ] (MODEL SELECTION SIGNAL MISMATCH) IS DISPLAYED . 588
ERROR CODE [DDK3KA] (RIGHT FNR SWITCH SIGNAL NOT INPUT) IS DISPLAYED . 590
ERROR CODE [DDK3KB] MULTIPLE RIGH FNR SWITCH SIGNAL INPUT) IS DISPLAYED 592
ERROR CODE [DDK4KA] (JOYSTICK FORWARD/REVERSE SWITCH SIGNAL IS NOT INPUT) IS DISPLAYED . 594
ERROR CODE [DDK4KB] (MULTIPLE JOYSTICK FORWARD/REVERSE SWITCH SIGNALS ARE INPUT) IS DISPLAYED 596
ERROR CODE [DDK5LD] (SHORT CIRCUIT WITH POWER SOURCE IN JOYSTICK SHIFT_UP/SHIFT_DOWN SWITCH) IS DISPLAYED 598
ERROR CODE [DDK6KA] (FORWARD-REVERSE LEVER SIGNAL NOT INPUT) IS DISPLAYED 599
ERROR CODE [DDK6KB] (MULTIPLE FORWARD-REVERSE LEVER SIGNAL OUTPUT) IS DISPLAYED 601
ERROR CODE [DDS5KA] (STEERING PRESSURE SWITCH DISCONNECTED) IS DISPLAYED . 603
ERROR CODE [DDS5KB] (STEERING PRESSURE SWITCH GROUNDED) IS DISPLAYED . 604
ERROR CODE [DDT0L4] (MANUAL/AUTO-SHIFT SELECTOR SWITCH SELECTION FAILURE) IS DISPLAYED . 605
ERROR CODE [DDT4LD] (GROUND FAULT OF TRANSMISSION CUT-OFF SETTING SWITCH) IS DISPLAYED . 607
ERROR CODE [DDW9LD] (GROUND FAULT OF KICKDOWN SWITCH SYSTEM) IS DISPLAYED 608
ERROR CODE [DDWLLD] (GROUND FAULT OF HOLD SWITCH SYSTEM) IS DISPLAYED 610
ERROR CODE [DF10KA] (NO INPUT OF GEAR SHIFT LEVER SIGNAL) IS DISPLAYED . 612
ERROR CODE [DF10KB] (INPUT OF MULTIPLE GEAR SHIFT LEVER SIGNALS) IS DISPLAYED 614
ERROR CODE [DGF1KX] (TRANSMISSION OIL TEMPERATURE SENSOR SYSTEM FAILURE) IS DISPLAYED 616
ERROR CODE [DGR2KA] (REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM DISCONNECTION) IS DISPLAYED 617
ERROR CODE [DGR2KB] (GROUND FAULT OF REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED 618
ERROR CODE [DHT1KX] TRANSMISSION CUT-OFF (LEFT BRAKE PRESSURE SENSOR SIGNAL DISCONTINUITY) IS DISPLAYED 619
ERROR CODE [DLE2KA] (ENGINE REVOLUTION SENSOR SYSTEM DISCONTINUITY) IS DISPLAYED . 620
ERROR CODE [DLE2LC] (ENGINE REVOLUTION SENSOR FAILURE) IS DISPLAYED 621
ERROR CODE [DLT3KA] (SPEED SENSOR (TRANSMISSION OUTPUT SHAFT REVOLUTION) SYSTEM DISCONTINUITY) IS DISPLAYED 622
ERROR CODE [DT20KB] (GROUND FAULT OF BUILT-IN INDICATOR LAMP SYSTEM OF TRANSMSSION CUT-OFF SWITCH) IS DISPLAYED 623
ERROR CODE [DW7BKA] (FAN PUMP REVERSE SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 624
ERROR CODE [DW7BKB] (FAN PUMP REVERSE SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED . 625
ERROR CODE [DW7CKA] (SWITCH PUMP CUT-OFF RELAY DISCONTINUITY) IS DISPLAYED . 626
ERROR CODE [DW7CKB] (SWITCH PUMP CUT-OFF RELAY GROUND FAULT) IS DISPLAYED 627
ERROR CODE [DX16KA] (FAN PUMP EPC SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 628
ERROR CODE [DX16KB] (FAN PUMP EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED . 629
ERROR CODE [DXH1KA] (LOCK-UP CLUTCH_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED . 630
ERROR CODE [DXH1KB] (LOCK-UP CLUTCH _ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED . 631
ERROR CODE [DXH4KA] (1ST_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 632
ERROR CODE [DXH4KB] (1ST_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED . 633
ERROR CODE [DXH5KA] (2ND_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 634
ERROR CODE [DXH5KB] (2ND_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED . 635
ERROR CODE [DXH6KA] (2ND_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED . 636
ERROR CODE [DXH6KB] (3RD_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 637
ERROR CODE [DXH7KA] (R_ECMV SOLENOID SSYTEM DISCONTINUITY) IS DISPLAYED 638
ERROR CODE [DXH7KB] (R_ECMV SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED . 639
ERROR CODE [DXH8KA] (F_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 640
ERROR CODE [DXH8KB] (F_ECMV SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED . 641
ERROR CODE [DXHHKA] (4TH_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 642
ERROR CODE [DXHHKB] (4TH_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED . 643
ERROR CODE [DY30MA] (MOTOR-DRIVEN EMERGENCY STEERING PUMP FAILURE (MALFUNCTION IN MANUAL MODE)) 644
ERROR CODE [DY30MC] (MOTOR-DRIVEN EMERGENCY STEERING PUMP FAILURE (MALFUNCTION IN MANUAL MODE)) 646
TROUBLESHOOTING CODE [TM-1] DISCONTINUITY OR HOT SHORT-CIRCUITING OF KICKDOWN SWITCH SYSTEM 648
TROUBLESHOOTING CODE [TM-2] HOLD SWITCH SYSTEM DISCONTINUITY OR HOT SHORT CIRCUITING . 650
TROUBLESHOOTING CODE [TM-3] TORQUE CONVERTER LOCK-UP SWITCH SYSTEM FAILURE . 652
TROUBLESHOOTING CODE [TM-4] NEUTRALIZER SIGNAL (PARKING BRAKE SWITCH SIGNAL) SYSTEM FAILURE 654
TROUBLESHOOTING CODE [TM-5] EMERGENCY STEERING SWITCH (MOTOR-DRIVEN EMERGENCY STEERING OPERATION SWITCH) SIGNAL SYSTEM FAILUR 656
TROUBLESHOOTING CODE [TM-6] TRANSMISSION CUT-OFF SWITCH SYSTEM DISCONTINUITY OR GROUND FAULT . 658
TROUBLESHOOTING CODE [TM-7] TRANSMISSION CUT-OFF SETTING SWITCH SYSTEM DISCONTINUITY OR HOT SHORT-CIRCUITING . 659
TROUBLESHOOTING CODE [TM-8] TRANSMISSION CUT-OFF (LEFT BRAKE SENSOR) SIGNAL SHORT-CIRCUITING . 660
TROUBLESHOOTING CODE [TM-9] JOYSTICK SHIFT_UP/SHIFT_DOWN SWITCH SYSTEM FAILURE (DISCONTINUITY OR GROUND FAULT) . 661
TROUBLESHOOTING CODE [TM-10-A] JOYSTICK ON/OFF CHANGE OVER SWITCH SYSTEM FAILURE . 662
TROUBLESHOOTING CODE [TM-10-B] STARTING SWITCH “C” (IGN_C) SIGNAL SYSTEM FAILURE . 664
TROUBLESHOOTING CODE [TM-11] FNR SWITCH MODE CHANGE OVER SWITCH SYSTEM FAILURE . 666
TROUBLESHOOTING CODE [TM-12] ENGINE POWER MODE SWITCH DICONTINUITY OR GROUND FAULT . 668
TROUBLESHOOTING CODE [TM-13] TRAVEL DAMPER ON/OFF SWITCH DISCONTINUITY OR GROUND FAULT . 669
TROUBLESHOOTING CODE [TM-14] HYDRAULIC FAN REVERSE SWITCH SIGNAL SYSTEM HOT SHORT-CIRCUITING OR DISCONTINUITY 670
TROUBLESHOOTING CODE [TM-15] MOTOR-DRIVEN EMERGENCY STEERING RELY OUTPUT SYSTEM HOT SHORT-CIRCUITING . 671
TROUBLESHOOTING CODE [TM-16] TRAVEL DAMPER RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING 672
TROUBLESHOOTING CODE [TM-17] SWITCH PUMP CUT-OFF RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING 673
TROUBLESHOOTING CODE [TM-18] BACK LAMP RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING 674
TROUBLESHOOTING CODE [TM-19] NEUTRAL OUTPUT SYSTEM HOT SHORT-CIRCUITING 675
TROUBLESHOOTING CODE [TM-20] FECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING 676
TROUBLESHOOTING CODE [TM-21] RECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING . 677
TROUBLESHOOTING CODE [TM-22] 1ST ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING . 678
TROUBLESHOOTING CODE [TM-23] 2ND ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING . 679
TROUBLESHOOTING CODE [TM-24] 3RD ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING . 680
TROUBLESHOOTING CODE [TM-25] 4TH ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING . 681
TROUBLESHOOTING CODE [TM-26] LOCK-UP ECMV SOLENOID SSYTEM HOT SHORT-CIRCUITING . 682
TROUBLESHOOTING CODE [TM-27] FAN PUMP EPC SOLENOID SYSTEM HOT SHORT-CIRCUITING . 683
TROUBLESHOOTING CODE [TM-28] FAN REVERSE SOLENOID SYSTEM HOT SHORT-CIRCUITING 684
TROUBLESHOOTING CODE [TM-29] SPEED SENSOR (TRANSMISSION OUTPUT SHAFT REVOLUTION) SYSTEM FAILURE 685
TROUBLESHOOTING OF WORK EQUIPMENT CONTROL SYSTEM (WORK MODE) . 687
CONNECTOR TYPES AND MOUNTING LOCATIONS . 690
CONNECTOR LAY OUT DRAWING 699
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM 705
ERROR CODE [D193KA] (DEFECTIVE JOYSTICK STEERING CUT RELAY SYSTEM (MAIN SYSTEM DISCONNECTED)) IS DISPLAYED . 708
ERROR CODE [D193KB] (THE JOYSTICK SOLENOID CUT RELAY OUTPUT SYSTEM IS GROUNDED PROPERLY) IS DISPLAYED . 709
ERROR CODE [DB90KK] (LOWERING WORK EQUIPMENT CONTROLLER POWER SUPPLY) IS DISPLAYED . 710
ERROR CODE [DB92KK] (DEFECTIVE SOLENOID ELECTRIC POWER SUPPLY SYSTEM) IS DISPLAYED . 711
ERROR CODE [DB95KX] (DEFECTIVE 5V ELECTRIC POWER SUPPLY SYSTEM) IS DISPLAYED . 713
ERROR CODE [DD1ALD] (DEFECTIVE REMOTE POSITIONER UP SET SWITCH (GROUND FAULT)) IS DISPLAYED 715
ERROR CODE [DD1BLD] (DEFECTIVE REMOTE POSITIONER DOWN SET SWITCH (GROUND FAULT)) IS DISPLAYED 716
ERROR CODE [DFA0KM] (DEFECTIVE NEUTRAL CAUTION FOR JOY STICK WORK EQUIPMENT LEVER) IS DISPLAYED 717
ERROR CODE [DK59KA] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPL 718
ERROR CODE [DK59KY] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (MAIN SHORT CIRCUIT)) IS DISPLAYED 719
ERROR CODE [DK59L8] (DEFECTIVE LIFT ARM EPC POTENTIOMETER SYSTEM (DISPLACEMENT OF MAIN AND SUB-CIRCUIT) IS DISPLAYED . 720
ERROR CODE [DK5AKA] (DEFECTIVE LIFT ARM EPC LEVER POTENTOIMETER SYSTEM (DISCONNECTION OF MAIN)(DISCONNECTION, GROUND OF SUB)) 721
ERROR CODE [DK5AKY] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED . 722
ERROR CODE [DK5BKA] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLA 723
ERROR CODE [DK5BKY] (DEFECTIVE BUCKT EPC LEVER POTENTIOMETER SYSTEM (MAIN SHORTED)) IS DISPLAYED . 724
ERROR CODE [DK5BL8] (DEFECTIVE INPUT SIGNAL FOR BUCKET EPC LEVER POTENTIOMETER SYSTEM(DISPLACEMENT OF MAIN AND SUB-CIRCUIT)) 725
ERROR CODE [DK5CKA] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (SUB-CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYE 726
ERROR CODE [DK5CKY] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED . 727
ERROR CODE [DK5DKA] (DEFECTIVE 3RD VALVE LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISONTINUITY OR GROUND FAULT)) IS DISPLAYED 728
ERROR CODE [DK5DKY] (DEFECTIVE 3RD VALVE LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT SHORT CIRCUIT)) IS DISPLAYED . 729
ERROR CODE [DK5DL8] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM INPUT SIGNAL (DISPLACEMENT OF MAIN AND SUB-CIRCUIT)) 730
ERROR CODE [DK5EKA] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM (SUB-CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISP 731
ERROR CODE [DK5EKY] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED . 732
ERROR CODE [DK5FKA] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) 733
ERROR CODE [DK5DKY] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT SHORTED)) IS DISPLAYED . 734
ERROR CODE [DK5FKM] (JOYSTICK STEERING EPC LEVER NEUTRAL SYSTEM CAUTION) IS DISPLAYED 735
ERROR CODE [DK5FL8] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM INPUT SIGNAL (DEVIATION OF POSITIONAL SIGNALS 736
ERROR CODE [DK5GKA] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OR GROUND FAULT OF SUB-CIRCUIT 737
ERROR CODE [DK5GKY] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (SUB-CIRCUIT SHORT CIRCUIT)) IS DISPLAYED 738
ERROR CODE [DKA0KA] (DEFECTIVE LIFT ARM ANGLE SENSOR SYSTEM (DISCONNECTION OR GROUND FAULT)) IS DISPLAYED . 739
ERROR CODE [DKA0KY] (DEFECTIVE LIFT ARM ANGLE SENSOR SYSTEM (SHORT CIRCUIT)) IS DISPLAYED 740
ERROR CODE [DLE2LC] (DEFECTIVE ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED 741
ERROR CODE [DLT3LC] (DEFECTIVE ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED 742
ERROR CODE [DUM1KB] (REMOTE POSITIONER RAISE LAMP SYSTEM GROUND FAULT) IS DISPLAYED . 743
ERROR CODE [DUM2KB] (REMOTE POSITIONER LOWER LAMP SYSTEM GROUND FAULT) IS DISPLAYED 744
ERROR CODE [DW4PKA] (DISCONNECTED LIFT ARM RAISE EPC SOLENOID SYSTEM) IS DISPLAYED . 745
ERROR CODE [DW4PKB] (LIFT ARM RAISE EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED . 746
ERROR CODE [DW4QKA] (DISCONNECTED LIFT ARM LOWER EPC SOLENOID SYSTEM) IS DISPLAYED . 747
ERROR CODE [DW4QKB] (LIFT ARM LOWER EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED . 748
ERROR CODE [DW4RKA] 9DISCONNECTED BUCKET TILT EPC SOLENOID SYSTEM) IS DISPLAYED 749
ERROR CODE [DW4RKB] (BUCKET TILT EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 750
ERROR CODE [DW4SKA] (BUCKET DUMP EPC SOLENOID SYSTEM DISCONNECTION0 IS DISPLAYED . 751
ERROR CODE [DW4SKB] (BUCKET DUMP EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 752
ERROR CODE [DWM1KA] (WORK EQUIPMENT NEUTRAL LOCK SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED . 753
ERROR CODE [DWM1KB] (WORK EQUIPMENT 754
ERROR CODE [DWN6KA] (LIFT ARM RAISE MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED 755
ERROR CODE [DWN6KB] (LIFT ARM RAISE MAGNET DETENT SYSTEM GROUND FAULT) IS DISPLAYED 756
ERROR CODE [DWN7KA] (LIFT ARM FLOATING MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED 757
ERROR CODE [DWN7KB] (LIFT ARM FLOATING MAGNET DETENT SYSTEM GROUND FAULT) IS DISPLAYED . 758
ERROR CODE [DWN8KA] BUCKET TILT MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED . 759
ERROR CODE [DWN8KB] (BUCKET TILT MAGNET DETENT SYSTEM FAILURE (POWER SUPPLY SYSTEM GROUND FAULT)) IS DISPLAYED . 760
ERROR CODE [DXHJKA] (3RD VALVE EXTENSION EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED . 761
ERROR CODE [DXHJKB] (3RD VALVE EXTENSION EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 762
ERROR CODE [DXHKKA] (3RD VALVE RETRACTION EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED 763
ERROR CODE [DXHKKB] (3RD VALVE RETRACTION EPC SOLENOID SYSTEM 764
ERROR CODE [DXHLKA] (JOYSTICK STEERING RIGHT-HAND EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED 765
ERROR CODE [DXHLKB] (JOYSTICK STEERING RIGH-HAND EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 766
ERROR CODE [DXHMKA] (JOYSTICK STEERING LEFT-HAND EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED . 767
ERROR CODE [DXHMKB] (JOYSTICK STEERING LEFT-HAND EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 768
TROUBLESHOOTING CODE [WRK-1] DEFECTIVE LIFT ARM LOCK SWITCH SYSTEM . 769
TROUBLESHOOTING CODE [WRK-2] DEFECTIVE REMOT POSITIONER RAISE SETTINGS SWITCH SYSTEM . 770
TROUBLESHOOTING CODE [WRK-3] DEFECTIVE REMOTE POSITIONER LOWER SETTING SWITCH SYSTEM . 771
TROUBLESHOOTING CODE [WRK-4] DEFECTIVE REMOTE POSITIONER RAISE SELECTIONSWITCH SYSTEM 773
TROUBLESHOOTING CODE [WRK-5] DEFECTIVE REMOTE POSITIONER LOWER ON/OFF SWITCH SYSTEM 775
TROUBLESHOOTING CODE [WRK-6] DEFECTIVE BUCKET CYLINDER PROXIMITY SWITCH SYSTEM . 777
TROUBLESHOOTING CODE [WRK-7] DEFECTIVE BUCKET CYLINDER FULL STROKE DETECTIONSWITCH SYSTEM 779
TROUBLESHOOTING CODE [WRK-8] DEFECTIVE SEMI-AUTOMATIC DIGGING AHRD SELECTION SWITCH SYSTEM . 780
TROUBLESHOOTING CODE [WRK-9] DEFECTIVE SEMI-AUTOMATIC DIGGING SOFT SELECTION SWTICH SYSTEM . 781
TROUBLESHOOTING CODE [WRK-10] DEFECTIVE JOYSTICK ON/OFF SWITCH SYSTEM 783
TROUBLESHOOTING CODE [WRK-11] DEFECTIVE JOYSTICK STEERING SPEED HI/LO SWITCH SYSTEM 785
TROUBLESHOOTING CODE [WRK-12] DEFECTIVE JOYSTICK SOLENOID CUT RELAY OUPUT SYSTEM . 786
TROUBLESHOOTING CODE [WRK-13] HOT SHORT-CIRCUITED LIFT ARM RAISE MAGNET DETENT OUTPUT SYSTEM . 787
TROUBLESHOOTING CODE [WRK-14] HOT SHORT -CIRCUITED LIFT ARM FLOATING MAGNET DETENT OUTPUT SYSTEM . 788
TROUBLESHOOTING CODE [WRK-15] HOT-SHORT CIRCUITED BUCKET TILT MAGNET DETENT OUTPUT SYSTEM 789
TROUBLESHOOTING CODE [WRK-16] HOT SHORT-CIRCUITED WORK EQUIPMETN NEUTRAL LOCK SOLENOID OUTPUT SYSTEM . 790
TROUBLESHOOTING CODE [WRK-17] HOT SHORT-CIRCUITED LIFT ARM RAISE EPC SOLENOID SYSTEM . 791
TROUBLESHOOTING CODE [WRK-18] HOT SHORT-CIRCUITED LIFT ARM LOWER EPC SOLENOID SYSTEM . 792
TROUBLESHOOTING CODE [WRK-19] HOT SHORT-CIRCUITED BUCKET TILT EPC SOLENOID SYSTEM 793
TROUBLESHOOTING CODE [WRK-20] HOT SHORT-CIRCUITED BUCKET DUMP EPC SOLENOID SYSTEM 794
TROUBLESHOOTING CODE [WRK-21] HOT SHORT-CIRCUITED 3 VALVES EXTENSION EPC SOLENOID SYSTEM . 795
TROUBLESHOOTING CODE [WRK-22] HOT SHORT-CIRCUITED 3 VALVES RETRACTION EPC SOLENOID SYSTEM 796
TROUBLESHOOTING CODE [WRK-23] HOT SHORT-CIRCUITED JOY STICK STEERING RIGH EPC SOLENOID SYSTEM 797
TROUBLESHOOTING CODE [WRK-24] HOT SHORT-CIRCUITED JOYSTICK STEERING LEFT EPC SOLENOID SYSTEM . 798
TROUBLESHOOTING CODE [WRK-25] DEFECTIVE BUCKET POSITIONER, LIFT ARM KICK-OUT AND FLOATING HOLDING FUNCTION . 799
TROUBLESHOOTING CODE [WRK-26] DEFECTIVE LIFT ARM KICK-OUT FUNCTION AND CANCELLATION 801
TROUBLESHOOTING CODE [WRK-27] DEFECTIVE BUCKET LEVELER FUNCTION AND CANCELLATION . 803
TROUBLESHOOTING CODE [WRK-28] DEFECTIVE LIFT ARM FLOATING HOLDING AND CANCELLATION . 805
TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE) . 808
CONNECTOR TYPES AND MOUNTING LOCATION 810
CONNECTOR LAYOUT DRAWING . 819
MONITOR SYSTEM DIAGRAM . 825
ERROR CODE [2F00KM] DRAGGING OF PARKING BRAKE 829
ERROR CODE [2G42ZG] ACCUMULATOR OIL PRSSURE (FRONT CIRCUIT) LOW 831
ERROR CODE [2G43ZG] ACCUMULATOR OIL PRESSURE (REAR BRAKE CIRCUIT LOW . 832
ERROR CODE [AA1ANX] AIR CLEANER 1 CLOGGED 833
ERROR CODE [AB00L6] DEFECTIVE BATTERY CHARGING CIRCUIT (ALTERNATOR TERMINAL R SIGNAL DETECTED WHEN ENGINE STOPPED . 835
ERROR CODE [AB00MA] DEFECTIVE BATTERY CHARGING CIRCUIT (NO ALTERNATOR TERMINAL R SIGNAL DETECTED, DETECTION FAILURE) . 836
ERROR CODE [B@BAZG] ENGINE OIL PRESSURE LOW 837
ERROR CODE [B@BAZK] ENGINE OIL LEVEL LOW . 838
ERROR CODE [B@BCNS] ENGINE WATER TEMPERATURE OVERHEATING . 839
ERROR CODE [B@BCZK] ALARM INDICATIONG LOW COOLANT LEVEL 840
ERROR CODE [B@HANS] HYDRAULIC OIL TEMPERATURE OVERHEATING 841
ERROR CODE [B@CENS] TORQUE CONVERTER OIL TEMPERATURE OVERHEATING . 842
ERROR CODE [D182KZ] THE PREHEATER RELAY COL IS DISCONNECTED OR SHORT-CIRCUITED . 843
ERROR CODE [D5ZHL6] STARTING SWITCH C (IGN “C”) INPUT FAILURE 845
ERROR CODE [DA80L4] AUTO GREASE INPUT FAILURE 846
ERROR CODE [DAF3KK] SW POWER SUPPLY (FOR OPERATION) = ON AND NSW POWER SUPPLY (FOR MEMORY)=OFF . 847
ERROR CODE [DAF5KP] 5-V POWER SUPPLY OUTPUT FAILURE 849
ERROR CODE [DAF6KP] 24-V POWER SUPPLY OUTPUT FAILURE . 851
ERROR CODE [DAFBKM] WRONG INFOMRAITON ON MODEL SELECTION . 853
ERROR CODE [DAFSKQ] WRONG INFORMATION ON METER DISPLAY SELECTION . 854
ERROR CODE [DAQSKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND TRANSMISSION CONTROLLER) 855
ERROR CODE [DB2SKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND ENGINE CONTROLLER) 856
ERROR CODE [DBQSKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER) 857
ERROR CODE [DB9SKR] S-NET COMMUNICATION FAILRUE (BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER) . 858
ERROR CODE [DD15LD] MONITOR PANEL MODE SELECTRO SWITCH 1[ ] (PANEL SW1) INPUT ERROR 859
ERROR CODE [DD16LD] MONITOR PANEL MODE SELECTOR SWITCH 1 [.] (PANEL SW2) INPUT ERROR . 860
ERROR CODE [DD17LD] THE MONITOR PANEL MODE SELECTRO SWITCH 2[<] (PANEL SW3] INPUT CIRCUIT REMAINS CLOSED FOR MORE THAN ONE MI 861
ERROR CODE [DD18LD] MONITOR PANEL MODE SELECTRO SWITCH 2 [>] (PANEL SW 4) INPUT ERROR CODE . 862
ERROR CODE [DD1CLD] SUB-TOTAL SWITCH FAILURE . 863
ERROR CODE [DDK3KM] RIGHT FNR SWITCH IS IN N (NEUTRAL) . 864
ERROR CODE[DDK4KM] JOYSTICK FNR SWITCH IS IN N (NEUTRAL) . 865
ERROR CODE [DDK6KM] FNR (FORWARD-REVERSE) LEVER SWITCH IS IN N (NEUTRAL) . 866
ERROR CODE [DDS5L6] DECREASED STEERING OIL PRESSURE 867
ERROR CODE [DDY0LD] CANCEL SWITCH FAILURE 868
ERROR CODE [DGE2KX] ENGINE WATER TEMPERATURE SENSOR SYSTEM FAILURE . 869
ERROR CODE [DGE3L6] ABNORMAL CONNECTION OF ENGINE WATER TEMPERATURE (LOW TEMPERATURE) SENSOR SYSTEM 870
ERROR CODE [DGH2KX] HYRAULIC OIL TEMPERATURE SENSOR SYSTEM FAILURE . 871
ERROR CODE [DGT1KX] TORQUE CONVERTER OIL TEMPERTURE SENSOR SYSTEM FAILURE 872
ERROR CODE [DHE4L6] ENGINE OIL PRESSURE SENSOR SYSTEM FAILURE1 [.] . 873
ERROR CODE [DHPCKX] BOTTOM PRESSURE SENSOR FAILURE . 875
ERROR CODE [DHPDKX] HEAD PRESSURE SENSOR FAILURE . 877
ERROR CODE [DKA0KX] LIFT ARM ANGLE SENSOR FAILURE 879
ERROR CODE [DV00KB] SHORT-CIRCUITED ALARM BUZZER OUTPUT SYSTEM . 880
ERROR CODE [DY30ME] THE EMERGENCY STEERING REMAINS ACTUATED FOR MORE THAN ONE MINUTE . 881
TROUBLESHOOTING CODE [MON-1] THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT UP WHEN PARKING BRAKE SWITCH IS TURNED ON (THE P 883
TROUBLESHOOTING CODE [MON-2] THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (FRONT 885
TROUBLESHOOTING CODE [MON-3] THE BRAKE OIIL PRESSURE CAUTIONLAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (REAR 886
TROUBLESHOOTING CODE [MON-4] THE AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT ON 887
TROUBLESHOOTING CODE [MON-5] THE ENGINE HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON . 889
TROUBLESHOOTING CODE [MON-6] THE ENGINE OIL LEVEL CAUTION LAMP DOES NOT LIGHT ON . 890
TROUBLESHOOTING CODE [MON-7] THE ENGINE WATER TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON . 891
TROUBLESHOOTING CODE [MON-8] THE RADIATOR WATER VOLUME CAUTION LAMP DOES NOT LIGHT ON 892
TROUBLESHOOTING CODE [MON-9] THE HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON 893
TROUBLESHOOTING CODE [MON-10] THE TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON 894
TROUBLESHOOTING CODE [MON-11] THE STEERING HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON 895
TROUBLESHOOTING CODE [MON-12] INPUT FAOULT IN MONITOR PANEL MODE SWITCH 1 [ ] (PANEL SW1) 896
TROUBLESHOOTING CODE [MON-13] INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 [ ] (PANEL SW2) . 897
TROUBLESHOOTING CODE [MON-14] INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 [<] (PANEL SW3) . 898
TROUBLESHOOTING CODE [MON-15] INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 [>] (PANEL SW4) . 899
TROUBLESHOOTING CODE [MON-16] DEFECTIVE SUBTOTAL SWITCH 900
TROUBLESHOOTING CODE [MON-17] DEFECTIVE CANCEL SWITCH 901
TROUBLESHOOTING CODE [MON-18] DEFECTIVE BOTTOM PRESSURE SENSOR (HOT SHORT FAULT) . 902
TROUBLESHOOTING CODE [MON-19] DEFECTIVE HEAD SENSOR 903
TROUBLESHOOTING CODE [MON-20] THE ALARM BUZZER DOES NOT SOUND OR STOP (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN 904
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) . 906
H-1 THE MACHINE DOES NOT START . 907
H-2 THE LOCK-UP CLUTCH IS NOT RELEASED (THE ENGINE STOPS) (WHEN THE LOCK-UP CLUTCH IS PROVIDED) 909
H-3 A. THE TRAVEL SPEED IS SLOW, THE THRUSTING FORCE IS WEAK, THE UPHILL TRAVELLING POWER IS WEAK, AND THE GEAR IS NOT SHIFTE 910
H-3 B. THE TORQUE CONVERTER LOCK-UP CLUTCH IS NOT LET IN (WHEN THE LOCK-UP CLUTCH IS PROVIDED) . 912
H-4 SHOCKS ARE LARGE AT THE TIME OF STARTING AND SHIFTING GEAR . 913
H-5 TIME LAG IS LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR . 915
H-6 THE TORQUE CONVERTER OIL TEMPERATURE IS HIGH . 917
H-7 STEERING WHEEL DOES NOT TURN . 918
H-8 THE STEERING WHEEL IS HEAVY 919
H-9 THE STEERING WHEEL FLUCTUATES OR IS STRONGLY SHOCKED . 920
H-10 THE MACHINE STEERS TO ONE SIDE WHEN TRAVELING . 920
H-11 THE RIGHT AND LEFT SWING RADII ARE DIFFERENT 920
H-12 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL . 921
H-13 THE BRAKE IS NOT RELEASE OR IS DRAGGED 922
H-14 THE BRAKE IS NOT RELEASED OR DRAGGED 923
H-15 THE LIFT ARM DOES NOT RISE 924
H-16 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT 925
H-17 WHEN RISING, THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT . 926
H-18 THE LIFT ARM CYLINDER CONNOT HOLD DOWN THE BUCKET (THE BUCKET RISES IN THE AIR) . 926
H-19 HYDRAULIC DRIFTS OF THE BOOM OCCUR OFTEN 926
H-20 THE LIFT ARM WOBBLES DURING OPERATION . 926
H-21 WHEN THE CONTROL LEVER IS SWITCHED FROM “HOLD” TO “RAISE,” THE LIFT ARM FALLS TEMPORARILY . 927
H-22 THE BUCKET DOES NOT TILT BACK . 928
H-23 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT . 929
H-24 THE BUCKET COMES TO OPERATE SLOWLY IN THE MIDST OF TILTING-BACK 930
H-25 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET . 930
H-26 HYDRAULIC DRIFT OF THE BUCKET OCCUR OFTEN . 930
H-27 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVE IS SET TO “HOLD”) . 931
H-28 WHEN THE CONTROL LEVER IS SWITCHED FROM “HOLD” TO “TILT,” THE BUCKET FALLS TEMPORARILY 931
H-29 THE CONTROL LEVERS OF LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY 932
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 934
CONNECTOR TYPES AND MOUNTING LOCATIONS . 936
CONNECTOR LAYOUT DRAWING . 945
ELECTRICAL SYSTEM DIAGRAM 951
ACTION CODE [E-1-A] (THE ENGINE DOES NOT START. (STARTING SYSTEM)) . 953
ACTION CODE [E-1-B] (THE ENGINE DOES NOT START. (ENGINE STOP SOLENOID SYSTEM)) . 957
ACTION CODE [E-2] (THE ENGINE DOES NOT STOP) . 959
ACTION CODE [E-3] (PREHEATING IS IMPOSSIBLE OR CONSTANT) . 961
ACTION CODE [E-4] (THE ENGINE POWER MODES CANNOT BE SELECTED) 963
ACTION CODE [E-5] (ALL OF THE BUCKET POSITIONER, LIFT ARM KICK-OUT, AND FLOATING HOLDER DO NOT FUNCTION) . 965
ACTION CODE [E-6] (THE LIFT ARM KICK-OUT DOES NOT FUNCTION OR CANNOT BE RELEASED) 968
ACTION CODE [E-7] (THE BUCKET POSITIONER DOES NOT FUNCTION OR CANNOT BE RELEASED) 969
ACTION CODE [E-8] (THE LIFT ARM FLOATING HOLDER DOES NOT FUNCTION OR CANNOT BE RELASED) 970
ACTION CODE [E-9] (THE FRONT WIPER DOES NOT FUNCTION) 973
ACTION CODE [E-10] (THE REAR WIPER DOES NOT FUCTION) . 976
ACTION CODE [E-11] (THE SIDE WIPER DOES NOT FUNCTION (OPT)) 978
ACTION CODE [E-12] (THE WINDOW WASHER DOES NOT FUNCTION) . 979
ACTION CODE [E-13] (THE HEADLAMP (LO BEAM) DOES NOT LIGHT ON) 981
ACTION CODE [E-14] (THE HEADLAMP (HI BEAM) DOES NOT FUNCTON) . 983
TROUBLESHOOTING OF ENGINE (S-MODE) . 986
METHOD OF USING TROUBLESHOOTING CHARTS . 987
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 991
S-2 ENGINE DOES NOT START 992
(1) ENGINE DOES NOT TURN . 992
(2) ENGINE TURNS BUT NOT EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED) 993
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) . 994
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) . 995
S-4 ENGINE STOPS DURING OPERATIONS . 996
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 997
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) . 998
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) . 999
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 1000
S-9 OIL BECOMES CONTAMINATED QUICKLY .1001
S-10 FUEL CONSUMPTION IS EXCESSIVE .1002
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN .1003
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 1004
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL) 1005
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 1006
S-15 ABNORMAL NOISE IS MADE 1007
S-16 VIBRATION IS EXCESSIVE 1008
30 DISASSEMBLY AND ASSEMBLY 1010
METHOD OF USING MANUAL .1011
PRECAUTIONS WHEN CARRYING OUT OPERATION 1012
SPECIAL TOOL LIST 1015
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY 1018
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY .1022
REMOVAL AND INSTALLATION OF RADIATOR AND FAN MOTOR ASSEMBLY 1027
REMOVAL AND INSTALLATIONOF AFTERCOOLER ASSEMBLY 1029
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP 1029
REMOVAL AND INSTALLATION OF NOZZLE HOLDER ASSEMLBY .1032
REMOVAL AND INSTALLATION OF FAN AND FAN MOTOR ASSEMBLY .1034
REMOVAL AND INSTALLATIONOF FUEL TANK ASSEMBLY 1035
REMOVAL AND INSTALLATION OF PARKING BRAKE DISC PLATE .1037
REMOVAL AND INSTALLATION OF TORQUE CONVERER AND TRANSMISSION ASSEMBLY 1041
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMLBY 1045
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH PACK ASSEMBLY 1058
DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ASSEMBLY .1073
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY (STANDARD SPECIFICATION) .1084
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMLBY (LOCK-UP SPECIFICATION) 1088
REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY .1094
REMOVAL AND INSTALLATION OF FRONT AXLE ASSEMBLY 1097
DISASSEMBLY AND ASSEMBLY OF AXLE HOUSING ASSEMBLY 1098
DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY 1108
REMOVAL AND INSTALLATION OF CENTER HINGE PIN .1124
REMOVAL AND INSTALLATION OF CAB ASSEMBLY .1131
REMOVAL AND INSTALLATIONOF CAB AND FLOOR FRAME ASSEMBLY 1132
REMOVAL AND INSTALLATION OF TRANSMISSION, WORK EQUIPMENT, AND PPC PUMP ASSEMBLY 1135
REMOVAL AND INSTALLATION OF STEERING, SWITCHING, AND FAN PUMP ASSEMBLY .1136
REMOVAL AND INSTALLATION OF STEERING DEMAND VALVE ASSEMBLY .1137
REMOVAL AND INSTALLATIONOF TRAVEL DUMPER VALVE ASSEMBLY 1138
REMOVAL AND INSTALLATION OF WORK EQUIPMENT VALVE ASSEMBLY 1139
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY (STEERING, LIFT, AND BUCKET CYLINDER ASSEMBLY) .1141
REMOVAL AND INSTALLATIONOF HYDRAULIC TANK ASSEMBLY .1148
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY 1150
REMOVAL AND INSTALLATION OF COUNTER WEIGHT .1154
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT .1155
REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY 1158
DISASSEMBLY, ASSEMBLY OF OPERATORS SEAT ASSEMBLY .1159
90 OTHERS .1169
POWER TRAIN OIL CIRCUIT DIAGRAM (WITHOUT TORQUE CONVERTER LOCKUP CLUTCH) .1171
POWER TRAIN OIL CIRCUIT DIAGRAM (WITH TORQUE CONVERTER LOCKUP CLUTCH) 1173
BRAKE OIL CIRCUIT DIAGRAM 1175
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM .1176
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (FOR ELECTRIC WORK EQUIPMENT LEVER) .1178
ELECTRICAL CIRCUIT DIAGRAM 1180
1/8 (1/4) 1180
1/8 (2/4) 1182
1/8 (3/4) 1184
1/8 (4/4) 1186
2/8 (1/4) 1188
2/8 (2/4) 1190
2/8 (3/4) 1192
2/8 (4/4) 1194
(3/8) 1196
(4/8) 1198
(5/8) 1200
(6/8) 1202
(7/8) 1204
(8/8) 1206

DESCRIPTION:

Komatsu WA380-5 Wheel Loader Shop Manual SEBM024708  – PDF DOWNLOAD

 MACHINE MODEL            SERIAL NUMBER

• WA380-5                            60001 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 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.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
standards.
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” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component,
as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.

G.B 29/12/24