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Komatsu WA380-5H Wheel Loader Shop Manual (PART I) VEBM920100 – PDF DOWNLOAD
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Komatsu WA380-5H Wheel Loader Shop Manual
MODEL SERIAL NUMBER
WA380-5H WA380H50051
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Description
Komatsu WA380-5H Wheel Loader Shop Manual (PART I)
FILE DETAILS:
Komatsu WA380-5H Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual (PART I)
Machine Model: WA380-5H
Serial Number: WA380H50051 and up
Book Code: VEBM920100
Language: English
Pages: 1170
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA380-5H Wheel Loader Shop Manual
FOREWORD:
General :
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accu- rate 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 work- shop. 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 under- standing 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 compo- nent, 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.
Others:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. in addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu WA380-5H Wheel Loader Shop Manual
WA380-5H............................................................................ 1 CONTENTS............................................................................ 2 00 SAFETY........................................................................... 3 SAFETY NOTICE................................................................... 3 FOREWORD........................................................................ 5 HOW TO READ THE SHOP MANUAL..................................................... 6 HOISTING INSTRUCTIONS........................................................... 7 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER...................... 8 COATING MATERIALS............................................................... 10 STANDARD TIGHTENING TORQUE...................................................... 12 ELECTRIC WIRE CODE.............................................................. 15 CONVERSION TABLE................................................................ 16 UNITS........................................................................... 22 01 GENERAL.......................................................................... 23 GENERAL ASSEMBLY DRAWING........................................................ 24 SPECIFICATIONS.................................................................. 25 WEIGHT TABLE.................................................................... 29 LIST OF LUBRICANT AND COOLANT................................................... 31 10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD..................................... 33 COOLING SYSTEM.................................................................. 34 ENGINE MOUNT, TRANSMISSION MOUNT................................................ 35 POWER TRAIN..................................................................... 36 POWER TRAIN SYSTEM DIAGRAM...................................................... 37 DRIVE SHAFT (PROPELLER SHAFT)................................................... 40 TORQUE CONVERTER, TRANSMISSION PIPING........................................... 41 TORQUE CONVERTER................................................................ 42 Without lock-up clutch...................................................... 42 With lock-up clutch......................................................... 45 TRANSMISSION.................................................................... 50 TRANSMISSION CONTROL VALVE...................................................... 66 AXLE............................................................................ 80 FRONT AXLE.................................................................. 80 REAR AXLE................................................................... 81 DIFFERENTIAL.................................................................... 82 FRONT DIFFERENTIAL.......................................................... 82 REAR DIFFERENTIAL........................................................... 83 ANTI-SLIP DIFFERENTIAL...................................................... 86 FINAL DRIVE..................................................................... 91 AXLE MOUNTING, CENTER HINGE PIN................................................. 94 STEERING PIPING................................................................. 98 STEERING COLUMN, ORBIT-ROLL..................................................... 99 STEERING VALVE.................................................................. 100 ORBIT-ROLL VALVE................................................................ 115 STOP VALVE...................................................................... 119 STEERING PUMP, SWITCH PUMP...................................................... 120 EMERGENCY STEERING PUMP (OP).................................................... 122 EMERGENCY STEERING MOTOR (OP)................................................... 123 STEERING CYLINDER............................................................... 124 JOYSTICK STEERING LEVER (OP).................................................... 126 STEERING LEVER (OP)............................................................. 127 STEERING SWITCH VALVE (OP)...................................................... 129 BRAKE PIPING.................................................................... 130 BRAKE VALVE..................................................................... 132 CHARGE VALVE.................................................................... 139 ACCUMULATOR (FOR BRAKE)......................................................... 143 BRAKE........................................................................... 145 PARKING BRAKE CONTROL........................................................... 150 PARKING BRAKE................................................................... 151 PARKING BRAKE SOLENOID VALVE.................................................... 153 PARKING BRAKE EMERGENCY RELEASE VALVE........................................... 155 HYDRAULIC PIPING................................................................ 156 WORK EQUIPMENT CONTROL LEVER.................................................... 159 HYDRAULIC TANK.................................................................. 161 TORQUE CONVERTER CHARGING, WORK EQUIPMENT, AND PILOT CONTROL PUMPS.............. 163 PPC RELIEF VALVE................................................................ 165 TRAVEL DAMPER VALVE (OP)........................................................ 167 WORK EQUIPMENT CONTROL VALVE.................................................... 169 WORK EQUIPMENT PPC VALVE........................................................ 186 EPC SOLENOID VALVE (OP)......................................................... 192 SHUT OFF VALVE (OP)............................................................. 195 ATTACHMENT PPC VALVE (OP)....................................................... 196 COOLING FAN MOTOR............................................................... 200 COOLING FAN MOTOR DRIVE PUMP.................................................... 205 WORK EQUIPMENT LINKAGE.......................................................... 213 BUCKET.......................................................................... 215 BUCKET POSITIONER, LIFT ARM KICK-OUT............................................ 216 WORK EQUIPMENT CYLINDER......................................................... 222 CAB (OP)........................................................................ 223 AIR CONDITIONER (OP)............................................................ 224 MACHINE MONITORING SYSTEM....................................................... 225 MACHINE MONITOR................................................................. 232 SPEED METER SPECIFICATIONS.................................................. 232 LOAD METER SPECIFICATION (OPTION)........................................... 233 TABLE OF MONITOR INDICATION ITEMS........................................... 234 SETTING OF THE MACHINE MONITOR.............................................. 239 TRANSMISSION CONTROL SYSTEM..................................................... 292 TRANSMISSION CONTROLLER......................................................... 316 WORK EQUIPMENT CONTROL SYSTEM (OP).............................................. 318 WORK EQUIPMENT CONTROLLER....................................................... 334 ELECTRIC TRANSMISSION CONTROL................................................... 336 KICK DOWN, HOLD SWITCH.......................................................... 340 ENGINE STARTING CIRCUIT......................................................... 341 ENGINE STOP CIRCUIT............................................................. 343 PREHEATING CIRCUIT.............................................................. 344 ENGINE POWER MODE SELECTOR CIRCUIT.............................................. 345 PARKING BRAKE CIRCUIT........................................................... 346 SENSORS......................................................................... 350 20 TESTING AND ADJUSTING............................................................ 361 STANDARD VALUE TABLE FOR ENGINE................................................. 362 STANDARD VALUE TABLE FOR CHASSIS................................................ 363 MEASURING ENGINE SPEED.......................................................... 372 MEASURING EXHAUST COLOR......................................................... 374 MEASURING EXHAUST TEMPERATURE................................................... 375 ADJUSTING VALVE CLEARANCE....................................................... 376 MEASURING COMPRESSION PRESSURE.................................................. 378 MEASURING BLOW-BY PRESSURE...................................................... 379 MEASURING ENGINE OIL PRESSURE................................................... 380 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE).................................. 381 TESTING AND ADJUSTING FUEL INJECTION TIMING..................................... 382 ADJUSTING ENGINE SPEED SENSOR................................................... 383 BLEEDING AIR FROM FUEL CIRCUIT.................................................. 384 ADJUSTING ENGINE STOP SOLENOID.................................................. 385 ADJUSTING ACCELERATOR PEDAL..................................................... 387 ADJUSTING TRANSMISSION SPEED SENSOR............................................. 389 TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE.................................. 390 DRAWING OF SPECIAL TOOL......................................................... 394 PROCEDURE FOR FLUSHING TORQUE CONVERTER, TRANSMISSION HYDRAULIC CIRCUIT......... 395 PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS...................... 396 TESTING AND ADJUSTING STEERING CONTROL.......................................... 398 TESTING AND ADJUSTING STEERING OIL PRESSURE..................................... 399 TESTING HYDRAULIC FAN........................................................... 401 MEASURING BRAKE OIL PRESSURE.................................................... 402 TESTING WEAR OF WHEEL BRAKE DISC................................................ 404 BLEEDING AIR FROM BRAKE CIRCUIT................................................. 405 TESTING WEAR OF PARKING BRAKE DISC.............................................. 406 MANUAL RELEASE METHOD FOR PARKING BRAKE......................................... 407 TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE............................... 408 TESTING AND ADJUSTING WORKING EQUIPMENT PPC OIL PRESSURE........................ 410 TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE......................... 412 TESTING AND ADJUSTING BUCKET POSITIONER......................................... 414 TESTING AND ADJUSTING LIFT ARM KICK-OUT......................................... 415 CHECKING PROXIMITY SWITCH ACTUATION PILOT LAMP.................................. 416 ADJUSTING MACHINE MONITOR....................................................... 417 TESTING AND ADJUSTING LOAD METER................................................ 420 BLEEDING AIR.................................................................... 421 RELEASING REMAINING PRESSURE IN HYDRAULIC CORCUIT............................... 422 RELEASING REMAINING PRESSURE IN TRAVEL DAMPER CIRCUIT........................... 422 20 TROUBLESHOOTING.................................................................. 423 POINTS TO REMEMBER WHEN TROUBLESHOOTING......................................... 424 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................... 425 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE....................................... 426 CHECKS BEFORE TROUBLESHOOTING................................................... 434 EQUIPMENT FOR TROUBLESHOOTING ELECTRICAL SYSTEM................................. 435 SPECIAL FUNCTIONS OF MACHINE MONITOR............................................ 436 CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS............... 471 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...................................... 476 20 TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (TM MODE)......................... 489 CONNECTOR TYPES AND MOUNTING LOCATIONS.......................................... 491 CONNECTOR LAYOUT DRAWING........................................................ 500 TRANSMISSION CONTROL SYSTEM DIAGRAM............................................. 506 ERROR CODE [1500L1]............................................................. 509 ERROR CODE [15SAL1]............................................................. 510 ERROR CODE [15SALH]............................................................. 511 ERROR CODE [15SBL1]............................................................. 512 ERROR CODE [15SBLH]............................................................. 513 ERROR CODE [15SEL1]............................................................. 514 ERROR CODE [15SELH]............................................................. 515 ERROR CODE [15SFL1]............................................................. 516 ERROR CODE [15SFLH]............................................................. 517 ERROR CODE [15SGL1]............................................................. 518 ERROR CODE [15SGLH]............................................................. 519 ERROR CODE [15SHL1]............................................................. 520 ERROR CODE [15SHLH]............................................................. 521 ERROR CODE [15SJL1]............................................................. 522 ERROR CODE [15SJLH]............................................................. 523 ERROR CODE [989F00]............................................................. 524 ERROR CODE [989G00]............................................................. 525 ERROR CODE [B@C7NS]............................................................. 526 ERROR CODE [D150KA]............................................................. 527 ERROR CODE [D150KB]............................................................. 528 ERROR CODE [D160KA]............................................................. 529 ERROR CODE [D160KB]............................................................. 530 ERROR CODE [D191KA]............................................................. 532 ERROR CODE [D191KB]............................................................. 534 ERROR CODE [D192KA]............................................................. 536 ERROR CODE [D192KB]............................................................. 537 ERROR CODE [DAQ0KK]............................................................. 538 ERROR CODE [DAQ2KK]............................................................. 539 ERROR CODE [DAQ9KQ]............................................................. 540 ERROR CODE [DDK3KA]............................................................. 542 ERROR CODE [DDK3KB]............................................................. 544 ERROR CODE [DDK4KA]............................................................. 545 ERROR CODE [DDK4KB]............................................................. 547 ERROR CODE [DDK5LD]............................................................. 549 ERROR CODE [DDK6KA]............................................................. 550 ERROR CODE [DDK6KB]............................................................. 552 ERROR CODE [DDS5KA]............................................................. 554 ERROR CODE [DDS5KB]............................................................. 555 ERROR CODE [DDT0L4]............................................................. 556 ERROR CODE [DDT4LD]............................................................. 558 ERROR CODE [DDW9LD]............................................................. 559 ERROR CODE [DDWLLD]............................................................. 560 ERROR CODE [DF10KA]............................................................. 562 ERROR CODE [DF10KB]............................................................. 564 ERROR CODE [DGF1KX]............................................................. 566 ERROR CODE [DGR2KA]............................................................. 567 ERROR CODE [DGR2KB]............................................................. 568 ERROR CODE [DHT1KX]............................................................. 569 ERROR CODE [DLE2KA]............................................................. 570 ERROR CODE [DLE2LC]............................................................. 571 ERROR CODE [DLT3KA]............................................................. 572 ERROR CODE [DT20KB]............................................................. 573 ERROR CODE [DW7BKA]............................................................. 574 ERROR CODE [DW7BKB]............................................................. 575 ERROR CODE [DW7CKA]............................................................. 576 ERROR CODE [DW7CKB]............................................................. 577 ERROR CODE [DX16KA]............................................................. 578 ERROR CODE [DX16KB]............................................................. 579 ERROR CODE [DXH1KA]............................................................. 580 ERROR CODE [DXH1KB]............................................................. 581 ERROR CODE [DXH4KA]............................................................. 582 ERROR CODE [DXH4KB]............................................................. 583 ERROR CODE [DXH5KA]............................................................. 584 ERROR CODE [DXH5KB]............................................................. 585 ERROR CODE [DXH6KA]............................................................. 586 ERROR CODE [DXH6KB]............................................................. 587 ERROR CODE [DXH7KA]............................................................. 588 ERROR CODE [DXH7KB]............................................................. 589 ERROR CODE [DXH8KA]............................................................. 590 ERROR CODE [DXH8KB]............................................................. 591 ERROR CODE [DXHHKA]............................................................. 592 ERROR CODE [DXHHKB]............................................................. 593 ERROR CODE [DY30MA]............................................................. 594 ERROR CODE [DY30MC]............................................................. 596 ACTION CODE [TM-1].............................................................. 598 ACTION CODE [TM-2].............................................................. 599 ACTION CODE [TM-3].............................................................. 600 ACTION CODE [TM-4].............................................................. 602 ACTION CODE [TM-5].............................................................. 604 ACTION CODE [TM-6].............................................................. 606 ACTION CODE [TM-7].............................................................. 607 ACTION CODE [TM-8].............................................................. 608 ACTION CODE [TM-9].............................................................. 609 ACTION CODE [TM-10-a]........................................................... 610 ACTION CODE [TM-10-b]........................................................... 612 ACTION CODE [TM-11]............................................................. 614 ACTION CODE [TM-12]............................................................. 616 ACTION CODE [TM-13]............................................................. 617 ACTION CODE [TM-14]............................................................. 618 ACTION CODE [TM-15]............................................................. 619 ACTION CODE [TM-16]............................................................. 620 ACTION CODE [TM-17]............................................................. 621 ACTION CODE [TM-18]............................................................. 622 ACTION CODE [TM-19]............................................................. 623 ACTION CODE [TM-20]............................................................. 624 ACTION CODE [TM-21]............................................................. 625 ACTION CODE [TM-22]............................................................. 626 ACTION CODE [TM-23]............................................................. 627 ACTION CODE [TM-24]............................................................. 628 ACTION CODE [TM-25]............................................................. 629 ACTION CODE [TM-26]............................................................. 630 ACTION CODE [TM-27]............................................................. 631 ACTION CODE [TM-28]............................................................. 632 ACTION CODE [TM-29]............................................................. 633 20 TROUBLESHOOTING OF WORK EQUIPMENT CONTROL SYSTEM (WRK MODE)...................... 635 CONNECTOR TYPES AND MOUNTING LOCATIONS.......................................... 637 CONNECTOR LAYOUT DRAWING........................................................ 646 WORK EQUIPMENT CONTROL SYSTEM DIAGRAM........................................... 652 ERROR CODE [D193KA]............................................................. 655 ERROR CODE [D193KB]............................................................. 656 ERROR CODE [DB90KK]............................................................. 657 ERROR CODE [DB92KK]............................................................. 658 ERROR CODE [DB95KX]............................................................. 660 ERROR CODE [DD1ALD]............................................................. 662 ERROR CODE [DD1BLD]............................................................. 663 ERROR CODE [DFAOKM]............................................................. 664 ERROR CODE [DK59KA]............................................................. 665 ERROR CODE [DK59KY]............................................................. 666 ERROR CODE [DK59L8]............................................................. 667 ERROR CODE [DK5AKA]............................................................. 668 ERROR CODE [DK5AKY]............................................................. 669 ERROR CODE [DK5BKA]............................................................. 670 ERROR CODE [DK5BKY]............................................................. 671 ERROR CODE [DK5BL8]............................................................. 672 ERROR CODE [DK5CKA]............................................................. 673 ERROR CODE [DK5CKY]............................................................. 674 ERROR CODE [DK5DKA]............................................................. 675 ERROR CODE [DK5DKY]............................................................. 676 ERROR CODE [DK5DL8]............................................................. 677 ERROR CODE [DK5EKA]............................................................. 678 ERROR CODE [DK5EKY]............................................................. 679 ERROR CODE [DK5FKA]............................................................. 680 ERROR CODE [DK5FKY]............................................................. 681 ERROR CODE [DK5FKM]............................................................. 682 ERROR CODE [DK5FL8]............................................................. 683 ERROR CODE [DK5GKA]............................................................. 684 ERROR CODE [DK5GKY]............................................................. 685 ERROR CODE [DKAOKA]............................................................. 686 ERROR CODE [DKAOKY]............................................................. 687 ERROR CODE [DLE2LC]............................................................. 688 ERROR CODE [DLT3LC]............................................................. 689 ERROR CODE [DUM1KB]............................................................. 690 ERROR CODE [DUM2KB]............................................................. 691 ERROR CODE [DW4PKA]............................................................. 692 ERROR CODE [DW4PKB]............................................................. 693 ERROR CODE [DW4QKA]............................................................. 694 ERROR CODE [DW4QKB]............................................................. 695 ERROR CODE [DW4RKA]............................................................. 696 ERROR CODE [DW4RKB]............................................................. 697 ERROR CODE [DW4SKA]............................................................. 698 ERROR CODE [DW4SKB]............................................................. 699 ERROR CODE [DWM1KA]............................................................. 700 ERROR CODE [DWM1KB]............................................................. 701 ERROR CODE [DWN6KA]............................................................. 702 ERROR CODE [DWN6KB]............................................................. 703 ERROR CODE [DWN7KA]............................................................. 704 ERROR CODE [DWN7KB]............................................................. 705 ERROR CODE [DWN8KA]............................................................. 706 ERROR CODE [DWN8KB]............................................................. 707 ERROR CODE [DXHJKA]............................................................. 708 ERROR CODE [DXHJKB]............................................................. 709 ERROR CODE [DXHKKA]............................................................. 710 ERROR CODE [DXHKKB]............................................................. 711 ERROR CODE: [DXHLKA]............................................................ 712 ERROR CODE: [DXHLKB]............................................................ 713 ERROR CODE: [DXHMKA]............................................................ 714 ERROR CODE: [DXHMKB]............................................................ 715 ACTION CODE: [WRK-1]............................................................ 716 ACTION CODE: [WRK-2]............................................................ 717 ACTION CODE: [WRK-3]............................................................ 718 ACTION CODE: [WRK-4]............................................................ 720 ACTION CODE: [WRK-5]............................................................ 722 ACTION CODE: [WRK-6]............................................................ 724 ACTION CODE: [WRK-7]............................................................ 726 ACTION CODE: [WRK-8]............................................................ 727 ACTION CODE: [WRK-9]............................................................ 728 ACTION CODE: [WRK-10]........................................................... 730 ACTION CODE: [WRK-11]........................................................... 732 ACTION CODE: [WRK-12]........................................................... 733 ACTION CODE: [WRK-13]........................................................... 734 ACTION CODE: [WRK-14]........................................................... 735 ACTION CODE: [WRK-15]........................................................... 736 ACTION CODE: [WRK-16]........................................................... 737 ACTION CODE: [WRK-17]........................................................... 738 ACTION CODE: [WRK-18]........................................................... 739 ACTION CODE: [WRK-19]........................................................... 740 ACTION CODE: [WRK-20]........................................................... 741 ACTION CODE: [WRK-21]........................................................... 742 ACTION CODE: [WRK-22]........................................................... 743 ACTION CODE: [WRK-23]........................................................... 744 ACTION CODE: [WRK-24]........................................................... 745 ACTION CODE: [WRK-25]........................................................... 746 ACTION CODE: [WRK-26]........................................................... 748 ACTION CODE: [WRK-27]........................................................... 750 ACTION CODE: [WRK-28]........................................................... 752 20 TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE)..................................... 755 CONNECTOR TYPES AND MOUNTING LOCATIONS.......................................... 757 CONNECTOR LAYOUT DRAWING........................................................ 766 MONITOR SYSTEM DIAGRAM.......................................................... 772 ERROR CODE [2F00KM]............................................................. 776 ERROR CODE [2G42ZG]............................................................. 778 ERROR CODE [2G43ZG]............................................................. 779 ERROR CODE [AA1ANX]............................................................. 780 ERROR CODE [AB00L6]............................................................. 782 ERROR CODE [AB00MA]............................................................. 783 ERROR CODE [B@BAZG]............................................................. 784 ERROR CODE [B@BAZK]............................................................. 785 ERROR CODE [B@BCNS]............................................................. 786 ERROR CODE [B@BCZK]............................................................. 787 ERROR CODE [B@HANS]............................................................. 788 ERROR CODE [B@CENS]............................................................. 789 ERROR CODE [D182KZ]............................................................. 790 ERROR CODE [D5ZHL6]............................................................. 792 ERROR CODE [DA80L4]............................................................. 793 ERROR CODE [DAF3KK]............................................................. 794 ERROR CODE [DAF5KP]............................................................. 796 ERROR CODE [DAF6KP]............................................................. 798 ERROR CODE [DAFBKM]............................................................. 800 ERROR CODE [DAFSKQ]............................................................. 801 ERROR CODE [DAQSKR]............................................................. 802 ERROR CODE [DB2SKR]............................................................. 803 ERROR CODE [DBQSKR]............................................................. 804 ERROR CODE [DB9SKR]............................................................. 805 ERROR CODE [DD15LD]............................................................. 806 ERROR CODE [DD16LD]............................................................. 807 ERROR CODE [DD17LD]............................................................. 808 ERROR CODE [DD18LD]............................................................. 809 ERROR CODE [DD1CLD]............................................................. 810 ERROR CODE [DDK3KM]............................................................. 811 ERROR CODE [DDK4KM]............................................................. 812 ERROR CODE [DDK6KM]............................................................. 813 ERROR CODE [DDS5L6]............................................................. 814 ERROR CODE [DDY0LD]............................................................. 815 ERROR CODE [DGE2KX]............................................................. 816 ERROR CODE [DGE3L6]............................................................. 817 ERROR CODE [DGH2KX]............................................................. 818 ERROR CODE [DGT1KX]............................................................. 819 ERROR CODE [DHE4L6]............................................................. 820 ERROR CODE [DHPCKX]............................................................. 822 ERROR CODE [DHPDKX]............................................................. 824 ERROR CODE [DKA0KX]............................................................. 826 ERROR CODE [DV00KB]............................................................. 827 ERROR CODE [DY30ME]............................................................. 828 ACTION CODE [MON-1]............................................................. 830 ACTION CODE [MON-2]............................................................. 832 ACTION CODE [MON-3]............................................................. 833 ACTION CODE [MON-4]............................................................. 834 ACTION CODE [MON-5]............................................................. 836 ACTION CODE [MON-6]............................................................. 837 ACTION CODE [MON-7]............................................................. 838 ACTION CODE [MON-8]............................................................. 839 ACTION CODE [MON-9]............................................................. 840 ACTION CODE [MON-10]............................................................ 841 ACTION CODE [MON-11]............................................................ 842 ACTION CODE [MON-12]............................................................ 843 ACTION CODE [MON-13]............................................................ 844 ACTION CODE [MON-14]............................................................ 845 ACTION CODE [MON-15]............................................................ 846 ACTION CODE [MON-16]............................................................ 847 ACTION CODE [MON-17]............................................................ 848 ACTION CODE [MON-18]............................................................ 849 ACTION CODE [MON-19]............................................................ 850 ACTION CODE [MON-20]............................................................ 851 20 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)......................... 853 H-1............................................................................. 854 H-2............................................................................. 855 H-3a............................................................................ 857 H-3b............................................................................ 859 H-4............................................................................. 860 H-5............................................................................. 862 H-6............................................................................. 864 H-7............................................................................. 864 H-8............................................................................. 866 H-9............................................................................. 867 H-10............................................................................ 868 H-11............................................................................ 869 H-12............................................................................ 870 H-13............................................................................ 871 H-14............................................................................ 872 H-15............................................................................ 873 H-16............................................................................ 874 H-17............................................................................ 875 H-18............................................................................ 875 H-19............................................................................ 875 H-20............................................................................ 875 H-21............................................................................ 876 H-22............................................................................ 877 H-23............................................................................ 878 H-24............................................................................ 879 H-25............................................................................ 879 H-26............................................................................ 879 H-27............................................................................ 880 H-28............................................................................ 880 H-29............................................................................ 881 20 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE).................................... 883 CONNECTOR TYPES AND MOUNTING LOCATIONS.......................................... 885 CONNECTOR LAYOUT DRAWING........................................................ 894 ELECTRICAL SYSTEM DIAGRAM....................................................... 900 ACTION CODE: [E-1-a]............................................................ 902 ACTION CODE: [E-1-b]............................................................ 906 ACTION CODE: [E-2].............................................................. 908 ACTION CODE: [E-3].............................................................. 910 ACTION CODE: [E-4].............................................................. 912 ACTION CODE: [E-5].............................................................. 914 ACTION CODE: [E-6].............................................................. 916 ACTION CODE: [E-7].............................................................. 918 ACTION CODE: [E-8].............................................................. 921 ACTION CODE: [E-9].............................................................. 922 ACTION CODE: [E-10]............................................................. 925 ACTION CODE: [E-11]............................................................. 926 ACTION CODE: [E-12]............................................................. 927 ACTION CODE: [E-13]............................................................. 930 ACTION CODE: [E-14]............................................................. 933 ACTION CODE: [E-15]............................................................. 935 ACTION CODE: [E-16]............................................................. 936 ACTION CODE: [E-17]............................................................. 938 ACTION CODE: [E-18]............................................................. 940 30 DISASSEMBLY AND ASSEMBLY......................................................... 947 Method of using manual.......................................................... 949 Precautions when carrying out operation......................................... 950 Engine assembly................................................................. 954 Removal..................................................................... 954 Installation................................................................ 958 Cylinder head assembly.......................................................... 959 Special tool................................................................ 959 Removal..................................................................... 959 Installation................................................................ 964 Radiator and fan motor assembly................................................. 967 Removal..................................................................... 967 Installation................................................................ 968 Aftercooler assembly............................................................ 969 Removal..................................................................... 969 Installation................................................................ 969 Fuel injection pump............................................................. 970 Special tool................................................................ 970 Removal..................................................................... 970 Installation................................................................ 972 Nozzle holder assembly.......................................................... 975 Removal..................................................................... 975 Installation................................................................ 977 Fan and fan motor assembly...................................................... 978 Removal..................................................................... 978 Installation................................................................ 979 Fuel tank assembly.............................................................. 980 Removal..................................................................... 980 Installation................................................................ 982 Parking brake disc plate........................................................ 983 Special tool................................................................ 983 Removal..................................................................... 983 Installation................................................................ 986 Sketch of special tool...................................................... 987 K1 Bracket.............................................................. 987 Torque converter and transmission assembly...................................... 988 Removal..................................................................... 988 Installation................................................................ 993 Bleeding air of brake circuit............................................... 993 Transmission assembly........................................................... 994 Special tool................................................................ 994 Disassembly................................................................. 994 Assembly....................................................................1001 Sketches of special tools...................................................1010 F1 Lifting tool.........................................................1010 F4 Bracket..............................................................1010 Transmission clutch pack assembly...............................................1011 Special tools...............................................................1011 Disassembly.................................................................1011 Disassembly of forward and reverse clutch packs.............................1011 [Forward clutch side]...................................................1011 [Reverse clutch side]...................................................1013 Disassembly of 1st and 4th clutch pack......................................1014 [1st clutch side].......................................................1014 [4th clutch side].......................................................1016 Disassembly of 2nd and 3rd clutch pack......................................1017 [3rd clutch side].......................................................1017 [2nd clutch side].......................................................1019 Assembly of the forward and reverse clutch packs............................1020 [Reverse clutch side]...................................................1020 [Forward clutch side]...................................................1022 Assembly of 1st and 4th clutch pack.........................................1024 [4th clutch side].......................................................1024 [1st clutch side].......................................................1026 Assembly of 2nd and 3rd clutch pack.........................................1029 [2nd clutch side].......................................................1029 [3rd clutch side].......................................................1031 Parking brake assembly..........................................................1033 Special tools...............................................................1033 Disassembly.................................................................1033 Assembly....................................................................1036 Special tool simplified drawings................................................1042 F10 Push tool...............................................................1042 H1 Bracket..................................................................1042 H4 Spacer...................................................................1043 H3 Push tool................................................................1043 H6 Push tool................................................................1044 H5 Push Tool................................................................1044 H9 Spacer...................................................................1045 H8 Push tool................................................................1045 Torque converter assembly (standard specification)..............................1046 Special tools...............................................................1046 Disassembly.................................................................1046 Assembly....................................................................1049 Torque converter assembly (lock-up specification)...............................1052 Special tools...............................................................1052 Disassembly.................................................................1052 Assembly....................................................................1056 Rear axle assembly..............................................................1060 Removal.....................................................................1060 Installation................................................................1063 Front axle assembly.............................................................1064 Removal.....................................................................1064 Installation................................................................1065 Axle housing assembly...........................................................1066 Special tools...............................................................1066 Disassembly.................................................................1066 Assembly....................................................................1071 Special tool simplified drawings................................................1077 J1 Spacer...................................................................1077 J2 Push Tool................................................................1077 J3 Push Tool................................................................1078 J1 Push Tool 54.............................................................1078 Differential assembly...........................................................1079 Special tools...............................................................1079 Disassembly.................................................................1079 Assembly....................................................................1085 Special tool illustrations......................................................1096 D3-2........................................................................1096 D3-1........................................................................1096 D5-1 Push tool..............................................................1097 D5-2 Push tool..............................................................1097 D4 Push tool................................................................1098 Center hinge pin................................................................1099 Special tools...............................................................1099 Removal.....................................................................1099 Installation................................................................1105 Cab assembly....................................................................1109 Removal.....................................................................1109 Installation................................................................1111 Cab and floor frame assembly....................................................1112 Removal.....................................................................1112 Installation................................................................1115 Transmission, work equipment, and PPC pump assembly.............................1116 Removal.....................................................................1116 Installation................................................................1116 Steering, switching, and fan pump assembly......................................1117 Removal.....................................................................1117 Installation................................................................1117 Steering demand valve assembly..................................................1118 Removal.....................................................................1118 Installation................................................................1118 Travel dumper valve assembly....................................................1119 Removal.....................................................................1119 Installation................................................................1119 Work equipment valve assembly...................................................1120 Removal.....................................................................1120 Installation................................................................1121 Hydraulic cylinder assembly (steering, lift, and bucket cylinder assembly)......1122 Special tools...............................................................1122 Disassembly.................................................................1123 Assembly....................................................................1127 Hydraulic tank assembly.........................................................1132 Removal.....................................................................1132 Attachment..................................................................1133 Work equipment assembly.........................................................1134 Removal.....................................................................1134 Installation................................................................1138 Counter weight..................................................................1140 Removal.....................................................................1140 Installation................................................................1140 Air conditioner unit assembly...................................................1141 Removal.....................................................................1141 Installation................................................................1144 Air conditioner compressor assembly.............................................1145 Removal.....................................................................1145 Installation................................................................1145 90 OTHERS...........................................................................1147 POWER TRAIN OIL CIRCUIT DIAGRAM (WITHOUT TORQUE CONVERTER LOCKUP CLUTCH)........1149 POWER TRAIN OIL CIRCUIT DIAGRAM (WITH TORQUE CONVERTER LOCKUP CLUTCH)...........1151 BRAKE OIL CIRCUIT DIAGRAM.......................................................1153 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM........................................1155 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (FOR ELECTRIC WORK EQUIPMENT LEVER)....1156 ELECTRIC CIRCUIT DIAGRAM (1/8)..................................................1157 ELECTRIC CIRCUIT DIAGRAM (1/8)..................................................1158 ELECTRIC CIRCUIT DIAGRAM (1/8)..................................................1159 ELECTRIC CIRCUIT DIAGRAM (1/8)..................................................1160 ELECTRIC CIRCUIT DIAGRAM (2/8)..................................................1161 ELECTRIC CIRCUIT DIAGRAM (2/8)..................................................1162 ELECTRIC CIRCUIT DIAGRAM (2/8)..................................................1163 ELECTRIC CIRCUIT DIAGRAM (2/8)..................................................1164 ELECTRIC CIRCUIT DIAGRAM (3/8)..................................................1165 ELECTRIC CIRCUIT DIAGRAM (4/8)..................................................1166 ELECTRIC CIRCUIT DIAGRAM (5/8)..................................................1167 ELECTRIC CIRCUIT DIAGRAM (6/8)..................................................1168 ELECTRIC CIRCUIT DIAGRAM (7/8)..................................................1169 ELECTRIC CIRCUIT DIAGRAM (8/8)..................................................1170
KOMATSU WA380-5H WHEEL LOADER SHOP MANUAL (PART I) VEBM920100 – PDF DOWNLOAD:
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