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KOMATSU WA380-6 WA380Z-6 WHEEL LOADER SHOP MANUAL SEN05717-01 – PDF DOWNLOAD
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KOMATSU WA380-6 WA380Z-6 WHEEL LOADER SHOP MANUAL SEN05717-01 – PDF DOWNLOAD
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KOMATSU WA380-6 WA380Z-6 WHEEL LOADER SHOP MANUAL SEN05717-01 – PDF DOWNLOAD
Language : English
Pages : 2116
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA380-6 WA380Z-6 WHEEL LOADER SHOP MANUAL SEN05717-01 – PDF DOWNLOAD
Cover.................................................................................................................................................... 1 00 Index and foreword.................................................................................................................................... 0 Index................................................................................................................................................ 3 Composition of shop manual....................................................................................................................... 4 Table of contents................................................................................................................................ 6 Foreword and general information..................................................................................................................... 19 Safety notice.................................................................................................................................... 20 How to read the shop manual...................................................................................................................... 25 Explanation of terms for maintenance standard.................................................................................................... 27 Handling of electric equipment and hydraulic component........................................................................................... 29 Handling of connectors newly used for engines.................................................................................................... 38 How to read electric wire code................................................................................................................... 41 Precautions when carrying out operation.......................................................................................................... 44 Method of disassembling and connecting push-pull type coupler.................................................................................... 47 Standard tightening torque table................................................................................................................. 50 Conversion table................................................................................................................................. 54 01 Specification......................................................................................................................................... 0 Specification and technical data..................................................................................................................... 61 Specification dimension drawing.................................................................................................................. 62 Specifications................................................................................................................................... 64 Weight table..................................................................................................................................... 72 Table of fuel, coolant and lubricants............................................................................................................ 76 10 Structure, function and maintenance standard.......................................................................................................... 0 Engine and cooling system............................................................................................................................ 79 Engine mount and transmission mount.............................................................................................................. 80 Cooling system................................................................................................................................... 81 Cooling fan pump................................................................................................................................. 83 Break and fan pump............................................................................................................................... 90 Cooling fan motor................................................................................................................................ 91 Power train.......................................................................................................................................... 105 Power train...................................................................................................................................... 107 Power train system diagram....................................................................................................................... 108 Drive shaft...................................................................................................................................... 111 Power train piping diagram....................................................................................................................... 112 Torque converter................................................................................................................................. 114 Transmission..................................................................................................................................... 122 Flow control valve............................................................................................................................... 156 Valve assembly................................................................................................................................... 158 ECMV............................................................................................................................................. 159 Main relief valve and torque converter relief valve.............................................................................................. 167 Differential..................................................................................................................................... 171 Limited slip differential........................................................................................................................ 175 Final drive...................................................................................................................................... 182 Steering system...................................................................................................................................... 187 Steering piping diagram.......................................................................................................................... 188 Steering column.................................................................................................................................. 190 Steering pump.................................................................................................................................... 192 Steering valve................................................................................................................................... 212 Orbit-roll valve................................................................................................................................. 227 Stop valve....................................................................................................................................... 235 Steering relief valve............................................................................................................................ 236 Steering cylinder................................................................................................................................ 237 Emergency steering motor......................................................................................................................... 239 Emergency steering pump.......................................................................................................................... 240 Joystick steering lever linkage.................................................................................................................. 241 Steering electric lever.......................................................................................................................... 242 Joystick EPC valve............................................................................................................................... 243 Brake system......................................................................................................................................... 245 Brake piping diagram............................................................................................................................. 246 Charge valve..................................................................................................................................... 248 Brake valve...................................................................................................................................... 255 Accumulator (for brake).......................................................................................................................... 260 Brake............................................................................................................................................ 262 Parking brake control............................................................................................................................ 267 Parking brake.................................................................................................................................... 268 Parking brake solenoid valve..................................................................................................................... 270 Emergency parking brake release valve............................................................................................................ 272 Undercarriage and frame.............................................................................................................................. 275 Axle mount and center hinge pin.................................................................................................................. 276 Tires............................................................................................................................................ 281 Hydraulic system, Part 1............................................................................................................................. 283 Hydraulic piping diagram......................................................................................................................... 284 Work equipment control lever linkage............................................................................................................. 290 Hydraulic tank................................................................................................................................... 293 Power train pump................................................................................................................................. 297 Work equipment pump.............................................................................................................................. 298 Work equipment control valve..................................................................................................................... 320 CLSS............................................................................................................................................. 348 Each function and operation of each valve........................................................................................................ 352 Hydraulic system, Part 2............................................................................................................................. 385 PPC valve........................................................................................................................................ 386 Stabilizer valve................................................................................................................................. 392 Accumulator (for PPC circuit).................................................................................................................... 398 Accumulator (for ECSS)........................................................................................................................... 399 Work equipment PPC cut-off solenoid valve........................................................................................................ 400 Work equipment....................................................................................................................................... 403 Work equipment linkage........................................................................................................................... 404 Bucket........................................................................................................................................... 408 Bucket positioner and boom kick-out.............................................................................................................. 410 Work equipment cylinder.......................................................................................................................... 416 Cab and its attachments.............................................................................................................................. 419 Cab.............................................................................................................................................. 421 Air conditioner.................................................................................................................................. 424 Electrical system, Part 1............................................................................................................................ 445 Machine monitor system........................................................................................................................... 446 Machine monitor.................................................................................................................................. 454 Electrical system, Part 2............................................................................................................................ 513 Electrical system (Transmission controller system)............................................................................................... 514 Transmission controller.......................................................................................................................... 558 Electrical system (Work equipment controller system)............................................................................................. 562 Work equipment controller........................................................................................................................ 568 Electrical system, Part 3............................................................................................................................ 571 Electric transmission control.................................................................................................................... 572 Kickdown switch and hold switch.................................................................................................................. 576 Multi-function knob.............................................................................................................................. 578 Joystick steering knob........................................................................................................................... 579 KOMTRAX terminal system.......................................................................................................................... 580 Engine starting circuit.......................................................................................................................... 585 Engine stopping circuit.......................................................................................................................... 589 Preheating circuit............................................................................................................................... 591 Engine power mode selector circuit............................................................................................................... 592 Engine output derating function.................................................................................................................. 593 Automatic warm-up function....................................................................................................................... 593 Parking brake circuit............................................................................................................................ 594 Sensor........................................................................................................................................... 596 20 Standard value table.................................................................................................................................. 0 Standard service value table......................................................................................................................... 607 Standard service value table for engine.......................................................................................................... 608 Standard service value table for chassis......................................................................................................... 610 30 Testing and adjusting................................................................................................................................. 0 Testing and adjusting, Part 1........................................................................................................................ 623 Tools for testing, adjusting, and troubleshooting................................................................................................ 625 Testing engine speed............................................................................................................................. 632 Testing exhaust gas color........................................................................................................................ 634 Adjusting valve clearance........................................................................................................................ 636 Testing compression pressure..................................................................................................................... 641 Testing blow-by pressure......................................................................................................................... 647 Testing engine oil pressure...................................................................................................................... 648 Testing intake air (boost) pressure.............................................................................................................. 650 Handling fuel system equipment................................................................................................................... 652 Releasing residual pressure in fuel system....................................................................................................... 652 Testing fuel pressure............................................................................................................................ 653 Testing fuel delivery, return and leak amount.................................................................................................... 658 Bleeding air from fuel circuit................................................................................................................... 666 Testing leakage in fuel system................................................................................................................... 667 Handling reduced cylinder mode operation......................................................................................................... 668 Handling no-injection cranking operation......................................................................................................... 668 Handling controller voltage circuit.............................................................................................................. 669 Testing muffler (main body) and muffler stack for looseness or damage............................................................................ 669 Testing muffler for functions.................................................................................................................... 670 Testing cylinder head and manifold parts for tightness........................................................................................... 670 Testing engine piping for damage and tightness................................................................................................... 671 Testing and adjusting air conditioner compressor belt tension.................................................................................... 672 Replacing alternator belt........................................................................................................................ 673 Adjusting transmission speed sensor.............................................................................................................. 675 Adjusting length of directional lever............................................................................................................ 676 Adjusting length of gearshift lever.............................................................................................................. 676 Testing directional lever........................................................................................................................ 677 Testing and adjusting power train oil pressure................................................................................................... 678 Procedure for flushing torque converter and transmission hydraulic circuit....................................................................... 707 Method of moving machine when transmission valve is broken....................................................................................... 708 Testing axel end for oil leakage................................................................................................................. 712 Testing drive shaft for looseness, backlash and damage........................................................................................... 712 Testing and adjusting steering stop valve........................................................................................................ 713 Testing and adjusting steering wheel............................................................................................................. 715 Testing and adjusting steering oil pressure...................................................................................................... 717 Bleeding air from steering circuit............................................................................................................... 720 Testing and adjusting, Part 2........................................................................................................................ 723 Testing hydraulic drive fan...................................................................................................................... 725 Bleeding air from hydraulic drive fan circuit.................................................................................................... 729 Testing brake pedal.............................................................................................................................. 732 Testing and adjusting brake pedal linkage........................................................................................................ 733 Testing brake performance........................................................................................................................ 734 Testing and adjusting accumulator charge pressure................................................................................................ 735 Testing wheel brake oil pressure................................................................................................................. 737 Testing wheel brake oil pressure drop............................................................................................................ 738 Testing wear of wheel brake disc1................................................................................................................ 740 Bleeding air from wheel brake circuit............................................................................................................ 741 Releasing residual pressure in brake accumulator circuit......................................................................................... 742 Testing parking brake performance................................................................................................................ 743 Testing parking brake oil pressure............................................................................................................... 744 Testing wear of parking brake disc............................................................................................................... 746 Method of releasing parking brake manually....................................................................................................... 747 Testing and adjusting work equipment control lever............................................................................................... 748 Testing and adjusting work equipment PPC oil pressure............................................................................................ 749 Testing and adjusting work equipment oil pressure................................................................................................ 755 Bleeding air from work equipment circuit......................................................................................................... 759 Releasing residual pressure in work equipment circuit............................................................................................ 760 Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of ECSS (Electronically Controlled Suspension System) accumulator.... 762 Testing and adjusting bucket positioner.......................................................................................................... 768 Testing and adjusting boom kick-out.............................................................................................................. 770 Checking proximity switch operation pilot lamp................................................................................................... 771 Procedure for testing diodes..................................................................................................................... 772 Preparation work for troubleshooting for electric system......................................................................................... 773 How to start operation of KOMTRAX terminal....................................................................................................... 782 Lamp display of KOMTRAX terminal................................................................................................................. 787 Testing and adjusting, Part 3........................................................................................................................ 791 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor........................................................... 793 Special functions of machine monitor (EMMS)...................................................................................................... 795 Pm-clinic inspection table....................................................................................................................... 864 40 Troubleshooting....................................................................................................................................... 0 Failure code table and fuse locations................................................................................................................ 871 Failure code table............................................................................................................................... 872 Fuse locations................................................................................................................................... 889 General information on troubleshooting............................................................................................................... 895 Points to remember when troubleshooting.......................................................................................................... 896 Sequence of events in troubleshooting............................................................................................................ 897 Testing before troubleshooting................................................................................................................... 899 Classification and procedures of troubleshooting................................................................................................. 900 Information contained in troubleshooting table................................................................................................... 903 Connection table for connector pin numbers....................................................................................................... 905 T- branch box and T- branch adapter table........................................................................................................ 941 Troubleshooting by failure code (Display of code), Part 1............................................................................................ 945 Failure code [1500L0] (TORQFLOW transmission: Double meshing).................................................................................... 947 Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)............................................................ 950 Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)............................................................ 952 Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)............................................................ 954 Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON).......................................................... 956 Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF).......................................................... 958 Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON).......................................................... 960 Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF).......................................................... 962 Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON).......................................................... 964 Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF).......................................................... 966 Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON).......................................................... 968 Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF).......................................................... 970 Failure code [2F00MA] (Parking brake: Malfunction)............................................................................................... 972 Failure code [2G43ZG] (Accumulator: Low oil pressure)............................................................................................ 975 Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree)............................................................................... 979 Troubleshooting by failure code (Display of code), Part 2............................................................................................ 983 Failure code [AA1ANX] (Air cleaner: Clogging).................................................................................................... 986 Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine).............................................................. 989 Failure code [AB00MA] (Alternator: Malfunction).................................................................................................. 993 Failure code [B@BAZG] (Rotation derating by low engine oil pressure)............................................................................. 997 Failure code [B@BAZK] (Engine oil: Low level).................................................................................................... 998 Failure code [B@BCNS] (Coolant: Overheating)..................................................................................................... 999 Failure code [B@BCZK] (Coolant: Low level).......................................................................................................1001 Failure code [B@BEBF] (Water in fuel error)......................................................................................................1004 Failure code [B@C7NS] (Brake oil: Overheating)...................................................................................................1006 Failure code [b@CENS] (Torque converter oil: Overheating)........................................................................................1008 Failure code [B@CENS] (Torque converter oil: Overheating)........................................................................................1011 Failure code [B@HANS] (Hydraulic oil: Overheating)...............................................................................................1014 Failure code [CA111] (Abnormality in engine controller)..........................................................................................1016 Failure code [CA115] (Engine Ne or Bkup speed sensor error)......................................................................................1017 Failure code [CA122] (Charge pressure sensor high error).........................................................................................1018 Failure code [CA123] (Charge pressure sensor low error)..........................................................................................1020 Failure code [CA131] (Throttle sensor high error)................................................................................................1022 Failure code [CA132] (Throttle sensor low error).................................................................................................1024 Failure code [CA144] (Coolant sensor high error).................................................................................................1026 Failure code [CA145] (Coolant sensor low error)..................................................................................................1028 Failure code [CA153] (Charge temperature sensor high error)......................................................................................1030 Failure code [CA154] (Charge temperature sensor low error).......................................................................................1032 Failure code [CA155] (Derating of speed by abnormally high charge temperature)...................................................................1034 Failure code [CA187] (Sensor power supply 2 low error)...........................................................................................1036 Failure code [CA221] (Atmospheric pressure sensor high error)....................................................................................1038 Failure code [CA222] (Atmospheric sensor low error)..............................................................................................1040 Failure code [CA227] (Sensor power supply 2 high error)..........................................................................................1042 Failure code [CA234] (Engine overspeed)..........................................................................................................1043 Failure code [CA238] (Ne speed sensor power supply error)........................................................................................1044 Troubleshooting by failure code (Display of code), Part 3............................................................................................1047 Failure code [CA271] (IMV/PCV1 Short circuit)....................................................................................................1049 Failure code [CA272] (IMV/PCV1 Disconnection)....................................................................................................1050 Failure code [CA322] (Injector #1 open/short error)..............................................................................................1052 Failure code [CA323] (Injector #5 open/short error)..............................................................................................1054 Failure code [CA324] (Injector #3 open/short error)..............................................................................................1056 Failure code [CA325] (Injector #6 open/short error)..............................................................................................1058 Failure code [CA331] (Injector #2 open/short error)..............................................................................................1060 Failure code [CA332] (Injector #4 open/short error)..............................................................................................1062 Failure code [CA342] (Calibration code inconsistency)............................................................................................1064 Failure code [CA351] (Injectors drive circuit error).............................................................................................1066 Failure code [CA352] (Sensor power supply 1 low error)...........................................................................................1069 Failure code [CA386] (Sensor power supply 1 high error)..........................................................................................1071 Failure code [CA428] (Abnormally high level in water sensor).....................................................................................1072 Failure code [CA429] (Abnormally low level in water sensor)......................................................................................1073 Failure code [CA431] (Idle validation switch error)..............................................................................................1074 Failure code [CA432] (Idle validation action error)..............................................................................................1077 Failure code [CA435] (Engine oil pressure switch error)..........................................................................................1079 Failure code [CA441] (Battery voltage low error).................................................................................................1080 Failure code [CA442] (Battery voltage high error)................................................................................................1084 Failure code [CA449] Common rail pressure high error 2...........................................................................................1087 Failure code [CA451] (Common rail pressure sensor high error)....................................................................................1089 Failure code [CA452] (Common rail pressure sensor low error).....................................................................................1091 Failure code [CA488] (Derating of torque by abnormally high charge temperature)..................................................................1093 Failure code [CA553] (Common rail pressure high error 1).........................................................................................1094 Failure code [CA559] (Supply pump pressure very low error).......................................................................................1095 Failure code [CA689] (Engine Ne speed sensor error)..............................................................................................1097 Failure code [CA731] (Engine Bkup speed sensor phase error)......................................................................................1099 Failure code [CA757] (All continuous data lost error)............................................................................................1100 Failure code [CA778] (Engine Bkup speed sensor error)............................................................................................1104 Failure code [CA1633] (KOMNET datalink timeout error)............................................................................................1107 Failure code [CA2185] (Throttle sensor power supply voltage high error)..........................................................................1110 Failure code [CA2186] (Throttle sensor power supply voltage low error)...........................................................................1111 Troubleshooting by failure code (Display of code), Part 4............................................................................................1113 Failure code [CA2249] (Supply pump pressure very low error 2)....................................................................................1115 Failure code [CA2311] (Abnormality in IMV solenoid)..............................................................................................1116 Failure code [CA2555] (Intake heater relay disconnection error)..................................................................................1118 Failure code [CA2556] (Intake heater relay short circuit error)..................................................................................1121 Failure code [D150KA] (Emergency steering relay: Disconnection)..................................................................................1124 Failure code [D150KB] (Emergency steering relay: Short circuit)..................................................................................1127 Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line)...........................................................1130 Failure code [D160KA] (Backup lamp relay: Disconnection).........................................................................................1133 Failure code [D160KB] (Backup lamp relay: Short circuit).........................................................................................1136 Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection)....................................................................1139 Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit)....................................................................1141 Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line).............................................1143 Failure code [D192KA] (ECSS solenoid: Disconnection).............................................................................................1145 Failure code [D192KB] (ECSS solenoid: Short circuit).............................................................................................1146 Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)......................................................................1147 Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection)......................................................................1148 Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit)......................................................................1150 Failure code [D193KY] (Joystick steering solenoid cut relay: Short circuit with power supply line)...............................................1152 Failure code [D5ZHKA] (Terminal C signal: Disconnection).........................................................................................1155 Failure code [D5ZHKB] (Terminal C signal: Short circuit).........................................................................................1161 Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit)........................................................................1166 Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state).................................................1173 Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)..........................................................................1178 Failure code [DAF3KK] (Machine monitor: Low source voltage (input)...............................................................................1180 Failure code [DAF5KP] (Machine monitor: Low output voltage)......................................................................................1184 Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system)..................1188 Troubleshooting by failure code (Display of code), Part 5............................................................................................1193 Failure code [DAQ0KK] (Transmission controller: Low source voltage)..............................................................................1196 Failure code [DAQ0KT] (Transmission controller: Abnormality in controller).......................................................................1200 Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input)................................................1201 Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals).........................................1204 Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system)..........1205 Failure code [DAQRMA] (Transmission controller option setting: Malfunction)......................................................................1211 Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system)................1212 Failure code [DB90KK] Work equipment controller: Low source voltage (input)......................................................................1216 Failure code [DB90KT] Work equipment controller: Abnormality in controller.......................................................................1218 Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)...............................................1219 Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range...................................................1221 Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals).......................................1224 Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system).........1225 Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)....................................................................1227 Failure code [DB9RMC] (CAN communication with transmission controller, engine controller and machine monitor: Defective operation)...............1228 Failure code [DD15LD] โ switch (Panel switch 1) : Switch is kept pressed for long time...........................................................1232 Failure code [DD16LD] <> switch (Panel switch 2) : Switch is kept pressed for long time..........................................................1235 Failure code [DD17LD] < switch (Panel switch 3) : Switch is kept pressed for long time...........................................................1238 Failure code [DD18LD] > switch (Panel switch 4) : Switch is kept pressed for long time...........................................................1241 Failure code [DD1ALD] Remote positioner raise/lower set switch (raise) : Switch is kept pressed for long time....................................1244 Failure code [DD1BLD] Remote positioner raise/lower set switch (lower) : Switch is kept pressed for long time....................................1246 Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time...........................................................1248 Failure code [DD1FLD] Load meter mode selector switch (A/B) : Switch is kept pressed for long time...............................................1250 Failure code [DD1GLD] Load meter mode selector switch (+/โ) : Switch is kept pressed for long time...............................................1252 Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time).................................................1254 Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time).................................................................1256 Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time).......................................................1258 Failure code [DDB6L4] (Parking brake switch (Neutralizer) : ON/OFF signals disagree).............................................................1260 Troubleshooting by failure code (Display of code), Part 6............................................................................................1265 Failure code [DDE5MA] (Emergency steering drive switch: Malfunction).............................................................................1268 Failure code [DDK3KA] (Right FNR switch: Disconnection)..........................................................................................1271 Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection)..............................................................................1274 Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)..........................................................1277 Failure code [DDK6KA] (FNR lever switch: Disconnection)..........................................................................................1279 Failure code [DDK6KB] (FNR lever switch: Short circuit)..........................................................................................1286 Failure code [DDS5KA] (Steering pressure switch: Disconnected)...................................................................................1290 Failure code [DDS5KB] (Steering pressure switch: Grounded).......................................................................................1292 Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)......................................................................1294 Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)....................................................1297 Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)...................................................................1300 Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)........................................................................1303 Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)...........................................................1306 Failure code [DF10KA] (Transmission shift lever switch: Disconnected)............................................................................1308 Failure code [DF10KB] (Transmission shift lever switch: Short circuit)...........................................................................1312 Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected)........................................................................1315 Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit).......................................................................1318 Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)..............................................................1321 Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)..........................................................................1323 Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range).............................................................1325 Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range).......................................................1327 Failure code [DH21KA] (Loader pump pressure sensor: Disconnection)...............................................................................1330 Failure code [DH21KB] (Loader pump pressure sensor: Power supply line short).....................................................................1332 Troubleshooting by failure code (Display of code), Part 7............................................................................................1335 Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)......................................................1338 Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)........................................................1340 Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range)..........................................................1342 Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection).............................................................................1346 Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit).............................................................................1348 Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)...................................................................1350 Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)............................................1353 Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree).........................................................1356 Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)....................................................................1359 Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line).............................................1362 Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection).....................................................................1365 Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)..............................................1368 Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree)...........................................................1371 Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)......................................................................1374 Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line)...............................................1377 Troubleshooting by failure code (Display of code), Part 8............................................................................................1381 Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection)..........................................................1383 Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line)...................................1386 Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)...........................................................1388 Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line)....................................1392 Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree)................................................1394 Failure code [DKA0KA] (Lift arm angle sensor: Disconnection).....................................................................................1398 Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)..............................................................1400 Failure code [DKA0L0] (Lift arm angle sensor: Dislocation of sensor).............................................................................1402 Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)....................................................................1404 Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range)........................................................1406 Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit).......................................................................1408 Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)................................................................1412 Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit)................................................................1414 Failure code [DV00KB] (Alarm buzzer: Short circuit)..............................................................................................1416 Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)...............................................................................1418 Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)...............................................................................1420 Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line)........................................................1422 Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)...............................................................................1424 Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)...............................................................................1425 Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line)........................................................1426 Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)..................................................................................1428 Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)..................................................................................1429 Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)...........................................................1430 Troubleshooting by failure code (Display of code), Part 9............................................................................................1433 Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)..................................................................................1435 Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)..................................................................................1436 Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line)...........................................................1438 Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)......................................................................................1440 Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)......................................................................................1442 Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)...............................................................1444 Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)......................................................................1446 Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)......................................................................1448 Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line)...............................................1450 Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection).....................................................................1452 Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit).....................................................................1454 Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line)..............................................1456 Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection).....................................................................1458 Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit).....................................................................1460 Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line)..............................................1462 Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection)........................................................................1464 Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)........................................................................1466 Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source)........................................................1468 Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection).....................................................................................1470 Failure code [DX16KA] (Fan motor EPC solenoid: Disconnection)....................................................................................1471 Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit).....................................................................................1472 Failure code [DX16KB] (Fan motor EPC solenoid: Short circuit)....................................................................................1473 Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)..............................................................1474 Failure code [DX16KY] (Fan motor EPC solenoid: Short circuit with power supply line).............................................................1475 Failure code [DXA1KA] (Loader pump EPC solenoid: Disconnection)..................................................................................1476 Failure code [DXA1KB] (Loader pump EPC solenoid: Short circuit)..................................................................................1478 Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)......................................................................................1480 Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)......................................................................................1482 Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)...............................................................1484 Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)..................................................................................1486 Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)..................................................................................1488 Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)...........................................................1490 Troubleshooting by failure code (Display of code), Part 10...........................................................................................1493 Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)..................................................................................1496 Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)..................................................................................1498 Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)...........................................................1500 Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)..................................................................................1502 Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)..................................................................................1504 Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)...........................................................1506 Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)....................................................................................1508 Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)....................................................................................1510 Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line).............................................................1512 Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)....................................................................................1514 Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)....................................................................................1516 Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line).............................................................1518 Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)..................................................................................1520 Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)..................................................................................1522 Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)...........................................................1524 Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)......................................................................1526 Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit)......................................................................1528 Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line)...............................................1530 Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection).......................................................................1532 Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit).......................................................................1534 Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line)................................................1536 Failure code [DY30MA] Motor-driven emergency steering pump failure (During operation of machine).................................................1538 Failure code [DY30MC] Motor-driven emergency steering pump failure (Malfunction in manual mode)..................................................1543 Troubleshooting of electrical system (E-mode)........................................................................................................1551 Installing positions of fuses....................................................................................................................1553 Information in troubleshooting table.............................................................................................................1558 E-1 Engine does not start........................................................................................................................1559 E-2 Wiper does not operate.......................................................................................................................1572 E-3 Windshield washer does not operate...........................................................................................................1577 E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off..............................................................1581 E-5 Working lamp does not light up or go off.....................................................................................................1597 E-6 Turn signal lamp and hazard lamp do not light up or go off...................................................................................1607 E-7 Brake lamp does not light or it keeps lighting up............................................................................................1619 E-8 Backup lamp does not light or it keeps lighting up...........................................................................................1623 E-9 Backup buzzer does not sound or it keeps sounding............................................................................................1627 E-10 Horn does not sound or it keeps sounding....................................................................................................1630 E-11 Alarm buzzer does not sound or it keeps sounding............................................................................................1634 E-12 Air conditioner does not operate or stop....................................................................................................1636 E-13 The KOMTRAX system does not work properly...................................................................................................1640 E-14 When kick-down switch is turned ON, kick-down operation does not start......................................................................1643 E-15 When hold switch is pressed, holding operation does not start...............................................................................1646 E-16 Transmission is kept in neutral, or brake drags when directional lever is operated while parking brake is applied...........................1649 E-17 Transmission cut-off mode cannot be set or reset............................................................................................1652 E-18 Transmission cut-off set cannot be reset....................................................................................................1655 E-19 FNR switch mode cannot be set or reset......................................................................................................1658 E-20 Fan reverse function cannot be used or reset................................................................................................1660 E-21 Discharge from loader pump does not rise from minimum level.................................................................................1662 E-22 ECSS function cannot be used or reset.......................................................................................................1664 E-23 When parking brake is turned ON, parking brake indicator lamp does not light up.............................................................1666 E-24 When emergency brake operates, brake oil pressure caution lamp does not operate.............................................................1670 E-25 Air cleaner clogging indicator lamp does not light up.......................................................................................1674 E-26 Radiator coolant level caution lamp does not light up.......................................................................................1677 E-27 Hydraulic oil temperature gauge does not rise and hydraulic oil temperature caution lamp does not light.....................................1679 ๅ็งฐๆช่จญๅฎ............................................................................................................................................1681 E-29 Steering oil pressure caution lamp does not light up........................................................................................1683 E-30 Abnormality in โ switch (panel switch 1) input..............................................................................................1686 E-31 Abnormality in <> switch (panel switch 2) input.............................................................................................1689 E-32 Abnormality in < switch (panel switch 3) input..............................................................................................1692 E-33 Abnormality in > switch (panel switch 4) input..............................................................................................1695 Troubleshooting of hydraulic and mechanical system (H-mode)..........................................................................................1699 Method of using troubleshooting chart............................................................................................................1701 Table of failure modes and causes................................................................................................................1704 H-1 The machine does not start...................................................................................................................1712 H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch].....................................................1714 H-3 Torque converter lockup is not switched on [Machine with lockup clutch]......................................................................1715 H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted.......................1716 H-5 Shocks are large at the times of starting and shifting gear..................................................................................1718 H-6 Time lag is large at the times of starting and shifting gear.................................................................................1720 H-7 The torque converter oil temperature is high.................................................................................................1722 H-8 Steering does not turn.......................................................................................................................1723 H-9 Steering does not turn [Machine with joystick steering]......................................................................................1724 H-10 Steering response is low....................................................................................................................1725 H-11 Turning, response of steering is poor [machine with joystick steering]......................................................................1726 H-12 Steering is heavy...........................................................................................................................1727 H-13 When machine turns, it shakes or makes large shocks.........................................................................................1728 H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering]........................................................1729 H-15 The wheel brake does not work or does not work well.........................................................................................1730 H-16 The wheel brake is not released or it drags.................................................................................................1731 H-17 The parking brake does not work or does not work well.......................................................................................1732 H-18 The parking brake is not released or it drags (including emergency release system)..........................................................1733 H-19 Lift arm does not rise......................................................................................................................1734 H-20 Lift arm speed is low or rising force of lift arm is insufficient...........................................................................1735 H-21 When rising, the lift arm comes to move slowly at specific height...........................................................................1736 H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats)...........................................................................1736 H-23 Hydraulic drifts of the lift arm is large...................................................................................................1736 H-24 The lift arm wobbles during operation.......................................................................................................1736 H-25 Bucket does not tilt back...................................................................................................................1737 H-26 Bucket speed is low or tilting back force is insufficient...................................................................................1738 H-27 The bucket comes to operate slowly in the midst of tilting-back.............................................................................1739 H-28 The bucket cylinder cannot hold down the bucket.............................................................................................1739 H-29 Hydraulic drifts of the bucket is large.....................................................................................................1739 H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to โHOLDโ).....................................................1739 H-31 Lift arm and bucket control levers do not move smoothly and are heavy.......................................................................1740 H-32 During operation of the machine, engine speed lowers remarkably or engine stalls............................................................1741 H-33 Large shock is made when work equipment starts and stops....................................................................................1741 H-34 When work equipment circuit is relieved singly, other work equipment moves..................................................................1741 H-35 ECSS does not operate, and pitching, bouncing occur.........................................................................................1742 H-36 Fan revolution is abnormal (Fan sound/ vibration is abnormally large or engine overheats)...................................................1743 Troubleshooting of engine (S-mode)...................................................................................................................1745 Method of using troubleshooting charts...........................................................................................................1747 S-1 Engine does not start easily.................................................................................................................1750 S-2 Engine does not start........................................................................................................................1751 S-3 Engine does not pick up smoothly.............................................................................................................1754 S-4 Engine stops during operations...............................................................................................................1755 S-5 Engine does not rotate smoothly..............................................................................................................1756 S-6 Engine lacks output (or lacks power).........................................................................................................1757 S-7 Exhaust smoke is black (Incomplete combustion)...............................................................................................1758 S-8 Oil consumption is excessive (or exhaust smoke is blue)......................................................................................1759 S-9 Engine oil becomes contaminated quickly......................................................................................................1760 S-10 Fuel consumption is excessive...............................................................................................................1761 S-11 Coolant contains oil (blows back or reduces)................................................................................................1762 S-12 Oil pressure drops..........................................................................................................................1763 S-13 Oil level rises (Water, fuel in oil)........................................................................................................1764 S-14 Coolant temperature rises too high (Overheating)............................................................................................1765 S-15 Abnormal noise is made......................................................................................................................1766 S-16 Vibration is excessive......................................................................................................................1767 50 Disassembly and assembly.............................................................................................................................. 0 General information on disassembly and assembly......................................................................................................1769 How to read this manual..........................................................................................................................1770 Special tools list...............................................................................................................................1775 Sketches of special tools........................................................................................................................1778 Engine and cooling system............................................................................................................................1785 Removal and installation of fuel supply pump assembly............................................................................................1786 Removal and installation of fue linjector assembly...............................................................................................1790 Removal and installation of cylinder head assembly...............................................................................................1804 Removal and installation of engine hood assembly.................................................................................................1826 Removal and installation of radiator assembly....................................................................................................1831 Removal and installation of air aftercooler......................................................................................................1836 Removal and installation of hydraulic oil cooler assembly........................................................................................1838 Removal and installation of engine assembly......................................................................................................1840 Removal and installation of engine front oil seal assembly.......................................................................................1845 Removal and installation of engine rear oil seal assembly........................................................................................1848 Removal and installation of cooling fan and fan motor assembly...................................................................................1851 Removal and installation of fuel tank assembly...................................................................................................1857 Power train..........................................................................................................................................1861 Removal and installation of torque converter and transmission assembly...........................................................................1862 Disassembly and assembly of torque converter assembly (Standard specification)...................................................................1868 Disassembly and assembly of torque converter assembly (Lockup specification).....................................................................1872 Disassembly and assembly of transmission assembly................................................................................................1878 Disassembly and assembly of transmission clutch pack assembly....................................................................................1895 Disassembly and assembly of parking brake assembly...............................................................................................1914 Removal and installation of front axle assembly..................................................................................................1923 Removal and installation of rear axle assembly...................................................................................................1925 Disassembly and assembly of axle housing.........................................................................................................1928 Disassembly and assembly of differential assembly................................................................................................1937 Steering system......................................................................................................................................1957 Removal and installation of steering valve assembly..............................................................................................1958 Brake system.........................................................................................................................................1963 Removal and installation of parking brake discs and plates.......................................................................................1964 Undercarriage and frame..............................................................................................................................1969 Removal and installation of center hinge pin.....................................................................................................1970 Removal and installation of counterweight........................................................................................................1978 Hydraulic system.....................................................................................................................................1983 Removal and installation of work equipment control valve assembly................................................................................1984 Removal and installation of power train pump and work equipment pump assembly....................................................................1990 Removal and installation of steering pump and cooling fan pump assembly..........................................................................1991 Removal and installation of hydraulic tank assembly..............................................................................................1993 Work equipment.......................................................................................................................................1997 Removal and installation of work equipment assembly..............................................................................................1998 Disassembly and assembly of hydraulic cylinder assembly..........................................................................................2002 Cab and its attachments..............................................................................................................................2011 Removal and installation of operator's cab and floor frame assembly..............................................................................2012 Removal and installation of operator's cab glass (stuck glass)...................................................................................2019 Disassembly and assembly of operator's seat assembly (Standard specification)....................................................................2027 Disassembly and assembly of operator's seat assembly (Manufactured by GRAMMER)...................................................................2036 Removal and installation of air conditioner unit assembly........................................................................................2069 Electrical system....................................................................................................................................2073 Removal and installation of engine controller assembly...........................................................................................2074 90 Diagrams and drawings................................................................................................................................. 0 Hydraulic diagrams and drawings......................................................................................................................2077 Power train hydraulic circuit diagram............................................................................................................2078 Automatic greasing circuit diagram...............................................................................................................2080 Hydraulic circuit diagram........................................................................................................................2083 Electrical diagrams and drawings.....................................................................................................................2087 Electrical circuit diagram.......................................................................................................................2089 Work equipment controller system electrical circuit diagram......................................................................................2112 Connector list and stereogram....................................................................................................................2113
DESCRIPTION:
KOMATSU WA380-6 WA380Z-6 WHEEL LOADER SHOP MANUAL SEN05717-01 – PDF DOWNLOAD
General precautionsย
- ย Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual.
- ย Locate a place in the repair workshop to keep the tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
- ย When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing.
1. Always wear the protective eyeglasses when hitting parts with a hammer.
2. Always wear the protective eyeglasses when grinding parts with a grinder, etc. - When performing any work with 2 or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of โUNDER WORKINGโ in the operatorโs compartment.
- Only qualified workers must perform the work and operation which require license or qualification.
- Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, lift truck, service vehicle, etc.
- If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc.
- Before starting work, warm up your body thoroughly to start work under good condition.
- Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place.
S.S 30/12/24
