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Komatsu WA380-6 WA380Z0-6 Wheel Loader Service Repair Manual – PDF Download
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- Komatsu WA380-6 WA380Z0-6 Wheel Loader Service Repair Manual
- SERIAL NUMBERS
- WA380- 65001 and up
WA380Z-66847 and up - PUBLICATION NUMBER:SEN06411-00
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Description
Komatsu WA380-6 WA380Z0-6 Wheel Loader Service Repair Manual
Description:
Komatsu WA380-6 WA380Z0-6 Wheel Loader Service Repair Manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Engine volume This section explains the method of reproducing, repairing, and replacing parts.
Table of Contents:
Komatsu WA380-6 WA380Z0-6 Wheel Loader Service Repair Manual
Cover.................................................................................................................................................... 1 00 Index and foreword.................................................................................................................................... 0 Index................................................................................................................................................ 2 Composition of shop manual....................................................................................................................... 3 Table of contents................................................................................................................................ 5 Foreword and general information..................................................................................................................... 18 Safety notice.................................................................................................................................... 19 How to read the shop manual...................................................................................................................... 24 Explanation of terms for maintenance standard.................................................................................................... 26 Handling of electric equipment and hydraulic component........................................................................................... 28 Handling of connectors newly used for engines.................................................................................................... 37 How to read electric wire code................................................................................................................... 40 Precautions when carrying out operation.......................................................................................................... 43 Method of disassembling and connecting push-pull type coupler.................................................................................... 46 Standard tightening torque table................................................................................................................. 49 Conversion table................................................................................................................................. 53 01 Specification......................................................................................................................................... 60 Specification and technical data..................................................................................................................... 0 Specification dimension drawing.................................................................................................................. 61 Specifications................................................................................................................................... 63 Weight table..................................................................................................................................... 71 Table of fuel, coolant and lubricants............................................................................................................ 75 10 Structure, function and maintenance standard.......................................................................................................... 0 Engine and cooling system............................................................................................................................ 78 Engine mount and transmission mount.............................................................................................................. 79 Cooling system................................................................................................................................... 80 Cooling fan pump................................................................................................................................. 82 Brake and fan pump............................................................................................................................... 89 Cooling fan motor................................................................................................................................ 90 Power train.......................................................................................................................................... 104 Power train...................................................................................................................................... 106 Power train system diagram....................................................................................................................... 107 Drive shaft...................................................................................................................................... 110 Power train piping diagram....................................................................................................................... 111 Torque converter................................................................................................................................. 113 Transmission..................................................................................................................................... 121 Flow control valve............................................................................................................................... 155 Valve assembly................................................................................................................................... 157 ECMV............................................................................................................................................. 158 Main relief valve and torque converter relief valve.............................................................................................. 166 Differential..................................................................................................................................... 170 Limited slip differential........................................................................................................................ 174 Final drive...................................................................................................................................... 181 Steering system...................................................................................................................................... 186 Steering piping diagram.......................................................................................................................... 187 Steering column.................................................................................................................................. 189 Steering pump.................................................................................................................................... 191 Steering valve................................................................................................................................... 211 Orbit-roll valve................................................................................................................................. 226 Stop valve....................................................................................................................................... 234 Steering relief valve............................................................................................................................ 235 Steering cylinder................................................................................................................................ 236 Emergency steering motor......................................................................................................................... 238 Emergency steering pump.......................................................................................................................... 239 Joystick steering lever linkage.................................................................................................................. 240 Steering electric lever.......................................................................................................................... 241 Joystick EPC valve............................................................................................................................... 242 Brake system......................................................................................................................................... 244 Brake piping diagram............................................................................................................................. 245 Charge valve..................................................................................................................................... 247 Brake valve...................................................................................................................................... 254 Accumulator (for brake).......................................................................................................................... 259 Brake............................................................................................................................................ 261 Parking brake control............................................................................................................................ 266 Parking brake.................................................................................................................................... 267 Parking brake solenoid valve..................................................................................................................... 269 Emergency parking brake release valve............................................................................................................ 271 Undercarriage and frame.............................................................................................................................. 274 Axle mount and center hinge pin.................................................................................................................. 275 Tires............................................................................................................................................ 280 Hydraulic system, Part 1............................................................................................................................. 282 Hydraulic piping diagram......................................................................................................................... 283 Work equipment control lever linkage............................................................................................................. 289 Hydraulic tank................................................................................................................................... 292 Power train pump................................................................................................................................. 296 Work equipment pump.............................................................................................................................. 297 Work equipment control valve..................................................................................................................... 319 CLSS............................................................................................................................................. 347 Each function and operation of each valve........................................................................................................ 351 Hydraulic system, Part 2............................................................................................................................. 384 PPC valve........................................................................................................................................ 385 Stabilizer valve................................................................................................................................. 391 Accumulator (for PPC circuit).................................................................................................................... 397 Accumulator (for ECSS)........................................................................................................................... 398 Work equipment PPC cut-off solenoid valve........................................................................................................ 399 Work equipment....................................................................................................................................... 402 Work equipment linkage........................................................................................................................... 403 Bucket........................................................................................................................................... 407 Bucket positioner and boom kick-out.............................................................................................................. 409 Work equipment cylinder.......................................................................................................................... 415 Cab and its attachments.............................................................................................................................. 418 Cab.............................................................................................................................................. 420 Air conditioner.................................................................................................................................. 421 Electrical system, Part 1............................................................................................................................ 442 Machine monitor system........................................................................................................................... 443 Machine monitor.................................................................................................................................. 451 Electrical system, Part 2............................................................................................................................ 510 Electrical system (Transmission controller system)............................................................................................... 511 Transmission controller.......................................................................................................................... 555 Electrical system (Work equipment controller system)............................................................................................. 559 Work equipment controller........................................................................................................................ 565 Electrical system, Part 3............................................................................................................................ 568 Electric transmission control.................................................................................................................... 569 Kickdown switch and hold switch.................................................................................................................. 573 Multi-function knob.............................................................................................................................. 575 Joystick steering knob........................................................................................................................... 576 KOMTRAX terminal system.......................................................................................................................... 577 Engine starting circuit.......................................................................................................................... 579 Engine stopping circuit.......................................................................................................................... 583 Preheating circuit............................................................................................................................... 585 Engine power mode selector circuit............................................................................................................... 586 Engine output derating function.................................................................................................................. 587 Automatic warm-up function....................................................................................................................... 587 Parking brake circuit............................................................................................................................ 589 Sensor........................................................................................................................................... 591 20 Standard value table.................................................................................................................................. 0 Standard service value table......................................................................................................................... 602 Standard service value table for engine.......................................................................................................... 603 Standard service value table for chassis......................................................................................................... 605 30 Testing and adjusting................................................................................................................................. 0 Testing and adjusting, Part 1........................................................................................................................ 618 Tools for testing, adjusting, and troubleshooting................................................................................................ 620 Testing engine speed............................................................................................................................. 627 Testing exhaust gas color........................................................................................................................ 629 Adjusting valve clearance........................................................................................................................ 631 Testing compression pressure..................................................................................................................... 636 Testing blow-by pressure......................................................................................................................... 642 Testing engine oil pressure...................................................................................................................... 643 Testing intake air (boost) pressure1............................................................................................................. 645 Handling fuel system equipment................................................................................................................... 647 Releasing residual pressure in fuel system....................................................................................................... 647 Testing fuel pressure............................................................................................................................ 648 Testing fuel delivery, return and leak amount.................................................................................................... 653 Bleeding air from fuel circuit................................................................................................................... 661 Testing leakage in fuel system................................................................................................................... 662 Handling reduced cylinder mode operation......................................................................................................... 663 Handling no-injection cranking operation......................................................................................................... 663 Handling controller voltage circuit1............................................................................................................. 664 Testing muffler (main body) and muffler stack for looseness or damage............................................................................ 664 Testing muffler for functions.................................................................................................................... 665 Testing cylinder head and manifold parts for tightness........................................................................................... 665 Testing engine piping for damage and tightness................................................................................................... 666 Testing and adjusting air conditioner compressor belt tension.................................................................................... 667 Replacing alternator belt........................................................................................................................ 668 Adjusting transmission speed sensor.............................................................................................................. 670 Adjusting length of directional lever............................................................................................................ 671 Adjusting length of gearshift lever.............................................................................................................. 671 Testing directional lever........................................................................................................................ 672 Testing and adjusting power train oil pressure................................................................................................... 673 Procedure for flushing torque converter and transmission hydraulic circuit....................................................................... 702 Method of moving machine when transmission valve is broken....................................................................................... 703 Testing axle end for oil leakage................................................................................................................. 707 Testing drive shaft for looseness, backlash and damage........................................................................................... 707 Testing and adjusting steering stop valve........................................................................................................ 708 Testing and adjusting steering wheel............................................................................................................. 710 Testing and adjusting steering oil pressure...................................................................................................... 712 Bleeding air from steering circuit............................................................................................................... 715 Testing and adjusting, Part 2........................................................................................................................ 718 Testing hydraulic drive fan...................................................................................................................... 720 Bleeding air from hydraulic drive fan circuit.................................................................................................... 724 Testing brake pedal.............................................................................................................................. 727 Testing and adjusting brake pedal linkage........................................................................................................ 728 Testing brake performance........................................................................................................................ 729 Testing and adjusting accumulator charge pressure................................................................................................ 730 Testing wheel brake oil pressure................................................................................................................. 732 Testing wheel brake oil pressure drop............................................................................................................ 733 Testing wear of wheel brake disc................................................................................................................. 735 Bleeding air from wheel brake circuit............................................................................................................ 736 Releasing residual pressure in brake accumulator circuit......................................................................................... 737 Testing parking brake performance................................................................................................................ 738 Testing parking brake oil pressure............................................................................................................... 739 Testing wear of parking brake disc............................................................................................................... 741 Method of releasing parking brake manually....................................................................................................... 742 Testing and adjusting work equipment control lever............................................................................................... 743 Testing and adjusting worke quipment PPC oil pressure............................................................................................ 744 Testing and adjusting work equipment oil pressure................................................................................................ 750 Bleeding air from work equipment circuit......................................................................................................... 754 Releasing residual pressure in work equipment circuit............................................................................................ 755 Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of ECSS (Electronically Controlled Suspension System) accumulator.... 757 Testing and adjusting bucket positioner.......................................................................................................... 763 Testing and adjusting boom kick-out.............................................................................................................. 765 Checking proximity switch operation pilot lamp................................................................................................... 766 Procedure for testing diodes..................................................................................................................... 767 Preparation work for troubleshooting for electric system......................................................................................... 768 How to start operation of KOMTRAX terminal....................................................................................................... 777 Lamp display of KOMTRAX terminal................................................................................................................. 782 Testing and adjusting, Part 3........................................................................................................................ 786 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor........................................................... 788 Special functions of machine monitor (EMMS)...................................................................................................... 790 Pm-clinic inspection table....................................................................................................................... 859 40 Troubleshooting....................................................................................................................................... 0 Failure code table and fuse locations................................................................................................................ 866 Failure code table............................................................................................................................... 867 Fuse locations................................................................................................................................... 884 General information on troubleshooting............................................................................................................... 890 Points to remember when troubleshooting.......................................................................................................... 891 Sequence of events in troubleshooting............................................................................................................ 892 Testing before troubleshooting................................................................................................................... 894 Classification and procedures of troubleshooting................................................................................................. 895 Information contained in troubleshooting table................................................................................................... 898 Connection table for connector pin numbers....................................................................................................... 900 T- branch box and T- branch adapter table........................................................................................................ 936 Troubleshooting by failure code (Display of code), Part 1............................................................................................ 940 Failure code [1500L0] (TORQFLOW transmission: Double meshing).................................................................................... 942 Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)............................................................ 943 Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)............................................................ 945 Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)............................................................ 947 Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)............................................................ 949 Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON).......................................................... 951 Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF).......................................................... 953 Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON).......................................................... 955 Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF).......................................................... 957 Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON).......................................................... 959 Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF).......................................................... 961 Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON).......................................................... 963 Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF).......................................................... 965 Failure code [2F00MA] (Parking brake: Malfunction)............................................................................................... 967 Failure code [2G43ZG] (Accumulator: Low oil pressure)............................................................................................ 970 Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree)............................................................................... 974 Troubleshooting by failure code (Display of code), Part 2............................................................................................ 978 Failure code [AA1ANX] (Air cleaner: Clogging).................................................................................................... 981 Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine).............................................................. 984 Failure code [AB00MA] (Alternator: Malfunction).................................................................................................. 988 Failure code [B@BAZG] (Rotation derating by low engine oil pressure)............................................................................. 992 Failure code [B@BAZK] (Engine oil: Low level).................................................................................................... 993 Failure code [B@BCNS] (Coolant: Overheating)..................................................................................................... 994 Failure code [B@BCZK] (Coolant: Low level)....................................................................................................... 996 Failure code [B@BEBF] (Water in fuel error)...................................................................................................... 999 Failure code [B@C7NS] (Brake oil: Overheating)...................................................................................................1001 Failure code [b@CENS] (Torque converter oil: Overheating)........................................................................................1003 Failure code [B@CENS] (Torque converter oil: Overheating)........................................................................................1006 Failure code [B@HANS] (Hydraulic oil: Overheating)...............................................................................................1009 Failure code [CA111] (Abnormality in engine controller)..........................................................................................1011 Failure code [CA115] (Engine Ne or Bkup speed sensor error)......................................................................................1012 Failure code [CA122] (Charge pressure sensor high error).........................................................................................1013 Failure code [CA123] (Charge pressure sensor low error)..........................................................................................1015 Failure code [CA131] (Throttle sensor high error)................................................................................................1017 Failure code [CA132] (Throttle sensor low error).................................................................................................1019 Failure code [CA144] (Coolant sensor high error).................................................................................................1021 Failure code [CA145] (Coolant sensor low error)..................................................................................................1023 Failure code [CA153] (Charge temperature sensor high error)......................................................................................1025 Failure code [CA154] (Charge temperature sensor low error).......................................................................................1027 Failure code [CA155] (Derating of speed by abnormally high charge temperature)...................................................................1029 Failure code [CA187] (Sensor power supply 2 low error)...........................................................................................1031 Failure code [CA221] (Atmospheric pressure sensor high error)....................................................................................1033 Failure code [CA222] (Atmospheric sensor low error)..............................................................................................1035 Failure code [CA227] (Sensor power supply 2 high error)..........................................................................................1037 Failure code [CA234] (Engine overspeed)..........................................................................................................1038 Failure code [CA238] (Ne speed sensor power supply error)........................................................................................1039 Troubleshooting by failure code (Display of code), Part 3............................................................................................1042 Failure code [CA271] (IMV/PCV1 Short circuit)....................................................................................................1044 Failure code [CA272] (IMV/PCV1 Disconnection)....................................................................................................1045 Failure code [CA322] (Injector #1 open/short error)..............................................................................................1047 Failure code [CA323] (Injector #5 open/short error)..............................................................................................1049 Failure code [CA324] (Injector #3 open/short error)..............................................................................................1051 Failure code [CA325] (Injector #6 open/short error)..............................................................................................1053 Failure code [CA331] (Injector #2 open/short error)..............................................................................................1055 Failure code [CA332] (Injector #4 open/short error)..............................................................................................1057 Failure code [CA342] (Calibration code inconsistency)............................................................................................1059 Failure code [CA351] (Injectors drive circuit error).............................................................................................1061 Failure code [CA352] (Sensor power supply 1 low error)...........................................................................................1064 Failure code [CA386] (Sensor power supply 1 high error)..........................................................................................1066 Failure code [CA428] (Abnormally high level in water sensor).....................................................................................1067 Failure code [CA429] (Abnormally low level in water sensor)......................................................................................1068 Failure code [CA431] (Idle validation switch error)..............................................................................................1069 Failure code [CA432] (Idle validation action error)..............................................................................................1072 Failure code [CA435] (Engine oil pressure switch error)..........................................................................................1074 Failure code [CA441] (Battery voltage low error).................................................................................................1075 Failure code [CA442] (Battery voltage high error)................................................................................................1079 Failure code [CA449] Common rail pressure high error 2...........................................................................................1082 Failure code [CA451] (Common rail pressure sensor high error)....................................................................................1084 Failure code [CA452] (Common rail pressure sensor low error).....................................................................................1086 Failure code [CA488] (Derating of torque by abnormally high charge temperature)..................................................................1088 Failure code [CA553] (Common rail pressure high error 1).........................................................................................1089 Failure code [CA559] (Supply pump pressure very low error).......................................................................................1090 Failure code [CA689] (Engine Ne speed sensor error)..............................................................................................1091 Failure code [CA731] (Engine Bkup speed sensor phase error)......................................................................................1094 Failure code [CA757] (All continuous data lost error)............................................................................................1095 Failure code [CA778] (Engine Bkup speed sensor error)............................................................................................1099 Failure code [CA1633] (KOMNET datalink timeout error)............................................................................................1102 Failure code [CA2185] (Throttle sensor power supply voltage high error)..........................................................................1105 Failure code [CA2186] (Throttle sensor power supply voltage low error)...........................................................................1106 Troubleshooting by failure code (Display of code), Part 4............................................................................................1108 Failure code [CA2249] (Supply pump pressure very low error 2)....................................................................................1110 Failure code [CA2311] (Abnormality in IMV solenoid)..............................................................................................1111 Failure code [CA2555] (Intake heater relay disconnection error)..................................................................................1113 Failure code [CA2556] (Intake heater relay short circuit error)..................................................................................1116 Failure code [D150KA] (Emergency steering relay: Disconnection)..................................................................................1119 Failure code [D150KB] (Emergency steering relay: Short circuit)..................................................................................1122 Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line)...........................................................1125 Failure code [D160KA] (Backup lamp relay: Disconnection).........................................................................................1128 Failure code [D160KB] (Backup lamp relay: Short circuit).........................................................................................1131 Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection)....................................................................1134 Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit)....................................................................1136 Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line).............................................1138 Failure code [D192KA] (ECSS solenoid: Disconnection).............................................................................................1140 Failure code [D192KB] (ECSS solenoid: Short circuit).............................................................................................1141 Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)......................................................................1142 Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection)......................................................................1143 Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit)......................................................................1145 Failure code [D193KY] (Joystick steering solenoid cut relay: Short circuit with power supply line)...............................................1147 Failure code [D5ZHKA] (Terminal C signal: Disconnection).........................................................................................1150 Failure code [D5ZHKB] (Terminal C signal: Short circuit).........................................................................................1156 Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit)........................................................................1161 Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state).................................................1168 Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)..........................................................................1173 Failure code [DAF3KK] (Machine monitor: Low source voltage (input)...............................................................................1175 Failure code [DAF5KP] (Machine monitor: Low output voltage)......................................................................................1179 Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system)..................1183 Troubleshooting by failure code (Display of code), Part 5............................................................................................1188 Failure code [DAQ0KK] (Transmission controller: Low source voltage)..............................................................................1191 Failure code [DAQ0KT] (Transmission controller: Abnormality in controller).......................................................................1195 Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input)................................................1196 Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals).........................................1199 Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system)..........1200 Failure code [DAQRMA] (Transmission controller option setting: Malfunction)......................................................................1206 Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system)................1207 Failure code [DB90KK] Work equipment controller: Low source voltage (input)......................................................................1211 Failure code [DB90KT] Work equipment controller: Abnormality in controller.......................................................................1213 Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)...............................................1214 Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range...................................................1216 Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals).......................................1219 Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system).........1220 Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)....................................................................1222 Failure code [DB9RMC] (CAN communication with transmission controller, engine controller and machine monitor: Defective operation)...............1223 Failure code [DD15LD] ■ switch (Panel switch 1): Switch is kept pressed for long time............................................................1227 Failure code [DD16LD] <> switch (Panel switch 2): Switch is kept pressed for long time...........................................................1230 Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time............................................................1233 Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time............................................................1236 Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time.....................................1239 Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time.....................................1241 Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time...........................................................1243 Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time................................................1245 Failure code [DD1GLD] Load meter mode selector switch (+/-): Switch is kept pressed for long time................................................1247 Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time).................................................1249 Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time).................................................................1251 Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time).......................................................1253 Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)..............................................................1255 Troubleshooting by failure code (Display of code), Part 6............................................................................................1260 Failure code [DDE5MA] (Emergency steering drive switch: Malfunction).............................................................................1263 Failure code [DDK3KA] (Right FNR switch: Disconnection)..........................................................................................1266 Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection)..............................................................................1269 Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)..........................................................1272 Failure code [DDK6KA] (FNR lever switch: Disconnection)..........................................................................................1274 Failure code [DDK6KB] (FNR lever switch: Short circuit)..........................................................................................1281 Failure code [DDS5KA] (Steering pressure switch: Disconnected)...................................................................................1285 Failure code [DDS5KB] (Steering pressure switch: Grounded).......................................................................................1287 Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)......................................................................1289 Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)....................................................1292 Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)...................................................................1295 Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)........................................................................1298 Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)...........................................................1301 Failure code [DF10KA] (Transmission shift lever switch: Disconnected)............................................................................1303 Failure code [DF10KB] (Transmission shift lever switch: Short circuit)...........................................................................1307 Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected)........................................................................1310 Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit).......................................................................1313 Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)..............................................................1316 Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)..........................................................................1318 Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range).............................................................1320 Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range).......................................................1322 Failure code [DH21KA] (Loader pump pressure sensor: Disconnection)...............................................................................1325 Failure code [DH21KB] (Loader pump pressure sensor: Power supply line short).....................................................................1327 Troubleshooting by failure code (Display of code), Part 7............................................................................................1330 Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)......................................................1333 Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)........................................................1335 Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range)..........................................................1337 Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection).............................................................................1341 Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit).............................................................................1343 Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)...................................................................1345 Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)............................................1348 Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree).........................................................1351 Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)....................................................................1354 Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line).............................................1357 Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection).....................................................................1360 Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)..............................................1363 Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree)...........................................................1366 Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)......................................................................1369 Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line)...............................................1372 Troubleshooting by failure code (Display of code), Part 8............................................................................................1376 Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection)..........................................................1378 Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line)...................................1381 Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)...........................................................1383 Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line)....................................1387 Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree)................................................1389 Failure code [DKA0KA] (Lift arm angle sensor: Disconnection).....................................................................................1393 Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)..............................................................1395 Failure code [DKA0L0] (Lift arm angle sensor: Dislocation of sensor).............................................................................1397 Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)....................................................................1399 Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range)........................................................1401 Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit).......................................................................1403 Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)................................................................1407 Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit)................................................................1409 Failure code [DV00KB] (Alarm buzzer: Short circuit)..............................................................................................1411 Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)...............................................................................1413 Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)...............................................................................1415 Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line)........................................................1417 Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)...............................................................................1419 Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)...............................................................................1420 Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line)........................................................1421 Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)..................................................................................1423 Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)..................................................................................1424 Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)...........................................................1425 Troubleshooting by failure code (Display of code), Part 9............................................................................................1428 Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)..................................................................................1430 Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)..................................................................................1431 Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line)...........................................................1433 Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)......................................................................................1435 Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)......................................................................................1437 Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)...............................................................1439 Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)......................................................................1441 Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)......................................................................1443 Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line)...............................................1445 Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection).....................................................................1447 Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit).....................................................................1449 Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line)..............................................1451 Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection).....................................................................1453 Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit).....................................................................1455 Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line)..............................................1457 Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection)........................................................................1459 Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)........................................................................1461 Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source)........................................................1463 Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection) (WA380-6)...........................................................................1465 Failure code [DX16KA] (Fan motor EPC solenoid: Disconnection) (WA380Z-6).........................................................................1466 Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit) (WA380-6)...........................................................................1467 Failure code [DX16KB] (Fan motor EPC solenoid: Short circuit) (WA380Z-6).........................................................................1468 Failure code [DX16KY] (Fan motor EPC solenoid: Short circuit with power supply line) (WA380Z-6)..................................................1470 Failure code [DXA1KA] (Loader pump EPC solenoid: Disconnection)..................................................................................1471 Failure code [DXA1KB] (Loader pump EPC solenoid: Short circuit)..................................................................................1473 Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)......................................................................................1475 Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)......................................................................................1477 Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)...............................................................1479 Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)..................................................................................1481 Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)..................................................................................1483 Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)...........................................................1485 Troubleshooting by failure code (Display of code), Part 10...........................................................................................1488 Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)..................................................................................1491 Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)..................................................................................1493 Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)...........................................................1495 Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)..................................................................................1497 Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)..................................................................................1499 Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)...........................................................1501 Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)....................................................................................1503 Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)....................................................................................1505 Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line).............................................................1507 Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)....................................................................................1509 Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)....................................................................................1511 Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line).............................................................1513 Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)..................................................................................1515 Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)..................................................................................1517 Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)...........................................................1519 Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)......................................................................1521 Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit)......................................................................1523 Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line)...............................................1525 Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection).......................................................................1527 Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit).......................................................................1529 Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line)................................................1531 Failure code [DY30MA] Motor-driven emergency steering pump failure (During operation of machine).................................................1533 Failure code [DY30MC] Motor-driven emergency steering pump failure (Malfunction in manual mode)..................................................1538 Troubleshooting of electrical system (E-mode)........................................................................................................1546 Installing positions of fuses....................................................................................................................1548 Information in troubleshooting table.............................................................................................................1553 E-1 Engine does not start........................................................................................................................1554 E-2 Wiper does not operate.......................................................................................................................1567 E-3 Windshield washer does not operate...........................................................................................................1572 E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off..............................................................1576 E-5 Working lamp does not light up or go off.....................................................................................................1592 E-6 Turn signal lamp and hazard lamp do not light up or go off...................................................................................1602 E-7 Brake lamp does not light or it keeps lighting up............................................................................................1614 E-8 Backup lamp does not light or it keeps lighting up...........................................................................................1618 E-9 Backup buzzer does not sound or it keeps sounding............................................................................................1622 E-10 Horn does not sound or it keeps sounding....................................................................................................1625 E-11 Alarm buzzer does not sound or it keeps sounding............................................................................................1629 E-12 Air conditioner does not operate or stop....................................................................................................1631 E-13 The KOMTRAX system does not work properly...................................................................................................1635 E-14 When kick-down switch is turned ON, kick-down operation does not start......................................................................1638 E-15 When hold switch is pressed, holding operation does not start...............................................................................1641 E-16 Transmission is kept in neutral, or brake drags when directional lever is operated while parking brake is applied...........................1644 E-17 Transmission cut-off mode cannot be set or reset............................................................................................1647 E-18 Transmission cut-off set cannot be reset....................................................................................................1650 E-19 FNR switch mode cannot be set or reset......................................................................................................1653 E-20 Fan reverse function cannot be used or reset................................................................................................1655 E-21 Discharge from loader pump does not rise from minimum level.................................................................................1657 E-22 ECSS function cannot be used or reset.......................................................................................................1659 E-23 When parking brake is turned ON, parking brake indicator lamp does not light up.............................................................1661 E-24 When emergency brake operates, brake oil pressure caution lamp does not operate.............................................................1665 E-25 Air cleaner clogging indicator lamp does not light up.......................................................................................1669 E-26 Radiator coolant level caution lamp does not light up.......................................................................................1672 E-27 Hydraulic oil temperature gauge does not rise and hydraulic oil temperature caution lamp does not light up..................................1674 E-28 Torque converter oil temperature gauge does not rise and torque converter oil temperature caution lamp does not light up....................1676 E-29 Steering oil pressure caution lamp does not light up........................................................................................1678 E-30 Abnormality in ■ switch (panel switch 1) input..............................................................................................1681 E-31 Abnormality in <> switch (panel switch 2) input.............................................................................................1684 名称未設定............................................................................................................................................1687 E-32 Abnormality in < switch (panel switch 3) input..............................................................................................1687 E-33 Abnormality in > switch (panel switch 4) input..............................................................................................1690 Troubleshooting of hydraulic and mechanical system (H-mode)..........................................................................................1694 Method of using troubleshooting chart............................................................................................................1696 Table of failure modes and causes................................................................................................................1699 H-1 The machine does not start...................................................................................................................1707 H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch].....................................................1709 H-3 Torque converter lockup is not switched on [Machine with lockup clutch]......................................................................1710 H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted.......................1711 H-5 Shocks are large at the times of starting and shifting gear..................................................................................1713 H-6 Time lag is large at the times of starting and shifting gear.................................................................................1715 H-7 The torque converter oil temperature is high.................................................................................................1717 H-8 Steering does not turn.......................................................................................................................1718 H-9 Steering does not turn [Machine with joystick steering]......................................................................................1719 H-10 Steering response is low....................................................................................................................1720 H-11 Turning, response of steering is poor [machine with joystick steering]......................................................................1721 H-12 Steering is heavy...........................................................................................................................1722 H-13 When machine turns, it shakes or makes large shocks.........................................................................................1723 H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering]........................................................1724 H-15 The wheel brake does not work or does not work well.........................................................................................1725 H-16 The wheel brake is not released or it drags.................................................................................................1726 H-17 The parking brake does not work or does not work well.......................................................................................1727 H-18 The parking brake is not released or it drags (including emergency release system)..........................................................1728 H-19 Lift arm does not rise......................................................................................................................1729 H-20 Lift arm speed is low or rising force of lift arm is insufficient...........................................................................1730 H-21 When rising, the lift arm comes to move slowly at specific height...........................................................................1731 H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats)...........................................................................1731 H-23 Hydraulic drifts of the lift arm is large...................................................................................................1731 H-24 The lift arm wobbles during operation.......................................................................................................1731 H-25 Bucket does not tilt back...................................................................................................................1732 H-26 Bucket speed is low or tilting back force is insufficient...................................................................................1733 H-27 The bucket comes to operate slowly in the midst of tilting-back.............................................................................1734 H-28 The bucket cylinder cannot hold down the bucket.............................................................................................1734 H-29 Hydraulic drifts of the bucket is large.....................................................................................................1734 H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”).....................................................1734 H-31 Lift arm and bucket control levers do not move smoothly and are heavy.......................................................................1735 H-32 During operation of the machine, engine speed lowers remarkably or engine stalls............................................................1736 H-33 Large shock is made when work equipment starts and stops....................................................................................1736 H-34 When work equipment circuit is relieved singly, other work equipment moves..................................................................1736 H-35 ECSS does not operate, and pitching, bouncing occur.........................................................................................1737 H-36 Fan revolution is abnormal (Fan sound/ vibration is abnormally large or engine overheats)...................................................1738 Troubleshooting of engine (S-mode)...................................................................................................................1740 Method of using troubleshooting charts...........................................................................................................1742 S-1 Engine does not start easily.................................................................................................................1745 S-2 Engine does not start........................................................................................................................1746 S-3 Engine does not pick up smoothly.............................................................................................................1749 S-4 Engine stops during operations...............................................................................................................1750 S-5 Engine does not rotate smoothly..............................................................................................................1751 S-6 Engine lacks output (or lacks power).........................................................................................................1752 S-7 Exhaust smoke is black (Incomplete combustion)...............................................................................................1753 S-8 Oil consumption is excessive (or exhaust smoke is blue)......................................................................................1754 S-9 Engine oil becomes contaminated quickly......................................................................................................1755 S-10 Fuel consumption is excessive...............................................................................................................1756 S-11 Coolant contains oil (blows back or reduces)................................................................................................1757 S-12 Oil pressure drops..........................................................................................................................1758 S-13 Oil level rises (Water, fuel in oil)........................................................................................................1759 S-14 Coolant temperature rises too high (Overheating)............................................................................................1760 S-15 Abnormal noise is made......................................................................................................................1761 S-16 Vibration is excessive......................................................................................................................1762 50 Disassembly and assembly.............................................................................................................................. 0 General information on disassembly and assembly......................................................................................................1764 How to read this manual..........................................................................................................................1765 Coating materials list...........................................................................................................................1767 Special tools list...............................................................................................................................1770 Sketches of special tools........................................................................................................................1773 Engine and cooling system............................................................................................................................1780 Removal and installation of fuel supply pump assembly............................................................................................1781 Removal and installation of fuel injector assembly...............................................................................................1785 Removal and installation of cylinder head assembly...............................................................................................1799 Removal and installation of engine hood assembly.................................................................................................1821 Removal and installation of radiator assembly....................................................................................................1826 Removal and installation of air aftercooler......................................................................................................1831 Removal and installation of hydraulic oil cooler assembly........................................................................................1833 Removal and installation of engine assembly......................................................................................................1835 Removal and installation of engine front oil seal assembly.......................................................................................1840 Removal and installation of engine rear oil seal assembly........................................................................................1844 Removal and installation of cooling fan and fan motor assembly...................................................................................1847 Removal and installation of fuel tank assembly...................................................................................................1853 Power train..........................................................................................................................................1856 Removal and installation of torque converter and transmission assembly...........................................................................1857 Disassembly and assembly of torque converter assembly (Standard specification)...................................................................1863 Disassembly and assembly of torque converter assembly (Lockup specification).....................................................................1867 Disassembly and assembly of transmission assembly................................................................................................1873 Disassembly and assembly of transmission clutch pack assembly....................................................................................1890 Disassembly and assembly of parking brake assembly...............................................................................................1909 Removal and installation of front axle assembly..................................................................................................1918 Removal and installation of rear axle assembly...................................................................................................1920 Disassembly and assembly of axle housing.........................................................................................................1923 Disassembly and assembly of differential assembly................................................................................................1932 Steering system......................................................................................................................................1952 Removal and installation of steering valve assembly..............................................................................................1953 Brake system.........................................................................................................................................1958 Removal and installation of parking brake discs and plates.......................................................................................1959 Undercarriage and frame..............................................................................................................................1964 Removal and installation of center hinge pin.....................................................................................................1965 Removal and installation of counterweight........................................................................................................1973 Hydraulic system.....................................................................................................................................1978 Removal and installation of work equipment control valve assembly................................................................................1979 Removal and installation of power train pump and work equipment pump assembly....................................................................1985 Removal and installation of steering pump and cooling fan pump assembly..........................................................................1986 Removal and installation of hydraulic tank assembly..............................................................................................1988 Work equipment.......................................................................................................................................1992 Removal and installation of work equipment assembly..............................................................................................1993 Disassembly and assembly of hydraulic cylinder assembly..........................................................................................1997 Cab and its attachments..............................................................................................................................2006 Removal and installation of operator's cab and floor frame assembly..............................................................................2007 Removal and installation of operator's cab glass (stuck glass)...................................................................................2011 Disassembly and assembly of operator's seat assembly (Standard specification)....................................................................2019 Removal and installation of air conditioner unit assembly........................................................................................2061 Electrical system....................................................................................................................................2066 Removal and installation of engine controller assembly...........................................................................................2067 90 Diagrams and drawings................................................................................................................................. 0 Hydraulic diagrams and drawings......................................................................................................................2070 Power train hydraulic circuit diagram............................................................................................................2071 Automatic greasing circuit diagram...............................................................................................................2073 Hydraulic circuit diagram (WA380-6)..............................................................................................................2076 Hydraulic circuit diagram (WA380Z-6).............................................................................................................2077 Electrical diagrams and drawings.....................................................................................................................2080 Electrical circuit diagram (WA380-6).............................................................................................................2082 Electrical circuit diagram (WA380Z-6)............................................................................................................2096 Work equipment controller system electrical circuit diagram (WA380-6)............................................................................2105 Connector list and stereogram (WA380-6)..........................................................................................................2106 Connector list and stereogram (WA380Z-6).........................................................................................................2107
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KOMATSU WA380-6 WA380Z0-6 WHEEL LOADER SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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