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KOMATSU WA380-6H SHOP MANUAL VEBM440100 – PDF DOWNLOAD
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KOMATSU WA380-6H SHOP MANUAL VEBM440100 – PDF DOWNLOAD
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KOMATSU WA380-6H SHOP MANUAL VEBM440100 – PDF DOWNLOAD
Language : English
Pages : 1296
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KOMATSU WA380-6H SHOP MANUAL VEBM440100 – PDF DOWNLOAD
VBAM440100 WA380-6H...................................................................................................................................... 1 00 Index and foreword................................................................................................................................ 3 Foreword and general information................................................................................................................. 17 Safety notice................................................................................................................................ 18 How to read the shop manual.................................................................................................................. 22 Explanation of terms for maintenance standard................................................................................................ 24 Handling electric equipment and hydraulic component.......................................................................................... 26 How to read electric wire code............................................................................................................... 34 Method of disassembling and connecting push-pull type coupler................................................................................ 37 Standard tightening torque table............................................................................................................. 40 Conversion table............................................................................................................................. 44 Table of contents................................................................................................................................ 6 Organization list of the shop manual............................................................................................................. 4 01 Specification..................................................................................................................................... 49 Specification and technical data................................................................................................................. 51 Specification dimension drawing.............................................................................................................. 51 Specifications............................................................................................................................... 52 Weight table................................................................................................................................. 56 Table of fuel, coolant and lubricants........................................................................................................ 58 10 Structure, function and maintenance standard...................................................................................................... 59 Engine and cooling system........................................................................................................................ 59 Engine mount and transmission mount.......................................................................................................... 60 Cooling system............................................................................................................................... 61 Cooling fan pump............................................................................................................................. 62 Cooling fan motor............................................................................................................................ 70 Power train...................................................................................................................................... 77 Power train.................................................................................................................................. 79 Power train system diagram................................................................................................................... 80 Drive shaft.................................................................................................................................. 82 Power train piping diagram................................................................................................................... 83 Torque converter............................................................................................................................. 84 Transmission................................................................................................................................. 92 Flow control valve........................................................................................................................... 109 Valve assembly............................................................................................................................... 110 ECMV......................................................................................................................................... 111 Main relief valve and torque converter relief valve.......................................................................................... 118 Axle......................................................................................................................................... 120 Differential................................................................................................................................. 122 Limited slip differential.................................................................................................................... 127 Final drive.................................................................................................................................. 134 Steering system.................................................................................................................................. 137 Steering piping diagram...................................................................................................................... 138 Steering column.............................................................................................................................. 139 Steering pump................................................................................................................................ 140 Steering valve............................................................................................................................... 151 Orbit-roll valve............................................................................................................................. 166 Stop valve................................................................................................................................... 170 Steering relief valve........................................................................................................................ 171 Steering cylinder............................................................................................................................ 172 Emergency steering motor..................................................................................................................... 174 Emergency steering pump...................................................................................................................... 175 Brake system..................................................................................................................................... 177 Brake piping diagram......................................................................................................................... 178 Charge valve................................................................................................................................. 179 Brake valve.................................................................................................................................. 186 Accumulator (for brake)...................................................................................................................... 191 Brake........................................................................................................................................ 192 Parking brake control........................................................................................................................ 197 Parking brake................................................................................................................................ 198 Parking brake solenoid valve................................................................................................................. 200 Emergency parking brake release valve........................................................................................................ 202 Undercarriage and frame.......................................................................................................................... 203 Axle mount and center hinge pin.............................................................................................................. 204 Tires........................................................................................................................................ 208 Hydraulic system, Part 1......................................................................................................................... 209 Hydraulic piping diagram..................................................................................................................... 210 Work equipment control lever linkage......................................................................................................... 213 Hydraulic tank............................................................................................................................... 214 Power train pump............................................................................................................................. 216 Work equipment pump.......................................................................................................................... 217 Work equipment control valve................................................................................................................. 228 CLSS......................................................................................................................................... 242 Each function and operation of each valve.................................................................................................... 246 Hydraulic system, Part 2......................................................................................................................... 269 PPC valve.................................................................................................................................... 270 Stabilizer valve............................................................................................................................. 276 Accumulator (for PPC circuit)................................................................................................................ 281 Accumulator (for ECSS)....................................................................................................................... 282 Work equipment................................................................................................................................... 283 Work equipment linkage....................................................................................................................... 284 Bucket....................................................................................................................................... 286 Bucket positioner and boom kick-out.......................................................................................................... 287 Work equipment cylinder...................................................................................................................... 293 Cab and its attachments.......................................................................................................................... 295 Cab.......................................................................................................................................... 297 Air conditioner.............................................................................................................................. 298 Electrical system, Part 1........................................................................................................................ 311 Machine monitor system....................................................................................................................... 312 Machine monitor.............................................................................................................................. 317 Electrical system, Part 2........................................................................................................................ 339 Electrical system (Transmission controller system)........................................................................................... 340 Transmission controller...................................................................................................................... 374 Electrical system, Part 3........................................................................................................................ 377 Electric transmission control................................................................................................................ 378 Kickdown switch and hold switch.............................................................................................................. 382 KOMTRAX terminal system...................................................................................................................... 384 Engine starting circuit...................................................................................................................... 386 Engine stopping circuit...................................................................................................................... 388 Preheating circuit........................................................................................................................... 389 Engine power mode selector circuit........................................................................................................... 390 Engine output derating function.............................................................................................................. 391 Automatic warm-up function................................................................................................................... 391 Parking brake circuit........................................................................................................................ 392 Sensor....................................................................................................................................... 394 20 Standard value table.............................................................................................................................. 403 Standard service value table..................................................................................................................... 403 Standard service value table for engine...................................................................................................... 404 Standard service value table for chassis..................................................................................................... 405 30 Testing and adjusting............................................................................................................................. 413 Testing and adjusting, Part 1.................................................................................................................... 413 Tools for testing, adjusting, and troubleshooting............................................................................................ 415 Measuring engine speed....................................................................................................................... 418 Measuring exhaust gas color.................................................................................................................. 420 Adjusting valve clearance.................................................................................................................... 422 Measuring compression pressure............................................................................................................... 424 Measuring blow-by pressure................................................................................................................... 427 Measuring engine oil pressure................................................................................................................ 428 Measuring intake air (boost) pressure........................................................................................................ 429 Handling fuel system equipment............................................................................................................... 430 Releasing residual pressure in fuel system................................................................................................... 430 Measuring fuel pressure...................................................................................................................... 431 Measuring fuel return rate and leakage....................................................................................................... 433 Bleeding air from fuel circuit............................................................................................................... 436 Testing leakage in fuel system............................................................................................................... 438 Handling reduced cylinder mode operation..................................................................................................... 439 Handling no-injection cranking operation..................................................................................................... 439 Handling controller voltage circuit.......................................................................................................... 440 Testing and adjusting air conditioner compressor belt tension................................................................................ 441 Adjusting transmission speed sensor.......................................................................................................... 442 Measuring directional lever.................................................................................................................. 443 Measuring and adjusting power train oil pressure............................................................................................. 444 Procedure for flushing torque converter and transmission hydraulic circuit................................................................... 459 Method of moving machine when transmission valve is broken................................................................................... 460 Testing and adjusting steering stop valve.................................................................................................... 462 Testing and adjusting steering wheel......................................................................................................... 464 Testing steering oil pressure................................................................................................................ 466 Bleeding air from steering circuit........................................................................................................... 469 Testing and adjusting, Part 2.................................................................................................................... 471 Testing hydraulic drive fan.................................................................................................................. 473 Bleeding air from hydraulic drive fan circuit................................................................................................ 475 Measuring brake pedal........................................................................................................................ 477 Measuring brake performance.................................................................................................................. 478 Testing and adjusting accumulator charge pressure............................................................................................ 479 Testing wheel brake oil pressure............................................................................................................. 480 Measuring wear of wheel brake disc........................................................................................................... 482 Bleeding air from wheel brake circuit........................................................................................................ 483 Releasing residual pressure in brake accumulator circuit..................................................................................... 484 Testing parking brake performance............................................................................................................ 485 Measuring parking brake oil pressure......................................................................................................... 486 Testing wear of parking brake disc........................................................................................................... 488 Method of releasing parking brake manually................................................................................................... 489 Measuring and adjusting work equipment control lever......................................................................................... 490 Measuring and adjusting work equipment PPC oil pressure...................................................................................... 491 Measuring and adjusting work equipment oil pressure.......................................................................................... 494 Bleeding air from work equipment circuit..................................................................................................... 498 Releasing residual pressure in work equipment circuit........................................................................................ 499 Testing and adjusting bucket positioner...................................................................................................... 500 Testing and adjusting boom kick- out......................................................................................................... 502 Checking proximity switch operation pilot lamp............................................................................................... 503 Procedure for testing diodes................................................................................................................. 504 Preparation work for troubleshooting for electric system..................................................................................... 505 How to start operation of KOMTRAX terminal................................................................................................... 510 Lamp display of KOMTRAX terminal............................................................................................................. 515 Adjusting machine monitor.................................................................................................................... 518 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor....................................................... 519 Testing and adjusting, Part 3.................................................................................................................... 521 Special functions of machine monitor (EMMS).................................................................................................. 522 Pm-click inspection table.................................................................................................................... 581 40 Troubleshooting................................................................................................................................... 583 Troubleshooting by failure code (Display of code), Part 1........................................................................................ 617 Failure codes list........................................................................................................................... 619 Before carrying out troubleshooting for electrical system.................................................................................... 626 Information contained troubleshooting table.................................................................................................. 629 Failure code [1500L0] (TORQFLOW transmission: Double meshing)................................................................................ 631 Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)........................................................ 632 Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)........................................................ 634 Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)........................................................ 636 Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)........................................................ 638 Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)...................................................... 640 Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF)...................................................... 642 Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON)...................................................... 644 Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF)...................................................... 646 Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON)...................................................... 648 Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF)...................................................... 650 Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)...................................................... 652 Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF)...................................................... 654 Failure code [2F00MA] (Parking brake: Malfunction)........................................................................................... 656 Troubleshooting by failure code (Display of code), Part 2........................................................................................ 659 Failure code [2G43ZG] (Accumulator: Low oil pressure)........................................................................................ 662 Failure code [AA1ANX] (Air cleaner: Clogging)................................................................................................ 664 Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine).......................................................... 666 Failure code [AB00MA] (Alternator: Malfunction).............................................................................................. 668 Failure code [B@BAZG] (Rotation derating by low engine oil pressure)......................................................................... 670 Failure code [B@BAZK] (Engine oil: Low level)................................................................................................ 671 Failure code [B@BCNS] (Coolant: Overheating)................................................................................................. 672 Failure code [B@BCZK] (Coolant: Low level)................................................................................................... 674 Failure code [B@C7NS] (Brake oil: Overheating)............................................................................................... 676 Failure code [b@CENS] (Torque converter oil: Overheating).................................................................................... 678 Failure code [B@CENS] (Torque converter oil: Overheating).................................................................................... 680 Failure code [B@HANS] (Hydraulic oil: Overheating)........................................................................................... 682 Failure code [CA111] (Abnormality in engine controller)...................................................................................... 684 Failure code [CA115] (Engine Ne or Bkup speed sensor error).................................................................................. 685 Failure code [CA122] (Charge pressure sensor high error)..................................................................................... 686 Failure code [CA123] (Charge pressure sensor low error)...................................................................................... 688 Failure code [CA131] (Throttle sensor high error)............................................................................................ 690 Failure code [CA132] (Throttle sensor low error)............................................................................................. 692 Failure code [CA144] (Coolant sensor high error)............................................................................................. 694 Failure code [CA145] (Coolant sensor low error).............................................................................................. 696 Failure code [CA153] (Charge temperature sensor high error).................................................................................. 698 Failure code [CA154] (Charge temperature sensor low error)................................................................................... 700 Failure code [CA155] (Derating of speed by abnormally high charge temperature)............................................................... 702 Failure code [CA187] (Sensor power supply 2 low error)....................................................................................... 704 Failure code [CA221] (Atmospheric pressure sensor high error)................................................................................ 706 Failure code [CA222] (Atmospheric sensor low error).......................................................................................... 708 Failure code [CA227] (Sensor power supply 2 high error)...................................................................................... 710 Troubleshooting by failure code (Display of code), Part 3........................................................................................ 711 Failure code [CA234] (Engine overspeed)...................................................................................................... 713 Failure code [CA238] (Ne speed sensor power supply error).................................................................................... 714 Failure code [CA271] (PCV1 Short circuit).................................................................................................... 715 Failure code [CA272] (PCV1 Disconnection).................................................................................................... 716 Failure code [CA322] (Injector #1 (L/B #1) open/short error)................................................................................. 718 Failure code [CA323] (Injector #5 (L/B #5) open/short error)................................................................................. 720 Failure code [CA324] (Injector #3 (L/B #3) open/short error)................................................................................. 722 Failure code [CA325] (Injector #6 (L/B #6) open/short error)................................................................................. 724 Failure code [CA331] (Injector #2 (L/B #2) open/short error)................................................................................. 726 Failure code [CA332] (Injector #4 (L/B #4) open/short error)................................................................................. 728 Failure code [CA342] (Calibration code inconsistency)........................................................................................ 730 Failure code [CA351] (Injectors drive circuit error)......................................................................................... 731 Failure code [CA352] (Sensor power supply 1 low error)....................................................................................... 733 Failure code [CA386] (Sensor power supply 1 high error)...................................................................................... 735 Failure code [CA428] (Abnormally high level in water sensor)................................................................................. 736 Failure code [CA429] (Abnormally low level in water sensor).................................................................................. 738 Failure code [CA431] (Idle validation switch error).......................................................................................... 740 Failure code [CA432] (Idle validation action error).......................................................................................... 742 Failure code [CA435] (Engine oil pressure switch error)...................................................................................... 744 Failure code [CA441] (Battery voltage low error)............................................................................................. 745 Failure code [CA442] (Battery voltage high error)............................................................................................ 748 Failure code [CA449] Common rail pressure high error 2....................................................................................... 750 Failure code [CA451] (Common rail pressure sensor high error)................................................................................ 751 Failure code [CA452] (Common rail pressure sensor low error)................................................................................. 753 Failure code [CA488] (Derating of torque by abnormally high charge temperature).............................................................. 755 Failure code [CA553] (Common rail pressure high error 1)..................................................................................... 756 Failure code [CA559] (Supply pump pressure very low error)................................................................................... 757 Failure code [CA689] (Engine Ne speed sensor error).......................................................................................... 758 Failure code [CA731] (Engine Bkup speed sensor phase error).................................................................................. 760 Failure code [CA757] (All continuous data lost error)........................................................................................ 761 Failure code [CA778] (Engine Bkup speed sensor error)........................................................................................ 764 Failure code [CA1117] (Partial engine controller data loss error)............................................................................ 766 Failure code [CA1633] (KOMNET datalink timeout error)........................................................................................ 769 Troubleshooting by failure code (Display of code), Part 4........................................................................................ 771 Failure code [CA2185] (Throttle sensor supply voltage high error)............................................................................ 773 Failure code [CA2186] (Throttle sensor power supply low error)............................................................................... 774 Failure code [CA2249] (Supply pump pressure very low error 2)................................................................................ 775 Failure code [CA2311] (Abnormality in IMV solenoid).......................................................................................... 776 Failure code [CA2555] (Intake heater relay disconnection error).............................................................................. 778 Failure code [CA2556] (Intake heater relay short circuit error).............................................................................. 780 Failure code [D150KA] (Emergency steering relay: Disconnection).............................................................................. 782 Failure code [D150KB] (Emergency steering relay: Short circuit).............................................................................. 784 Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line)....................................................... 786 Failure code [D160KA] (Backup lamp relay: Disconnection)..................................................................................... 788 Failure code [D160KB] (Backup lamp relay: Short circuit)..................................................................................... 790 Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection)................................................................ 792 Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit)................................................................ 794 Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line)......................................... 796 Failure code [D192KA] (ECSS solenoid: Disconnection)......................................................................................... 798 Failure code [D192KB] (ECSS solenoid: Short circuit)......................................................................................... 799 Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line).................................................................. 800 Failure code [D5ZHKA] (Terminal C signal: Disconnection)..................................................................................... 801 Failure code [D5ZHKB] (Terminal C signal: Short circuit)..................................................................................... 805 Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state)............................................. 809 Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)...................................................................... 812 Failure code [DAF3KK] (Machine monitor: Low source voltage (input)).......................................................................... 814 Failure code [DAF5KP] (Machine monitor: Low output voltage).................................................................................. 816 Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system))............. 819 Failure code [DAQ0KK] (Transmission controller: Low source voltage).......................................................................... 821 Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)................................................................... 823 Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input))........................................... 824 Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals)..................................... 826 Troubleshooting by failure code (Display of code), Part 5........................................................................................ 827 Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system))..... 829 Failure code [DAQRMA] (Transmission controller option setting: Malfunction).................................................................. 831 Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system)............ 832 Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals)................................... 835 Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system)).... 836 Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)................................................................ 838 Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time........................................................ 840 Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time........................................................ 842 Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time........................................................ 844 Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time........................................................ 846 Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time....................................................... 848 Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time............................................ 850 Failure code [DD1GLD] Load meter mode selector switch (+/-): Switch is kept pressed for long time............................................ 852 Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time)............................................. 854 Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time)............................................................. 856 Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time)................................................... 858 Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree).......................................................... 860 Troubleshooting by failure code (Display of code), Part 6........................................................................................ 863 Failure code [DDK3KA] (Right FNR switch: Disconnection)...................................................................................... 866 Failure code [DDK6KA] (FNR lever switch: Disconnection)...................................................................................... 869 Failure code [DDK6KB] (FNR lever switch: Short circuit)...................................................................................... 872 Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree).................................................................. 874 Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)................................................ 876 Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)............................................................... 878 Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time).................................................................... 880 Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)....................................................... 882 Failure code [DF10KA] (Transmission shift lever switch: Disconnected)........................................................................ 884 Failure code [DF10KB] (Transmission shift lever switch: Short circuit)....................................................................... 888 Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected).................................................................... 890 Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)................................................................... 892 Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range).......................................................... 894 Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)...................................................................... 896 Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)......................................................... 898 Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)................................................... 900 Troubleshooting by failure code (Display of code), Part 7........................................................................................ 903 Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range).................................................. 904 Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range).................................................... 906 Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range)...................................................... 908 Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection)......................................................................... 910 Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit)......................................................................... 912 Troubleshooting by failure code (Display of code), Part 8........................................................................................ 915 Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)................................................................ 916 Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range).................................................... 918 Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)................................................................... 920 Failure code [DV00KB] (Alarm buzzer: Short circuit).......................................................................................... 922 Troubleshooting by failure code (Display of code), Part 9........................................................................................ 925 Failure code [DW7BKA] (Fan reverse solenoid: Disconnection).................................................................................. 926 Failure code [DW7BKB] (Fan reverse solenoid: Short circuit).................................................................................. 927 Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)........................................................... 928 Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)................................................................................. 930 Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)................................................................................. 931 Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line).......................................................... 932 Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection).................................................................................. 934 Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit).................................................................................. 936 Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)........................................................... 938 Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection).............................................................................. 940 Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit).............................................................................. 942 Troubleshooting by failure code (Display of code), Part 10....................................................................................... 945 Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)....................................................... 948 Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection).............................................................................. 950 Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit).............................................................................. 952 Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)....................................................... 954 Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection).............................................................................. 956 Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit).............................................................................. 958 Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)....................................................... 960 Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)................................................................................ 962 Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)................................................................................ 964 Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)......................................................... 966 Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)................................................................................ 968 Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)................................................................................ 970 Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)......................................................... 972 Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection).............................................................................. 974 Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit).............................................................................. 976 Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)....................................................... 978 Troubleshooting of electrical system (E-mode).................................................................................................... 981 Before carrying out troubleshooting for electrical system.................................................................................... 983 Information in troubleshooting table......................................................................................................... 986 E-1 Engine does not start.................................................................................................................... 987 E-2 Wiper does not operate................................................................................................................... 994 E-3 Windshield washer does not operate....................................................................................................... 998 E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off..........................................................1002 E-5 Working lamp does not light up or go off.................................................................................................1010 E-6 Turn signal lamp and hazard lamp do not light up or go off...............................................................................1015 E-7 Brake lamp does not light or it keeps lighting up........................................................................................1021 E-8 Backup lamp does not light or it keeps lighting up.......................................................................................1023 E-9 Backup buzzer does not sound or it keeps sounding........................................................................................1025 E-10 Horn does not sound or it keeps sounding................................................................................................1027 E-11 Alarm buzzer does not sound or it keeps sounding........................................................................................1030 E-12 Air conditioner does not operate or stop................................................................................................1032 E-13 The KOMTRAX system does not work properly...............................................................................................1035 General information on troubleshooting........................................................................................................... 583 Points to remember when troubleshooting...................................................................................................... 584 Sequence of events in troubleshooting........................................................................................................ 585 Testing before troubleshooting............................................................................................................... 586 Classification and procedures of troubleshooting............................................................................................. 587 Connection table for connector pin numbers................................................................................................... 590 T-branch box and T-branch adapter table...................................................................................................... 613 Troubleshooting of hydraulic and mechanical system (H-mode)......................................................................................1037 Method of using troubleshooting chart........................................................................................................1039 Table of failure modes and causes............................................................................................................1042 H-1 The machine does not start...............................................................................................................1046 H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)]...................................1048 H-3 Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)]....................................................1049 H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted...................1050 H-5 Shocks are large at the times of starting and shifting gear..............................................................................1052 H-6 Time lag is large at the times of starting and shifting gear.............................................................................1054 H-7 The torque converter oil temperature is high.............................................................................................1056 H-8 Steering does not turn...................................................................................................................1057 H-9 Steering does not turn [Machine with joystick steering (if equipped)]....................................................................1058 H-10 Steering response is low................................................................................................................1059 H-11 Turning, response of steering is poor [machine with joystick steering (if equipped)]....................................................1060 H-12 Steering is heavy.......................................................................................................................1061 H-13 When machine turns, it shakes or makes large shocks.....................................................................................1062 H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)]......................................1063 H-15 The wheel brake does not work or does not work well.....................................................................................1064 H-16 The wheel brake is not released or it drags.............................................................................................1065 H-17 The parking brake does not work or does not work well...................................................................................1066 H-18 The parking brake is not released or it drags (including emergency release system)......................................................1067 H-19 Lift arm does not rise..................................................................................................................1068 H-20 Lift arm speed is low or rising force of lift arm is insufficient.......................................................................1069 H-21 When rising, the lift arm comes to move slowly at specific height.......................................................................1070 H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats).......................................................................1070 H-23 Hydraulic drifts of the lift arm is large...............................................................................................1070 H-24 The lift arm wobbles during operation...................................................................................................1070 H-25 Bucket does not tilt back...............................................................................................................1071 H-26 Bucket speed is low or tilting back force is insufficient...............................................................................1072 H-27 The bucket comes to operate slowly in the midst of tilting-back.........................................................................1073 H-28 The bucket cylinder cannot hold down the bucket.........................................................................................1073 H-29 Hydraulic drifts of the bucket is large.................................................................................................1073 H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”).................................................1073 H-31 Lift arm and bucket control levers do not move smoothly and are heavy...................................................................1074 H-32 During operation of the machine, engine speed lowers remarkably or engine stalls........................................................1075 H-33 Large shock is made when work equipment starts and stops................................................................................1075 H-34 When work equipment circuit is relieved singly, other work equipment moves..............................................................1075 H-35 ECSS does not operate, and pitching, bouncing occur.....................................................................................1076 Troubleshooting of engine (S-mode)...............................................................................................................1077 Method of using troubleshooting chart........................................................................................................1079 S-1 Engine does not start easily.............................................................................................................1082 S-2 Engine does not start....................................................................................................................1083 S-3 Engine does not pick up smoothly.........................................................................................................1086 S-4 Engine stops during operations...........................................................................................................1087 S-5 Engine does not rotate smoothly..........................................................................................................1088 S-6 Engine lacks output (or lacks power).....................................................................................................1089 S-7 Exhaust smoke is black (Incomplete combustion)...........................................................................................1090 S-8 Oil consumption is excessive (or exhaust smoke is blue)..................................................................................1091 S-9 Engine oil becomes contaminated quickly..................................................................................................1092 S-10 Fuel consumption is excessive...........................................................................................................1093 S-11 Coolant contains oil (blows back or reduces)............................................................................................1094 S-12 Oil pressure drops......................................................................................................................1095 S-13 Oil level rises (Water, fuel in oil)....................................................................................................1096 S-14 Coolant temperature rises too high (Overheating)........................................................................................1097 S-15 Abnormal noise is made..................................................................................................................1098 S-16 Vibration is excessive..................................................................................................................1099 50 Disassembly and assembly..........................................................................................................................1101 General information on disassembly and assembly..................................................................................................1101 How to read this manual......................................................................................................................1102 Coating materials list.......................................................................................................................1104 Special tools list...........................................................................................................................1107 Engine and cooling system........................................................................................................................1109 Removal and installation of fuel supply pump assembly........................................................................................1110 Removal and installation of fuel injector assembly...........................................................................................1112 Removal and installation of cylinder head assembly...........................................................................................1117 Removal and installation of engine hood......................................................................................................1126 Removal and installation of radiator assembly................................................................................................1128 Removal and installation of air aftercooler..................................................................................................1130 Removal and installation of hydraulic oil cooler assembly....................................................................................1132 Removal and installation of engine assembly..................................................................................................1134 Removal and installation of cooling fan and fan motor assembly...............................................................................1139 Removal and installation of fuel tank assembly...............................................................................................1142 Power train......................................................................................................................................1145 Removal and installation of torque converter and transmission assembly.......................................................................1146 Disassembly and assembly of torque converter assembly (Standard specification)...............................................................1152 Disassembly and assembly of torque converter assembly (Lockup specification).................................................................1156 Disassembly and assembly of transmission assembly............................................................................................1162 Disassembly and assembly of transmission clutch pack assembly................................................................................1177 Disassembly and assembly of parking brake assembly...........................................................................................1193 Removal and installation of front axle assembly..............................................................................................1198 Removal and installation of rear axle assembly...............................................................................................1200 Disassembly and assembly of axle housing.....................................................................................................1203 Disassembly and assembly of differential assembly............................................................................................1212 Steering system..................................................................................................................................1225 Removal and installation of steering demand valve assembly...................................................................................1226 Brake system.....................................................................................................................................1229 Removal and installation of parking brake discs and plates...................................................................................1230 Undercarriage and frame..........................................................................................................................1233 Removal and installation of center hinge pin.................................................................................................1234 Removal and installation of counterweight....................................................................................................1242 Hydraulic system.................................................................................................................................1245 Removal and installation of work equipment control valve assembly............................................................................1246 Removal and installation of power train pump and work equipment pump assembly................................................................1248 Removal and installation of steering pump and cooling fan pump assembly......................................................................1249 Removal and installation of hydraulic tank assembly..........................................................................................1250 Work equipment...................................................................................................................................1253 Removal and installation of work equipment assembly..........................................................................................1254 Disassembly and assembly of hydraulic cylinder assembly......................................................................................1258 Cab and its attachments..........................................................................................................................1267 Removal and installation of operator's cab and floor frame assembly..........................................................................1268 Removal and installation of operator's cab glass (stuck glass)...............................................................................1271 Removal and installation of air conditioner unit assembly....................................................................................1279 Electrical system................................................................................................................................1283 Removal and installation of engine controller assembly.......................................................................................1284 90 Diagrams and drawings.............................................................................................................................1285 Electrical diagrams and drawings.................................................................................................................1291 Electrical circuit diagram (1/2).............................................................................................................1293 Electrical circuit diagram (2/2).............................................................................................................1295 Hydraulic diagrams and drawings..................................................................................................................1285 Power train hydraulic circuit diagram........................................................................................................1286 Hydraulic circuit diagram....................................................................................................................1289
DESCRIPTION:
KOMATSU WA380-6H SHOP MANUAL VEBM440100 – PDF DOWNLOAD
1. General precautions
1) Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates and detailed explanation of precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
Always wear safety glasses when hitting parts with a hammer.
Always wear safety glasses when grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs in the operator’s compartment.
5) Only qualified workers must carry out work and operation which require license or qualification.
6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
8) Before starting work, warm up your body thoroughly to start work under good condition.
S.S 27/12/24
