Komatsu WA380Z-6 Wheel Loader Shop Manual SEN06411-C6 PDF

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Komatsu WA380Z-6 Wheel Loader Shop Manual SEN06411-C6 – PDF DOWNLOAD

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Komatsu WA380Z-6 Wheel Loader Shop Manual SEN06411-C6 – PDF DOWNLOAD 

Language : English
Pages : 2122
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu WA380Z-6 Wheel Loader Shop Manual SEN06411-C6 – PDF DOWNLOAD

SERIAL NUMBERS C50001 and up

SEN06411-06-MC4 1
SEN06411-06-MA4 3
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword and general information 19
Safety notice 20
How to read the shop manual 25
Explanation of terms for maintenance standard 27
Handling of electric equipment and hydraulic component 29
Handling of connectors newly used for engines 38
How to read electric wire code 41
Precautions when carrying out operation 44
Method of disassembling and connecting push-pull type coupler 47
Standard tightening torque table 50
Conversion table 54
01 Specification 61
Specification and technical data 61
Specification dimension drawing 62
Specifications 64
Weight table 72
Table of fuel, coolant and lubricants 76
10 Structure, function and maintenance standard 79
Engine and cooling system 79
Engine mount and transmission mount 80
Cooling system 81
Cooling fan pump 83
Brake and fan pump 90
Cooling fan motor 91
Power train 105
Power train 107
Power train system diagram 108
Drive shaft 111
Power train piping diagram 112
Torque converter 114
Transmission 122
Flow control valve 156
Valve assembly 158
ECMV 159
Main relief valve and torque converter relief valve 167
Axle 169
Differential 171
Limited slip differential 175
Final drive 182
Steering system 187
Steering piping diagram 188
Steering column 190
Steering pump 192
Steering valve 212
Orbit-roll valve 227
Stop valve 235
Steering relief valve 236
Steering cylinder 237
Emergency steering motor 239
Emergency steering pump 240
Joystick steering lever linkage 241
Steering electric lever 242
Joystick EPC valve 243
Brake system 245
Brake piping diagram 246
Charge valve 248
Brake valve 255
Accumulator (for brake) 260
Brake 262
Parking brake control 267
Parking brake 268
Parking brake solenoid valve 270
Emergency parking brake release valve 272
Undercarriage and frame 275
Axle mount and center hinge pin 276
Tires 281
Hydraulic system, Part 1 283
Hydraulic piping diagram 284
Work equipment control lever linkage 290
Hydraulic tank 293
Power train pump 297
Work equipment pump 298
Work equipment control valve 320
CLSS 348
Each function and operation of each valve 352
Hydraulic system, Part 2 385
PPC valve 386
Stabilizer valve 392
Accumulator (for PPC circuit) 398
Accumulator (for ECSS) 399
Work equipment PPC cut-off solenoid valve 400
Work equipment 403
Work equipment linkage 404
Bucket 408
Bucket positioner and boom kick-out 410
Work equipment cylinder 416
Cab and its attachments 419
Cab 421
Air conditioner 422
Electrical system, Part 1 443
Machine monitor system 444
Machine monitor 452
Electrical system, Part 2 511
Electrical system (Transmission controller system) 512
Transmission controller 556
Electrical system (Work equipment controller system) 560
Work equipment controller 566
Electrical system, Part 3 569
Electric transmission control 570
Kickdown switch and hold switch 574
Multi-function knob 576
Joystick steering knob 577
KOMTRAX terminal system 578
Engine starting circuit 580
Engine stopping circuit 584
Preheating circuit 586
Engine power mode selector circuit 587
Engine output derating function 588
Automatic warm-up function 588
Parking brake circuit 590
Sensor 592
20 Standard value table 603
Standard service value table 603
Standard service value table for engine 604
Standard service value table for chassis 606
30 Testing and adjusting 619
Testing and adjusting, Part 1 619
Tools for testing, adjusting, and troubleshooting 621
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) pressure 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 663
Handling reduced cylinder mode operation 664
Handling no-injection cranking operation 664
Handling controller voltage circuit 665
Testing muffler (main body) and muffler stack for looseness or damage 665
Testing muffler for functions 666
Testing cylinder head and manifold parts for tightness 666
Testing engine piping for damage and tightness 667
Testing and replacing alternator belt 668
Testing and replacing auto-tensioner 671
Adjusting transmission speed sensor 674
Adjusting length of directional lever 675
Adjusting length of gearshift lever 675
Testing directional lever 676
Testing and adjusting power train oil pressure 677
Procedure for flushing torque converter and transmission hydraulic circuit 706
Method of moving machine when transmission valve is broken 707
Testing axle end for oil leakage 711
Testing drive shaft for looseness, backlash and damage 711
Testing and adjusting steering stop valve 712
Testing and adjusting steering wheel 714
Testing and adjusting steering oil pressure 716
Bleeding air from steering circuit 719
Testing and adjusting, Part 2 721
Testing hydraulic drive fan 723
Bleeding air from hydraulic drive fan circuit 727
Testing brake pedal 730
Testing and adjusting brake pedal linkage 731
Testing brake performance 732
Testing and adjusting accumulator charge pressure 733
Testing wheel brake oil pressure 735
Testing wheel brake oil pressure drop 736
Testing wear of wheel brake disc 738
Bleeding air from wheel brake circuit 739
Releasing residual pressure in brake accumulator circuit 740
Testing parking brake performance 741
Testing parking brake oil pressure 742
Testing wear of parking brake disc 744
Method of releasing parking brake manually 745
Testing and adjusting work equipment control lever 746
Testing and adjusting worke quipment PPC oil pressure 747
Testing and adjusting work equipment oil pressure 753
Bleeding air from work equipment circuit 757
Releasing residual pressure in work equipment circuit 758
Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of ECSS (Electronically Controlled Suspension System) accumulator 760
Testing and adjusting bucket positioner 766
Testing and adjusting boom kick-out 768
Checking proximity switch operation pilot lamp 769
Procedure for testing diodes 770
Preparation work for troubleshooting for electric system 771
How to start operation of KOMTRAX terminal 780
Lamp display of KOMTRAX terminal 785
Testing and adjusting, Part 3 789
Adjusting replaced, reassembled or added sensor, controller, etc with machine monitor 791
Special functions of machine monitor (EMMS) 793
Pm-clinic inspection table 862
40 Troubleshooting 869
Failure code table and fuse locations 869
Failure code table 870
Fuse locations 887
General information on troubleshooting 893
Points to remember when troubleshooting 894
Sequence of events in troubleshooting 895
Testing before troubleshooting 897
Classification and procedures of troubleshooting 898
Information contained in troubleshooting table 901
Connection table for connector pin numbers 903
T- branch box and T- branch adapter table 939
Troubleshooting by failure code (Display of code), Part 1 943
Failure code [1500L0] (TORQFLOW transmission: Double meshing) 945
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON) 946
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF) 948
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON) 950
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF) 952
Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON) 954
Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF) 956
Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON) 958
Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF) 960
Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON) 962
Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF) 964
Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON) 966
Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF) 968
Failure code [2F00MA] (Parking brake: Malfunction) 970
Failure code [2G43ZG] (Accumulator: Low oil pressure) 973
Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree) 977
Troubleshooting by failure code (Display of code), Part 2 981
Failure code [AA1ANX] (Air cleaner: Clogging) 984
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine) 987
Failure code [AB00MA] (Alternator: Malfunction) 991
Failure code [B@BAZG] (Rotation derating by low engine oil pressure) 995
Failure code [B@BAZK] (Engine oil: Low level) 996
Failure code [B@BCNS] (Coolant: Overheating) 997
Failure code [B@BCZK] (Coolant: Low level) 999
Failure code [B@BEBF] (Water in fuel error) 1002
Failure code [b@CENS] (Torque converter oil: Overheating) 1004
Failure code [B@CENS] (Torque converter oil: Overheating) 1007
Failure code [B@HANS] (Hydraulic oil: Overheating) 1010
Failure code [CA111] (Abnormality in engine controller) 1012
Failure code [CA115] (Engine Ne or Bkup speed sensor error) 1013
Failure code [CA122] (Charge pressure sensor high error) 1014
Failure code [CA123] (Charge pressure sensor low error) 1016
Failure code [CA131] (Throttle sensor high error) 1018
Failure code [CA132] (Throttle sensor low error) 1020
Failure code [CA144] (Coolant sensor high error) 1022
Failure code [CA145] (Coolant sensor low error) 1024
Failure code [CA153] (Charge temperature sensor high error) 1026
Failure code [CA154] (Charge temperature sensor low error) 1028
Failure code [CA155] (Derating of speed by abnormally high charge temperature) 1030
Failure code [CA187] (Sensor power supply 2 low error) 1032
Failure code [CA221] (Atmospheric pressure sensor high error) 1034
Failure code [CA222] (Atmospheric sensor low error) 1036
Failure code [CA227] (Sensor power supply 2 high error) 1038
Failure code [CA234] (Engine overspeed) 1039
Failure code [CA238] (Ne speed sensor power supply error) 1040
Troubleshooting by failure code (Display of code), Part 3 1043
Failure code [CA271] (IMV/PCV1 Short circuit) 1045
Failure code [CA272] (IMV/PCV1 Disconnection) 1046
Failure code [CA322] (Injector #1 open/short error) 1048
Failure code [CA323] (Injector #5 open/short error) 1050
Failure code [CA324] (Injector #3 open/short error) 1052
Failure code [CA325] (Injector #6 open/short error) 1054
Failure code [CA331] (Injector #2 open/short error) 1056
Failure code [CA332] (Injector #4 open/short error) 1058
Failure code [CA342] (Calibration code inconsistency) 1060
Failure code [CA351] (Injectors drive circuit error) 1062
Failure code [CA352] (Sensor power supply 1 low error) 1065
Failure code [CA386] (Sensor power supply 1 high error) 1067
Failure code [CA428] (Abnormally high level in water sensor) 1068
Failure code [CA429] (Abnormally low level in water sensor) 1069
Failure code [CA431] (Idle validation switch error) 1070
Failure code [CA432] (Idle validation action error) 1073
Failure code [CA435] (Engine oil pressure switch error) 1075
Failure code [CA441] (Battery voltage low error) 1076
Failure code [CA442] (Battery voltage high error) 1080
Failure code [CA449] Common rail pressure high error 2 1083
Failure code [CA451] (Common rail pressure sensor high error) 1085
Failure code [CA452] (Common rail pressure sensor low error) 1087
Failure code [CA488] (Derating of torque by abnormally high charge temperature) 1089
Failure code [CA553] (Common rail pressure high error 1) 1090
Failure code [CA559] (Supply pump pressure very low error) 1091
Failure code [CA689] (Engine Ne speed sensor error) 1092
Failure code [CA731] (Engine Bkup speed sensor phase error) 1095
Failure code [CA757] (All continuous data lost error) 1096
Failure code [CA778] (Engine Bkup speed sensor error) 1100
Failure code [CA1633] (KOMNET datalink timeout error) 1103
Failure code [CA2185] (Throttle sensor power supply voltage high error) 1109
Failure code [CA2186] (Throttle sensor power supply voltage low error) 1110
Troubleshooting by failure code (Display of code), Part 4 1113
Failure code [CA2249] (Supply pump pressure very low error 2) 1115
Failure code [CA2311] (Abnormality in IMV solenoid) 1116
Failure code [CA2555] (Intake heater relay disconnection error) 1118
Failure code [CA2556] (Intake heater relay short circuit error) 1121
Failure code [D150KA] (Emergency steering relay: Disconnection) 1124
Failure code [D150KB] (Emergency steering relay: Short circuit) 1127
Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line) 1130
Failure code [D160KA] (Backup lamp relay: Disconnection) 1133
Failure code [D160KB] (Backup lamp relay: Short circuit) 1136
Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection) 1139
Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit) 1141
Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line) 1143
Failure code [D192KA] (ECSS solenoid: Disconnection) 1145
Failure code [D192KB] (ECSS solenoid: Short circuit) 1146
Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line) 1147
Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection) 1148
Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit) 1150
Failure code [D193KY] (Joystick steering solenoid cut relay: Short circuit with power supply line) 1152
Failure code [D5ZHKA] (Terminal C signal: Disconnection) 1155
Failure code [D5ZHKB] (Terminal C signal: Short circuit) 1161
Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit) 1166
Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state) 1173
Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree) 1178
Failure code [DAF3KK] (Machine monitor: Low source voltage (input) 1180
Failure code [DAF5KP] (Machine monitor: Low output voltage) 1184
Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system) 1188
Troubleshooting by failure code (Display of code), Part 5 1193
Failure code [DAQ0KK] (Transmission controller: Low source voltage) 1196
Failure code [DAQ0KT] (Transmission controller: Abnormality in controller) 1200
Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input) 1201
Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals) 1204
Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system) 1205
Failure code [DAQRMA] (Transmission controller option setting: Malfunction) 1211
Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system) 1212
Failure code [DB90KK] Work equipment controller: Low source voltage (input) 1216
Failure code [DB90KT] Work equipment controller: Abnormality in controller 1218
Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input) 1219
Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range 1221
Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals) 1224
Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system) 1225
Failure code [DB9RMA] (Work equipment controller option setting: Malfunction) 1227
Failure code [DB9RMC] (CAN communication with transmission controller, engine controller and machine monitor: Defective operation) 1228
Failure code [DD15LD] ■ switch (Panel switch 1): Switch is kept pressed for long time 1232
Failure code [DD16LD] <> switch (Panel switch 2): Switch is kept pressed for long time 1235
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time 1238
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time 1241
Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time 1244
Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time 1246
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time 1248
Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time 1250
Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is kept pressed for long time 1252
Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time) 1254
Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time) 1256
Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time) 1258
Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree) 1260
Troubleshooting by failure code (Display of code), Part 6 1265
Failure code [DDE5MA] (Emergency steering drive switch: Malfunction) 1268
Failure code [DDK3KA] (Right FNR switch: Disconnection) 1271
Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection) 1274
Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree) 1277
Failure code [DDK6KA] (FNR lever switch: Disconnection) 1279
Failure code [DDK6KB] (FNR lever switch: Short circuit) 1286
Failure code [DDS5KA] (Steering pressure switch: Disconnected) 1290
Failure code [DDS5KB] (Steering pressure switch: Grounded) 1292
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree) 1294
Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time) 1297
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time) 1300
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time) 1303
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time) 1306
Failure code [DF10KA] (Transmission shift lever switch: Disconnected) 1308
Failure code [DF10KB] (Transmission shift lever switch: Short circuit) 1312
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected) 1315
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit) 1318
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range) 1321
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected) 1323
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range) 1325
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range) 1327
Failure code [DH21KA] (Loader pump pressure sensor: Disconnection) 1330
Failure code [DH21KB] (Loader pump pressure sensor: Power supply line short) 1332
Troubleshooting by failure code (Display of code), Part 7 1335
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range) 1338
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range) 1340
Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range) 1342
Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection) 1346
Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit) 1348
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection) 1350
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line) 1353
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree) 1356
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection) 1359
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line) 1362
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection) 1365
Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line) 1368
Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree) 1371
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection) 1374
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line) 1377
Troubleshooting by failure code (Display of code), Part 8 1381
Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection) 1383
Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line) 1386
Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection) 1388
Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line) 1392
Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree) 1394
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection) 1398
Failure code [DKA0KX] (Lift arm angle sensor: Out of input signal range) 1400
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line) 1402
Failure code [DKA0L0] (Lift arm angle sensor: Dislocation of sensor) 1404
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection) 1406
Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range) 1408
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit) 1410
Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit) 1414
Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit) 1416
Failure code [DV00KB] (Alarm buzzer: Short circuit) 1418
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection) 1420
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit) 1422
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line) 1424
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection) 1426
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit) 1427
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line) 1428
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection) 1430
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit) 1431
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line) 1432
Troubleshooting by failure code (Display of code), Part 9 1435
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection) 1437
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit) 1438
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line) 1440
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection) 1442
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit) 1444
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line) 1446
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection) 1448
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit) 1450
Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line) 1452
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection) 1454
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit) 1456
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line) 1458
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection) 1460
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit) 1462
Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line) 1464
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection) 1466
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit) 1468
Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source) 1470
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection) (WA380-6) 1472
Failure code [DX16KA] (Fan motor EPC solenoid: Disconnection) (WA380Z-6) 1473
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit) (WA380-6) 1474
Failure code [DX16KB] (Fan motor EPC solenoid: Short circuit) (WA380Z-6) 1475
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line) (WA380-6) 1476
Failure code [DX16KY] (Fan motor EPC solenoid: Short circuit with power supply line) (WA380Z-6) 1477
Failure code [DXA1KA] (Loader pump EPC solenoid: Disconnection) 1478
Failure code [DXA1KB] (Loader pump EPC solenoid: Short circuit) 1480
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection) 1482
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit) 1484
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line) 1486
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection) 1488
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit) 1490
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line) 1492
Troubleshooting by failure code (Display of code), Part 10 1495
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection) 1498
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit) 1500
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line) 1502
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection) 1504
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit) 1506
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line) 1508
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection) 1510
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit) 1512
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line) 1514
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection) 1516
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit) 1518
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line) 1520
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection) 1522
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit) 1524
Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line) 1526
Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection) 1528
Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit) 1530
Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line) 1532
Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection) 1534
Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit) 1536
Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line) 1538
Failure code [DY30MA] Motor-driven emergency steering pump failure (During operation of machine) 1540
Failure code [DY30MC] Motor-driven emergency steering pump failure (Malfunction in manual mode) 1545
Troubleshooting of electrical system (E-mode) 1553
Installing positions of fuses 1555
Information in troubleshooting table 1560
E-1 Engine does not start 1561
E-2 Wiper does not operate 1574
E-3 Windshield washer does not operate 1579
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off 1583
E-5 Working lamp does not light up or go off 1599
E-6 Turn signal lamp and hazard lamp do not light up or go off 1609
E-7 Brake lamp does not light or it keeps lighting up 1621
E-8 Backup lamp does not light or it keeps lighting up 1625
E-9 Backup buzzer does not sound or it keeps sounding 1629
E-10 Horn does not sound or it keeps sounding 1632
E-11 Alarm buzzer does not sound or it keeps sounding 1636
E-12 Air conditioner does not operate or stop 1638
E-13 The KOMTRAX system does not work properly 1642
E-14 When kick-down switch is turned ON, kick-down operation does not start 1645
E-15 When hold switch is pressed, holding operation does not start 1648
E-16 Transmission is kept in neutral, or brake drags when directional lever is operated while parking brake is applied 1651
E-17 Transmission cut-off mode cannot be set or reset 1654
E-18 Transmission cut-off set cannot be reset 1657
E-19 FNR switch mode cannot be set or reset 1660
E-20 Fan reverse function cannot be used or reset 1662
E-21 Discharge from loader pump does not rise from minimum level 1664
E-22 ECSS function cannot be used or reset 1666
E-23 When parking brake is turned ON, parking brake indicator lamp does not light up 1668
E-24 When emergency brake operates, brake oil pressure caution lamp does not operate 1672
E-25 Air cleaner clogging indicator lamp does not light up 1676
E-26 Radiator coolant level caution lamp does not light up 1679
E-27 Hydraulic oil temperature gauge does not rise and hydraulic oil temperature caution lamp does not light up 1681
E-28 Torque converter oil temperature gauge does not rise and torque converter oil temperature caution lamp does not light up 1683
E-29 Steering oil pressure caution lamp does not light up 1685
E-30 Abnormality in ■ switch (panel switch 1) input 1688
E-31 Abnormality in <> switch (panel switch 2) input 1691
E-32 Abnormality in < switch (panel switch 3) input 1694
E-33 Abnormality in > switch (panel switch 4) input 1697
Troubleshooting of hydraulic and mechanical system (H-mode) 1701
Method of using troubleshooting chart 1703
Table of failure modes and causes 1706
H-1 The machine does not start 1714
H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch] 1716
H-3 Torque converter lockup is not switched on [Machine with lockup clutch] 1717
H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted 1718
H-5 Shocks are large at the times of starting and shifting gear 1720
H-6 Time lag is large at the times of starting and shifting gear 1722
H-7 The torque converter oil temperature is high 1724
H-8 Steering does not turn 1725
H-9 Steering does not turn [Machine with joystick steering] 1726
H-10 Steering response is low 1727
H-11 Turning, response of steering is poor [machine with joystick steering] 1728
H-12 Steering is heavy 1729
H-13 When machine turns, it shakes or makes large shocks 1730
H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering] 1731
H-15 The wheel brake does not work or does not work well 1732
H-16 The wheel brake is not released or it drags 1733
H-17 The parking brake does not work or does not work well 1734
H-18 The parking brake is not released or it drags (including emergency release system) 1735
H-19 Lift arm does not rise 1736
H-20 Lift arm speed is low or rising force of lift arm is insufficient 1737
H-21 When rising, the lift arm comes to move slowly at specific height 1738
H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats) 1738
H-23 Hydraulic drifts of the lift arm is large 1738
H-24 The lift arm wobbles during operation 1738
H-25 Bucket does not tilt back 1739
H-26 Bucket speed is low or tilting back force is insufficient 1740
H-27 The bucket comes to operate slowly in the midst of tilting-back 1741
H-28 The bucket cylinder cannot hold down the bucket 1741
H-29 Hydraulic drifts of the bucket is large 1741
H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”) 1741
H-31 Lift arm and bucket control levers do not move smoothly and are heavy 1742
H-32 During operation of the machine, engine speed lowers remarkably or engine stalls 1743
H-33 Large shock is made when work equipment starts and stops 1743
H-34 When work equipment circuit is relieved singly, other work equipment moves 1743
H-35 ECSS does not operate, and pitching, bouncing occur 1744
H-36 Fan revolution is abnormal (Fan sound/ vibration is abnormally large or engine overheats) 1745
Troubleshooting of engine (S-mode) 1747
Method of using troubleshooting charts 1749
S-1 Engine does not start easily 1752
S-2 Engine does not start 1753
S-3 Engine does not pick up smoothly 1756
S-4 Engine stops during operations 1757
S-5 Engine does not rotate smoothly 1758
S-6 Engine lacks output (or lacks power) 1759
S-7 Exhaust smoke is black (Incomplete combustion) 1760
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1761
S-9 Engine oil becomes contaminated quickly 1762
S-10 Fuel consumption is excessive 1763
S-11 Coolant contains oil (blows back or reduces) 1764
S-12 Oil pressure drops 1765
S-13 Oil level rises (Water, fuel in oil) 1766
S-14 Coolant temperature rises too high (Overheating) 1767
S-15 Abnormal noise is made 1768
S-16 Vibration is excessive 1769
50 Disassembly and assembly 1771
General information on disassembly and assembly 1771
How to read this manual 1772
Coating materials list 1774
Special tools list 1777
Sketches of special tools 1780
Engine and cooling system 1789
Removal and installation of fuel supply pump assembly 1790
Removal and installation of fuel injector assembly 1794
Removal and installation of cylinder head assembly 1808
Removal and installation of engine hood assembly 1830
Removal and installation of radiator assembly 1835
Removal and installation of air aftercooler 1840
Removal and installation of hydraulic oil cooler assembly 1842
Removal and installation of engine assembly 1844
Removal and installation of engine front oil seal assembly 1849
Removal and installation of engine rear oil seal assembly 1853
Removal and installation of cooling fan and fan motor assembly 1856
Removal and installation of fuel tank assembly 1862
Power train 1865
Removal and installation of torque converter and transmission assembly 1866
Disassembly and assembly of torque converter assembly (Standard specification) 1872
Disassembly and assembly of torque converter assembly (Lockup specification) 1876
Disassembly and assembly of transmission assembly 1882
Disassembly and assembly of transmission clutch pack assembly 1899
Disassembly and assembly of parking brake assembly 1918
Removal and installation of front axle assembly 1927
Removal and installation of rear axle assembly 1929
Disassembly and assembly of axle housing 1932
Disassembly and assembly of differential assembly 1941
Steering system 1963
Removal and installation of steering valve assembly 1964
Removal and installation of steering valve oil seal 1968
Brake system 1971
Removal and installation of parking brake discs and plates 1972
Undercarriage and frame 1977
Removal and installation of center hinge pin 1978
Removal and installation of counterweight 1986
Hydraulic system 1991
Removal and installation of work equipment control valve assembly 1992
Removal and installation of power train pump and work equipment pump assembly 1998
Removal and installation of steering pump and cooling fan pump assembly 1999
Removal and installation of hydraulic tank assembly 2001
Work equipment 2005
Removal and installation of work equipment assembly 2006
Disassembly and assembly of hydraulic cylinder assembly 2010
Cab and its attachments 2019
Removal and installation of operator’s cab and floor frame assembly 2020
Removal and installation of operator’s cab glass (stuck glass) 2024
Disassembly and assembly of operator’s seat assembly (Standard specification) 2032
Disassembly and assembly of operator’s seat assembly (Manufactured by GRAMMER) 2041
Removal and installation of air conditioner unit assembly 2074
Electrical system 2079
Removal and installation of engine controller assembly 2080
90 Diagrams and drawings 2083
Hydraulic diagrams and drawings 2083
Power train hydraulic circuit diagram 2084
Automatic greasing circuit diagram 2086
Hydraulic circuit diagram 2089
Electrical diagrams and drawings 2093
Electrical circuit diagram 2095
Work equipment controller system electrical circuit diagram 2118
Connector list and stereogram 2119

DESCRIPTION:

Komatsu WA380Z-6 Wheel Loader Shop Manual SEN06411-C6 – PDF DOWNLOAD 

SERIAL NUMBERS C50001 and up

How to read the shop manual 
1. Composition of shop 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)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

S.V 26/12/24