Komatsu Wheel Loader WA380, WA380Z-6 Workshop Repair Service Manual PDF - MKMTSWA380.zip
A full factory-level service and repair guide, complete with electrical wiring schematics, covering the Komatsu WA380- and WA380Z-series wheel loaders — everything you need to service, troubleshoot, overhaul, and rebuild these machines the way a trained technician would.
Inside the Komatsu WA380-/WA380Z-series wheel loader workshop manual you'll find:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 32,564 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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TABLE OF CONTENTS
VEBM440101 WA380-6...1
00 Index and foreword...3
Composition of shop manual...4
Table of contents...6
Index and foreword...17
Safety notice...18
How to read the shop manual...23
Explanation of terms for maintenance standard...25
Handling electric equipment and hydraulic component...27
How to read electric wire code...39
Precautions when carrying out operation...42
Method of disassembling and connecting push-pull type coupler...45
Standard tightening torque table...48
Conversion table...52
01 Specification...57
Specification and technical data...59
Specification dimension drawing...59
Specifications...60
Weight table...64
Table of fuel, coolant and lubricants...66
10 Structure, function and maintenance standard...67
Engine and cooling system...68
Engine mount and transmission mount...68
Cooling system...69
Cooling fan pump...70
Cooling fan motor...78
Power train...87
Power train...87
Power train system diagram...88
Drive shaft...90
Power train piping diagram...91
Torque converter...92
Transmission...100
Flow control valve...117
Valve assembly...118
ECMV...119
Main relief valve and torque converter relief valve...126
Axle...128
Differential...130
Limited slip differential...135
Final drive...142
Steering system...146
Steering piping diagram...146
Steering column...147
Steering pump...148
Steering valve...159
Orbit-roll valve...174
Stop valve...178
Steering relief valve...179
Steering cylinder...180
Emergency steering motor...182
Emergency steering pump...183
Brake system...186
Brake piping diagram...186
Charge valve...187
Brake valve...194
Accumulator (for brake)...199
Brake...200
Parking brake control...205
Parking brake...206
Parking brake solenoid valve...208
Emergency parking brake release valve...210
Undercarriage and frame...212
Axle mount and center hinge pin...212
Tires...216
Hydraulic system, Part 1...218
Hydraulic piping diagram...218
Work equipment control lever linkage...221
Hydraulic tank...222
Power train pump...224
Work equipment pump...225
Work equipment control valve...236
CLSS...250
Each function and operation of each valve...254
Hydraulic system, Part 2...278
PPC valve...278
Stabilizer valve...284
Accumulator (for PPC circuit)...289
Accumulator (for ECSS)...290
Work equipment...292
Work equipment linkage...292
Bucket...294
Bucket positioner and boom kick-out...295
Work equipment cylinder...301
Cab and its attachments...305
Cab...305
Air conditioner...306
Electrical system, Part 1...320
Machine monitor system...320
Machine monitor...325
Electrical system, Part 2...348
Electrical system (Transmission controller system)...348
Transmission controller...382
Electrical system, Part 3...386
Electric transmission control...386
Kickdown switch and hold switch...390
KOMTRAX terminal system...392
Engine starting circuit...394
Engine stopping circuit...396
Preheating circuit...397
Engine power mode selector circuit...398
Engine output derating function...399
Automatic warm-up function...399
Parking brake circuit...400
Sensor...402
Standard service value table...412
Standard service value table for engine...412
Standard service value table for chassis...413
20 Standard value table...411
Standard service value table...412
30 Testing and adjusting...421
Testing and adjusting, Part 1...423
Tools for testing, adjusting, and troubleshooting...423
Measuring engine speed...426
Measuring exhaust gas color...428
Adjusting valve clearance...430
Measuring compression pressure...432
Measuring blow-by pressure...435
Measuring engine oil pressure...436
Measuring intake air (boost) pressure...437
Handling fuel system equipment...438
Releasing residual pressure in fuel system...438
Measuring fuel pressure...439
Measuring fuel return rate and leakage...441
Bleeding air from fuel circuit...444
Testing leakage in fuel system...446
Handling reduced cylinder mode operation...447
Handling no-injection cranking operation...447
Handling controller voltage circuit...448
Testing and adjusting air conditioner compressor belt tension...449
Adjusting transmission speed sensor...450
Measuring directional lever...451
Measuring and adjusting power train oil pressure...452
Procedure for flushing torque converter and transmission hydraulic circuit...467
Method of moving machine when transmission valve is broken...468
Testing and adjusting steering stop valve...470
Testing and adjusting steering wheel...472
Testing steering oil pressure...474
Bleeding air from steering circuit...477
Testing and adjusting, Part 2...481
Testing hydraulic drive fan...481
Bleeding air from hydraulic drive fan circuit...483
Measuring brake pedal...485
Measuring brake performance...486
Testing and adjusting accumulator charge pressure...487
Testing wheel brake oil pressure...488
Measuring wear of wheel brake disc...490
Bleeding air from wheel brake circuit...491
Releasing residual pressure in brake accumulator circuit...492
Testing parking brake performance...493
Measuring parking brake oil pressure...494
Testing wear of parking brake disc...496
Method of releasing parking brake manually...497
Measuring and adjusting work equipment control lever...498
Measuring and adjusting work equipment PPC oil pressure...499
Measuring and adjusting work equipment oil pressure...502
Bleeding air from work equipment circuit...506
Releasing residual pressure in work equipment circuit...507
Testing and adjusting bucket positioner...508
Testing and adjusting boom kick- out...510
Checking proximity switch operation pilot lamp...511
Procedure for testing diodes...512
Preparation work for troubleshooting for electric system...513
How to start operation of KOMTRAX terminal...518
Lamp display of KOMTRAX terminal...523
Adjusting machine monitor...526
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor...527
Testing and adjusting, Part 3...530
Special functions of machine monitor (EMMS)...530
Pm-click inspection table...589
40 Troubleshooting...591
General information on troubleshooting...592
Points to remember when troubleshooting...592
Sequence of events in troubleshooting...593
Testing before troubleshooting...594
Classification and procedures of troubleshooting...595
Connection table for connector pin numbers...598
T-branch box and T-branch adapter table...621
Troubleshooting by failure code (Display of code), Part 1...627
Failure codes list...627
Before carrying out troubleshooting for electrical system...634
Information contained troubleshooting table...637
Failure code [1500L0] (TORQFLOW transmission: Double meshing)...639
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)...640
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)...642
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)...644
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)...646
Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)...648
Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF)...650
Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON)...652
Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF)...654
Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON)...656
Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF)...658
Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)...660
Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF)...662
Failure code [2F00MA] (Parking brake: Malfunction)...664
Troubleshooting by failure code (Display of code), Part 2...670
Failure code [2G43ZG] (Accumulator: Low oil pressure)...670
Failure code [AA1ANX] (Air cleaner: Clogging)...672
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine)...674
Failure code [AB00MA] (Alternator: Malfunction)...676
Failure code [B@BAZG] (Rotation derating by low engine oil pressure)...678
Failure code [B@BAZK] (Engine oil: Low level)...679
Failure code [B@BCNS] (Coolant: Overheating)...680
Failure code [B@BCZK] (Coolant: Low level)...682
Failure code [B@C7NS] (Brake oil: Overheating)...684
Failure code [b@CENS] (Torque converter oil: Overheating)...686
Failure code [B@CENS] (Torque converter oil: Overheating)...688
Failure code [B@HANS] (Hydraulic oil: Overheating)...690
Failure code [CA111] (Abnormality in engine controller)...692
Failure code [CA115] (Engine Ne or Bkup speed sensor error)...693
Failure code [CA122] (Charge pressure sensor high error)...694
Failure code [CA123] (Charge pressure sensor low error)...696
Failure code [CA131] (Throttle sensor high error)...698
Failure code [CA132] (Throttle sensor low error)...700
Failure code [CA144] (Coolant sensor high error)...702
Failure code [CA145] (Coolant sensor low error)...704
Failure code [CA153] (Charge temperature sensor high error)...706
Failure code [CA154] (Charge temperature sensor low error)...708
Failure code [CA155] (Derating of speed by abnormally high charge temperature)...710
Failure code [CA187] (Sensor power supply 2 low error)...712
Failure code [CA221] (Atmospheric pressure sensor high error)...714
Failure code [CA222] (Atmospheric sensor low error)...716
Failure code [CA227] (Sensor power supply 2 high error)...718
Troubleshooting by failure code (Display of code), Part 3...721
Failure code [CA234] (Engine overspeed)...721
Failure code [CA238] (Ne speed sensor power supply error)...722
Failure code [CA271] (PCV1 Short circuit)...723
Failure code [CA272] (PCV1 Disconnection)...724
Failure code [CA322] (Injector #1 (L/B #1) open/short error)...726
Failure code [CA323] (Injector #5 (L/B #5) open/short error)...728
Failure code [CA324] (Injector #3 (L/B #3) open/short error)...730
Failure code [CA325] (Injector #6 (L/B #6) open/short error)...732
Failure code [CA331] (Injector #2 (L/B #2) open/short error)...734
Failure code [CA332] (Injector #4 (L/B #4) open/short error)...736
Failure code [CA342] (Calibration code inconsistency)...738
Failure code [CA351] (Injectors drive circuit error)...739
Failure code [CA352] (Sensor power supply 1 low error)...741
Failure code [CA386] (Sensor power supply 1 high error)...743
Failure code [CA428] (Abnormally high level in water sensor)...744
Failure code [CA429] (Abnormally low level in water sensor)...746
Failure code [CA431] (Idle validation switch error)...748
Failure code [CA432] (Idle validation action error)...750
Failure code [CA435] (Engine oil pressure switch error)...752
Failure code [CA441] (Battery voltage low error)...753
Failure code [CA442] (Battery voltage high error)...756
Failure code [CA449] Common rail pressure high error 2...758
Failure code [CA451] (Common rail pressure sensor high error)...759
Failure code [CA452] (Common rail pressure sensor low error)...761
Failure code [CA488] (Derating of torque by abnormally high charge temperature)...763
Failure code [CA553] (Common rail pressure high error 1)...764
Failure code [CA559] (Supply pump pressure very low error)...765
Failure code [CA689] (Engine Ne speed sensor error)...766