Komatsu WA380-3 Wheel Loader Service Repair Shop Manual (50001 and up) - SEBM006104

This complete service repair workshop manual PDF download for the WA380-3 Avance Komatsu Wheel Loader (SN: 50001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Machine Model : WA380-3
Serial Numbers : 50001 and up


TABLE OF CONTENTS :

01 GENERAL
10 STRUCTURE AND FUNCTION
20 TESTING AND ADJUSTING
30 DISASSEMBLY AND ASSEMBLY
40 MAINTENANCE STANDARD


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM006104
Total Pages : 802


This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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COVER
CONTENTS
01 GENERAL
GENERAL ASSEMBLY DRAWING
SPECIFICATIONS
WEIGHT TABLE
LIST OF LUBRICANT AND WATER

10 STRUCTURE AND FUNCTION
POWER TRAIN
POWER TRAIN SYSTEM
TORQUE CONVERTER, TRANSMISSION PIPING
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
TORQUE CONVERTER
TORQUE CONVERTER OIL FILTER
TRANSMISSION
TRANSMISSION CONTROL VALVE
DRIVE SHAFT
AXLE
DIFFERENTIAL
FINAL DRIVE
AXLE MOUNT, CENTER HINGE PIN
STEERING PIPING
STEERING COLUMN
STEERING VALVE
ORBIT-ROLL VALVE
STOP VALVE
EMERGENCY STEERING PUMP
DIVERTER VALVE
BREAK PIPING
BRAKE HYDRAULIC CIRCUIT DIAGRAM
BRAKE VALVE
ACCUMULATOR CHARGE VALVE
ACCUMULATOR (FOR BRAKE)
BRAKE
PARKING BRAKE CONTROL
PARKING BRAKE
PARKING BRAKE SOLENOID VALVE
PARKING BRAKE VALVE
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE
HYDRAULIC PIPING
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIPMENT LEVER LINKAGE
HYDRAULIC TANK
PPC VALVE
PPC RELIEF VALVE
ACCUMULATOR (FOR PPC VALVE)
MAIN CONTROL VALVE
WORK EQUIPMENT LINKAGE
BUCKET
BUCKET POSITIONER AND BOOM KICK-OUT
CAB
ROPS CAB
AIR CONDITIONER
ELECTRIC CIRCUIT DIAGRAM
MACHINE MONITOR SYSTEM
MAIN MONITOR
MAINTENANCE MONITOR
WORK EQUIPMENT CONTROL SYSTEM
E.C.S.S. (Electronically Controlled Suspension System)
SENSORS
ENGINE STARTING CIRCUIT
ENGINE STOP CIRCUIT
PREHEATING CIRCUIT
ELECTRIC TRANSMISSION CONTROL
KICK-DOWN SWITCH
KICK-DOWN ELECTRIC CIRCUIT DIAGRAM
TRANSMISSION CUT-OFF SWITCH
TRANSMISSION CUT-OFF FUNCTION
ELECTRIC PARKING BRAKE CONTROL

20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING BLOW-BY PRESSURE
TESTING AND ADJUSTING FUEL INJECTION TIMING
MEASURING EXHAUST COLOR
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASURING EXHAUST GAS TEMPERATURE
MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE SPEED
TESTING AND ADJUSTING FAN BELT TENSION
METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE
MEASURING ACCELERATOR PEDAL
MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER
MEASURING STALL SPEED
MEASURING TORQUE CONVERTER, TRANSMISSION, PARKING BRAKE OIL PRESSURE
METHOD OF OPERATING EMERGENCY MANUALSPOOL
MEASURING CLEARANCE BETWEEN TIRE AND WHEEL
TESTING AND ADJUSTING STEERING WHEEL
TESTING AND ADJUSTING STEERING CONTROL
MEASURING STEERING OIL PRESSURE
MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL
MEASURING BRAKE PERFORMANCE
TESTING BRAKE OIL PRESSURE
TESTING FOR BRAKE DISC WEAR
BLEEDING AIR FROM BRAKE SYSTEM
MEASURING PARKING BRAKE PERFORMANCE
MANUAL RELEASE METHOD FOR PARKING BRAKE
TESTING WEAR OF PARKING BRAKE DISC
MEASURING WORK EQUIPMENT CONTROL LEVER
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE
MEASURING PPC VALVE PRESSURE
MEASURING WORK EQUIPMENT
TESTING AND ADJUSTING BUCKET POSITIONER
TESTING AND ADJUSTING BOOM KICK-OUT
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)
ADJUSTING BOOM, BUCKET ANGLE POTENTIOMETER
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
HANDLING CONNECTORS
CHECKS BEFORE TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR PIN ARRANGEMENT DIAGRAM
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)
S-1 Starting performance is poor (Starting always takes time)
S-2 Engine does not start
(1) Engine does not turn
(2) Engine turns but no exhaust gas comes out (Fuel is not being injected)
(3) Exhaust gas comes out but engine does not start (Fuel is being injected)
S-3 Engine does not pick up smoothly (Follow-up is poor)
S-4 Engine stops during operations
S-5 Engine does not rotate smoothly (hunting)
S-6 Engine lacks output (no power)
S-7 Exhaust gas is black (incomplete combustion)
S-8 Oil consumption is excessive (or exhaust gas is blue)
S-9 Oil becomes contaminated quickly
S-10 Fuel consumption is excessive
S-11 Oil is in cooling water, or water spurts back, or water level goes down
S-12 Oil pressure lamp lights up (drop in oil pressure)
S-13 Oil level rises
S-14 Water temperature becomes too high (overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)
TROUBLE DATA DISPLAY
M-1 Main monitor does not work
M-2 When starting switch is turned ON and engine is started immediately, all lamps stay lighted up
M-3 Speedometer display does not work properly
M-4 Abnormality in shift indicator
(a) Stays at N even when directional lever is at F
(b) Stays at N even when directional lever is at R
(c) Does not display N even when directional lever is at N and displays R when directional lever is at F
(d) Does not display N even when directional lever is at N and displays F when directional lever is at R
(e) Does not display lst, 4th
(f) Does not display 3rd, 4th
(g) Does not display 2nd, 3rd
(h) Does not display 1st, 2nd
M-5 High beam does not light up
M-6 Turn signal display does not light up
(a) L.H. turn signal does not light up
(b) R.H. turn signal does not light up
M-7 Abnormality in parking display
(a) Parking lamp does not light up
(b) Parking lamp stays lighted up
M-8 Abnormality in preheating system (QGS)
(a) Does not carry out preheating
(b) Always carries out preheating for 1 minute
(c) Preheating stays on
(d) Preheating time becomes shorter, or there is variation
M-9 Night lighting does not light up
M-10 Abnormality in front working lamp
(a) Neither monitor display nor front working lamp light up
(b) Working lamp lights up but monitor display does not light up
(c) Monitor lights up but working lamp does not light up
M-11 Abnormality in rear working lamp
(a) Neither monitor display nor rear working lamp light up
(b) Working lamp lights up but monitor display does not light up
(c) Monitor lights up but working lamp does not light up
M-12 Abnormality in transmission cut-off
(a) When monitor switch is pressed, cut-off function is not switched and display is not given
(b) Monitor display goes out but cut-off function stays on
(c) Monitor display lights up but cut-off function is not actuated
M-13 Abnormality in parking brake dragging warning
(a) When parking brake is applied, buzzer sounds (intermittently) even when directional lever is at N, and caution lamp flashes
(b) When parking brake is applied, buzzer does not sound and caution lamp does not light up even when directional lever is at po
M-14 When parking brake dragging warning is given, buzzer and caution lamp are actuated continuously, or they are not actuated
(a) Actuated continuously
(b) Not actuated
M-15 Abnormality in buzzer
(a) Buzzer does not sound when starting switch is turned ON (during self-check)
(b) Buzzer always sounds
M-16 Condition of monitor switches is not stored in memory
M-17 Abnormality in failure display mode
(a) Does not enter failure display mode
(b) Time for time elapsed since failure on failure display mode does not advance
M-18 Abnormality in emergency steering normal display
(a) Emergency steering normal display does not light up
(b) Emergency steering normal display stays lighted up
M-19 Abnormality in emergency steering actuation display
(a) Emergency steering actuation display does not light up
(b) Emergency steering actuation display stays lighted up
M-20 Abnormality in auto-greasing system
(a) Forced greasing cannot be carried out
(b) Monitor display flashes rapidly (2 times/sec)
(c) When no more grease remains, monitor display flashes rapidly (2 times/sec)
(d) Monitor display flashes slowly (1 time/sec)
(e) Monitor display goes out
M-21 Abnormality in ECSS system
(a) Display does not change when switch is pressed
(b) Monitor display lights up but ECSS function does not work
M-22 Buzzer does not sound when auto-leveling switch is actuated
M-23 Failure code is not sent to main monitor (abnormality in network)
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)
K-1 When starting switch is turned ON, all lamps on maintenance monitor do not light up for 3 sec., maintenance monitor does not
(a) All lamps on maintenance monitor do not light up for 3 seconds
(b) Some lamps do not light up
K-2 When starting switch is turned ON, all lamps on maintenance monitor light up but do not go out
K-3 When engine is started immediately after starting switch is turned ON (within 3 seconds), all lamps on maintenance monitor do not go out
K-4 When starting switch is turned ON (engine stopped), CHECK items flash
(a) Engine oil level display flashes
(b) Engine water level display flashes
K-5 When starting switch is turned ON (engine started), CAUTION items flash
(a) Engine oil pressure display flashes
(b) Battery charge level display flashes
(c) Brake oil pressure display flashes
(d) Air cleaner display flashes
K-6 CAUTION items are flashing but alarm buzzer does not sound
K-7 There is no abnormality in monitor display but alarm buzzer sounds
K-8 CAUTION items are flashing but warning lamp (CHECK lamp, CAUTION lamp) does not light up
(a) CHECK lamp
(b) CAUTION lamp
K-9 There is no abnormality in maintenance monitor display but warning lamp (CHECK lamp, CAUTION lamp) lights up
(a) CHECK lamp
(b) CAUTION lamp
K-10 Night lighting does not light up when lamp switch is turned ON (only lighting of maintenance monitor does not light up)
K-11 Night lighting lights up even when lamp switch is OFF, night lighting stays lighted up
K-12 Service meter does not work
K-13 Service meter is running even when engine is stopped
K-14 Abnormality in gauge items
(a) Abnormality in fuel gauge
(b) Abnormality in engine water temperature gauge
(c) Abnormality in torque converter oil temperature gauge
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
E-1 Engine does not start
(a) Starting motor does not turn
(b) Starting motor turns
E-2 Engine does not stop
E-3 Engine stops when machine is traveling
E-4 Parking brake does not work
(a) Parking brake has no effect when parking brake switch is turned ON (parking)
(b) Parking brake has no effect when brake pressure drops (Does not work as emergency brake)
E-5 Parking brake is applied when machine is traveling
E-6 Parking brake is released when starting switch is turned ON
E-7 Transmission does when parking brake is applied (but parking brake works normally)
E-8 Transmission does not work normally
(a) Problem in common circuit for transmission (always stays in 2nd)
(b) Problem in H-L circuit
(c) Problem in speed circuit
(d) Problem in 4th circuit (does not enter 4th)
(e) Contact in H-L circuit
(f) Contact in speed circuit
(g) Contact in 4th circuit (always stays in 4th)
(h) Problem in FORWARD circuit (REVERSE is normal)
(i) Problem in REVERSE circuit (FORWARD is normal)
(j) Problem in common circuit for FORWARD and REVERSE (does not travel forward, parking brake is normal)
(k) Contact in FORWARD circuit
(I) Contact in REVERSE circuit
(m) Problem in common circuit for FORWARD and REVERSE
E-9 Kick-down switch does not work (the regular F1 to F4 shifts normally)
E-10 Kick-down works only when kick-down switch is ON (Kick-down switch relay does not hold in position (self-holding function)
E-11 Kick-down operation cannot be canceled
(a) Not canceled even when directional lever is moved from F to N or R
(b) Not canceled even when speed lever is moved from 2nd to other position (becomes 4th)
E-12 Kick-down switch is actuated by mistake when traveling in 2nd
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (T MODE)
POWER TRAIN
T-1 Machine does not start
T-2 Travel speed is slow, thrusting power is weak, lacks power on slopes
T-3 Excessive shock when starting machine or shifting gear
T-4 Excessive time lag when starting machine or shifting gear
T-5 Torque converter oil temperature is high
STEERING SYSTEM
T-6 Steering does not turn
T-7 Steering wheel is heavy
T-8 Steering wheel wobbles or there is excessive shock
T-9 Machine steers to one side when traveling
T-10 Turning radius to left and right is different
BRAKE SYSTEM
T-11 Brakes do not work or braking effect is poor
T-12 Brakes are not released or brakes drag
T-13 Parking brake is not released or brake drags
WORK EQUIPMENT
T-14 Boom does not rise
T-15 Boom movement is slow or boom lacks lifting power
T-16 When boom is raised, it moves slowly at a certain height
T-17 Bucket cannot be pushed with cylinder (bucket floats)
T-18 Excessive hydraulic drift of boom
T-19 Boom shakes during operation
T-20 Boom drops momentarily when control lever is operated from HOLD to RAISE
T-21 Bucket does not tilt back
T-22 Bucket movement is slow or tilt-back lacks power
T-23 Bucket movement becomes slow during tilt-back operation
T-24 Bucket cannot be pushed with bucket cylinder
T-25 Excessive hydraulic drift of bucket
T-26 Bucket shakes during loading operation (Main control valve at HOLD)
T-27 Bucket dumps momentarily when control lever is operated from HOLD to TILT
T-28 Boom, bucket control levers are heavy or do not move smoothly
TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE)
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM
D-1 ECSS does not work
(a) Error code [d0] is displayed
(b) Error code [d1] is displayed
(c) Error code [d2] is displayed
(d) Error code [d3] is displayed
(e) Error code [d4] is displayed
(f) No abnormality display is given
D-2 ECSS cannot be canceled
D-3 Output is turned ON (travel speed does not become 5 km/h) (deviates around 5 km/h)
D-4 Output is turned ON when transmission
D-5 Output is turned ON when transmission is in 4th
D-6 Controller LED code is not displayed
D-7 ECSS is abnormal but main monitor does not give abnormality display
TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER SYSTEM (W MODE)
OUTLINE
1. Function
2. When carrying out troubleshooting
3. Failure code table
4. Table of troubleshooting modes and causes
W-1 Failure code [40] Abnormality in bucket dump solenoid system
W-2 Failure code [41] Short circuit in power source when bucket DUMP, TILT solenoids are OFF
W-3 Failure code [42] Abnormality in bucket tilt solenoid system
W-4 Failure code [43] Abnormality in damping solenoid system
W-5 Failure code [44]Short circuit in power source at hot end of damping solenoid
W-6 Failure code [45]Short circuit in power source at return end of damping solenoid
W-7 Failure code [48] Abnormality in bucket lever kick-out relay system
W-8 Failure code [49] Abnormality in boom lever kick-out relay system
W-9 Failure code [50] Abnormality in auto-leveler relay system
W-10 Failure code [51] Disconnection in boom RAISE, LOWER detection pressure switch
W-11 Failure code [52] Abnormality in boom angle potentiometer system
W-12 Failure code [53] Abnormality in bucket angle potentiometer system
W-13 Failure code [54] Abnormality in model selection wiring harness
W-14 Sensor cannot be adjusted
W-15 Does not carry out auto-leveling
(a) Auto-leveler switch system
(b) Auto-leveler LED system
(c) Bucket lever neutral switch system
(d) Engine speed signal system
W-16 Auto-leveler cannot be set
(a) Auto-leveler set switch system
(b) Auto-leveler set LED system
W-17 Remote positioner RAISE, LOWER LEDs do not light up
(a) Remote positioner switch system
(b) Remote positioner LED system
W-18 Remote positioner set LEDs do not flash
(a) Remote positioner switch system
(b) Remote positioner LED system
W-19 Bucket does not tilt immediately at boom FLOAT detent when remote positioner is at RAISE and auto mode is ON
W-20 Buzzer for switch operation does not sound
W-21 Bucket correction, boom stop response are slow
W-22 Bucket (lever) control
(a) Bucket kick-out does not work even when bucket is at maximum tilt
(b) Lever is not held by detent
W-23 Failure code is not displayed on main monitor
W-24 Maintenance monitor check

30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
STARTING MOTOR
REMOVAL AND INSTALLATION
ALTERNATOR
REMOVAL AND INSTALLATION
ENGINE OIL COOLER
REMOVAL AND INSTALLATION
FUEL INJECTION PUMP
REMOVAL
INSTALLATION
WATER PUMP
REMOVAL AND INSTALLATION
TURBOCHARGER
REMOVAL AND INSTALLATION
NOZZLE HOLDER
REMOVAL AND INSTALLATION
THERMOSTAT
REMOVAL AND INSTALLATION
CYLINDER HEAD
REMOVAL
INSTALLATION
RADIATOR
REMOVAL
INSTALLATION
ENGINE
REMOVAL
INSTALLATION
TORQUE CONVERTER CHARGING PUMP
REMOVAL
INSTALLATION
TORQUE CONVERTER, TRANSMISSION
REMOVAL
INSTALLATION
TORQUE CONVERTER
DISASSEMBLY
ASSEMBLY
TRANSMISSION
DISASSEMBLY
ASSEMBLY
TRANSMISSION CLUTCH PACK
DISASSEMBLY
ASSEMBLY
TRANSMISSION CONTROL VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
TRANSMISSION ACCUMULATOR VALVE
DISASSEMBLY
ASSEMBLY
TRANSMISSION MODULATING VALVE
DISASSEMBLY
ASSEMBLY
DRIVE SHAFT
DISASSEMBLY
ASSEMBLY
FRONT AXLE
REMOVAL
INSTALLATION
REAR AXLE
REMOVAL
INSTALLATION
DIFFERENTIAL
DISASSEMBLY
ASSEMBLY
AXLE HOUSING
DISASSEMBLY
ASSEMBLY
CENTER HINGE PIN
REMOVAL
INSTALLATION
STEERING VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
ORBIT-ROLL VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
STEERING CYLINDER
REMOVAL
INSTALLATION
BRAKE VALVE
REMOVAL
INSTALLATION
RIGHT BRAKE VALVE (TANDEM)
DISASSEMBLY
ASSEMBLY
LEFT BRAKE VALVE (SINGLE)
DISASSEMBLY
ASSEMBLY
PARKING BRAKE DISC
REMOVAL
INSTALLATION
HYDRAULIC TANK
REMOVAL
INSTALLATION
HYDRAULIC FILTER
REMOVAL AND INSTALLATION
HYDRAULIC, STEERING, SWITCH, PPC PUMP
REMOVAL
INSTALLATION
MAIN CONTROL VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
PPC VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
BUCKET CYLINDER
REMOVAL
INSTALLATION
BOOM CYLINDER
REMOVAL
INSTALLATION
HYDRAULIC CYLINDER
DISASSEMBLY
ASSEMBLY
WORK EQUIPMENT
REMOVAL
INSTALLATION
COUNTERWEIGHT
REMOVAL AND INSTALLATION
FUEL TANK
REMOVAL
INSTALLATION
CAB, FLOOR FRAME
REMOVAL
INSTALLATION
CAB
REMOVAL
INSTALLATION
MAIN MONITOR
REMOVAL
INSTALLATION
MAINTENANCE MONITOR
REMOVAL AND INSTALLATION
AIR CONDITIONER UNIT
REMOVAL
INSTALLATION
AIR CONDITIONER CONDENSER
REMOVAL
INSTALLATION
DRY RECEIVER
REMOVAL AND INSTALLATION
AIR CONDITIONER CONDENSER COMPRESSOR
REMOVAL AND INSTALLATION

40 MAINTENANCE STANDARD
ENGINE MOUNT, TRANSMISSION MOUNT
TORQUE CONVERTER CHARGING PUMP
TORQUE CONVERTER
TRANSMISSION
TRANSMISSION CONTROL VALVE
MODULATION VALVE ASSEMBLY
ACCUMULATOR VALVE
DRIVE SHAFT
DIFFERENTIAL
FINAL DRIVE
AXLE MOUNT
CENTER HINGE PIN
STEERING COLUMN
STEERING VALVE
STEERING CYLINDER MOUNT
BRAKE
BRAKE VALVE
PARKING BRAKE
HYDRAULIC PUMP
MAIN CONTROL VALVE
PPC VALVE
HYDRAULIC CYLINDER
WORK EQUIPMENT LINKAGE
BUCKET
BUCKET POSITIONER AND BOOM KICK-OUT

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