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Komatsu WA380-6 Wheel Loader Workshop Repair Service Manual

Komatsu WA380-6 Wheel Loader Workshop Repair Service Manual

This is a COMPLETE Service and Repair Manual for your Komatsu WA380-6 Wheel Loader. It covers every single detail.

This QUALITY manual is 100 percents COMPLETE and INTACT, no MISSING/CORRUPT pages/sections to freak you out! Detailed illustrations, exploded diagrams, drawings and photos guide you through every service repair procedure. This manual for Komatsu WA380-6 Wheel Loader can be viewed on any computer, as well as zoomed and printed. All repair procedures are covered A-Z. This manual makes any repair job easy to do with very easy to follow step-by-step instructions & pictures on all areas of repair.

Fixing problems in your vehicle is a do-it-approach with the this Repair Manual for Komatsu WA380-6 Wheel Loader as they contain comprehensive instructions and procedures on how to fix the problems in your ride. Repair Manuals can come in handy especially when you have to do immediate repair. The durability of your vehicle/bike is unquestionable but you also know that no matter how tough they are, constant use can cause them to deteriorate. When this happens, and ultimately it will, you will have to replace them. Some car/bike parts are very simple to mount and do not require professional help. By having a trusty repair manual you not only save money but you also get to experience the fun of do-it-yourself projects. A repair manual comes with comprehensive details regarding technical data, diagrams, a complete list of car parts and pictures. Even the most novice can easily follow the step-by-step guides which are made simple by the illustrations and drawings. You can find a complete list of accessories that can further enhance the performance of your engine. This Repair Manual for Komatsu WA380-6 Wheel Loader can save you a lot of time. These packages are complete with all the information needs. You will surely enjoy browsing through the pages and learning how to repair the different parts. It makes you up-to-date and more knowledge. Now, you dont have to rely on your mechanic for the simplest repair. You can do it at the comfort of your garage. All pages are printable, so print off what you need and take it with you into the garage or workshop. This manual will never get dirty and rip as you can keep it safely on your PC and print the pages you need in matter of seconds.

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Format: PDF
System: All Versions of Windows, Mac, iOS, BB, Android, etc..
Requirements: PDF Reader.
Printable: Yes

Komatsu WA380-6 Wheel Loader
===========
Table of contents
1
00 Index and foreword
Index
SEN01019-04
Composition of shop manual ...................................................................................................
2
Table of contents......................................................................................................................
4
Foreword and general information
SEN01020-01
Safety notice ............................................................................................................................
2
How to read the shop manual..................................................................................................
7
Explanation of terms for maintenance standard ......................................................................
9
Handling electric equipment and hydraulic component ........................................................... 11
How to read electric wire code................................................................................................. 23
Precautions when carrying out operation ................................................................................ 26
Method of disassembling and connecting push-pull type coupler ........................................... 29
Standard tightening torque table.............................................................................................. 32
Conversion table...................................................................................................................... 36
01 Specification
Specification and technical data
SEN01021-00
Specification and technical data ..................................................................................................
3
Specification dimension drawing..............................................................................................
3
Specifications...........................................................................................................................
4
Weight table .............................................................................................................................
8
Table of fuel, coolant and lubricants ........................................................................................ 10
10 Structure, function and maintenance standard
Engine and cooling system
SEN01040-00
Engine and cooling system .........................................................................................................
2
Engine mount and transmission mount ...................................................................................
2
Cooling system ........................................................................................................................
3
Cooling fan pump.....................................................................................................................
4
Cooling fan motor .................................................................................................................... 12
Power train
SEN01041-00
Power train ..................................................................................................................................
3
Power train...............................................................................................................................
3
Power train system diagram ....................................................................................................
4
Drive shaft................................................................................................................................
6
Power train piping diagram ......................................................................................................
7
Torque converter......................................................................................................................
8
Transmission............................................................................................................................ 16
Flow control valve .................................................................................................................... 33
Valve assembly........................................................................................................................ 34
ECMV ...................................................................................................................................... 35
Main relief valve and torque converter relief valve .................................................................. 42
Axle.......................................................................................................................................... 44
Front axle................................................................................................................................. 44
Rear axle ................................................................................................................................. 45
Differential................................................................................................................................ 46
Front differential ....................................................................................................................... 46
Rear differential ....................................................................................................................... 47
Limited slip differential ............................................................................................................. 51
Final drive ................................................................................................................................ 58
4
WA380-6 VEBM44010100 Index and foreword
SEN01019-04
Steering system
SEN01042-00
Steering system...........................................................................................................................
2
Steering piping diagram...........................................................................................................
2
Steering column.......................................................................................................................
3
Steering pump .........................................................................................................................
4
Steering valve .......................................................................................................................... 15
Orbit-roll valve ......................................................................................................................... 30
Stop valve ................................................................................................................................ 34
Steering relief valve ................................................................................................................. 35
Steering cylinder ...................................................................................................................... 36
Emergency steering motor ...................................................................................................... 38
Emergency steering pump....................................................................................................... 39
Brake system
SEN01043-00
Brake system ..............................................................................................................................
2
Brake piping diagram...............................................................................................................
2
Charge valve ...........................................................................................................................
3
Brake valve.............................................................................................................................. 10
Accumulator (for brake) ........................................................................................................... 15
Brake ....................................................................................................................................... 16
Parking brake control............................................................................................................... 21
Parking brake .......................................................................................................................... 22
Parking brake solenoid valve................................................................................................... 24
Emergency parking brake release valve ................................................................................. 26
Undercarriage and frame
SEN01044-00
Undercarriage and frame ............................................................................................................
2
Axle mount and center hinge pin .............................................................................................
2
Tires.........................................................................................................................................
6
Hydraulic system, Part 1
SEN01045-00
Hydraulic system, Part 1 .............................................................................................................
2
Hydraulic piping diagram .........................................................................................................
2
Work equipment control lever linkage .....................................................................................
5
Hydraulic tank..........................................................................................................................
6
Breather...................................................................................................................................
7
Power train pump ....................................................................................................................
8
Work equipment pump ............................................................................................................
9
Work equipment control valve ................................................................................................. 20
CLSS ....................................................................................................................................... 34
Outline of CLSS....................................................................................................................... 34
Basic principle ......................................................................................................................... 35
Each function and operation of each valve.............................................................................. 38
Hydraulic circuit diagram and names of valves ....................................................................... 38
Area ratio of pressure compensation valve ............................................................................. 48
Hydraulic system, Part 2
SEN01046-00
Hydraulic system, Part 2 .............................................................................................................
2
PPC valve................................................................................................................................
2
Stabilizer valve.........................................................................................................................
8
Accumulator (for PPC circuit) .................................................................................................. 13
Accumulator (for ECSS) .......................................................................................................... 14
Work equipment
SEN01047-00
Work equipment ..........................................................................................................................
2
Work equipment linkage ..........................................................................................................
2
Bucket......................................................................................................................................
4
Bucket positioner and boom kick-out.......................................................................................
5
Work equipment cylinder ......................................................................................................... 11
WA380-6 VEBM440101
5SEN01019-04
00 Index and foreword
Cab and its attachments
SEN01048-00
Cab and its attachments..............................................................................................................
3
Cab ..........................................................................................................................................
3
Air conditioner..........................................................................................................................
4
Air conditioner piping diagram .................................................................................................
4
Air conditioner unit ...................................................................................................................
7
Blower and intake unit .............................................................................................................
9
Compressor ............................................................................................................................. 10
Condenser ............................................................................................................................... 11
Receiver................................................................................................................................... 12
Air conditioner panel ................................................................................................................ 14
Electrical system, Part 1
SEN01049-00
Electrical system, Part 1..............................................................................................................
2
Machine monitor system..........................................................................................................
2
Machine monitor ......................................................................................................................
7
Electrical system, Part 2
SEN01050-00
Electrical system, Part 2..............................................................................................................
2
Electrical system (Transmission controller system) .................................................................
2
Transmission controller............................................................................................................ 36
Electrical system, Part 3
SEN01051-00
Electrical system, Part 3..............................................................................................................
2
Electric transmission control ....................................................................................................
2
Kickdown switch and hold switch.............................................................................................
6
KOMTRAX terminal system.....................................................................................................
8
Engine starting circuit .............................................................................................................. 10
Engine stopping circuit............................................................................................................. 12
Preheating circuit ..................................................................................................................... 13
Engine power mode selector circuit......................................................................................... 14
Engine output derating function ............................................................................................... 15
Automatic warm-up function .................................................................................................... 15
Parking brake circuit ................................................................................................................ 16
Sensor ..................................................................................................................................... 18
20 Standard value table
Standard service value table
SEN01024-01
Standard service value table .......................................................................................................
2
Standard service value table for engine...................................................................................
2
Standard service value table for chassis .................................................................................
3
30 Testing and adjusting
Testing and adjusting, Part 1
SEN01025-01
Testing and adjusting, Part 1 .......................................................................................................
3
Tools for testing, adjusting, and troubleshooting......................................................................
3
Measuring engine speed .........................................................................................................
6
Measuring exhaust gas color...................................................................................................
8
Adjusting valve clearance ........................................................................................................ 10
Measuring compression pressure............................................................................................ 12
Measuring blow-by pressure.................................................................................................... 15
Measuring engine oil pressure................................................................................................. 16
Measuring intake air (boost) pressure ..................................................................................... 17
Handling fuel system equipment.............................................................................................. 18
Releasing residual pressure in fuel system ............................................................................. 18
Measuring fuel pressure .......................................................................................................... 19
Measuring fuel return rate and leakage ................................................................................... 21
Bleeding air from fuel circuit .................................................................................................... 24
Testing leakage in fuel system................................................................................................. 26
6
WA380-6 VEBM44010100 Index and foreword
SEN01019-04
Handling reduced cylinder mode operation ............................................................................. 27
Handling no-injection cranking operation ................................................................................ 27
Handling controller voltage circuit............................................................................................ 28
Testing and adjusting air conditioner compressor belt tension ................................................ 29
Adjusting transmission speed sensor ...................................................................................... 30
Measuring directional lever...................................................................................................... 31
Measuring and adjusting power train oil pressure ................................................................... 32
Procedure for flushing torque converter and transmission hydraulic circuit ............................ 47
Method of moving machine when transmission valve is broken.............................................. 48
Testing and adjusting steering stop valve................................................................................ 50
Testing and adjusting steering wheel....................................................................................... 52
Testing steering oil pressure.................................................................................................... 54
Bleeding air from steering circuit ............................................................................................. 57
Testing and adjusting, Part 2
SEN01026-01
Testing and adjusting, Part 2.......................................................................................................
3
Testing hydraulic drive fan .......................................................................................................
3
Bleeding air from hydraulic drive fan circuit.............................................................................
5
Measuring brake pedal ............................................................................................................
7
Measuring brake performance.................................................................................................
8
Testing and adjusting accumulator charge pressure ...............................................................
9
Testing wheel brake oil pressure ............................................................................................. 10
Measuring wear of wheel brake disc ....................................................................................... 12
Bleeding air from wheel brake circuit....................................................................................... 13
Releasing residual pressure in brake accumulator circuit ....................................................... 14
Testing parking brake performance ......................................................................................... 15
Measuring parking brake oil pressure ..................................................................................... 16
Testing wear of parking brake disc .......................................................................................... 18
Method of releasing parking brake manually ........................................................................... 19
Measuring and adjusting work equipment control lever .......................................................... 20
Measuring and adjusting work equipment PPC oil pressure ................................................... 21
Measuring and adjusting work equipment oil pressure ........................................................... 24
Bleeding air from work equipment circuit................................................................................. 28
Releasing residual pressure in work equipment circuit ........................................................... 29
Testing and adjusting bucket positioner................................................................................... 30
Testing and adjusting boom kick-out ....................................................................................... 32
Checking proximity switch operation pilot lamp....................................................................... 33
Procedure for testing diodes.................................................................................................... 34
Preparation work for troubleshooting for electric system......................................................... 35
How to start operation of KOMTRAX terminal ......................................................................... 40
Lamp display of KOMTRAX terminal....................................................................................... 45
Adjusting machine monitor ...................................................................................................... 48
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ...... 49
Testing and adjusting, Part 3
SEN01027-01
Testing and adjusting, Part 3.......................................................................................................
2
Special functions of machine monitor (EMMS)........................................................................
2
Pm-click inspection table ......................................................................................................... 61
40 Troubleshooting
General information on troubleshooting
SEN01212-00
General information on troubleshooting ......................................................................................
2
Points to remember when troubleshooting ..............................................................................
2
Sequence of events in troubleshooting ...................................................................................
3
Testing before troubleshooting ................................................................................................
4
Classification and procedures of troubleshooting....................................................................
5
Connection table for connector pin numbers ...........................................................................
8
T-branch box and T-branch adapter table ............................................................................... 31
WA380-6 VEBM440101
7SEN01019-04
00 Index and foreword
Troubleshooting by failure code (Display of code), Part 1
SEN01213-00
Troubleshooting by failure code (Display of code), Part 1...........................................................
3
Failure codes list......................................................................................................................
3
Before carrying out troubleshooting for electrical system ........................................................ 10
Information contained troubleshooting table ............................................................................ 13
Failure code [1500L0] (TORQFLOW transmission: Double meshing)..................................... 15
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON) .... 16
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF) ... 18
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON).... 20
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF) ... 22
Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON).. 24
Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF). 26
Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON). 28
Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF) 30
Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON). 32
Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF) 34
Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON) . 36
Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF) 38
Failure code [2F00MA] (Parking brake: Malfunction) .............................................................. 40
Troubleshooting by failure code (Display of code), Part 2
SEN01214-00
Troubleshooting by failure code (Display of code), Part 2...........................................................
4
Failure code [2G43ZG] (Accumulator: Low oil pressure).........................................................
4
Failure code [AA1ANX] (Air cleaner: Clogging) .......................................................................
6
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine)..............
8
Failure code [AB00MA] (Alternator: Malfunction) .................................................................... 10
Failure code [[email protected]] (Rotation derating by low engine oil pressure)................................. 12
Failure code [[email protected]] (Engine oil: Low level) ...................................................................... 13
Failure code [[email protected]] (Coolant: Overheating)..................................................................... 14
Failure code [[email protected]] (Coolant: Low level).......................................................................... 16
Failure code [[email protected]] (Brake oil: Overheating) ................................................................... 18
Failure code [[email protected]] (Torque converter oil: Overheating).................................................. 20
Failure code [[email protected]] (Torque converter oil: Overheating) ................................................. 22
Failure code [[email protected]] (Hydraulic oil: Overheating) ............................................................. 24
Failure code [CA111] (Abnormality in engine controller).......................................................... 26
Failure code [CA115] (Engine Ne or Bkup speed sensor error) .............................................. 27
Failure code [CA122] (Charge pressure sensor high error)..................................................... 28
Failure code [CA123] (Charge pressure sensor low error) ...................................................... 30
Failure code [CA131] (Throttle sensor high error) ................................................................... 32
Failure code [CA132] (Throttle sensor low error)..................................................................... 34
Failure code [CA144] (Coolant sensor high error) ................................................................... 36
Failure code [CA145] (Coolant sensor low error) .................................................................... 38
Failure code [CA153] (Charge temperature sensor high error) ............................................... 40
Failure code [CA154] (Charge temperature sensor low error)................................................. 42
Failure code [CA155] (Derating of speed by abnormally high charge temperature)................ 44
Failure code [CA187] (Sensor power supply 2 low error) ........................................................ 46
Failure code [CA221] (Atmospheric pressure sensor high error) ............................................ 48
Failure code [CA222] (Atmospheric sensor low error)............................................................. 50
Failure code [CA227] (Sensor power supply 2 high error)....................................................... 52
Troubleshooting by failure code (Display of code), Part 3
SEN01215-00
Troubleshooting by failure code (Display of code), Part 3...........................................................
3
Failure code [CA234] (Engine overspeed)...............................................................................
3
Failure code [CA238] (Ne speed sensor power supply error)..................................................
4
Failure code [CA271] (PCV1 Short circuit) ..............................................................................
5
Failure code [CA272] (PCV1 Disconnection)...........................................................................
6
Failure code [CA322] (Injector #1 (L/B #1) open/short error) ..................................................
8
Failure code [CA323] (Injector #5 (L/B #5) open/short error) .................................................. 10
Failure code [CA324] (Injector #3 (L/B #3) open/short error) .................................................. 12
8
WA380-6 VEBM44010100 Index and foreword
SEN01019-04
Failure code [CA325] (Injector #6 (L/B #6) open/short error) .................................................. 14
Failure code [CA331] (Injector #2 (L/B #2) open/short error) .................................................. 16
Failure code [CA332] (Injector #4 (L/B #4) open/short error) .................................................. 18
Failure code [CA342] (Calibration code inconsistency)........................................................... 20
Failure code [CA351] (Injectors drive circuit error) .................................................................. 21
Failure code [CA352] (Sensor power supply 1 low error) ........................................................ 23
Failure code [CA386] (Sensor power supply 1 high error) ...................................................... 25
Failure code [CA428] (Abnormally high level in water sensor) ................................................ 26
Failure code [CA429] (Abnormally low level in water sensor) ................................................. 28
Failure code [CA431] (Idle validation switch error).................................................................. 30
Failure code [CA432] (Idle validation action error) .................................................................. 32
Failure code [CA435] (Engine oil pressure switch error) ......................................................... 34
Failure code [CA441] (Battery voltage low error) .................................................................... 35
Failure code [CA442] (Battery voltage high error) ................................................................... 38
Failure code [CA449] Common rail pressure high error 2 ....................................................... 40
Failure code [CA451] (Common rail pressure sensor high error)............................................ 41
Failure code [CA452] (Common rail pressure sensor low error) ............................................. 43
Failure code [CA488] (Derating of torque by abnormally high charge temperature) ............... 45
Failure code [CA553] (Common rail pressure high error 1)..................................................... 46
Failure code [CA559] (Supply pump pressure very low error)................................................. 47
Failure code [CA689] (Engine Ne speed sensor error) ........................................................... 48
Failure code [CA731] (Engine Bkup speed sensor phase error) ............................................. 50
Failure code [CA757] (All continuous data lost error) .............................................................. 51
Failure code [CA778] (Engine Bkup speed sensor error) ........................................................ 54
Failure code [CA1117] (Partial engine controller data loss error) ............................................ 56
Failure code [CA1633] (KOMNET datalink timeout error) ....................................................... 59
Troubleshooting by failure code (Display of code), Part 4
SEN01216-00
Troubleshooting by failure code (Display of code), Part 4...........................................................
3
Failure code [CA2185] (Throttle sensor supply voltage high error) .........................................
3
Failure code [CA2186] (Throttle sensor power supply low error) ............................................
4
Failure code [CA2249] (Supply pump pressure very low error 2)............................................
5
Failure code [CA2311] (Abnormality in IMV solenoid) .............................................................
6
Failure code [CA2555] (Intake heater relay disconnection error) ............................................
8
Failure code [CA2556] (Intake heater relay short circuit error)................................................ 10
Failure code [D150KA] (Emergency steering relay: Disconnection)........................................ 12
Failure code [D150KB] (Emergency steering relay: Short circuit) ........................................... 14
Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line) ....... 16
Failure code [D160KA] (Backup lamp relay: Disconnection)................................................... 18
Failure code [D160KB] (Backup lamp relay: Short circuit) ...................................................... 20
Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection) ...................... 22
Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit) .......................... 24
Failure code [D191KY] (Joystick steering neutral safety relay:
Short circuit with power supply line) ................................................................................. 26
Failure code [D192KA] (ECSS solenoid: Disconnection) ........................................................ 28
Failure code [D192KB] (ECSS solenoid: Short circuit)............................................................ 29
Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)........................ 30
Failure code [D5ZHKA] (Terminal C signal: Disconnection) .................................................... 31
Failure code [D5ZHKB] (Terminal C signal: Short circuit)........................................................ 35
Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or
stopped state)................................................................................................................... 39
Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)............................ 42
Failure code [DAF3KK] (Machine monitor: Low source voltage (input)).................................. 44
Failure code [DAF5KP] (Machine monitor: Low output voltage).............................................. 46
Failure code [DAFRKR] (CAN communication with machine monitor:
Defective communication (Abnormality in target component system))............................. 49
Failure code [DAQ0KK] (Transmission controller: Low source voltage).................................. 51
Failure code [DAQ0KT] (Transmission controller: Abnormality in controller) .......................... 53
WA380-6 VEBM440101
9SEN01019-04
00 Index and foreword
Failure code [DAQ2KK] (Transmission controller load power supply line:
Low source voltage (input)) .............................................................................................. 54
Failure code [DAQ9KQ] (Transmission controller model selection:
Disagreement of model selection signals)........................................................................ 56
Troubleshooting by failure code (Display of code), Part 5
SEN01217-00
Troubleshooting by failure code (Display of code), Part 5...........................................................
3
Failure code [DAQRKR] (CAN communication with transmission controller:
Defective communication (Abnormality in target component system)).............................
3
Failure code [DAQRMA] (Transmission controller option setting: Malfunction) .......................
5
Failure code [DB2RKR] (CAN communication with engine controller:
Defective communication (Abnormality in target component system) ..............................
6
Failure code [DB99KQ] (Work equipment controller model selection:
Disagreement in model selection signals) ........................................................................
9
Failure code [DB9RKR] CAN communication with work equipment controller:
Defective communication (Abnormality in target component system))............................. 10
Failure code [DB9RMA] (Work equipment controller option setting: Malfunction) ................... 12
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time ........ 14
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time ....... 16
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time ......... 18
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time ......... 20
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time ..... 22
Failure code [DD1FLD] Load meter mode selector switch (A/B):
Switch is kept pressed for long time ................................................................................. 24
Failure code [DD1GLD] Load meter mode selector switch (+/):
Switch is kept pressed for long time ................................................................................. 26
Failure code [DD1HLD] (Load meter display selector switch:
Switch is kept pressed for long time)................................................................................ 28
Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time) ............... 30
Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time) 32
Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree) ........ 34
Troubleshooting by failure code (Display of code), Part 6
SEN01218-00
Troubleshooting by failure code (Display of code), Part 6...........................................................
4
Failure code [DDK3KA] (Right FNR switch: Disconnection)....................................................
4
Failure code [DDK6KA] (FNR lever switch: Disconnection) ....................................................
7
Failure code [DDK6KB] (FNR lever switch: Short circuit) ........................................................ 10
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree) ..................... 12
Failure code [DDT4LD] (Transmission cut-off set switch:
Switch is kept pressed for long time)................................................................................ 14
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time) ................. 16
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time) .......................... 18
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time) ..... 20
Failure code [DF10KA] (Transmission shift lever switch: Disconnected)................................. 22
Failure code [DF10KB] (Transmission shift lever switch: Short circuit) ................................... 26
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected) ...................... 28
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit) ......................... 30
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)........... 32
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected) ......................... 34
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range) ........ 36
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range) 38
Troubleshooting by failure code (Display of code), Part 7
SEN01219-00
Troubleshooting by failure code (Display of code), Part 7...........................................................
2
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range) 2
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range) .
4
Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range) ....
6
Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection)..............................
8
Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit) ................................. 10
10
WA380-6 VEBM44010100 Index and foreword
SEN01019-04
Troubleshooting by failure code (Display of code), Part 8
SEN01220-00
Troubleshooting by failure code (Display of code), Part 8...........................................................
2
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection) .................
2
Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range).
4
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit) ............................
6
Failure code [DV00KB] (Alarm buzzer: Short circuit) ..............................................................
8
Troubleshooting by failure code (Display of code), Part 9
SEN01221-00
Troubleshooting by failure code (Display of code), Part 9...........................................................
2
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection) .............................................
2
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit).................................................
3
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line) ............
4
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection) .........................................
6
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit).............................................
7
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line) ........
8
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection) .......................................... 10
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit).............................................. 12
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line) ......... 14
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection) ...................................... 16
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit) .......................................... 18
Troubleshooting by failure code (Display of code), Part 10
SEN01222-00
Troubleshooting by failure code (Display of code), Part 10.........................................................
4
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line) ......
4
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection) .....................................
6
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit) .........................................
8
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)..... 10
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection) ...................................... 12
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit).......................................... 14
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line) ..... 16
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)......................................... 18
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit) ............................................ 20
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line) ........ 22
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection) ......................................... 24
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)............................................. 26
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line) ........ 28
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)...................................... 30
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit) ......................................... 32
Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line) ..... 34
Troubleshooting of electrical system (E-mode)
SEN01223-00
Troubleshooting of electrical system (E-mode) ...........................................................................
3
Before carrying out troubleshooting for electrical system........................................................
3
Information in troubleshooting table ........................................................................................
6
E-1 Engine does not start ........................................................................................................
7
E-2 Wiper does not operate..................................................................................................... 14
E-3 Windshield washer does not operate................................................................................ 18
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off ............. 22
E-5 Working lamp does not light up or go off........................................................................... 30
E-6 Turn signal lamp and hazard lamp do not light up or go off .............................................. 35
E-7 Brake lamp does not light or it keeps lighting up .............................................................. 41
E-8 Backup lamp does not light or it keeps lighting up ............................................................ 43
E-9 Backup buzzer does not sound or it keeps sounding ....................................................... 45
E-10 Horn does not sound or it keeps sounding ..................................................................... 47
E-11 Alarm buzzer does not sound or it keeps sounding ........................................................ 50
E-12 Air conditioner does not operate or stop ......................................................................... 52
E-13 The KOMTRAX system does not work properly ............................................................. 55
Troubleshooting of hydraulic and mechanical system (H-mode)
SEN01224-00
Troubleshooting of hydraulic and mechanical system (H-mode) ................................................
3
Method of using troubleshooting chart ....................................................................................
3
WA380-6 VEBM440101
11SEN01019-04
00 Index and foreword
Table of failure modes and causes ..........................................................................................
6
H-1 The machine does not start .............................................................................................. 10
H-2 Torque converter lockup is not switched off (engine stalls)
[Machine with lockup clutch (if equipped)]........................................................................ 12
H-3 Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)] ... 13
H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak,
and the gear is not shifted ................................................................................................ 14
H-5 Shocks are large at the times of starting and shifting gear ............................................... 16
H-6 Time lag is large at the times of starting and shifting gear ................................................ 18
H-7 The torque converter oil temperature is high .................................................................... 20
H-8 Steering does not turn....................................................................................................... 21
H-9 Steering does not turn [Machine with joystick steering (if equipped)] ............................... 22
H-10 Steering response is low ................................................................................................. 23
H-11 Turning, response of steering is poor [machine with joystick steering (if equipped)] ...... 24
H-12 Steering is heavy............................................................................................................. 25
H-13 When machine turns, it shakes or makes large shocks.................................................. 26
H-14 When machine turns, it shakes or makes large shocks
[machine with joystick steering (if equipped)] ................................................................... 27
H-15 The wheel brake does not work or does not work well ................................................... 28
H-16 The wheel brake is not released or it drags .................................................................... 29
H-17 The parking brake does not work or does not work well................................................. 30
H-18 The parking brake is not released or it drags (including emergency release system) .... 31
H-19 Lift arm does not rise ...................................................................................................... 32
H-20 Lift arm speed is low or rising force of lift arm is insufficient ........................................... 33
H-21 When rising, the lift arm comes to move slowly at specific height .................................. 34
H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats) .................................. 34
H-23 Hydraulic drifts of the lift arm is large .............................................................................. 34
H-24 The lift arm wobbles during operation............................................................................. 34
H-25 Bucket does not tilt back ................................................................................................. 35
H-26 Bucket speed is low or tilting back force is insufficient ................................................... 36
H-27 The bucket comes to operate slowly in the midst of tilting-back ..................................... 37
H-28 The bucket cylinder cannot hold down the bucket .......................................................... 37
H-29 Hydraulic drifts of the bucket is large .............................................................................. 37
H-30 The bucket wobbles during travel with cargo (The work equipment valve is
set to HOLD) .................................................................................................................. 37
H-31 Lift arm and bucket control levers do not move smoothly and are heavy ....................... 38
H-32 During operation of the machine, engine speed lowers remarkably or engine stalls ...... 39
H-33 Large shock is made when work equipment starts and stops......................................... 39
H-34 When work equipment circuit is relieved singly, other work equipment moves .............. 39
H-35 ECSS does not operate, and pitching, bouncing occur .................................................. 40
Troubleshooting of engine (S-mode)
SEN01225-00
Troubleshooting of engine (S-mode) ...........................................................................................
3
Method of using troubleshooting chart.....................................................................................
3
S-1 Engine does not start easily. .............................................................................................
6
S-2 Engine does not start ........................................................................................................
7
S-3 Engine does not pick up smoothly .................................................................................... 10
S-4 Engine stops during operations......................................................................................... 11
S-5 Engine does not rotate smoothly....................................................................................... 12
S-6 Engine lacks output (or lacks power) ................................................................................ 13
S-7 Exhaust smoke is black (Incomplete combustion) ............................................................ 14
S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 15
S-9 Engine oil becomes contaminated quickly ........................................................................ 16
S-10 Fuel consumption is excessive ....................................................................................... 17
S-11 Coolant contains oil (blows back or reduces) .................................................................. 18
S-12 Oil pressure drops........................................................................................................... 19
S-13 Oil level rises (Water, fuel in oil) ...................................................................................... 20
S-14 Coolant temperature rises too high (Overheating) .......................................................... 21
S-15 Abnormal noise is made.................................................................................................. 22
12
WA380-6 VEBM44010100 Index and foreword
SEN01019-04
S-16 Vibration is excessive ..................................................................................................... 23
50 Disassembly and assembly
General information on disassembly and assembly
SEN01461-00
General information on disassembly and assembly....................................................................
2
How to read this manual..........................................................................................................
2
Coating materials list ...............................................................................................................
4
Special tools list .......................................................................................................................
7
Engine and cooling system
SEN01462-00
Engine and cooling system .........................................................................................................
2
Removal and installation of fuel supply pump assembly .........................................................
2
Removal and installation of fuel injector assembly ..................................................................
4
Removal and installation of cylinder head assembly ...............................................................
9
Removal and installation of engine hood................................................................................. 18
Removal and installation of radiator assembly ........................................................................ 20
Removal and installation of air aftercooler............................................................................... 22
Removal and installation of hydraulic oil cooler assembly ...................................................... 24
Removal and installation of engine assembly ......................................................................... 26
Removal and installation of cooling fan and fan motor assembly............................................ 31
Removal and installation of fuel tank assembly....................................................................... 34
Power train
SEN01463-00
Power train ..................................................................................................................................
2
Removal and installation of torque converter and transmission assembly ..............................
2
Disassembly and assembly of torque converter assembly (Standard specification) ...............
8
Disassembly and assembly of torque converter assembly (Lockup specification).................. 12
Disassembly and assembly of transmission assembly............................................................ 18
Disassembly and assembly of transmission clutch pack assembly......................................... 33
Disassembly and assembly of parking brake assembly .......................................................... 49
Removal and installation of front axle assembly ..................................................................... 54
Removal and installation of rear axle assembly ...................................................................... 56
Disassembly and assembly of axle housing............................................................................ 59
Disassembly and assembly of differential assembly ............................................................... 68
Steering system
SEN01464-00
Steering system...........................................................................................................................
2
Removal and installation of steering demand valve assembly ................................................
2
Brake system
SEN01465-00
Brake system ..............................................................................................................................
2
Removal and installation of parking brake discs and plates ....................................................
2
Undercarriage and frame
SEN01466-00
Undercarriage and frame ............................................................................................................
2
Removal and installation of center hinge pin ...........................................................................
2
Removal and installation of counterweight .............................................................................. 10
Hydraulic system
SEN01467-00
Hydraulic system.........................................................................................................................
2
Removal and installation of work equipment control valve assembly......................................
2
Removal and installation of power train pump and work equipment pump assembly .............
4
Removal and installation of steering pump and cooling fan pump assembly ..........................
5
Removal and installation of hydraulic tank assembly ..............................................................
6
Work equipment
SEN01468-00
Work equipment ..........................................................................................................................
2
Removal and installation of work equipment assembly ...........................................................
2
Disassembly and assembly of hydraulic cylinder assembly ....................................................
6
Cab and its attachments
SEN01469-00
Cab and its attachments..............................................................................................................
2
Removal and installation of operator's cab and floor frame assembly ....................................
2
WA380-6 VEBM440101
13SEN01019-04
00 Index and foreword
Removal and installation of operator's cab glass (stuck glass) ...............................................
5
Removal and installation of air conditioner unit assembly ....................................................... 13
Electrical system
SEN01470-00
Electrical system .........................................................................................................................
2
Removal and installation of engine controller assembly..........................................................
2
90 Diagrams and drawings
Hydraulic diagrams and drawings
SEN01022-00
Hydraulic diagrams and drawings ...............................................................................................
2
Power train hydraulic circuit diagram.......................................................................................
2
Hydraulic circuit diagram .........................................................................................................
5
Electrical diagrams and drawings
SEN01023-01
Electrical diagrams and drawings................................................................................................
3
Electrical circuit diagram (1/2) .................................................................................................
3
Electrical circuit diagram (2/2) .................................................................................................
5
Connector arrangement diagram.............................................................................................
7
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