Komatsu Service Wa380-5 Shop Manual Wheel Loader Repair Book

Komatsu Service Wa380-5 Shop Manual Wheel Loader Repair Book

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Komatsu Bulldozer provider guide presents step-through-step commands primarily based totally at the entire disassembly of the machine. It is that this stage of detail, together with loads of pix and illustrations, that manual the reader thru every provider and restore system.

Komatsu Service Wa380-5 Shop Manual Wheel Loader Repair Book

Safety notice

How to read the shop manual

Explanation of terms for maintenance standard

Handling electric equipment and hydraulic component
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
Specification
Specification and technical data
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Specification and technical data

Specification dimension drawing

Specifications

Weight table

Table of fuel, coolant and lubricants
Structure, function and maintenance standard
Engine and cooling system
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Engine and cooling system

Engine mount and transmission mount

Cooling system

Cooling fan pump

Cooling fan motor
Power train
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Power train

Power train

Power train system diagram

Drive shaft

Power train piping diagram

Torque converter

Transmission
Flow control valve
Valve assembly
ECMV
Main relief valve and torque converter relief valve
Axle
Front axle
Rear axle
Differential
Front differential
Rear differential
Limited slip differential
Final drive

WA- VEBM Index and foreword
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Steering system
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Steering system

Steering piping diagram

Steering column

Steering pump

Steering valve
Orbit-roll valve
Stop valve
Steering relief valve
Steering cylinder
Emergency steering motor
Emergency steering pump
Brake system
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Brake system

Brake piping diagram

Charge valve

Brake valve
Accumulator (for brake)
Brake
Parking brake control
Parking brake
Parking brake solenoid valve
Emergency parking brake release valve
Undercarriage and frame
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Undercarriage and frame

Axle mount and center hinge pin

Tires

Hydraulic system, Part
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Hydraulic system, Part

Hydraulic piping diagram

Work equipment control lever linkage

Hydraulic tank

Breather

Power train pump

Work equipment pump

Work equipment control valve
CLSS
Outline of CLSS
Basic principle
Each function and operation of each valve
Hydraulic circuit diagram and names of valves
Area ratio of pressure compensation valve
Hydraulic system, Part
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Hydraulic system, Part

PPC valve

Stabilizer valve

Accumulator (for PPC circuit)
Accumulator (for ECSS)
Work equipment
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Work equipment

Work equipment linkage

Bucket

Bucket positioner and boom kick-out

Work equipment cylinder
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Index and foreword
Cab and its attachments
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Cab and its attachments

Cab

Air conditioner

Air conditioner piping diagram

Air conditioner unit

Blower and intake unit

Compressor
Condenser
Receiver
Air conditioner panel
Electrical system, Part
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Electrical system, Part

Machine monitor system

Machine monitor

Electrical system, Part
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Electrical system, Part

Electrical system (Transmission controller system)

Transmission controller
Electrical system, Part
SEN-
Electrical system, Part

Electric transmission control

Kickdown switch and hold switch

KOMTRAX terminal system

Engine starting circuit
Engine stopping circuit
Preheating circuit
Engine power mode selector circuit
Engine output derating function
Automatic warm-up function
Parking brake circuit
Sensor
Standard value table
Standard service value table
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Standard service value table

Standard service value table for engine

Standard service value table for chassis

Testing and adjusting
Testing and adjusting, Part
SEN-
Testing and adjusting, Part

Tools for testing, adjusting, and troubleshooting

Measuring engine speed

Measuring exhaust gas color

Adjusting valve clearance
Measuring compression pressure
Measuring blow-by pressure
Measuring engine oil pressure
Measuring intake air (boost) pressure
Handling fuel system equipment
Releasing residual pressure in fuel system
Measuring fuel pressure
Measuring fuel return rate and leakage
Bleeding air from fuel circuit
Testing leakage in fuel system

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Handling reduced cylinder mode operation
Handling no-injection cranking operation
Handling controller voltage circuit
Testing and adjusting air conditioner compressor belt tension
Adjusting transmission speed sensor
Measuring directional lever
Measuring and adjusting power train oil pressure
Procedure for flushing torque converter and transmission hydraulic circuit
Method of moving machine when transmission valve is broken
Testing and adjusting steering stop valve
Testing and adjusting steering wheel
Testing steering oil pressure
Bleeding air from steering circuit
Testing and adjusting, Part
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Testing and adjusting, Part

Testing hydraulic drive fan

Bleeding air from hydraulic drive fan circuit

Measuring brake pedal

Measuring brake performance

Testing and adjusting accumulator charge pressure

Testing wheel brake oil pressure
Measuring wear of wheel brake disc
Bleeding air from wheel brake circuit
Releasing residual pressure in brake accumulator circuit
Testing parking brake performance
Measuring parking brake oil pressure
Testing wear of parking brake disc
Method of releasing parking brake manually
Measuring and adjusting work equipment control lever
Measuring and adjusting work equipment PPC oil pressure
Measuring and adjusting work equipment oil pressure
Bleeding air from work equipment circuit
Releasing residual pressure in work equipment circuit
Testing and adjusting bucket positioner
Testing and adjusting boom kick-out
Checking proximity switch operation pilot lamp
Procedure for testing diodes
Preparation work for troubleshooting for electric system
How to start operation of KOMTRAX terminal
Lamp display of KOMTRAX terminal
Adjusting machine monitor
Adjusting replaced, reassembled or added sensor, controller, etc with machine monitor
Testing and adjusting, Part
SEN-
Testing and adjusting, Part

Special functions of machine monitor (EMMS)

Pm-click inspection table
Troubleshooting
General information on troubleshooting
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General information on troubleshooting

Points to remember when troubleshooting

Sequence of events in troubleshooting

Testing before troubleshooting

Classification and procedures of troubleshooting

Connection table for connector pin numbers

T-branch box and T-branch adapter table
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Index and foreword
Troubleshooting by (Display of code), Part
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Troubleshooting by (Display of code), Part

Failure codes list

Before carrying out troubleshooting for electrical system
Information contained troubleshooting table
[L] (TORQFLOW transmission: Double meshing)
[SAL] (ECMV F clutch: When command current is OFF, fill signal is ON)
[SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)
[SBL] (ECMV R clutch: When command current is OFF, fill signal is ON)
[SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)
[SEL] (ECMV st clutch: When command current is OFF, fill signal is ON)
[SELH] (ECMV st clutch: When command current is ON, fill signal is OFF)
[SFL] (ECMV nd clutch: When command current is OFF, fill signal is ON)
[SFLH] (ECMV nd clutch: When command current is ON, fill signal is OFF)
[SGL] (ECMV rd clutch: When command current is OFF, fill signal is ON)
[SGLH] (ECMV rd clutch: When command current is ON, fill signal is OFF)
[SHL] (ECMV th clutch: When command current is OFF, fill signal is ON)
[SHLH] (ECMV th clutch: When command current is ON, fill signal is OFF)
[FMA] (Parking brake: Malfunction)
Troubleshooting by (Display of code), Part
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Troubleshooting by (Display of code), Part

[GZG] (Accumulator: Low oil pressure)

[AAANX] (Air cleaner: Clogging)

[ABL] (Alternator: Signal disagrees with operating state of engine)

[ABMA] (Alternator: Malfunction)
[B@BAZG] (Rotation derating by low engine oil pressure)
[B@BAZK] (Engine oil: Low level)
[B@BCNS] (Coolant: Overheating)
[B@BCZK] (Coolant: Low level)
[B@CNS] (Brake oil: Overheating)
[b@CENS] (Torque converter oil: Overheating)
[B@CENS] (Torque converter oil: Overheating)
[B@HANS] (Hydraulic oil: Overheating)
[CA] (Abnormality in engine controller)
[CA] (Engine Ne or Bkup speed sensor error)
[CA] (Charge pressure sensor high error)
[CA] (Charge pressure sensor low error)
[CA] (Throttle sensor high error)
[CA] (Throttle sensor low error)
[CA] (Coolant sensor high error)
[CA] (Coolant sensor low error)
[CA] (Charge temperature sensor high error)
[CA] (Charge temperature sensor low error)
[CA] (Derating of speed by abnormally high charge temperature)
[CA] (Sensor power supply low error)
[CA] (Atmospheric pressure sensor high error)
[CA] (Atmospheric sensor low error)
[CA] (Sensor power supply high error)
Troubleshooting by (Display of code), Part
SEN-
Troubleshooting by (Display of code), Part

[CA] (Engine overspeed)

[CA] (Ne speed sensor power supply error)

[CA] (PCV Short circuit)

[CA] (PCV Disconnection)

[CA] (Injector # (L/B #) open/short error)

[CA] (Injector # (L/B #) open/short error)
[CA] (Injector # (L/B #) open/short error)

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[CA] (Injector # (L/B #) open/short error)
[CA] (Injector # (L/B #) open/short error)
[CA] (Injector # (L/B #) open/short error)
[CA] (Calibration code inconsistency)
[CA] (Injectors drive circuit error)
[CA] (Sensor power supply low error)
[CA] (Sensor power supply high error)
[CA] (Abnormally high level in water sensor)
[CA] (Abnormally low level in water sensor)
[CA] (Idle validation switch error)
[CA] (Idle validation action error)
[CA] (Engine oil pressure switch error)
[CA] (Battery voltage low error)
[CA] (Battery voltage high error)
[CA] Common rail pressure high error
[CA] (Common rail pressure sensor high error)
[CA] (Common rail pressure sensor low error)
[CA] (Derating of torque by abnormally high charge temperature)
[CA] (Common rail pressure high error )
[CA] (Supply pump pressure very low error)
[CA] (Engine Ne speed sensor error)
[CA] (Engine Bkup speed sensor phase error)
[CA] (All continuous data lost error)
[CA] (Engine Bkup speed sensor error)
[CA] (Partial engine controller data loss error)
[CA] (KOMNET datalink timeout error)
Troubleshooting by (Display of code), Part
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Troubleshooting by (Display of code), Part

[CA] (Throttle sensor supply voltage high error)

[CA] (Throttle sensor power supply low error)

[CA] (Supply pump pressure very low error )

[CA] (Abnormality in IMV solenoid)

[CA] (Intake heater relay disconnection error)

[CA] (Intake heater relay short circuit error)
[DKA] (Emergency steering relay: Disconnection)
[DKB] (Emergency steering relay: Short circuit)
[DKY] (Emergency steering relay: Short circuit with power supply line)
[DKA] (Backup lamp relay: Disconnection)
[DKB] (Backup lamp relay: Short circuit)
[DKA] (Joystick steering neutral safety relay: Disconnection)
[DKB] (Joystick steering neutral safety relay: Short circuit)
[DKY] (Joystick steering neutral safety relay:
Short circuit with power supply line)
[DKA] (ECSS solenoid: Disconnection)
[DKB] (ECSS solenoid: Short circuit)
[DKY] (ECSS solenoid: Short circuit with power supply line)
[DZHKA] (Terminal C signal: Disconnection)
[DZHKB] (Terminal C signal: Short circuit)
[DZHL] (Terminal C signal: Signal does not match engine running or
stopped state)
[DAL] (Auto grease controller: ON/OFF signals disagree)
[DAFKK] (Machine monitor: Low source voltage (input))
[DAFKP] (Machine monitor: Low output voltage)
[DAFRKR] (CAN communication with machine monitor:
Defective communication (Abnormality in target component system))
[DAQKK] (Transmission controller: Low source voltage)
[DAQKT] (Transmission controller: Abnormality in controller)
WA- VEBM
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Index and foreword
[DAQKK] (Transmission controller load power supply line:
Low source voltage (input))
[DAQKQ] (Transmission controller model selection:
Disagreement of model selection signals)
Troubleshooting by (Display of code), Part
SEN-
Troubleshooting by (Display of code), Part

[DAQRKR] (CAN communication with transmission controller:
Defective communication (Abnormality in target component system))

[DAQRMA] (Transmission controller option setting: Malfunction)

[DBRKR] (CAN communication with engine controller:
Defective communication (Abnormality in target component system)

[DBKQ] (Work equipment controller model selection:
Disagreement in model selection signals)

[DBRKR] CAN communication with work equipment controller:
Defective communication (Abnormality in target component system))
[DBRMA] (Work equipment controller option setting: Malfunction)
[DDLD] t switch (Panel switch ): Switch is kept pressed for long time
[DDLD] U switch (Panel switch ): Switch is kept pressed for long time
[DDLD] < switch (Panel switch ): Switch is kept pressed for long time [DDLD] > switch (Panel switch ): Switch is kept pressed for long time
[DDCLD] Load meter subtotal switch: Switch is kept pressed for long time
[DDFLD] Load meter mode selector switch (A/B):
Switch is kept pressed for long time
[DDGLD] Load meter mode selector switch (+/):
Switch is kept pressed for long time
[DDHLD] (Load meter display selector switch:
Switch is kept pressed for long time)
[DDNLD] (Fan reverse switch: Switch is kept pressed for long time)
[DDNL] (Fan automatic reverse switch: Switch is kept pressed for long time)
[DDBL] (Parking brake switch (Neutralizer): ON/OFF signals disagree)
Troubleshooting by (Display of code), Part
SEN-
Troubleshooting by (Display of code), Part

[DDKKA] (Right FNR switch: Disconnection)

[DDKKA] (FNR lever switch: Disconnection)

[DDKKB] (FNR lever switch: Short circuit)
[DDTL] (Shift mode selector switch: ON/OFF signals disagree)
[DDTLD] (Transmission cut-off set switch:
Switch is kept pressed for long time)
[DDWLD] (Kick-down switch: Switch is kept pressed for long time)
[DDWLLD] (Hold switch: Switch is kept pressed for long time)
[DDYLD] (Load meter cancel switch: Switch is kept pressed for long time)
[DFKA] (Transmission shift lever switch: Disconnected)
[DFKB] (Transmission shift lever switch: Short circuit)
[DGFKA] (Transmission oil temperature sensor: Disconnected)
[DGFKB] (Transmission oil temperature sensor: Short circuit)
[DGHKX] (Hydraulic oil temperature sensor: Out of input signal range)
[DGRKA] (Rear brake oil temperature sensor: Disconnected)
[DGRKX] (Rear brake oil temperature sensor: Out of input signal range)
[DGTKX] (Torque converter oil temperature sensor: Out of input signal range)
Troubleshooting by (Display of code), Part
SEN-
Troubleshooting by (Display of code), Part

[DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)
[DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)

[DHTKX] (Transmission cut-off pressure sensor: Out of input signal range)

[DHTKA] (Steering pump pressure sensor: Disconnection)

[DHTKB] (Steering pump pressure sensor: Short circuit)

WA- VEBM Index and foreword
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Troubleshooting by (Display of code), Part
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Troubleshooting by (Display of code), Part

[DLTKA] (Transmission output shaft speed sensor: Disconnection)

[DLTLC] (Transmission output shaft speed sensor: Out of input signal range)

[DTKB] (Transmission cut-off indicator lamp: Short circuit)

[DVKB] (Alarm buzzer: Short circuit)

Troubleshooting by (Display of code), Part
SEN-
Troubleshooting by (Display of code), Part

[DWBKA] (Fan reverse solenoid: Disconnection)

[DWBKB] (Fan reverse solenoid: Short circuit)

[DWBKY] (Fan reverse solenoid: Short circuit with power supply line)

[DXKA] (Fan pump EPC solenoid: Disconnection)

[DXKB] (Fan pump EPC solenoid: Short circuit)

[DXKY] (Fan pump EPC solenoid: Short circuit with power supply line)

[DXHKA] (Lockup ECMV solenoid: Disconnection)
[DXHKB] (Lockup ECMV solenoid: Short circuit)
[DXHKY] (Lockup ECMV solenoid: Short circuit with power supply line)
[DXHKA] (st clutch ECMV solenoid: Disconnection)
[DXHKB] (st clutch ECMV solenoid: Short circuit)
Troubleshooting by (Display of code), Part
SEN-
Troubleshooting by (Display of code), Part

[DXHKY] (st clutch ECMV solenoid: Short circuit with power supply line)

[DXHKA] (nd clutch ECMV solenoid: Disconnection)

[DXHKB] (nd clutch ECMV solenoid: Short circuit)

[DXHKY] (nd clutch ECMV solenoid: Short circuit with power supply line)
[DXHKA] (rd clutch ECMV solenoid: Disconnection)
[DXHKB] (rd clutch ECMV solenoid: Short circuit)
[DXHKY] (rd clutch ECMV solenoid: Short circuit with power supply line)
[DXHKA] (R clutch ECMV solenoid: Disconnection)
[DXHKB] (R clutch ECMV solenoid: Short circuit)
[DXHKY] (R clutch ECMV solenoid: Short circuit with power supply line)
[DXHKA] (F clutch ECMV solenoid: Disconnection)
[DXHKB] (F clutch ECMV solenoid: Short circuit)
[DXHKY] (F clutch ECMV solenoid: Short circuit with power supply line)
[DXHHKA] (th clutch ECMV solenoid: Disconnection)
[DXHHKB] (th clutch ECMV solenoid: Short circuit)
[DXHHKY] (th clutch ECMV solenoid: Short circuit with power supply line)
Troubleshooting of electrical system (E-mode)
SEN-
Troubleshooting of electrical system (E-mode)

Before carrying out troubleshooting for electrical system

Information in troubleshooting table

E- Engine does not start

E- Wiper does not operate
E- Windshield washer does not operate
E- Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off
E- Working lamp does not light up or go off
E- Turn signal lamp and hazard lamp do not light up or go off
E- Brake lamp does not light or it keeps lighting up
E- Backup lamp does not light or it keeps lighting up
E- Backup buzzer does not sound or it keeps sounding
E- Horn does not sound or it keeps sounding
E- Alarm buzzer does not sound or it keeps sounding
E- Air conditioner does not operate or stop
E- The KOMTRAX system does not work properly
Troubleshooting of hydraulic and mechanical system (H-mode)
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Troubleshooting of hydraulic and mechanical system (H-mode)

Method of using troubleshooting chart

WA- VEBM
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Index and foreword
Table of failure modes and causes

H- The machine does not start
H- Torque converter lockup is not switched off (engine stalls)
[Machine with lockup clutch (if equipped)]
H- Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)]
H- The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak,
and the gear is not shifted
H- Shocks are large at the times of starting and shifting gear
H- Time lag is large at the times of starting and shifting gear
H- The torque converter oil temperature is high
H- Steering does not turn
H- Steering does not turn [Machine with joystick steering (if equipped)]
H- Steering response is low
H- Turning, response of steering is poor [machine with joystick steering (if equipped)]
H- Steering is heavy
H- When machine turns, it shakes or makes large shocks
H- When machine turns, it shakes or makes large shocks
[machine with joystick steering (if equipped)]
H- The wheel brake does not work or does not work well
H- The wheel brake is not released or it drags
H- The parking brake does not work or does not work well
H- The parking brake is not released or it drags (including emergency release system)
H- Lift arm does not rise
H- Lift arm speed is low or rising force of lift arm is insufficient
H- When rising, the lift arm comes to move slowly at specific height
H- The lift arm cylinder cannot hold down the bucket (Bucket floats)
H- Hydraulic drifts of the lift arm is large
H- The lift arm wobbles during operation
H- Bucket does not tilt back
H- Bucket speed is low or tilting back force is insufficient
H- The bucket comes to operate slowly in the midst of tilting-back
H- The bucket cylinder cannot hold down the bucket
H- Hydraulic drifts of the bucket is large
H- The bucket wobbles during travel with cargo (The work equipment valve is
set to HOLD)
H- Lift arm and bucket control levers do not move smoothly and are heavy
H- During operation of the machine, engine speed lowers remarkably or engine stalls
H- Large shock is made when work equipment starts and stops
H- When work equipment circuit is relieved singly, other work equipment moves
H- ECSS does not operate, and pitching, bouncing occur
Troubleshooting of engine (S-mode)
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Troubleshooting of engine (S-mode)

Method of using troubleshooting chart

S- Engine does not start easily

S- Engine does not start

S- Engine does not pick up smoothly
S- Engine stops during operations
S- Engine does not rotate smoothly
S- Engine lacks output (or lacks power)
S- Exhaust smoke is black (Incomplete combustion)
S- Oil consumption is excessive (or exhaust smoke is blue)
S- Engine oil becomes contaminated quickly
S- Fuel consumption is excessive
S- Coolant contains oil (blows back or reduces)
S- Oil pressure drops
S- Oil level rises (Water, fuel in oil)
S- Coolant temperature rises too high (Overheating)
S- Abnormal noise is made

WA- VEBM Index and foreword
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S- Vibration is excessive
Disassembly and assembly
General information on disassembly and assembly
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General information on disassembly and assembly

How to read this manual

Coating materials list

Special tools list

Engine and cooling system
SEN-
Engine and cooling system

Removal and installation of fuel supply pump assembly

Removal and installation of fuel injector assembly

Removal and installation of cylinder head assembly

Removal and installation of engine hood
Removal and installation of radiator assembly
Removal and installation of air aftercooler
Removal and installation of hydraulic oil cooler assembly
Removal and installation of engine assembly
Removal and installation of cooling fan and fan motor assembly
Removal and installation of fuel tank assembly
Power train
SEN-
Power train

Removal and installation of torque converter and transmission assembly

Disassembly and assembly of torque converter assembly (Standard specification)

Disassembly and assembly of torque converter assembly (Lockup specification)
Disassembly and assembly of transmission assembly
Disassembly and assembly of transmission clutch pack assembly
Disassembly and assembly of parking brake assembly
Removal and installation of front axle assembly
Removal and installation of rear axle assembly
Disassembly and assembly of axle housing
Disassembly and assembly of differential assembly
Steering system
SEN-
Steering system

Removal and installation of steering demand valve assembly

Brake system
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Brake system

Removal and installation of parking brake discs and plates

Undercarriage and frame
SEN-
Undercarriage and frame

Removal and installation of center hinge pin

Removal and installation of counterweight
Hydraulic system
SEN-
Hydraulic system

Removal and installation of work equipment control valve assembly

Removal and installation of power train pump and work equipment pump assembly

Removal and installation of steering pump and cooling fan pump assembly

Removal and installation of hydraulic tank assembly

Work equipment
SEN-
Work equipment

Removal and installation of work equipment assembly

Disassembly and assembly of hydraulic cylinder assembly

Cab and its attachments
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Cab and its attachments

Removal and installation of operator’s cab and floor frame assembly

WA- VEBM
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Index and foreword
Removal and installation of operator’s cab glass (stuck glass)

Removal and installation of air conditioner unit assembly
Electrical system
SEN-
Electrical system

Removal and installation of engine controller assembly

Diagrams and drawings
Hydraulic diagrams and drawings
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Hydraulic diagrams and drawings

Power train hydraulic circuit diagram

Hydraulic circuit diagram

Electrical diagrams and drawings
SEN-
Electrical diagrams and drawings

Electrical circuit diagram (/)

Electrical circuit diagram (/)

Connector arrangement diagram

Komatsu Service Wa380-5 Shop Manual Wheel Loader Repair Book