Komatsu Wheel Loader WA380-5L service & repair manual

Description Komatsu Wheel Loader WA380-5L service & repair manual

Komatsu Wheel Loader WA380-5L pdf workshop service repair manual + operation & maintenance manual

Serial number A52001 and up

MANUAL CONTENT:
GENERAL
SPECIFICATIONS
WEIGHT TABLE
FUEL, COOLANT AND LUBRICANTS
GENERAL ASSEMBLY DRAWING

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
COOLING SYSTEM
Specifications
ENGINE MOUNT, TRANSMISSION MOUNT
POWER TRAIN
POWER TRAIN SYSTEM DIAGRAM
Without Torque Converter Lockup Clutch
With Torque Converter Lock-up Clutch
DRIVE SHAFT (PROPELLER SHAFT)
TORQUE CONVERTER, TRANSMISSION PIPING
TORQUE CONVERTER
Without Lock-up Clutch
Path Of Power Transmission
Power Flow
Oil Flow
With Lock-up Clutch
Path Of Power Transmission
Lock-up Clutch Disengaged
Lock-up Clutch Engaged
Oil Flow
TRANSMISSION
Outline
F and R Clutches: Without Lock-up Clutch
F and R Clutches: With Lock-up Clutch
1st and 4th Clutch
2nd and 3rd Clutch
Clutch Operation
Clutch Engaged
Clutch Disengaged
Operation
TRANSMISSION CONTROL VALVE
Without Lock-up Clutch (Transmission S/N 110643)
Without Lock-up Clutch (Transmission S/N 110644 and up)
With Lock-up Clutch (Transmission S/N 110643)
With Lock-up Clutch (Transmission S/N 110644 and up)
Electronic Control Modulation Valve (ECMV)
ECMV for Speed Clutch
Outline of ECMV
ECMV and Proportional Solenoid
ECMV and Fill Switch
ECMV Actuation
ECMV for Lock-up Clutch
Main Relief, Torque Converter Relief Valve
Flow Valve
AXLE
Front Axle
Rear Axle
DIFFERENTIAL
Front Differential
Rear Differential
Limited Slip Differential
Operation of Limited Slip Differential
FINAL DRIVE
AXLE MOUNTING, CENTER HINGE PIN
STEERING PIPING
STEERING COLUMN, ORBIT ROLL
STEERING VALVE
Overload Relief Valve
Steering Relief Valve
Steering Relief Valve Operation
Demand Valve Operation
Flow amp
Steering Valve Operation
Neutral
Turning Right
Turning Left
ORBIT-ROLL VALVE
Connection Between the Hand Pump and Sleeve
Function of Center Spring
STOP VALVE
STEERING PUMP, SWITCH PUMP
EMERGENCY STEERING PUMP
EMERGENCY STEERING MOTOR
STEERING CYLINDER
JOYSTICK STEERING
Joystick PPC Valve
Steering Switch Valve
BRAKE PIPING
BRAKE VALVE
Brake Valve - Left
Brake Valve - Right
CHARGE VALVE
ACCUMULATOR - BRAKE
Specifications
BRAKE
Front
Rear
PARKING BRAKE CONTROL
PARKING BRAKE
Parking Brake Solenoid Valve
Parking Brake Emergency Release Valve
HYDRAULIC PIPING
WORK EQUIPMENT CONTROL LEVER
For PPC Valve
For EPC Valve (If Equipped)
HYDRAULIC TANK
Breather
TORQUE CONVERTER CHARGING, WORK EQUIPMENT,AND PILOT CONTROL PUMPS
PPC RELIEF VALVE
E.C.S.S. VALVE (If Equipped)
WORK EQUIPMENT CONTROL VALVE
2-Spool Valve
3-Spool Valve
Relief Valve
Safety-suction Valve
Suction Valve
Cut-off Valve
Work Equipment Control Valve Operation
NEUTRAL Position of Lift Arm and Bucket Spools
RAISE Position for Lift Arm Spool
LOWER Position of Lift Arm Spool
FLOAT Position of Lift Arm Spool
DUMP Position for Bucket Spool
TILT Position for Bucket Spool
WORK EQUIPMENT PPC VALVE
Operation
PPC VALVE (FOR MULTI FUNCTION MONO LEVER)
EPC SOLENOID VALVE (If equipped)
SHUT OFF VALVE (If equipped)
ATTACHMENT PPC VALVE (If equipped)
COOLING FAN MOTOR
Hydraulic Motor
Suction Valve
Operation of Revolution Direction Changeover Valve
COOLING FAN MOTOR DRIVE PUMP
Servo Valve
Safety Valve
WORK EQUIPMENT LINKAGE
BUCKET
BUCKET POSITIONER, BOOM KICK-OUT
Bucket Positioner
Boom Kick-out
Proximity Switch Operation
When Lift Arm Is Raised
When Bucket Is Tilted
WORK EQUIPMENT CYLINDER
Lift Arm Cylinder
Bucket Cylinder
CAB
AIR CONDITIONER
Air Conditioner Piping
MACHINE MONITORING SYSTEM
Individual Circuit Diagrams of the Machine Monitor
Starting and Lighting Functions
Load Meter
Sensing Functions
Power Supply and Network
Automatic Preheating Function
MACHINE MONITOR
Speedometer Specifications
Load Meter Specification (If Equipped)
Table of Monitor Indication Items
Setting the Machine Monitor
Service Mode Functions
Items Related To The Fault History Of Electric System
Items Related to the Fault History Of Machine System
Items Related to Maintenance Monitor
Load Meter Function (If equipped)
Machine Setting
Setting Necessary For Option Mounting
Optional Device Setting For Machine Monitor
Adjustment for Each EPC
TRANSMISSION CONTROL SYSTEM
System Diagram
Control Function
Electric Circuit Diagram (Standard)
Electric Circuit Diagram (If Equipped)
TRANSMISSION CONTROLLER
WORK EQUIPMENT CONTROL SYSTEM
System Diagram
Electric Circuit Diagram
WORK EQUIPMENT CONTROLLER
ELECTRIC TRANSMISSION CONTROL
Functions
Combination Switch
KICK DOWN, HOLD SWITCH
ENGINE STARTING CIRCUIT
ENGINE STOP CIRCUIT
OPERATION
PREHEATING CIRCUIT
ENGINE POWER MODE SELECTOR CIRCUIT
PARKING BRAKE CIRCUIT
SENSORS
Engine Speed Sensor
Engine Oil Pressure Sensor
Engine Oil Level Sensor
Temperature Sensor
Coolant Temperature - For Monitor
Torque Converter Oil Temperature
Hydraulic Oil Temperature
Transmission Oil Temperature
Brake Oil Temperature
Coolant Temperature - Preheating
Transmission Cut-off Pressure Sensor
Coolant Level Sensor
Fuel Level Sensor
Lift Arm Angle Sensor (If Equipped)
Air Cleaner Clogging Sensor
Load Meter Pressure Sensor (If Equipped)
Battery Electrolyte Level Sensor(If Equipped)
Relay

STANDARD VALUE TABLES
STANDARD SERVICE VALUE TABLE
Standard Service Value Table For Engine
Standard Value Table For Chassis

TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Special Tool Drawing
ENGINE COMPONENTS
Determining a Defective Cylinder
Procedures
Determining Cylinder Group
Isolating the Defective Cylinder
Measuring Engine Speed
Measuring Exhaust Temperature
Measuring Exhaust Smoke
Adjusting Valve Clearance
Measuring Compression Pressure
Measuring Blow-by Pressure
Measuring Engine Oil Pressure
Measuring Intake Air Pressure (Boost Pressure)
Testing And Adjusting Fuel Injection Timing
Adjusting Engine Speed Sensor
Bleeding Air From Fuel Circuit
Adjusting Engine Stop Solenoid
ADJUSTING ACCELERATOR PEDAL
Adjusting the Power Mode
Adjusting the Normal Mode
ADJUSTING TRANSMISSION SPEED SENSOR
POWER TRAIN OIL PRESSURE
FLUSHING TORQUE CONVERTER, TRANSMISSION AND HYDRAULIC CIRCUIT
TRANSMISSION VALVE FAILS
MOVING MACHINE
STEERING CONTROL
STEERING OIL PRESSURE
TESTING HYDRAULIC FAN
BRAKE SYSTEM
Measuring Brake Oil Pressure
Testing Wear of Wheel Brake Disc
Bleeding Air from Brake Circuit
Testing Wear of Parking Brake Disc
Manual Release Method for Parking Brake
ACCUMULATOR CHARGE PRESSURE
PPC OIL PRESSURE
WORK EQUIPMENT HYDRAULIC PRESSURE
BUCKET POSITIONER
BOOM KICK-OUT
PROXIMITY SWITCH ACTUATION
ADJUSTING MACHINE MONITOR
LOAD METER
BLEEDING AIR
Fan Motor Circuit
Work Equipment PPC Circuit
Cylinders
RELEASING REMAINING PRESSURE
In Hydraulic Circuit
E.C.S.S. Damper Circuit
PM-CLINIC INSPECTION TABLE

TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
Precautions When Handling Electrical Equipment
Handling Electronic Control Unit
When Troubleshooting Electrical Circuits
ELECTRIC WIRE CODE
Classification by Thickness
Classification by Color and Code
How to Read Electric Wire Code
Points to Remember When Handling Hydraulic Equipment
CHECKS BEFORE TROUBLESHOOTING
SPECIAL FUNCTIONS OF MACHINE MONITOR
Flow of Modes and Functions
Failure Code Table
Monitoring Code Table
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
T-ADAPTER TABLE
CONNECTOR TYPES AND LOCATIONS
CONNECTOR LAYOUT DRAWING
TRANSMISSION CONTROL SYSTEM DIAGRAM
TRANSMISSION CONTROL SYSTEM (TM MODE)

DISASSEMBLY AND ASSEMBLY
Removal and Installation of Assemblies
Disassembly and Assembly of Assemblies
SPECIAL TOOLS LIST
Special Tool Illustrations
CONNECTOR REPAIR PROCEDURES
Stripping Insulation
Wire Inspection
Contact Terminal Removal (HD30 Type)
Crimping Contact Terminal (HD30 Type)
Insertion of Contact Terminal (HD30 Type)
Contact Terminal Removal (DT Type)
Crimping Contact Terminal (DT Type)
Insertion of Contact Terminal (DT Type)
BULKHEAD ASSEMBLY
ENGINE HOOD ASSEMBLY
ENGINE ASSEMBLY
ENGINE CYLINDER HEAD ASSEMBLY
RADIATOR FAN MOTOR
AFTERCOOLER
FUEL INJECTION PUMP
NOZZLE HOLDER
FAN AND FAN MOTOR
FUEL TANK
PARKING BRAKE DISCS AND PLATES
TORQUE CONVERTER AND TRANSMISSION
Bleeding the Hydraulic Brake Circuit
TRANSMISSION ASSEMBLY
TRANSMISSION CLUTCH PACK
Forward and Reverse Clutch Packs
1st and 4th Clutch Pack
2nd and 3rd Clutch Pack
Forward and Reverse Clutch Packs
1st and 4th Clutch Pack
2nd and 3rd Clutch Pack
PARKING BRAKE
TORQUE CONVERTER (STANDARD)
TORQUE CONVERTER (LOCK-UP)
REAR AXLE
FRONT AXLE
AXLE HOUSING
DIFFERENTIAL
CAB ASSEMBLY
CAB AND FLOOR FRAME
OPERATOR'S CAB GLASS (SEALED GLASS)
HYDRAULIC PUMP ASSEMBLY
Steering, Switching, and Fan Pump Assembly
ORBITROL VALVE
ECSS VALVE
WORK EQUIPMENT VALVE
HYDRAULIC CYLINDERS
Steering, Lift, and Bucket
HYDRAULIC TANK ASSEMBLY
WORK EQUIPMENT
COUNTERWEIGHT
AIR CONDITIONER ASSEMBLY
OPERATOR’S SEAT ASSEMBLY

OTHERS
HYDRAULIC CIRCUIT SCHEMATIC
ELECTRICAL SCHEMATIC

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