Komatsu Wheel Loader WA380-6 sn: H60051 and up Workshop Service Manual

MACHINE MODEL SERIAL NUMBER WA380-6 H60051 and up • This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. • WA380-6 mounts the SAA6D107E-1 engine. VEBM440101 © 2007 All Rights Reserved Printed in Europe 04-07 WA380-6

WA380-6 – VEBM440101 1 SEN01019-04 WHEEL LOADER 1SHOP MANUAL WA380-6 Machine model Serial number WA380-6 H60051 and up 00 Index and foreword 1 Index Composition of shop manual ................................................................................................................ 2 Table of contents .................................................................................................................................. 4

SEN01019-04 00 Index and foreword 2 WA380-6 – VEBM440101 Composition of shop manual 1 The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No. denote the following: Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.) Note 2: This shop manual can be supplied for each Form No. Note 3: To file this shop manual in the special binder for management, handle it as follows: • Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below: • File overview and other materials in sections in the order shown below and utilize them accordingly. Section Title Form Number Shop Manual, contents binder, binder label and tabs VEBM440101 00 Index and foreword SEN01011-04 Index SEN01019-04 q Foreword and general information SEN01020-01 q 01 Specification SEN01012-00 Specification and technical data SEN01021-00 10 Structure, function and maintenance standard SEN01013-01 Engine and cooling system SEN01040-00 Power train SEN01041-00 Steering system SEN01042-00 Brake system SEN01043-00 Undercarriage and frame SEN01044-00 Hydraulic system, Part 1 SEN01045-00 Hydraulic system, Part 2 SEN01046-00 Work equipment SEN01047-00 Cab and its attachments SEN01048-00 Electrical system, Part 1 SEN01049-00 Electrical system, Part 2 SEN01050-00 Electrical system, Part 3 SEN01051-00 20 Standard value table SEN01014-01 Standard service value table SEN01024-01 30 Testing and adjusting SEN01015-01 Testing and adjusting, Part 1 SEN01025-01 Testing and adjusting, Part 2 SEN01026-01 Testing and adjusting, Part 3 SEN01027-01 40 Troubleshooting SEN01016-00 General information on troubleshooting SEN01212-00 Troubleshooting by failure code (Display of code), Part 1 SEN01213-00 Troubleshooting by failure code (Display of code), Part 2 SEN01214-00 Troubleshooting by failure code (Display of code), Part 3 SEN01215-00 Troubleshooting by failure code (Display of code), Part 4 SEN01216-00

00 Index and foreword SEN01019-04 WA380-6 – VEBM440101 3 Troubleshooting by failure code (Display of code), Part 5 SEN01217-00 Troubleshooting by failure code (Display of code), Part 6 SEN01218-00 Troubleshooting by failure code (Display of code), Part 7 SEN01219-00 Troubleshooting by failure code (Display of code), Part 8 SEN01220-00 Troubleshooting by failure code (Display of code), Part 9 SEN01221-00 Troubleshooting by failure code (Display of code), Part 10 SEN01222-00 Troubleshooting of electrical system (E-mode) SEN01223-00 Troubleshooting of hydraulic and mechanical system (H-mode) SEN01224-00 Troubleshooting of engine (S-mode) SEN01225-00 50 Disassembly and assembly SEN01017-00 General information on disassembly and assembly SEN01461-00 Engine and cooling system SEN01462-00 Power train SEN01463-00 Steering system SEN01464-00 Brake system SEN01465-00 Undercarriage and frame SEN01466-00 Hydraulic system SEN01467-00 Work equipment SEN01468-00 Cab and its attachments SEN01469-00 Electrical system SEN01470-00 90 Diagrams and drawings SEN01018-02 Hydraulic diagrams and drawings SEN01022-00 Electrical diagrams and drawings SEN01023-01 q

SEN01019-04 00 Index and foreword 4 WA380-6 – VEBM440101 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

00 Index and foreword SEN01019-04 WA380-6 – VEBM440101 5 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

SEN01019-04 00 Index and foreword 6 WA380-6 – VEBM440101 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

00 Index and foreword SEN01019-04 WA380-6 – VEBM440101 7 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

SEN01019-04 00 Index and foreword 8 WA380-6 – VEBM440101 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 [B@BAZG] (Rotation derating by low engine oil pressure) ................................. 12 Failure code [B@BAZK] (Engine oil: Low level) ...................................................................... 13 Failure code [B@BCNS] (Coolant: Overheating)..................................................................... 14 Failure code [B@BCZK] (Coolant: Low level).......................................................................... 16 Failure code [B@C7NS] (Brake oil: Overheating) ................................................................... 18 Failure code [b@CENS] (Torque converter oil: Overheating) .................................................. 20 Failure code [B@CENS] (Torque converter oil: Overheating) ................................................. 22 Failure code [B@HANS] (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

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Komatsu Wheel Loader WA380-6 sn: H60051 and up Workshop Service Manual

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