Komatsu WA380-6, WA380Z-6 - Service Manual / Repair Manual - Wiring Diagrams

KOMATSU WA380-6, WA380Z-6 - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual and Wiring Diagrams, for Komatsu WA380-6, WA380Z-6.
 

CONTENTS:

00 Index and foreword
- Index
- Composition of shop manual
- Table of contents
- Foreword and general information
- Safety notice
- How to read the shop manual
- Explanation of terms for maintenance standard
- Handling of electric equipment and hydraulic component
- Handling of connectors newly used for engines
- 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
01 Specification
- Specification and technical data
- Specification dimension drawing
- Specifications
- Weight table
- Table of fuel, coolant and lubricants
10 Structure, function and maintenance standard
- Engine and cooling system
- Engine mount and transmission mount
- Cooling system
- Cooling fan pump
- Brake and fan pump
- Cooling fan motor
- 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
- Differential
- Limited slip differential
- Final drive
- 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
- Joystick steering lever linkage
- Steering electric lever
- Joystick EPC valve
- 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
- Axle mount and center hinge pin
- Tires
- Hydraulic system, Part 1
- Hydraulic piping diagram
- Work equipment control lever linkage
- Hydraulic tank
- Power train pump
- Work equipment pump
- Work equipment control valve
- CLSS
- Each function and operation of each valve
- Hydraulic system, Part 2
- PPC valve
- Stabilizer valve
- Accumulator (for PPC circuit)
- Accumulator (for ECSS)
- Work equipment PPC cut-off solenoid valve
- Work equipment
- Work equipment linkage
- Bucket
- Bucket positioner and boom kick-out
- Work equipment cylinder
- Cab and its attachments
- Cab
- Air conditioner
- Electrical system, Part 1
- Machine monitor system
- Machine monitor
- Electrical system, Part 2
- Electrical system (Transmission controller system)
- Transmission controller
- Electrical system (Work equipment controller system)
- Work equipment controller
- Electrical system, Part 3
- Electric transmission control
- Kickdown switch and hold switch
- Multi-function knob
- Joystick steering knob
- 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
20 Standard value table
- Standard service value table
- Standard service value table for engine
- Standard service value table for chassis
30 Testing and adjusting
- Testing and adjusting, Part 1
- Tools for testing, adjusting, and troubleshooting
- Testing engine speed
- Testing exhaust gas color
- Adjusting valve clearance
- Testing compression pressure
- Testing blow-by pressure
- Testing engine oil pressure
- Testing intake air (boost) pressure1
- Handling fuel system equipment
- Releasing residual pressure in fuel system
- Testing fuel pressure
- Testing fuel delivery, return and leak amount
- Bleeding air from fuel circuit
- Testing leakage in fuel system
- Handling reduced cylinder mode operation
- Handling no-injection cranking operation
- Handling controller voltage circuit1
- Testing muffler (main body) and muffler stack for looseness or damage
- Testing muffler for functions
- Testing cylinder head and manifold parts for tightness
- Testing engine piping for damage and tightness
- Testing and adjusting air conditioner compressor belt tension
- Replacing alternator belt
- Adjusting transmission speed sensor
- Adjusting length of directional lever
- Adjusting length of gearshift lever
- Testing directional lever
- Testing 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 axle end for oil leakage
- Testing drive shaft for looseness, backlash and damage
- Testing and adjusting steering stop valve
- Testing and adjusting steering wheel
- Testing and adjusting steering oil pressure
- Bleeding air from steering circuit
- Testing and adjusting, Part 2
- Testing hydraulic drive fan
- Bleeding air from hydraulic drive fan circuit
- Testing brake pedal
- Testing and adjusting brake pedal linkage
- Testing brake performance
- Testing and adjusting accumulator charge pressure
- Testing wheel brake oil pressure
- Testing wheel brake oil pressure drop
- Testing wear of wheel brake disc
- Bleeding air from wheel brake circuit
- Releasing residual pressure in brake accumulator circuit
- Testing parking brake performance
- Testing parking brake oil pressure
- Testing wear of parking brake disc
- Method of releasing parking brake manually
- Testing and adjusting work equipment control lever
- Testing and adjusting worke quipment PPC oil pressure
- Testing and adjusting work equipment oil pressure
- Bleeding air from work equipment circuit
- Releasing residual pressure in work equipment circuit
- Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of ECSS (Electronically Controlled Suspension System) accumulator
- 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
- Testing and adjusting, Part 3
- Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor
- Special functions of machine monitor (EMMS)
- Pm-clinic inspection table
40 Troubleshooting
- Failure code table and fuse locations
- Failure code table
- Fuse locations
- General information on troubleshooting
- Points to remember when troubleshooting
- Sequence of events in troubleshooting
- Testing before troubleshooting
- Classification and procedures of troubleshooting
- Information contained in troubleshooting table
- Connection table for connector pin numbers
- T- branch box and T- branch adapter table
- Troubleshooting by failure code (Display of code), Part 1
- Failure code [1500L0] (TORQFLOW transmission: Double meshing)
- Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)
- Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)
- Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)
- Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)
- Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)
- Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF)
- Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON)
- Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF)
- Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON)
- Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF)
- Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)
- Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF)
- Failure code [2F00MA] (Parking brake: Malfunction)
- Failure code [2G43ZG] (Accumulator: Low oil pressure)
- Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree)
- Troubleshooting by failure code (Display of code), Part 2
- Failure code [AA1ANX] (Air cleaner: Clogging)
- Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine)
- Failure code [AB00MA] (Alternator: Malfunction)
- Failure code [B@BAZG] (Rotation derating by low engine oil pressure)
- Failure code [B@BAZK] (Engine oil: Low level)
- Failure code [B@BCNS] (Coolant: Overheating)
- Failure code [B@BCZK] (Coolant: Low level)
- Failure code [B@BEBF] (Water in fuel error)
- Failure code [B@C7NS] (Brake oil: Overheating)
- Failure code [b@CENS] (Torque converter oil: Overheating)
- Failure code [B@CENS] (Torque converter oil: Overheating)
- Failure code [B@HANS] (Hydraulic oil: Overheating)
- Failure code [CA111] (Abnormality in engine controller)
- Failure code [CA115] (Engine Ne or Bkup speed sensor error)
- Failure code [CA122] (Charge pressure sensor high error)
- Failure code [CA123] (Charge pressure sensor low error)
- Failure code [CA131] (Throttle sensor high error)
- Failure code [CA132] (Throttle sensor low error)
- Failure code [CA144] (Coolant sensor high error)
- Failure code [CA145] (Coolant sensor low error)
- Failure code [CA153] (Charge temperature sensor high error)
- Failure code [CA154] (Charge temperature sensor low error)
- Failure code [CA155] (Derating of speed by abnormally high charge temperature)
- Failure code [CA187] (Sensor power supply 2 low error)
- Failure code [CA221] (Atmospheric pressure sensor high error)
- Failure code [CA222] (Atmospheric sensor low error)
- Failure code [CA227] (Sensor power supply 2 high error)
- Failure code [CA234] (Engine overspeed)
- Failure code [CA238] (Ne speed sensor power supply error)
- Troubleshooting by failure code (Display of code), Part 3
- Failure code [CA271] (IMV/PCV1 Short circuit)
- Failure code [CA272] (IMV/PCV1 Disconnection)
- Failure code [CA322] (Injector #1 open/short error)
- Failure code [CA323] (Injector #5 open/short error)
- Failure code [CA324] (Injector #3 open/short error)
- Failure code [CA325] (Injector #6 open/short error)
- Failure code [CA331] (Injector #2 open/short error)
- Failure code [CA332] (Injector #4 open/short error)
- Failure code [CA342] (Calibration code inconsistency)
- Failure code [CA351] (Injectors drive circuit error)
- Failure code [CA352] (Sensor power supply 1 low error)
- Failure code [CA386] (Sensor power supply 1 high error)
- Failure code [CA428] (Abnormally high level in water sensor)
- Failure code [CA429] (Abnormally low level in water sensor)
- Failure code [CA431] (Idle validation switch error)
- Failure code [CA432] (Idle validation action error)
- Failure code [CA435] (Engine oil pressure switch error)
- Failure code [CA441] (Battery voltage low error)
- Failure code [CA442] (Battery voltage high error)
- Failure code [CA449] Common rail pressure high error 2
- Failure code [CA451] (Common rail pressure sensor high error)
- Failure code [CA452] (Common rail pressure sensor low error)
- Failure code [CA488] (Derating of torque by abnormally high charge temperature)
- Failure code [CA553] (Common rail pressure high error 1)
- Failure code [CA559] (Supply pump pressure very low error)
- Failure code [CA689] (Engine Ne speed sensor error)
- Failure code [CA731] (Engine Bkup speed sensor phase error)
- Failure code [CA757] (All continuous data lost error)
- Failure code [CA778] (Engine Bkup speed sensor error)
- Failure code [CA1633] (KOMNET datalink timeout error)
- Failure code [CA2185] (Throttle sensor power supply voltage high error)
- Failure code [CA2186] (Throttle sensor power supply voltage low error)
- Troubleshooting by failure code (Display of code), Part 4
- Failure code [CA2249] (Supply pump pressure very low error 2)
- Failure code [CA2311] (Abnormality in IMV solenoid)
- Failure code [CA2555] (Intake heater relay disconnection error)
- Failure code [CA2556] (Intake heater relay short circuit error)
- Failure code [D150KA] (Emergency steering relay: Disconnection)
- Failure code [D150KB] (Emergency steering relay: Short circuit)
- Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line)
- Failure code [D160KA] (Backup lamp relay: Disconnection)
- Failure code [D160KB] (Backup lamp relay: Short circuit)
- Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection)
- Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit)
- Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line)
- Failure code [D192KA] (ECSS solenoid: Disconnection)
- Failure code [D192KB] (ECSS solenoid: Short circuit)
- Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)
- Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection)
- Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit)
- Failure code [D193KY] (Joystick steering solenoid cut relay: Short circuit with power supply line)
- Failure code [D5ZHKA] (Terminal C signal: Disconnection)
- Failure code [D5ZHKB] (Terminal C signal: Short circuit)
- Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit)
- Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state)
- Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)
- Failure code [DAF3KK] (Machine monitor: Low source voltage (input)
- Failure code [DAF5KP] (Machine monitor: Low output voltage)
- Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system)
- Troubleshooting by failure code (Display of code), Part 5
- Failure code [DAQ0KK] (Transmission controller: Low source voltage)
- Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)
- Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input)
- Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals)
- Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system)
- Failure code [DAQRMA] (Transmission controller option setting: Malfunction)
- Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system)
- Failure code [DB90KK] Work equipment controller: Low source voltage (input)
- Failure code [DB90KT] Work equipment controller: Abnormality in controller
- Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)
- Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range
- Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals)
- Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system)
- Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)
- Failure code [DB9RMC] (CAN communication with transmission controller, engine controller and machine monitor: Defective operation)
- Failure code [DD15LD] ¦ switch (Panel switch 1): Switch is kept pressed for long time
- Failure code [DD16LD] <> switch (Panel switch 2): Switch is kept pressed for long time
- Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time
- Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time
- Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time
- Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time
- Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time
- Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time
- Failure code [DD1GLD] Load meter mode selector switch (+/-): Switch is kept pressed for long time
- Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time)
- Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time)
- Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time)
- Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)
- Troubleshooting by failure code (Display of code), Part 6
- Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)
- Failure code [DDK3KA] (Right FNR switch: Disconnection)
- Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection)
- Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)
- Failure code [DDK6KA] (FNR lever switch: Disconnection)
- Failure code [DDK6KB] (FNR lever switch: Short circuit)
- Failure code [DDS5KA] (Steering pressure switch: Disconnected)
- Failure code [DDS5KB] (Steering pressure switch: Grounded)
- Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)
- Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)
- Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)
- Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)
- Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)
- Failure code [DF10KA] (Transmission shift lever switch: Disconnected)
- Failure code [DF10KB] (Transmission shift lever switch: Short circuit)
- Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected)
- Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)
- Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)
- Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)
- Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)
- Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)
- Failure code [DH21KA] (Loader pump pressure sensor: Disconnection)
- Failure code [DH21KB] (Loader pump pressure sensor: Power supply line short)
- Troubleshooting by failure code (Display of code), Part 7
- Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)
- Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)
- Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range)
- Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection)
- Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit)
- Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)
- Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)
- Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree)
- Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)
- Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line)
- Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection)
- Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)
- Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree)
- Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)
- Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line)
- Troubleshooting by failure code (Display of code), Part 8
- Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection)
- Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line)
- Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)
- Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line)
- Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree)
- Failure code [DKA0KA] (Lift arm angle sensor: Disconnection)
- Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)
- Failure code [DKA0L0] (Lift arm angle sensor: Dislocation of sensor)
- Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)
- Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range)
- Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)
- Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)
- Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit)
- Failure code [DV00KB] (Alarm buzzer: Short circuit)
- Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)
- Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)
- Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line)
- Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)
- Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)
- Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line)
- Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)
- Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)
- Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)
- Troubleshooting by failure code (Display of code), Part 9
- Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)
- Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)
- Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line)
- Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)
- Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)
- Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)
- Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)
- Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)
- Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line)
- Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection)
- Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit)
- Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line)
- Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection)
- Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit)
- Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line)
- Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection)
- Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)
- Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source)
- Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection) (WA380-6)
- Failure code [DX16KA] (Fan motor EPC solenoid: Disconnection) (WA380Z-6)
- Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit) (WA380-6)
- Failure code [DX16KB] (Fan motor EPC solenoid: Short circuit) (WA380Z-6)
- Failure code [DX16KY] (Fan motor EPC solenoid: Short circuit with power supply line) (WA380Z-6)
- Failure code [DXA1KA] (Loader pump EPC solenoid: Disconnection)
- Failure code [DXA1KB] (Loader pump EPC solenoid: Short circuit)
- Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)
- Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)
- Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)
- Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)
- Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)
- Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)
- Troubleshooting by failure code (Display of code), Part 10
- Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)
- Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)
- Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)
- Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)
- Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)
- Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)
- Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)
- Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)
- Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)
- Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)
- Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)
- Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)
- Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)
- Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)
- Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)
- Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)
- Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit)
- Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line)
- Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection)
- Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit)
- Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line)
- Failure code [DY30MA] Motor-driven emergency steering pump failure (During operation of machine)
- Failure code [DY30MC] Motor-driven emergency steering pump failure (Malfunction in manual mode)
- Troubleshooting of electrical system (E-mode)
- Installing positions of fuses
- Information in troubleshooting table
- E-1 Engine does not start
- E-2 Wiper does not operate
- E-3 Windshield washer does not operate
- E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off
- E-5 Working lamp does not light up or go off
- E-6 Turn signal lamp and hazard lamp do not light up or go off
- E-7 Brake lamp does not light or it keeps lighting up
- E-8 Backup lamp does not light or it keeps lighting up
- E-9 Backup buzzer does not sound or it keeps sounding
- E-10 Horn does not sound or it keeps sounding
- E-11 Alarm buzzer does not sound or it keeps sounding
- E-12 Air conditioner does not operate or stop
- E-13 The KOMTRAX system does not work properly
- E-14 When kick-down switch is turned ON, kick-down operation does not start
- E-15 When hold switch is pressed, holding operation does not start
- E-16 Transmission is kept in neutral, or brake drags when directional lever is operated while parking brake is applied
- E-17 Transmission cut-off mode cannot be set or reset
- E-18 Transmission cut-off set cannot be reset
- E-19 FNR switch mode cannot be set or reset
- E-20 Fan reverse function cannot be used or reset
- E-21 Discharge from loader pump does not rise from minimum level
- E-22 ECSS function cannot be used or reset
- E-23 When parking brake is turned ON, parking brake indicator lamp does not light up
- E-24 When emergency brake operates, brake oil pressure caution lamp does not operate
- E-25 Air cleaner clogging indicator lamp does not light up
- E-26 Radiator coolant level caution lamp does not light up
- E-27 Hydraulic oil temperature gauge does not rise and hydraulic oil temperature caution lamp does not light up
- E-28 Torque converter oil temperature gauge does not rise and torque converter oil temperature caution lamp does not light up
- E-29 Steering oil pressure caution lamp does not light up
- E-30 Abnormality in ¦ switch (panel switch 1) input
- E-31 Abnormality in <> switch (panel switch 2) input
- ?????
- E-32 Abnormality in < switch (panel switch 3) input
- E-33 Abnormality in > switch (panel switch 4) input
- Troubleshooting of hydraulic and mechanical system (H-mode)
- Method of using troubleshooting chart
- Table of failure modes and causes
- H-1 The machine does not start
- H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch]
- H-3 Torque converter lockup is not switched on [Machine with lockup clutch]
- H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted
- H-5 Shocks are large at the times of starting and shifting gear
- H-6 Time lag is large at the times of starting and shifting gear
- H-7 The torque converter oil temperature is high
- H-8 Steering does not turn
- H-9 Steering does not turn [Machine with joystick steering]
- H-10 Steering response is low
- H-11 Turning, response of steering is poor [machine with joystick steering]
- H-12 Steering is heavy
- H-13 When machine turns, it shakes or makes large shocks
- H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering]
- H-15 The wheel brake does not work or does not work well
- H-16 The wheel brake is not released or it drags
- H-17 The parking brake does not work or does not work well
- H-18 The parking brake is not released or it drags (including emergency release system)
- H-19 Lift arm does not rise
- H-20 Lift arm speed is low or rising force of lift arm is insufficient
- H-21 When rising, the lift arm comes to move slowly at specific height
- H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats)
- H-23 Hydraulic drifts of the lift arm is large
- H-24 The lift arm wobbles during operation
- H-25 Bucket does not tilt back
- H-26 Bucket speed is low or tilting back force is insufficient
- H-27 The bucket comes to operate slowly in the midst of tilting-back
- H-28 The bucket cylinder cannot hold down the bucket
- H-29 Hydraulic drifts of the bucket is large
- H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”)
- H-31 Lift arm and bucket control levers do not move smoothly and are heavy
- H-32 During operation of the machine, engine speed lowers remarkably or engine stalls
- H-33 Large shock is made when work equipment starts and stops
- H-34 When work equipment circuit is relieved singly, other work equipment moves
- H-35 ECSS does not operate, and pitching, bouncing occur
- H-36 Fan revolution is abnormal (Fan sound/ vibration is abnormally large or engine overheats)
- Troubleshooting of engine (S-mode)
- Method of using troubleshooting charts
- S-1 Engine does not start easily
- S-2 Engine does not start
- S-3 Engine does not pick up smoothly
- S-4 Engine stops during operations
- S-5 Engine does not rotate smoothly
- S-6 Engine lacks output (or lacks power)
- S-7 Exhaust smoke is black (Incomplete combustion)
- S-8 Oil consumption is excessive (or exhaust smoke is blue)
- S-9 Engine oil becomes contaminated quickly
- S-10 Fuel consumption is excessive
- S-11 Coolant contains oil (blows back or reduces)
- S-12 Oil pressure drops
- S-13 Oil level rises (Water, fuel in oil)
- S-14 Coolant temperature rises too high (Overheating)
- S-15 Abnormal noise is made
- S-16 Vibration is excessive
50 Disassembly and assembly
- General information on disassembly and assembly
- How to read this manual
- Coating materials list
- Special tools list
- Sketches of special tools
- 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 assembly
- 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 engine front oil seal assembly
- Removal and installation of engine rear oil seal assembly
- Removal and installation of cooling fan and fan motor assembly
- Removal and installation of fuel tank assembly
- 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
- Removal and installation of steering valve assembly
- Brake system
- Removal and installation of parking brake discs and plates
- Undercarriage and frame
- Removal and installation of center hinge pin
- Removal and installation of counterweight
- 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
- Removal and installation of work equipment assembly
- Disassembly and assembly of hydraulic cylinder assembly
- Cab and its attachments
- Removal and installation of operator's cab and floor frame assembly
- Removal and installation of operator's cab glass (stuck glass)
- Disassembly and assembly of operator's seat assembly (Standard specification)
- Removal and installation of air conditioner unit assembly
- Electrical system
- Removal and installation of engine controller assembly
90 Diagrams and drawings
- Hydraulic diagrams and drawings
- Power train hydraulic circuit diagram
- Automatic greasing circuit diagram
- Hydraulic circuit diagram (WA380-6)
- Hydraulic circuit diagram (WA380Z-6)
- Electrical diagrams and drawings
- Electrical circuit diagram (WA380-6)
- Electrical circuit diagram (WA380Z-6)
- Work equipment controller system electrical circuit diagram (WA380-6)
- Connector list and stereogram (WA380-6)
- Connector list and stereogram (WA380Z-6)