Komatsu Wheel Loader WA380-5H - Workshop Manual / Repair Manual - Wiring Schematics

KOMATSU WHEEL LOADER WA380-5H - WORKSHOP, SERVICE, REPAIR MANUAL


- English Workshop Manual and Wiring Schematics to Komatsu Wheel Loader WA380-5H.

 

INDEX:


CONTENTS
00 SAFETY
- Safety notice
- Foreword
- How to read the shop manual
- Hoisting instructions
- Method of disassembling, connecting push-pull type coupler
- Coating materials
- Standard tightening torque
- Electric wire code
- Conversion table
- Units
01 GENERAL
- General assembly drawing
- Specifications
- Weight table
- List of lubricant and coolant
10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
- Cooling system
- Engine mount, transmission mount
- Power train
- Power train system diagram
- Drive shaft (propeller shaft)
- Torque converter, transmission piping
- Torque converter
      - Without lock-up clutch
      - With lock-up clutch
- Transmission
- Transmission control valve
- Axle
      - Front axle
      - Rear axle
- Differential
      - Front differential
      - Rear differential
      - Anti-slip differential
- Final drive
- Axle mounting, center hinge pin
- Steering piping
- Steering column, orbit-roll
- Steering valve
- Orbit-roll valve
- Stop valve
- Steering pump, switch pump
- Emergency steering pump (op)
- Emergency steering motor (op)
- Steering cylinder
- Joystick steering lever (op)
- Steering lever (op)
- Steering switch valve (op)
- Brake piping
- Brake valve
- Charge valve
- Accumulator (for brake)
- Brake
- Parking brake control
- Parking brake
- Parking brake solenoid valve
- Parking brake emergency release valve
- Hydraulic piping
- Work equipment control lever
- Hydraulic tank
- Torque converter charging, work equipment, and pilot control pumps
- Ppc relief valve
- Travel damper valve (op)
- Work equipment control valve
- Work equipment ppc valve
- Epc solenoid valve (op)
- Shut off valve (op)
- Attachment ppc valve (op)
- Cooling fan motor
- Cooling fan motor drive pump
- Work equipment linkage
- Bucket
- Bucket positioner, lift arm kick-out
- Work equipment cylinder
- Cab (op)
- Air conditioner (op)
- Machine monitoring system
- Machine monitor
      - Speed meter specifications
      - Load meter specification (option)
      - Table of monitor indication items
      - Setting of the machine monitor
- Transmission control system
- Transmission controller
- Work equipment control system (op)
- Work equipment controller
- Electric transmission control
- Kick down, hold switch
- Engine starting circuit
- Engine stop circuit
- Preheating circuit
- Engine power mode selector circuit
- Parking brake circuit
- Sensors
20 TESTING AND ADJUSTING
- Standard value table for engine
- Standard value table for chassis
- Measuring engine speed
- Measuring exhaust color
- Measuring exhaust temperature
- 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 transmission speed sensor
- Testing and adjusting power train oil pressure
- Drawing of special tool
- Procedure for flushing torque converter, transmission hydraulic circuit
- Procedure for moving machine when transmission valve fails
- Testing and adjusting steering control
- Testing and adjusting steering oil pressure
- Testing hydraulic fan
- 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
- Testing and adjusting accumulator charge pressure
- Testing and adjusting working equipment ppc oil pressure
- Testing and adjusting work equipment hydraulic pressure
- Testing and adjusting bucket positioner
- Testing and adjusting lift arm kick-out
- Checking proximity switch actuation pilot lamp
- Adjusting machine monitor
- Testing and adjusting load meter
- Bleeding air
- Releasing remaining pressure in hydraulic corcuit
- Releasing remaining pressure in travel damper circuit
20 TROUBLESHOOTING
- Points to remember when troubleshooting
- Sequence of events in troubleshooting
- Precautions when carrying out maintenance
- Checks before troubleshooting
- Equipment for troubleshooting electrical system
- Special functions of machine monitor
- Categories, procedure, and method of using troubleshooting charts
- Connection table for connector pin numbers
20 TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (TM MODE)
- Connector types and mounting locations
- Connector layout drawing
- Transmission control system diagram
- Error code [1500l1]
- Error code [15sal1]
- Error code [15salh]
- Error code [15sbl1]
- Error code [15sblh]
- Error code [15sel1]
- Error code [15selh]
- Error code [15sfl1]
- Error code [15sflh]
- Error code [15sgl1]
- Error code [15sglh]
- Error code [15shl1]
- Error code [15shlh]
- Error code [15sjl1]
- Error code [15sjlh]
- Error code [989f00]
- Error code [989g00]
- Error code [b@c7ns]
- Error code [d150ka]
- Error code [d150kb]
- Error code [d160ka]
- Error code [d160kb]
- Error code [d191ka]
- Error code [d191kb]
- Error code [d192ka]
- Error code [d192kb]
- Error code [daq0kk]
- Error code [daq2kk]
- Error code [daq9kq]
- Error code [ddk3ka]
- Error code [ddk3kb]
- Error code [ddk4ka]
- Error code [ddk4kb]
- Error code [ddk5ld]
- Error code [ddk6ka]
- Error code [ddk6kb]
- Error code [dds5ka]
- Error code [dds5kb]
- Error code [ddt0l4]
- Error code [ddt4ld]
- Error code [ddw9ld]
- Error code [ddwlld]
- Error code [df10ka]
- Error code [df10kb]
- Error code [dgf1kx]
- Error code [dgr2ka]
- Error code [dgr2kb]
- Error code [dht1kx]
- Error code [dle2ka]
- Error code [dle2lc]
- Error code [dlt3ka]
- Error code [dt20kb]
- Error code [dw7bka]
- Error code [dw7bkb]
- Error code [dw7cka]
- Error code [dw7ckb]
- Error code [dx16ka]
- Error code [dx16kb]
- Error code [dxh1ka]
- Error code [dxh1kb]
- Error code [dxh4ka]
- Error code [dxh4kb]
- Error code [dxh5ka]
- Error code [dxh5kb]
- Error code [dxh6ka]
- Error code [dxh6kb]
- Error code [dxh7ka]
- Error code [dxh7kb]
- Error code [dxh8ka]
- Error code [dxh8kb]
- Error code [dxhhka]
- Error code [dxhhkb]
- Error code [dy30ma]
- Error code [dy30mc]
- Action code [tm-1]
- Action code [tm-2]
- Action code [tm-3]
- Action code [tm-4]
- Action code [tm-5]
- Action code [tm-6]
- Action code [tm-7]
- Action code [tm-8]
- Action code [tm-9]
- Action code [tm-10-a]
- Action code [tm-10-b]
- Action code [tm-11]
- Action code [tm-12]
- Action code [tm-13]
- Action code [tm-14]
- Action code [tm-15]
- Action code [tm-16]
- Action code [tm-17]
- Action code [tm-18]
- Action code [tm-19]
- Action code [tm-20]
- Action code [tm-21]
- Action code [tm-22]
- Action code [tm-23]
- Action code [tm-24]
- Action code [tm-25]
- Action code [tm-26]
- Action code [tm-27]
- Action code [tm-28]
- Action code [tm-29]
20 TROUBLESHOOTING OF WORK EQUIPMENT CONTROL SYSTEM (WRK MODE)
- Connector types and mounting locations
- Connector layout drawing
- Work equipment control system diagram
- Error code [d193ka]
- Error code [d193kb]
- Error code [db90kk]
- Error code [db92kk]
- Error code [db95kx]
- Error code [dd1ald]
- Error code [dd1bld]
- Error code [dfaokm]
- Error code [dk59ka]
- Error code [dk59ky]
- Error code [dk59l8]
- Error code [dk5aka]
- Error code [dk5aky]
- Error code [dk5bka]
- Error code [dk5bky]
- Error code [dk5bl8]
- Error code [dk5cka]
- Error code [dk5cky]
- Error code [dk5dka]
- Error code [dk5dky]
- Error code [dk5dl8]
- Error code [dk5eka]
- Error code [dk5eky]
- Error code [dk5fka]
- Error code [dk5fky]
- Error code [dk5fkm]
- Error code [dk5fl8]
- Error code [dk5gka]
- Error code [dk5gky]
- Error code [dkaoka]
- Error code [dkaoky]
- Error code [dle2lc]
- Error code [dlt3lc]
- Error code [dum1kb]
- Error code [dum2kb]
- Error code [dw4pka]
- Error code [dw4pkb]
- Error code [dw4qka]
- Error code [dw4qkb]
- Error code [dw4rka]
- Error code [dw4rkb]
- Error code [dw4ska]
- Error code [dw4skb]
- Error code [dwm1ka]
- Error code [dwm1kb]
- Error code [dwn6ka]
- Error code [dwn6kb]
- Error code [dwn7ka]
- Error code [dwn7kb]
- Error code [dwn8ka]
- Error code [dwn8kb]
- Error code [dxhjka]
- Error code [dxhjkb]
- Error code [dxhkka]
- Error code [dxhkkb]
- Error code: [dxhlka]
- Error code: [dxhlkb]
- Error code: [dxhmka]
- Error code: [dxhmkb]
- Action code: [wrk-1]
- Action code: [wrk-2]
- Action code: [wrk-3]
- Action code: [wrk-4]
- Action code: [wrk-5]
- Action code: [wrk-6]
- Action code: [wrk-7]
- Action code: [wrk-8]
- Action code: [wrk-9]
- Action code: [wrk-10]
- Action code: [wrk-11]
- Action code: [wrk-12]
- Action code: [wrk-13]
- Action code: [wrk-14]
- Action code: [wrk-15]
- Action code: [wrk-16]
- Action code: [wrk-17]
- Action code: [wrk-18]
- Action code: [wrk-19]
- Action code: [wrk-20]
- Action code: [wrk-21]
- Action code: [wrk-22]
- Action code: [wrk-23]
- Action code: [wrk-24]
- Action code: [wrk-25]
- Action code: [wrk-26]
- Action code: [wrk-27]
- Action code: [wrk-28]
20 TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE)
- Connector types and mounting locations
- Connector layout drawing
- Monitor system diagram
- Error code [2f00km]
- Error code [2g42zg]
- Error code [2g43zg]
- Error code [aa1anx]
- Error code [ab00l6]
- Error code [ab00ma]
- Error code [b@bazg]
- Error code [b@bazk]
- Error code [b@bcns]
- Error code [b@bczk]
- Error code [b@hans]
- Error code [b@cens]
- Error code [d182kz]
- Error code [d5zhl6]
- Error code [da80l4]
- Error code [daf3kk]
- Error code [daf5kp]
- Error code [daf6kp]
- Error code [dafbkm]
- Error code [dafskq]
- Error code [daqskr]
- Error code [db2skr]
- Error code [dbqskr]
- Error code [db9skr]
- Error code [dd15ld]
- Error code [dd16ld]
- Error code [dd17ld]
- Error code [dd18ld]
- Error code [dd1cld]
- Error code [ddk3km]
- Error code [ddk4km]
- Error code [ddk6km]
- Error code [dds5l6]
- Error code [ddy0ld]
- Error code [dge2kx]
- Error code [dge3l6]
- Error code [dgh2kx]
- Error code [dgt1kx]
- Error code [dhe4l6]
- Error code [dhpckx]
- Error code [dhpdkx]
- Error code [dka0kx]
- Error code [dv00kb]
- Error code [dy30me]
- Action code [mon-1]
- Action code [mon-2]
- Action code [mon-3]
- Action code [mon-4]
- Action code [mon-5]
- Action code [mon-6]
- Action code [mon-7]
- Action code [mon-8]
- Action code [mon-9]
- Action code [mon-10]
- Action code [mon-11]
- Action code [mon-12]
- Action code [mon-13]
- Action code [mon-14]
- Action code [mon-15]
- Action code [mon-16]
- Action code [mon-17]
- Action code [mon-18]
- Action code [mon-19]
- Action code [mon-20]
20 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)
- H-1
- H-2
- H-3a
- H-3b
- H-4
- H-5
- H-6
- H-7
- H-8
- H-9
- H-10
- H-11
- H-12
- H-13
- H-14
- H-15
- H-16
- H-17
- H-18
- H-19
- H-20
- H-21
- H-22
- H-23
- H-24
- H-25
- H-26
- H-27
- H-28
- H-29
20 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
- Connector types and mounting locations
- Connector layout drawing
- Electrical system diagram
- Action code: [e-1-a]

- Action code: [e-1-b]
- Action code: [e-2]
- Action code: [e-3]
- Action code: [e-4]
- Action code: [e-5]
- Action code: [e-6]
- Action code: [e-7]
- Action code: [e-8]
- Action code: [e-9]
- Action code: [e-10]
- Action code: [e-11]
- Action code: [e-12]
- Action code: [e-13]
- Action code: [e-14]
- Action code: [e-15]
- Action code: [e-16]
- Action code: [e-17]
- Action code: [e-18]
30 DISASSEMBLY AND ASSEMBLY
- Method of using manual
- Precautions when carrying out operation
- Engine assembly
      - Removal
      - Installation
- Cylinder head assembly
      - Special tool
      - Removal
      - Installation
- Radiator and fan motor assembly
      - Removal
      - Installation
- Aftercooler assembly
      - Removal
      - Installation
- Fuel injection pump
      - Special tool
      - Removal
      - Installation
- Nozzle holder assembly
      - Removal
      - Installation
- Fan and fan motor assembly
      - Removal
      - Installation
- Fuel tank assembly
      - Removal
      - Installation
- Parking brake disc plate
      - Special tool
      - Removal
      - Installation
      - Sketch of special tool
      - K1 bracket
- Torque converter and transmission assembly
      - Removal
      - Installation
      - Bleeding air of brake circuit
- Transmission assembly
      - Special tool
      - Disassembly
      - Assembly
      - Sketches of special tools
      - F1 lifting tool
      - F4 bracket
- Transmission clutch pack assembly
      - Special tools
      - Disassembly
      - Disassembly of forward and reverse clutch packs
      - [forward clutch side]
      - [reverse clutch side]
      - Disassembly of 1st and 4th clutch pack
      - [1st clutch side]
      - [4th clutch side]
      - Disassembly of 2nd and 3rd clutch pack
      - [3rd clutch side]
      - [2nd clutch side]
      - Assembly of the forward and reverse clutch packs
      - [reverse clutch side]
      - [forward clutch side]
      - Assembly of 1st and 4th clutch pack
      - [4th clutch side]
      - [1st clutch side]
      - Assembly of 2nd and 3rd clutch pack
      - [2nd clutch side]
      - [3rd clutch side]
- Parking brake assembly
      - Special tools
      - Disassembly
      - Assembly
- Special tool simplified drawings
      - F10 push tool
      - H1 bracket
      - H4 spacer
      - H3 push tool
      - H6 push tool
      - H5 push tool
      - H9 spacer
      - H8 push tool
- Torque converter assembly (standard specification)
      - Special tools
      - Disassembly
      - Assembly
- Torque converter assembly (lock-up specification)
      - Special tools
      - Disassembly
      - Assembly
- Rear axle assembly
      - Removal
      - Installation
- Front axle assembly
      - Removal
      - Installation
- Axle housing assembly
      - Special tools
      - Disassembly
      - Assembly
- Special tool simplified drawings
      - J1 spacer
      - J2 push tool
      - J3 push tool
      - J1 push tool 54
- Differential assembly
      - Special tools
      - Disassembly
      - Assembly
- Special tool illustrations
      - D3-2
      - D3-1
      - D5-1 push tool
      - D5-2 push tool
      - D4 push tool
- Center hinge pin
      - Special tools
      - Removal
      - Installation
- Cab assembly
      - Removal
      - Installation
- Cab and floor frame assembly
      - Removal
      - Installation
- Transmission, work equipment, and ppc pump assembly
      - Removal
      - Installation
- Steering, switching, and fan pump assembly
      - Removal
      - Installation
- Steering demand valve assembly
      - Removal
      - Installation
- Travel dumper valve assembly
      - Removal
      - Installation
- Work equipment valve assembly
      - Removal
      - Installation
- Hydraulic cylinder assembly (steering, lift, and bucket cylinder assembly)
      - Special tools
      - Disassembly
      - Assembly
- Hydraulic tank assembly
      - Removal
      - Attachment
- Work equipment assembly
      - Removal
      - Installation
- Counter weight
      - Removal
      - Installation
- Air conditioner unit assembly
      - Removal
      - Installation
- Air conditioner compressor assembly
      - Removal
      - Installation
90 OTHERS
- Power train oil circuit diagram (without torque converter lockup clutch)
- Power train oil circuit diagram (with torque converter lockup clutch)
- Brake oil circuit diagram
- Work equipment hydraulic circuit diagram
- Work equipment hydraulic circuit diagram (for electric work equipment lever)
- Electric circuit diagram (1/8)
- Electric circuit diagram (1/8)
- Electric circuit diagram (1/8)
- Electric circuit diagram (1/8)
- Electric circuit diagram (2/8)
- Electric circuit diagram (2/8)
- Electric circuit diagram (2/8)
- Electric circuit diagram (2/8)
- Electric circuit diagram (3/8)
- Electric circuit diagram (4/8)
- Electric circuit diagram (5/8)
- Electric circuit diagram (6/8)
- Electric circuit diagram (7/8)
- Electric circuit diagram (8/8)