Komatsu WA380-5 Wheel Loader Shop Manual SEBM024711

Description

• Model List:
  • WA380-5 Wheel Loader

• 1. COVER
• 2. CONTENTS
• 3. GENERAL
• 3.1. GENERAL ASSEMBLY DRAWING
• 3.2. SPECIFICATIONS
• 3.3. WEIGHT TABLE
• 3.4. LIST OF LUBRICANT AND COOLANT
• 4. STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
• 4.1. COOLING SYSTEM
• 4.2. ENGINE MOUNT, TRANSMISSION MOUNT
• 4.3. POWER TRAIN
• 4.4. POWER TRAIN SYSTEM DIAGRAM
• 4.5. DRIVE SHAFT (PROPELLER SHAFT)
• 4.6. TORQUE CONVERTER, TRANSMISSION PIPING
• 4.7. TORQUE CONVERTER
• 4.8. TRANSMISSION
• 4.9. TRANSMISSION CONTROL VALVE
• 4.10. AXLE
• 4.11. DIFFERENTIAL
• 4.12. FINAL DRIVE
• 4.13. AXLE MOUNTING,CENTER HINGE PIN
• 4.14. STEERING PIPING
• 4.15. STEERING COLUMN, ORBITROLL
• 4.16. STEERING VALVE
• 4.17. ORBITROLL VALVE
• 4.18. STOP VALVE
• 4.19. STEERING PUMP, SWITCH PUMP
• 4.20. EMERGENCY STEERING PUMP (IF EQUIPPED)
• 4.21. EMERGENCY STEERING MOTOR (IF EQUIPPED)
• 4.22. STEERING CYLINDER
• 4.23. JOYSTICK STEERING LEVER (IF EQUIPPED)
• 4.24. STEERING LEVER (IF EQUIPPED)
• 4.25. STEERING SWITCH VALVE (IF EQUIPPED)
• 4.26. BRAKE PIPING
• 4.27. BRAKE VALVE
• 4.28. CHARGE VALVE
• 4.29. ACCUMULATOR (FOR BRAKE)
• 4.30. BRAKE
• 4.31. PARKING BRAKE CONTROL
• 4.32. PARKING BRAKE
• 4.33. PARKING BRAKE SOLENOID VALVE
• 4.34. PARKING BRAKE EMERGENCY RELEASE VALVE
• 4.35. HYDRAULI PIPING
• 4.36. WORK EQUIPMENT CONTROL LEVER
• 4.37. HYDRAULIC TANK
• 4.38. TORQUE CONVERTER CHARGING, WORK EQUIPMENT, AND PILOT CONTROL PUMPS
• 4.39. PPC RELIEF VALVE
• 4.40. VALVE (IF EQUIPPED)
• 4.41. WORK EQUIPMENT CONTROL VALVE
• 4.42. WORK EQUIPMENT PPC VALVE
• 4.43. PPC VALVE (FOR MULTI FUNCTION MONO LEVER)
• 4.44. EPC SOLENOID VALVE (IF EQUIPPED)
• 4.45. SHUT OFF VALVE (IF EQUIPPED)
• 4.46. ATTACHMENT PPC VALVE (IF EQUIPPED)
• 4.47. COOLING FAN MOTOR
• 4.48. COOLING FAN MOTOR DRIVE PUMP
• 4.49. WORK EQUIPMENT LINKAGE
• 4.50. BUCKET
• 4.51. BUCKET POSITIONER, LIFT ARM KICKOUT
• 4.52. WORK EQUIPMENT CYLINDER
• 4.54. AIR CONDITIONER (IF EQUIPPED)
• 4.55. MACHINE MONITORING SYSTEM
• 4.56. MACHINE MONITOR
• 4.57. TRANSMISSION CONTROL SYSTEM
• 4.58. TRANSMISSION CONTROLLER
• 4.59. WORK EQUIPMENT CONTROL SYSTEM (IF EQUIPPED)
• 4.60. WORK EQUIPMENT CONTROLLER (IF EQUIPPED)
• 4.61. ELECTRIC TRANSMISSION CONTROL
• 4.62. KICK DOWN, HOLD SWITCH
• 4.63. ENGINE STARTING CIRCUIT
• 4.64. ENGINE STOP CIRCUIT
• 4.65. PREHEATING CIRCUIT
• 4.66. ENGINE POWER MODE SELECTOR CIRCUIT
• 4.67. PARKING BRAKE CIRCUIT
• 4.68. SENSORS
• 5. TESTING AND ADJUSTING
• 5.1. STANDARD VALUE TABLE FOR ENGINE
• 5.2. STANDARD VALUE TABLE FOR CHASSIS
• 5.3. TESTING AND ADJUSTING
• 5.3.1. TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
• 5.3.2. MEASURING ENGINE SPEED
• 5.3.3. MEASURING EXHAUST COLOR
• 5.3.4. MEASURING EXHAUST TEMPERATURE
• 5.3.5. ADJUSTING VALVE CLEARANCE
• 5.3.6. MEASURING COMPRESSION PRESSURE
• 5.3.7. MEASURING BLOWBY PRESSURE
• 5.3.8. MEASURING ENGINE OIL PRESSURE
• 5.3.9. MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
• 5.3.10. TESTING AND ADJUSTING FUEL INJECTION TIMING
• 5.3.11. ADJUSTING ENGINE SPEED SENSOR
• 5.3.12. BLEEDING AIR FROM FUEL CIRCUIT
• 5.3.13. ADJUSTING ENGINE STOP SOLENOID
• 5.3.14. ADJUSTING ACCELERATOR PEDAL
• 5.3.15. ADJUSTING TRANSMISSION SPEED SENSOR
• 5.3.16. TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE
• 5.3.17. DRAWING OF SPECIAL TOOL
• 5.3.18. PROCEDURE FOR FLUSHING TORQUE CONVERTER, TRANSMISSION HYDRAULIC CIRCUIT
• 5.3.19. PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS
• 5.3.20. TESTING AND ADJUSTING STEERING CONTROL
• 5.3.21. TESTING AND ADJUSTING STEERING OIL PRESSURE
• 5.3.22. TESTING HYDRAULIC FAN
• 5.3.23. MEASURING BRAKE OIL PRESSURE
• 5.3.24. TESTING WEAR OF WHEEL BRAKE DISC
• 5.3.25. BLEEDING AIR FROM BRAKE CIRCUIT
• 5.3.26. TESTING WEAR OF PARKING BRAKE DISC
• 5.3.27. MANUAL RELEASE METHOD FOR PARKING BRAKE
• 5.3.28. TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE
• 5.3.29. TESTING AND ADJUSTING WORKING EQUIPMENT PPC OIL PRESSURE
• 5.3.30. TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE
• 5.3.31. TESTING AND ADJUSTING BUCKET POSITIONER
• 5.3.32. TESTING AND ADJUSTING LIFT ARM KICKOUT
• 5.3.33. CHECKING PROXIMITY SWITCH ACTUATION PILOT LAMP
• 5.3.34. ADJUSTING MACHINE MONITOR
• 5.3.35. TESTING AND ADJUSTING LOAD METER
• 5.3.36. BLEEDING AIR
• 5.3.37. RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
• 5.3.38. RELEASING REMAINING PRESSURE IN E.C.S.S. CIRCUIT
• 5.3.39. PM CLINIC INSPECTION TABLE
• 5.4. TROUBLESHOOTING
• 5.4.1. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 5.4.2. SEQUENCE OF EVENTS IN TROUBLESHOOTING
• 5.4.3. PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
• 5.4.4. CHECKS BEFORE TROUBLESHOOTING
• 5.4.5. SPECIAL FUNCTIONS OF MACHINE MONITOR
• 5.4.6. CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS
• 5.4.7. CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
• 5.4.8. TADAPTER TABLE
• 5.4.9. TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (TM MODE)
• 5.4.10. TROUBLESHOOTING OF WORK EQUIPMENT CONTROL SYSTEM (WRK MODE)
• 5.4.11. TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE)
• 5.4.12. TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)
• 5.4.13. TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
• 5.4.14. TROUBLESHOOTING OF ENGINE (S MODE)
• 6. DISASSEMBLY AND ASSEMBLY
• 6.1. METHOD OF USING MANUAL
• 6.2. PRECAUTIONS WHEN CARRYING OUT OPERATION
• 6.3. SPECIAL TOOL LIST
• 6.4. REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
• 6.5. REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY
• 6.6. REMOVAL AND INSTALLATION OF RADIATOR AND FAN MOTOR ASSEMBLY
• 6.7. REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY
• 6.8. REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP
• 6.9. REMOVAL AND INSTALLATION OF NOZZLE HOLDER ASSEMBLY
• 6.10. REMOVAL AND INSTALLATION OF FAN AND MOTOR ASSEMBLY
• 6.11. REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY
• 6.12. REMOVAL AND INSTALLATION OF PARKING BRAKE DISC PLATE
• 6.13. REMOVAL AND INSTALLATION OF TORQUE CONVERTER AND TRANSMISSION ASSEMBLY
• 6.14. DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY
• 6.15. DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH PACK ASSEMBLY
• 6.16. DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ASSEMBLY
• 6.17. DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY (STANDARD SPECIFICATION)
• 6.18. DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY (LOCKUP SPECIFICATION)
• 6.19. REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY
• 6.20. REMOVAL AND INSTALLATION OF FRONT AXLE ASSEMBLY
• 6.21. DISASSEMBLY AND ASSEMBLY OF AXLE HOUSING ASSEMBLY
• 6.22. DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
• 6.23. REMOVAL AND INSTALLATION OF CENTER HINGE PIN
• 6.24. REMOVAL AND INSTALLATION OF CAB ASSEMBLY
• 6.25. REMOVAL AND INSTALLATION OF CAB AND FLOOR FRAME ASSEMBLY
• 6.26. REMOVAL AND INSTALLATION OF TRANSMISSION OF OPERATORS CAB GLASS (STUCK GLASS)
• 6.27. REMOVAL AND INSTALLATION OF TRANSMISSION, WORK EQUIPMENT, AND PPC PUMP ASSEMBLY
• 6.28. REMOVAL AND INSTALLATION OF STEERING, SWITCHING, AND FAN PUMP ASSEMBLY
• 6.29. REMOVAL AND INSTALLATION OF STEERING DEMAND VALVE ASSEMBLY
• 6.30. REMOVAL AND INSTALLATION OF E.C.S.S. VALVE ASSEMBLY
• 6.31. REMOVAL AND INSTALLATION OF WORK EQUIPMENT VALVE ASSEMBLY
• 6.32. DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY (STEERING, LIFT, AND BUCKET CYLINDER ASSEMBLY)
• 6.33. REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY
• 6.34. REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY
• 6.35. REMOVAL AND INSTALLATION OF COUNTER WEIGHT
• 6.36. REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY
• 6.37. REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY
• 6.38. DISASSEMBLY, ASSEMBLY OF OPERATORS SEAT ASSEMBLY
• 7. OTHERS
• 7.1. POWER TRAIN OIL CIRCUIT DIAGRAM (WITHOUT TORQUE CONVERTER LOCKUP CLUTCH)
• 7.2. POWER TRAIN OIL CIRCUIT DIAGRAM (WITH TORQUE CONVERTER LOCKUP CLUTCH)
• 7.3. BRAKE OIL CIRCUIT DIAGRAM
• 7.4. WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
• 7.5. WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (FOR ELECTRIC WORK EQUIPMENT LEVER)
• 7.6. ELECTRICAL CIRCUIT DIAGRAM