Komatsu WA380-5 Wheel Loader Shop Manual SEBM024716

Description

• Model List:
  • WA380-5 Wheel Loader

• 1. CONTENTS
• 2. GENERAL
• 2.1. GENERAL ASSEMBLY DRAWING
• 2.2. SPECIFICATIONS
• 2.3. WEIGHT TABLE
• 2.4. LIST OF LUBRICANT AND COOLANT
• 3. STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
• 3.1. COOLING SYSTEM
• 3.2. ENGINE MOUNT, TRANSMISSION MOUNT
• 3.3. POWER TRAIN
• 3.4. POWER TRAIN SYSTEM DIAGRAM
• 3.5. DRIVE SHAFT (PROPELLER SHAFT)
• 3.6. TORQUE CONVERTER, TRANSMISSION PIPING
• 3.7. TORQUE CONVERTER
• 3.8. TRANSMISSION
• 3.9. TRANSMISSION CONTROL VALVE
• 3.10. AXLE
• 3.11. DIFFERENTIAL
• 3.12. FINAL DRIVE
• 3.13. AXLE MOUNTING,CENTER HINGE PIN
• 3.14. STEERING PIPING
• 3.15. STEERING COLUMN, ORBITROLL
• 3.16. STEERING VALVE
• 3.17. ORBITROLL VALVE
• 3.18. STOP VALVE
• 3.19. STEERING PUMP, SWITCH PUMP
• 3.20. EMERGENCY STEERING PUMP (IF EQUIPPED)
• 3.21. EMERGENCY STEERING MOTOR (IF EQUIPPED)
• 3.22. STEERING CYLINDER
• 3.23. JOYSTICK STEERING LEVER (IF EQUIPPED)
• 3.24. STEERING LEVER (IF EQUIPPED)
• 3.25. STEERING SWITCH VALVE (IF EQUIPPED)
• 3.26. BRAKE PIPING
• 3.27. BRAKE VALVE
• 3.28. CHARGE VALVE
• 3.29. ACCUMULATOR (FOR BRAKE)
• 3.30. BRAKE
• 3.31. PARKING BRAKE CONTROL
• 3.32. PARKING BRAKE
• 3.33. PARKING BRAKE SOLENOID VALVE
• 3.34. PARKING BRAKE EMERGENCY RELEASE VALVE
• 3.35. HYDRAULI PIPING
• 3.36. WORK EQUIPMENT CONTROL LEVER
• 3.37. HYDRAULIC TANK
• 3.38. TORQUE CONVERTER CHARGING, WORK EQUIPMENT, AND PILOT CONTROL PUMPS
• 3.39. PPC RELIEF VALVE
• 3.40. VALVE (IF EQUIPPED)
• 3.41. WORK EQUIPMENT CONTROL VALVE
• 3.42. WORK EQUIPMENT PPC VALVE
• 3.43. PPC VALVE (FOR MULTI FUNCTION MONO LEVER)
• 3.44. EPC SOLENOID VALVE (IF EQUIPPED)
• 3.45. SHUT OFF VALVE (IF EQUIPPED)
• 3.46. ATTACHMENT PPC VALVE (IF EQUIPPED)
• 3.47. COOLING FAN MOTOR
• 3.48. COOLING FAN MOTOR DRIVE PUMP
• 3.49. WORK EQUIPMENT LINKAGE
• 3.50. BUCKET
• 3.51. BUCKET POSITIONER, LIFT ARM KICKOUT
• 3.52. WORK EQUIPMENT CYLINDER
• 3.54. AIR CONDITIONER (IF EQUIPPED)
• 3.55. MACHINE MONITORING SYSTEM
• 3.56. MACHINE MONITOR
• 3.57. TRANSMISSION CONTROL SYSTEM
• 3.58. TRANSMISSION CONTROLLER
• 3.59. WORK EQUIPMENT CONTROL SYSTEM (IF EQUIPPED)
• 3.60. WORK EQUIPMENT CONTROLLER (IF EQUIPPED)
• 3.61. ELECTRIC TRANSMISSION CONTROL
• 3.62. KICK DOWN, HOLD SWITCH
• 3.63. ENGINE STARTING CIRCUIT
• 3.64. ENGINE STOP CIRCUIT
• 3.65. PREHEATING CIRCUIT
• 3.66. ENGINE POWER MODE SELECTOR CIRCUIT
• 3.67. PARKING BRAKE CIRCUIT
• 3.68. SENSORS
• 4. TESTING AND ADJUSTING
• 4.1. STANDARD VALUE TABLE FOR ENGINE
• 4.2. STANDARD VALUE TABLE FOR CHASSIS
• 4.3. TESTING AND ADJUSTING
• 4.3.1. TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
• 4.3.2. MEASURING ENGINE SPEED
• 4.3.3. MEASURING EXHAUST COLOR
• 4.3.4. MEASURING EXHAUST TEMPERATURE
• 4.3.5. ADJUSTING VALVE CLEARANCE
• 4.3.6. MEASURING COMPRESSION PRESSURE
• 4.3.7. MEASURING BLOWBY PRESSURE
• 4.3.8. MEASURING ENGINE OIL PRESSURE
• 4.3.9. MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
• 4.3.10. TESTING AND ADJUSTING FUEL INJECTION TIMING
• 4.3.11. ADJUSTING ENGINE SPEED SENSOR
• 4.3.12. BLEEDING AIR FROM FUEL CIRCUIT
• 4.3.13. ADJUSTING ENGINE STOP SOLENOID
• 4.3.14. ADJUSTING ACCELERATOR PEDAL
• 4.3.15. ADJUSTING TRANSMISSION SPEED SENSOR
• 4.3.16. TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE
• 4.3.17. DRAWING OF SPECIAL TOOL
• 4.3.18. PROCEDURE FOR FLUSHING TORQUE CONVERTER, TRANSMISSION HYDRAULIC CIRCUIT
• 4.3.19. PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS
• 4.3.20. TESTING AND ADJUSTING STEERING CONTROL
• 4.3.21. TESTING AND ADJUSTING STEERING OIL PRESSURE
• 4.3.22. TESTING HYDRAULIC FAN
• 4.3.23. MEASURING BRAKE OIL PRESSURE
• 4.3.24. TESTING WEAR OF WHEEL BRAKE DISC
• 4.3.25. BLEEDING AIR FROM BRAKE CIRCUIT
• 4.3.26. TESTING WEAR OF PARKING BRAKE DISC
• 4.3.27. MANUAL RELEASE METHOD FOR PARKING BRAKE
• 4.3.28. TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE
• 4.3.29. TESTING AND ADJUSTING WORKING EQUIPMENT PPC OIL PRESSURE
• 4.3.30. TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE
• 4.3.31. TESTING AND ADJUSTING BUCKET POSITIONER
• 4.3.32. TESTING AND ADJUSTING LIFT ARM KICKOUT
• 4.3.33. CHECKING PROXIMITY SWITCH ACTUATION PILOT LAMP
• 4.3.34. ADJUSTING MACHINE MONITOR
• 4.3.35. TESTING AND ADJUSTING LOAD METER
• 4.3.36. BLEEDING AIR
• 4.3.37. RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
• 4.3.38. RELEASING REMAINING PRESSURE IN E.C.S.S. CIRCUIT
• 4.3.39. PM CLINIC INSPECTION TABLE
• 4.4. TROUBLESHOOTING
• 4.4.1. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 4.4.2. SEQUENCE OF EVENTS IN TROUBLESHOOTING
• 4.4.3. PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
• 4.4.4. CHECKS BEFORE TROUBLESHOOTING
• 4.4.5. SPECIAL FUNCTIONS OF MACHINE MONITOR
• 4.4.6. CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS
• 4.4.7. CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
• 4.4.8. TADAPTER TABLE
• 4.4.9. TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (TM MODE)
• 4.4.10. TROUBLESHOOTING OF WORK EQUIPMENT CONTROL SYSTEM (WRK MODE)
• 4.4.11. TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE)
• 4.4.12. TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)
• 4.4.13. TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
• 4.4.14. TROUBLESHOOTING OF ENGINE (S MODE)
• 5. DISASSEMBLY AND ASSEMBLY
• 5.1. How To Read This Manual
• 5.2. Precautions When Carrying Out Operation
• 5.3. Special tool list
• 5.4. Removal and Installation of Engine Assembly
• 5.5. Removal and Installation of Cylinder Head Assembly
• 5.6. Removal and Installation of Radiator and Fan Motor Assembly
• 5.7. Removal and Installation of Aftercooler Assembly
• 5.8. Removal and Installation of Fuel Injection Pump
• 5.9. Removal and Installation of Nozzle Holder Assembly
• 5.10. Removal and installation of fan and fan motorassembly
• 5.11. Removal and Installation of Fuel Tank Assembly
• 5.12. Removal and Installation of Parking Brake Disc Plate
• 5.13. Removal and Installation of Torque Converter and Transmission Assembly
• 5.14. Disassembly and Assembly of Transmission Assembly
• 5.15. Disassembly and Assembly of Transmission Clutch Pack Assembly
• 5.16. Disassembly and Assembly of Parking Brake Assembly
• 5.17. Disassembly and Assembly of Torque Converter Assembly (Standard Specification)
• 5.18. Disassembly and Assembly of Torque Converter Assembly (LockUp Specification)
• 5.19. Removal and Installation of Rear Axle Assembly
• 5.20. Removal and Installation of Front Axle Assembly
• 5.21. Disassembly and Assembly of Axle Housing Assembly
• 5.22. Disassembly and Assembly of Differential Assembly
• 5.23. Removal and Installation of Center Hinge Pin
• 5.24. Removal and Installation of Cab Assembly
• 5.25. Removal and Installation of Cab and Floor Frame Assembly
• 5.26. Removal and installation of operators cab glass (Stuck glass)
• 5.27. Removal and Installation of Transmission, Work Equipment, and PPC Pump Assembly
• 5.28. Removal and Installation of Steering, Switching, and Fan Pump Assembly
• 5.29. Removal and Installation of Steering Demand Valve Assembly
• 5.30. Removal and installation of steering valve oil seal
• 5.31. Removal and Installation of E.C.S.S. Valve Assembly
• 5.32. Removal and Installation of Work Equipment Valve Assembly
• 5.33. Disassembly and Assembly of Hydraulic Cylinder Assembly (Steering, Lift, and Bucket Cylinder Assembly)
• 5.34. Removal and Installation of Hydraulic Tank Assembly
• 5.35. Removal and Installation of Work Equipment Assembly
• 5.36. Removal and Installation of Counter Weight
• 5.37. Removal and Installation of Air Conditioner Unit Assembly
• 5.38. Removal and Installation of Air Conditioner Compressor Assembly
• 5.39. Disassembly, Assembly of Operators Seat Assembly
• 6. OTHERS
• 6.1. POWER TRAIN OIL CIRCUIT DIAGRAM (WITHOUT TORQUE CONVERTER LOCKUP CLUTCH)
• 6.2. POWER TRAIN OIL CIRCUIT DIAGRAM (WITH TORQUE CONVERTER LOCKUP CLUTCH)
• 6.3. BRAKE OIL CIRCUIT DIAGRAM
• 6.4. WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
• 6.5. WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (FOR ELECTRIC WORK EQUIPMENT LEVER)
• 6.6. ELECTRICAL CIRCUIT DIAGRAM