Komatsu Wheel Loader WA380L Repair Service Manuals
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Model:
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader WA380L, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Wheel Loader WA380-5L workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
CEBM009703 - Wheel Loader WA380-5L Shop Manual.pdf
CEAM009301 - Wheel Loader GALEO WA380-5L Operation & Maintenance Manual.pdf
Total Pages: 1,432 pages
File Format: PDF
Language: English
CEAM009301 - Wheel Loader GALEO WA380-5L Operation & Maintenance Manual...2
COVER...2
INTRODUCTION...8
FOREWORD...9
SAFETY INFORMATION...11
APPROVED AND NON-APPROVED USES...12
NON-APPROVED...12
PRODUCT IDENTIFICATION...13
MACHINE SERIAL NUMBER...13
ENGINE SERIAL NUMBER AND EMISSION LABEL...14
SERVICE METER LOCATION...14
SERIAL NUMBERS AND DEALER INFORMATION...15
CONTENTS...16
SAFETY...28
GENERAL SAFETY RULES AND PRECAUTIONS...29
GENERAL SAFETY RULES...29
SAFETY FEATURES...30
PERSONAL PROTECTIVE EQUIPMENT...30
UNAUTHORIZED MODIFICATIONS...31
LEAVING OPERATOR’S COMPARTMENT...31
MOUNTING AND DISMOUNTING...32
WASTE HANDLER APPLICATIONS...32
FIRE PREVENTION FOR FUEL AND OIL...33
DUST HAZARD PRECAUTIONS...33
CRUSH OR PINCH POINT DANGERS...34
FIRE EXTINGUISHER AND FIRST AID KIT...34
INSIDE OPERATOR’S COMPARTMENT...35
PRECAUTIONS WHEN USING ROPS...35
PRECAUTIONS FOR ATTACHMENTS...35
STARTING YOUR WORK OPERATIONS...36
WORK SITE HAZARDS...36
AVOIDING DANGEROUS SITUATIONS...36
WORKING CLEARANCES...38
RULES FOR ROAD TRAVEL...39
TRAVELING IN REVERSE...39
TRAVELING ON ICY OR SNOW-COVERED SURFACES...39
WORKING ON LOOSE OR UNSTABLE GROUND...39
TRAVEL ON SLOPES...40
PARKING THE MACHINE...41
PRECAUTIONS DURING MAINTENANCE OPERATIONS...42
WARNING TAGS...42
EQUIPMENT STORAGE...42
WORKING UNDER THE MACHINE...43
USING DROP LAMPS...43
KEEPING THE MACHINE CLEAN...44
RUNNING THE MACHINE DURING MAINTENANCE...44
RULES FOR REFUELING THE MACHINE...45
COOLING SYSTEM PRECAUTIONS...45
BATTERY PRECAUTIONS...46
STARTING THE MACHINE...46
HIGH PRESSURE HOSES...47
HIGH TEMPERATURES AREAS...47
DISPOSAL OF WASTE MATERIALS...47
INFLATING TIRES...48
ACCUMULATOR...48
CRITICAL PARTS...48
VIBRATIONS TO WHICH THE OPERATOR IS EXPOSED...48
SAFETY AND WARNING DECALS...49
LOCATION OF THE SAFETY DECALS...49
LOCATION OF SAFETY LABELS...50
SAFETY LABELS...50
OPERATION...58
GENERAL VIEW OF MACHINE...59
OUTSIDE VIEW OF THE MACHINE...59
INSIDE VIEW OF THE CAB...60
DESCRIPTION OF ALERTS, GAUGES AND SWITCHED SYSTEMS...61
INSTRUMENT BEZEL...61
SWITCH PANELS...63
DESCRIPTION OF ALERTS, GAUGES AND MONITOR SYSTEM...64
INSTRUMENT BEZEL...64
TYPES OF WARNING...65
MACHINE ELECTRONIC MONITORING DISPLAY...66
MONITOR MODE SELECTOR SWITCHES...66
MODE SELECTOR SWITCH 1...67
MODE SELECTOR SWITCH 2...67
MONITOR DISPLAY INFORMATION...67
HOUR METER AND ODOMETER DISPLAY...67
ADJUSTING MONITOR BRIGHTNESS...68
PROGRAMMING TELEPHONE NUMBER...68
ACTION CODE DISPLAY...68
FAILURE CODE DISPLAY...69
SERVICE DISPLAY...70
SELECTING LANGUAGE...71
EMERGENCY STOP WARNING SYSTEM...72
BRAKE PRESSURE WARNING LAMP...72
ENGINE OIL PRESSURE WARNING LAMP...73
BATTERY CHARGE WARNING LAMP...73
STEERING OIL PRESSURE WARNING LAMP...73
CAUTION ALERT WARNING SYSTEM...74
AXLE OIL TEMPERATURE CAUTION LAMP...74
TORQUE CONVERTER CAUTION LAMP...75
COOLANT TEMPERATURE CAUTION LAMP...75
HYDRAULIC OIL TEMPERATURE CAUTION LAMP...75
FUEL LEVEL CAUTION LAMP...75
INSPECTION AND MAINTENANCE ALERT WARNING SYSTEM...76
ENGINE OIL LEVEL CAUTION LAMP...76
RADIATOR COOLANT LEVEL CAUTION LAMP...77
AIR CLEANER CLOGGING CAUTION LAMP...77
MAINTENANCE CAUTION LAMP...77
MODE ALERT LAMPS...78
PARKING BRAKE PILOT LAMP...78
COOLING FAN REVERSE ROTATION PILOT LAMP...79
EMERGENCY STEERING PILOT LAMP...79
OUTPUT MODE PILOT LAMP (POWER MODE)...79
PREHEATING PILOT LAMP...80
JOYSTICK PILOT LAMP...80
SHIFT INDICATOR...80
AUTO-SHIFT PILOT LAMP...80
LOCKUP PILOT LAMP...81
SHIFT HOLD PILOT LAMP...81
SHIFT LEVER POSITION PILOT LAMP...81
TURN SIGNAL PILOT LAMP...81
HEADLAMP HIGH BEAM PILOT LAMP...82
GAUGE DISPLAY...83
TORQUE CONVERTER OIL TEMPERATURE GAUGE...83
ENGINE TEMPERATURE GAUGE...84
HYDRAULIC TEMPERATURE GAUGE...84
FUEL GAUGE...84
SPEEDOMETER...84
METER DISPLAY PILOT LAMP...85
MACHINE MONITOR...85
DISPLAYING ODOMETER...85
RESET FOR FILTER, OIL REPLACEMENT TIME...85
ENTERING A TELEPHONE NUMBER...86
SELECTING A LANGUAGE...87
ADJUSTING MONITOR BRIGHTNESS...88
MACHINE SWITCHES AND CONTROLS...89
SWITCH LOCATION...89
IGNITION SWITCH...90
POWER MODE SELECTOR SWITCH...90
TRANSMISSION MODE SELECTOR SWITCH...91
TRANSMISSION CUT-OFF SWITCH...91
TRANSMISSION CUT-OFF SET SWITCH...92
LAMP SWITCH...92
TURN SIGNAL LEVER...92
DIMMER SWITCH...93
HORN BUTTON...93
HAZARD LAMP SWITCH...93
PARKING BRAKE SWITCH...93
FRONT WORKING LAMP SWITCH...94
REAR WORKING LAMP SWITCH...94
MONITOR PANEL MODE SELECTOR SWITCH 1...95
MONITOR PANEL MODE SELECTOR SWITCH 2...95
KICKDOWN SWITCH...95
HOLD SWITCH...96
FRONT WIPER SWITCH...96
REAR WIPER SWITCH...96
CIGARETTE LIGHTER...97
CAB LAMP SWITCH...97
REAR DEFROSTER SWITCH...97
E.C.S.S. SWITCH...98
EMERGENCY STEERING SWITCH...98
COOLING FAN REVERSE ROTATION SWITCH...99
DIRECTIONAL SELECTOR SWITCH...99
DIRECTIONAL SELECTOR SWITCH ACTUATION SWITCH...100
TORQUE CONVERTER LOCK-UP SWITCH...100
LOAD METER CANCEL SWITCH...100
LOAD METER SUBTOTAL SWITCH...100
SOUND SYSTEM...101
DIGITAL ESPERIA RADIO SERIAL NUMBER A52001 - A52189...101
POWER SWITCH/VOLUME...101
TONE CONTROL KNOB...102
DISPLAY...102
CLOCK BUTTON/DISPLAYING FREQUENCY...102
AST...102
PRESET BUTTON...103
SEEK...103
BAND SELECTOR SWITCH...103
TUNING SWITCH...103
LISTENING TO THE RADIO...104
AUTOMATIC TUNING...104
MANUAL TUNING...104
SETTING THE PRESET BUTTONS...104
AUTOMATIC MEMORY...105
AUTOMATIC SWITCHING RECEPTION OF MONAURAL/STEREO...105
ADJUSTING THE TIME...105
BLAUPUNKT CALAIS RADIO SERIAL NUMBER A52190 AND UP...106
POWER SWITCH/MUTE...106
VOLUME CONTROL...107
FMT CONTROL...107
IR REMOTE CONTROL (OPTIONAL)...107
RDS CONTROL...107
ML CONTROL...108
EJECT CASSETTE...108
CASSETTE COMPARTMENT...108
FF AND RW BUTTONS...108
GEO BUTTON...109
SRC BUTTON...109
AUDIO BUTTON...109
MULTIFUNCTION ROCKER SWITCH...109
MENU BUTTON...110
KEYPAD 1-5...110
TRAFFIC...110
DISPLAY...110
THEFT PROTECTION...111
PRECAUTIONS WHEN USING...111
AIR CONDITIONER CONTROL PANEL...112
FAN SWITCH...112
AIR CONDITIONER SWITCH...113
MODE SELECTOR SWITCH...113
FRESH/RECIRC SELECTOR SWITCH...113
EXTERNAL AIR INTAKE...113
TEMPERATURE CONTROL SWITCH...114
METHOD OF OPERATION...114
WHEN NOT USING THE AIR CONDITIONER REGULARLY...115
COOL BOX...116
PRECAUTIONS WHEN USING THE AIR CONDITIONER...116
CONTROL LEVERS, PEDALS...117
SPEED CONTROL LEVER...117
DIRECTIONAL LEVER...119
SPEED CONTROL LEVER STOPPER...119
SAFETY LOCK LEVER...120
BUCKET CONTROL LEVER...120
LIFT ARM CONTROL LEVER...121
BRAKE PEDAL...121
ACCELERATOR PEDAL...122
STEERING TILT LOCK LEVER...122
SECURITY AND LOCKS...123
IGNITION KEY LOCKED AREAS...123
CAB DOOR LOCKS...123
ENGINE ACCESS DOORS...123
REAR GRILL...124
FUEL CAP...124
PADLOCKED AREAS...125
BATTERY AND TOOL BOX...125
TRANSFER CASE...125
UPPER HOOD ACCESS PANNEL...125
SAFETY FEATURES...126
PASSIVE SAFETY FEATURES...126
ROLL-OVER PROTECTIVE STRUCTURE (ROPS)...126
CAB FRONTAL GUARD (WASTE HANDLER APPLICATION ONLY)...126
BACKUP WARNING ALARM...126
ACTIVE SAFETY FEATURES...127
SAFETY BAR...127
SEAT BELT...127
EQUIPMENT LOCK LEVER...128
MACHINE FEATURES...129
CAB DOORS...129
OPEN LOCK...129
ELECTRICAL...129
FUSE...129
FUSE CAPACITY AND NAME OF CIRCUIT...130
SLOW BLOW FUSE...131
AUXILIARY POWER...131
MACHINE CAB AND CHASSIS...132
SEAT ADJUSTMENT...132
HANDLING CAB WIPER...134
DUST INDICATOR...134
GREASE PUMP...134
PRECAUTIONS BEFORE STARTING WORK OPERATIONS...135
PRE-OPERATIONAL CHECKS...135
PERFORM A WALK AROUND CHECK OF YOUR MACHINE...135
UNDER THE HOOD...135
CHECK COOLANT LEVEL...136
CHECK ENGINE OIL LEVEL, ADD OIL...137
REAR-VIEW MIRROR ADJUSTMENT...137
IN THE OPERATOR’S CAB...138
SEAT BELT ADJUSTMENT...138
LEVER STAND ADJUSTMENT...139
LEVER STAND ANGLE ADJUSTMENT...139
START-UP PROCEDURES...140
CHECK FUEL LEVEL, ADD FUEL...140
CHECK THE BRAKE PEDALS...141
CHECK THE PARKING BRAKE...141
STARTING THE ENGINE...142
OPERATIONS AND CHECKS AFTER STARTING ENGINE...145
BREAKING IN THE MACHINE...145
NORMAL START-UP AND WARM-UP...145
STOPPING THE ENGINE...146
TRAVELING, STOPPING AND PARKING THE MACHINE...147
TRAVELING...147
TURNING ON SLOPES...149
CHANGING GEAR SPEED RANGES...149
CHANGING DIRECTION...150
WHEN USING AUTO-SHIFT...151
STOPPING AND PARKING THE MACHINE...152
TRANSMISSION CUT-OFF SWITCH...154
ADJUSTING THE TRANSMISSION CUT-OFF...154
STOPPING WHEN TRANSMISSION CUT-OFF IS ON...155
TURNING...155
EMERGENCY STEERING...156
USING THE EMERGENCY STEERING...156
EMERGENCY STEERING SELF-CHECK FUNCTION...157
STARTING YOUR WORK OPERATIONS...158
WORK EQUIPMENT...158
LIFT ARM LEVER...158
BUCKET LEVER...159
SCOOPING A LOAD OR CUTTING A GRADE...160
LOADING PILED SOIL OR BLASTED ROCK...160
CUTTING A GRADE ON LEVEL GROUND...162
LEVELING OPERATIONS...163
PUSHING OPERATION...163
LOAD AND CARRY OPERATIONS...163
LOADING OPERATIONS...164
CROSS DRIVE LOADING...164
V-SHAPE LOADING...164
PRECAUTIONS WHEN PILING UP LOADS...164
LOADING TRUCKS OR HOPPERS...165
PRECAUTIONS DURING OPERATION...166
PERMISSIBLE WATER DEPTH...166
IF WHEEL BRAKE DOES NOT WORK...166
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...166
BRAKING ON DOWNHILL SLOPE...166
IF THE ENGINE STOPS...166
PRECAUTIONS WHEN DRIVING THE MACHINE...167
PRECAUTIONS REGARDING BRAKE FUNCTION...167
WORK EQUIPMENT AND MACHINE POSTURE...168
ADJUSTING BUCKET...168
BOOM KICKOUT ADJUSTMENT...168
BUCKET POSITIONER ADJUSTMENT...169
BUCKET LEVEL INDICATOR...169
TRANSPORTING THE MACHINE...170
LOADING AND SECURING THE MACHINE...170
LIFTING THE MACHINE...171
LIFTING LOCATIONS AND PROCEDURES...171
USING WIRE ROPE...172
PRE LIFTING PROCEDURES...172
TOWING THE MACHINE...174
COLD WEATHER OPERATION...175
FUEL AND LUBRICANTS...175
COOLANT...175
PRECAUTIONS AFTER COMPLETION OF WORK...175
AFTER COLD WEATHER...175
WARMING UP THE STEERING...175
MAINTENANCE...176
GUIDES TO MAINTENANCE...177
CHECK SERVICE METER...177
KOMATSU GENUINE REPLACEMENT PARTS...177
KOMATSU GENUINE OILS...177
ALWAYS USE CLEAN WASHER FLUID...177
ALWAYS USE CLEAN OIL AND GREASE...177
CHECKING FOR FOREIGN MATERIALS IN DRAINED OIL AND ON FILTERS...177
FUEL STRAINER...177
WELDING INSTRUCTIONS...177
DO NOT DROP THINGS INSIDE THE MACHINE...178
DUSTY WORKSITES...178
AVOID MIXING OIL...178
LOCKING INSPECTION COVERS...178
BLEEDING AIR FROM HYDRAULIC CIRCUIT...178
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES...178
CHECKS AFTER INSPECTION AND MAINTENANCE...179
SYSTEMS TROUBLESHOOTING CHARTS...180
ELECTRICAL SYSTEM...180
CHASSIS...181
ENGINE...185
OUTLINES OF SERVICE...187
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...187
OIL...187
FUEL...187
COOLANT...187
GREASE...188
PERFORMING KOWA (Komatsu Oil Wear Analysis)...188
KOWA ANALYSIS ITEMS...189
OIL SAMPLING...189
STORING OIL AND FUEL...189
FILTERS...190
OUTLINE OF ELECTRIC SYSTEM...190
WEAR PARTS LIST...191
FUEL, COOLANT AND LUBRICANTS...192
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS...192
LUBRICANT AND COOLANT SUPPLIER RECOMMENDATIONS...194
STANDARD TIGHTENING TORQUES FOR FASTNERS AND HOSES...196
TORQUE LIST...196
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...197
MAINTENANCE SCHEDULE CHART...198
INITIAL 250 HOURS SERVICE...198
WHEN REQUIRED...198
EVERY 50 HOURS SERVICE...198
EVERY 100 HOURS SERVICE...198
EVERY 250 HOURS SERVICE...198
EVERY 500 HOURS SERVICE...199
EVERY 1000 HOURS SERVICE...199
EVERY 2000 HOURS SERVICE...199
EVERY 4000 HOURS SERVICE...199
EVERY 8000 HOURS SERVICE...199
GENERAL MAINTENANCE AND INSPECTION...200
INITIAL 250 HOURS SERVICE...200
CHANGE TRANSMISSION OIL FILTER CARTRIDGE...200
REPLACE HYDRAULIC TANK FILTER ELEMENT...200
WHEN REQUIRED...200
CLEANING THE MACHINE...200
ENGINE AIR FILTER...202
CLEANING THE COOLING SYSTEM...205
WATER SEPARATOR...207
TRANSMISSION OIL LEVEL...209
AXLE OIL LEVEL...210
CHECK AXLE VENT...212
AIR CONDITIONER CONDENSER...212
WINDOW WASHING FLUID LEVEL...213
CLEAN RADIATOR FINS...214
CHECK ELECTRICAL INTAKE AIR HEATER...217
REPLACE BOLT-ON CUTTING EDGE...217
REPLACE BUCKET TEETH...218
REPLACING SLOW-BLOW FUSE...219
INSPECTION OF TIRES...220
EVERY SPECIFIC HOURS SERVICE...222
EVERY 50 HOURS OF SERVICE...222
DRAIN SEDIMENT FROM FUEL TANK...222
EVERY 100 HOURS SERVICE...222
LUBRICATE THE REAR AXLE PIVOT PIN...222
CHECKING THE HYDRAULIC TANK OIL LEVEL AND ADDING OIL...222
CLEANING THE AIR CONDITIONER FRESH AIR FILTER ELEMENT...223
EVERY 250 HOURS OF SERVICE...224
CHECK BATTERY ELECTROLYTE LEVEL...224
CHECK PARKING BRAKE...226
ALTERNATOR BELT TENSION...226
AIR CONDITIONER COMPRESSOR BELT TENSION...226
WHEEL HUB NUTS...227
AIR CONDITIONER RECIRCULATION FILTER...227
LUBRICATING POINTS...228
EVERY 500 HOURS SERVICE...229
CHANGE THE ENGINE OIL, REPLACE THE ENGINE OIL FILTER CARTRIDGE...229
REPLACING FUEL FILTER CARTRIDGE...230
EVERY 1000 HOURS SERVICE...231
CHANGE TRANSMISSION OIL AND FILTER CARTRIDGE, CLEAN STRAINER...231
CLEAN THE TRANSMISSION CASE VENT...232
LUBRICATING POINTS...233
CHECKING PARTS OF TURBOCHARGER...233
REPLACE CORROSION RESISTOR CARTRIDGE...233
EVERY 2000 HOURS SERVICE...234
CHANGE HYDRAULIC OIL, REPLACE HYDRAULIC OIL FILTER ELEMENT...234
HYDRAULIC TANK VENT ELEMENT...236
CHANGE THE AXLE OIL...237
AIR CONDITIONER RECIRCULATION FILTER...237
CLEAN PPC CIRCUIT STRAINER...238
CLEAN THE ENGINE VENT ELEMENT...238
CHECK ALTERNATOR, STARTER MOTOR...239
CHECK ENGINE VALVE CLEARANCE...239
CHECK TURBOCHARGER...239
CHECK INJECTOR...239
CHECK ACCUMULATOR GAS PRESSURE...239
CHECK VIBRATION DAMPER...239
CHECKING BRAKE DISC WEAR...240
EVERY 4000 HOURS SERVICE...241
LUBRICATING POINTS...241
CHECK WATER PUMP...242
CHECK AIR CONDITIONER COMPRESSOR...242
REPLACE INJECTOR NOZZLE TIP...242
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER...242
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER...243
EVERY 8000 HOURS SERVICE...244
REPLACE HIGH-PRESSURE PIPING CLAMP...244
REPLACE FUEL SPRAY PREVENTION CAP...244
LONG-TERM STORAGE...245
BEFORE STORAGE...245
DURING STORAGE...245
AFTER STORAGE...245
TROUBLESHOOTING EMERGENCY PROBLEMS...246
WHEN MACHINE RUNS OUT OF FUEL...246
PROCEDURE FOR BLEEDING AIR...246
TOWING THE MACHINE...247
WHEN ENGINE CAN BE USED...248
WHEN ENGINE CANNOT BE USED...248
RELEASING THE PARKING BRAKE...248
RELEASE PARKING BRAKE WITH EMERGENCY PARKING BRAKE RELEASE VALVE...248
MECHANICAL RELEASE...250
EMERGENCY TRAVEL OPERATION...251
SPECIFICATIONS...252
SPECIFICATIONS...253
MACHINE DIMENSIONS AND WEIGHTS...253
TIRES...253
WORK EQUIPMENT...254
WEIGHT CHANGES...254
MACHINE SYSTEMS SPECIFICATIONS...255
ENGINE...255
TRANSMISSION...256
AXLES AND FINAL DRIVES...256
BRAKES...256
STEERING SYSTEM...256
SERVICE REFILL CAPACITIES...256
OPTIONS, ATTACHMENTS...258
MONITOR WITH LOAD METER...259
LOAD METER...259
SWITCHES...259
LOAD METER CANCEL SWITCH...260
LOAD METER SUB TOTAL SWITCH...260
LOAD METER FUNCTIONS...261
LOAD METER ADDITION MODE...261
LOAD METER REMAIN MODE...262
SELECTION OF DISPLAY FOR TYPE OF LOAD...262
METHOD OF CALIBRATION (ADJUSTING 0 POINT)...263
DELETING LOAD METER DISPLAY...263
SPEED DISPLAY...263
USING LOAD METER DISPLAY...264
SETTING ADDITION MODE...264
SETTING THE REMAIN MODE...265
TOTAL LOAD DATA DISPLAY...267
STOPPING THE CALCULATION...268
PERFORMING CALIBRATION (ADJUSTING 0 POINT) WHEN EMPTY...269
PERFORMING CALIBRATION (ADJUSTING 0 POINT) WHEN LOADED...270
SUBTRACTION FUNCTION...272
SETTING THE TIME ON THE CLOCK...275
PRINTER OUTPUT...277
PRINTOUT MODE...277
SELECTING THE PRINTOUT MODE...278
TORQUE CONVERTER LOCK-UP...279
GENERAL LOCATIONS...279
TORQUE CONVERTER LOCK-UP SWITCH...279
TORQUE CONVERTER LOCK-UP PILOT LAMP...280
METHOD OF OPERATION...280
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED...281
TRAVEL SPEED WARNING FUNCTION...281
TRAVEL SPEED LIMIT FUNCTION...281
WASTE HANDLER ENGINE COOLING FAN CONTROL SYSTEM...282
FAN SYSTEM OPERATION...282
MODE SELECTOR SWITCH...283
FORWARD/REVERSE TIMER...283
REVERSE/FORWARD INDICATOR LAMPS...283
FORWARD SETTING KNOB...284
REVERSE SETTING KNOB...284
FORWARD TIME UNIT SELECTOR SWITCH...285
SCALE FIGURE SELECTOR SWITCH...285
DIRECTION SELECTOR SWITCH...286
REVERSE PILOT LAMP...286
CONTROL BOX...286
CLEANING RADIATOR AND COOLER FINS...287
HANDLING JOYSTICK STEERING SYSTEM...289
EXPLANATION OF COMPONENTS...289
SHIFT UP, SHIFT DOWN SWITCHES...289
FNR SWITCH...290
JOYSTICK STEERING LEVER...290
JOYSTICK ON/OFF SWITCH...290
HI/LOW SELECTOR SWITCH...290
HORN SWITCH...291
CONSOLE LOCK LEVER...291
HEIGHT ADJUSTMENT LOCK LEVER...291
ANGLE, FORE/AFT ADJUSTMENT LOCK LEVER...291
STRUCTURE AND FUNCTION OF JOYSTICK STEERING...292
JOYSTICK AND STEERING WHEEL OPERATION...293
GETTING IN OR OUT OF THE OPERATOR'S CAB...293
JOYSTICK CONSOLE ADJUSTMENT...294
JOYSTICK OPERATION...294
SELECTING BUCKET AND TIRES...297
CEBM009703 - Wheel Loader WA380-5L Shop Manual...300
COVER...300
FOREWORD...301
CONTENTS...301
SAFETY...320
SAFETY NOTICE...320
IMPORTANT SAFETY NOTICE...320
GENERAL PRECAUTIONS...320
PREPARATIONS FOR WORK...320
PRECAUTIONS DURING WORK...320
GENERAL...322
HOW TO READ THE SHOP MANUAL...323
VOLUMES...323
DISTRIBUTION AND UPDATING...323
FILING METHOD...323
REVISED EDITION MARK...323
REVISIONS...323
SYMBOLS...323
HOISTING INSTRUCTIONS...324
HOISTING...324
WIRE ROPES...324
PUSH PULL COUPLER...325
TYPE 1...325
DISCONNECTION...325
CONNECTION...325
TYPE 2...326
DISCONNECTION...326
CONNECTION...326
TYPE 3...327
DISCONNECTION...327
CONNECTION...327
COATING MATERIALS...328
STANDARD TIGHTENING TORQUE...330
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS...330
TIGHTENING TORQUE OF HOSE NUTS...331
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS...331
TIGHTENING TORQUE FOR FLARED NUTS...331
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS...332
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS...332
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)...332
ELECTRIC WIRE CODE...333
CLASSIFICATION BY THICKNESS...333
CLASSIFICATION BY COLOR AND CODE...333
CONVERSION TABLES...334
METHOD OF USING THE CONVERSION TABLE...334
01 GENERAL...340
SPECIFICATIONS...341
WEIGHT TABLE...345
FUEL, COOLANT AND LUBRICANTS...347
GENERAL ASSEMBLY DRAWING...350
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD...352
COOLING SYSTEM...358
Specifications...358
ENGINE MOUNT, TRANSMISSION MOUNT...359
POWER TRAIN...360
POWER TRAIN SYSTEM DIAGRAM...361
Without Torque Converter Lockup Clutch...361
With Torque Converter Lock-up Clutch...362
Outline...363
DRIVE SHAFT (PROPELLER SHAFT)...364
Outline...364
TORQUE CONVERTER, TRANSMISSION PIPING...365
TORQUE CONVERTER...366
Without Lock-up Clutch...366
Path Of Power Transmission...368
Power Flow...368
Oil Flow...368
With Lock-up Clutch...369
Path Of Power Transmission...373
Lock-up Clutch Disengaged...373
Lock-up Clutch Engaged...373
Oil Flow...374
TRANSMISSION...375
Outline...381
F and R Clutches: Without Lock-up Clutch...382
F and R Clutches: With Lock-up Clutch...383
1st and 4th Clutch...384
2nd and 3rd Clutch...385
Clutch Operation...386
Clutch Engaged...386
Clutch Disengaged...386
Forward 1st...387
Operation...387
Forward 2nd...388
Operation...388
Forward 3rd...389
Operation...389
Forward 4th...390
Operation...390
Reverse 1st...391
Operation...391
TRANSMISSION CONTROL VALVE...392
Without Lock-up Clutch (Transmission S/N 110643)...392
Without Lock-up Clutch (Transmission S/N 110644 and up)...393
With Lock-up Clutch (Transmission S/N 110643)...395
With Lock-up Clutch (Transmission S/N 110644 and up)...396
Electronic Control Modulation Valve (ECMV)...398
ECMV for Speed Clutch...399
Outline of ECMV...399
ECMV and Proportional Solenoid...399
ECMV and Fill Switch...400
ECMV Actuation...400
ECMV for Lock-up Clutch...401
Outline...401
Operation...402
Main Relief, Torque Converter Relief Valve...403
Outline...404
Operation...404
Flow Valve...406
Operation...406
AXLE...407
Front Axle...407
Rear Axle...408
DIFFERENTIAL...409
Front Differential...409
Rear Differential...411
Outline...413
Limited Slip Differential...414
Operation of Limited Slip Differential...416
FINAL DRIVE...419
Outline...421
AXLE MOUNTING, CENTER HINGE PIN...423
Outline...423
STEERING PIPING...427
STEERING COLUMN, ORBIT ROLL...428
STEERING VALVE...429
Overload Relief Valve...431
Function...431
Operation...431
Steering Relief Valve...432
Function...432
Steering Relief Valve Operation...433
Demand Valve Operation...434
Flow amp...437
Steering Valve Operation...440
Neutral...440
Turning Right...441
Turning Left...442
ORBIT-ROLL VALVE...443
Outline...444
Structure...444
Connection Between the Hand Pump and Sleeve...445
Function of Center Spring...446
STOP VALVE...447
STEERING PUMP, SWITCH PUMP...449
Outline...450
EMERGENCY STEERING PUMP...451
Function...452
EMERGENCY STEERING MOTOR...453
Function...453
STEERING CYLINDER...455
JOYSTICK STEERING...457
Joystick PPC Valve...458
Function...458
Steering Switch Valve...460
Operation...460
BRAKE PIPING...461
BRAKE VALVE...463
Brake Valve - Left...463
Brake Valve - Right...465
Outline...466
Operation...467
CHARGE VALVE...471
Function...472
Operation...473
PPC RELIEF VALVE...475
Outline...475
Operation...475
ACCUMULATOR - BRAKE...477
Function...477
Specifications...477
Function...478
Specifications...478
BRAKE...479
Front...479
Outline...480
Rear...481
Outline...482
Operation...483
PARKING BRAKE CONTROL...484
Outline...484
PARKING BRAKE...485
OUTLINE...485
Parking Brake Solenoid Valve...487
Operation...488
Parking Brake Emergency Release Valve...488
Outline...488
HYDRAULIC PIPING...489
Outline...491
WORK EQUIPMENT CONTROL LEVER...493
For PPC Valve...493
For EPC Valve (If Equipped)...494
HYDRAULIC TANK...495
Breather...496
TORQUE CONVERTER CHARGING, WORK EQUIPMENT, AND PILOT CONTROL PUMPS...497
PPC RELIEF VALVE...499
Outline...499
Operation...499
E.C.S.S. VALVE (If Equipped)...501
WORK EQUIPMENT CONTROL VALVE...504
2-Spool Valve...504
3-Spool Valve...508
Relief Valve...511
Function...511
Operation...511
Safety-suction Valve...512
Function...512
Operation...512
Suction Valve...513
Function...513
Operation...513
Cut-off Valve...514
Function...514
Operation...514
Work Equipment Control Valve Operation...516
NEUTRAL Position of Lift Arm and Bucket Spools...516
RAISE Position for Lift Arm Spool...517
LOWER Position of Lift Arm Spool...518
FLOAT Position of Lift Arm Spool...519
DUMP Position for Bucket Spool...520
TILT Position for Bucket Spool...521
WORK EQUIPMENT PPC VALVE...523
Operation...525
PPC VALVE (FOR MULTI FUNCTION MONO LEVER)...529
Operation...531
EPC SOLENOID VALVE (If equipped)...534
Function...535
Operation...535
SHUT OFF VALVE (If equipped)...537
Function...537
ATTACHMENT PPC VALVE (If equipped)...539
Operation...541
COOLING FAN MOTOR...543
Model: LMF28...543
Hydraulic Motor...545
Suction Valve...546
Operation of Revolution Direction Changeover Valve...547
COOLING FAN MOTOR DRIVE PUMP...549
Model: LPV...549
Servo Valve...555
Safety Valve...557
WORK EQUIPMENT LINKAGE...559
BUCKET...561
BUCKET POSITIONER, BOOM KICK-OUT...562
Bucket Positioner...563
Boom Kick-out...563
Proximity Switch Operation...564
When Lift Arm Is Raised...564
When Bucket Is Tilted...566
WORK EQUIPMENT CYLINDER...569
Lift Arm Cylinder...569
Bucket Cylinder...569
CAB...571
AIR CONDITIONER...572
Air Conditioner Piping...572
MACHINE MONITORING SYSTEM...573
Outline...573
Individual Circuit Diagrams of the Machine Monitor...575
Starting and Lighting Functions...575
Load Meter...575
Sensing Functions...576
Power Supply and Network...577
Automatic Preheating Function...578
MACHINE MONITOR...581
Speedometer Specifications...581
Load Meter Specification (If Equipped)...582
Table of Monitor Indication Items...583
Setting the Machine Monitor...590
Service Mode Functions...593
Items Related To The Fault History Of Electric System...597
Items Related to the Fault History Of Machine System...599
Items Related to Maintenance Monitor...601
Real-Time Monitoring Function...603
Real-Time Monitoring Items...605
Load Meter Function (If equipped)...615
Machine Setting...625
Setting Necessary For Option Mounting...626
Optional Device Setting For Machine Monitor...627
Adjustment for Each EPC...635
TRANSMISSION CONTROL SYSTEM...653
System Diagram...653
Control Function...654
Electric Circuit Diagram (Standard)...677
Electric Circuit Diagram (If Equipped)...679
TRANSMISSION CONTROLLER...681
WORK EQUIPMENT CONTROL SYSTEM...683
System Diagram...683
Electric Circuit Diagram...697
WORK EQUIPMENT CONTROLLER...699
ELECTRIC TRANSMISSION CONTROL...701
Functions...702
Combination Switch...703
Overview...703
Functions...703
Operation...704
KICK DOWN, HOLD SWITCH...705
Functions...705
ENGINE STARTING CIRCUIT...706
Function...706
Operation...707
ENGINE STOP CIRCUIT...708
OPERATION...708
PREHEATING CIRCUIT...709
Outline...709
Operation...709
ENGINE POWER MODE SELECTOR CIRCUIT...710
Function...710
Operation...710
PARKING BRAKE CIRCUIT...711
Operation...711
SENSORS...715
Engine Speed Sensor...715
Engine Oil Pressure Sensor...716
Engine Oil Level Sensor...716
Temperature Sensor...717
Coolant Temperature - For Monitor...717
Torque Converter Oil Temperature...717
Hydraulic Oil Temperature...717
Transmission Oil Temperature...717
Brake Oil Temperature...717
Coolant Temperature - Preheating...717
Transmission Cut-off Pressure Sensor...718
Coolant Level Sensor...719
Fuel Level Sensor...720
Lift Arm Angle Sensor (If Equipped)...721
Air Cleaner Clogging Sensor...722
Load Meter Pressure Sensor (If Equipped)...722
Battery Electrolyte Level Sensor(If Equipped)...723
Relay...724
20 STANDARD VALUE TABLES...726
STANDARD SERVICE VALUE TABLE...727
Standard Service Value Table For Engine...727
Standard Value Table For Chassis...728
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...739
Special Tool Drawing...741
30 TESTING AND ADJUSTING...736
ENGINE COMPONENTS...742
Determining a Defective Cylinder...742
Procedures...742
Determining Cylinder Group...742
Isolating the Defective Cylinder...742
Measuring Engine Speed...743
Measuring Exhaust Temperature...745
Measuring Exhaust Smoke...747
Adjusting Valve Clearance...748
Measuring Compression Pressure...750
Measuring Blow-by Pressure...752
Measuring Engine Oil Pressure...753
Measuring Intake Air Pressure (Boost Pressure)...754
Testing And Adjusting Fuel Injection Timing...755
Adjusting Engine Speed Sensor...756
Bleeding Air From Fuel Circuit...757
Adjusting Engine Stop Solenoid...758
ADJUSTING ACCELERATOR PEDAL...759
Adjusting the Power Mode...759
Adjusting the Normal Mode...760
ADJUSTING TRANSMISSION SPEED SENSOR...761
POWER TRAIN OIL PRESSURE...762
FLUSHING TORQUE CONVERTER, TRANSMISSION AND HYDRAULIC CIRCUIT...766
TRANSMISSION VALVE FAILS...767
MOVING MACHINE...767
STEERING CONTROL...769
STEERING OIL PRESSURE...770
TESTING HYDRAULIC FAN...772
BRAKE SYSTEM...773
Measuring Brake Oil Pressure...773
Testing Wear of Wheel Brake Disc...775
Bleeding Air from Brake Circuit...776
Testing Wear of Parking Brake Disc...777
Manual Release Method for Parking Brake...778
ACCUMULATOR CHARGE PRESSURE...779
PPC OIL PRESSURE...781
WORK EQUIPMENT HYDRAULIC PRESSURE...784
BUCKET POSITIONER...786
BOOM KICK-OUT...787
PROXIMITY SWITCH ACTUATION...788
ADJUSTING MACHINE MONITOR...789
LOAD METER...792
BLEEDING AIR...796
Fan Motor Circuit...796
Work Equipment PPC Circuit...796
Cylinders...796
RELEASING REMAINING PRESSURE...797
In Hydraulic Circuit...797
E.C.S.S. Damper Circuit...798
PM-CLINIC INSPECTION TABLE...799
40 TROUBLESHOOTING...802
POINTS TO REMEMBER WHEN TROUBLESHOOTING...816
SEQUENCE OF EVENTS IN TROUBLESHOOTING...818
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...819
Precautions When Handling Electrical Equipment...819
Handling Electronic Control Unit...823
When Troubleshooting Electrical Circuits...825
ELECTRIC WIRE CODE...826
Classification by Thickness...826
Classification by Color and Code...826
How to Read Electric Wire Code...827
Points to Remember When Handling Hydraulic Equipment...829
CHECKS BEFORE TROUBLESHOOTING...831
2. Check for impurities in fuel...831
3. Check hydraulic oil level...831
4. Check hydraulic strainer...831
5. Check swing machinery oil level...831
6. Check engine oil level...831
7. Check coolant level...831
8. Check dust indicator for clogging...831
9. Check hydraulic filter...831
10. Check final drive oil level...831
11. Check for looseness, corrosion of battery terminal, wiring...831
12. Check for looseness, corrosion of alternator terminal, wiring...831
13. Check for looseness, corrosion of starting motor terminal, wiring...831
14. Check operation of instruments...831
15. Check for abnormal noise, smell...831
16. Check for oil leakage...831
17. Carry out air bleeding...831
18. Check battery voltage (Engine stopped)...831
19. Check battery electrolyte level...831
20. Check for discolored, burnt, exposed wiring...831
21. Check for missing wiring clamps, hanging wire...831
22. Check for water leaking on wiring (Pay particular attention to water leaking on connectors or terminals)...831
23. Check for blown, corroded fuses...831
24. Check alternator voltage (Engine running at 1/2 throttle or above)...831
25. Sound of actuation of battery relay (When starting switch is turned ON, OFF)...831
SPECIAL FUNCTIONS OF MACHINE MONITOR...832
Flow of Modes and Functions...833
Failure Code Table...841
Monitoring Code Table...854
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...866
T-ADAPTER TABLE...889
CONNECTOR TYPES AND LOCATIONS...892
CONNECTOR LAYOUT DRAWING...899
TRANSMISSION CONTROL SYSTEM DIAGRAM...905
TRANSMISSION CONTROL SYSTEM (TM MODE)...908
Failure Code [1500L1]...908
Double Engagement Detected...908
Failure Code [15SAL1]...909
Short Circuit in F_ECM Fill Switch System...909
Failure Code [15SALH]...911
F_ECM Fill Switch System Disconnected...911
Failure Code [15SBL1]...913
Short Circuit in R_ECM Fill Switch System...913
Failure Code [15SBLH]...915
R_ECM Fill Switch System Disconnected...915
Failure Code [15SEL1]...917
Short Circuit in 1st_ECM Fill Switch System...917
Failure Code [15SELH]...919
1st_ECM Fill Switch System Disconnected...919
Failure Code [15SFL1]...921
Short Circuit in 2nd_ECM Fill Switch System...921
Failure Code [15SFLH]...923
2nd_ECM Fill Switch System Disconnected...923
Failure Code [15SGL1]...925
Short Circuit in 3rd_ECM Fill Switch System...925
Failure Code [15SGLH]...927
3rd_ECM Fill Switch System Disconnected...927
Failure Code [15SHL1]...929
Short Circuit in 4th_ECM Fill Switch System...929
Failure Code [15SHLH]...931
4th_ECM Fill Switch System Disconnected...931
Failure Code [15SJL1]...933
Short Circuit in Lock-up_ECM Fill Switch System...933
Failure Code [15SJLH]...934
Lock-up_ECM Fill Switch System Disconnected...934
Failure Code [989F00]...935
Transmission Protection Caution...935
Failure Code [B@C7NS]...936
Rear Brake Cooling Oil Overheat...936
Failure Code [D150KA]...937
Emergency Steering Relay Output System Disconnected...937
Failure Code [D150KB]...938
Short Circuit in Emergency Steering Relay Output System...938
Failure Code [D160KA]...939
Back-up Alarm Relay Output System Disconnected...939
Failure Code [D160KB]...940
Short Circuit in Back-up Alarm Relay Output System...940
Failure Code [D191KA]...941
Neutral Safety Relay Output System Disconnected...941
Failure Code [D191KB]...943
Short Circuit in Neutral Safety Relay Output System...943
Failure Code [D192KA]...945
E.C.S.S. Relay Output System Disconnected...945
Failure Code [D192KB]...946
Short Circuit in E.C.S.S. Relay Output System...946
Failure Code [D198KB]...947
Ground Fault in the Low Temperature By-pass Relay System...947
Failure Code [D198KY]...949
Hot-short in the Low-temperature By-pass Relay System...949
Failure Code [DAQ0KK]...951
Controller Power Supply Voltage Lowered...951
Failure Code [DAQ2KK]...953
Defective Solenoid Power Supply System...953
Failure Code [DAQ9KQ]...955
Model Selection Signal Mismatch...955
Failure Code [DDK3KA]...957
No Right FNR Switch Signal Input...957
Failure Code [DDK3KB]...959
Multiple Right FNR Switch Signal Input...959
Failure Code [DDK4KA]...961
No Input Signal to Joystick Forward/Reverse Switch...961
Failure Code [DDK4KB]...963
Multiple Joystick Forward/Reverse Switch Signals are Input...963
Failure Code [DDK5LD]...965
Hot Short in Joystick Shift_Up/Shift_Down Switch...965
Failure Code [DDK6KA]...967
No Input Signal from Forward-Reverse Lever...967
Failure Code [DDK6KB]...969
Multiple Forward-Reverse Lever Signal Input...969
Failure Code [DDS5KA]...971
Steering Pressure Switch Open...971
Failure Code [DDS5KB]...973
Steering Pressure Switch Grounded...973
Failure Code [DDT0L4]...975
Manual/Auto-Shift Selector Switch Selection Failure...975
Failure Code [DDT4LD]...977
Ground Fault in Transmission Cut-off Switch...977
Failure Code [DDW9LD]...979
Short in Kickdown Switch System...979
Failure Code [DDWLLD]...981
Ground Fault in Hold Switch System...981
Failure Code [DF10KA]...983
No Input Signal in Gear Shift Lever...983
Failure Code [DF10KB]...985
Multiple Gear Shift Lever Signals...985
Failure Code [DGF1KX]...987
Transmission Oil Temperature Sensor System Failure...987
Failure Code [DGR2KA]...989
Rear Brake Oil Temperature Sensor System Open...989
Failure Code [DGR2KB]...991
Ground Fault In Rear Brake Oil Temperature Sensor System...991
Failure Code [DHT1KX]...993
Transmission Cut-off (Left Brake Pressure Sensor) Signal Open...993
Failure Code [DLE2KA]...995
Engine Speed Sensor Open...995
Failure Code [DLE2LC]...996
Engine Speed Sensor Shorted...996
Failure Code [DLT3KA]...997
Speed Sensor System Open...997
Failure Code [DT20KB]...998
Ground Fault In Indicator Lamp System (Transmission Cut-off Switch)...998
Failure Code [DW7BKA]...999
Fan Pump Reverse Solenoid System Open...999
Failure Code [DW7BKB]...1000
Fan Reverse Solenoid System Shorted...1000
Failure Code [DW7CKA]...1001
Switch Pump Cut-off Relay Open...1001
Failure Code [DW7CKB]...1002
Switch Pump Cut-off Relay Ground Fault...1002
Failure Code [DX16KA]...1003
Fan Pump EPC Solenoid System Open...1003
Failure Code [DX16KB]...1004
Fan Pump EPC Solenoid System Ground Fault...1004
Failure Code [DXH1KA]...1005
Lock-up Clutch_ECMV Solenoid System Open...1005
Failure Code [DXH1KB]...1006
Lock-up Clutch ECMV Solenoid System Shorted...1006
Failure Code [DXH4KA]...1007
1st_ECMV Solenoid System Open...1007
Failure Code [DXH4KB]...1008
1st_ECMV Solenoid System Shorted...1008
Failure Code [DXH5KA]...1009
2nd_ECMV Solenoid System Open...1009
Failure Code [DXH5KB]...1010
2nd_ECMV Solenoid System Shorted...1010
Failure Code [DXH6KA]...1011
3rd_ECMV Solenoid System Open...1011
Failure Code [DXH6KB]...1012
3rd_ECMV Solenoid System Shorted...1012
Failure Code [DXH7KA]...1013
R_ECMV Solenoid System Open...1013
Failure Code [DXH7KB]...1014
R_ECMV Solenoid System Shorted...1014
Failure Code [DXH8KA]...1015
F_ECMV Solenoid System Open...1015
Failure Code [DXH8KB]...1016
F_ECMV Solenoid System Ground Fault...1016
Failure Code [DXHHKA]...1017
4th_ECMV Solenoid System Open...1017
Failure Code [DXHHKB]...1018
4th_ECMV Solenoid System Shorted...1018
Failure Code [DY30MA]...1019
Motor-Driven Emergency Steering Pump Failure...1019
Failure Code [DY30MC]...1021
Motor-Driven Emergency Steering Pump Failure...1021
Failure Code [TM-1]...1023
Open or Short in Kickdown Switch System...1023
Failure Code [TM-2]...1025
Hold Switch System Open Or Short...1025
Failure Code [TM-3]...1027
Torque Converter Lock-up Switch System Failure...1027
Failure Code [TM-4]...1029
Neutral Signal System Failure...1029
Failure Code [TM-5]...1031
Emergency Steering Switch Signal System Failure...1031
Failure Code [TM-6]...1033
Transmission Cut-off Switch System Open or Shorted...1033
Failure Code [TM-7]...1035
Transmission Cut-off Setting Switch System Open or Shorted...1035
Failure Code [TM-8]...1037
Transmission Cut-off (Left Brake Sensor) Signal Shorted...1037
Failure Code [TM-9A]...1039
Joystick Shift Up/shift Down Switch System Failure...1039
Failure Code [TM-9B]...1041
Joystick Shift Up/shift Down Switch System Failure...1041
Failure Code [TM-10]...1043
FNR Switch Mode Change Over Switch System Failure...1043
Failure Code [TM-11]...1045
Starting Switch "C" (IGN_C) Signal System Failure...1045
Failure Code [TM-12]...1049
Engine Power Mode Switch Open or Shorted...1049
Failure Code [TM-13]...1051
Open or Short in Travel Damper ON/OFF Switch...1051
Failure Code [TM-14]...1053
Open or Short in Hydraulic Fan Reverse Signal System...1053
Failure Code [TM-15]...1055
Short in Motor Driven Emergency Steering Relay System...1055
Failure Code [TM-16]...1056
Short in Travel Damper Relay System...1056
Failure Code [TM-17]...1057
Switch Pump Cut-off Relay System Shorted...1057
Failure Code [TM-18]...1058
Back Lamp Relay System Shorted...1058
Failure Code [TM-19]...1059
Neutral System Shorted...1059
Failure Code [TM-20]...1060
F_ECMV Solenoid System Shorted...1060
Failure Code [TM-21]...1061
R_ECMV Solenoid System Shorted...1061
Failure Code [TM-22]...1062
1st_ECMV Solenoid System Shorted...1062
Failure Code [TM-23]...1063
2nd_ECMV Solenoid System Shorted...1063
Failure Code [TM-24]...1064
3rd_ECMV Solenoid System Shorted...1064
Failure Code [TM-25]...1065
4th_ECMV Solenoid System Shorted...1065
Failure Code [TM-26]...1066
Lock-Up ECMV Solenoid System Shorted...1066
Failure Code [TM-27]...1067
Fan Pump EPC Solenoid System Shorted...1067
Failure Code [TM-28]...1068
Fan Reverse Solenoid System Shorted...1068
Failure Code [TM-29]...1069
Speed Sensor System Failure...1069
Failure Code [TM-30]...1071
E.C.S.S. Solenoid System...1071
WORK EQUIPMENT CONTROL SYSTEM (WRK MODE)...1073
Connector Types And Locations...1073
Connector Layout Drawing...1081
Work Equipment Control System Diagram...1087
Failure Code [D193KA]...1091
Defective Joystick Steering Relay System...1091
Failure Code [D193KB]...1093
The Joystick Solenoid Relay Output System Shorted...1093
Failure Code [DB90KK]...1095
Lowering Work Equipment Controller Power Supply Fault...1095
Failure Code [DB92KK]...1097
Defective Solenoid Power Supply...1097
Failure Code [DB95KX]...1099
Open in 5 V Power Supply...1099
Failure Code [DD1ALD]...1101
Defective Remote Positioner UP Set Switch...1101
Failure Code [DD1BLD]...1103
Defective Remote Positioner DOWN Set Switch...1103
Failure Code [DFAOKM]...1105
Defective Neutral Caution for Joystick Work Equipment...1105
Failure Code [DK59KA]...1107
Defective Lift Arm EPC Lever Potentiometer System (Main Circuit Discontinuity or Ground Fault)...1107
Failure Code [DK59KY]...1109
Defective Lift Arm EPC Lever Potentiometer System (Main Short Circuit)...1109
Failure Code [DK59L8]...1111
Defective Lift Arm EPC Potentiometer System (Displacement of Main and Sub Circuit)...1111
Failure Code [DK5AKA]...1113
Defective Lift Arm EPC Lever Potentiometer System (Disconnection of Main)...1113
Failure Code [DK5AKY]...1115
Defective Lift Arm EPC Lever Potentiometer System (Short Sub Circuit)...1115
Failure Code [DK5BKA]...1116
Defective Bucket EPC Lever Potentiometer System (Disconnection of Main)...1116
Failure Code [DK5BKY]...1117
Defective Bucket EPC Lever Potentiometer System (Main Short Circuit)...1117
Failure Code [DK5BL8]...1119
Defective Bucket EPC Potentiometer System (Displacement of Main and Sub Circuit)...1119
Failure Code [DK5CKA]...1121
Defective Bucket EPC Lever Potentiometer System (Disconnection of Main)...1121
Failure Code [DK5CKY]...1122
Defective Bucket EPC Lever Potentiometer System (Short Sub Circuit)...1122
Failure Code [DK5DKA]...1123
Defective 3rd Valve Lever Potentiometer System (Main Circuit Discontinuity or Ground Fault)...1123
Failure Code [DK5DKY]...1125
Defective Lift Arm EPC Lever Potentiometer System (Main Circuit Short Circuit)...1125
Failure Code [DK5DL8]...1127
Defective 3rd Valve EPC Potentiometer System (Displacement of Main and Sub Circuit)...1127
Failure Code [DK5EKA]...1129
Defective 3rd Valve Lever EPC Potentiometer System (Sub Circuit Discontinuity or Ground Fault)...1129
Failure Code [DK5EKY]...1130
Defective Lift Arm EPC Lever Potentiometer System (Short Sub Circuit)...1130
Failure Code [DK5FKA]...1131
Defective Joystick Steering EPC System (Main Circuit Open or Shorted)...1131
Failure Code [DK5FKY]...1132
Defective Joystick Steering EPC Potentiometer System (Main Circuit Shorted)...1132
Failure Code [DK5FKM]...1133
Joystick Steering EPC Lever Neutral System Caution...1133
Failure Code [DK5FL8]...1135
Defective Joystick Steering EPC Lever Potentiometer Input Signal...1135
Failure Code [DK5GKA]...1137
Defective Joystick Steering EPC Potentiometer System (Open or Short in Sub Circuit)...1137
Failure Code [DK5GKY]...1138
Defective Joystick Steering EPC Potentiometer System (Sub Circuit Short)...1138
Failure Code [DKAOKA]...1139
Defective Lift Arm Angle Sensor System (Open or Short)...1139
Failure Code [DKAOKY]...1141
Defective Lift Arm Angle Sensor (System Shorted)...1141
Failure Code [DLE2LC]...1143
Defective Engine Speed Sensor System...1143
Failure Code [DLT3LC]...1144
Defective Transmission Output AXIS Speed Sensor System (Open)...1144
Failure Code: [DUM1KB]...1145
Remote Positioner RAISE Lamp System Ground Fault...1145
Failure Code: [DUM2KB]...1146
Remote Positioner LOWER Lamp System Ground Fault...1146
Failure Code: [DW4PKA]...1147
Disconnected Lift Arm RAISE EPC Solenoid System...1147
Failure Code: [DW4PKB]...1148
Lift Arm RAISE EPC Solenoid System Ground Fault...1148
Failure Code: [DW4QKA]...1149
Disconnected Lift Arm LOWER EPC Solenoid System...1149
Failure Code: [DW4QKB]...1150
Lift Arm LOWER EPC Solenoid System Ground Fault...1150
Failure Code: [DW4RKA]...1151
Disconnected Bucket TILT EPC Solenoid System...1151
Failure Code: [DW4RKB]...1152
Bucket TILT EPC Solenoid System Ground Fault...1152
Failure Code: [DW4SKA]...1153
Disconnected Bucket DUMP EPC Solenoid System...1153
Failure Code: [DW4SKB]...1154
Bucket DUMP EPC Solenoid System Ground Fault...1154
Failure Code: [DWM1KA]...1155
Work Equipment Neutral Lock Solenoid System Disconnection...1155
Failure Code: [DWM1KB]...1156
Work Equipment Neutral Lock Solenoid System Ground Fault...1156
Failure Code: [DWN6KA]...1157
Lift Arm RAISE Magnet Detent System Disconnection...1157
Failure Code: [DWN6KB]...1159
Lift Arm RAISE Magnet Detent System Ground Fault...1159
Failure Code: [DWN7KA]...1161
Lift Arm FLOATING Magnet Detent System Disconnection...1161
Failure Code: [DWN7KB]...1163
Lift Arm FLOATING Magnet Detent System Ground Fault...1163
Failure Code: [DWN8KA]...1165
Lift Arm TILT Magnet Detent System Disconnection...1165
Failure Code: [DWN8KB]...1166
Lift Arm TILT Magnet Detent System Ground Fault...1166
Failure Code: [DXHJKA]...1167
3rd Valve Extension EPC Solenoid System Disconnection...1167
Failure Code: [DXHJKB]...1168
3rd Valve Extension EPC Solenoid System Ground Fault...1168
Failure Code: [DXHKKA]...1169
3rd Valve Retraction EPC Solenoid System Disconnection...1169
Failure Code: [DXHKKB]...1170
3rd Valve Retraction EPC Solenoid System Ground Fault...1170
Failure Code: [DXHLKA]...1171
Open in Joystick Steering Right-Hand EPC Solenoid System...1171
Failure Code: [DXHLKB]...1173
Joystick Steering Right-Hand EPC Solenoid System Ground Fault...1173
Failure Code: [DXHMKA]...1175
Joystick Steering Left-Hand EPC Solenoid System Open...1175
Failure Code: [DXHMKB]...1177
Joystick Steering Left-Hand EPC Solenoid System Ground Fault...1177
Failure Code: [WRK-1]...1179
Defective Lift Arm Lock Switch System...1179
Failure Code: [WRK-2]...1181
Defective Remote Positioner RAISE Setting Switch System...1181
Failure Code: [WRK-3]...1183
Defective Remote Positioner LOWER Setting Switch System...1183
Failure Code: [WRK-4]...1185
Defective Remote Positioner RAISE Selection Switch System...1185
Failure Code: [WRK-5]...1187
Defective Remote Positioner LOWER ON/OFF Switch System...1187
Failure Code: [WRK-6]...1189
Defective Bucket Cylinder Proximity Switch System...1189
Failure Code: [WRK-7]...1191
Defective Bucket Cylinder Full Stroke Detection Switch System...1191
Failure Code: [WRK-8]...1193
Defective Semi-Automatic Digging HARD Selection Switch System...1193
Failure Code: [WRK-9]...1195
Defective Semi-Automatic Digging SOFT Selection Switch System...1195
Failure Code: [WRK-10]...1197
Defective Joystick ON/OFF Switch System...1197
Failure Code: [WRK-11]...1199
Defective Joystick Steering Speed HI/LO Switch System...1199
Failure Code: [WRK-12]...1201
Defective Joystick Solenoid Cut Relay Output System...1201
Failure Code: [WRK-13]...1202
Hot Short-Circuited Lift Arm RAISE Magnet Detent Output System...1202
Failure Code: [WRK-14]...1203
Hot Short-Circuited Lift Arm FLOAT Magnet Detent Output System...1203
Failure Code: [WRK-15]...1204
Hot Short-Circuited Bucket TILT Magnet Detent Output System...1204
Failure Code: [WRK-16]...1205
Hot Short-Circuited Work Equipment Neutral Lock Solenoid Output System...1205
Failure Code: [WRK-17]...1206
Hot Short-Circuited Lift Arm RAISE EPC Solenoid System...1206
Failure Code: [WRK-18]...1207
Hot Short- Circuited Lift Arm LOWER EPC Solenoid System...1207
Failure Code: [WRK-19]...1208
Hot Short- Circuited Bucket TILT EPC Solenoid System...1208
Failure Code: [WRK-20]...1209
Hot Short- Circuited Bucket DUMP EPC Solenoid System...1209
Failure Code: [WRK-21]...1210
Hot Short- Circuited 3 Valves Extension EPC Solenoid System...1210
Failure Code: [WRK-22]...1211
Hot Short- Circuited 3 Valves Retraction EPC Solenoid System...1211
Failure Code: [WRK-23]...1212
Short in Joystick Steering Right EPC Solenoid System...1212
Failure Code: [WRK-24]...1213
Short in Joystick Steering Left EPC Solenoid System...1213
Failure Code: [WRK-25]...1215
Failure Code: [WRK-26]...1217
Defective Boom Kick-Out Function and Cancellation...1217
Failure Code: [WRK-27]...1220
Defective Bucket Leveler Function and Cancellation...1220
Failure Code: [WRK-28]...1223
Defective Lift Arm FLOAT Holding and Cancellation...1223
MONITOR SYSTEM (MON MODE)...1225
Connector Types and Locations...1225
Connector Layout Drawing...1232
Monitor System Diagram...1238
Failure Code [2F00KM]...1242
Dragging Parking Brake...1242
Failure Code [2G42ZG]...1245
Accumulator Oil Pressure (Front Brake Circuit) Low...1245
Failure Code [2G43ZG]...1247
Accumulator Oil Pressure (Rear Brake Circuit) Low...1247
Failure Code [AA1ANX]...1249
Air Cleaner 1 Clogged...1249
Failure Code [AB00L6]...1251
Defective Battery Charging Circuit...1251
Failure Code [AB00MA]...1253
The Battery Charging Circuit is Out of Order...1253
Failure Code [B@BAZG]...1255
Engine Oil Pressure Low...1255
Failure Code [B@BAZK]...1256
Engine Oil Level Low...1256
Failure Code [B@BCNS]...1257
Engine Coolant Temperature Overheating...1257
Failure Code [B@BCZK]...1259
Alarm Indicating Low Coolant Level...1259
Failure Code [B@HANS]...1260
Hydraulic Oil Temperature Overheating...1260
Failure Code [B@CENS]...1261
Torque Converter Oil Temperature Overheating...1261
Failure Code [D182KZ]...1263
The Preheater Relay Coil is Open or Shorted...1263
Failure Code [D5ZHL6]...1265
Start Switch C (IGN "C") Input Failure...1265
Failure Code [DA80L4]...1267
Auto Grease Input is Abnormal...1267
Failure Code [DAF3KK]...1269
When the SW Power Supply (for Operation) is ON, the NSW Power Supply (for Memory) is OFF...1269
Failure Code [DAF5KP]...1271
5-V Power Supply Output Failure...1271
Failure Code [DAF6KP]...1273
24-V Power Supply Output Failure...1273
Failure Code [DAFBKM]...1275
Incorrect Information on Model Selection...1275
Failure Code [DAFSKQ]...1276
Incorrect Information on Meter Indication Selection...1276
Failure Code [DAQSKR]...1277
S-NET Communication Failure (Between Monitor Panel and Transmission Controller)...1277
Failure Code [DBQSKR]...1279
S-NET Communication Failure (Between Monitor Panel and Work Equipment Controller)...1279
Failure Code [DB9SKR]...1281
S-NET Communication Failure (Between Monitor Panel and Work Equipment Controller)...1281
Failure Code [DD15LD]...1283
Monitor Panel Mode Selector Switch 1 [n] (Panel SW1) Input Error...1283
Failure Code [DD16LD]...1285
Monitor Panel Mode Selector Switch 1 [‡] (Panel SW2) Input Error...1285
Failure Code [DD17LD]...1287
Monitor Panel Mode Selector Switch 2 [<] (Panel SW3) Input Error...1287
Failure Code [DD18LD]...1289
Monitor Panel Mode Selector Switch 2 [>] (Panel SW4) Input Error...1289
Failure Code [DD1CLD]...1291
Sub-Total Switch Failure...1291
Failure Code [DDK3KM]...1293
CAUTION: Right FNR Switch is in "N" (Neutral)...1293
Failure Code [DDK4KM]...1294
CAUTION: Joystick FNR Switch is in "N" (Neutral)...1294
Failure Code [DDK6KM]...1295
CAUTION: FNR (Forward- Reverse) Lever Switch is in "N" (Neutral)...1295
Failure Code [DDS5L6]...1297
Decreased Steering Oil Pressure...1297
Failure Code [DDY0LD]...1299
Cancel Switch Failure...1299
Failure Code [DGE2KX]...1301
Engine Coolant Temperature (High Temperature) Sensor System Failure...1301
Failure Code [DGE3L6]...1303
Abnormal Connection of Engine Coolant Temperature (Low Temperature) Sensor System...1303
Failure Code [DGH2KX]...1305
Hydraulic Oil Temperature Sensor System Failure...1305
Failure Code [DGT1KX]...1306
Torque Converter Oil Temperature Sensor System Failure...1306
Failure Code [DHE4L6]...1307
Engine Oil Pressure Sensor System Failure...1307
Failure Code [DHPCKX]...1309
Bottom Pressure Sensor Failure...1309
Failure Code [DHPDKX]...1311
Head Pressure Sensor Failure...1311
Failure Code [DKA0KX]...1313
Lift Arm Angle Sensor Failure...1313
Failure Code [DV00KB]...1315
Shorted Alarm Buzzer Output System...1315
Failure Code [DY30ME]...1317
The Emergency Steering Remains Actuated For More Than One Minute...1317
Troubleshooting Code [MON-1]...1321
The Parking Brake Indicator Lamp Does Not Light Up When the Parking Brake Switch is Turned ON...1321
Troubleshooting Code [MON-2]...1323
Circuit Diagnostic Procedures for Error Code...1323
Troubleshooting Code [MON-3]...1325
The Brake Oil Pressure Caution Lamp Does Not Light Up When the Emergency Brake is Applied (Rear Circuit)...1325
Troubleshooting Code [MON-4]...1327
The Air Cleaner Clogging Indicator Lamp Does Not Light...1327
Troubleshooting Code [MON-5]...1329
The Engine Oil Pressure Caution Lamp Does Not Light...1329
Troubleshooting Code [MON-6]...1330
The Engine Oil Level Caution Lamp Does Not Light...1330
Troubleshooting Code [MON-7]...1331
The Engine Coolant Temperature Caution Lamp Does Not Light...1331
Troubleshooting Code [MON-8]...1332
The Coolant Level Caution Lamp Does Not Light...1332
Troubleshooting Code [MON-9]...1333
The Hydraulic Oil Temperature Caution Lamp Does Not Light...1333
Troubleshooting Code [MON-10]...1334
The Torque Converter Oil Temperature Caution Lamp Does Not Light...1334
Troubleshooting Code [MON-11]...1335
The Steering Hydraulic Caution Lamp Does Not Light...1335
Troubleshooting Code [MON-12]...1337
Input Fault in Monitor Panel Mode Switch 1 [n] (Panel SW1)...1337
Troubleshooting Code [MON-13]...1339
Input Fault in Monitor Panel Mode Switch 1 [‡] (Panel SW2)...1339
Troubleshooting Code [MON-14]...1341
Input Fault in Monitor Panel Mode Switch 2 [<] (Panel SW3)...1341
Troubleshooting Code [MON-15]...1343
Input Fault in Monitor Panel Mode Switch 2 [>] (Panel SW4)...1343
Troubleshooting Code [MON-16]...1345
Defective Subtotal Switch...1345
Troubleshooting Code [MON-17]...1347
Defective Cancel Switch...1347
Troubleshooting Code [MON-18]...1349
Defective Bottom Pressure Sensor (Short Fault)...1349
Troubleshooting Code [MON-19]...1351
Defective Head Sensor...1351
Troubleshooting Code [MON-20]...1353
The Alarm Buzzer Does Not Sound or Stop...1353
HYDRAULIC AND MECHINCAL SYSTEMS (H MODE)...1355
H-1 - The Machine Does Not Move...1355
H-2 - The Lock-up Clutch is Not Released (The Engine Stops) (When the Lock-up Clutch is Provided)...1357
H-3A - The Travel Speed is Slow, Thrusting Force is Weak, Uphill Traveling Power is Weak, and the Gear is Not Shifted...1358
H-3B - The Torque Converter Lock-up Clutch is Not Let in (When Lock-up Clutch is Provided)...1360
H-4 - Shocks are Large at the Times of Starting and Shifting Gear...1361
H-5 - Time Lag is Large at the Times of Starting and Shifting Gear...1363
H-6 - Torque Converter Oil Temperature is High...1365
H-7 - Steering Wheel Does Not Turn...1366
H-8 - Steering Does Not Turn [Machine With Joystick]...1367
H-9 - Turning, Response of Steering is Poor...1368
H-10 - Steering is Heavy...1369
H-11 - Steering Wheel Shakes or Jerks...1370
H-12 - The Brake Does Not Work...1371
H-13 - The Brake is Not Released or is Draging...1372
H-14 - The Parking Brake is Not Released or Draging...1373
H-15 - The Boom Does Not Rise...1374
H-16 - The Boom Moves Slowly or the Boom Rising Force is Insufficient...1375
H-17 - When Rising, the Boom Comes to Move Slowly at Specific Height...1376
H-18 - The Boom Cylinder Cannot Hold Down the Bucket (the Bucket Rises in the Air)...1376
H-19 - Hydraulic Drifts of the Boom Occur Often...1376
H-20 - The Boom Wobbles During Operation...1377
H-21 - When the Control Lever is Switched From “Hold” to “Raise,” the Boom Falls Temporarily...1377
H-22 - The Bucket Does Not Tilt Back...1378
H-23 - The Bucket Moves Slowly or the Tilting Back Force is Insufficient...1379
H-24 - The Bucket Comes to Operate Slowly in the Midst of Tilting-back...1380
H-25 - The Bucket Cylinder Cannot Hold Down the Bucket...1380
H-26 - Hydraulic Drifts of the Bucket Occur Often...1380
H-27 - The Bucket Wobbles During Travel with Cargo (The Work Equipment Valve is Set to “Hold”)...1381
H-28 - When the Control Lever is Switched From “Hold” to “Tilt,” The Bucket Falls Temporarily...1381
H-29 - The Control Levers of Boom and Bucket Do Not Move Smoothly and Heavy...1382
H-30 - E.C.S.S. Does Not Work and There is Pitching and Bouncing...1383
ELECTRICAL SYSTEM (E MODE)...1384
Connector Types and Locations...1384
Connector Layout Drawing...1391
Electrical System Diagram...1397
Action Code: [E-1-a]...1398
The Engine Does Not Crank (Ignition System)...1398
Action Code: [E-1-b]...1403
The Engine Does Not Start. (Engine Stop Solenoid System)...1403
Action Code: [E-2]...1407
The Engine Does Not Shut Down...1407
Action Code: [E-3]...1409
Preheating Inoperable or Remains ON...1409
Action Code: [E-4]...1413
The Engine Power Mode Inoperable...1413
Action Code: [E-5]...1417
The Front Wiper Does Not Function...1417
Action Code: [E-6]...1421
The Rear Wiper Does Not Function...1421
Action Code: [E-7]...1425
The Side Wiper Does Not Function (If Equipped)...1425
Action Code: [E-8]...1429
The Window Washer Does Not Function...1429
Action Code: [E-9]...1433
The Headlamp (Lo Beam) Does Not Function...1433
Action Code: [E-10]...1437
The Headlamp (Hi Beam) Does Not Function...1437
Action Code: [E-11]...1441
Clearance Lamps Do Not Function...1441
Action Code: [E-12]...1445
Turn Signal Does Not Function...1445
Action Code: [E-13]...1449
Horn Does Not Sound...1449
Action Code: [E-14]...1451
Air Conditioner Does Not Work or Does Not Shut Down...1451
ENGINE SYSTEM (S-MODE)...1455
Method Of Using Troubleshooting Charts...1455
(S-1) Engine Starting Performance Is Poor...1459
(S-2) Engine Does Not Crank...1460
Engine Cranks But No Exhaust Smoke Comes Out Of Stack...1461
Smoke Comes Out Of Stack But Engine Does Not Start...1462
(S-3) Engine Does Not Run Smoothly...1463
(S-4) Engine Stops During Operations...1464
(S-5) Engine Speed Hunts...1465
(S-6) Engine Lacks Power...1466
(S-7) Exhaust Smoke Is Black...1468
(S-8) Oil Consumption Is Excessive Or Exhaust Smoke Is Blue...1469
(S-9) Oil Becomes Contaminated Quickly...1470
(S-10) Fuel Consumption Is Excessive...1471
(S-11) Oil Found In Coolant, Or Coolant Spurts From Radiator...1472
(S-12) Oil Pressure Caution Lamp Lights Up...1473
(S-13) Oil Level Rises (Coolant Or Fuel Found In Oil)...1474
(S-14) Coolant Temperature Too High (Overheating)...1475
(S-15) Abnormal Noise Is Heard When Engine Is Running...1476
(S-16) Excessive Vibration When Engine Is Running...1477
50 DISASSEMBLY AND ASSEMBLY...1478
HOW TO READ THIS MANUAL...1482
Removal and Installation of Assemblies...1482
Special Tools...1482
Removal...1482
Installation...1482
Disassembly and Assembly of Assemblies...1483
Special Tools...1483
Disassembly...1483
Assembly...1484
SPECIAL TOOLS LIST...1485
Special Tool Illustrations...1488
CONNECTOR REPAIR PROCEDURES...1497
Stripping Insulation...1497
Wire Inspection...1497
Contact Terminal Removal (HD30 Type)...1498
Crimping Contact Terminal (HD30 Type)...1499
Insertion of Contact Terminal (HD30 Type)...1500
Contact Terminal Removal (DT Type)...1501
Crimping Contact Terminal (DT Type)...1502
Insertion of Contact Terminal (DT Type)...1503
BULKHEAD ASSEMBLY...1504
Removal...1504
Installation...1505
ENGINE HOOD ASSEMBLY...1506
Removal...1506
Installation...1507
ENGINE ASSEMBLY...1508
Removal...1508
Installation...1511
ENGINE CYLINDER HEAD ASSEMBLY...1513
Special Tool...1513
Removal...1513
Installation...1518
RADIATOR FAN MOTOR...1521
Removal...1521
Installation...1522
AFTERCOOLER...1523
Removal...1523
Installation...1523
FUEL INJECTION PUMP...1524
Special Tools...1524
Removal...1524
Installation...1527
NOZZLE HOLDER...1529
Removal...1529
Installation...1531
FAN AND FAN MOTOR...1532
Removal...1532
Installation...1533
FUEL TANK...1534
Removal...1534
Installation...1536
PARKING BRAKE DISCS AND PLATES...1537
Special Tools...1537
Removal...1537
Installation...1539
TORQUE CONVERTER AND TRANSMISSION...1541
Removal...1541
Installation...1546
Bleeding the Hydraulic Brake Circuit...1546
TRANSMISSION ASSEMBLY...1547
Special Tools...1547
Disassembly...1547
Assembly...1554
TRANSMISSION CLUTCH PACK...1563
Special Tools...1563
Disassembly...1563
Forward and Reverse Clutch Packs...1563
1st and 4th Clutch Pack...1565
2nd and 3rd Clutch Pack...1569
Assembly...1572
Forward and Reverse Clutch Packs...1572
1st and 4th Clutch Pack...1576
2nd and 3rd Clutch Pack...1580
PARKING BRAKE...1585
Special Tools...1585
Disassembly...1585
Assembly...1588
TORQUE CONVERTER (STANDARD)...1594
Special Tools...1594
Disassembly...1594
Assembly...1597
TORQUE CONVERTER (LOCK-UP)...1600
Special Tools...1600
Disassembly...1600
Assembly...1604
REAR AXLE...1608
Removal...1608
Installation...1610
FRONT AXLE...1612
Removal...1612
Installation...1613
AXLE HOUSING...1614
Special Tools...1614
Disassembly...1614
Assembly...1619
DIFFERENTIAL...1625
Special Tools...1625
Disassembly...1626
Assembly...1634
CENTER HINGE PIN...1649
Special Tools...1649
Removal...1649
Installation...1655
CAB ASSEMBLY...1659
Removal...1659
Installation...1660
CAB AND FLOOR FRAME...1661
Removal...1661
Installation...1664
OPERATOR'S CAB GLASS (SEALED GLASS)...1665
Special Tools...1665
Removal...1665
Installation...1667
HYDRAULIC PUMP ASSEMBLY...1675
Removal...1675
Installation...1675
Steering, Switching, and Fan Pump Assembly...1676
Removal...1676
Installation...1676
STEERING DEMAND VALVE ASSEMBLY...1677
Removal...1677
Installation...1678
Disassembly...1679
Assembly...1683
ORBITROL VALVE...1687
Removal...1687
Installation...1689
Disassembly...1689
Assembly...1692
ECSS VALVE...1697
Removal...1697
Installation...1697
WORK EQUIPMENT VALVE...1698
Removal...1698
Installation...1700
HYDRAULIC CYLINDERS...1701
Steering, Lift, and Bucket...1701
Special Tools...1701
Disassembly...1702
Assembly...1706
HYDRAULIC TANK ASSEMBLY...1713
Removal...1713
Installation...1714
WORK EQUIPMENT...1715
Removal...1715
Installation...1719
COUNTERWEIGHT...1721
Removal...1721
Installation...1721
AIR CONDITIONER ASSEMBLY...1722
Special Tools...1722
Removal...1722
Installation...1725
AIR CONDITIONER COMPRESSOR...1727
Special Tools...1727
Removal...1727
Installation...1728
OPERATOR’S SEAT ASSEMBLY...1729
Disassembly...1729
Assembly...1737
90 OTHERS...1742
POWER TRAIN OIL CIRCUIT DIAGRAM...1743
WITHOUT TORQUE CONVERTER LOCKUP CLUTCH...1743
WITH TORQUE CONVERTER LOCKUP CLUTCH...1744
BRAKE OIL CIRCUIT DIAGRAM...1745
HYDRAULIC CIRCUIT SCHEMATIC...1746
ELECTRICAL SCHEMATIC...1748
STANDARD...1748
FLOOR HARNESS - CAB...1748
FLOOR HARNESS - TRANSMISSION CONTROLLER...1750
FLOOR HARNESS - TRANSMISSION HARNESS...1752
FLOOR HARNESS - REAR HARNESS...1754
FLOOR HARNESS - RELAY UNITS...1756
WITH JOYSTICK STEERING...1758
FLOOR HARNESS - CAB...1758
FLOOR HARNESS - TRANSMISSION CONTROLLER...1760
FLOOR HARNESS - JOYSTICK HARNESS...1762
FLOOR HARNESS - TRANSMISSION HARNESS...1764
FLOOR HARNESS - REAR HARNESS...1766
FLOOR HARNESS - RELAY UNITS...1768
ENGINE HARNESS...1770
REAR HARNESS...1772
FRONT FRAME HARNESS...1774
CAB HARNESS...1776
MONITOR PANEL CONTROLLER...1778
A/C RELAY HARNESS...1780
TRANSMISSION HARNESS...1782
JOYSTICK CONTROLLER HARNESS...1784
KOMTRAX HARNESS...1786
Komatsu Wheel Loader WA380L Repair Service Manuals
