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

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

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

CONTENTS:

00 Index and foreword
- Index
- Composition of shop manual
- Table of contents
- Foreword and general information
- Safety notice
- How to read the shop manual
- Explanation of terms for maintenance standard
- Handling of electric equipment and hydraulic component
- Handling of connectors newly used for engines
- How to read electric wire code
- Precautions when carrying out operation
- Method of disassembling and connecting push-pull type coupler
- Standard tightening torque table
- Conversion table
01 Specification
- Specification and technical data
- Specification dimension drawing
- Specifications
- Weight table
- Table of fuel, coolant and lubricants
10 Structure, function and maintenance standard
- Engine and cooling system
- Engine mount and transmission mount
- Cooling system
- Cooling fan pump
- Brake and fan pump
- Cooling fan motor
- Power train
- Power train
- Power train system diagram
- Drive shaft
- Power train piping diagram
- Torque converter
- Transmission
- Flow control valve
- Valve assembly
- ECMV
- Main relief valve and torque converter relief valve
- Differential
- Limited slip differential
- Final drive
- Steering system
- Steering piping diagram
- Steering column
- Steering pump
- Steering valve
- Orbit-roll valve
- Stop valve
- Steering relief valve
- Steering cylinder
- Emergency steering motor
- Emergency steering pump
- Joystick steering lever linkage
- Steering electric lever
- Joystick EPC valve
- Brake system
- Brake piping diagram
- Charge valve
- Brake valve
- Accumulator (for brake)
- Brake
- Parking brake control
- Parking brake
- Parking brake solenoid valve
- Emergency parking brake release valve
- Undercarriage and frame
- Axle mount and center hinge pin
- Tires
- Hydraulic system, Part 1
- Hydraulic piping diagram
- Work equipment control lever linkage
- Hydraulic tank
- Power train pump
- Work equipment pump
- Work equipment control valve
- CLSS
- Each function and operation of each valve
- Hydraulic system, Part 2
- PPC valve
- Stabilizer valve
- Accumulator (for PPC circuit)
- Accumulator (for ECSS)
- Work equipment PPC cut-off solenoid valve
- Work equipment
- Work equipment linkage
- Bucket
- Bucket positioner and boom kick-out
- Work equipment cylinder
- Cab and its attachments
- Cab
- Air conditioner
- Electrical system, Part 1
- Machine monitor system
- Machine monitor
- Electrical system, Part 2
- Electrical system (Transmission controller system)
- Transmission controller
- Electrical system (Work equipment controller system)
- Work equipment controller
- Electrical system, Part 3
- Electric transmission control
- Kickdown switch and hold switch
- Multi-function knob
- Joystick steering knob
- KOMTRAX terminal system
- Engine starting circuit
- Engine stopping circuit
- Preheating circuit
- Engine power mode selector circuit
- Engine output derating function
- Automatic warm-up function
- Parking brake circuit
- Sensor
20 Standard value table
- Standard service value table
- Standard service value table for engine
- Standard service value table for chassis
30 Testing and adjusting
- Testing and adjusting, Part 1
- Tools for testing, adjusting, and troubleshooting
- Testing engine speed
- Testing exhaust gas color
- Adjusting valve clearance
- Testing compression pressure
- Testing blow-by pressure
- Testing engine oil pressure
- Testing intake air (boost) pressure1
- Handling fuel system equipment
- Releasing residual pressure in fuel system
- Testing fuel pressure
- Testing fuel delivery, return and leak amount
- Bleeding air from fuel circuit
- Testing leakage in fuel system
- Handling reduced cylinder mode operation
- Handling no-injection cranking operation
- Handling controller voltage circuit1
- Testing muffler (main body) and muffler stack for looseness or damage
- Testing muffler for functions
- Testing cylinder head and manifold parts for tightness
- Testing engine piping for damage and tightness
- Testing and adjusting air conditioner compressor belt tension
- Replacing alternator belt
- Adjusting transmission speed sensor
- Adjusting length of directional lever
- Adjusting length of gearshift lever
- Testing directional lever
- Testing and adjusting power train oil pressure
- Procedure for flushing torque converter and transmission hydraulic circuit
- Method of moving machine when transmission valve is broken
- Testing axle end for oil leakage
- Testing drive shaft for looseness, backlash and damage
- Testing and adjusting steering stop valve
- Testing and adjusting steering wheel
- Testing and adjusting steering oil pressure
- Bleeding air from steering circuit
- Testing and adjusting, Part 2
- Testing hydraulic drive fan
- Bleeding air from hydraulic drive fan circuit
- Testing brake pedal
- Testing and adjusting brake pedal linkage
- Testing brake performance
- Testing and adjusting accumulator charge pressure
- Testing wheel brake oil pressure
- Testing wheel brake oil pressure drop
- Testing wear of wheel brake disc
- Bleeding air from wheel brake circuit
- Releasing residual pressure in brake accumulator circuit
- Testing parking brake performance
- Testing parking brake oil pressure
- Testing wear of parking brake disc
- Method of releasing parking brake manually
- Testing and adjusting work equipment control lever
- Testing and adjusting worke quipment PPC oil pressure
- Testing and adjusting work equipment oil pressure
- Bleeding air from work equipment circuit
- Releasing residual pressure in work equipment circuit
- Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of ECSS (Electronically Controlled Suspension System) accumulator
- Testing and adjusting bucket positioner
- Testing and adjusting boom kick-out
- Checking proximity switch operation pilot lamp
- Procedure for testing diodes
- Preparation work for troubleshooting for electric system
- How to start operation of KOMTRAX terminal
- Lamp display of KOMTRAX terminal
- Testing and adjusting, Part 3
- Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor
- Special functions of machine monitor (EMMS)
- Pm-clinic inspection table
40 Troubleshooting
- Failure code table and fuse locations
- Failure code table
- Fuse locations
- General information on troubleshooting
- Points to remember when troubleshooting
- Sequence of events in troubleshooting
- Testing before troubleshooting
- Classification and procedures of troubleshooting
- Information contained in troubleshooting table
- Connection table for connector pin numbers
- T- branch box and T- branch adapter table
- Troubleshooting by failure code (Display of code), Part 1
- Failure code [1500L0] (TORQFLOW transmission: Double meshing)
- Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)
- Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)
- Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)
- Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)
- Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)
- Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF)
- Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON)
- Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF)
- Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON)
- Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF)
- Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)
- Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF)
- Failure code [2F00MA] (Parking brake: Malfunction)
- Failure code [2G43ZG] (Accumulator: Low oil pressure)
- Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree)
- Troubleshooting by failure code (Display of code), Part 2
- Failure code [AA1ANX] (Air cleaner: Clogging)
- Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine)
- Failure code [AB00MA] (Alternator: Malfunction)
- Failure code [B@BAZG] (Rotation derating by low engine oil pressure)
- Failure code [B@BAZK] (Engine oil: Low level)
- Failure code [B@BCNS] (Coolant: Overheating)
- Failure code [B@BCZK] (Coolant: Low level)
- Failure code [B@BEBF] (Water in fuel error)
- Failure code [B@C7NS] (Brake oil: Overheating)
- Failure code [b@CENS] (Torque converter oil: Overheating)
- Failure code [B@CENS] (Torque converter oil: Overheating)
- Failure code [B@HANS] (Hydraulic oil: Overheating)
- Failure code [CA111] (Abnormality in engine controller)
- Failure code [CA115] (Engine Ne or Bkup speed sensor error)
- Failure code [CA122] (Charge pressure sensor high error)
- Failure code [CA123] (Charge pressure sensor low error)
- Failure code [CA131] (Throttle sensor high error)
- Failure code [CA132] (Throttle sensor low error)
- Failure code [CA144] (Coolant sensor high error)
- Failure code [CA145] (Coolant sensor low error)
- Failure code [CA153] (Charge temperature sensor high error)
- Failure code [CA154] (Charge temperature sensor low error)
- Failure code [CA155] (Derating of speed by abnormally high charge temperature)
- Failure code [CA187] (Sensor power supply 2 low error)
- Failure code [CA221] (Atmospheric pressure sensor high error)
- Failure code [CA222] (Atmospheric sensor low error)
- Failure code [CA227] (Sensor power supply 2 high error)
- Failure code [CA234] (Engine overspeed)
- Failure code [CA238] (Ne speed sensor power supply error)
- Troubleshooting by failure code (Display of code), Part 3
- Failure code [CA271] (IMV/PCV1 Short circuit)
- Failure code [CA272] (IMV/PCV1 Disconnection)
- Failure code [CA322] (Injector #1 open/short error)
- Failure code [CA323] (Injector #5 open/short error)
- Failure code [CA324] (Injector #3 open/short error)
- Failure code [CA325] (Injector #6 open/short error)
- Failure code [CA331] (Injector #2 open/short error)
- Failure code [CA332] (Injector #4 open/short error)
- Failure code [CA342] (Calibration code inconsistency)
- Failure code [CA351] (Injectors drive circuit error)
- Failure code [CA352] (Sensor power supply 1 low error)
- Failure code [CA386] (Sensor power supply 1 high error)
- Failure code [CA428] (Abnormally high level in water sensor)
- Failure code [CA429] (Abnormally low level in water sensor)
- Failure code [CA431] (Idle validation switch error)
- Failure code [CA432] (Idle validation action error)
- Failure code [CA435] (Engine oil pressure switch error)
- Failure code [CA441] (Battery voltage low error)
- Failure code [CA442] (Battery voltage high error)
- Failure code [CA449] Common rail pressure high error 2
- Failure code [CA451] (Common rail pressure sensor high error)
- Failure code [CA452] (Common rail pressure sensor low error)
- Failure code [CA488] (Derating of torque by abnormally high charge temperature)
- Failure code [CA553] (Common rail pressure high error 1)
- Failure code [CA559] (Supply pump pressure very low error)
- Failure code [CA689] (Engine Ne speed sensor error)
- Failure code [CA731] (Engine Bkup speed sensor phase error)
- Failure code [CA757] (All continuous data lost error)
- Failure code [CA778] (Engine Bkup speed sensor error)
- Failure code [CA1633] (KOMNET datalink timeout error)
- Failure code [CA2185] (Throttle sensor power supply voltage high error)
- Failure code [CA2186] (Throttle sensor power supply voltage low error)
- Troubleshooting by failure code (Display of code), Part 4
- Failure code [CA2249] (Supply pump pressure very low error 2)
- Failure code [CA2311] (Abnormality in IMV solenoid)
- Failure code [CA2555] (Intake heater relay disconnection error)
- Failure code [CA2556] (Intake heater relay short circuit error)
- Failure code [D150KA] (Emergency steering relay: Disconnection)
- Failure code [D150KB] (Emergency steering relay: Short circuit)
- Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line)
- Failure code [D160KA] (Backup lamp relay: Disconnection)
- Failure code [D160KB] (Backup lamp relay: Short circuit)
- Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection)
- Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit)

AND MORE....