Komatsu WA380-7 Wheel Loader Shop Manual SEN05650-10 – PDF DOWNLOAD

Komatsu WA380-7 Wheel Loader Shop Manual SEN05650-10 – PDF DOWNLOAD

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Komatsu WA380-7 Wheel Loader Shop Manual SEN05650-10 – PDF DOWNLOAD

Language : English
Pages : 2386
Downloadable : Yes
File Type : PDF
Size: 76.1 MB

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Komatsu WA380-7 Wheel Loader Shop Manual SEN05650-10 – PDF DOWNLOAD

SERIAL NUMBERS 10001 and up

Foreword, safety and general information 
Important safety notice 
• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The
shop manual describes the effective and safe servicing and repair methods recommended by Komatsu.
Some of these methods require the use of the special tools designed by Komatsu for the specific purpose.
• The symbol markkis used for such matters that require special cautions during the work. The work
indicated by the caution mark should be performed according to the instructions with special attention to
the cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe
first and take every necessary measure.

Safety points
• Good arrangement
• Correct work clothes
• Observance of work standard
• Practice of making and checking signals
• Prohibition of operation and handling by
unlicensed workers
• Safety check before starting work
• Wearing protective goggles (for cleaning or
grinding work)
• Wearing shielding goggles and protectors (for
welding work)
• Good physical condition and preparation
• Precautions against work which you are not used to or you are used to too much

General precautions:

• Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual.• Locate a place in the repair workshop to keep the tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.• When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing. 1. Always wear the protective eyeglasses when hitting parts with a hammer.Always wear the protective eyeglasses when grinding parts with a grinder, etc.• When performing any work with 2 or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator’s compartment.• Only qualified workers must perform the work and operation which require license or qualification.• Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, lift truck, service vehicle, etc.• If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc.• Before starting work, warm up your body thoroughly to start work under good condition.• Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place.

How to read the shop manual :
• Some attachments and optional parts described in this shop manual may not be arranged for certain
areas. Contact your Komatsu distributor if one or some of them are required.
• Materials and specifications are subject to change without notice.
• The shop manuals are available for “Machine part” and “Engine part”. For the engine, see the shop
manual for the same model of the engine as the one which is mounted on the machine.
Composition of shop manual
• This shop manual describes the technical information required for the services performed in a workshop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of “Structure and function”
serves not only to give an understanding for the structure of each component, but also serves as
reference material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are indicated. This standard value table is
used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for
the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for
the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or
component and the special tools for the works as well as precautions for doing them safely. In addition,
tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the
works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the
criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or
equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.

TABLE OF CONTENTS:

Komatsu WA380-7 Wheel Loader Shop Manual SEN05650-10 – PDF DOWNLOAD

Index
00 Index and foreword 00-1
Index 00-2
Foreword, safety and general information 00-18
Important safety notice 00-18
How to read the shop manual 00-25
Explanation of terms for maintenance standard 00-27
Handling equipment of fuel system devices 00-29
Handling of intake system parts 00-30
Handling of hydraulic equipment 00-31
Method of disconnecting and connecting of push-pull type coupler 00-33
Handling of electrical equipment 00-36
How to read electric wire code 00-44
Precautions when performing operation 00-47
Practical use of KOMTRAX 00-52
Standard tightening torque table 00-53
List of abbreviation 00-59
Conversion table 00-64
01 Specification 01-1
Table of contents 01-2
Specifications 01-3
Specification drawing 01-3
Specification 01-5
Weight table 01-11
Table of fuel, coolant and lubricants 01-13
10 Structure and function 10-1
Table of contents 10-2
Engine and cooling system 10-4
Engine related parts 10-4
KVGT 10-6
EGR system piping drawing 10-13
EGR system circuit diagram 10-15
EGR valve 10-17
EGR cooler 10-19
KCCV layout drawing 10-20
KCCV ventilator 10-22
KDPF 10-24
Cooling system 10-28
Cooling fan pump 10-31
Cooling fan motor 10-40
Power train 10-48
Power train system 10-48
Drive shaft 10-51
Power train piping drawing 10-52
Transmission control 10-53
Torque converter 10-55
Transmission 10-60
Transmission control valve 10-79
Forward and reverse clutch ECMV and gear speed clutch ECMV 10-82
Lockup clutch ECMV 10-89
Main relief and torque converter relief valve 10-93
Axle 10-95
Differential 10-97
Limited slip differential 10-101
Final drive 10-105
Steering system 10-107
Layout of steering devices 10-107
Steering column 10-108
00-2 WA380-7
00 Index and foreword
Index
Steering pump 10-109
Steering valve 10-121
Orbit-roll valve 10-135
Stop valve 10-141
Emergency steering motor 10-142
Emergency steering pump 10-143
Brake system 10-144
Layout of brake parts 10-144
Charge valve 10-146
Brake valve 10-152
Accumulator (for brake) 10-156
Brake 10-157
Parking brake control 10-160
Parking brake 10-161
Parking brake solenoid valve 10-162
Parking brake emergency release valve 10-165
Undercarriage and frame 10-166
Axle mount and center hinge pin 10-166
Tire 10-167
Hydraulic system 10-169
Hydraulic component layout 10-169
Work equipment control 10-171
Hydraulic tank 10-173
Double type gear pump 10-175
Work equipment pump 10-176
Control valve 10-188
CLSS 10-198
Hydraulic circuit diagram and name of valves 10-202
ECCS accumulator charge valve 10-217
Stabilizer valve 10-221
Work equipment lock solenoid valve 10-226
Accumulator (for PPC circuit) 10-227
ECSS accumulator 10-228
Work equipment 10-229
Work equipment linkage 10-229
Bucket 10-230
Bucket positioner and boom positioner 10-231
Cab and its attachments 10-232
ROPS cab 10-232
Electrical system 10-233
Engine control system 10-233
Preheating system 10-235
Engine power mode selector circuit 10-237
Engine output limit function 10-238
Automatic warm-up function 10-239
Parking brake control system 10-240
System operating lamp function 10-242
Battery disconnect switch function 10-244
Transmission controller system 10-246
Work equipment control system 10-281
Machine monitor system 10-302
Rear view monitor system 10-328
KOMTRAX system 10-331
System component parts 10-334
Sensor 10-368
20 Standard value tables 20-1
Table of contents 20-2
Standard service value table 20-3
Standard value table for engine 20-3
WA380-7 00-3
00 Index and foreword
Index
Standard value table for machine 20-5
30 Testing and adjusting 30-1
Table of contents 30-2
Related information on testing and adjusting 30-4
Tools for testing and adjusting 30-4
Sketch of tools for testing and adjusting 30-9
Engine and cooling system 30-10
Testing engine speed 30-10
Testing boost pressure 30-11
Testing exhaust gas temperature 30-13
Testing exhaust gas color 30-15
Testing and adjusting valve clearance 30-17
Testing compression pressure 30-19
Testing blowby pressure 30-23
Testing engine oil pressure 30-25
Testing EGR valve and KVGToil pressure 30-26
Testing fuel pressure 30-27
Testing fuel delivery, return and leakage 30-32
Bleeding air from fuel system 30-38
Testing fuel circuit for leakage 30-40
Handling cylinder cutout mode operation 30-41
Handling no-injection cranking operation 30-42
Testing of KDPF and muffler stack for looseness and damage 30-43
Testing of installed condition of cylinder heads and manifolds 30-44
Testing engine piping for damage and looseness 30-45
Testing and adjusting air conditioner compressor belt tension 30-46
Check alternator belt, replace 30-47
Check auto-tensioner, replace 30-49
Writing compensation amount for soot accumulation caused by ash on engine
controller 30-51
Power train 30-53
Adjusting transmission output speed sensor 30-53
Adjusting transmission input speed sensor 30-54
Flushing procedure for torque converter and transmission hydraulic circuit 30-55
Retrieval of disabled machine due to transmission valve failure 30-56
Testing oil leakage from axle final drive 30-58
Testing drive shaft for looseness, backlash, and damage 30-59
Testing and adjusting power train oil pressure 30-60
Steering system 30-75
Testing directional lever 30-75
Testing steering wheel 30-76
Testing work equipment control lever 30-78
Testing and adjusting steering circuit pressure 30-80
Bleeding air from steering cylinder circuit 30-83
Testing and adjusting steering stopper valve 30-84
Brake system 30-85
Testing brake pedal 30-85
Testing and adjusting brake pedal linkage 30-86
Testing braking performance 30-87
Measuring accumulator nitrogen gas pressure and charging procedure for accumulator
nitrogen gas 30-88
Testing and adjusting of brake accumulator charge pressure 30-92
Testing wheel brake oil pressure 30-94
Testing lowering of wheel brake pressure 30-95
Testing wear of wheel brake disc 30-98
Bleeding air from wheel brake circuit 30-99
Releasing remaining pressure in brake accumulator circuit 30-100
Testing parking brake performance 30-101
Testing parking brake oil pressure 30-102
00-4 WA380-7
00 Index and foreword
Index
Testing wear of parking brake disc 30-104
Method of releasing parking brake manually 30-105
Hydraulic system 30-106
Testing cooling fan speed 30-106
Testing cooling fan pump circuit oil pressure 30-107
Bleeding air from hydraulic fan circuit 30-108
Testing and adjusting work equipment PPC oil pressure 30-109
Testing and adjusting work equipment oil pressure 30-112
Bleeding air from work equipment circuit 30-116
Releasing remaining pressure from work equipment circuit 30-117
Checking of E C S S accumulator nitrogen gas pressure and procedure for charging
accumulator with nitrogen gas 30-118
Work equipment 30-122
Testing and adjusting bucket position detection lever 30-122
Testing and adjusting boom position detection lever 30-123
Electrical system 30-124
Adjusting replaced, reassembled or added sensor, controller, etc with machine
monitor 30-124
Special functions of machine monitor 30-126
Adjusting rearview camera angle 30-220
Handling voltage circuit of engine controller 30-221
Handling battery disconnect switch 30-222
Testing diodes 30-223
Pm clinic 30-224
Pm Clinic service 30-224
Check sheet 30-225
40 Troubleshooting 40-1
Table of contents 40-2
Related information on troubleshooting 40-12
Troubleshooting points 40-12
Sequence of events in troubleshooting 40-14
Check before troubleshooting 40-16
Inspection procedure before troubleshooting 40-18
Preparation work for troubleshooting of electrical system 40-35
Classification and procedures for troubleshooting 40-41
Symptom and troubleshooting numbers 40-44
Information in troubleshooting table 40-47
Connector list and layout 40-49
Procedure for troubleshooting wiring harness of pressure sensor system for open
circuit 40-65
Fuse location table 40-68
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement 40-71
Precautions when performing troubleshooting of machine monitor 40-74
Processing procedure of harness checker for troubleshooting of machine monitor LCD
unit 40-76
Preparation of dummy temperature sensor (for KDOC and KDPF temperature
sensors) 40-81
Preparation of short circuit electrical connector (for failure codes [CA1883] and
[CA3135]) 40-82
Failure codes table 40-83
Troubleshooting by failure code (Display of code) 40-97
Failure code [1500L0] Double Engagement of T/M Clutches 40-97
Failure code [15SAL1] Release Trouble of ECMV (Forward) 40-98
Failure code [15SALH] Malfunction of ECMV (Forward) 40-100
Failure code [15SBL1] Release Trouble of ECMV (Reverse) 40-102
Failure code [15SBLH] Malfunction of ECMV (Reverse) 40-104
Failure code [15SEL1] Release Trouble of ECMV (1st) 40-106
Failure code [15SELH] Malfunction of ECMV (1st) 40-108
Failure code [15SFL1] Release Trouble of ECMV (2nd) 40-110
WA380-7 00-5
00 Index and foreword
Index
Failure code [15SFLH] Malfunction of ECMV (2nd) 40-112
Failure code [15SGL1] Release Trouble of ECMV (3rd) 40-114
Failure code [15SGLH] Malfunction of ECMV (3rd) 40-116
Failure code [15SHL1] Release Trouble of ECMV (4th) 40-118
Failure code [15SHLH] Malfunction of ECMV (4th) 40-120
Failure code [2F00MA] Failure of Parking Brake Circuit 40-122
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) 40-125
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) 40-127
Failure code [879AKA] A/C Inner Sensor Open Circuit 40-129
Failure code [879AKB] A/C Inner Sensor Short Circuit 40-130
Failure code [879BKA] A/C Outer Sensor Open Circuit 40-131
Failure code [879BKB] A/C Outer Sensor Short Circuit 40-132
Failure code [879CKA] Ventilating Sensor Open Circuit 40-133
Failure code [879CKB] Ventilating Sensor Short Circuit 40-134
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit 40-135
Failure code [879EMC] Ventilation Damper Abnormality 40-136
Failure code [879FMC] Air Mix Damper Abnormality 40-137
Failure code [989A00] Engine Overrun Prevention Activated 40-138
Failure code [989L00] Engine Controller Lock Caution 1 40-139
Failure code [989M00] Engine Controller Lock Caution 2 40-140
Failure code [989N00] Engine Controller Lock Caution 3 40-141
Failure code [A1U0N3] HC Desorb Request 1 40-142
Failure code [A1U0N4] HC Desorb Request 2 40-144
Failure code [AA10NX] Air Cleaner Clogging 40-146
Failure code [AB00KE] Charge Voltage Low 40-148
Failure code [AB00KY] Hot Short of Alternator R Terminal 40-150
Failure code [B@BAZG] Eng Oil Press Low 40-151
Failure code [B@BAZK] Engine Oil Level Low 40-152
Failure code [B@BCNS] Eng Water Overheat 40-153
Failure code [B@BCZK] Eng Water Level Low 40-154
Failure code [B@C7NS] High Brake Oil Temp 40-156
Failure code [B@CENS] T/C Oil Temp Overheat 40-158
Failure code [B@HANS] HYD Oil Temp Overheat 40-159
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 40-160
Failure code [CA122] Chg Air Press Sensor High Error 40-161
Failure code [CA123] Chg Air Press Sensor Low Error 40-163
Failure code [CA131] Throttle Sensor High Error 40-165
Failure code [CA132] Throttle Sensor Low Error 40-167
Failure code [CA144] Coolant Temp Sens High Error 40-169
Failure code [CA145] Coolant Temp Sens Low Error 40-171
Failure code [CA153] Chg Air Temp Sensor High Error 40-173
Failure code [CA154] Chg Air Temp Sensor Low Error 40-175
Failure code [CA187] Sensor 2 Supply Volt Low Error 40-177
Failure code [CA221] Ambient Press Sensor High Error 40-179
Failure code [CA222] Ambient Press Sensor Low Error 40-181
Failure code [CA227] Sensor 2 Supply Volt High Error 40-183
Failure code [CA234] Eng Overspeed 40-184
Failure code [CA238] Ne Speed Sensor Supply Volt Error 40-185
Failure code [CA239] Ne Speed Sens Supply Volt High Error 40-186
Failure code [CA271] IMV/PCV1 Short Error 40-187
Failure code [CA272] IMV/PCV1 Open Error 40-189
Failure code [CA295] Ambient Press Sens In Range Error 40-191
Failure code [CA322] Inj #1(L#1) Open/Short Error 40-192
Failure code [CA323] Inj #5(L#5) Open/Short Error 40-194
Failure code [CA324] Inj #3(L#3) Open/Short Error 40-196
Failure code [CA325] Inj #6(L#6) Open/Short Error 40-198
Failure code [CA331] Inj #2(L#2) Open/Short Error 40-200
Failure code [CA332] Inj #4(L#4) Open/Short Error 40-202
Failure code [CA343] ECM Critical Internal Failure 40-204
00-6 WA380-7
00 Index and foreword
Index
Failure code [CA351] Injectors Drive Circuit Error 40-205
Failure code [CA352] Sensor 1 Supply Volt Low Error 40-206
Failure code [CA356] Mass Air Flow Sensor High Error 40-208
Failure code [CA357] Mass Air Flow Sensor Low Error 40-210
Failure code [CA386] Sensor 1 Supply Volt High Error 40-212
Failure code [CA428] Water in Fuel Sensor High Error 40-213
Failure code [CA429] Water in Fuel Sensor Low Error 40-215
Failure code [CA431] Idle Validation Sw Error 40-217
Failure code [CA432] Idle Validation Process Error 40-220
Failure code [CA435] Eng Oil Press Sw Error 40-223
Failure code [CA441] Battery Voltage Low Error 40-224
Failure code [CA442] Battery Voltage High Error 40-226
Failure code [CA449] Rail Press Very High Error 40-227
Failure code [CA451] Rail Press Sensor High Error 40-228
Failure code [CA452] Rail Press Sensor Low Error 40-230
Failure code [CA488] Chg Air Temp High Torque Derate 40-232
Failure code [CA515] Rail Press Sens Sup Volt High Error 40-233
Failure code [CA516] Rail Press Sens Sup Volt Low Error 40-235
Failure code [CA553] Rail Press High Error 40-237
Failure code [CA555] Crankcase Press High Error 1 40-238
Failure code [CA556] Crankcase Press High Error 2 40-239
Failure code [CA559] Rail Press Low Error 40-240
Failure code [CA595] Turbo Speed High Error 2 40-242
Failure code [CA687] Turbo Speed Low Error 40-243
Failure code [CA689] Eng Ne Speed Sensor Error 40-245
Failure code [CA691] Intake Air Temp Sens High Error 40-247
Failure code [CA692] Intake Air Temp Sens Low Error 40-249
Failure code [CA697] ECM Internal Temp Sensor High Error 40-251
Failure code [CA698] ECM Int Temp Sensor Low Error 40-252
Failure code [CA731] Eng Bkup Speed Sens Phase Error 40-253
Failure code [CA778] Eng Bkup Speed Sensor Error 40-255
Failure code [CA1117] Persistent Data Lost Error 40-260
Failure code [CA1664] KDOC Malfunction 40-261
Failure code [CA1691] Regeneration Ineffective 40-264
Failure code [CA1695] Sensor 5 Supply Volt High Error 40-267
Failure code [CA1696] Sensor 5 Supply Volt Low Error 40-268
Failure code [CA1843] Crankcase Press Sens High Error 40-270
Failure code [CA1844] Crankcase Press Sens Low Error 40-272
Failure code [CA1879] KDPF Delta P Sensor High Error 40-274
Failure code [CA1881] KDPF Delta P Sensor Low Error 40-276
Failure code [CA1883] KDPF Delta P Sens In Range Error 40-278
Failure code [CA1921] KDPF Soot Load High Error 1 40-282
Failure code [CA1922] KDPF Soot Load High Error 2 40-285
Failure code [CA1942] Crankcase Press Sens In Range Error 40-290
Failure code [CA1993] KDPF Delta Pressure Low Error 40-291
Failure code [CA2185] Throt Sensor Sup Volt High Error 40-294
Failure code [CA2186] Throt Sensor Sup Volt Low Error 40-296
Failure code [CA2249] Rail Press Very Low Error 40-298
Failure code [CA2271] EGR Valve Pos Sens High Error 40-299
Failure code [CA2272] EGR Valve Pos Sens Low Error 40-301
Failure code [CA2288] Turbo Speed High Error 1 40-304
Failure code [CA2311] IMV Solenoid Error 40-305
Failure code [CA2349] EGR Valve Solenoid Open Error 40-306
Failure code [CA2353] EGR Valve Solenoid Short Error 40-308
Failure code [CA2357] EGR Valve Servo Error 40-310
Failure code [CA2373] Exhaust Manifold Press Sens High error 40-311
Failure code [CA2374] Exhaust Manifold Press Sens Low error 40-313
Failure code [CA2375] EGR Orifice Temp Sens High Error 40-315
Failure code [CA2376] EGR Orifice Temp Sens Low Error 40-317
WA380-7 00-7
00 Index and foreword
Index
Failure code [CA2381] KVGT Pos Sens High Error 40-319
Failure code [CA2382] KVGT Pos Sens Low Error 40-321
Failure code [CA2383] KVGT Solenoid Open Error 40-324
Failure code [CA2386] KVGT Solenoid Short Error 40-326
Failure code [CA2387] KVGT Servo Error 40-328
Failure code [CA2554] Exh Manifold Press Sens In Range Error 40-329
Failure code [CA2555] Grid Htr Relay Volt Low Error 40-330
Failure code [CA2556] Grid Htr Relay Volt High Error 40-332
Failure code [CA2637] KDOC Face Plugging 40-334
Failure code [CA2639] Manual Stationary Regeneration Request 40-336
Failure code [CA2961] EGR Orifice Temp High Error 1 40-339
Failure code [CA2973] Chg Air Press Sensor In Range Error 40-340
Failure code [CA3133] KDPF Outlet Press Sens High Error 40-341
Failure code [CA3134] KDPF Outlet Press Sens Low Error 40-343
Failure code [CA3135] KDPF Outlet Press Sens In Range Error 40-345
Failure code [CA3251] KDOC Inlet Temp High Error 40-349
Failure code [CA3253] KDOC Temp Error – Non Regeneration 40-352
Failure code [CA3254] KDOC Outlet Temp High Error 1 40-355
Failure code [CA3255] KDPF Temp Error – Non Regeneration 40-358
Failure code [CA3256] KDPF Outlet Temp High Error 1 40-361
Failure code [CA3311] KDOC Outlet Temp High Error 2 40-364
Failure code [CA3312] KDPF Outlet Temp High Error 2 40-368
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error 40-372
Failure code [CA3314] KDOC Inlet Temp Sens High Error 40-375
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error 40-378
Failure code [CA3316] KDOC Outlet Temp Sens Low Error 40-383
Failure code [CA3317] KDOC Outlet Temp Sens High Error 40-386
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error 40-390
Failure code [CA3319] KDPF Outlet Temp Sens High Error 40-395
Failure code [CA3321] KDPF Outlet Temp Sens Low Error 40-399
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error 40-402
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 40-406
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error 40-408
Failure code [CA3741] Rail Press Valve Trip Error 40-410
Failure code [D150KA] Disconnection of Emerg Steering Relay 40-411
Failure code [D150KB] Ground Fault of Emerg Steering Relay 40-413
Failure code [D150KY] Hot Short of Emergency Steering Relay 40-415
Failure code [D160KA] Disconnection of Backup Lamp Relay Output 40-417
Failure code [D160KB] Ground Fault of Backup Lamp Relay Output 40-419
Failure code [D160KY] Hot Short of Backup Lamp Relay Output 40-421
Failure code [D191KA] Disconnection of Neutral Output Relay 40-423
Failure code [D191KB] Ground Fault of Neutral Output Relay 40-426
Failure code [D191KY] Hot Short of Neutral Output Relay 40-429
Failure code [D192KA] Disconnection of ECSS Solenoid 40-431
Failure code [D192KB] Ground Fault of ECSS Solenoid 40-433
Failure code [D192KY] Hot Short of ECSS Solenoid 40-434
Failure code [D19JKZ] Personal Code Relay Abnormality 40-435
Failure code [D1E6KA] Disconnection of Parking Brake Relay 40-437
Failure code [D1E6KB] Ground Fault of Parking Brake Relay 40-439
Failure code [D1E6KY] Hot Short of Parking Brake Relay 40-441
Failure code [D5ZHKA] Failure of Key SW C Signal 40-443
Failure code [D5ZHKB] Key SW C Signal Short Circuit 40-445
Failure code [D5ZHKZ] Failure of Key SW C Signal 40-447
Failure code [D5ZHL6] Disconnection of Key SW C 40-449
Failure code [D811MC] KOMTRAX Error 40-451
Failure code [D862KA] GPS Antenna Open Circuit 40-452
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) 40-453
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) 40-455
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 40-457
00-8 WA380-7
00 Index and foreword
Index
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 40-458
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) 40-459
Failure code [DAF0MB] Monitor ROM Abnormality 40-460
Failure code [DAF0MC] Monitor Error 40-461
Failure code [DAF3KK] Controller Power Source Low (MON) 40-462
Failure code [DAF8KB] Camera Power Supply Short Circuit 40-464
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit 40-465
Failure code [DAFGMC] GPS Module Error 40-467
Failure code [DAFLKA] Operating Lamp Open Circuit (MON) 40-468
Failure code [DAFLKB] Operating Lamp Short Circuit (MON) 40-470
Failure code [DAFQKR] CAN2 Discon (Monitor) 40-472
Failure code [DAQ0KK] Controller Power Source Low (T/M) 40-473
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) 40-476
Failure code [DAQ0MC] T/M Con Error 40-477
Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) 40-478
Failure code [DAQ2KK] Solenoid Power Source Low (T/M) 40-480
Failure code [DAQ4KB] Ground Fault of Sol Self-Holding Relay 40-483
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) 40-485
Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) 40-486
Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) 40-488
Failure code [DAQQKR] CAN2 Discon (Transmission Con) 40-490
Failure code [DAQRKR] CAN1 Discon (Transmission Con) 40-491
Failure code [DAQRMA] Inconsistency of Option Selection (T/M) 40-492
Failure code [DAZ9KQ] A/C Model Selection Abnormality 40-493
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) 40-494
Failure code [DB2QKR] CAN2 Discon (Engine Con) 40-495
Failure code [DB2RKR] CAN1 Discon (Engine Con) 40-500
Failure code [DB90KK] Drop in BBC Controller Main Power Source 40-506
Failure code [DB90KT] Abnormality of Non-volatile Memory (BBC) 40-508
Failure code [DB90MC] BBC Error 40-509
Failure code [DB91KA] Disconnection of Key SW ACC (BBC) 40-510
Failure code [DB92KK] Solenoid Power Source Low (BBC) 40-512
Failure code [DB95KX] Failure of 5 V Power Source 1 40-514
Failure code [DB96KX] Failure of 5 V Power Source 2 40-518
Failure code [DB99KQ] Inconsistency of Model Selection (BBC) 40-522
Failure code [DB9LKA] Operating Lamp Open Circuit (BBC) 40-523
Failure code [DB9LKB] Operating Lamp Short Circuit (BBC) 40-525
Failure code [DB9QKR] CAN2 Discon (Bucket Boom Con) 40-527
Failure code [DB9RKR] CAN1 Discon (Bucket Boom Con) 40-528
Failure code [DB9RMA] Inconsistency of Option Selection (BBC) 40-529
Failure code [DBE5KX] Failure of 5V Power Source 40-530
Failure code [DBE6KX] Failure of 24 V Power Source 40-532
Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW 40-534
Failure code [DDAAL6] Discon Engine Shutdown Secondary Switch 40-538
Failure code [DDB6L4] Neutral Signal Malfunction 40-540
Failure code [DDD1LD] Failure of Bucket Positioner Set Switch 40-543
Failure code [DDK3KA] FNR SW Input Signal Disconnection 40-547
Failure code [DDK3KB] FNR SW Input Signal Short Circuit 40-552
Failure code [DDK6KA] FNR Lever Input Signal Disconnection 40-556
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit 40-559
Failure code [DDNRKY] Hot Short of Work Equipment Lock SW 40-561
Failure code [DDT0L4] Failure of Shift Mode Select SW 40-565
Failure code [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal 40-569
Failure code [DDT9LD] Ground Fault of T/M Cut Off SW Signal 40-573
Failure code [DDW9LD] Ground Fault of Kickdown Switch 40-577
Failure code [DDWLLD] Ground Fault of T/M Shift Hold SW 40-581
Failure code [DF10KA] Disconnection of Shift Lever Input 40-585
Failure code [DF10KB] Ground Fault of Shift Lever Input 40-587
Failure code [DGF1KA] Disconnection of T/M Oil Temp Sensor 40-590
WA380-7 00-9
00 Index and foreword
Index
Failure code [DGF1KB] Ground Fault of T/M Oil Temp Sensor 40-592
Failure code [DGH2KX] Out of Range of HYD Oil Temp Sensor 40-594
Failure code [DGR2KB] Ground Fault of Brake Oil Temp Sensor 40-596
Failure code [DGR2KZ] Failure of Brake Oil Temp Sensor 40-597
Failure code [DGT1KA] Disconnection of T/C Oil Temp Sensor 40-599
Failure code [DGT1KB] Ground Fault of T/C Oil Temp Sensor 40-601
Failure code [DH21KA] Failure of Loader Pump Press Sensor 40-603
Failure code [DH21KB] Loader Pump Press Sensor Short Circuit 40-605
Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit 40-607
Failure code [DHPCKX] Out of Range of Boom Bottom Press Sensor 40-609
Failure code [DHPDKX] Out of Range of Boom Head Press Sensor 40-611
Failure code [DHT1KX] Out of Range of T/M Cut Off Press Sensor 40-613
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor 40-615
Failure code [DHT7KX] Out of Range of T/C Output Pressure Sensor 40-618
Failure code [DHT8KA] Failure of Steering Pump Press Sensor 40-620
Failure code [DHT8KB] Steering Pump Press Sensor Short Circuit 40-622
Failure code [DHT8ZG] Steering Oil Pressure Low 40-624
Failure code [DHUDKA] Failure of Emrg Steering Press Sensor 40-625
Failure code [DHUDKB] Emrg Steering Press S Short Circuit 40-627
Failure code [DJF1KA] Disconnection of Fuel Level Sensor 40-629
Failure code [DK55KA] Failure of FNR Lever Potentio 40-631
Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit 40-634
Failure code [DK55L5] Failure of FNR Lever Potentio 40-636
Failure code [DK59KA] Failure of Boom Lever Potentio (Main) 40-637
Failure code [DK59KY] Hot Short of Boom Lever Potentio (Main) 40-643
Failure code [DK59L8] Boom Lever Potentio (Main & Sub) Disagree 40-648
Failure code [DK5AKA] Failure of Boom Lever Potentio (Sub) 40-655
Failure code [DK5AKY] Hot Short of Boom Lever Potentio (Sub) 40-661
Failure code [DK5BKA] Failure of Bucket Lever Potentio (Main) 40-666
Failure code [DK5BKY] Hot Short of Bucket Lever Potentio (Main) 40-671
Failure code [DK5BL8] Bucket Lever Potentio (Main&Sub) Disagree 40-676
Failure code [DK5CKA] Failure of Bucket Lever Potentio (Sub) 40-683
Failure code [DK5CKY] Hot Short of Bucket Lever Potentio (Sub) 40-688
Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) 40-693
Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) 40-698
Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree 40-702
Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) 40-708
Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) 40-713
Failure code [DK5KKA] Failure of 4th Lever Potentio (Main) 40-717
Failure code [DK5KKY] Hot Short of 4th Lever Potentio (Main) 40-722
Failure code [DK5KL8] 4th Lever Potentio (Main & Sub) Disagree 40-726
Failure code [DK5LKA] Failure of 4th Lever Potentio (Sub) 40-732
Failure code [DK5LKY] Hot Short of 4th Lever Potentio (Sub) 40-737
Failure code [DKA0KA] Failure of Boom Angle Sensor 40-741
Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit 40-743
Failure code [DKA0L0] Boom Angle Sensor Dislocation 40-745
Failure code [DKA1KA] Failure of Bucket Angle Sensor 40-747
Failure code [DKA1KY] Hot Short of Bucket Angle Sensor Circuit 40-750
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor 40-752
Failure code [DLF1LC] Failure of T/M Input Speed Sensor 40-754
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor 40-756
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor 40-758
Failure code [DLT3KA] Disconnection of Output Speed Sens (Main) 40-760
Failure code [DLT3LC] Failure of Output Speed Sensor (Main) 40-762
Failure code [DPQ1KR] LIN Discon (Switch Panel) 40-764
Failure code [DPQ2KR] LIN Discon (LED Unit) 40-767
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) 40-770
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) 40-773
Failure code [DT20KB] Ground Fault of T/M Cut Off Indicator 40-775
00-10 WA380-7
00 Index and foreword
Index
Failure code [DT22KB] Ground Fault of Work Equip Lock Indic 40-779
Failure code [DV00KB] Ground Fault of Buzzer Output 40-783
Failure code [DW4PKA] Disconnection of Boom EPC Solenoid (Raise) 40-785
Failure code [DW4PKB] Ground Fault of Boom EPC Solenoid (Raise) 40-787
Failure code [DW4PKY] Hot Short of Boom EPC Solenoid (Raise) 40-789
Failure code [DW4QKA] Disconnection of Boom EPC Solenoid (Lower) 40-791
Failure code [DW4QKB] Ground Fault of Boom EPC Solenoid (Lower) 40-793
Failure code [DW4QKY] Hot Short of Boom EPC Solenoid (Lower) 40-795
Failure code [DW4RKA] Disconnection of Bucket EPC Sol (Tilt) 40-797
Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) 40-799
Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) 40-801
Failure code [DW4SKA] Disconnection of Bucket EPC Sol (Dump) 40-803
Failure code [DW4SKB] Ground Fault of Bucket EPC Solenoid (Dump) 40-805
Failure code [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump) 40-807
Failure code [DW7BKA] Disconnection of Fan Reverse Solenoid 40-809
Failure code [DW7BKB] Ground Fault of Radiator Fan Rev Sol 40-810
Failure code [DW7BKY] Hot Short of Radiator Fan Rev Sol 40-812
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid 40-813
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid 40-815
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid 40-817
Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) 40-819
Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) 40-823
Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) 40-827
Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) 40-831
Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) 40-835
Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) 40-839
Failure code [DX16KA] Disconnection of Rad Fan Pump EPC Sol 40-843
Failure code [DX16KB] Ground Fault of Rad Fan Pump EPC Sol 40-845
Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol 40-847
Failure code [DXA1KA] Disconnection of Loader Pump EPC Solenoid 40-849
Failure code [DXA1KB] Ground Fault of Loader Pump EPC Solenoid 40-851
Failure code [DXA1KY] Hot Short of Loader Pump EPC Solenoid 40-853
Failure code [DXANKA] Disconnection of Steering Pump EPC Sol 40-855
Failure code [DXANKB] Ground Fault of Steering Pump EPC Solenoid 40-857
Failure code [DXANKY] Hot Short of Steering Pump EPC Solenoid 40-859
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) 40-860
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) 40-862
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) 40-864
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st) 40-866
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) 40-868
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) 40-870
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) 40-872
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) 40-874
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) 40-876
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) 40-878
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) 40-880
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) 40-882
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) 40-884
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) 40-886
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) 40-888
Failure code [DXH8KA] Disconnection of ECMV Solenoid (Forward) 40-890
Failure code [DXH8KB] Ground Fault of ECMV Solenoid (Forward) 40-892
Failure code [DXH8KY] Hot Short of ECMV Solenoid (Forward) 40-894
Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) 40-896
Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th) 40-898
Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th) 40-900
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) 40-902
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) 40-904
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) 40-906
WA380-7 00-11
00 Index and foreword
Index
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) 40-908
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) 40-910
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) 40-912
Failure code [DXJEKA] Disconnection of 4th EPC Solenoid (EXT) 40-914
Failure code [DXJEKB] Ground Fault of 4th EPC Solenoid (EXT) 40-916
Failure code [DXJEKY] Hot Short of 4th EPC Solenoid (EXT) 40-918
Failure code [DXJFKA] Disconnection of 4th EPC Solenoid (RET) 40-920
Failure code [DXJFKB] Ground Fault of 4th EPC Solenoid (RET) 40-922
Failure code [DXJFKY] Hot Short of 4th EPC Solenoid (RET) 40-924
Failure code [DY30MA] Malfunction 1 of Emerg Steering Motor 40-926
Failure code [DY30MC] Malfunction 2 of Emerg Steering Motor 40-929
Failure code [DY30ME] Emerg Steering Long-Time Activated 40-933
Failure code [H2K0KA] Failure of Quick Coupler Lock Signal 40-935
Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal 40-938
Failure code [LA00L3] Failure of Fan Reverse 40-940
Troubleshooting of electrical system (E-mode) 40-941
E-1 Engine does not start 40-941
E-2 Manual preheating system does not work 40-948
E-3 Automatic preheating system does not work 40-951
E-4 While preheating is working, preheating monitor does not light up 40-953
E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing 40-955
E-6 LCD unit on machine monitor displays nothing 40-958
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or
flickers) 40-960
E-8 LCD on machine monitor does not display properly 40-962
E-9 Meter unit display on machine monitor is abnormal 40-964
E-10 Night lighting lamp of meter unit on machine monitor is abnormal 40-967
E-11 Caution LED on machine monitor is abnormal 40-970
E-12 LED of switch panel on machine monitor is abnormal or switches does not operate
properly 40-972
E-13 Two switches operation of switch panel on machine monitor does not function 40-974
E-14 Switch panel buzzer of machine monitor is abnormal 40-977
E-15 Rear view monitor does not light up or backlight flickers 40-979
E-16 Rear view monitor images are not displayed clearly 40-982
E-17 Rear view monitor brightness cannot be adjusted 40-985
E-18 Night lighting lamp of rear view monitor is abnormal 40-988
E-19 Some items of gauges and caution lamps on machine monitor are not displayed
properly 40-990
E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking)
position 40-991
E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not
light 40-995
E-22 Air cleaner clogging indicator lamp does not light 40-997
E-23 Radiator coolant level caution lamp does not light 40-998
E-24 Indication of hydraulic oil temperature gauge does not increase, or hydraulic oil
temperature caution lamp does not light 40-1000
E-25 Indication of torque converter oil temperature gauge does not increase, or torque
converter oil temperature caution lamp does not light 40-1002
E-26 Fuel level gauge does not indicate correct level 40-1003
E-27 Seat belt caution lamp indication is abnormal 40-1005
E-28 Horn does not sound 40-1006
E-29 Horn does not stop sounding 40-1009
E-30 Alarm buzzer does not sound 40-1011
E-31 When starting switch is in ON position, alarm buzzer does not stop sounding 40-1012
E-32 Kickdown does not work when kickdown switch is turned ON 40-1013
E-33 The hold switch does not work when it is pressed 40-1015
E-34 Parking brake does not work even if it is applied, or the brake drags when parking brake
is released and FR drive is operated 40-1017
E-35 Transmission cut-off mode is not selected or not released 40-1020
00-12 WA380-7
00 Index and foreword
Index
E-36 Transmission cut-off setting cannot be released 40-1022
E-37 Directional selector (FNR) switch mode is not selected or not released 40-1024
E-38 When operating engine power selection switch, engine power selection function does not
operate properly 40-1026
E-39 Flow of loader pump does not increase from the minimum rate 40-1028
E-40 ECSS function cannot be selected or cannot be released 40-1029
E-41 None of headlamp, clearance lamp, and tail lamp lights 40-1031
E-42 Clearance lamp and tail lamp do not light up or go out 40-1033
E-43 Both High and Low beams of headlamp do not light up or go out 40-1036
E-44 Low beam of headlamp does not light up or go out 40-1040
E-45 High beam of headlamp does not light up or go out 40-1042
E-46 Front working lamp does not light up or go out 40-1044
E-47 Rear working lamp does not light up or go out 40-1047
E-48 All of turn signal lamps and hazard lamps do not light up or go out 40-1050
E-49 Turn signal lamps do not light up or go out 40-1053
E-50 Hazard lamp does not light up or go out 40-1056
E-51 Brake lamp does not light up or stays lighted 40-1059
E-52 Backup lamp does not light or continues to light 40-1062
E-53 Backup buzzer does not sound or continues to sound 40-1065
E-54 Front wiper does not operate 40-1067
E-55 Rear wiper does not operate 40-1070
E-56 Window washer does not operate 40-1072
E-57 Fan does not rotate in reverse 40-1075
E-58 Fan remains in reverse rotation mode 40-1076
E-59 KOMTRAX system does not operate properly 40-1077
Troubleshooting of hydraulic and mechanical system (H-mode) 40-1079
Information described in troubleshooting table (H-mode) 40-1079
System chart of hydraulic and mechanical systems 40-1080
Failure mode and cause table 40-1082
H-1 Machine does not start 40-1088
H-2 Torque converter lockup clutch is not disengaged (engine stalls) 40-1091
H-3 Torque converter lockup clutch is not engaged 40-1092
H-4 Travel speed is slow, bucket thrust force is weak, gradability is low, or gear speed does not
shift 40-1093
H-5 Large shock is made when machine starts or gear is shifted 40-1096
H-6 Machine starts or gear speed shifts with long time lag 40-1099
H-7 Torque converter oil temperature is high 40-1101
H-8 Machine does not turn 40-1104
H-9 Turning response is poor 40-1106
H-10 Steering wheel is heavy to turn 40-1108
H-11 Machine sways or large shocks are made while machine turns 40-1109
H-12 Turning radius differs between right and left turns 40-1111
H-13 Wheel brakes do not work or are weak 40-1112
H-14 Wheel brakes are not released or drag 40-1113
H-15 Parking brake does not work or it is weak 40-1114
H-16 Parking brake is not released or drags (including emergency release system) 40-1115
H-17 Boom does not rise 40-1116
H-18 Boom moves slow or boom lacks lifting force 40-1118
H-19 Rising boom slows down at certain height 40-1120
H-20 Lift cylinders do not serve to hold bucket on ground 40-1121
H-21 Hydraulic drift of boom is large 40-1122
H-22 Boom moves up and down during operation 40-1123
H-23 Bucket does not tilt back 40-1124
H-24 Bucket moves slow or bucket lacks tilt-back force 40-1126
H-25 Bucket decelerates during tilt-back operation 40-1128
H-26 Bucket cylinder does not hold bucket on ground 40-1129
H-27 Hydraulic drift of bucket is large 40-1130
H-28 Bucket tilts back and forth during carrying load (work equipment valve in
HOLD) 40-1131
WA380-7 00-13
00 Index and foreword
Index
H-29 Boom and bucket control levers do not move smoothly and heavy to move 40-1132
H-30 Operating work equipment causes engine speed to lower significantly or engine to
stall 40-1134
H-31 Large shocks are made when work equipment starts to move and stops 40-1135
H-32 When certain work equipment stalls hydraulically, other work equipment
moves 40-1137
H-33 E C S S (travel damper) does not work and machine pitches and bounces 40-1138
H-34 Air conditioner does not work while cooling fan rotates in reverse mode 40-1139
H-35 Fan speed is abnormal (too high or low, or fan doe not rotate) 40-1140
H-36 Unusual noise is heard from around fan 40-1141
Troubleshooting of engine (S-mode) 40-1142
Information described in troubleshooting table (S mode) 40-1142
S-1 Engine does not crank when starting switch is turned to START position 40-1143
S-2 Engine cranks but no exhaust smoke comes out 40-1144
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not
start) 40-1145
S-4 Engine startability is poor 40-1146
S-5 Engine does not pick up smoothly 40-1148
S-6 Engine stops during operation 40-1150
S-7 Engine runs rough or is unstable 40-1152
S-8 Engine lacks power 40-1153
S-9 KDPF gets clogged in a short time 40-1155
S-10 Engine oil consumption is excessive 40-1157
S-11 Engine oil becomes contaminated early 40-1158
S-12 Fuel consumption is excessive 40-1159
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) 40-1160
S-14 Oil pressure drops 40-1161
S-15 Fuel mixes into engine oil 40-1162
S-16 Water mixes into engine oil (milky) 40-1163
S-17 Coolant temperature rises too high (overheating) 40-1164
S-18 Unusual noise is heard 40-1165
S-19 Vibration is excessive 40-1166
S-20 Air cannot be bled from fuel circuit 40-1167
S-21 Active regeneration is executed frequently 40-1168
S-22 Active regeneration takes time 40-1169
S-23 White smoke is exhausted during active regeneration 40-1170
50 Disassembly and assembly 50-1
Table of contents 50-2
Related information on disassembly and assembly 50-4
How to read this manual 50-4
Coating materials list 50-6
Special tools list 50-10
Sketches of special tools 50-13
Engine and cooling system 50-20
Removal and installation of supply pump assembly 50-20
Removal and installation of injector assembly 50-23
Removal and installation of cylinder head assembly 50-34
Removal and installation of engine hood assembly 50-53
Removal and installation of grille assembly 50-56
Removal and installation of cooling system assembly 50-57
Removal and installation of radiator core assembly 50-60
Removal and installation of aftercooler 50-63
Removal and installation of hydraulic oil cooler assembly 50-65
Removal and installation of fuel cooler assembly 50-66
Removal and installation of engine, torque converter and transmission assemblies 50-67
Disconnection and connection of engine, torque converter and transmission assembly 50-74
Removal and installation of engine front oil seal 50-76
Removal and installation of engine rear oil seal 50-79
Removal and installation of cooling fan and fan motor assembly 50-82
00-14 WA380-7
00 Index and foreword
Index
Removal and installation of KDPF assembly 50-84
Disassembly and assembly of KDPF assembly 50-87
Removal and installation of KCCV assembly 50-96
Removal and installation of air cleaner assembly 50-97
Removal and installation of fuel tank assembly 50-99
Power train 50-102
Disassembly and assembly of torque converter assembly 50-102
Disassembly and assembly of transmission assembly 50-109
Disassembly and assembly of transmission clutch pack assembly 50-122
Disassembly and assembly of differential assembly 50-136
Disassembly and assembly of parking brake assembly 50-155
Removal and installation of front axle assembly 50-163
Removal and installation of rear axle assembly 50-165
Disassembly and assembly of axle housing assembly 50-167
Steering system 50-176
Removal and installation of steering valve assembly 50-176
Brake system 50-178
Removal and installation of parking brake disc and plate 50-178
Undercarriage and frame 50-181
Removal and installation of center hinge pin 50-181
Removal and installation of counterweight assembly 50-189
Removal and installation of full-length fender assembly 50-191
Hydraulic system 50-192
Removal and installation of hydraulic tank assembly 50-192
Removal and installation of work equipment controll valve assembly 50-195
Removal and installation of power train pump and work equipment hydraulic pump
assembly 50-198
Removal and installation of steering pump and cooling fan pump assembly 50-199
Disassembly and assembly of hydraulic cylinder assembly 50-201
Work equipment 50-208
Removal and installation of work equipment assembly 50-208
Cab and its attachments 50-213
Removal and installation of operator’s cab and floor frame assembly 50-213
Removal and installation of operator’s cab glass (stuck window glass) 50-217
Removal and installation of operator’s seat assembly 50-225
Removal and installation of seat belt 50-227
Electrical system 50-228
Removal and installation of machine monitor assembly 50-228
Removal and installation of engine controller assembly 50-229
Removal and installation of work equipment controller assembly 50-230
Removal and installation of transmission controller assembly 50-232
Removal and installation of monitor controller assembly 50-233
Removal and installation of mass air flow and temperature sensor 50-235
Removal and installation of KOMTRAX terminal assembly 50-236
60 Maintenance standard 60-1
Table of contents 60-2
Engine and cooling system 60-3
Engine related parts 60-3
Cooling fan pump 60-4
Cooling fan motor 60-7
Power train 60-9
Drive shaft 60-9
Torque converter 60-10
Transmission 60-12
Transmission control valve 60-19
Forward and reverse clutch ECMV and gear speed clutch ECMV 60-20
Lockup clutch ECMV 60-21
WA380-7 00-15
Main relief and torque converter relief valve 60-22
Front axle 60-22-1
00 Index and foreword
Index
Limited slip differential 60-26
Final drive 60-30
Steering system 60-32
Steering column 60-32
Steering pump 60-33
Steering valve 60-37
Steering cylinder 60-39
Emergency steering pump 60-41
Brake system 60-42
Charge valve 60-42
Brake 60-44
Parking brake 60-46
Parking brake solenoid valve 60-47
Undercarriage and frame 60-48
Axle mount and center hinge pin 60-48
Hydraulic system 60-53
Hydraulic tank 60-53
Double type gear pump 60-54
Work equipment pump 60-55
Control valve 60-60
Stabilizer valve 60-71
Work equipment 60-72
Work equipment linkage 60-72
Bucket 60-75
Work equipment cylinder 60-76
80 Appendix 80-1
Table of contents 80-2
Air conditioner components 80-3
Precautions for refrigerant 80-3
Air conditioner component 80-4
Configuration and function of refrigeration cycle 80-6
Outline of refrigeration cycle 80-7
Air conditioner unit 80-9
Dual pressure switch 80-14
Air conditioner controller 80-15
Compressor 80-16
Condenser 80-17
Receiver drier 80-18
Sunlight sensor 80-20
Outer temperature sensor (outside air temperature sensor) 80-21
Procedure for testing and troubleshooting 80-22
Circuit diagram and arrangement of connector pins 80-24
System diagram 80-26
Parts and connectors layout 80-29
Testing with self-diagnosis function 80-34
Testing temperature control system 80-37
Testing vent (mode) changeover 80-39
Testing FRESH/RECIRC air changeover 80-41
Check evaporator temperature sensor 80-43
Testing relays 80-45
Troubleshooting chart 1 80-47
Troubleshooting chart 2 80-48
Information in troubleshooting table 80-50
Failure code list related to air conditioner 80-51
Failure code [879AKA] A/C Inner Sensor Open Circuit 80-52
Failure code [879AKB] A/C Inner Sensor Short Circuit 80-54
00-16 WA380-7
Differential 60-23
Rear axle 60-22-2
Failure code [879BKA] A/C Outer Sensor Open Circuit 80-56
00 Index and foreword
Index
Failure code [879CKB] Ventilating Sensor Short Circuit 80-62
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit 80-64
Failure code [879EMC] Ventilation Damper Abnormality 80-66
Failure code [879FMC] Air Mix Damper Abnormality 80-69
A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does
not operate) 80-72
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) 80-75
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) 80-78
A-4 Troubleshooting for FRESH/RECIRC air changeover 80-81
Troubleshooting with gauge pressure 80-83
Connection of service tool 80-86
Precautions for disconnecting and connecting hoses and tubes in air conditioner
circuit 80-88
Handling of compressor oil 80-90
90 Diagrams and drawings 90-1
Table of contents 90-2
Hydraulic circuit diagram 90-3
Symbols in hydraulic circuit diagram 90-3
Power train hydraulic circuit diagram 90-7
Hydraulic circuit diagram 90-9
Electric circuit diagram 90-11
Symbols in electric circuit diagram 90-11
Electric circuit diagram of machine body 90-15
Electric circuit diagram of floor 90-27
Index 1
WA380-7 00-17
Failure code [879BKB] A/C Outer Sensor Short Circuit 80

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