Komatsu WA380-6 Wheel Loader Service Manual
1,341 pages · Publication SEN00769-03
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- Models
- WA380-6
- Serial coverage
- 65001 and up
- Manual type
- Service Manual
- Pages
- 1,341
- Publication
- SEN00769-03
- Condition
- Brand new
What's inside
From the manual's own table of contents: 217 sections, 470 entries. See sample pages (PDF, 1318 KB)
Composition of shop manual
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling electric equipment and hydraulic component
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
Specification and technical data
Specification dimension drawing
Specifications
Weight table
Table of fuel, coolant and lubricants
Engine and cooling system
Engine mount and transmission mount
Cooling system
Cooling fan pump
Cooling fan motor
Power train
Power train system diagram
Drive shaft
Power train piping diagram
Show all 217 sections
Torque converter
Transmission
Flow control valve
Valve assembly
ECMV
Main relief valve and torque converter relief valve
Axle
Front axle
Rear axle
Differential
Front differential
Rear differential
Limited slip differential
Final drive48 topics
- 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
- 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
- Breather
- Power train pump
- Work equipment pump
- Work equipment control valve
- CLSS
- Outline of CLSS
- Basic principle
- Each function and operation of each valve
- Hydraulic circuit diagram and names of valves
- Area ratio of pressure compensation valve
- Hydraulic system, Part 2
- PPC valve
- Stabilizer valve
- Accumulator (for PPC circuit)
- Accumulator (for ECSS)
- Work equipment
- Work equipment linkage
- Bucket
- Bucket positioner and boom kick-out
- Work equipment cylinder
Cab and its attachments
Air conditioner
Air conditioner piping diagram
Air conditioner unit
Blower and intake unit
Compressor
Condenser
Receiver
Air conditioner panel
Electrical system, Part 1
Machine monitor system
Machine monitor
Electrical system, Part 2
Electrical system (Transmission controller system)
Transmission controller
Electrical system, Part 3
Electric transmission control
Kickdown switch and hold switch
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
Standard service value table
Standard service value table for engine
Standard service value table for chassis
Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting
Measuring engine speed
Measuring exhaust gas color
Adjusting valve clearance
Measuring compression pressure
Measuring blow-by pressure
Measuring engine oil pressure
Measuring intake air (boost) pressure
Handling fuel system equipment
Releasing residual pressure in fuel system
Measuring fuel pressure
Measuring fuel return rate and leakage
Bleeding air from fuel circuit
Testing leakage in fuel system51 topics
- Handling reduced cylinder mode operation
- Handling no-injection cranking operation
- Handling controller voltage circuit
- Testing and adjusting air conditioner compressor belt tension
- Adjusting transmission speed sensor
- Measuring directional lever
- Measuring 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 and adjusting steering stop valve
- Testing and adjusting steering wheel
- Testing steering oil pressure
- Bleeding air from steering circuit
- Testing and adjusting, Part 2
- Testing hydraulic drive fan
- Bleeding air from hydraulic drive fan circuit
- Measuring brake pedal
- Measuring brake performance
- Testing and adjusting accumulator charge pressure
- Testing wheel brake oil pressure
- Measuring wear of wheel brake disc
- Bleeding air from wheel brake circuit
- Releasing residual pressure in brake accumulator circuit
- Testing parking brake performance
- Measuring parking brake oil pressure
- Testing wear of parking brake disc
- Method of releasing parking brake manually
- Measuring and adjusting work equipment control lever
- Measuring and adjusting work equipment PPC oil pressure
- Measuring and adjusting work equipment oil pressure
- Bleeding air from work equipment circuit
- Releasing residual pressure in work equipment circuit
- 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
- Adjusting machine monitor
- Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor
- Testing and adjusting, Part 3
- Special functions of machine monitor (EMMS)
- Pm-click inspection table
- General information on troubleshooting
- Points to remember when troubleshooting
- Sequence of events in troubleshooting
- Testing before troubleshooting
- Classification and procedures of troubleshooting
- Connection table for connector pin numbers
- T-branch box and T-branch adapter table
Troubleshooting by failure code (Display of code), Part 1
Failure codes list
Before carrying out troubleshooting for electrical system
Information contained troubleshooting table
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 [2F00MA] (Parking brake: Malfunction)
Troubleshooting by failure code (Display of code), Part 2
Failure code [2G43ZG] (Accumulator: Low oil pressure)
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@C7NS] (Brake 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)
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA234] (Engine overspeed)
Failure code [CA238] (Ne speed sensor power supply error)
Failure code [CA271] (PCV1 Short circuit)
Failure code [CA272] (PCV1 Disconnection)
Failure code [CA322] (Injector #1 (L/B #1) open/short error)
Failure code [CA323] (Injector #5 (L/B #5) open/short error)
Failure code [CA324] (Injector #3 (L/B #3) open/short error)55 topics
- Failure code [CA325] (Injector #6 (L/B #6) open/short error)
- Failure code [CA331] (Injector #2 (L/B #2) open/short error)
- Failure code [CA332] (Injector #4 (L/B #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 [CA1117] (Partial engine controller data loss error)
- Failure code [CA1633] (KOMNET datalink timeout error)
- Troubleshooting by failure code (Display of code), Part 4
- Failure code [CA2185] (Throttle sensor supply voltage high error)
- Failure code [CA2186] (Throttle sensor power supply low error)
- 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)
- Short circuit with power supply line)
- Failure code [D192KA] (ECSS solenoid: Disconnection)
- Failure code [D192KB] (ECSS solenoid: Short circuit)
- Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)
- Failure code [D5ZHKA] (Terminal C signal: Disconnection)
- Failure code [D5ZHKB] (Terminal C signal: Short circuit)
- stopped state)
- Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)
- Failure code [DAF3KK] (Machine monitor: Low source voltage (input))
- Failure code [DAF5KP] (Machine monitor: Low output voltage)
- Defective communication (Abnormality in target component system))
- Failure code [DAQ0KK] (Transmission controller: Low source voltage)
- Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)
- Low source voltage (input))
- Disagreement of model selection signals)
Troubleshooting by failure code (Display of code), Part 51 topic
- Defective communication (Abnormality in target component system))
Failure code [DAQRMA] (Transmission controller option setting: Malfunction)2 topics
- Defective communication (Abnormality in target component system)
- Disagreement in model selection signals)
Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time2 topics
- Switch is kept pressed for long time
- Switch is kept pressed for long time)
Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time)
Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)
Troubleshooting by failure code (Display of code), Part 6
Failure code [DDK3KA] (Right FNR switch: Disconnection)
Failure code [DDK6KA] (FNR lever switch: Disconnection)
Failure code [DDK6KB] (FNR lever switch: Short circuit)
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)
Failure code [DF10KA] (Transmission shift lever switch: Disconnected)
Failure code [DF10KB] (Transmission shift lever switch: Short circuit)
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected)
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)
Troubleshooting by failure code (Display of code), Part 7
Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range)
Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection)
Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit)51 topics
- Troubleshooting by failure code (Display of code), Part 8
- Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)
- Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)
- Failure code [DV00KB] (Alarm buzzer: Short circuit)
- Troubleshooting by failure code (Display of code), Part 9
- Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)
- Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)
- Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)
- Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)
- Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)
- Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)
- Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)
- Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)
- Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)
- Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)
- Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)
- Troubleshooting by failure code (Display of code), Part 10
- Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)
- Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)
- Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)
- Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)
- Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)
- Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)
- Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)
- Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)
- Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)
- Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)
- Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)
- Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)
- Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)
- Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)
- Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)
- Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)
- Troubleshooting of electrical system (E-mode)
- Before carrying out troubleshooting for electrical system
- Information in troubleshooting table
- Engine does not start
- Wiper does not operate
- Windshield washer does not operate
- Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off
- Working lamp does not light up or go off
- Turn signal lamp and hazard lamp do not light up or go off
- Brake lamp does not light or it keeps lighting up
- Backup lamp does not light or it keeps lighting up
- Backup buzzer does not sound or it keeps sounding
- Horn does not sound or it keeps sounding
- Alarm buzzer does not sound or it keeps sounding
- Air conditioner does not operate or stop
- The KOMTRAX system does not work properly
- Troubleshooting of hydraulic and mechanical system (H-mode)
- Method of using troubleshooting chart
Table of failure modes and causes
The machine does not start1 topic
- [Machine with lockup clutch (if equipped)]
Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)]1 topic
- and the gear is not shifted
Shocks are large at the times of starting and shifting gear
Time lag is large at the times of starting and shifting gear
The torque converter oil temperature is high
Steering does not turn
Steering does not turn [Machine with joystick steering (if equipped)]
Steering response is low
Turning, response of steering is poor [machine with joystick steering (if equipped)]
Steering is heavy
When machine turns, it shakes or makes large shocks1 topic
- [machine with joystick steering (if equipped)]
The wheel brake does not work or does not work well
The wheel brake is not released or it drags
The parking brake does not work or does not work well
The parking brake is not released or it drags (including emergency release system)
Lift arm does not rise
Lift arm speed is low or rising force of lift arm is insufficient
When rising, the lift arm comes to move slowly at specific height
The lift arm cylinder cannot hold down the bucket (Bucket floats)
Hydraulic drifts of the lift arm is large
The lift arm wobbles during operation
Bucket does not tilt back
Bucket speed is low or tilting back force is insufficient
The bucket comes to operate slowly in the midst of tilting-back
The bucket cylinder cannot hold down the bucket
Hydraulic drifts of the bucket is large1 topic
- set to “HOLD”)
Lift arm and bucket control levers do not move smoothly and are heavy
During operation of the machine, engine speed lowers remarkably or engine stalls
Large shock is made when work equipment starts and stops
When work equipment circuit is relieved singly, other work equipment moves
ECSS does not operate, and pitching, bouncing occur
Troubleshooting of engine (S-mode)
Engine does not start easily
Engine does not start
Engine does not pick up smoothly
Engine stops during operations
Engine does not rotate smoothly
Engine lacks output (or lacks power)
Exhaust smoke is black (Incomplete combustion)
Oil consumption is excessive (or exhaust smoke is blue)
Engine oil becomes contaminated quickly
Fuel consumption is excessive
Coolant contains oil (blows back or reduces)
Oil pressure drops
Oil level rises (Water, fuel in oil)
Coolant temperature rises too high (Overheating)
Abnormal noise is made39 topics
- Vibration is excessive
- General information on disassembly and assembly
- How to read this manual
- Coating materials list
- Special tools list
- Removal and installation of fuel supply pump assembly
- Removal and installation of fuel injector assembly
- Removal and installation of cylinder head assembly
- Removal and installation of engine hood
- Removal and installation of radiator assembly
- Removal and installation of air aftercooler
- Removal and installation of hydraulic oil cooler assembly
- Removal and installation of engine assembly
- Removal and installation of cooling fan and fan motor assembly
- Removal and installation of fuel tank assembly
- Power train
- Removal and installation of torque converter and transmission assembly
- Disassembly and assembly of torque converter assembly (Standard specification)
- Disassembly and assembly of torque converter assembly (Lockup specification)
- Disassembly and assembly of transmission assembly
- Disassembly and assembly of transmission clutch pack assembly
- Disassembly and assembly of parking brake assembly
- Removal and installation of front axle assembly
- Removal and installation of rear axle assembly
- Disassembly and assembly of axle housing
- Disassembly and assembly of differential assembly
- Removal and installation of steering demand valve assembly
- Removal and installation of parking brake discs and plates
- Removal and installation of center hinge pin
- Removal and installation of counterweight
- Hydraulic system
- Removal and installation of work equipment control valve assembly
- Removal and installation of power train pump and work equipment pump assembly
- Removal and installation of steering pump and cooling fan pump assembly
- Removal and installation of hydraulic tank assembly
- Removal and installation of work equipment assembly
- Disassembly and assembly of hydraulic cylinder assembly
- Cab and its attachments
- Removal and installation of operator's cab and floor frame assembly
Removal and installation of operator's cab glass (stuck glass)
Removal and installation of air conditioner unit assembly
Electrical system
Removal and installation of engine controller assembly
Hydraulic diagrams and drawings
Power train hydraulic circuit diagram
Hydraulic circuit diagram
Electrical diagrams and drawings
Electrical circuit diagram (1/2)
Electrical circuit diagram (2/2)
Connector arrangement diagram
Inside this manual
Real pages from this service manual (1,341 pages). Open the sample pages (PDF, 1318 KB)
- Specifications, page 436: 30 Testing and adjusting
- Troubleshooting, page 796: Failure code [CA1633] (KOMNET datalink timeout error)
- Diagram, page 1,056: Circuit diagram related to backup lamp relay
- Foldout diagram, page 1,337: WA380-6 (KA SPEC.)
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the WA380-6 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 1,341 pages
Quantity one is the manual described above.
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Other editions and similar models
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