Service manual Komatsu WA270-7 80001 & Up | SEN06255-01

Komatsu WA270-7 80001 & Up SEN06255-01 (Preview)

Cover
00 Index and foreword
– Index
– Foreword, safety and general information
— Important safety notice
— How to read the shop manual
— Explanation of terms for maintenance standard
— Handling equipment of fuel system devices
— Handling of intake system parts
— Handling of hydraulic equipment
— Method of disconnecting and connecting of push-pull type coupler
— Handling of electrical equipment
— How to read electric wire code
— Precautions when performing operation
— Practical use of KOMTRAX
— Standard tightening torque table
— List of abbreviation
— Conversion table
01 Specification
– Table of contents
– Specifications
— Specification drawing
— Specifications
— Weight table
— Table of fuel, coolant, and lubricants
10 Structure and function
– Table of contents
– Engine and cooling system
— Engine related parts
— KVGT
— EGR system piping drawing
— EGR system circuit diagram
— EGR valve
— EGR cooler
— KCCV layout drawing
— KCCV ventilator
— KDPF
— Cooling system
— Cooling fan motor
– Power train
— Power train system
— Layout of power train parts
— Damper
— HST pump
— HST motor1
— HST motor2
— Transfer
— Clutch solenoid valve
— Drive shaft
— Axle
— Differential
— Torque proportional differential
— Limited slip differential
— Final drive
– Steering system
— Layout of steering devices
— Steering column
— Priority valve
— Cushion valve
— Emergency steering valve
— Orbitrol valve
— 2way restrictor valve
– Brake system
— Layout of brake parts
— Brake accumulator charge valve
— Brake valve
— Brake accumulator
— Slack adjuster
— Brake
— Parking brake control
— Parking brake
— Parking brake solenoid valve
– Undercarriage and frame
— Axle mount
— Center hinge pin
— Tire
– Hydraulic system
— Hydraulic component layout
— Work equipment control
— Hydraulic tank
— Double type gear pump
— Steering and work equipment pump
— Control valve
— CLSS
— Hydraulic circuit diagram and names of valves
— Self-pressure reducing valve
— Work equipment PPC valve
— Work equipment lock solenoid valve
— PPC circuit accumulator
— ECSS accumulator
– Work equipment
— Work equipment linkage
— Bucket
– Cab and its attachments
— ROPS cab
— Cab mount
– Electrical system
— Engine control system
— Preheating system
— Engine output limit function
— Automatic warm-up function
— Parking brake control system
— System operating lamp function
— Battery disconnect switch function
— HST controller system
— Machine monitor system
— Rearview monitor system
— KOMTRAX system
— System component parts
— Sensor
20 Standard value tables
– Table of contents
– Standard service value table
— Standard value table for engine
— Standard value table for machine
— Standard value table for electrical system
30 Testing and adjusting
– Table of contents
– Related information on testing and adjusting
— Tools for testing and adjusting
— Sketch of tools for testing and adjusting
– Engine and cooling system
— Testing engine speed
— Testing boost pressure
— Testing exhaust gas temperature
— Testing exhaust gas color
— Testing and adjusting valve clearance
— Testing compression pressure
— Testing blowby pressure
— Testing engine oil pressure
— Testing EGR valve and KVGT driving oil pressure
— Testing fuel pressure
— Testing fuel discharge, return and leakage
— Bleeding air from fuel system
— Testing fuel circuit for leakage
— Handling cylinder cutout mode operation
— Handling no-injection cranking operation
— Testing of KDPF and muffler stack for looseness and damage
— Testing of installed condition of cylinder heads and manifolds
— Testing engine piping for damage and looseness
— Testing and adjusting air conditioner compressor belt tension
— Replacing alternator belt
– Power train
— Testing oil leakage from axle final drive
— Testing drive shaft for looseness, backlash, and damage
— Testing accelerator pedal
— Testing and adjusting HST oil pressure
— Testing transfer clutch control pressure
– Steering system
— Testing directional lever
— Testing steering wheel
— Testing work equipment control lever
— Testing and adjusting steering circuit oil pressure
— Bleeding air from steering cylinder circuit
– Brake system
— Testing brake pedal
— Testing braking performance
— Testing and adjusting of accumulator charge pressure
— Testing wheel brake oil pressure
— Testing lowering of wheel brake pressure
— Testing wear of wheel brake disc
— Bleeding air from wheel brake circuit
— Releasing remaining pressure in brake accumulator circuit
— Testing parking brake performance
— Testing wear of parking brake disc
— Testing parking brake release pressure
— Method of releasing parking brake manually
– Hydraulic system
— Testing cooling fan speed
— Testing cooling fan pump circuit oil pressure
— Bleeding air from hydraulic fan circuit
— Testing and adjusting work equipment PPC oil pressure
— Testing and adjusting work equipment oil pressure
— Bleeding air from work equipment circuit
— Releasing remaining pressure from work equipment circuit
— Testing ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas
– Work equipment
— Testing and adjusting bucket positioner and bucket proximity switch
— Testing and adjusting boom position detection lever
– Electrical system
— Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor
— Special functions of machine monitor
— Adjusting rearview camera angle
— Handling voltage circuit of engine controller
— Handling battery disconnect switch
— Testing diodes
– Pm clinic
— Pm Clinic service
— Check sheet
40 Troubleshooting
– Table of contents
– Related information on troubleshooting
— Troubleshooting points
— Sequence of events in troubleshooting
— Checks before troubleshooting
— Inspection procedure before troubleshooting
— Preparation for troubleshooting of electrical system
— Classification and procedures for troubleshooting
— Symptom and troubleshooting numbers
— Information described in troubleshooting table
— Procedure for troubleshooting wiring harness of pressure sensor system for open circuit
— Connector list and layout
— Connector contact identification
— T-branch box and T-branch adapter table
— Fuse location table
— Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement
— Precautions when performing troubleshooting of machine monitor
— Processing procedure of harness checker for troubleshooting of machine monitor LCD unit
— Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors)
— Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135])
— Failure codes table
– Troubleshooting by failure code (Display of code)
— Failure code [2F00MA] Failure of Parking Brake Circuit
— Failure code [2F00MB] Malfunction of Parking Brake
— Failure code [2G42ZG] Accumulator Oil Pressure Low (Front)
— Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear)
— Failure code [6091NX] HST Oil Filter Clogging
— Failure code [7RHYKA] Disconnection of Fan Variable Control Sol.
— Failure code [7RHYKB] Ground Fault of Fan Variable Control Sol.
— Failure code [7RHYKY] Hot Short of Fan Variable Control Sol.
— Failure code [879AKA] A/C Inner Sensor Open Circuit
— Failure code [879AKB] A/C Inner Sensor Short Circuit
— Failure code [879BKA] A/C Outer Sensor Open Circuit
— Failure code [879BKB] A/C Outer Sensor Short Circuit
— Failure code [879CKA] Ventilating Sensor Open Circuit
— Failure code [879CKB] Ventilating Sensor Short Circuit
— Failure code [879DKZ] Sunlight Sensor Open or Short Circuit
— Failure code [879EMC] Ventilation Damper Abnormality
— Failure code [879FMC] Air Mix Damper Abnormality
— Failure code [989L00] Engine Controller Lock Caution 1
— Failure code [989M00] Engine Controller Lock Caution 2
— Failure code [989N00] Engine Controller Lock Caution 3
— Failure code [A1U0N3] HC Desorb Request 1
— Failure code [A1U0N4] HC Desorb Request 2
— Failure code [B@BAZG] Eng Oil Press Low
— Failure code [B@BCNS] Eng Water Overheat
— Failure code [B@BCZK] Eng Water Level Low
— Failure code [B@CRNS] HST Oil Temp. Overheat
— Failure code [CA115] Eng Ne and Bkup Speed Sens Error
— Failure code [CA122] Chg Air Press Sensor High Error
— Failure code [CA123] Chg Air Press Sensor Low Error
— Failure code [CA131] Throttle Sensor High Error
— Failure code [CA132] Throttle Sensor Low Error
— Failure code [CA144] Coolant Temp Sens High Error
— Failure code [CA145] Coolant Temp Sens Low Error
— Failure code [CA153] Chg Air Temp Sensor High Error
— Failure code [CA154] Chg Air Temp Sensor Low Error
— Failure code [CA187] Sensor 2 Supply Volt Low Error
— Failure code [CA221] Ambient Press Sensor High Error
— Failure code [CA222] Ambient Press Sensor Low Error
— Failure code [CA227] Sensor 2 Supply Volt High Error
— Failure code [CA234] Eng Overspeed
— Failure code [CA238] Ne Speed Sensor Supply Volt Error
— Failure code [CA239] Ne Speed Sens Supply Volt High Error
— Failure code [CA271] IMV/PCV1 Short Error
— Failure code [CA272] IMV/PCV1 Open Error
— Failure code [CA295] Ambient Press Sens In Range Error
— Failure code [CA322] Inj #1(L#1) Open/Short Error
— Failure code [CA323] Inj #5(L#5) Open/Short Error
— Failure code [CA324] Inj #3(L#3) Open/Short Error
— Failure code [CA325] Inj #6(L#6) Open/Short Error
— Failure code [CA331] Inj #2(L#2) Open/Short Error
— Failure code [CA332] Inj #4(L#4) Open/Short Error
— Failure code [CA343] ECM Critical Internal Failure
— Failure code [CA351] Injectors Drive Circuit Error
— Failure code [CA352] Sensor 1 Supply Volt Low Error
— Failure code [CA356] Mass Air Flow Sensor High Error
— Failure code [CA357] Mass Air Flow Sensor Low Error
— Failure code [CA386] Sensor 1 Supply Volt High Error
— Failure code [CA428] Water in Fuel Sensor High Error
— Failure code [CA429] Water in Fuel Sensor Low Error
— Failure code [CA431] Idle Validation Sw Error
— Failure code [CA432] Idle Validation Process Error
— Failure code [CA435] Eng Oil Press Sw Error
— Failure code [CA441] Battery Voltage Low Error
— Failure code [CA442] Battery Voltage High Error
— Failure code [CA449] Rail Press Very High Error
— Failure code [CA451] Rail Press Sensor High Error
— Failure code [CA452] Rail Press Sensor Low Error
— Failure code [CA488] Chg Air Temp High Torque Derate
— Failure code [CA515] Rail Press Sens Sup Volt High Error
— Failure code [CA516] Rail Press Sens Sup Volt Low Error
— Failure code [CA553] Rail Press High Error
— Failure code [CA555] Crankcase Press High Error 1
— Failure code [CA556] Crankcase Press High Error 2
— Failure code [CA559] Rail Press Low Error
— Failure code [CA595] Turbo Speed High Error 2
— Failure code [CA687] Turbo Speed Low Error
— Failure code [CA689] Eng Ne Speed Sensor Error
— Failure code [CA691] Intake Air Temp Sens High Error
— Failure code [CA692] Intake Air Temp Sens Low Error
— Failure code [CA697] ECM Internal Temp Sensor High Error
— Failure code [CA698] ECM Int Temp Sensor Low Error
— Failure code [CA731] Eng Bkup Speed Sens Phase Error
— Failure code [CA778] Eng Bkup Speed Sensor Error
— Failure code [CA1117] Persistent Data Lost Error
— Failure code [CA1664] KDOC Malfunction
— Failure code [CA1691] Regeneration Ineffective
— Failure code [CA1695] Sensor 5 Supply Volt High Error
— Failure code [CA1696] Sensor 5 Supply Volt Low Error
— Failure code [CA1843] Crankcase Press Sens High Error
— Failure code [CA1844] Crankcase Press Sens Low Error
— Failure code [CA1879] KDPF Delta P Sensor High Error
— Failure code [CA1881] KDPF Delta P Sensor Low Error
— Failure code [CA1883] KDPF Delta P Sens In Range Error
— Failure code [CA1921] KDPF Soot Load High Error 1
— Failure code [CA1922] KDPF Soot Load High Error 2
— Failure code [CA1942] Crankcase Press Sens In Range Error
— Failure code [CA1993] KDPF Delta Pressure Low Error
— Failure code [CA2185] Throt Sensor Sup Volt High Error
— Failure code [CA2186] Throt Sensor Sup Volt Low Error
— Failure code [CA2249] Rail Press Very Low Error
— Failure code [CA2271] EGR Valve Pos Sens High Error
— Failure code [CA2272] EGR Valve Pos Sens Low Error
— Failure code [CA2288] Turbo Speed High Error 1
— Failure code [CA2311] IMV Solenoid Error
— Failure code [CA2349] EGR Valve Solenoid Open Error
— Failure code [CA2353] EGR Valve Solenoid Short Error
— Failure code [CA2357] EGR Valve Servo Error
— Failure code [CA2373] Exhaust Manifold Press Sens High error
— Failure code [CA2374] Exhaust Manifold Press Sens Low error
— Failure code [CA2375] EGR Orifice Temp Sens High Error
— Failure code [CA2376] EGR Orifice Temp Sens Low Error
— Failure code [CA2381] KVGT Pos Sens High Error
— Failure code [CA2382] KVGT Pos Sens Low Error
— Failure code [CA2383] KVGT Solenoid Open Error
— Failure code [CA2386] KVGT Solenoid Short Error
— Failure code [CA2387] KVGT Servo Error
— Failure code [CA2554] Exh Manifold Press Sens In Range Error
— Failure code [CA2555] Grid Htr Relay Volt Low Error
— Failure code [CA2556] Grid Htr Relay Volt High Error
— Failure code [CA2637] KDOC Face Plugging
— Failure code [CA2639] Manual Stationary Regeneration Request
— Failure code [CA2961] EGR Orifice Temp High Error 1
— Failure code [CA2973] Chg Air Press Sensor In Range Error
— Failure code [CA3133] KDPF Outlet Press Sens High Error
— Failure code [CA3134] KDPF Outlet Press Sens Low Error
— Failure code [CA3135] KDPF Outlet Press Sens In Range Error
— Failure code [CA3251] KDOC Inlet Temp High Error
— Failure code [CA3253] KDOC Temp Error – Non Regeneration
— Failure code [CA3254] KDOC Outlet Temp High Error 1
— Failure code [CA3255] KDPF Temp Error – Non Regeneration
— Failure code [CA3256] KDPF Outlet Temp High Error 1
— Failure code [CA3311] KDOC Outlet Temp High Error 2
— Failure code [CA3312] KDPF Outlet Temp High Error 2
— Failure code [CA3313] KDOC Inlet Temp Sensor Low Error
— Failure code [CA3314] KDOC Inlet Temp Sens High Error
— Failure code [CA3315] KDOC Inlet Temp Sens In Range Error
— Failure code [CA3316] KDOC Outlet Temp Sens Low Error
— Failure code [CA3317] KDOC Outlet Temp Sens High Error
— Failure code [CA3318] KDOC Outlet Temp Sens In Range Error
— Failure code [CA3319] KDPF Outlet Temp Sens High Error
— Failure code [CA3321] KDPF Outlet Temp Sens Low Error
— Failure code [CA3322] KDPF Outlet Temp Sens In Range Error
— Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error
— Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error
— Failure code [CA3741] Rail Press Valve Trip Error
— Failure code [D110L4] Disconnection of Battery Relay Signal
— Failure code [D160KA] Disconnection of Backup Lamp Relay Output
— Failure code [D160KY] Hot Short of Backup Lamp Relay Output
— Failure code [D191KA] Disconnection of Neutral Output Relay
— Failure code [D191KB] Ground Fault of Neutral Output Relay
— Failure code [D191KY] Hot Short of Neutral Output Relay
— Failure code [D192KA] Disconnection of ECSS Solenoid
— Failure code [D192KB] Ground Fault of ECSS Solenoid
— Failure code [D192KY] Hot Short of ECSS Solenoid
— Failure code [D19JKZ] Personal Code Relay Abnormality
— Failure code [D1B0KA] Disconnection of HST Safety Relay
— Failure code [D1B0KB] Ground Fault of HST Safety Relay
— Failure code [D1B0KY] Hot Short of HST Safety Relay
— Failure code [D1B0MC] Malfunction of HST Safety Relay
— Failure code [D1E6KA] Disconnection of Parking Brake Relay
— Failure code [D1E6KB] Ground Fault of Parking Brake Relay
— Failure code [D1E6KY] Hot Short of Parking Brake Relay
— Failure code [D5ZHKA] Failure of Key SW C Signal
— Failure code [D5ZHKB] Key SW C Signal Short Circuit
— Failure code [D5ZHL6] Disconnection of Key SW C
— Failure code [D811MC] KOMTRAX Error
— Failure code [D862KA] GPS Antenna Open Circuit
— Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX)
— Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX)
— Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2
— Failure code [D8AQKR] CAN2 Discon (KOMTRAX)
— Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON)
— Failure code [DAF0MB] Monitor ROM Abnormality
— Failure code [DAF0MC] Monitor Error
— Failure code [DAF3KK] Controller Power Source Low (MON)
— Failure code [DAF8KB] Camera Power Supply Short Circuit
— Failure code [DAFDKB] Monitor 12V Power Output Short Circuit
— Failure code [DAFGMC] GPS Module Error
— Failure code [DAFLKA] Operating Lamp Open Circuit (MON)
— Failure code [DAFLKB] Operating Lamp Short Circuit (MON)
— Failure code [DAFQKR] CAN2 Discon (Monitor)
— Failure code [DAJ0KK] Controller Power Source Low (HST)
— Failure code [DAJ0KT] Abnormality of Non-volatile Memory (HST)
— Failure code [DAJ0MC] HST Con Error
— Failure code [DAJ1KA] Disconnection of Key SW ACC (HST)
— Failure code [DAJ2KK] Solenoid Power Source Low (HST)
— Failure code [DAJ4KB] Ground Fault of Sol. Self-Holding Relay
— Failure code [DAJ4KZ] Failure of Sol. Self-Holding Relay
— Failure code [DAJ5KX] Failure of 5V Power Source 0
— Failure code [DAJ6KX] Failure of 5V Power Source 1
— Failure code [DAJ9KQ] Inconsistency of Model Selection (HST)
— Failure code [DAJLKA] Operating Lamp Open Circuit (HST)
— Failure code [DAJLKB] Operating Lamp Short Circuit (HST)
— Failure code [DAJQKR] CAN2 Discon ( HST Con)
— Failure code [DAJRKR] CAN1 Discon ( HST Con)
— Failure code [DAJRMA] Inconsistency of Option Selection (HST)
— Failure code [DAZ9KQ] A/C Model Selection Abnormality
— Failure code [DAZQKR] CAN2 Discon (Aircon ECU)
— Failure code [DB2QKR] CAN2 Discon (Engine Con)
— Failure code [DB2RKR] CAN1 Discon (Engine Con)
— Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW
— Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch
— Failure code [DDB2L4] Stop Lamp Switch Signal Malfunction
— Failure code [DDB6L4] Parking Brake Signal Malfunction
— Failure code [DDD7KA] Failure of Variable Speed Control
— Failure code [DDD7KY] Hot Short of Variable Speed Control
— Failure code [DDK3KA] FNR SW Input Signal Disconnection
— Failure code [DDK3KB] FNR SW Input Signal Short Circuit
— Failure code [DDK6KA] FNR Lever Input Signal Disconnection
— Failure code [DDK6KB] FNR Lever Input Signal Short Circuit
— Failure code [DDNRLD] Ground Fault of Work Equip. Lock Switch
— Failure code [DF10KA] Disconnection of Speed Range Input
— Failure code [DF10KB] Ground Fault of Speed Range Input
— Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor
— Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor
— Failure code [DHG1KX] Out of Range of HST Oil Temp. Sensor
— Failure code [DHHBKA] Failure of HST Press. Sens. Circuit (MA)
— Failure code [DHHBKY] Hot Short of HST Press. Sens. Circuit (MA)
— Failure code [DHHCKA] Failure of HST Press. Sens. Circuit (MB)
— Failure code [DHHCKY] Hot Short of HST Press. Sens. Circuit (MB)
— Failure code [DHPCKA] Failure of Boom Press. Sensor (Bottom)
— Failure code [DHPCKY] Hot Short of Boom Press. Sensor (Bottom)
— Failure code [DHPEKA] Failure of Steering & Loader Pump Press.
— Failure code [DHPEKY] Hot Short of Steering & Loader Pump Press.
— Failure code [DHS8KA] Failure of Boom Raise PPC Sens. Circuit
— Failure code [DHS8KY] Hot Short of Boom Raise PPC Sens. Circuit
— Failure code [DHS9KA] Failure of Boom Lower PPC Sens. Circuit
— Failure code [DHS9KY] Hot Short of Boom Lower PPC Sens. Circuit
— Failure code [DHSDKA] Failure of Bucket Dump PPC Sens. Circuit
— Failure code [DHSDKY] Hot Short of Bucket Dump PPC Sens. Circuit
— Failure code [DHSNKA] Failure of Bucket Tilt PPC Sens. Circuit
— Failure code [DHSNKY] Hot Short of Bucket Tilt PPC Sens. Circuit
— Failure code [DHT8ZG] Steering Oil Pressure Low
— Failure code [DHTCL6] Failure of HST Oil Filter Sensor Circuit
— Failure code [DJF1KA] Disconnection of Fuel Level Sensor
— Failure code [DK55KA] Failure of FNR Lever Potentio
— Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit
— Failure code [DK55L5] Failure of FNR Lever Potentio
— Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main)
— Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main)
— Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree
— Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub)
— Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub)
— Failure code [DK70KA] Failure of inching sensor Circuit
— Failure code [DK70KY] Hot Short of inching sensor Circuit
— Failure code [DKA0KA] Failure of Boom Angle Sensor
— Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit
— Failure code [DKA0L0] Boom Angle Sensor Dislocation
— Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor
— Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor
— Failure code [DLT3KX] Vehicle Speed Sensor Circuit Failure (B)
— Failure code [DLT4KX] Vehicle Speed Sensor Circuit Failure (A)
— Failure code [DLT4L0] Vehicle Speed Sensor Failure (A & B)
— Failure code [DLT4LC] Vehicle Speed Sensor Failure (A or B)
— Failure code [DPQ1KR] LIN Discon (Switch Panel)
— Failure code [DPQ2KR] LIN Discon (LED Unit)
— Failure code [DPQ3KR] LIN Discon (Rear View Monitor)
— Failure code [DSJ0KR] CAN2 Discon (Meter Unit)
— Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic.
— Failure code [DV00KB] Ground Fault of Buzzer Output
— Failure code [DW26KA] Disconnection of Motor 2 Solenoid
— Failure code [DW26KB] Ground Fault of Motor 2 Solenoid
— Failure code [DW26KY] Hot Short of Motor 2 Solenoid
— Failure code [DW4BKA] Disconnection of Parking Brake Valve
— Failure code [DW4BKB] Ground Fault of Parking Brake Valve
— Failure code [DW4BKY] Hot Short of Parking Brake Valve
— Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt)
— Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt)
— Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt)
— Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid
— Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid
— Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid
— Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom)
— Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom)
— Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom)
— Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket)
— Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket)
— Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket)
— Failure code [DX19KA] Disconnection of Motor 1 Solenoid
— Failure code [DX19KB] Ground Fault of Motor 1 Solenoid
— Failure code [DX19KY] Hot Short of Motor 1 Solenoid
— Failure code [DX20KA] Disconnection of Clutch Control Solenoid
— Failure code [DX20KB] Ground Fault of Clutch Control Solenoid
— Failure code [DX20KY] Hot Short of Clutch Control Solenoid
— Failure code [DXAWKA] Disconnection of HST Pump EPC Sol.
— Failure code [DXAWKB] Ground Fault of HST Pump EPC Sol.
— Failure code [DXAWKY] Hot Short of HST Pump EPC Sol.
— Failure code [DXH7KA] Disconnection of Reverse Solenoid
— Failure code [DXH7KB] Ground Fault of Reverse Solenoid
— Failure code [DXH7KY] Hot Short of Reverse Solenoid
— Failure code [DXH8KA] Disconnection of Forward Solenoid
— Failure code [DXH8KB] Ground Fault of Forward Solenoid
— Failure code [DXH8KY] Hot Short of Forward Solenoid
— Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT)
— Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT)
— Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT)
— Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET)
— Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET)
— Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET)
— Failure code [H2K0KA] Failure of Quick Coupler Lock Signal
— Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal
— Failure code [J141N1] Steering Pump Over Run
— Failure code [LA00L3] Failure of Fan Reverse
— Failure code [M100N1] HST Pump Over Run
— Failure code [M400N1] HST Motor 1 Over Run
– Troubleshooting of electrical system (E-mode)
— E-1 Engine does not start
— E-2 Manual preheating system does not work
— E-3 Automatic preheating system does not work
— E-4 While preheating is working, preheating monitor does not light up
— E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing
— E-6 LCD unit on machine monitor displays nothing
— E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers)
— E-8 LCD on machine monitor does not display properly
— E-9 Meter unit display on machine monitor is abnormal
— E-10 Night lighting lamp of meter unit on machine monitor is abnormal
— E-11 Caution LED on machine monitor is abnormal
— E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly
— E-13 Two switches operation of switch panel on machine monitor does not function
— E-14 Switch panel buzzer of machine monitor is abnormal
— E-15 Rearview monitor does not light up or backlight flickers
— E-16 Rearview monitor images are not displayed clearly
— E-17 Rearview monitor brightness cannot be adjusted
— E-18 Night lighting lamp of rearview monitor is abnormal
— E-19 Some items of gauges and caution lamps on machine monitor are not displayed properly
— E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking) position
— E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not light
— E-22 The HST oil filter clogging caution lamp does not light up
— E-23 Radiator coolant level caution lamp does not light
— E-24 Indication of HST oil temperature gauge does not increase, or HST oil temperature caution lamp does not light
— E-25 When brake pedal (inching pedal) is depressed, inching function does not work (travel speed or traction force does not lower), or while not depressed, inching function operates
— E-26 Fuel level gauge does not indicate correct level
— E-27 Seat belt caution lamp indication is abnormal
— E-28 Horn does not sound
— E-29 Horn does not stop sounding
— E-30 Alarm buzzer does not sound
— E-31 When starting switch is in ON position, alarm buzzer does not stop sounding
— E-32 When emergency HST pump drive switch is operated, emergency HST pump does not work or when emergency HST pump drive switch is not operated, emergency HST pump works
— E-33 Setting does not change while operating traction control switch
— 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
— E-35 Remote positioner does not work or cannot be released
— E-36 Bucket positioner does not work or cannot be released
— E-37 Direction selector (FNR) switch mode is not selected or not released
— E-38 PZ auto tilt-in does not work
— E-39 Tracktion level does not display MAX when max traction switch is turned ON
— E-40 ECSS function cannot be selected or cannot be released
— E-41 None of headlamp, clearance lamp, and tail lamp lights
— E-42 Clearance lamp ,tail lamp and license plate lamp do not light up or go out
— E-43 Both High and Low beams of headlamp do not light up or go out
— E-44 Low beam of headlamp does not light up or go out
— E-45 High beam of headlamp does not light up or go out
— E-46 Front working lamp does not light up or go out
— E-47 Rear working lamp does not light up or go out
— E-48 All of turn signal lamps and hazard lamps do not flash or go out
— E-49 Turn signal lamps do not flash or go out
— E-50 Hazard lamp does not flash or go out
— E-51 Brake lamp does not light or stays lighted
— E-52 Backup lamp does not light up or does not go out
— E-53 Backup buzzer does not sound or continues to sound
— E-54 Front wiper does not operate
— E-55 Rear wiper does not operate
— E-56 Window washer does not operate
— E-57 KOMTRAX system does not operate normally
– Troubleshooting of hydraulic and mechanical system (H-mode)
— Information described in troubleshooting table (H-mode)
— System chart of hydraulic and mechanical systems
— Failure mode and cause table
— H-1 Machine does not travel forward or backward
— H-2 Machine does not travel forward (Machine travels backward normally)
— H-3 Machine does not travel backward (Machine travels forward normally)
— H-4 Machine does not travel forward or backward fast
— H-5 Machine does not travel forward fast (Machine travel backward fast)
— H-6 Machine does not travel backward fast (Machine travel forward fast)
— H-7 Machine lacks power neither when traveling forward nor backward
— H-8 Machine lacks power when traveling forward (Machine has sufficient power when traveling backward)
— H-9 Machine lacks power when traveling backward (Machine have sufficient power when traveling forward)
— H-10 Engine stalls during travel or engine speed drops significantly
— H-11 Steering wheel is too heavy to turn
— H-12 Steering wheel is heavy to turn
— H-13 Machine sways or large shocks are made while machine turns
— H-14 Machine unintentionally turns when machine travels
— H-15 Wheel brakes do not work or are weak
— H-16 Wheel brakes are not released or drag
— H-17 Parking brake does not work or it is weak
— H-18 Parking brake is not released or drags.
— H-19 Boom does not rise
— H-20 Boom moves slow or boom lacks lifting force
— H-21 Rising boom slows down at certain height
— H-22 Lift cylinders do not serve to hold bucket on ground (bucket rises off ground).
— H-23 Hydraulic drift of boom is large
— H-24 Boom moves up and down during operation
— H-25 Bucket does not tilt back
— H-26 Bucket moves slow or lacks tilt-back force
— H-27 Bucket decelerates during tilt-back operation
— H-28 Bucket cylinder does not hold bucket on ground
— H-29 Hydraulic drift of bucket is large
— H-30 Bucket tilts back and forth during carrying load (work equipment valve in HOLD)
— H-31 Boom and bucket control levers do not move smoothly and are heavy to move
— H-32 Operating work equipment causes engine speed to lower significantly or engine to stall
— H-33 Large shocks are made when work equipment starts to move and stops
— H-34 When certain work equipment is relieved hydraulically, other work equipment moves
— H-35 E.C.S.S. (travel damper) does not work and machine pitches and bounces
— H-36 Fan speed is abnormal (too high or low, or fan does not rotate)
— H-37 Unusual noise is heard from around fan
– Troubleshooting of engine (S-mode)
— Information described in troubleshooting table (S mode)
— S-1 Engine does not crank when starting switch is turned to START position
— S-2 Engine cranks but no exhaust smoke comes out
— S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start)
— S-4 Engine startability is poor
— S-5 Engine does not pick up smoothly
— S-6 Engine stops during operation
— S-7 Engine runs rough or is unstable
— S-8 Engine lacks power
— S-9 KDPF gets clogged in a short time
— S-10 Engine oil consumption is excessive
— S-11 Engine oil becomes contaminated early
— S-12 Fuel consumption is excessive
— S-13 Oil is in coolant (or coolant spurts or coolant level goes down)
— S-14 Oil pressure drops
— S-15 Fuel mixes into engine oil
— S-16 Water mixes into engine oil (milky)
— S-17 Coolant temperature rises too high (overheating)
— S-18 Unusual noise is heard
— S-19 Vibration is excessive
— S-20 Air cannot be bled from fuel circuit
— S-21 Active regeneration is executed frequently
— S-22 Active regeneration takes time
— S-23 White smoke is exhausted during active regeneration
50 Disassembly and assembly
– Table of contents
– Related information on disassembly and assembly
— How to read this manual
— Coating materials list
— Special tools list
— Sketches of special tools
– Engine and cooling system
— Removal and installation of supply pump assembly
— Removal and installation of injector assembly
— Removal and installation of cylinder head assembly
— Removal and installation of engine hood assembly
— Removal and installation of grille assembly
— Removal and installation of radiator core assembly
— Removal and installation of aftercooler
— Removal and installation of hydraulic oil cooler
— Removal and installation of engine assembly
— Removal and installation of engine front oil seal
— Removal and installation of engine rear oil seal
— Removal and installation of cooling fan and fan motor assembly
— Removal and installation of KDPF assembly
— Disassembly and assembly of KDPF assembly
— Removal and installation of KCCV assembly
— Removal and installation of air cleaner assembly
— Removal and installation of KVGT assembly
— Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly
— Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly
— Removal and installation of alternator belt
— Removal and installation of fuel tank assembly
– Power train
— Removal and installation of transfer assembly
— Disassembly and assembly of transfer assembly
— Disassembly and assembly of parking brake assembly
— Disassembly and assembly of differential assembly
— Removal and installation of front axle assembly
— Removal and installation of rear axle assembly
— Disassembly and assembly of axle housing assembly
– Undercarriage and frame
— Removal and installation of center hinge pin
— Removal and installation of counterweight assembly
– Hydraulic system
— Removal and installation of hydraulic tank assembly
— Removal and installation of control valve assembly
— Disassembly and assembly of control valve assembly
— Removal and installation of hydraulic pump assembly
— Removal and installation of HST motor1 assembly
— Removal and installation of HST motor2 assembly
— Disassembly and assembly of hydraulic cylinder assembly
– Work equipment
— Removal and installation of work equipment assembly
– Cab and its attachments
— Removal and installation of operator’s cab and floor frame assembly
— Removal and installation of operator’s cab glass (adhered glass)
— Removal and installation of operator’s seat assembly
— Removal and installation of seat belt
– Electrical system
— Removal and installation of machine monitor assembly
— Removal and installation of engine controller assembly
— Removal and installation of HST controller assembly
— Removal and installation of air conditioner controller assembly
— Removal and installation of monitor controller assembly
— Removal and installation of mass air flow and temperature sensor
— Removal and installation of KOMTRAX terminal assembly
– Air conditioner unit
— Removal and installation of air conditioner compressor
— Removal and installation of air conditioner condenser
— Removal and installation of air conditioner unit assembly
60 Maintenance standard
– Table of contents
– Engine and cooling system
— Engine related parts
— Cooling fan motor
– Power train
— Damper
— Transfer
— Drive shaft
— Axle
— Differential
— Limited slip differential
— Final drive
– Steering system
— Steering column
— Priority valve
— Emergency steering valve
— Steering cylinder
– Brake system
— Brake accumulator charge valve
— Slack adjuster
— Brake
— Parking brake
— Parking brake solenoid valve
– Undercarriage and frame
— Axle mount
— Center hinge pin
– Hydraulic system
— Hydraulic tank
— Double type gear pump
— Steering and work equipment pump
— Control valve
— Self-pressure reducing valve
— Work equipment PPC valve
— Work equipment lock solenoid valve
– Work equipment
— Work equipment linkage
— Bucket
— Work equipment cylinder
– Cab and its attachments
— Cab mount
– Electrical system
— Bucket positioner
— Fork positioner
— Remote boom positioner
80 Appendix
– Table of contents
– Air conditioner components
— Precautions for refrigerant
— Air conditioner component
— Configuration and function of refrigeration cycle
— Outline of refrigeration cycle
— Air conditioner unit
— Dual pressure switch
— Air conditioner controller
— Compressor
— Condenser
— Receiver drier
— Sunlight sensor
— Outer temperature sensor (outside air temperature sensor)
— Procedure for testing and troubleshooting
— Circuit diagram and arrangement of connector pins
— System diagram
— Parts and connectors layout
— Testing with self-diagnosis function
— How to open the electrical system abnormality record screen in service mode of the machine monitor
— Testing temperature control system
— Testing vent (mode) changeover
— Testing FRESH/RECIRC air changeover
— Testing evaporator temperature sensor
— Testing relays
— Troubleshooting chart 1
— Troubleshooting chart 2
— Information in troubleshooting table
— Failure code list related to air conditioner
— Failure code [879AKA] A/C Inner Sensor Open Circuit
— Failure code [879AKB] A/C Inner Sensor Short Circuit
— Failure code [879BKA] A/C Outer Sensor Open Circuit
— Failure code [879BKB] A/C Outer Sensor Short Circuit
— Failure code [879CKA] Ventilating Sensor Open Circuit
— Failure code [879CKB] Ventilating Sensor Short Circuit
— Failure code [879DKZ] Sunlight Sensor Open or Short Circuit
— Failure code [879EMC] Ventilation Damper Abnormality
— Failure code [879FMC] Air Mix Damper Abnormality
— A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)
— A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled)
— A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
— A-4 Troubleshooting for FRESH/RECIRC air changeover
— Troubleshooting with gauge pressure
— Connection of service tool
— Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit
— Handling of compressor oil
90 Diagrams and drawings
– Table of contents
– Hydraulic circuit diagram
— Symbols in hydraulic circuit diagram
— Hydraulic circuit diagram
– Electric circuit diagram
— Symbols in electric circuit diagram
— Electrical circuit diagram of machine body
— Electrical circuit diagram of floor
INDEX