Service manual Komatsu WA500-7 10001 & Up | SEN05693-03

Komatsu WA500-7 10001 & Up SEN05693-03 (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
— Specification
— 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
— Engine mount and transmission mount
— Joint
— Cooling system
— Cooling fan pump
— Cooling fan motor
– Power train
— Power train system
— Drive shaft
— Power train piping drawing
— Transmission control
— Torque converter
— Torque converter regulator valve
— Transmission
— Transfer
— Transmission control valve
— Forward and reverse clutch ECMV and gear speed clutch ECMV
— Lockup clutch ECMV
— Main relief valve, torque converter relief valve, and main flow selector valve
— Torque converter oil cooler
— Center support
— Lubricating oil relief valve
— Axle
— Differential
— Final drive
– Steering system
— Layout of steering parts
— Steering column
— Joystick steering lever linkage
— Steering pump
— Steering control valve
— Orbitrol valve
— Stop valve
— Emergency steering piping diagram
— Diverter valve
— Emergency steering pump
– Brake system
— Layout of brake parts
— Charge valve
— Brake valve
— Slack adjuster
— Accumulator (for brake)
— Brake
— Parking brake control
— Parking brake
— Parking brake solenoid valve
— Parking brake emergency release valve
– Undercarriage and frame
— Axle mount
— Center hinge pin
— Tire
– Hydraulic system
— Hydraulic component layout
— Work equipment control
— Hydraulic tank
— Double type gear pump
— Work equipment pump
— Control valve
— CLSS
— Hydraulic circuit diagram and names of valves
— Accumulator charge valve
— Work equipment lock solenoid valve
— Accumulator (for PPC circuit)
— Accumulator (for ECSS)
– Work equipment
— Work equipment linkage
— Bucket
— Bucket positioner and boom positioner
— Lubrication of work equipment
– Cab and its attachments
— ROPS cab
– Electrical system
— Engine control system
— Preheating system
— Power mode selector circuit
— Engine output limit function
— Automatic warm-up function
— Parking brake control system
— System operating lamp function
— Battery disconnect switch function
— Backup lamp and brake lamp
— Clearance lamp and headlamp
— Working lamp
— Horn circuit
— Wiper and window washer circuit
— Transmission controller system
— Work equipment control system
— Machine monitor system
— Rear view 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
– General 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 return rate 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 head and manifolds
— Testing engine piping for damage and looseness
— Replacing and adjusting belt for alternator and air conditioner compressor
— Procedures for cleaning fuel doser
— Writing compensation values at replacement of injector and engine controller
– Power train
— Adjusting transmission output speed sensor
— Adjusting transmission input speed sensor
— Flushing procedure for torque converter and transmission hydraulic circuit
— Retrieval of disabled machine due to transmission valve failure
— Testing oil leakage from axle final drive
— Testing drive shaft for looseness, backlash, and damage
— Testing and adjusting power train oil 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.
— Testing and adjusting steering stopper valve
– Brake system
— Testing brake pedal
— Testing and adjusting brake pedal linkage
— Adjustment procedure of transmission cut-off proximity switch of left 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 parking brake oil pressure
— Testing wear of parking brake disc
— Method of releasing parking brake manually
– Hydraulic system
— Testing fan speed
— Testing fan pump circuit oil pressure
— Bleeding air from hydraulic fan circuit
— Testing work equipment EPC oil pressure
— Testing and adjusting work equipment oil pressure
— Bleeding air from work equipment circuit
— Releasing remaining pressure from work equipment circuit
— Checking of ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas
– Work equipment
— Testing and adjusting bucket position detection lever
— 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
– General information on troubleshooting
— Troubleshooting points
— Sequence of events in troubleshooting
— Check before troubleshooting
— Inspection procedure before troubleshooting
— Preparation work for troubleshooting of electrical system
— Classification and procedures for troubleshooting
— Symptom and troubleshooting numbers
— Information in troubleshooting table
— 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 on troubleshooting of machine monitor
— Processing procedure of harness checker for troubleshooting of machine monitor LCD unit
— Fabrication of dummy temperature sensor (for KDOC and KDPF temperature sensors)
— Fabrication of short-circuit connector (for CA1883 and CA3135)
— Failure codes table
– Troubleshooting by failure code (Display of code)
— Failure code [1500L0] Double Engagement of T/M Clutches
— Failure code [15B0NX] Transmission Oil Filter Clogging
— Failure code [15SAL1] Release Trouble of ECMV (Forward)
— Failure code [15SALH] Malfunction of ECMV (Forward)
— Failure code [15SBL1] Release Trouble of ECMV (Reverse)
— Failure code [15SBLH] Malfunction of ECMV (Reverse)
— Failure code [15SEL1] Release Trouble of ECMV (1st clutch)
— Failure code [15SELH] Malfunction of ECMV (1st)
— Failure code [15SFL1] Release Trouble of ECMV (2nd)
— Failure code [15SFLH] Malfunction of ECMV (2nd)
— Failure code [15SGL1] Release Trouble of ECMV (3rd)
— Failure code [15SGLH] Malfunction of ECMV (3rd)
— Failure code [15SHL1] Release Trouble of ECMV (4th)
— Failure code [15SHLH] Malfunction of ECMV (4th)
— Failure code [2F00MA] Failure of Parking Brake Circuit
— Failure code [2G42ZG] Accumulator Oil Pressure Low (Front)
— Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear)
— 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 [989A00] Engine Overrun Prevention Activated
— 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 [AA10NX] Air Cleaner Clogging
— 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@CENS] T/C Oil Temp. Overheat
— Failure code [B@HANS] HYD 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 [CA135] Eng Oil Press Sensor High Error
— Failure code [CA141] Eng Oil Press 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 Sens High Error
— Failure code [CA222] Ambient Press Sens 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 [CA273] PCV2 Short Error
— Failure code [CA274] PCV2 Open 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 [CA431] Idle Validation Sw Error
— Failure code [CA432] Idle Validation Process 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 [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 2
— Failure code [CA556] Crankcase Press High Error 3
— 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 [CA1923] Dosing Fuel Valve 1 High Error
— Failure code [CA1924] Dosing Fuel Valve 1 Low Error
— Failure code [CA1925] Dosing Fuel Valve 1 In Range Error
— Failure code [CA1927] Dosing Fuel Press Sens High Error
— Failure code [CA1928] Dosing Fuel Press Sens Low Error
— Failure code [CA1942] Crankcase Press Sens In Range Error
— Failure code [CA1963] Dosing Fuel Valve 1 Servo Error
— Failure code [CA1977] Fuel Doser Open/Short 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 [CA2265] Fuel Feed Pump Open Error
— Failure code [CA2266] Fuel Feed Pump Short Error
— Failure code [CA2271] EGR Valve Pos Sens High Error
— Failure code [CA2272] EGR Valve Pos Sens Low 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 [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 [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 [CA2732] Dosing Fuel Valve 2 High Error
— Failure code [CA2733] Dosing Fuel Valve 2 Low Error
— Failure code [CA2741] Dosing Fuel Valve Swap Error
— Failure code [CA2765] Inj Trim Data Error
— Failure code [CA2878] Dosing Fuel Valve 2 Servo Error
— Failure code [CA2881] Dosing Fuel Pressure Low Error 1
— 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 [CA3167] Fuel Doser Degradation
— 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 [D160KA] Disconnection of Backup Lamp Relay Output
— Failure code [D160KB] Ground Fault 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 [D193KA] Disconnection of J/S Solenoid Cut Relay
— Failure code [D193KB] Ground Fault of J/S Solenoid Cut Relay
— Failure code [D193KY] Hot Short of J/S Solenoid Cut Relay
— Failure code [D193MC] Malfunction of J/S Solenoid Cut Relay
— Failure code [D19JKZ] Personal Code Relay Abnormality
— 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 [D5ZHKZ] Failure of Key SW C Signal
— 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 [DAQ0KK] Controller Power Source Low (T/M)
— Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M)
— Failure code [DAQ0MC] T/M Con Error
— Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M)
— Failure code [DAQ2KK] Solenoid Power Source Low (T/M)
— Failure code [DAQ4KB] Ground Fault of Sol. Self-Holding Relay
— Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M)
— Failure code [DAQLKA] Operating Lamp Open Circuit (T/M)
— Failure code [DAQLKB] Operating Lamp Short Circuit (T/M)
— Failure code [DAQQKR] CAN2 Discon (Transmission Con)
— Failure code [DAQRKR] CAN1 Discon (Transmission Con)
— Failure code [DAQRMA] Inconsistency of Option Selection (T/M)
— 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 [DB90KK] Drop in BBC Controller Main Power Source
— Failure code [DB90KT] Abnormality of Non-volatile Memory (BBC)
— Failure code [DB90MC] BBC Error
— Failure code [DB91KA] Disconnection of Key SW ACC (BBC)
— Failure code [DB92KK] Solenoid Power Source Low (BBC)
— Failure code [DB95KX] Failure of 5 V Power Source 1
— Failure code [DB96KX] Failure of 5 V Power Source 2
— Failure code [DB99KQ] Inconsistency of Model Selection (BBC)
— Failure code [DB9LKA] Operating Lamp Open Circuit (BBC)
— Failure code [DB9LKB] Operating Lamp Short Circuit (BBC)
— Failure code [DB9QKR] CAN2 Discon (Bucket Boom Con)
— Failure code [DB9RKR] CAN1 Discon (Bucket Boom Con)
— Failure code [DB9RMA] Inconsistency of Option Selection (BBC)
— Failure code [DBE5KX] Failure of 5V Power Source
— Failure code [DBE6KX] Failure of 24 V Power Source
— Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW
— Failure code [DDA8KY] Hot Short of Throttle Lock Set SW
— Failure code [DDA9KY] Hot Short of Throttle Lock Resume SW
— Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch
— Failure code [DDB6L4] Neutral Signal Malfunction
— Failure code [DDD1LD] Failure of Bucket Positioner Set Switch
— Failure code [DDE5KA] Failure of Emergency Steering Signal
— Failure code [DDK3KA] FNR SW Input Signal Disconnection
— Failure code [DDK3KB] FNR SW Input Signal Short Circuit
— Failure code [DDK4KA] J/S FNR Input Signal Disconnection
— Failure code [DDK4KB] J/S FNR Input Signal Short Circuit
— Failure code [DDK5L4] Failure of J/S Shift Up/Down SW
— Failure code [DDK6KA] FNR Lever Input Signal Disconnection
— Failure code [DDK6KB] FNR Lever Input Signal Short Circuit
— Failure code [DDNRKY] Hot Short of Work Equipment Lock SW
— Failure code [DDT0L4] Failure of Shift Mode Select SW
— Failure code [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal
— Failure code [DDT9LD] Ground Fault of T/M Cut Off SW Signal
— Failure code [DDW9LD] Ground Fault of Kickdown Switch
— Failure code [DDWLLD] Ground Fault of T/M Shift Hold SW
— Failure code [DF10KA] Disconnection of Shift Lever Input
— Failure code [DF10KB] Ground Fault of Shift Lever Input
— Failure code [DGF1KA] Disconnection of T/M Oil Temp. Sensor
— Failure code [DGF1KB] Ground Fault of T/M Oil Temp. Sensor
— Failure code [DGH2KX] Out of Range of HYD Oil Temp. Sensor
— Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor
— Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor
— Failure code [DGT1KA] Disconnection of T/C Oil Temp. Sensor
— Failure code [DGT1KB] Ground Fault of T/C Oil Temp. Sensor
— Failure code [DH21KA] Failure of Loader Pump Press. Sensor
— Failure code [DH21KB] Loader Pump Press. Sensor Short Circuit
— Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit
— Failure code [DHPCKX] Out of Range of Boom Bottom Press. Sensor
— Failure code [DHPDKX] Out of Range of Boom Head Press. Sensor
— Failure code [DHQ2KX] Out of Range of Main Flow Sel. Valve S.
— Failure code [DHT1KX] Out of Range of T/M Cut Off Press. Sensor
— Failure code [DHT2L6] Failure of T/M Oil Filter Sensor Circuit
— Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor
— Failure code [DHT7KX] Out of Range of T/C Output Pressure Sensor
— Failure code [DHT8KA] Failure of Steering Pump Press. Sensor
— Failure code [DHT8KB] Steering Pump Press. Sensor Short Circuit
— Failure code [DHT8ZG] Steering Oil Pressure Low
— 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 [DK59KA] Failure of Boom Lever Potentio (Main)
— Failure code [DK59KY] Hot Short of Boom Lever Potentio (Main)
— Failure code [DK59L8] Boom Lever Potentio (Main & Sub) Disagree
— Failure code [DK5AKA] Failure of Boom Lever Potentio (Sub)
— Failure code [DK5AKY] Hot Short of Boom Lever Potentio (Sub)
— Failure code [DK5BKA] Failure of Bucket Lever Potentio (Main)
— Failure code [DK5BKY] Hot Short of Bucket Lever Potentio (Main)
— Failure code [DK5BL8] Bucket Lever Potentio (Main&Sub) Disagree
— Failure code [DK5CKA] Failure of Bucket Lever Potentio (Sub)
— Failure code [DK5CKY] Hot Short of Bucket Lever Potentio (Sub)
— 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 [DK5FKA] Failure of J/S Lever Potentio (Main)
— Failure code [DK5FKY] Hot Short of J/S Lever Potentio (Main)
— Failure code [DK5FL8] J/S Lever Potentio (Main & Sub) Disagree
— Failure code [DK5GKA] Failure of J/S Lever Potentio (Sub)
— Failure code [DK5GKY] Hot Short of J/S Lever Potentio (Sub)
— 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 [DKA1KA] Failure of Bucket Angle Sensor
— Failure code [DKA1KY] Hot Short of Bucket Angle Sensor Circuit
— Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor
— Failure code [DLF1LC] Failure of T/M Input Speed Sensor
— Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor
— Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor
— Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main)
— Failure code [DLT3LC] Failure of Output Speed Sensor (Main)
— 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 [DT20KB] Ground Fault of T/M Cut Off Indicator
— Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic.
— Failure code [DV00KB] Ground Fault of Buzzer Output
— Failure code [DW2BKA] Disconnection of Main Flow Selector Sol.
— Failure code [DW2BKB] Ground Fault of Main Flow Selector Sol.
— Failure code [DW2BKY] Hot Short of Main Flow Selector Sol.
— Failure code [DW2BL1] Release Trouble of Main Flow Sel. Valve
— Failure code [DW2BLH] Malfunction of Main Flow Selector Valve
— Failure code [DW4PKA] Disconnection of Boom EPC Solenoid (Raise)
— Failure code [DW4PKB] Ground Fault of Boom EPC Solenoid (Raise)
— Failure code [DW4PKY] Hot Short of Boom EPC Solenoid (Raise)
— Failure code [DW4QKA] Disconnection of Boom EPC Solenoid (Lower)
— Failure code [DW4QKB] Ground Fault of Boom EPC Solenoid (Lower)
— Failure code [DW4QKY] Hot Short of Boom EPC Solenoid (Lower)
— 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 [DW4SKA] Disconnection of Bucket EPC Sol. (Dump)
— Failure code [DW4SKB] Ground Fault of Bucket EPC Solenoid (Dump)
— Failure code [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump)
— Failure code [DW7BKA] Disconnection of Fan Reverse Solenoid
— Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol.
— Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol.
— 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 [DX16KA] Disconnection of Rad. Fan Pump EPC Sol.
— Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol.
— Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol.
— Failure code [DXA1KA] Disconnection of Loader Pump EPC Solenoid
— Failure code [DXA1KB] Ground Fault of Loader Pump EPC Solenoid
— Failure code [DXA1KY] Hot Short of Loader Pump EPC Solenoid
— Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup)
— Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup)
— Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup)
— Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st)
— Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st)
— Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st)
— Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd)
— Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd)
— Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd)
— Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd)
— Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd)
— Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd)
— Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse)
— Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse)
— Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse)
— Failure code [DXH8KA] Disconnection of ECMV Solenoid (Forward)
— Failure code [DXH8KB] Ground Fault of ECMV Solenoid (Forward)
— Failure code [DXH8KY] Hot Short of ECMV Solenoid (Forward)
— Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th)
— Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th)
— Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th)
— 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 [DXHLKA] Disconnection of J/S Right EPC Solenoid
— Failure code [DXHLKB] Ground Fault of J/S Right EPC Solenoid
— Failure code [DXHLKY] Hot Short of J/S Right EPC Solenoid
— Failure code [DXHMKA] Disconnection of J/S Left EPC Solenoid
— Failure code [DXHMKB] Ground Fault of J/S Left EPC Solenoid
— Failure code [DXHMKY] Hot Short of J/S Left EPC Solenoid
— Failure code [LA00L3] Failure of Fan Reverse
– Troubleshooting of electrical system (E-mode)
— E-1 Engine does not start (Engine does not crank)
— 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 Air cleaner clogging indicator lamp does not light
— E-23 Radiator coolant level caution lamp does not light
— E-24 Indication of hydraulic oil temperature gauge does not increase, or hydraulic oil temperature caution lamp does not light
— E-25 Indication of torque converter oil temperature gauge does not increase, or torque converter oil temperature caution lamp does not light
— 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 Kickdown does not work when kickdown switch is turned ON
— E-33 The hold switch does not work when it is pressed
— E-34 Transmission is always shifted to Neutral, or the brake drags when parking brake applies and FR drive is selected
— E-35 Transmission cut-off mode is not selected or not released
— E-36 Transmission cut-off setting cannot be released
— E-37 FNR switch mode is not selected or not released
— E-38 When operating engine mode selector switch, engine mode selector function does not operate properly
— E-39 Flow of loader pump does not increase from the minimum rate
— 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 and tail 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 light up or go out
— E-49 Turn signal lamps do not light up or go out
— E-50 Hazard lamp does not light up or go out
— E-51 Brake lamp does not light up or stays lighted
— E-52 Backup lamp does not light or continues to light
— 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 Fuel feed pump does not operate or stop automatically
— E-58 KOMTRAX system does not operate properly
– 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 start
— H-2 Torque converter lockup clutch is not disengaged (engine stalls)
— H-3 Torque converter lockup clutch is not engaged
— H-4 Travel speed is slow, bucket thrust force is weak, gradability is low, or gear speed does not shift
— H-5 Large shock is made when machine starts or gear is shifted
— H-6 Machine starts or gear speed shifts with long time lag
— H-7 Torque converter oil temperature is high
— H-8 Machine does not turn
— H-9 Turning response is poor
— H-10 Steering wheel is heavy to turn
— H-11 Machine sways or large shocks are made while machine turns
— H-12 Turning radius differs between right and left turns
— H-13 Wheel brakes do not work or are weak
— H-14 Wheel brakes are not released or drag
— H-15 Parking brake does not work or it is weak
— H-16 Parking brake is not released or drags (including emergency release system)
— H-17 Boom does not rise
— H-18 Boom moves slow or boom lacks lifting force
— H-19 Rising boom slows down at certain height
— H-20 Lift cylinders do not serve to hold bucket on ground
— H-21 Hydraulic drift of boom is large
— H-22 Boom moves up and down during operation
— H-23 Bucket does not tilt back
— H-24 Bucket moves slow or bucket lacks tilt-back force
— H-25 Bucket decelerates during tilt-back operation
— H-26 Bucket cylinder does not hold bucket on ground
— H-27 Hydraulic drift of bucket is large
— H-28 Bucket tilts back and forth during carrying load (work equipment valve in HOLD)
— H-29 Boom and bucket control levers do not move smoothly and are heavy to move
— H-30 Operating work equipment causes engine speed to lower significantly or engine to stall
— H-31 Large shocks are made when work equipment starts to move and stops
— H-32 When certain work equipment stalls hydraulically, other work equipment moves
— H-33 E.C.S.S. (travel damper) does not work and machine pitches and bounces
— H-34 Fan speed is abnormal (too high or low, or fan does not rotate)
— H-35 Unusual noise is heard from around fan
– Troubleshooting of engine (S-mode)
— Information mentioned in troubleshooting table (S mode)
— S-1 When starting switch is turned to START position, engine is not cranked
— S-2 The engine cranks but exhaust smoke does not come out
— S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not)
— 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 a long time
— S-23 White smoke is exhausted during active regeneration
50 Disassembly and assembly
– Table of contents
– General 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 radiator core assembly
— Removal and installation of aftercooler
— Removal and installation of hydraulic oil cooler
— Removal and installation of power train oil cooler assembly
— 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 KVGT assembly
— Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly
— Removal and installation of air cleaner assembly
— Removal and installation of air conditioner compressor assembly
— Removal and installation of air conditioner condenser assembly
— Removal and installation of belt for alternator and air conditioner compressor
— Removal and installation of fuel tank assembly
– Power train
— Removal and installation of power train unit assembly
— Disconnection and connection of power train unit assembly
— Disassembly and assembly of input transfer assembly
— Disassembly and assembly of torque converter assembly
— Disassembly and assembly of transmission assembly
— Disassembly and assembly of transfer and parking brake assembly
— Removal and installation of front differential assembly
— Disassembly and assembly of differential assembly (with LSD)
— Disassembly and assembly of differential assembly (without LSD)
— Removal and installation of front axle assembly
— Removal and installation of rear axle assembly
— Disassembly and assembly of final drive assembly (front and rear)
– Steering system
— Removal and installation of steering valve assembly
– Brake system
— Removal and installation of brake assembly (front and rear)
— Disassembly and assembly of brake assembly (front and rear)
— Disassembly and assembly of slack adjuster assembly
— Disassembly and assembly of brake accumulator charge valve assembly
– Undercarriage and frame
— Removal and installation of center hinge pin
— Removal and installation of large counterweight assembly
— Removal and installation of small counterweight assembly
– Hydraulic system
— Removal and installation of hydraulic tank assembly
— Removal and installation of work equipment pump assembly
— Removal and installation of steering and power train pump assembly
— Removal and installation of cooling fan pump assembly
— Removal and installation of work equipment control valve assembly
— Disassembly and assembly of work equipment control valve assembly
— Removal and installation of diverter valve assembly
— Disassembly and assembly of steering cylinder assembly
— Disassembly and assembly of work equipment cylinder assembly
– Work equipment
— Removal and installation of work equipment assembly
– Cab and its attachments
— Removal and installation of operator’s cab assembly (separate cab and floor specification)
— Removal and installation of operator’s cab glass (stuck window glass)
— Removal and installation of operator’s seat assembly
— Removal and installation of seat belt
— Removal and installation of air conditioner unit assembly
– Electrical system
— Removal and installation of machine monitor assembly
— Removal and installation of work equipment controller assembly
— Removal and installation of rear view monitor assembly
— Removal and installation of engine controller assembly
— Removal and installation of transmission 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
60 Maintenance standard
– Table of contents
– Engine and cooling system
— Engine mount and transmission mount
— Joint
— Cooling fan pump
— Servo valve
— Cooling fan motor
– Power train
— Drive shaft
— Torque converter
— Torque converter regulator valve
— Transmission
— Transmission control valve
— Forward and reverse clutch ECMV and gear speed clutch ECMV
— Lockup clutch ECMV
— Main relief valve, torque converter relief valve, and main flow selector valve
— Center support
— Lubricating oil relief valve
— Axle
— Differential
— Final drive
– Steering system
— Steering column
— Steering pump
— Steering control valve
— Steering cylinder
— Diverter valve
— Emergency steering pump
– Brake system
— Charge valve
— Brake valve
— Slack adjuster
— Accumulator (for brake)
— Brake
— Parking brake
— Parking brake solenoid valve
– Undercarriage and frame
— Axle mount
— Center hinge pin
– Hydraulic system
— Hydraulic tank
— Double type gear pump
— Work equipment pump
— Control valve
— Accumulator charge valve
– Work equipment
— Work equipment linkage
— Bucket
— Bucket positioner and boom positioner
— Work equipment cylinder
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
— Parts and connectors layout
— Testing with self-diagnosis function
— Testing temperature control system
— Testing vent (mode) changeover
— Testing FRESH/RECIRC air changeover
— Check 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
— Power train hydraulic circuit diagram
— Brake hydraulic circuit diagram
— Hydraulic circuit diagram
– Electric circuit diagram
— Symbols in electric circuit diagram
— Electrical circuit diagram
— Electrical circuit diagram of floor
INDEX